ESAB EMP235ic Instruction Manual Download Page 1

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Instruction manual

0463 641 001 GB 20181220

Valid for: serial no. 821-xxx-xxxx

EMP 235ic

Multi-Process Welding Inverter

Summary of Contents for EMP235ic

Page 1: ...Instruction manual 0463 641 001 GB 20181220 Valid for serial no 821 xxx xxxx EMP 235ic Multi Process Welding Inverter...

Page 2: ......

Page 3: ...e wire feed pressure 19 5 6 Changing the feed pressure rollers 20 5 7 Shielding gas 20 5 8 Duty cycle 21 5 9 Overheating protection 22 5 10 Voltage Reduction Device VRD 22 6 CONTROL PANEL 23 6 1 How t...

Page 4: ...ESAB AB 2018 7 4 Torch and liner maintenance 31 8 TROUBLESHOOTING 32 9 ORDERING SPARE PARTS 34 DIAGRAM 35 ORDERING NUMBERS 36 WEAR PARTS 37 ACCESSORIES 39 REPLACEMENTS PARTS 40 Rights reserved to alte...

Page 5: ...y precautions must meet the requirements that apply to this type of equipment The following recommendations should be observed in addition to the standard regulations that apply to the workplace All w...

Page 6: ...ELECTRIC AND MAGNETIC FIELDS Can be dangerous to health Welders having pacemakers should consult their physician before welding EMF may interfere with some pacemakers Exposure to EMF may have other he...

Page 7: ...uipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic...

Page 8: ...apabilities MIG MMA and Lift TIG Automatic recognition of input power with PFC 120 V 230 V Large 11 cm 4 3 in high resolution customizable user interface Rugged case design and internal hardware High...

Page 9: ...A 16 4 V 50 duty cycle 200 A 18 0 V 35 duty cycle 235 A 19 4 V Setting range DC 5 A 10 2 V 240 A 19 6 V Permissible load at SMAW MMA 100 duty cycle 110 A 24 4 V 50 duty cycle 150 A 26 0 V 35 duty cyc...

Page 10: ...MAW MMA Breaker 15 A 14 7 A Permissible load at GMAW MIG 100 duty cycle Breaker 20 A 90 A 18 5 V Breaker 15 A 75 A 17 75 V 60 duty cycle Breaker 20 A 110 A 19 5 V Breaker 15 A 90 A 18 5 V 40 duty cycl...

Page 11: ...ture 10 to 40 C 14 to 104 F Enclosure class IP23S Application classification Duty cycle The duty cycle refers to the time as a percentage of a ten minute period that you can weld or cut at a certain l...

Page 12: ...ndustrial use In a domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions 4 1 Location Position the power source so that its coolin...

Page 13: ...low supply voltage may cause poor welding performance Too high welding supply voltage will cause components to overheat and possibly fail Contact the local electric utility for information about the...

Page 14: ...nded fuse or circuit breaker rating Time delay fuse 33 0 A 30 0 A Maximum recommended fuse or circuit breaker rating 50 0 A 50 0 A Minimum recommended cord size 2 5 mm2 13 AWG 2 5 mm2 13 AWG Maximum r...

Page 15: ...quipment NOTE When moving the equipment use intended handle Never pull the cables WARNING Rotating parts can cause injury take great care WARNING Electric shock Do not touch the workpiece or the weldi...

Page 16: ...changeover cable 2 Display 9 Positive output 3 Knob for voltage selection 10 Euro torch connection 4 Main knob for menu navigation 11 Mains cable 5 Gas outlet optional TIG torch 12 Mains supply switc...

Page 17: ...s optional TIG accessories connect the TIG torch power cable to the negative terminal 7 see illustration of front and rear Connect the gas inlet nut from the TIG torch to the gas outlet connector 5 lo...

Page 18: ...elding torch for the wire diameter used The torch is fitted with a contact tip for 0 8 mm 0 030 in wire If you use another diameter you must change the contact tip and drive roll The wire liner fitted...

Page 19: ...al for the Fusion 250 for ordering number 5 5 Setting the wire feed pressure Illustration A Illustration B Start by making sure that the wire moves smoothly through the wire guide Then set the pressur...

Page 20: ...kwise 3 Change the feed roll 4 Tighten the feed roll retaining screw by turning it clockwise 5 Close the spool side door NOTE The visual wire stamp designates the wire diameter groove in use 5 7 Shiel...

Page 21: ...If the power source operates at a 25 duty cycle it will provide the rated amperage for a maximum of 2 5 minutes out of every 10 minute period The remaining time 7 5 minutes the power source must be a...

