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

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Rebel EMP 215ic
Instruction manual
Valid for: CD315-xxx-xxxx
0463 789 001   US   20230714

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Summary of Contents for ESAB Rebel EMP 215ic

  • Page 1 Rebel EMP 215ic Instruction manual Valid for: CD315-xxx-xxxx 0463 789 001   US   20230714...

  • Page 2: Table Of Contents

    6.1.7 LIFT-GTAW basic mode ................6.1.8 DC-PULSE GTAW Basic mode ......................6.1.9 Settings ......................6.1.10 Reset mode ....................... 6.1.11 User manual ................... 6.1.12 Icon reference guide ..................... LIFT GTAW welding 0463 789 001 - 2 - © ESAB AB 2023...
  • Page 3 User interface (UI) software displayed error codes ....................... ORDERING SPARE PARTS ......................MIG WELD PARAMETER CHART ..........................WIRING DIAGRAM ......................... ORDERING NUMBERS ............................WEAR PARTS ............................. ACCESSORIES ........................REPLACEMENTS PARTS 0463 789 001 - 3 - © ESAB AB 2023...

  • Page 4: Safety

    7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly for long distances. Bystanders should also wear goggles over safety glasses. 0463 789 001 - 4 - © ESAB AB 2023...
  • Page 5 ELECTRIC AND MAGNETIC FIELDS May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 0463 789 001 - 5 - © ESAB AB 2023...
  • Page 6 1. Keep all doors, panels, guards, and covers closed and securely in place. 2. Stop the engine or drive systems before installing or connecting a unit. 3. Have only qualified people remove covers for maintenance and troubleshooting as necessary 0463 789 001 - 6 - © ESAB AB 2023...
  • Page 7 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 789 001 - 7 - © ESAB AB 2023...

  • Page 8: User Responsibility

    1   SAFETY 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 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.
  • Page 9 • To handle hot parts, use proper tools and/or insulated welding gloves to prevent burns. MALFUNCTION - Call for expert assistance in the event of malfunction. PROTECT YOURSELF AND OTHERS! 0463 789 001 - 9 - © ESAB AB 2023...

  • Page 10: California Proposition 65 Warning

    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. California proposition 65 warning WARNING! Welding or cutting equipment produces fumes or gases which contain chemicals known in the State of California to cause birth defects and, in some cases, cancer.

  • Page 11: Introduction

    For more advanced users a number of functions could be introduced and customized to give maximum flexibility. Exclusive to ESAB, sMIG provides users with excellent short circuit transfer arc characteristics. The Rebel EMP 215ic family connects to 120 V – 230 V, 1 ~ 50/60 Hz input power supplies, supplied by mains or generator power.

  • Page 12: Technical Data

    130 A / 25.2 V Setting range (DC) 6 A / 20.6 V – 130 A / 25.2 V 16 A / 20.6 V – 180 A / 27.2 V Open circuit voltage (OCV) VRD deactivated 52 V 52 V 0463 789 001 - 12 - © ESAB AB 2023...
  • Page 13 Equipment marked IP23S is intended for indoor and outdoor use; however, it 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 789 001 - 13 - © ESAB AB 2023...

  • Page 14: Installation

    1. 4 in. (100 mm) 2. 4 in. (100 mm) Lifting instructions The power source can be lifted using any of the handles. Secure the equipment - particularly if the ground is uneven or sloping. 0463 789 001 - 14 - © ESAB AB 2023...

  • Page 15: Electrical Supply

    30 A 30 A *Time delay fuse UL class RK5, refer to UL 248 Maximum recommended fuse* or circuit breaker rating 50 A 50 A *Normal operating UL class K5, refer to UL 248 0463 789 001 - 15 - © ESAB AB 2023...

  • Page 16: Connecting The Power Source To Input Supply

    Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with 8 kW rated power, 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 789 001 - 16 - © ESAB AB 2023...

  • Page 17: Operation

    Rotating parts can cause injury, take great care. WARNING! Electric shock! Do not touch the workpiece or the welding head during operation! WARNING! Make sure that the side covers are closed during operation. 0463 789 001 - 17 - © ESAB AB 2023...

  • Page 18: Connections And Control Devices

    3. Main knob for menu navigation 9. Display 4. Torch/remote control connection 10. Gas inlet for GMAW 5. Torch connection 11. Main power switch ON/OFF 6. Negative output [-] 12. Main power cable 0463 789 001 - 18 - © ESAB AB 2023...

