ESAB EMP 255ic Service Manual
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ESAB EMP 255ic Service Manual

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SERVICE MANUAL
MODEL EMP 255ic & EMP 320ic
Valid for: serial nos. 730-xxx-xxxx, 735-xxx-xxxx
Rights reserved to alter specifications without notice.
PART # 0463 617 001
© ESAB AB 2018

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  • Page 1 SERVICE MANUAL MODEL EMP 255ic & EMP 320ic Valid for: serial nos. 730-xxx-xxxx, 735-xxx-xxxx Rights reserved to alter specifications without notice. PART # 0463 617 001 © ESAB AB 2018...
  • Page 2 (Intentionally Blank)
  • Page 4 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 equip ment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,"...

  • Page 5: Table Of Contents

    ESD (ELECTROSTATIC DISCHARGE) ..............2-11 SECTION 3 INTRODUCTION KEY FEATURES ....................3-1 EQUIPMENT ...................... 3-1 3.2.1 EMP 255IC SERIES: ....................3-1 3.2.2 EMP 320IC SERIES: ....................3-1 SECTION 4 TECHNICAL SPECIFICATIONS EMP 255IC SPECIFICATIONS ................4-1 EMP 320IC SPECIFICATIONS ................4-3 SECTION 5 INSTALLATION LOCATION ......................
  • Page 6 SECTION TABLE OF CONTENTS Paragraph Page RECOMMENDED ELECTRICAL-SUPPLY SPECIFICATIONS ........5-6 SUPPLY FROM POWER GENERATORS ..............5-6 SECTION 6 OPERATION USER CONNECTIONS AND CONTROLS ..............6-2 CONNECTION OF WELDING AND RETURN CABLES ..........6-3 6.2.1 FOR MIG/MMA PROCESS ..................6-3 6.2.2 FOR TIG PROCESS....................
  • Page 7 SECTION TABLE OF CONTENTS Paragraph Page FLUX CORED WIRE MODE: BASIC ............... 7-3 FLUX CORED WIRE MODE: ADVANCED .............. 7-3 MMA MODE: BASIC ................... 7-4 7.10 MMA MODE: ADVANCED .................. 7-4 7.11 LIFT-TIG MODE: BASIC ..................7-4 7.12 LIFT-TIG MODE: ADVANCED ................7-5 7.13 SETTINGS......................
  • Page 8 SECTION TABLE OF CONTENTS Paragraph Page 9.7.12 OKC Capacitor Board ..................9-34 9.7.13 Gas Valves ......................9-35 TESTING PROCEDURES ..................9-36 9.8.1 Initial Set up conditions ..................9-36 9.8.2 Power-UP Procedure ..................9-37 POWER UP FAULTS ..................9-39 9.9.1 Mains Power fuses blow/ breaker trips when SW1 is turned on: ..... 9-39 9.9.2 Unit is completely inactive, front panel display is off, no output voltage.
  • Page 9 SECTION LIST OF FIGURES Figure Page Figure 2-1. Danger and Warning Symbols ................2-1 Figure 5-1. Minimum Safe Clearances ..................5-1 Figure 5-2. Lifting lustrated ..................... 5-4 Figure 5-3. Sloping Ground ..................... 5-4 Figure 5-4. Rating plate (1) with supply connection data ............5-6 Figure 6-1.
  • Page 10 SECTION LIST OF FIGURES Figure Page Figure 9-4. Connector Location on UI board ................9-8 Figure 9-5. UI Structure ......................9-9 Figure 9-6. Location of Mounting Screws for UI ..............9-9 Figure 9-7. Main Power Switch Functional Location ............. 9-10 Figure 9-8.
  • Page 11 SECTION LIST OF FIGURES Figure Page Figure 9-36. Location of Output Inductor ................9-31 Figure 9-37. Output Inductor Functional Location ............... 9-31 Figure 9-38. Location of Current Sensor ................9-32 Figure 9-39. Current Sensor Functional Location ..............9-32 Figure 9-40. Location of Cooling Fans ................... 9-33 Figure 9-41.
  • Page 12 SECTION LIST OF FIGURES Figure Page Figure 10-1. Unit-Part Example ..................... 10-2 Figure 10-2. Wire-Feed Assembly, Wear-Parts ..............10-3...
  • Page 13 SECTION LIST OF TABLES Table Page Table 4-1. Specifications for EMP 255ic .................. 4-1 Table 4-2. Specifications for EMP 320ic .................. 4-3 Table 5-1. Recommended Electrical-Supply Specifications: 400V ± 10%, 3 ɸ, 50/60 Hz ..5-6 Table 8-1. Maintenance Schedule During Normal Conditions ..........8-2 Table 9-1.
  • Page 14 APPENDIX TABLE OF CONTENTS Paragraph Page DIAGRAMS FUNCTIONAL BLOCK DIAGRAM ................ A-1 SCHEMATIC 255, 320 SCHEMATIC, PAGE 1 OF 2 ....ERROR! BOOKMARK NOT DEFINED. 255, 320 SCHEMATIC, PAGE 2 OF 2 ....ERROR! BOOKMARK NOT DEFINED. Lift-TIG Welding 2-STROKE AND 4-STROKE WELDING PROCESS ILLUSTRATED......C-1 Roller &...

