ESAB EMP 215ic Instruction Manual
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ESAB EMP 215ic Instruction Manual

Arc welding equipment
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See also: Service Manual
EMP 215ic, EMS 215ic, EM 215ic
Instruction manual
Valid for: serial no. EMP215ic: 552-xxx-xxxx,
EMS215ic: 612-xxx-xxxx, EM215ic: 623-xxx-xxxx
0463 407 001 GB 20170123

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Summary of Contents for ESAB EMP 215ic

  • Page 1 EMP 215ic, EMS 215ic, EM 215ic Instruction manual Valid for: serial no. EMP215ic: 552-xxx-xxxx, EMS215ic: 612-xxx-xxxx, EM215ic: 623-xxx-xxxx 0463 407 001 GB 20170123...

  • Page 2: Table Of Contents

    ..................... 6.1.3 Manual MIG mode .................. 6.1.4 Flux cored wire mode ................6.1.5 Stick mode....................6.1.6 LIFT-TIG mode (EMP 215ic only)............6.1.7 Settings ....................6.1.8 User manual information ................ 6.1.9 Icon reference guide................How to navigate - EM 215ic ..............
  • Page 3 ORDERING SPARE PARTS ................41 MIG WELD PARAMETER CHART ............... FRACTION TO DECIMAL CONVERSION ............DIAGRAM ......................ORDERING NUMBERS ..................WEAR PARTS....................... ACCESSORIES ....................REPLACEMENTS PARTS..................Rights reserved to alter specifications without notice. 0463 407 001 © ESAB AB 2017...

  • Page 4: Safety Precautions

    Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal. 0463 407 001 - 4 - © ESAB AB 2017...
  • Page 5 Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. Use well-maintained equipment. Replace worn or damaged cables. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source. 0463 407 001 - 5 - © ESAB AB 2017...
  • Page 6 Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated hydrocarbon vapors or liquids to form phosgene, a highly toxic gas and other irritant gases. 0463 407 001 - 6 - © ESAB AB 2017...
  • Page 7 Keep hands, hair, loose clothing and tools away from moving parts. Do not use gloves near moving parts. Reinstall panels or covers and close doors when service is finished and before starting engine. 0463 407 001 - 7 - © ESAB AB 2017...
  • Page 8 NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot Work" CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders” ANSI Z87.1, "Occupational and Educational Personal Eye and Face Protection Devices" 0463 407 001 - 8 - © ESAB AB 2017...

  • Page 9: User Responsibility

    1 SAFETY PRECAUTIONS User responsibility Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet or exceed the standard requirements that apply to this type of equipment.
  • Page 10 CAUTION! This product is solely intended for arc welding. ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website. 0463 407 001 - 10 -...

  • Page 11: Introduction

    Stick & Lift-TIG (EMP) MIG & Stick (EMS) and MIG only (EM) welding power sources. The EMP 215ic, EMS 215ic and EM 215ic power sources are designed to match the needs of the user. They are tough, durable and portable, providing excellent arc performance across a variety of welding applications.

  • Page 12: Equipment

    Package consists of the following: EMP series • ESAB EMP 215ic power source • Tweco Fusion™ 180 Amp MIG torch w/10 ft (3 m) cable / Tweco® pigtail w/(qty 1 ea contact tip .023" (0.6 mm), .030" (0.8 mm), .035" (0.9 mm) w/Operator manual all in one bag •...
  • Page 13 2 INTRODUCTION EM series • ESAB EM 215ic power source • Tweco Fusion™ 180 Amp MIG torch w/10 ft (3 m) cable / Tweco® pigtail w/(qty 1 ea contact tip .023 in. (0.6 mm), .030 in. (0.8 mm), .035 in. (0.9 mm) w/Operator manual all in one bag •...

  • Page 14: Technical Data

    16 A / 20.6 V - 180 A / 27.2 V 16 A / 20.6 V - 130 A / 25.2 V Open circuit voltage (OCV) VRD deactivated 68 V 68 V VRD activated 35 V 35 V Efficiency Power factor 0.98 0.99 0463 407 001 - 14 - © ESAB AB 2017...
  • Page 15 100% duty cycle 100 A / 24 V 65 A / 22.6 V 60% duty cycle 125 A / 25 V 80 A / 23.2 V 40% duty cycle 85 A / 23.4 V 0463 407 001 - 15 - © ESAB AB 2017...
  • Page 16 205 A / 24.25 V 20% duty cycle Breaker 20 A: 130 A / 20.5 V Setting range (DC) 15 A / 14.75 V - 15 A / 14.75 V - 235 A / 26.0 V 130 A / 20.5 V 0463 407 001 - 16 - © ESAB AB 2017...
  • Page 17 Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be operated in precipitation. Application class The symbol indicates that the power source is designed for use in areas with increased electrical hazard. 0463 407 001 - 17 - © ESAB AB 2017...

