ESAB REBEL EMP 205ic AC/DC Instruction Manual
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ESAB REBEL EMP 205ic AC/DC Instruction Manual

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EMP 205ic AC/DC
Instruction manual
0463 703 001GB
20190927
Valid for: serial no. 937-xxx-xxxx

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Summary of Contents for ESAB REBEL EMP 205ic AC/DC

  • Page 1 EMP 205ic AC/DC Instruction manual 0463 703 001GB 20190927 Valid for: serial no. 937-xxx-xxxx...
  • Page 2 Record the following information for Warranty purposes: Where Purchased:_______________________________ __________________ Purchase Date:__________________________________ _________________ Power Supply Serial #:___________________________ __________________ ESAB operates a policy of continuous improvement. We therefore reserve the right to make changes and improvements to any of our products without notice. 0463 703 001GB 20190927...
  • Page 3 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1 SAFETY ..........................7 Meaning of symbols......................7 Safety precautions ........................7 User responsibility ......................11 2 INTRODUCTION ........................13 Equipment ..........................13 Overheating protection ....................13 3 TECHNICAL DATA ......................14 EMP 205ic AC/DC speci cations ................... 14 4 INSTALLATION ........................16 User’s responsibility ......................
  • Page 6 TABLE OF CONTENTS 6 CONTROL PANEL .......................36 How to navigate ......................... 36 EMP 205ic AC/DC Home screen ..................36 6.2.1 sMIG mode ......................... 36 6.2.2 Manual MIG mode ....................37 6.2.3 Gasless ux cored wire mode ................37 6.2.4 MMA mode ......................... 38 6.2.5 DC TIG mode ......................

  • Page 7: Safety

    SAFETY 1 SAFETY Meaning of symbols As used throughout this manual: Means Attention! Be Alert! NOTE! An operation, procedure, or background information which requires additional em- phasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment. WARNING A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.
  • Page 8 SAFETY 6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains. 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. FIRES AND EXPLOSIONS Heat from flames and arcs can start fires.
  • Page 9 SAFETY FUMES AND GASES Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Shielding gases can cause asphyxiation. Therefore: 1. Keep your head out of the fumes. Do not breathe the fumes and gases. 2. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead beryllium or cadmium unless positive me- chanical ventilation is provided.
  • Page 10 SAFETY WARNING! EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death. Therefore: 1. Always have qualified personnel perform the installation, troubleshooting and mainte- nance work. Do not perform any electrical work unless you are qualified to perform such work.

  • Page 11: User Responsibility

    SAFETY User responsibility Users of ESAB welding and plasma cutting 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 welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
  • Page 12 SAFETY Arc welding and cutting can be injurious to yourself and others. Take WARNING precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill. - Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

  • Page 13: Introduction

    The ESAB EMP 205ic AC/DC power source is supplied with: • ESAB EMP 205ic AC/DC power source • ESAB MXL 201 MIG torch, 3 m (10 ft) with contact tips M6 for 0.8 mm and 1.0 mm • ESAB SR-B 26 TIG Torch with accessories •...

  • Page 14: Technical Data

    3 TECHNICAL DATA 3 TECHNICAL DATA EMP 205ic AC/DC specifications EMP 205ic AC/DC Voltage 230 V,1 ph, 50/60 Hz 120 V, 1 ph, 50/60 Hz Primary current Breaker 20 A: 27.1 A GMAW - MIG 29.6 A max. Breaker 15 A: 20.2 A GTAW - DC TIG 24.0 A Breaker 15 A: 20.7 A...
  • Page 15 3 TECHNICAL DATA EMP 205ic AC/DC Open circuit voltage (OCV) VRD deactivated 68 V VRD activated Efficiency Power factor 0.98 Wire-feed speed 2-12.1 m/min (80-475 in./min) Wire diameter Mild steel solid wire 0.6 - 0.9 mm (0.023 - 0.035 in.) Stainless steel solid wire 0.8 - 0.9 mm (0.030 - 0.035 in.) Flux-cored wire...

  • Page 16: Installation

    INSTALLATION 4 INSTALLATION The installation must be carried out by a professional. CAUTION! This product is intended for industrial use. In a domestic environment, this product may cause radio interference. It is the user's responsibility to take adequate precautions. User’s responsibility The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.