  • Page 19: Connecting Welding And Return Cables

    For GMAW process, the output to which the welding cable is connected depends on type of electrode (solid wire/flux cored). Solid wire - Connect the polarity changeover cable to positive OKC. Flux cored - Connect the polarity changeover cable to negative OKC. 0463 789 001 - 19 - © ESAB AB 2023...

  • Page 20: For Stick (Smaw) Process

    Check the recommended polarity for the welding wire you want to use. Refer to electrode packaging for information relating to the correct electrode polarity. The polarity can be changed by moving the polarity changeover cable to suit the applicable welding process. 0463 789 001 - 20 - © ESAB AB 2023...

  • Page 21: Spool Hub Assembly

    Risk of crushing or pinching when replacing the wire spool! Do not use safety gloves when inserting the welding wire between the feed rollers. NOTE! Make sure the correct feed/pressure rollers are used. For more information see "WEAR PARTS" chapter of this manual. 0463 789 001 - 21 - © ESAB AB 2023...

  • Page 22: Installing Wire

    9) Close the side cover. Wire-feed mechanism 5.5.2 Removing wire 1) Turn power to the unit OFF. 2) Cut off end of GMAW welding wire protruding from torch. 3) Open the side cover. 0463 789 001 - 22 - © ESAB AB 2023...

  • Page 23: Welding With Aluminum Wire

    Correct adjustment results in the wire reel circumference continuing no further than 1/8 in.-3/16 in. (3-5 mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool. 0463 789 001 - 23 - © ESAB AB 2023...

  • Page 24: Changing The Feed/Pressure Rollers

    The choice of suitable shielding gas depends on the material. Typically mild steel is welded with mixed gas (Ar + CO ) or 100% carbon dioxide (CO ). Stainless Steel can be welded with mixed gas (Ar + 0463 789 001 - 24 - © ESAB AB 2023...

  • Page 25: Volt-Ampere Curves

    Other settings result in curves that fall between these curves. A=Welding current, V=Output voltage SMAW (Stick) 120 V SMAW (Stick) 230 V GMAW (MIG) 120 V 0463 789 001 - 25 - © ESAB AB 2023...
  • Page 26 5   OPERATION GMAW (MIG) 230 V   GTAW (TIG) 120 V GTAW (TIG) 230 V   0463 789 001 - 26 - © ESAB AB 2023...

  • Page 27: Duty Cycle

    A different combination of duty cycle and welding current can be selected. Use the graphs below to determine the correct duty cycle for a given welding current. Duty cycle on 120 V AC Welding current (A)   0463 789 001 - 27 - © ESAB AB 2023...

  • Page 28: Overheating Protection

    When this occurs the welding current is interrupted and an overheating symbol appears in the display. The overheating protection resets automatically when the temperature has returned to normal working temperature. 0463 789 001 - 28 - © ESAB AB 2023...

  • Page 29: User Interface

    After power on has completed the main menu appears on the control panel. 1. Current / Wire feed speed adjustment 3. Menu navigation. Rotate and push to select menu option. 2. Voltage adjustment 4. Display - Home view 0463 789 001 - 29 - © ESAB AB 2023...

  • Page 30: Home Screen

    4. Stick mode 8. Dialogue box 6.1.2 sMIG mode basic 1. Home selection 4. Material selection 2. Information selection 5. Wire feed speed display 3. Memory selection 6. Dialogue box 0463 789 001 - 30 - © ESAB AB 2023...

  • Page 31: Manual Gmaw Basic Mode

    5. Parameter selection 6.1.3 Manual GMAW basic mode 1. Home selection 5. Wire feed speed display 2. Information selection 6. Voltage display 3. Memory selection 7. Dialogue box 4. Material selection 0463 789 001 - 31 - © ESAB AB 2023...

  • Page 32: Flux Cored Basic Mode

    4. Material selection 8. Dialogue box 6.1.4 Flux cored basic mode 1. Home selection 4. Wire feed speed display 2. Information selection 5. Voltage display 3. Memory selection 6. Dialogue box 0463 789 001 - 32 - © ESAB AB 2023...

