ESAB EMP 285ic 1ph Instruction Manual
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ESAB EMP 285ic 1ph Instruction Manual

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EMP 285ic 1ph & EMP 285ic 3ph
Instruction manual
Valid for: serial no. 745-, 747-xxx-xxxx
0463 618 001 US 20190326

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Summary of Contents for ESAB EMP 285ic 1ph

  • Page 1 EMP 285ic 1ph & EMP 285ic 3ph Instruction manual Valid for: serial no. 745-, 747-xxx-xxxx 0463 618 001 US 20190326...

  • Page 2: Table Of Contents

    Safety precautions ................. User responsibility ................. California Proposition 65 Warning............INTRODUCTION ..................Equipment ....................2.1.1 EMP 285ic 1ph ..................2.1.2 EMP 285ic 3ph ..................Overheating protection ................TECHNICAL DATA ..................EMP 285ic (1ph) specifications ............. EMP 285ic (3ph) specifications .............
  • Page 3 Wire-feeder assembly cleaning ............EMP-unit power side maintenance ............Torch liner maintenance ................ 7.4.1 Torch liner cleaning ................TROUBLESHOOTING ................. Preliminary checks................. User interface (UI) software displayed error codes ......ORDERING SPARE PARTS ................ 0463 618 001 © ESAB AB 2019...
  • Page 4 TABLE OF CONTENTS DIAGRAM ......................ORDERING NUMBERS ..................72 WEAR PARTS...................... ACCESSORIES ....................74 REPLACEMENT PARTS ..................75 ROLLER & WIRE-GUIDE SELECTION .............. 76 Rights reserved to alter specifications without notice. 0463 618 001 © ESAB AB 2019...

  • Page 5: Safety

    A flameproof apron may also be desirable as protection against radiated heat and sparks. 0463 618 001 - 5 - © ESAB AB 2019...
  • Page 6 Put on dry, hole-free gloves before turning on the power. Turn off the power, before removing your gloves. 10. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not mistake the work lead for a earth cable. 0463 618 001 - 6 - © ESAB AB 2019...
  • Page 7 Do not use adapters. Maintain hoses and fittings in good condition. Follow the manufacturer's operating instructions for mounting a regulator to a compressed gas cylinder. 0463 618 001 - 7 - © ESAB AB 2019...
  • Page 8 Keep all safety devices and cabinet covers in position and in good repair. Use equipment only for its intended purpose. Do not modify it in any manner. 0463 618 001 - 8 - © ESAB AB 2019...

  • Page 9: User Responsibility

    Protection Devices" 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 10 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 ear defenders or other hearing protection. 0463 618 001 - 10 - © ESAB AB 2019...

  • Page 11: California Proposition 65 Warning

    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. California Proposition 65 Warning...

  • Page 12: Introduction

    2 INTRODUCTION INTRODUCTION The ESAB, EMP product family is a new generation of multi-process (MIG/Stick/TIG) welding power sources. All Rebel 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 13: 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 618 001 - 13 - © ESAB AB 2019...

  • Page 14: Technical Data

    60% duty cycle* 240 A (V = 19.6 V) Breaker 15 A: 90 A  = 18.5 V) Breaker 20 A: 110 A  = 19.5 V) 40% duty cycle* 285 A (V = 21.4 V) Breaker 15 A: 100 A  = 19 V) Permissible load at SMAW - Stick 0463 618 001 - 14 - © ESAB AB 2019...

  • Page 15: Emp 285Ic (3Ph) Specifications

    GMAW - MIG eff. GTAW - TIG / 10.5 A per phase / 10.7 A per phase / max. 7.0 A per phase 7.4 A per phase GTAW - TIG eff. 0463 618 001 - 15 - © ESAB AB 2019...
  • Page 16 27.0 × 11.5 × 19.5 in. (686 × 292 × 495 mm) Weight 70 lb. (31.75 kg) Operating temperature 14 to 104 °F (-10 to +40 °C) Enclosure class IP23S Application class 0463 618 001 - 16 - © ESAB AB 2019...
  • 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 618 001 - 17 - © ESAB AB 2019...