  • Page 15: Section 1 Welcome To Esab

    DESCRIPTION The ESAB EMP 255ic and the EMP 320ic are 400V, 3 ɸ, 50/60 Hz, constant current welding capable of performing SMAW (STICK), GTAW (HF TIG) and GTAW (LIFT TIG) welding processes and constant voltage welding capable of performing GMAW (MIG) welding processes. The unit is equipped with amperage and voltage meters which display on its User Interface during welding.

  • Page 16: Section 2 Safety

    Failure to observe the Safety Precautions could result in injury or death. 2.1.2 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...
  • Page 17 SAFETY 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. All work must be carried out by trained personnel well-acquainted with the operation of the equipment.

  • Page 18: Fires And Explosions

    SAFETY Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned (closed) and open pockets should be eliminated from the front of the clothing. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

  • Page 19: Electrical Shock

    SAFETY 8. After completing work, inspect the work area to make sure there are no hot sparks or hot metal that could cause a fire later. Use fire watchers when necessary. 2.1.4 ELECTRICAL SHOCK ELECTRIC SHOCK - Can kill Therefore: 1.

  • Page 20: Fumes And Gases

    SAFETY 1. Welders with medical pacemakers fitted should consult their doctor before welding. EMF may interfere with some pacemakers. 2. Exposure to EMF may have other health effects which are unknown. 3. Welders should use the following procedures to minimize exposure to EMF: a.

  • Page 21: Cylinder Handling

    SAFETY 5. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated hydrocarbon vapors or liquids to form phosgene, a highly toxic gas, and other irritant gases. 6. If you develop momentary eye, nose or throat irritation while operating, this is an indication that the ventilation is not adequate.

  • Page 22: Moving Parts

    SAFETY Maintain hoses and fittings in good condition. Follow the manufacturer's operating instructions for mounting a regulator to a compressed gas cylinder. 6. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit. 7.

  • Page 23: Falling Equpment

    SAFETY 2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power. 3. Maintain cables, earthing wire, connections, power cord and power supply in safe working order. Do not operate faulty equipment in a faulty condition. 4.

  • Page 24: User Responsibility

    This equipment or any of its parts should not be altered from standard specification without prior written approval of ESAB. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by ESAB.
  • Page 25 SAFETY the relevant safety precautions welding and cutting methods or other applicable operations of the equipment 2. THE OPERATOR MUST ENSURE THAT: no unauthorized person is within the working area of the equipment when it is started no-one is unprotected when the arc is struck, or work is started with the equipment 3.

  • Page 26: Esd (Electrostatic Discharge)

    SAFETY Keep your head out of the fumes Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area ARC RAYS - Can injure eyes and burn skin Protect your eyes and body. Use the correct welding darkening screen and filter lens, and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD...
  • Page 27 SAFETY discharge from persons to prevent the risk of ESD damage. This is done by simple devices: wrist straps, connected to ground, and conductive shoes. Work surfaces, carts and containers must be conductive and grounded. Use only antistatic packaging materials. Overall, handling of ESD-sensitive devices should be minimized to prevent damage.

  • Page 28: Section 3 Introduction

    INTRODUCTION INTRODUCTION SECTION 3 The ESAB, EMP 255ic and EMP 350ic 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 29 INTRODUCTION Input cable 10 ft. (3 m) with 230 V plug (part of power source) Gas hose with Quick Connector, 4.5 m Drive rolls: 1.0 mm (0.040 in)/1.2 mm (0.045 in) 0.8 mm (0.030 in)/1.0 mm (0.040 in) Guide tubes: 0.8 mm (0.030 in) – 1.2 mm (0.045 in) Thickness gauge tool USB stick including manuals Safety manual...

  • Page 30: Section 4 Technical Specifications

    TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS SECTION 4 This section lists the specifications for the EMP 255ic and the EMP 320ic models. TECHNICAL SPECIFICATION PUBLISHED IN THIS MANUAL: Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capabilities, measurements, dimensions and weights quoted are approximate only.
  • Page 31 TECHNICAL SPECIFICATIONS SPECIFICATION Supply = 400V, 3 ɸ, 50/60 Hz 5 A/10.2V – 300A/22V Setting range (DC) PERMISSIBLE LOAD AT SMAW - STICK 100% duty cycle* 130A/25.2V 60% duty cycle* 170A/26.8V 40% duty cycle* 255A/30.2V 16 A/20.6V – 255A/30.2V Setting range (DC) OPEN CIRCUIT VOLTAGE (OCV) VRD deactivated 68 V...

  • Page 32: Emp 320Ic Specifications

    TECHNICAL SPECIFICATIONS EMP 320ic SPECIFICATIONS Table 4-2. Specifications for EMP 320ic SPECIFICATION Supply = 400V, 3 ɸ, 50/60 Hz PRIMARY CURRENT GMAW - MIG 18A per Phase max. GTAW - TIG 16A per Phase max. SMAW - Stick 18A per Phase max.
  • Page 33 TECHNICAL SPECIFICATIONS SPECIFICATION Supply = 400V, 3 ɸ, 50/60 Hz Dimensions l × w × h 686 × 292 × 495 mm (27.0 × 11.5 × 19.5 in.) Weight 31.75 kg (70 lb.) Operating temperature 14 to104 °F (-10 to+40°C) Enclosure class** IP23S Application class***...

