ESAB EM 215ic Instruction Manual
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ESAB EM 215ic Instruction Manual

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EMP 215ic, EM 215ic
Instruction manual
Valid for: serial no. EMP: 615-xxx-xxxx, EM: 627-xxx-xxxx
0463 408 001 GB 20170228

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Summary of Contents for ESAB EM 215ic

  • Page 1 EMP 215ic, EM 215ic Instruction manual Valid for: serial no. EMP: 615-xxx-xxxx, EM: 627-xxx-xxxx 0463 408 001 GB 20170228...

  • Page 3: Table Of Contents

    6.1.7 Settings ....................6.1.8 User manual information ................ 6.1.9 Icon reference guide................How to navigate - EM 215ic ..............6.2.1 Symbol reference EM 215ic ..............MAINTENANCE ..................... 30 Routine maintenance ................Power source and wire feeder maintenance ......... Torch and liner maintenance..............
  • Page 4 TABLE OF CONTENTS ORDERING NUMBERS ..................WEAR PARTS....................... ACCESSORIES ....................REPLACEMENTS PARTS..................Rights reserved to alter specifications without notice. 0463 408 001 © ESAB AB 2017...

  • Page 5: Safety

    Data Sheets (SDSs). Safety precautions 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 6 • Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. • Protect bystanders with suitable screens or curtains. NOISE - Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection. 0463 408 001 - 6 - © ESAB AB 2017...
  • Page 7 For further information contact the nearest ESAB dealer. 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 408 001 - 7 -...

  • Page 8: Introduction

    The ESAB EM and EMP product family is a new generation of MIG and Multi-Process (MIG/MMA/TIG) welding power sources. The EMP 215ic and EM 215ic power sources are designed to match the needs of the light-medium fabrication user. They are tough, durable and portable, providing excellent arc performance across a variety of welding applications.
  • Page 9 2 INTRODUCTION EM series • ESAB EM 215ic power source • ESAB MXL 200 MIG torch, 3 m (10 ft) • Contact tip M6 for 0.8 mm (0.030 in.) wire (qty 2) • Contact tip M6 for 1.0 mm (0.040 in.) wire (qty 2) • Gas hose, 4.5 m (14.8 ft), Quick connector •...

  • Page 10: Technical Data

    16 A / 20.6 V – 180 A / 27.2 V 16 A / 20.6 V – 110 A / 24.4 V Open circuit voltage (OCV) VRD deactivated, nominal 68 V / (90 V) 68 V / (90 V) OCV (Boost OCV) Efficiency Power factor 0.98 0.99 0463 408 001 - 10 - © ESAB AB 2017...
  • Page 11 68 V 68 V VRD activated 35 V 35 V Efficiency Power factor 0.98 0.99 Wire feed speed 2–12.1 m/min 2–12.1 m/min (80–475 in./min) (80–475 in./min) Wire diameter Mild steel solid wire 0.6–0.9 mm (0.023–0.035 in.) 0.6–0.9 mm (0.023–0.035 in.) 0463 408 001 - 11 - © ESAB AB 2017...
  • Page 12 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 408 001 - 12 - © ESAB AB 2017...

  • Page 13: Installation

    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.) Lifting instructions The power source can be lifted using any of the handles. 0463 408 001 - 13 - © ESAB AB 2017...

  • Page 14: Mains Supply

    Disconnect input power and secure employing ‘Lock-out’ / ‘Tagging’ procedures. Ensure input power line disconnect switch is locked (lock-out/Tagging) in the ‘Open’ position BEFORE removing input power fuses. Connection/Disconnect should be carried out by competent persons. 0463 408 001 - 14 - © ESAB AB 2017...

  • Page 15: Recommended Fuse Sizes And Minimum Cable Area

    Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power 8 kW, are recommended. 0463 408 001 - 15 - © ESAB AB 2017...

  • Page 16: 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. 100 mm (4 in.) 200 mm (8 in.)   0463 408 001 - 16 - © ESAB AB 2017...

  • Page 17: 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 408 001 - 17 - © ESAB AB 2017...

  • Page 18: Connection Of Welding And Return Cables

    The polarity can be changed by moving the polarity changeover cable to suit the applicable welding process. Inserting and replacing wire The EMP 215ic and EM 215ic will handle bobbin sizes of 100 mm (4 in.) and 200 mm (8 in.). See TECHNICAL DATA chapter for suitable wire dimensions for each wire type. 0463 408 001 - 18 - ©...
  • Page 19 Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure if necessary. With the MIG torch lead reasonably straight, feed the wire through the MIG torch by depressing the trigger switch. Close the side cover. 0463 408 001 - 19 - © ESAB AB 2017...

  • Page 20: Setting The Wire Feed Pressure

    One dual groove feed roller is 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 slot for proper operation. 0463 408 001 - 20 - © ESAB AB 2017...

  • Page 21: 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 408 001 - 21 - © ESAB AB 2017...

  • Page 22: Duty Cycle

    5 OPERATION Duty cycle The EMP 215ic and EM 215ic 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 minutes out of every 10 minute period.

  • Page 23: Overheating Protection

    When this occurs the welding current is interrupted and an overheating symbol appears on the display. The overheating protection resets automatically when the temperature has returned to normal working temperature. 0463 408 001 - 23 - © ESAB AB 2017...