  • Page 18: Installation

    Welders with medical pacemakers should consult their doctor before welding. EMF may interfere with some pacemakers. 0463 618 001 - 18 - © ESAB AB 2019...

  • Page 19: User's Responsibility

    The health of people around, e.g. the use of pace-makers and hearing aids. Equipment used for calibration and measurement. The time of day that welding or other activities are to be carried out. 0463 618 001 - 19 - © ESAB AB 2019...

  • Page 20: Lifting Instructions

    Effective grounding of such objects will prevent re-radiation in most cases. Lifting instructions The power source can be lifted using any of the handles. 0463 618 001 - 20 - © ESAB AB 2019...

  • Page 21: 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 618 001 - 21 - © ESAB AB 2019...

  • Page 22: Recommended Electrical-Supply Specifications

    Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated minimum power 15 kW, is recommended. 0463 618 001 - 22 - © ESAB AB 2019...

  • Page 23: Operation

    Electric shock! Do not touch the workpiece or the welding head during operation! WARNING! Assure that the side covers are closed during operation. WARNING! Tighten the bobbin bolt to prevent it from sliding off the hub. 0463 618 001 - 23 - © ESAB AB 2019...

  • Page 24: Unit's Connections And Controls

    Main knob for menu navigation Display Gas outlet Gas inlet for MIG/MAG Torch/remote control connection Gas inlet for TIG Torch connection Main power switch ON/OFF Negative output [-] Main power cable 0463 618 001 - 24 - © ESAB AB 2019...

  • Page 25: Connection Of Welding And Return Cables

    (12), on rear panel, to a regulated shielding gas supply. Connect the work return lead to the return-cable terminal (9). Connect the torch connector to the torch connection (6) (see Figure 0463 618 001 - 25 - © ESAB AB 2019...

  • Page 26: Polarity Change

    Other settings result in curves that fall between these curves. A= Welding current (AMPS), V = Output voltage 5.5.1 1ph Volt-ampere curves 5.5.1.1 SMAW (Stick) 120 V, 1ph 0463 618 001 - 26 - © ESAB AB 2019...

  • Page 27: Smaw (Stick) 230 V, 1Ph

    5 OPERATION 5.5.1.2 SMAW (Stick) 230 V, 1ph 5.5.1.3 GMAW (MIG) 120 V, 1ph 0463 618 001 - 27 - © ESAB AB 2019...

  • Page 28: Gmaw (Mig) 230 V, 1Ph

    5 OPERATION 5.5.1.4 GMAW (MIG) 230 V, 1ph 5.5.1.5 GTAW (TIG) 120 V, 1ph 0463 618 001 - 28 - © ESAB AB 2019...

  • Page 29: Gtaw (Tig) 230 V, 1Ph

    5 OPERATION 5.5.1.6 GTAW (TIG) 230 V, 1ph 5.5.2 3ph Volt-ampere curve 5.5.2.1 SMAW (Stick) 460 V, 3ph / SMAW (Stick) 575 V, 3ph 0463 618 001 - 29 - © ESAB AB 2019...

  • Page 30: Gmaw (Mig) 460 V, 3Ph / Gmaw (Mig) 575 V, 3Ph

    The duty cycle refers to the time as a percentage of a 10-minute period that you can weld or cut at a certain load without overloading. If this occurs, let the unit cool down for 10 minutes, lower amperage, voltage, or duty cycle before welding. 0463 618 001 - 30 - © ESAB AB 2019...
  • Page 31 Figure 2. Example of 40 % 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. 0463 618 001 - 31 - © ESAB AB 2019...
  • Page 32 5 OPERATION Figure 3. Example of 50 % duty cycle Figure 4. Plotting duty cycle for 120 V, 1ph AC 0463 618 001 - 32 - © ESAB AB 2019...