Page 22: ...of the welding power source when operating in MMAW stick mode Note that the presence of VRD should not be used as a substitute for the use of appropriate safety practices as indicated in the SAFETY c...

Page 23: ...using the equipment After power on has completed the main menu appears on the control panel 6 1 How to navigate 1 Current Wire feed speed selection 2 Voltage selection 3 Menu navigation Rotate and pu...

Page 24: ...alogue box 6 1 4 Flux cored wire mode 1 Home screen 2 Information 3 Memory 4 Wire feed speed 5 Voltage 6 Dialogue box 6 1 5 MMA mode 1 Home screen 2 Information 3 Memory 4 Parameter 5 Amperage 6 Volta...

Page 25: ...fts position if the stick out during welding changes if the gas mix changes to some extent This duty cycle is adjustable by the Trim setting using the lower encoder when in Advanced Mode NOTE As sMIG...

Page 26: ...y achieve good weld results on up to 12 mm material 6 1 11 Icon reference guide Home Spot time on off selection Information MIG Torch Spot time on adjustment Parameters Flux cored Parameters Manual MI...

Page 27: ...uce or eliminate the freezing of the stick electrode in the weld puddle Trim bar Changing the weld bead profile from flat to convex or flat to concave Downslope Sloping the current down over a period...

Page 28: ...speed VRD ON indicator Voltage Reduction Device active Wire diameter VRD OFF indicator Voltage Reduction Device inactive 6 1 12 Lift TIG operation Touch the Tungsten Electrode to the work piece prior...

Page 29: ...awareness of the disconnected power connections when performing work Detect and prevent premature reconnection of the power NOTE Perform maintenance more often during severe dusty conditions Before ea...

Page 30: ...uide 4 outlet wire outlet 2 or the feeder roller 3 are worn and need replacement See appendix WEAR PARTS for ordering numbers of parts 6 Remove and clean the feeder roller with a soft brush Clean the...

Page 31: ...he tension from the pressure roller by turning the tension screw 1 counter clockwise and then pull it toward you 3 Remove the wire and the wire bobbin 4 Remove the torch from the power source 5 Remove...

Page 32: ...e correct pressure is set on the feed rollers Make sure the proper direction of motion is set based on the wire type into the weld pool for aluminium away from the weld pool for steel Make sure the co...

Page 33: ...meter The flow rate should be between 4 72 11 80 l min 1 25 3 12 gpm Make sure the power source is turned on and TIG welding process is selected Make sure all connections are tight and leak free See...

Page 34: ...ts The EMP 235ic is designed and tested in accordance with international standards IEC EN 60974 1 IEC EN 60974 5 and IEC EN 60974 10 It is the obligation of the authorized service centre carrying out...

Page 35: ...DIAGRAM 0463 641 001 35 ESAB AB 2018 DIAGRAM EMP 235ic...

Page 36: ...ORDERING NUMBERS 0463 641 001 36 ESAB AB 2018 ORDERING NUMBERS Ordering no Denomination Note 0700 303 880 EMP 235ic Bobbin 100 300 mm 4 12 in Euro Connector...

Page 37: ...102 457 Key drive shaft crescent N A N A 6 7977036 Feed roll V groove Fe SS 0 6 mm 0 8 mm 0 023 in 0 030 in 7977660 Feed roll V groove Fe SS 0 9 mm 1 2 mm 0 035 in 0 045 in 7977732 Feed roll V knurled...

Page 38: ...WEAR PARTS 0463 641 001 38 ESAB AB 2018...

Page 39: ...H 201 4 m 13 ft TIG torch c w 8 pin plug 0558 102 491 Rebel Single Cylinder Cart Accommodates maximum 228 6 mm 9 in diameter cylinder Rebel 215 and Rebel 235 brackets included W4014450 Foot control Co...

Page 40: ...62 Nozzle 16 mm 6 OTW14 23 Contact tip 0 6 mm OTW14 30 Contact tip 0 8 mm OTW14 35 Contact tip 0 9 mm OTW14 40 Contact tip 1 0 mm OTW14 45 Contact tip 1 2 mm 7 OTW32 Insulator 8 OTW52 Gas diffuser 9 6...

Page 41: ...REPLACEMENTS PARTS 0463 641 001 41 ESAB AB 2018...

Page 42: ...For contact information visit esab com ESAB AB Lindholmsall n 9 Box 8004 402 77 Gothenburg Sweden Phone 46 0 31 50 90 00 http manuals esab com...

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