  • Page 34: Section 5 Installation

    INSTALLATION INSTALLATION SECTION 5 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. LOCATION Position the power source so that its cooling air inlets and outlets are not obstructed.

  • Page 35: High Frequency Interference

    INSTALLATION HIGH FREQUENCY INTERFERENCE WARNING The high frequency section of this machine has an output like a radio transmitter. The machine 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 36 INSTALLATION WARNING The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation. A duly authorized person such as a properly licensed electrician should perform the installation to avoid injury, death, or any equipment damage.

  • Page 37: Lifting Instructions

    INSTALLATION Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways. Direct Radiation: Radiation from the machine can occur if the case is metal and is not properly grounded. It can occur through apertures such as open access panels. The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properly grounded.
  • Page 38 INSTALLATION NOTE Mains supply requirements: This equipment complies with IEC 61000-3-12 provided that the short-circuit power is greater than or equal to Sscmin at the interface point between the user’s supply and the 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...

  • Page 39: Recommended Electrical-Supply Specifications

    INSTALLATION Figure 5-4. Rating plate (1) with supply connection data 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.
  • Page 40 INSTALLATION The power source can be supplied from different types of generators. However, some generators may not provide sufficient power for the welding power source to operate correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power 15kW 3-phase, are recommended.

  • Page 41: Section 6 Operation

    OPERATION OPERATION SECTION 6 General safety regulations for handling the equipment can be found in the "SAFETY PRECAUTIONS" section of this manual. Read it through before you start using the equipment! NOTE When moving the equipment use intended handle. Never pull the cables. WARNING Electric Shock! Do not touch the workpiece or the welding head during operation.

  • Page 42: User Connections And Controls

    OPERATION USER CONNECTIONS AND CONTROLS Figure 6-1. Front & Rear Views: Model EMP255ic & EMP320ic 1. Knob for current or wire feed speed selection 8. Positive output ( + ) 2. Knob for voltage selection 9. Polarity changeover cable 3. Main Knob for navigation and parameter selection 10.

  • Page 43: Connection Of Welding And Return Cables

    OPERATION 1. (U) UPPER CONTROL KNOB: a. SET CURRENT OUTPUT VALUE b. SET WIRE FEED SPEED 2. (L) LOWER CONTROL KNOB: a. MIG VOLTAGE SELECTION b. SMIG VOLTAGE TRIM c. MMA MODE: ARC ON/OFF 3. (M) MENU NAVIGATION: (PUSH TO SELECT) Figure 6-2.

  • Page 44: Polarity Change

    OPERATION (4) located on the front of the machine. Connect the gas inlet nut (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 Euro-Torch connection (6) (See Figure 6-1 ). POLARITY CHANGE The unit’s power source is delivered with the polarity changeover cable (see Figure 6-1 for location) connected to the positive terminal.

  • Page 45: Maw (Stick) 400 V

    OPERATION 6.5.1 MAW (Stick) 400 V SMAW(Stick) Welding current (Amps) Figure 6-3. SMAW (Stick) V-A Curve 6.5.2 GMAW (MIG) 400 V Figure 6-4. GMAW (MIG) V-A Curve...

  • Page 46: Gtaw (Tig) 400 V

    Figure 6-5. GTAW (TIG) V-A Curve DUTY CYCLE The EMP 255ic and EMP 320ic have a welding current output of 320 A at 40% duty cycle. A self- resetting thermostat will protect the power source if the duty cycle is exceeded.
  • Page 47 OPERATION 4 minutes 6 minutes Figure 6-6. Example of 40% Duty Cycle Duty cycle Vs Weld Current Weld Current (Amps) Figure 6-7. Plotting Duty Cycle Selection...

  • Page 48: Removing/Installing Bobbin

    OPERATION REMOVING/INSTALLING BOBBIN NOTE The gas need not 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 Figure 6-8 or Figure 6-9) until spool does not free- wheel.
  • Page 49 OPERATION NOTE The larger Bobbin may come in the wire form shown in the Figure or may be molded plastic form. Either mounts the same way as shown. Figure 6-9. Tightening the Bobbin Locking Nut (A) for 200 mm (8 in.), 300 mm (12 in.)

  • Page 50: Removing/Installing Wire

    The EMP 255ic or the EMP 320ic will handle bobbin sizes of 100 mm (4 in.), 200 mm (8 in.) and 300 mm (12 in.). See TECHNICAL SPECIFICATIONS section for suitable wire dimensions for each wire type.

  • Page 51: Removing Wire

    OPERATION 6.8.1 REMOVING WIRE 1. Disconnect the electrical power source from the unit. 2. Open the wire-bobbin side door of the EMP unit. WIRE BOBBIN WIRE-FEED ASSEMBLY Figure 6-11. Wire-Bobbin Side Exposed View 3. Locate the Wire-Feed Assembly and its Tension-Arm (see Figure 6-11). 4.
  • Page 52 OPERATION SCALE FOR SETTING CORRECT WIRE TENSION Figure 6-12. Tension Scale on Tension Arm of Wire-Feed Assembly 5. On the Wire-Feed Assembly release the tensioning arm by partially unscrewing the Tension Knob, pulling it up out of its detent and rotating it toward you (see (1) in Figure 6-13).
  • Page 53 OPERATION 6. IF WIRE REMAINS IN THE TORCH ASSEMBLY: Near the input end of the wire-feed guide on the wire-feed assembly (see Figure 6-13) cut the wire while holding the bobbin-end (so the wire does not unravel from the bobbin after cutting it loose). 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.