  • Page 33: Removing/Installing Bobbin

    The spring sets the “braking value” working against the wire-feed motor and the pull of the roller-feed wheels. Tighten the bolt “A”, see illustrations below, hand tight. Remove/Install the bobbin as shown in below. Tightening the bobbin locking nut for 100 mm (4 in.): 0463 618 001 - 33 - © ESAB AB 2019...

  • Page 34: Removing/Installing Wire

    The EMP 285ic 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. 0463 618 001 - 34 - © ESAB AB 2019...
  • Page 35 Do not place or point the torch near the face, hand or body as this may result in injury. NOTE! Make sure the correct wire-feed rollers are selected. NOTE! Remember to use the correct contact tip in the welding torch for the wire diameter used. 0463 618 001 - 35 - © ESAB AB 2019...

  • Page 36: Removing Wire

    5.8.1 Removing wire Disconnect the electrical power source from the unit. Open the wire-bobbin side cover of the EMP unit. Figure 8. Wire-bobbin side exposed view Wire-bobbin Quad wire-feed assembly 0463 618 001 - 36 - © ESAB AB 2019...
  • Page 37 Secure the cut end of the wire to the bobbin (if any wire is left on the bobbin) to prevent the wire from unraveling from the bobbin. 0463 618 001 - 37 - © ESAB AB 2019...

  • Page 38: Installing Wire

    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. 0463 618 001 - 38 - © ESAB AB 2019...

  • Page 39: Welding With Aluminum Wire

    Refer to the relevant torch manual for length of wire-protrusion at tip end. ○ Model EMP 285ic 1ph uses torch model: Spray Master Velocity 250V ○ Model EMP 285ic 3ph uses torch model: Spray Master Velocity 350V 11.

  • Page 40: Setting Wire-Feed Pressure

    Figure 12. Checking for proper feed-roller pressure 5.11 Removing/installing wire-feed rollers WARNING! Power should be turned off for this procedure. NOTE! Gas does not need to be connected for this procedure. 0463 618 001 - 40 - © ESAB AB 2019...

  • Page 41: Removing Wire-Feed Rollers

    If new rollers are being installed select the correct size and type (steel or aluminum) for wire being installed (see Appendix C). Disconnect the electrical power source from the unit. Open the cover on the wire-bobbin side of the EMP unit. 0463 618 001 - 41 - © ESAB AB 2019...
  • Page 42 Failure to comply will render the entire unit useless until this part is replaced. Remove the two wire-feed rollers by removing their thumb screws and sliding each roller from their shaft (see Figure 15 and 16). 0463 618 001 - 42 - © ESAB AB 2019...
  • Page 43 5 OPERATION Figure 15. Drive gear with woodruff key on motor shaft Drive gear CAUTION! Avoid removing drive gear (see (1) in Figure 15). (Risk loosing drive-shaft woodruff key.) 0463 618 001 - 43 - © ESAB AB 2019...

  • Page 44: Installing Wire-Feed Rollers

    When installing the wire-feed rollers avoid (and do not force) installing a roller if either wire guide’s position interferes. Slide the offending wire guide slightly to provide clearance for the roller. The wire-guides are adjusted after the rollers are installed. 0463 618 001 - 44 - © ESAB AB 2019...
  • Page 45 Adjust the wire-feed pressure by adjusting the tension on the wire at the wire-feed rollers by turning the tension knob using the procedure in "Setting wire-feed pressure" section. Close the cover on the wire-bobbin side of the EMP unit. 0463 618 001 - 45 - © ESAB AB 2019...