  • Page 33: Flux Cored Advanced Mode

    7. Dialogue box 4. Parameter selection 6.1.6 Stick basic mode 1. Home selection 5. Voltage 2. Information selection 6. Dialogue box 3. Memory selection 7. OFF/ON mode indication 4. Amperage 0463 789 001 - 33 - © ESAB AB 2023...
  • Page 34 Also the background color indicates the output state, where blue indicates an "off" state and orange indicates an "on" state. 1. Home selection 5. Amperage display 2. Information selection 6. Voltage display 3. Memory selection 7. Dialogue box 4. Parameter selection 8. OFF/ON mode indication 0463 789 001 - 34 - © ESAB AB 2023...

  • Page 35: Lift-Gtaw Basic Mode

    6. Amperage display DC-GTAW advanced mode (EMP 215ic only) 1. Home selection 5. Parameter selection 2. Information selection 6. Amperage display 3. Memory selection 7. Dialogue box 4. Pulse selection 0463 789 001 - 35 - © ESAB AB 2023...

  • Page 36: Dc-Pulse Gtaw Basic Mode

    6. Amperage display DC-PULSE GTAW advanced mode 1. Home selection 5. Parameter selection 2. Information selection 6. Dialog Box 3. Memory selection 7. Amperage display 4. Pulse selection 8. Frequency display 0463 789 001 - 36 - © ESAB AB 2023...

  • Page 37: Settings

    6.1.10 Reset mode Weld data reset 1. Home selection 5. Imperial/Metric selection 2. Information selection 6. Reset mode 3. Language selection 7. Dialogue box 4. Basic/Advanced mode selection 8. Weld data reset 0463 789 001 - 37 - © ESAB AB 2023...

  • Page 38: 6.1.11 User Manual

    3. Language selection 7. Dialogue box 4. Basic/Advanced mode selection 8. Factory reset 6.1.11 User manual 1. Home selection 4. Maintenance 2. Settings 5. Dialogue box 3. Wear parts selection 0463 789 001 - 38 - © ESAB AB 2023...

  • Page 39: 6.1.12 Icon Reference Guide

    Post-flow The time the Cancel shielding gas stays on after the welding arc is stopped Seconds Saving welding programs for a specific application when in the Memory Mode 0463 789 001 - 39 - © ESAB AB 2023...
  • Page 40 Arc dynamics Preflow/Postflow The addition of inductance into the arc characteristics to stabilize the arc and reduce spatter when in the short circuit process 0463 789 001 - 40 - © ESAB AB 2023...
  • Page 41 Volts Bead profile, convex Wire feed speed Wire diameter Manual GMAW Dual Current Lift Arc Pulse ON/OFF Amin Retrieve Erase DC GTAW AC GTAW 0463 789 001 - 41 - © ESAB AB 2023...
  • Page 42 6   USER INTERFACE ICON MEANING ICON MEANING Peak Time Balance Smart GMAW Wire feed speed Wire diameter (sMIG Material thickness mode only) (sMIG mode only) Frequency (Hz) PEAK time Background current Settings 0463 789 001 - 42 - © ESAB AB 2023...

  • Page 43: Lift Gtaw Welding

    In basic mode DC GTAW pulse has default settings as Background current = 50%, Peak Time = 50%, PPS = 2. User must be in advance mode to adjust these parameters. Below illustration shows the navigation/setup of DC GTAW pulse in basic mode (A-B-C-D). 0463 789 001 - 43 - © ESAB AB 2023...
  • Page 44 Frequency can be adjusted by the Lower control knob. Range can be adjusted between 0.1 and 500. Below illustration shows the navigation/setup of DC GTAW pulse in advanced mode (A-B-C-D-E-F-G-H-I-J). 0463 789 001 - 44 - © ESAB AB 2023...
  • Page 45 6   USER INTERFACE Below illustration shows an example of DC GTAW pulse output current default waveforms in basic and recommended waveform in advanced modes. 0463 789 001 - 45 - © ESAB AB 2023...
  • Page 46 75% then, Peak current = 75 A, Background current = 37 A Below illustration shows the above example in terms of output current waveforms in basic mode. 0463 789 001 - 46 - © ESAB AB 2023...
  • Page 47 6   USER INTERFACE Basic mode welding state with remote set to maximum Basic mode welding state with remote set to 50% 0463 789 001 - 47 - © ESAB AB 2023...
  • Page 48 Peak current = 75 A, Background current = 60 A Below illustration shows the above example in terms of output current waveforms in advanced mode. 0463 789 001 - 48 - © ESAB AB 2023...
  • Page 49 6   USER INTERFACE Advanced mode welding state with remote set to maximum Advanced mode welding state with remote set to 50% 0463 789 001 - 49 - © ESAB AB 2023...
  • Page 50 6   USER INTERFACE Advanced mode welding state with remote set to 75% 0463 789 001 - 50 - © ESAB AB 2023...