  • Page 54: Installling Wire

    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 GB) Model EMP 320ic uses torch model: PSF 305 (Manual 0458 870 201 GB) 11.

  • Page 55: Setting Wire-Feed Pressure

    To weld aluminum using the standard supplied 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 250 Model EMP 320ic uses torch model: PSF 305 Order the following accessories: Torch Teflon Conduit Liner (PTFE liner), 3 m (10 ft.): See PARTS section (Wire Liner...
  • Page 56 OPERATION Figure 6-14. Checking Feed-Roller Slip b. If you hold the welding torch approximately 50 mm (2 in.) from the piece of wood, the wire should be fed out and bend (Figure 6-15). Figure 6-15. Checking Feed-Roller Pressure 6-16...

  • Page 57: Removing/Installing Wire-Feed Rollers

    OPERATION 6.11 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. Two different-size pairs of dual-groove feed-rollers is supplied as standard (Listed in Appendix D as “DEFAULT” and as “ACCESSORY”). Change the feed rollers to match the wire size/type on the wire bobbin.
  • Page 58 OPERATION CAUTION AVOID REMOVING DRIVE GEAR (RISK LOOSING DRIVE-SHAFT WOODRUFF KEY) Figure 6-16. Drive Gear with Woodruff Key on Motor Shaft Figure 6-17. Feed Roller Removal and Installation 6-18...

  • Page 59: Installing Wire-Feed Rollers

    OPERATION 6.11.2 INSTALLING WIRE-FEED ROLLERS CAUTION 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. 1.

  • Page 60: Removing/Installing/Adjusting Wire-Guides

    OPERATION NOTE If the wire was removed the wire will have to be re- installed. Refer to Section 6.8.2 INSTALLLING WIRE. 4. Close the pressure rollers on the wire. 5. 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 SETTING WIRE-FEED PRESSURE.
  • Page 61 OPERATION 1. Select and Obtain the Correct Replacement Wire Guides (See Appendix D). NOTE Since this is based on the size and type (steel or aluminum) wire selected, it is assumed that the wire is already-selected, obtained and available for this procedure.

  • Page 62: Output Wire-Guide Removal/Installation

    OPERATION any convenient means to the wire frame of the bobbin to mechanically restrain it while this procedure continues. 7. Remove the torch assembly from the EMP unit and remove the remainder of the old wire still in the torch assembly and properly dispose of it. The torch assembly will be re-connected near the end of this procedure.

  • Page 63: Center Wire-Guide Removal/Installation

    OPERATION NOTE It is not necessary to remove the Euro-Adapter Assembly to access the Output Wire-Guide. A slight, quick, tap on the input-side of the Output Wire-Guide (after loosening its thumb screw) should be sufficient to project it out far enough on its output side to be able to grasp it and pull it out.
  • Page 64 OPERATION ADJUST FOR, AND VERIFY, APPROXIMATELY 1 MM CLEARANCE BETWEEN ROLLER AND GUIDE TUBES Figure 6-21. Verify Clearance of Both Guide Tubes 3. Access the bitter-end of the wire on the bobbin and cut off the length from the bitter end to have a clean, straight, bitter-end. This is needed to allow a low- resistance-travel re-install of the wire along the length of the torch cable to the torch tip.

  • Page 65: Overheating Protection

    OPERATION 6.13 OVERHEATING PROTECTION CAUTION! CAUTION! This unit is equipped with overheating protection for its power supply. This unit is equipped with overheating protection for its power supply. The welding power source has overheating protection that operates if the internal temperature becomes too high.

  • Page 66: Section 7 Control Panel

    CONTROL PANEL CONTROL PANEL SECTION 7 NOTE After power-on has completed the main menu appears on the control panel. HOW TO NAVIGATE 1. (U) UPPER CONTROL KNOB: a. SET CURRENT OUTPUT VALUE b. SET WIRE FEED SPEED 2. (L) LOWER CONTROL KNOB: a.

  • Page 67: Smig Mode: Basic

    CONTROL PANEL SMIG MODE: BASIC 1. HOME SCREEN 2. INFORMATION 3. MEMORY 4. MATERIAL SELECTION 5. WIRE-FEED SPEED SELECTION (U) 6. MATERIAL THICKNESS INDICATOR 7. DIALOGUE BOX SMIG MODE: ADVANCED 1. HOME SCREEN 2. INFORMATION 3. MEMORY 4. MATERIAL SELECTION 5.

  • Page 68: Manual Mig Mode: Advanced

    CONTROL PANEL MANUAL MIG MODE: ADVANCED 1. HOME SCREEN 2. INFORMATION 3. MEMORY 4. MATERIAL SELECTION 5. PARAMETER 6. WIRE-FEED SPEED (U) 7. VOLTAGE ADJUSTMENT (L) 8. DIALOGUE BOX FLUX CORED WIRE MODE: BASIC 1. HOME SCREEN 2. INFORMATION 3. MEMORY 4.