  • Page 17: Location

    INSTALLATION Location Position the power source so that its cooling air inlets and outlets are not obstructed. A. 152 mm (6 in.) B. 100 mm (4 in.) C. 152 mm (6 in.) If in a permanent installation leave enough room to open door and access bobbin side. 4.3.1 Assessment of area Before installing welding equipment, the user/installer shall assess potential electromagnetic problems in the surrounding...

  • Page 18: High Frequency Interference

    INSTALLATION High frequency interference WARNING! The high frequency section of this machine has an output like a radio transmitter. The power source should NOT be used near blasting operations due to the danger of premature firing. WARNING! Operation close to computer installations may cause computer malfunction. WARNING! HIGH FREQUENCY FIELDS CAN BE DANGEROUS TO HEALTH.

  • Page 19: Main Supply

    INSTALLATION Main supply NOTE! Mains supply requirements This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to S at the interface point between the user's supply and the scmin public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power greater than or equal to S scmin...

  • Page 20: Recommended Electrical-Supply Specifications

    INSTALLATION Recommended electrical-supply specifications WARNING! An electrical shock or fire hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. Recommended electrical supply specifications: 120–230 V, 1 –...

  • Page 21: Operation

    OPERATION 5 OPERATION General safety regulations for handling the equipment can be found in the chapter "Safety." Read it through before you start the equipment. NOTE! When moving the equipment use intended handle. Never pull the cables. WARNING! Rotating parts can cause injury, take great care. WARNING! Electric shock! Do not touch the workpiece or the welding head during operation! WARNING!

  • Page 22: Connections And Controls

    OPERATION Connections and controls Figure 1. Front & rear views: Model EMP 205ic AC/DC 1. Knob for current or wire-feed speed selection 9. Polarity changeover cable 10. Display 2. Knob for voltage selection 11. Gas inlet for MIG/MAG 3. Main knob for menu navigation 12.

  • Page 23: Connection Of Welding And Return Cables

    OPERATION Connection of welding and return cables The power source has two outputs for connecting welding and return cables: a negative [-] terminal (7) and a positive [+] terminal (8) (see Figure 1). 5.2.1 For MIG/MMA process For MIG/MMA process, the output to which the welding cable is connected depends on the type of electrode. Refer to electrode packaging for information relating to the correct electrode polarity.

  • Page 24: Shielding Gas

    OPERATION Shielding gas The choice of suitable shielding gas depends on the material. Typically, mild steel is welded with mixed gas (Ar + CO2) or 100% carbon dioxide (CO2). Stainless steel can be welded with mixed gas (Ar + CO2) or trimix (He + Ar + CO2). Aluminum and silicon bronze use pure argon gas (Ar).

  • Page 25: Gmaw (Mig) 120 V

    OPERATION 5.5.3 GMAW (MIG) 120 V Figure 6. GMAW (MIG) 120 V Duty cycle 5.5.4 GMAW (MIG) 230 V Figure 7. GMAW (MIG) 230 V Duty cycle 0463 703 001GB -25-...

  • Page 26: Gtaw (Dc Tig) 120 V

    OPERATION 5.5.5 GTAW (DC TIG) 120 V Figure 8. GTAW (DC TIG) 120 V Duty cycle 5.5.6 GTAW (DC TIG) 230 V Figure 9. GTAW (DC TIG) 230 V Duty cycle 0463 703 001GB -26-...

  • Page 27: Gtaw (Ac Tig) 120 V

    OPERATION 5.5.7 GTAW (AC TIG) 120 V Figure 10. GTAW (AC TIG) 120 V Duty cycle 5.5.8 GTAW (AC TIG) 230 V Figure 11. GTAW (AC TIG) 230 V Duty cycle 0463 703 001GB -27-...

  • Page 28: Duty Cycle

    OPERATION 5.5.9 Duty cycle 25% duty cycle The EMP 205ic AC/DC has 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 29: Removing/Installing Bobbin

    OPERATION Removing/installing bobbin NOTE! The gas does not need to be connected for this procedure. Power should be turned OFF for this procedure. 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.

  • Page 30: Installing Wire

    OPERATION WARNING! Do not place or point the torch near the face, hand or body as this may result in injury. WARNING! Risk of crushing or pinching when replacing the wire bobbin! Do not use safety gloves when inserting the welding wire between the feed rollers. NOTE! Make sure the correct feed/pressure rollers are used.