  • Page 18: Installation

    Position the power source so that its cooling air inlets and outlets are not obstructed. A. 4” (100 mm) B. 4” (100 mm) Lifting instructions The power source can be lifted using any of the handles. 0463 407 001 - 18 - © ESAB AB 2017...

  • Page 19: Mains Supply

    An electrical shock or fire hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. 0463 407 001 - 19 - © ESAB AB 2017...

  • Page 20: Connecting The Power Source To Input Supply

    8 kW, are recommended. 4.3.2 Connecting the power source to input supply Use one of the supplied adapters to connect the power source to mains. 0463 407 001 - 20 - © ESAB AB 2017...

  • Page 21: Operation

    Assure that the side covers are closed during operation. WARNING! Tighten the bobbin locking nut in order to prevent it from sliding off the hub. 4” (100 mm) 8” (200 mm)   0463 407 001 - 21 - © ESAB AB 2017...

  • Page 22: Connections

    Knob for voltage selection (EM) Negative output [-] Display - Volt/Ampere (EM) Polarity changeover cable Knob for plate thickness or wire feed speed (EM) Positive output [+] Knob for process selection (EM) 0463 407 001 - 22 - © ESAB AB 2017...

  • Page 23: Connection Of Welding And Return Cables

    Inserting and replacing wire EMS 215ic, EMP 215ic and EM 215ic will handle bobbin sizes of 4” (100 mm) and 8” (200 mm). See TECHNICAL DATA chapter for suitable wire dimensions for each wire type. 0463 407 001 - 23 - ©...
  • Page 24 With the MIG torch lead reasonably straight, feed the wire through the MIG torch by depressing the trigger switch. Fit the appropriate velocity nozzle and contact tip. Close the side cover. 0463 407 001 - 24 - © ESAB AB 2017...

  • Page 25: Setting The Wire Feed Pressure

    Three dual groove feed rollers are supplied as standard. Change the feed roller to match the filler metal. NOTE! Be sure not to lose the key that is located on the drive motor shaft. This key must align with drive roll groove for proper operation. 0463 407 001 - 25 - © ESAB AB 2017...

  • Page 26: Shielding Gas

    ). Aluminium and silicon bronze use pure argon gas (Ar). In the sMIG mode (see section "sMIG mode" in the CONTROL PANEL chapter) the optimal welding arc with the gas you use will be automatically set. 0463 407 001 - 26 - © ESAB AB 2017...

  • Page 27: Volt-Ampere Curves

    Other settings result in curves that fall between these curves. A=Welding current (AMPS), V=Output voltage SMAW (Stick) 230 V   SMAW (Stick) 120 V   GMAW (MIG) 230 V   0463 407 001 - 27 - © ESAB AB 2017...
  • Page 28 5 OPERATION GMAW (MIG) 120 V   GTAW (TIG) 230 V   GTAW (TIG) 120 V   0463 407 001 - 28 - © ESAB AB 2017...

  • Page 29: Duty Cycle

    5 OPERATION Duty cycle The EMS 215ic, EMP 215ic and EM215ic all have a welding current output of 205 A at 25% duty cycle (230 V). A self-resetting thermostat will protect the power source if the duty cycle is exceeded. Example: If the power source operates at a 25% duty cycle, it will provide the rated amperage for a maximum of 2.5 minute out of every 10 minute period.

  • Page 30: Overheating Protection

    (EMP and EMS), or the overtemperature indicator is illuminated (EM). The overheating protection resets automatically when the temperature has returned to normal working temperature. 0463 407 001 - 30 - © ESAB AB 2017...

  • Page 31: Control Panel

    Flux cored wire mode Stick/MMA mode Lift-TIG mode Settings User manual information Dialogue box EMS 215ic sMIG mode Manual MIG mode Flux cored wire mode Stick/MMA mode Settings User manual information Dialogue box 0463 407 001 - 31 - © ESAB AB 2017...

  • Page 32: Smig Mode

    Home screen Information Memory MIG/Spool gun selection Parameter Wire feed speed Voltage Dialogue box 6.1.4 Flux cored wire mode Home screen Information Memory Parameter Wire feed speed Voltage Dialogue box 0463 407 001 - 32 - © ESAB AB 2017...

  • Page 33: Stick Mode

    The user must select the ON position to have output voltage and weld current. Also the background color indicates output state where blue indicates "off" state and orange indicates "on" state. 6.1.6 LIFT-TIG mode (EMP 215ic only) Home screen Information Memory Parameter Amperage Dialogue box 6.1.7...

  • Page 34: User Manual Information

    Postflow The time the shielding gas stays on after Cancel the welding arc is stopped Saving welding programs for Seconds a specific application when in the Memory Mode 0463 407 001 - 34 - © ESAB AB 2017...
  • Page 35 Diagnostics the arc and reduce spatter when in the short circuit process Memory, able to save welding programs for a Language selection specific application Stick electrode choice Unit of Measure 0463 407 001 - 35 - © ESAB AB 2017...