  • Page 69: Mma Mode: Basic

    CONTROL PANEL MMA MODE: BASIC 1. HOME SCREEN 2. INFORMATION 3. MEMORY 4. AMPERAGE ADJUSTMENT (U) 5. POWER-SUPPLY OUTPUT VOLTAGE (OPEN CIRCUIT VOLTAGE OR ARC) 6. DIALOGUE BOX 7. ARC ON/OFF (L) BLUE CHANGES TO ORANGE WHEN OUTPUT IS “HOT” 7.10 MMA MODE: ADVANCED 1.

  • Page 70: Lift-Tig Mode: Advanced

    CONTROL PANEL 7.12 LIFT-TIG MODE: ADVANCED 1. Home screen 1. HOME SCREEN 2. Information 2. INFORMATION 3. Memory 3. MEMORY 4. Parameter 4. PARAMETER 5. AMPERAGE (U) 5. Amperage 6. DIALOGUE BOX 6. Dialogue box 7.13 SETTINGS 1. RESET MODES 2.

  • Page 71: Icon Reference Guide

    CONTROL PANEL 7.15 Icon reference guide Heading Heading Heading Heading Home Spot time on/off selection Information Spot time on adjustment MIG Torch Parameters Flux cored Parameters Manual MIG Percent Pre-flow The time the Smart MIG shielding gas stays on before the welding arc is started Post-flow...
  • Page 72 CONTROL PANEL Saving welding Seconds programs specific application when Memory Mode Settings on user Cancel manual menu Spool Gun Remote (Not all markets) Settings Foot control Burn back Adjusting the time 2T, Trigger On/OFF when the voltage stays on after the wire feed is stopped to keep the wire from freezing in the...
  • Page 73 CONTROL PANEL Downslope Sloping the current Advanced Settings down over a period of time at the end of the weld cycle Hot start The increase of Basic Settings amps when striking the electrode to reduce sticking Inductance The addition of inductance into the Diagnostics arc characteristics...

  • Page 74: Section 8 Maintenance

    Perform maintenance more often during severe dusty conditions. NOTE 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.

  • Page 75: Routine Maintenance

    MAINTENANCE ROUTINE MAINTENANCE Table 8-1. Maintenance Schedule During Normal Conditions Interval Area to maintain Every 3 months Clean or replace Clean weld Check or replace weld cables. unreadable labels. terminals. Every 6 months Clean inside equipment.

  • Page 76: Wire-Side Maintenance

    MAINTENANCE WIRE-SIDE MAINTENANCE General good practice is to perform the cleaning procedure each time a Wire Bobbin is replaced. 8.2.1 WIRE-FEEDER ASSEMBLY CLEANING WARNING Always use hand and eye protection when cleaning. NOTE Use the following three figures for reference during this procedure.
  • Page 77 MAINTENANCE PRESSURE ROLLERS WIRE-FEED ROLLERS Figure 8-2. Wire-Feed & Pressure-Roller Locations TENSION ARM QUAD WIRE-FEED ASSEMBLY COVER Figure 8-3. Tension Scale on Tension Arm of Wire-Feed Assembly...
  • Page 78 MAINTENANCE 1. Disconnect the electrical power source from the unit. 2. Open the door on the wire-bobbin side of the EMP unit. Before moving the Tension Knob: note its numerical setting as indicated on its body immediately below the handle (see Figure 6-12). Record this number to re-set the tension in its approximate range.

  • Page 79: Emp-Unit Power-Side Maintenance

    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. Model EMP 255ic uses torch model: PSF 250 Model EMP 320ic uses torch model: PSF 305...

  • Page 80: Torch Liner Cleaning

    MAINTENANCE 8.4.1 TORCH LINER CLEANING Disconnect the power source from the input power socket. Disconnect the torch assembly from the unit Remove the wire from the torch wire-liner by pulling the wire out from the torch wire- liner and laying it neatly for re-installation at the end of this procedure. Remove the liner from the torch hose and inspect it for damage or kinks.

  • Page 81: Section 9 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 82 TROUBLESHOOTING • Make sure the MIG torch is connected to the correct MIG (GMAW/FCAW) welding problems polarity. Refer to the electrode wire manufacturer for the correct polarity. • Replace contact tip if it has arc marks in the bore causing excessive drag on the wire. •...

  • Page 83: Using Generators Or Extension Cords

    TROUBLESHOOTING • Make sure the TIG torch is connected to the power TIG (GTAW) welding problems source: Connect the TIG torch to the negative [-] welding terminal. Connect the welding ground cable to the positive [+] welding terminal. • Use only 100% Argon gas for TIG welding. •...

  • Page 84: User Interface (Ui) Software-Displayed Fault Codes

    TROUBLESHOOTING Contact Tip – Size and condition Wire type Gun Polarity USER INTERFACE (UI) SOFTWARE-DISPLAYED FAULT CODES Before troubleshooting deeper use the following list of fault codes if any are displayed. The following table exhibits fault codes that may appear to assist in troubleshooting. Severity Level Meaning (see Severity Level Column in table): (C) Critical Service Required - Unit not functional or locked, not recoverable (NC) Non-Critical - Service may be desired - unit functional with limited performance...
  • Page 85 TROUBLESHOOTING Open circuit Voltage error, OKC We start sensing this voltage only when weld activity is expected to be occurring. If voltage signal not sensed at Control this failure happens check control board Board CN1 as expected connectors CN1 to OKC and CN18 to current sensor for continuity.