  • Page 31: Removing Wire

    Model EMP 205ic AC/DC uses torch model: MXL™ 270 A MIG torch with 3 m (10 ft) cable (for FCW 1.2 mm) Order the following accessories: • Torch Teflon® conduit liner (PTFE liner), 3 m (10 ft): See PARTS section (Wire liner Table) in the ESAB Torch Instruction Manual (see Note above). •...

  • Page 32: Setting Wire-Feed Pressure

    OPERATION 5.10 Setting wire-feed pressure NOTE! This procedure requires the unit be powered ON. The gas does not need to be connected for this procedure. 1. Turn power to the unit ON. 2. Start by making sure that the wire moves smoothly through the wire guide. CAUTION! It is important that the feed-pressure is not too high or too low.

  • Page 33: Changing Wire-Feed Roller

    OPERATION 5.11 Changing wire-feed roller WARNING! Disconnect power to the unit before starting this task. NOTE! Gas does not need to be connected for this procedure. Different-size pairs of dual-groove feed-rollers are supplied as standard (Listed in Wear parts section). Change the feed rollers to match the wire size/type on the wire bobbin.

  • Page 34: Removing Wire-Feed Roller

    OPERATION 5.11.1 Removing wire-feed roller 1. If new rollers are being installed select the correct size and type (U-groove, V-groove or knurled) for wire being installed (see Wear parts section). 2. Disconnect the electrical power source from the unit. 3. Open the cover on the wire-bobbin side of the EMP unit. 4.

  • Page 35: Installing Wire-Feed Roller

    OPERATION 5.11.2 Installing wire-feed roller 1. Install the drive roller (in the correct size and in the correct groove orientation). Verify that the correct size groove is oriented on the inside (see Figure 21). NOTE! The wire-feed rollers will either be replaced (to correspond with the size and type of the new wire being installed) or reused if the same size and type of wire is being replaced.

  • Page 36: Control Panel

    CONTROL PANEL 6 CONTROL PANEL General safety regulations for handling the equipment can be found in the "Safety precautions" section in the "SAFETY" chapter of this manual. General information about operation can be found in the "OPERATION" chapter of this manual. Read and follow your employer’s safety practices before installing, operating, or servicing this equipment.

  • Page 37: Manual Mig Mode

    CONTROL PANEL • Advanced: 1. Home screen 2. Information 3. Memory 4. Material selection 5. Parameter selection 6. Wire-feed speed 7. Material thickness indicator 8. Voltage trim adjustment 9. Dialogue box 6.2.2 Manual MIG mode • Basic: 1. Home screen 2.

  • Page 38: Mma Mode

    CONTROL PANEL • Advanced: 1. Home screen 2. Information 3. Memory 4. Parameter selection 5. Wire-feed speed 6. Voltage adjustment 7. Dialogue box 6.2.4 MMA mode • Basic: 1. Home screen 2. Information 3. Memory 4. Amperage adjustment 5. Weld output voltage (Open Circuit Voltage or Arc) 6.

  • Page 39: Ac Tig Mode

    CONTROL PANEL • Advanced with Pulse OFF: 1. Home screen 2. Information 3. Memory 4. Pulse 5. Parameter selection 6. Amperage 7. Dialogue box • Advanced with Pulse ON: 1. Home screen 2. Information 3. Memory 4. Pulse 5. Parameter selection 6.

  • Page 40: Settings

    CONTROL PANEL Settings 1. Reset modes 2. Inch/Metric 3. Basic/Advanced 4. Language settings 5. Information 6. Home screen 7. Dialogue box User manual information 1. Maintenance information 2. Wear/Spare parts 3. Operation information 4. Home screen 5. Dialogue box Icon reference guide NOTE! SCT –...
  • Page 41 CONTROL PANEL ICON MEANING ICON MEANING MIG Torch Spot time ON adjustment Parameters Flux cored Parameters Manual MIG Percent STICK Pre-flow The time the shielding Smart MIG gas stays on before the welding arc is started Post-flow The time the shielding Lift-TIG gas stays on after the welding arc is stopped...
  • Page 42 CONTROL PANEL ICON MEANING ICON MEANING Inductance The addition of Language selection inductance into the arc charac- teristics to stabilize the arc and reduce spatter when in the short circuit process Memory Stick electrode choice Ability to save welding programs for a specific application Up-Slope Unit of Measure...

