Installing Wire; Welding With Aluminum Wire - ESAB EMP 255ic Instruction Manual

5 OPERATION
5.8.2

Installing wire

CAUTION!
Too long a torch liner risks damage to the wire-feed assembly if forced to fit when
attempting to connect the torch to the power unit.
Refer to the torch manual for instructions for torch liner replacement.
NOTE!
If wire replacement requires a replacement of the torch liner in the torch assembly, the
liner may be too long and will then require trimming. For installing a new liner in the
torch hose, refer to the torch manual.
1. Disconnect the electrical power source from the unit.
2. Open the Wire-Bobbin side door of the EMP unit.
3. Install the new Bobbin (see "Removing/installing bobbin" section).
4. On the Wire-feed assembly release the tensioning knob by pulling it up out of its
detent and rotating it toward you. The tension arm is spring-loaded. It will pop-up
when the tension knob in the previous step is rotated out-of-the-way.
5. Install correct rollers for wire size (See "Removing/installing wire-feed rollers" section).
6. With a clean-cut (no bends) strait end pull the wire from the newly-installed bobbin
and feed it into the input wire-feed guide, through the center wire-guide, then across
the feed roller grove and through the output wire-feed guide until it protrudes out of the
Euro-adapter output end about three centimeters (3 cm).
7. Close the tension-arm on to the wire in its groove on the wire-feed rollers and secure
with the tension arm. Verify that the wire is in its groove and not floating out of the
groove on the roller surface.
8. Re-connect the torch assembly to the EMP unit being careful to insert the bitter end of
the wire protruding from the Euro-adapter into its proper guide tube on the torch
connector.
9. Power up the EMP unit. Gas does not need to be connected for this procedure.
10. With the torch cable laid out reasonably straight, feed the wire through the torch cable
till visible at its welding tip by depressing the trigger switch on the torch. Refer to the
relevant torch manual for length of wire-protrusion at tip end.
○ Model EMP 255ic uses torch model: PSF 305 (Manual 0458 870 201)
○ Model EMP 320ic uses torch model: PSF 305 (Manual 0458 870 201)
11. To more accurately set and verify the wire-feed tension for correct wire-feed pressure,
see "Setting wire-feed pressure" section.
12. Close the door on the wire-bobbin side of the EMP unit.
5.9

Welding with aluminum wire

NOTE!
After completing the instructions in this section return to "Removing/installing wire"
section.
To weld aluminum using the standard torch, refer to MIG torch instruction manual for
replacing standard steel torch conduit liner with a teflon torch conduit liner.
• Model EMP 255ic uses torch model: PSF 305
• Model EMP 320ic uses torch model: PSF 305
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