  • Page 86: The Power Source Side

    TROUBLESHOOTING THE POWER SOURCE SIDE If the above checks failed to discover the problem a deeper investigation of the Power Source side is warranted. DESIGN OF THE POWER SOURCE Figure 9-1 illustrates the design theory used to generate and control the welder’s output. DESCRIPTION Main Power Switch EMI Filter Board...

  • Page 87: Emi Filter Board

    TROUBLESHOOTING The EMP 255ic and EMP 320ic power source is operating on the inverter principle. It consists of modules - each one serving a certain function. CONTROL BOARD EMI FILTER BOARD MAIN POWER BOARD BOARD POWER SWITCH OUTPUT INDUCTOR WIRE-FEED...
  • Page 88 TROUBLESHOOTING is not considered repairable except the encoders (dials) are replaceable and are listed in the parts manual. AFTER ROTATION OVER SELECTION PRESS TO SELECT Figure 9-3. User Interface (UI) CONNECTION TO CONTROL BOARD FOR FACTORY USE ONLY (USED TO DOWNLOAD SOFTWARE) Figure 9-4.
  • Page 89 TROUBLESHOOTING UI Disassembly REMOVE 2 SCREWS FROM INSIDE ON POWER SIDE REMOVE THESE 4 SCREWS TO OPEN UI ASSEMBLY REMOVE 2 SCREWS FROM INSIDE ON BOBBIN SIDE PART SNAPS ON/OFF (SEE NOTCHES ON TOP AND BOTTOM) Figure 9-5. UI Structure SCREWS HOLDING UI ASSEMBLY TO FRAME POWER SIDE...
  • Page 90 TROUBLESHOOTING 9.7.2 Main Power Switch The Main Power Switch, mounted on the rear panel of the welder is the ON/OFF control for the welder. Figure 9-7. Main Power Switch Functional Location Figure 9-8. Main Power Switch Connection Labels 9-10...
  • Page 91 TROUBLESHOOTING POWER IN FROM POWER OUT TO LINE CORD EMI FILTER BOARD Figure 9-9. Main Power Switch 9.7.3 EMI Filter Board The EMI (Electromagnetic Interference) Filter Board’s primary purpose is to suppress any EMI from feeding back into the electrical systems connected to the power grid. EMI FILTER BOARD Figure 9-10.
  • Page 92 TROUBLESHOOTING J111, J112, J113 ( IN FROM MAIN POWER SWITCH CAUTION DO NOT CROSS-CONNECT PHASES. BE SURE TO RETURN ALL CONNECTIONS TO THEIR ORIGINAL LOCATION. J115, J116, J119 ( OUT TO PRIMARY RECTIFIER: BR1, BR2) J114, J117, J118 ( OUT TO IPS BOARD INPUT) Figure 9-11.

  • Page 93: Main Power Board

    TROUBLESHOOTING EMI FILTER BOARD DISASSEMBLY The IPS Board must be removed to access the EMI Board. Be sure to record location of connectors BEFORE disconnecting. Note any connectors present but not used. Figure 9-13. EMI Board Disassembly 9.7.4 Main Power Board The Main Power Board contains the Primary Rectifier, the Filter Capacitor, and the Primary Inverter.
  • Page 94 TROUBLESHOOTING MAIN POWER BOARD Figure 9-14. Location of Main Power Board DC out = 535 Vdc – 680 Vdc (Filter Caps C70, C72, C400 connected in parallel across DC out of BR1/BR2) C 400 C 72 C 70 LINE – WHITE WIRE LINE +...
  • Page 95 TROUBLESHOOTING CN4 TO CB CN19 AND TO IPS CN30 CN1 TO CB CN17 CN9 TO OD CN21 CN18 TO IPS CN17 LINE- HOLE IPS- HOLE TO IPS J111 TO BR1, BR2 LINE+ HOLE TO BR1, BR2 HVDC+ NOT USED BR1, BR2 P1 HOLE TO OD LINE2 CN7 TO MT TEMP SENSOR DANGER...
  • Page 96 TROUBLESHOOTING PRIMARY C70, C72, C400 INVERTER ( CONNECTED IN PARALLEL) BR1, BR2 ( CONNECTED IN PARALLEL) Figure 9-17. Main Power Board Functional Location MAIN POWER BOARD DISASSEMBLY The Heat Sink Support Bracket must be removed to access these assemblies: Main Power Board, Output Diode Board, or Fans (see Figure 9-18).
  • Page 97 TROUBLESHOOTING HEAT SINK SUPPORT BRACKET Figure 9-18. Heat Sink Support Bracket Figure 9-19. Main Power Supply Board Disassembly 9-17...

  • Page 98: Internal Power Supply (Ips) Board

    TROUBLESHOOTING 9.7.5 Internal Power Supply (IPS) Board The Internal Power Supply Board (IPS) receives its 400 VAC input from the Main Power Board and converts it to two output DC levels (24 Vdc which feeds the Control Board and 18 Vdc which feeds the low-voltage needs of the Primary Inverter).
  • Page 99 TROUBLESHOOTING 400 Vac, 3ɸ ( INPUT FROM EMI FB ) TEST POINTS J111 ( TO MPB IPS- HOLE ) CN 17 ( TO MPB CN18 ) D 53 +24 Vdc OUTPUT IS D 42 PRESENT +18 Vdc OUTPUT IS PRESENT ( TO CB CN2 ) CN 30 ( TO MPB CN4 )
  • Page 100 TROUBLESHOOTING +18 VDC ( INTO PRIMARY INVERTER ) 400 VAC ( FROM EMI BOARD ) +24 VDC ( INTO CONTROL BOARD) Figure 9-22. ISP Board Functional Location IPS BOARD DISASSEMBLY Fastener hardware is shown in Figure 9-23 . Be sure to record location of connectors BEFORE disconnecting.

