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4 INSTALLATION

0463 641 001

- 12 -

© ESAB AB 2018

4

INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial 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 cooling air inlets and outlets are not obstructed.

A. 100 mm (4 in.)

B. 100 mm (4 in.)

4.2

Lifting instructions

The power source can be lifted using any of the handles.

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Содержание EMP235ic

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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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