  • Page 24: Control Panel

    Flux cored wire mode MMA mode Lift-TIG mode Settings User manual information Dialogue box 6.1.2 sMIG mode Home screen Information Memory MIG/Spool gun Selection Wire feed speed Material thickness Dialogue box 0463 408 001 - 24 - © ESAB AB 2017...

  • Page 25: Manual Mig Mode

    Wire feed speed Voltage Dialogue box 6.1.5 MMA mode Home screen Information Memory Parameter Amperage Voltage (OCV or Arc) Dialogue box 6.1.6 LIFT-TIG mode Home screen Information Memory Parameter Amperage Dialogue box 0463 408 001 - 25 - © ESAB AB 2017...

  • Page 26: Settings

    Wear & Spare parts Operation information Home screen Dialogue box 6.1.9 Icon reference guide Home Spot time on/off selection Information MIG Torch Spot time on adjustment Parameters Flux cored Parameters Manual MIG Percent 0463 408 001 - 26 - © ESAB AB 2017...
  • Page 27 Downslope Sloping the current down over a period Advanced Settings of time at the end of the weld cycle 0463 408 001 - 27 - © ESAB AB 2017...
  • Page 28 Unit of Measure Upslope, Sloping the current up over a period of Bead profile, concave time at the beginning of the weld cycle Volts Bead profile, convex Wire feed speed Wire diameter 0463 408 001 - 28 - © ESAB AB 2017...

  • Page 29: How To Navigate - Em 215Ic

    6 CONTROL PANEL How to navigate - EM 215ic Over temperature indication: Symbol illuminates when product is overheated. Volt/Amp display: LED displays the Volts and Amps values during welding. It holds the last used parameter. In sMIG "V" displays the wire diameter while idle "A"...

  • Page 30: Maintenance

    Every 6 month Clean inside equipment. Power source and wire feeder maintenance Perform a power source cleaning each time you replace a Ø100 mm (4 in.) or Ø200 mm (8 in.) wire bobbin. 0463 408 001 - 30 - © ESAB AB 2017...

  • Page 31: 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 408 001 - 31 - © ESAB AB 2017...

  • Page 32: Troubleshooting

    • Make sure the work clamp has proper contact with the work piece. • Make sure the gas valve on the TIG torch is on. 0463 408 001 - 32 - © ESAB AB 2017...
  • Page 33 See section "Duty cycle" in the OPERATION chapter. • Make sure the air inlets or outlets are not clogged. 0463 408 001 - 33 - © ESAB AB 2017...

  • Page 34: Ordering Spare Parts

    Repair and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. The EMP 215ic and EM 215ic are designed and tested in accordance with international standards IEC-/EN 60974-1, IEC-/EN 60974-5, IEC-/EN 60974-7, IEC-/EN 60974-10, IEC-/EN 60974-12 and IEC-/EN 60974-13.

  • Page 35: Diagram

    DIAGRAM DIAGRAM EMP 215ic, EM 215ic 0463 408 001 - 35 - © ESAB AB 2017...

  • Page 36: Ordering Numbers

    Bobbin Ø100–200 mm (4–8 in.) CE, euro connection 0700 300 986 EM 215ic Bobbin Ø100–200 mm (4–8 in.) CE, euro connection 0463 412 001 Spare parts list 0459 560 101 Instruction manual for MXL™ 200 0463 408 001 - 36 - © ESAB AB 2017...

  • Page 37: Wear Parts

    0367 556 004 Feed roll "U" groove Aluminium 1.0 mm / 1.2 mm (0.040 in. / 0.045 in.) 0558 102 329 Locking knob 0558 102 331 Pressure arm complete assembly 0558 102 330 Screw 0558 102 459 Euro adapter locating screw 0463 408 001 - 37 - © ESAB AB 2017...
  • Page 38 WEAR PARTS 0463 408 001 - 38 - © ESAB AB 2017...

  • Page 39: Accessories

    0700 200 004 MIG Torch MXL™ 270 3 m (for FCW 1.2 mm) 0459 366 887 Trolley W4014450 Foot control Contactor on/off and current control with 4.6 m (15 ft) cable and 8-pin male plug 0463 408 001 - 39 - © ESAB AB 2017...

  • Page 40: Replacements Parts

    MIG Torch MXL™ 200, 3 m (10 ft) 0349 312 105 Gas hose, 4.5 m (14.8 ft) 0700 006 900 MMA welding cable kit, 3 m (10 ft) 0700 006 901 Return welding cable kit, 3 m (10 ft) 0463 408 001 - 40 - © ESAB AB 2017...
  • Page 41 REPLACEMENTS PARTS 0463 408 001 - 41 - © ESAB AB 2017...
  • Page 42 ESAB subsidiaries and representative offices Europe THE NETHERLANDS North and South America SOUTH KOREA ESAB Nederland B.V. ESAB SeAH Corporation AUSTRIA Amersfoort ARGENTINA Kyungnam ESAB Ges.m.b.H Tel: +31 33 422 35 55 CONARCO Tel: +82 55 269 8170 Vienna-Liesing Fax: +31 33 422 35 44...

This manual is also suitable for:

Emp 215ic

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