  • Page 101: Control Board

    TROUBLESHOOTING 9.7.6 Control Board The Control Board, with a microprocessor, monitors and controls the welding process. It is powered by the 24 Vdc out from the Internal Power Supply. The Control Board directly controls both gas valves and both cooling fans. The Control Board also serves as the DC power supply source for the UI circuits (+15 and -15 Vdc).
  • Page 102 TROUBLESHOOTING D 87 D 89 D 33 D 40 D 43 D 44 D 45 D 36 D 88 D 35 D 86 D 90 D 85 Figure 9-25. Control Board LED Locations 9-22...

  • Page 103: Dip Switch Settings

    TROUBLESHOOTING Table 9-3. Control Board LED Meanings LED # Status Meaning D 33 Dim to PWM IGBT: Gate signals are enabled (Brightness depends on PWM bright demand) D 35 +15 Vdc supply on this board is present. D 36 +3.3 Vdc supply on this board is present D 40 +24 Vdc supply on this board is low.
  • Page 104 TROUBLESHOOTING +15 and -15 VDC (TO UI BOARD) +24 VDC ( INTO CONTROL BOARD ) +24 VDC ( OUT TO: WIRE-FEED MOTOR, GAS VALVE, FANS ) Figure 9-27. Control Board Functional Location 9-24...
  • Page 105 TROUBLESHOOTING 24V OUT TO MIG GAS SOLENOID CN10 V SENSE IN FROM OKC 24 V OUTTO CN11 TIG GAS SOLENOID TO MPB CN1 CN17 (GATE TRIGGER PULSE) IN FROM CN18 CURRENT SENSOR FOR FACTORY PROGRAMMING CN19 FOR FACTORY PROGRAMMING TO MPB CN4 COMMS &...

  • Page 106: Main Transformer

    TROUBLESHOOTING CONTROL BOARD DISASSEMBLY Fastener hardware is shown in Figure 9-29. Be sure to record location of connectors BEFORE disconnecting. Note any connectors present but not used. Figure 9-29. Control Board Disassembly 9.7.7 Main Transformer The Main Transformer is a step-down transformer that takes the output from the Main Power Board (specifically the output from the Primary Inverter on the Main Power Board: 47 KHz square wave, 535 Vdc –...
  • Page 107 TROUBLESHOOTING MAIN TRANSFORMER Figure 9-30. Location of Main Transformer ( 7:1 STEP-DOWN TURNS RATIO ) Figure 9-31. Main Transformer Functional Location 9-27...

  • Page 108: Output Diode Assembly

    TROUBLESHOOTING 9.7.8 Output Diode Assembly The Output Diode Assembly takes the 47 K Hz AC square wave from the Main Transformer’s Secondary output and converts it to the actual DC voltage used by the torch. OUTPUT DIODE ASSEMBLY Figure 9-32. Location of Output Diode Assembly 9-28...
  • Page 109 TROUBLESHOOTING INPUT FROM MAIN TRANFORMER WELD OUTPUT CURRENT FROM ALUMINUM HEAT SINKS LINE 2 HOLE CN21 TO MPB C9 TO MPB P1 HOLE ( HIGH VOLTAGE DC + ) Figure 9-33. Map of Output Diode Board Figure 9-34. Output Diode Assembly Functional Location 9-29...

  • Page 110: Output Inductor

    TROUBLESHOOTING OUTPUT DIODE BOARD DISASSEMBLY The Output Diode Assembly heat sinks are wrapped in an air duct. This air duct must be removed to gain access to remove the two output current connectors. OUTPUT WELDING CURRENT CONNECTIONS (BOLTED TO HEAT SINK) Figure 9-35.
  • Page 111 TROUBLESHOOTING OUTPUT INDUCTOR Figure 9-36. Location of Output Inductor Figure 9-37. Output Inductor Functional Location 9-31...

  • Page 112: Current Sensor

    TROUBLESHOOTING 9.7.10 Current Sensor The Current Sensor is the sensing element for the Control Board to monitor the actual welder output DC current level. When weld current is flowing, the voltage measured should be approximately 0.5VDC per 100A of output welding current. Current Sensor requires calibration when replaced.

  • Page 113: Cooling Fans

    TROUBLESHOOTING 9.7.11 Cooling Fans The two Cooling Fans provide forced-air cooling for the massive heat sinks used on the Main Power Board and on the Output Rectifier Board. These are 24 V, DC-motor fans which run only when output welding current is sensed. FANS Figure 9-40.

  • Page 114: Okc Capacitor Board

    TROUBLESHOOTING 9.7.12 OKC Capacitor Board The OKC Capacitor Board is located in the bottom, front area just behind the current sensor. It provides a final capacitive filter for the output DC voltage. The filter is connected directly across the two DC output terminals. OKC FILTER CAP BOARD (BEHIND CURRENT SENSOR) Figure 9-42.

