ESAB EMP 235ic Instruction Manual
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ESAB EMP 235ic Instruction Manual

Multi-process welding inverter
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EMP 235ic
Multi-Process Welding Inverter
Instruction manual
Valid for: serial no. 821-xxx-xxxx
0463 641 001 GB 20181220

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Summary of Contents for ESAB EMP 235ic

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

  • Page 3: Table Of Contents

    Why is sMIG limited to 6 mm plate? ............. 6.1.11 Icon reference guide................6.1.12 Lift TIG operation.................. MAINTENANCE ..................Routine maintenance ................Power source and wire feeder maintenance ........VRD periodic tests ................. 0463 641 001 © ESAB AB 2018...
  • Page 4 Torch and liner maintenance..............TROUBLESHOOTING ................. ORDERING SPARE PARTS ................ DIAGRAM ......................ORDERING NUMBERS ..................36 WEAR PARTS ..................... ACCESSORIES ....................39 REPLACEMENTS PARTS .................. 40 Rights reserved to alter specifications without notice. 0463 641 001 © ESAB AB 2018...

  • Page 5: Safety

    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 641 001 - 6 - © ESAB AB 2018...
  • 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 641 001 - 7 - ©...

  • Page 8: Introduction

    The ESAB EMP product family is a new generation of MIG and Multi-Process (MIG/MMA/TIG) welding power sources. The EMP 235ic power source is designed to match the needs of the light-medium fabrication user. It is tough, durable and portable, providing excellent arc performance across a variety of welding applications.

  • Page 9: Technical Data

    3 TECHNICAL DATA TECHNICAL DATA EMP 235ic, 230 V Voltage 230 V, 1~ 50/60 Hz Primary current GMAW - MIG 32.1 A max. GTAW - TIG 24.9 A max. SMAW - MMA 31.2 A max. GMAW - MIG 14.6 A eff.
  • Page 10 3 TECHNICAL DATA EMP 235ic, 230 V Dimensions l×w×h 686 × 292 × 495 mm (27.0 × 11.5 × 19.5 in.) Weight 28.6 kg (63 lb) Operating temperature -10 to +40 °C (+14 to +104 °F) Enclosure class IP23S Application classification EMP 235ic, 120 V Voltage 120 V, 1~ 50/60 Hz Primary current GMAW - MIG Breaker 20 A: 28.6 A...
  • Page 11 3 TECHNICAL DATA EMP 235ic, 120 V VRD deactivated, nominal OCV (Boost OCV) 68 V / (90 V) Efficiency Power factor 0.99 Wire feed speed 2.0–17.8 m/min (80–700 in./min) Wire diameter Mild steel solid wire 0.6–1.0 mm (0.023–0.040 in.) Stainless steel solid wire 0.9–1.0 mm (0.035–0.040 in.)

  • Page 12: 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 641 001 - 12 - © ESAB AB 2018...

  • Page 13: Mains Supply

    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. Rating plate with supply connection data 0463 641 001 - 13 - © ESAB AB 2018...

  • Page 14: 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 641 001 - 14 - © ESAB AB 2018...

  • Page 15: Operation

    Assure that the side panels 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.), 300 mm (12 in.) 0463 641 001 - 15 - © ESAB AB 2018...

  • Page 16: Connections

    Main knob for menu navigation Mains cable Gas outlet, optional: TIG torch Mains supply switch ON/OFF Torch/Remote/Spool Gun connection Gas inlet, optional: TIG torch Negative output [-] Gas inlet for MIG/MAG/Spool Gun 0463 641 001 - 16 - © ESAB AB 2018...

  • Page 17: Connection Of Welding And Return Cables

    Check the recommended polarity for the welding wire you want to use. The polarity can be changed by moving the polarity changeover cable to suit the applicable welding process. 0463 641 001 - 17 - © ESAB AB 2018...

  • Page 18: Inserting And Replacing Wire

    5 OPERATION Inserting and replacing wire The EMP 235ic will handle bobbin sizes of 100 mm (4 in.), 200 mm (8 in.) and 300 mm (12 in.). See TECHNICAL DATA chapter for suitable wire dimensions for each wire type. WARNING! Do not place or point the torch near the face, hand or body as this may result in personal injury.

  • Page 19: Setting The Wire Feed Pressure

    (illustration A), the feed rollers should slip. If you hold the welding torch approximately 50 mm (2 in.) from the piece of wood, the wire should be fed out and bend (Illustration B). 0463 641 001 - 19 - © ESAB AB 2018...

  • Page 20: Changing The Feed/Pressure Rollers

    ). Aluminium and silicon bronze use pure argon gas (Ar). In the sMIG mode (see section "sMIG mode" in the USER INTERFACE chapter), the optimal welding arc with the gas used will be automatically set. 0463 641 001 - 20 - © ESAB AB 2018...