  • Page 43: Tig Welding Operation

    7 TIG WELDING OPERATION 7 TIG WELDING OPERATION DC TIG Welding Below illustration shows the navigation/setup of DC TIG Welding in advanced mode (A-B-C-D-E-F-G-H-I-J-K-L-M-N-O-P-Q- R-S-T). 0463 703 001 GB -43-...

  • Page 44: Dc Tig Pulse

    7 TIG WELDING OPERATION 7.1.1 DC TIG Pulse DC TIG Pulse welding is used mainly on thin metals but can also be used on thicker material based on the application. Pulsing allows the user to control the amount of heat applied to the work piece. Pulse setting gives user far more control over the welding process without compromising the strength and integrity of the weld and helps in having a smooth and clean weld.
  • Page 45 7 TIG WELDING OPERATION Below illustration shows the navigation/setup of DC TIG Pulse in advanced mode (A-B-C-D-E-F-G-H-I-J). 0463 703 001 GB -45-...
  • Page 46 7 TIG WELDING OPERATION Below illustration shows an example of DC TIG Pulse output current ideal waveforms in Basic and Advanced modes. User Settings: = 100A PEAK Default Settings: Background = 50% Peak Time = 50% Hz/PPS = 2.0 Dual Current Mode = OFF = 100A PEAK = 50A...
  • Page 47 7 TIG WELDING OPERATION DC TIG Pulse Operation with Remote Current Controller Connected: EMP 205 machine supports following different Remote Current Controllers supplied by ESAB. Foot Pedal Remote Hand Pendant Remote Thumb Controller (separate or as part of TIG Torch assembly) When Remote controller is connected to EMP 205 machine using 8-pin receptacle on the front panel, the background current calculations are different than that with regular TIG torch with trigger.
  • Page 48 7 TIG WELDING OPERATION Below illustration shows the above example in terms of output current waveforms in basic mode. User Settings: = 100A PEAK Default Settings: Background = 50% Peak Time = 50% Hz/PPS = 2.0 Dual Current Mode = OFF = 100A PEAK = 50A...
  • Page 49 7 TIG WELDING OPERATION Advanced Mode: If user sets parameters as (A) = 100 peak Background (%) = 80 Peak Time (%) = 70 Hz/PPS (Pulses Per Second) = 3.0 (A) = 5 The calculated value of (A) = 80A (I * 80% = 100 * 0.8) back peak...
  • Page 50 7 TIG WELDING OPERATION User Settings: = 100A PEAK Background = 80% Peak Time = 70% Hz/PPS = 3.0 Dual Current Mode = OFF = 100A PEAK = 80A BACK 70% PEAK 70% PEAK 70% PEAK 30% BACK 30% BACK 30% BACK ADVANCED MODE WELDING STATE WITH REMOTE SET TO ALL THE WAY User Settings:...

  • Page 51: Dc Tig Dual Current

    7 TIG WELDING OPERATION 7.1.2 DC TIG Dual Current EMP 205 CE introduces new feature called Dual Current operation in DC TIG (both straight and pulse DC operation) in Rebel family. Dual Current feature lets the user to switch to lower current during welding the corners or edges without stopping the weld.
  • Page 52 7 TIG WELDING OPERATION The “Current B” value is the percentage of user set current (“Current A”). From above illustration the Dual Current percentage set to 55% and user set current (“Current A”) set to 103A, the “Current B” value is 103 x 55% = 56A. When pulsing the “Current B”...

  • Page 53: Ac Tig Welding

    7 TIG WELDING OPERATION AC TIG Welding AC TIG Welding is used mainly for non-ferrous materials like aluminum. In AC TIG Welding the output current polarity is switched between Electrode Positive (EP) and Electrode Negative (EN). In Rebel 205ic AC/DC the switching of output polarity ranges from 25 –...
  • Page 54 7 TIG WELDING OPERATION Benefits of decreasing the balance (i.e., increasing the EP portion of the AC TIG waveform): • Better cleaning action to remove heavier oxidation on the work plate • Minimizes penetration which help prevent burn-through on thin materials •...
  • Page 55 7 TIG WELDING OPERATION Below illustration shows the navigation/setup of AC TIG Welding in advanced mode (A-B-C-D-E-F-G-H-I-J-K). 0463 703 001 GB -55-...
  • Page 56 7 TIG WELDING OPERATION Below illustration shows an example of AC TIG output current ideal waveforms in Basic and Advanced modes. User Settings: I = 100A Default Settings: Balance = 70% Frequency = 120Hz O set = 0A = 100A = 100A 70% EN 70% EN...