  • Page 46: Removing/Installing/Adjusting Wire-Feed-Guides

    This section requires that the wire-feed rollers have been removed to provide access to the wire-guides. Perform wire-feed roller removal and, later in this procedure, roller install steps. See "Removing/Installing wire-feed rollers" section when referred in the steps below. 0463 618 001 - 46 - © ESAB AB 2019...
  • Page 47 Figure 18. Location of wire-guides and their set screws Wire from bobbin Wire-path through assembly Input wire-guide Output wire-guide thumb screw Center wire-guide Center wire-guide set screw Output wire-guide tube Wire-feed rollers 0463 618 001 - 47 - © ESAB AB 2019...
  • Page 48 Output wire-guide: 4 sizes for steel, 3 sizes for aluminum (select from table in Appendix C). Disconnect the electrical power source from the unit. Open the cover on the wire-bobbin side of the EMP unit. 0463 618 001 - 48 - © ESAB AB 2019...
  • Page 49 The torch assembly will be re-connected near the end of this procedure. Remove wire-feed rollers: See steps in "Removing/Installing wire-feed rollers" section for removing. 0463 618 001 - 49 - © ESAB AB 2019...

  • Page 50: Output Wire-Guide Removal/Installation

    This center wire-guide tube removes/installs only from the left side. Install the new center wire-guide tube. Slide this tube (narrow part first and from the left side) into its center post until it stops and hand-tighten its set screw. 0463 618 001 - 50 - © ESAB AB 2019...

  • Page 51: Adjusting Wire Guides

    Continue feeding the wire until it projects beyond the torch-adapter output side by a few centimeters. Close the pressure rollers on the wire. Re-connect the torch assembly on the EMP unit. 0463 618 001 - 51 - © ESAB AB 2019...
  • Page 52 "Setting the wire-feed pressure" section for a more accurate adjustment of this tension knob. 10. Close the cover on the wire-bobbin side of the EMP unit. 0463 618 001 - 52 - © ESAB AB 2019...

  • Page 53: Control Panel

    Manual MIG mode Flux-cored wire mode MMA mode Lift-TIG mode Settings User manual Dialogue box sMIG mode: Basic Home screen Information Memory Material selection Wire-feed speed selection Material thickness indicator Dialogue box 0463 618 001 - 53 - © ESAB AB 2019...

  • Page 54: Smig Mode: Advanced

    Manual MIG mode: Advanced Home screen Information Memory Material selection Parameter Wire-feed speed Voltage adjustment Dialogue box Flux cored wire mode: Basic Home screen Information Memory Wire-feed speed Voltage adjustment Dialogue box 0463 618 001 - 54 - © ESAB AB 2019...

  • Page 55: Flux Cored Wire Mode: Advanced

    Blue changes to orange when output is "hot". 6.10 MMA mode: Advanced Home screen Information Memory Parameter Amperage Power-supply output voltage (Open Circuit Voltage or Arc) Arc ON/OFF Dialogue box Blue changes to orange when output is "hot". 0463 618 001 - 55 - © ESAB AB 2019...

  • Page 56: Lift-Tig Mode: Basic

    Parameter Amperage Dialogue box 6.13 Settings Reset modes Inch/Metric Basic/Advanced Language Information Home screen Dialogue box 6.14 User manual information Maintenance information Wear/Spare parts Operation information Home screen Dialogue box 0463 618 001 - 56 - © ESAB AB 2019...

  • Page 57: Icon Reference Guide

    OFF: burnback set to puddle non-zero. Information Wire feed speed MIG Torch Spot time on adjustment Parameters Flux cored Parameters Manual MIG Percent STICK 0463 618 001 - 57 - © ESAB AB 2019...
  • Page 58 0463 618 001 - 58 - © ESAB AB 2019...
  • Page 59 Upslope, Unit of Measure Sloping the current up over a period of time at the beginning of the weld cycle Wire diameter Bead profile, concave Bead profile, convex 0463 618 001 - 59 - © ESAB AB 2019...

  • Page 60: Maintenance

    There are no user serviceable parts inside of the power supply side of the EMP unit. Any need for service on the electronics/electrical-power side should be referred to the nearest ESAB service center. Routine maintenance Maintenance schedule during normal conditions:...