  • Page 36: How To Navigate - Em 215Ic

    Process selection knob: Enables selection between sMIG mode (left, in yellow) and manual MIG mode (right, in white). 6.2.1 Symbol reference EM 215ic Overtemperature Volts (manual MIG mode only) Spool Gun Amps 0463 407 001 - 36 - © ESAB AB 2017...
  • Page 37 6 CONTROL PANEL Smart MIG Wire feed speed Wire diameter (sMIG mode Thickness gauge (sMIG only) mode only) Manual MIG 0463 407 001 - 37 - © ESAB AB 2017...

  • Page 38: Maintenance

    Every 6 month Clean inside equipment. Power source and wire feeder maintenance Perform a power source cleaning each time you replace a Ø4” (100 mm) or Ø8” (200 mm) wire bobbin. 0463 407 001 - 38 - © ESAB AB 2017...

  • Page 39: Torch And Liner Maintenance

    Remove the liner from the torch and inspect it. Clean the liner by blowing compressed air (max 5 bar) through the end of the liner that was mounted closest to the power source. Re-install the liner. 0463 407 001 - 39 - © ESAB AB 2017...

  • Page 40: Troubleshooting

    See section "Duty cycle" in the OPERATION chapter. • Make sure the air inlets or outlets are not clogged. 0463 407 001 - 40 - © ESAB AB 2017...

  • Page 41: 0463 407 001 © Esab Ab 2017

    Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. The EM 215ic, EMS 215ic, and EMP 215ic are designed and tested in accordance with international standards IEC 60974-1, IEC 60974-5, Canadian and US standards CAN/CSA-E60974-1:12 and US standards ANSI/IEC 60974-1:2008.

  • Page 42: Mig Weld Parameter Chart

    Wire speed E71T-11 .035" 11 .030" required display (0.9 mm) (0.8 mm) Voltage display Inductance display Aluminum E4043 100% Ar Wire speed Use spool .035" display gun. (0.9 mm) Voltage 14.5 15.5 display Inductance display 0463 407 001 - 42 - © ESAB AB 2017...

  • Page 43: Mig Weld Parameter Chart

    11 .030" required display (0.8 mm) Voltage 17.5 display Inductance display Aluminum E4043 100% Ar Wire speed Use spool .035" display gun. (0.9 mm) Voltage 14.5 15.5 display Inductance 35% 35% 35% display 0463 407 001 - 43 - © ESAB AB 2017...

  • Page 44: Fraction To Decimal Conversion

    FRACTION TO DECIMAL CONVERSION FRACTION TO DECIMAL CONVERSION 0463 407 001 - 44 - © ESAB AB 2017...

  • Page 45: Diagram

    DIAGRAM DIAGRAM EM 215ic, EMS 215ic, EMP 215ic 0463 407 001 - 45 - © ESAB AB 2017...

  • Page 46: Ordering Numbers

    Bobbin Ø4-8" (100-200 mm). CSA/Bayonet 0558 102 240 EMP 215ic Bobbin Ø4-8" (100-200 mm). CSA/Bayonet 0558 102 436 EM 215ic Bobbin Ø4-8" (100-200 mm). CSA/Bayonet 0463 412 001 Spare parts list 0463 407 001 - 46 - © ESAB AB 2017...

  • Page 47: Wear Parts

    Feed roll "V" Flux Cored 0.045" (1.1 mm) knurled 0558 102 329 Locking knob 0558 102 331 Pressure arm complete assembly 0558 102 330 Screw 0558 102 332 MIG gun locking knob 0463 407 001 - 47 - © ESAB AB 2017...

  • Page 48: Wear Parts

    WEAR PARTS 0463 407 001 - 48 - © ESAB AB 2017...

  • Page 49: Accessories

    Single Cylinder Cart Accommodates maximum 9" diameter cylinder with accessory drawer plus 1 parts storage box W4014000 Foot control Contactor on/off and current control with 15 ft (4.6 m) cable and 8-pin male plug 0463 407 001 - 49 - © ESAB AB 2017...

  • Page 50: Replacements Parts

    Tweco® 200 Amp ground clamp & lead assembly, 10 ft (3 m), WS200G10 50 mm dinse 0781-9411 Victor® GF-250-50-580 argon flowgauge regulator W4013900 Gas hose, 12.5 ft (3.8 m) Male 5/8-18UNF W4014000 Power adapter (230 V to 120 V, 15 A) 0463 407 001 - 50 - © ESAB AB 2017...

  • Page 51: Replacements Parts

    REPLACEMENTS PARTS 0463 407 001 - 51 - © ESAB AB 2017...
  • Page 52 ESAB subsidiaries and representative offices Europe THE NETHERLANDS North and South America SOUTH KOREA ESAB Nederland B.V. ESAB SeAH Corporation Amersfoort Kyungnam AUSTRIA ARGENTINA Tel: +31 33 422 35 55 Tel: +82 55 269 8170 ESAB Ges.m.b.H CONARCO Vienna-Liesing Fax: +31 33 422 35 44...

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Ems 215icEm 215ic

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