  • Page 57: Dc Tig Lift Arc And 2-Stroke/4-Stroke Illustration

    7 TIG WELDING OPERATION DC TIG Lift Arc and 2-stroke/4-stroke Illustration 2-stroke and 4-stroke welding process illustrated The trigger is used and some current flows already when lifting away the electrode to strike it. 2- Stroke In 2-stroke mode, press the TIG torch trigger switch (1) to start the shielding gas flow and initiate the arc. The current slopes up to the set current value.

  • Page 58: Selection And Preparation Of Tungsten Electrodes

    • Green: pure tungsten (DC only) * Shipped with Rebel EMP 205ic AC/DC machines. Tungsten Electrode Grinding Techniques: The shape of the tungsten electrode tip plays an important role in TIG welding. So care must be taken when grinding the tungsten electrode.

  • Page 59: Maintenance

    Additional maintenance should be performed if you operate in severe dusty condition. NOTE! There are no user serviceable parts inside of the power supply side of the EMP unit. Any need for service on the power supply side should be referred to the nearest ESAB service center. Routine maintenance...

  • Page 60: Power Source And Wire-Feeder Maintenance

    MAINTENANCE 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. WARNING! Always use hand and eye protection when cleaning. 1. Disconnect the power source from the input power socket. 2.

  • Page 61: Wire-Feeder Assembly Cleaning

    MAINTENANCE 8.2.1 Wire-feeder assembly cleaning WARNING! Always use hand and eye protection when cleaning. 1. Disconnect the electrical power source from the unit. 2. Open the cover on the wire-bobbin side of the EMP unit. 3. Before moving the tension knob (1): note its numerical setting as indicated on its body right below the handle. Record this number to reset the tension in its approximate range.

  • Page 62: 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 63: Troubleshooting

    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 64: User Interface (Ui) Software Displayed Error Codes

    9 TROUBLESHOOTING Type of fault Corrective action • Check that the input power supply switch is turned ON. • Check if a temperature fault is shown on display. No power/No • Check if system breaker is tripped. • Check that the input power, welding and return cables are correctly connected. •...

  • Page 65: Ordering Spare/Wear 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 66: Diagram

    DIAGRAM DIAGRAM Functional block diagram Schematic 0463 703 001GB -66-...

  • Page 67: Ordering Numbers

    ORDERING NUMBERS ORDERING NUMBERS Ordering number Denomination Notes 0700 300 998 EMP 205ic AC/DC Bobbin size 100–200 mm (4–8 in.) 0463 704 001 Spare parts list 0463 703 001GB -67-...

  • Page 68: Wear Parts

    WEAR PARTS WEAR PARTS Item Ordering no. Denomination Wire type Wire dimensions 0558 102 460 Wire outlet guide steel Fe/SS/Flux Cored 1.0 mm - 1.2 mm (0.040 in. - 0.045 in.) 0558 102 461 Wire outlet guide steel Fe/SS/Flux Cored 0.6 mm - 0.8 mm (0.023 in.

  • Page 69: Accessories

    ACCESSORIES ACCESSORIES TIG Torch 0700 025 557 TIG torch, 4 m, 200A, flexible head 0700 200 004 MIG Torch 270 3 m (for FCW 1.2 mm) Trolley 0459 366 887 Foot control W4014450 Contactor ON/OFF and current control with 4.6 m (15 ft) cable and 8-pin male plug 0463 703 001GB -69-...

  • Page 70: Replacements Parts

    Denomination 0700 200 002 MIG Torch MXL™ 201, 3 m (10 ft) 0700 025 556 ESAB SR-B 26 TIG Torch, 4 m, 200 A 0349 312 105 Gas hose, 4.5 m (14.8 ft) 0700 006 900 MMA welding cable kit, 3 m (10 ft)
  • Page 71 MEXICO Bucharest SOUTH AFRICA ESAB VAMBERK s.r.o. ESAB Mexico S.A. Tel: +40 316 900 600 ESAB Africa Welding & Cutting Ltd Vamberk Monterrey Fax: +40 316 900 601 Durbanvill 7570 - Cape Town Tel: +420 2 819 40 885 Tel: +52 8 350 5959...

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