  • Page 61: Wire-Feeder Assembly Cleaning

    Wire from bobbin Output wire-guide (inside of Euro-adapter assy.) Input wire-guide Wire-path through assembly Center wire-guide Output wire-guide thumb Output wire-guide tube Center wire-guide set screw Eurro-adapter assembly Wire-feed rollers Wire-feed assembly parts location 0463 618 001 - 61 - © ESAB AB 2019...
  • Page 62 7 MAINTENANCE Pressure rollers Wire-feed rollers Wire-feed & pressure-roller locations 0463 618 001 - 62 - © ESAB AB 2019...
  • Page 63 Woodruff key on the motor shaft. Losing this key renders the unit useless until the key is replaced. Remove the wire-feed rollers per "Removing wire-feed rollers" subsection in "OPERATION" chapter. Clean the wire-feed rollers with a soft brush. 0463 618 001 - 63 - © ESAB AB 2019...

  • Page 64: Emp-Unit 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 MIG torch instruction manual for replacing standard steel torch conduit liner with a Teflon torch conduit liner.
  • Page 65 Re-install the liner. Re-install the wire through the wire-feed assembly until visible at the torch tip. Verify that the wire does correctly feed out of the torch. 0463 618 001 - 65 - © ESAB AB 2019...

  • Page 66: 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 67: 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. 0463 618 001 - 67 - © ESAB AB 2019...
  • Page 68 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. 0463 618 001 - 68 - © ESAB AB 2019...

  • Page 69: 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 285ic 1ph and the EMP 285ic 3ph is 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 70: Diagram

    Internal Power Supply Power Board Primary Rectifier on Power Board Control Board Primary Inverter on Power Board User Interface (UI) Main Transformer Wire Feeder Ferrite Cores Gas Valves Output Diode Assembly Fans Current Sensor 0463 618 001 - 70 - © ESAB AB 2019...
  • Page 71 Internal Power Supply on Power Board Boost PFC Control Board Primary Inverter on Power Board User Interface (UI) Main Transformer Wire Feeder Ferrite Rings Gas Valves Output Diode Assembly Fans Current Sensor 0463 618 001 - 71 - © ESAB AB 2019...

  • Page 72: Ordering Numbers

    ORDERING NUMBERS ORDERING NUMBERS Ordering no. Description Note 0558 102 554 EMP 285ic 1ph Bobbin Size 4–12 in (100–300 mm), bayonet 0558 102 556 EMP 285ic 3ph Bobbin Size 4–12 in (100–300 mm), bayonet 0463 619 001 Spare Parts List 0463 618 001 - 72 -...

  • Page 73: Wear Parts

    THUMB SCREW M4 X 10 KNURLED 13 0558 102 603 QUAD WF COVER 14 0558 102 604 THUMB SCREW M5 X 14 KNURLED 15 0558 102 625 WIRE DRIVE KNOB, BAYONET 0463 618 001 - 73 - © ESAB AB 2019...

  • Page 74: Accessories

    0558 102 491 Rebel single cylinder cart Accommodates 1 × 9 in. (228.6 mm) diameter cylinder 0558 102 492 Rebel dual cylinder cart Accommodates 2 × 9 in. (228.6 mm) diameter cylinders 0463 618 001 - 74 - © ESAB AB 2019...

  • Page 75: Replacement Parts

    Electrode Holder 200A and Lead Assembly, 13 ft. (4 m), 50 mm Dinse W4014000 Power adapter cable 230 V to 120 V, 15 A 354TA8 Adapter cable 4 pin to 8 pin 0463 618 001 - 75 - © ESAB AB 2019...

  • Page 76: Roller & Wire-Guide Selection

    PURCHASE 0558 102 588 TUBE, WIRE GUIDE .052 (1.4) - .062 (1.6), OPTIONAL FOR ALUM PURCHASE * DEFAULT (size included in package) ** ACCESSORY (optional size included with each model) 0463 618 001 - 76 - © ESAB AB 2019...
  • Page 77 ROLLER & WIRE-GUIDE SELECTION 0463 618 001 - 77 - © ESAB AB 2019...
  • Page 78 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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Emp 285ic 3ph

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