  • Page 21: Duty Cycle

    5 OPERATION Duty cycle The EMP 235ic has a welding current output of 235 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 22: Overheating Protection

    The red VRD OFF light illuminates (green light is off) when the VRD is inactive. Under this condition the output voltage of the unit will be at welding potential which in some cases may exceed 35 V DC. 0463 641 001 - 22 - © ESAB AB 2018...

  • Page 23: 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 Material selection Wire feed speed Material thickness Dialogue box 0463 641 001 - 23 - © ESAB AB 2018...

  • Page 24: Manual Mig Mode

    Home screen Information Memory Parameter Amperage Voltage (OCV or Arc) VRD indicator (VRD ON or VRD OFF) Dialogue box 6.1.6 LIFT-TIG mode Home screen Information Memory Parameter Amperage Dialogue box 0463 641 001 - 24 - © ESAB AB 2018...

  • Page 25: Settings

    When in spray there are no shorts during welding, and as sMIG works off short-arc, it will automatically limit the wire feed speed to ensure you stay 0463 641 001 - 25 - © ESAB AB 2018...

  • Page 26: Icon Reference Guide

    For more information, see the welding arc is stopped section "Lift TIG operation" Saving welding programs for Seconds a specific application when in the Memory Mode Settings on user manual Cancel menu 0463 641 001 - 26 - © ESAB AB 2018...
  • Page 27 Diagnostics the arc and reduce spatter when in the short circuit process Memory Save welding programs for a specific Language selection application Stick electrode choice Unit of Measure 0463 641 001 - 27 - © ESAB AB 2018...

  • Page 28: Lift Tig Operation

    Touch the Tungsten Electrode to the work piece prior to pressing the TIG Torch Trigger Switch. With the Trigger depressed lift the Tungsten Electrode from the work piece to initiate the arc. Once arc initiated refer to 2T/4T Trigger Operation. 0463 641 001 - 28 - © ESAB AB 2018...

  • Page 29: 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 641 001 - 29 - © ESAB AB 2018...

  • Page 30: Vrd Periodic Tests

    Required parameters VRD Open circuit voltage Less than 35 V (at nominal input voltage) VRD Turn on resistance Less than 200 ohms VRD Turn off time Less than 0.3 seconds 0463 641 001 - 30 - © ESAB AB 2018...

  • 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 641 001 - 31 - © ESAB AB 2018...

  • Page 32: Troubleshooting

    Make sure you are using the correct polarity. The welding problems electrode holder is usually connected to the positive polarity and the work lead to the negative polarity. If in doubt, consult the electrode data sheet. 0463 641 001 - 32 - © ESAB AB 2018...
  • Page 33 See section "Duty cycle" in the OPERATION chapter. • Make sure the air inlets or outlets are not clogged. 0463 641 001 - 33 - © ESAB AB 2018...

  • 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 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 the service or repair work to ensure that the product still conforms to the aforementioned standards.

  • Page 35: Diagram

    DIAGRAM DIAGRAM EMP 235ic 0463 641 001 - 35 - © ESAB AB 2018...

  • Page 36: Ordering Numbers

    ORDERING NUMBERS ORDERING NUMBERS   Ordering no. Denomination Note 0700 303 880 EMP 235ic Bobbin Ø100–300 mm (4–12 in.) Euro Connector 0463 641 001 - 36 - © ESAB AB 2018...

  • Page 37: Wear Parts

    0558 102 550 Shoulder screw 0558 102 459 Euro adapter locating screw 0464 636 880 Euro adapter assembly 0558 102 528 Polarity change cable 0558 102 548 UI panel assembly 0463 641 001 - 37 - © ESAB AB 2018...
  • Page 38 WEAR PARTS 0463 641 001 - 38 - © ESAB AB 2018...

  • Page 39: Accessories

    Accommodates maximum 228.6 mm (9 in.) diameter cylinder Rebel 215 and Rebel 235 brackets included W4014450 Foot control Contactor on/off and current control with 4.6 m (15 ft) cable and 8-pin male plug 0463 641 001 - 39 - © ESAB AB 2018...

  • Page 40: Replacements Parts

    Trigger assembly W7005000 Handle mouldings OTW42/3035 Liner 0.8-0.9 mm Hard wire OTW42/4045 Liner 1.0-1.2 mm Hard wire OTW42N/3545 Liner 0.9-1.2 mm Soft wire 301526 CIGWELD COMET Argon Regulator/Flowmeter 210254 CIGWELD CutSkill Argon Regulator/Flowmeter 0463 641 001 - 40 - © ESAB AB 2018...
  • Page 41 REPLACEMENTS PARTS 0463 641 001 - 41 - © ESAB AB 2018...
  • Page 42 For contact information visit esab.com ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 http://manuals.esab.com...

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