  • Page 51: Maintenance

    WARNING! The mains supply must be disconnected during cleaning and maintenance. CAUTION! Repair and electrical work should be performed by an authorized ESAB service technician. Use only ESAB original spare and wear parts. CAUTION! All warranty undertakings from the supplier cease to apply if the customer attempts any work to rectify any faults in the product during the warranty period.

  • Page 52: Wire-Feeder Assembly Maintenance

    5. Use (as needed) either soft-bristle brush or a forced air source by blowing compressed air (max. 5 bar) to remove all debris which may have accumulated in this space. WEAR EYE PROTECTION. 0463 789 001 - 52 - © ESAB AB 2023...

  • Page 53: Power Side Maintenance

    Because of the electro-static sensitive components and exposed circuit boards any maintenance on this side should be done by an authorized ESAB service technician. Torch liner maintenance Refer to GMAW gun instruction manual for replacing standard steel torch conduit liner with a Teflon torch conduit liner.

  • Page 54: Troubleshooting

    Preliminary checks Try these checks and inspections before sending for an authorized service technician. Before attempting to troubleshoot the ESAB Rebel it is recommended to first perform a WELD DATA RESET (navigate to HOME/SETTING/RESET/WELD DATA RESET). A WELD DATA RESET of the system will restore the unit to its default welding condition.

  • Page 55: User Interface (Ui) Software Displayed Error Codes

    Critical - If occurred at power-up under no-load condition. DC bus (400 V) fault droop under load, PFC not supplying 400 V to inverter. Output voltage is above VRD levels when VRD switch is active. IPS voltage is low 0463 789 001 - 55 - © ESAB AB 2023...
  • Page 56 The image read from the flash is corrupted Failed two attempts of saving user memory to permanent memory in SPI flash. Failed two attempts of recovering user memory permanent memory from SPI flash. Control firmware error 0463 789 001 - 56 - © ESAB AB 2023...

  • Page 57: Ordering Spare Parts

    Spare parts and wear parts can be ordered through your nearest ESAB dealer, see the back cover of this document. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.

  • Page 58: Mig Weld Parameter Chart

    APPENDIX APPENDIX MIG WELD PARAMETER CHART 0463 789 001 - 58 - © ESAB AB 2023...

  • Page 59: Wiring Diagram

    APPENDIX WIRING DIAGRAM 0463 789 001 - 59 - © ESAB AB 2023...

  • Page 60: Ordering Numbers

    APPENDIX ORDERING NUMBERS Ordering number Denomination Notes 0558 102 240 Rebel EMP 215ic Full Package Spool Ø4–8 in. (100–200 mm), CSA/Bayonet 0463 789 * Instruction manual 0463 791 001 Spare parts list The three last digits in the document number of the manual show the version of the manual. Therefore they are replaced with * here.

  • Page 61: Wear Parts

    0558 102 329 Locking knob (Wire tension) 0558 102 518 Feed roller retaining knob 0558 102 331 Pressure arm complete assembly 0558 102 330 Screw 0558 102 333 MIG gun locking knob 0463 789 001 - 61 - © ESAB AB 2023...
  • Page 62 APPENDIX 0463 789 001 - 62 - © ESAB AB 2023...

  • Page 63: Accessories

    Dual cylinder cart Accommodates maximum 9 in. diameter cylinder with accessory drawer plus 1 parts storage box. W4014000 Foot control Contactor on/off andcurrent control with 15 ft. (4.5 m) cable and 8-pin male plug. 0463 789 001 - 63 - © ESAB AB 2023...

  • Page 64: Replacements Parts

    0558 102 749 Tweco® 200 A ground clamp and lead assembly, 10 ft (3 m), 50 mm dinse 0781-2743 Victor CutSkill Flow Meter HRF 1425 Argon/CO2 CGA 580 10ft W4014000 Power adapter (230 V – 120 V, 15 A) 0463 789 001 - 64 - © ESAB AB 2023...
  • Page 65 APPENDIX 0463 789 001 - 65 - © ESAB AB 2023...
  • Page 66 For contact information visit http://esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...

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