  • Page 115: Gas Valves

    TROUBLESHOOTING 9.7.13 Gas Valves Both Gas Valves are identical. One serves for TIG gas and the lower one serves for MIG gas. Each operates on a 24 Vdc command from the Control Board. WIRE TO CONTROL BOARD Figure 9-44. Gas Valves 9-35...

  • Page 116: Testing Procedures

    TROUBLESHOOTING TESTING PROCEDURES The welder has multiple reporting LEDs on its Control Board. They are useful to troubleshooting. The following table lists them and defines their meaning. 9.8.1 Initial Set up conditions • SW1- OFF • No remote device installed •...

  • Page 117: Power-Up Procedure

    TROUBLESHOOTING 9.8.2 Power-UP Procedure Connect the welder to a correct power source and then turn SW1 to ON position and observe the following LEDs: NOTE The unit will come up is whichever process the unit was in when the unit was last turned off. For this Power Up Procedure the LED status should show: LED # Status...
  • Page 118 TROUBLESHOOTING D 87 D 89 D 33 D 40 D 43 D 44 D 45 D 36 D 88 D 35 D 86 D 90 D 85 Figure 9-46. Control Board LED Locations 9-38...

  • Page 119: Power Up Faults

    TROUBLESHOOTING POWER UP FAULTS 9.9.1 Mains Power fuses blow/ breaker trips when SW1 is turned on: 1. Faulty Mains Power Cable and/or Plug a. Perform Power Cord/Plug, Power Switch, and EMI Board Test (see 9.13.1). 2. Shorted BR1 or BR2 rectifiers. a.
  • Page 120 TROUBLESHOOTING When any of these devices are heated they will enable the OVERTEMP Protection to disable the output of the unit. The OVER TEMPERATURE symbol will appear on the UI Display and the Fan will turn on. When the error is displayed, the unit should remain powered on allowing the fans to run, properly cooling the unit components.

  • Page 121: Smaw Process Test

    TROUBLESHOOTING 9.10 SMAW PROCESS TEST If unit is not in SMAW process, use MAIN ENCODER dial on the UI to select SMAW (STICK) process. Approx. 54 Vdc present between +/- weld output connectors. 9.10.1 SMAW Process Test: LED status LED # Status Meaning SMAW...

  • Page 122: Smaw Process Test Problems

    TROUBLESHOOTING 9.10.2 SMAW Process Test Problems 1. Cannot change weld process a. Defective encoder: replace 2. No voltage between +/- Weld Output Connectors a. Defective Control Board (D33 should be ON (Very dim). b. Defective Output Diode board. Perform Output Diode Board test (see 9.13.7) 3.

  • Page 123: Gtaw Lift Tig Process Test

    TROUBLESHOOTING 9.11 GTAW LIFT TIG PROCESS TEST 1. Turn SW1 to OFF Position. 2. Connect TIG torch power cable to negative weld output connector and work cable to positive weld output connector. 3. Connect gas hose to flow meter regulator. And turn regulator on and set flow. 4.

  • Page 124: Gtaw Lift Tig Process Test Problems

    TROUBLESHOOTING 9.11.2 GTAW LIFT TIG Process Test Problems 1. Cannot change weld process from SMAW to GTAW a. Defective ENCODER on UI board. Perform UI Board test (see 9.13.6). 2. No output voltage from unit when remote device trigger is closed a.

  • Page 125: Gmaw Mig Process Test

    TROUBLESHOOTING 9.12 GMAW MIG PROCESS TEST 1. Turn SW1 to Off Position. Remove TIG torch. Connect MIG gun, connect polarity cable to + weld output connector and work cable to – weld output connector. Connect appropriate gas supply inlet to rear panel gas inlet fitting. 9.12.1 GMAW Process Test: LED status LED # Status...
  • Page 126 TROUBLESHOOTING b. Control Board (1) Check that LED D87 turns on when trigger is activated. If it is not illuminated, replace Control Board. c. Defective GMAW Gas Solenoid. Gas valve supply voltage is 24vdc. Measure at CN10 on Control Board between pins 1 &...
  • Page 127 TROUBLESHOOTING Open wire tension adjustment arm. Depress trigger and measure for DCV at Control Board connector CN13 between pins 1 & 2. If voltage is present replace motor M1 (wire feed assembly). b. Defective Control Board. Depress trigger and measure for DCV at Control Board connector CN13 between pins 1 &...

  • Page 128: Component, Sub-Assembly Tests

    TROUBLESHOOTING 9.13 COMPONENT, SUB-ASSEMBLY TESTS The section is referenced in the above sections for tests called out for a specific component or subassembly to be tested. 9.13.1 Power Cord/Plug, Power Switch, and EMI Board Test 1. With power OFF, the unit DISCONNECTED from its main power source, turn the power switch to its ON position.

  • Page 129: Primary Rectifier Test

    TROUBLESHOOTING POWER SWITCH CLOSED TEST POINTS ON IPS BOARD PLUG PRONGS AT END OF POWER CORD Figure 9-50. Test Point Schematic for Continuity 9.13.2 Primary Rectifier Test DC out = 535 Vdc – 680 Vdc (Filter Caps C70, C72, C400 connected in parallel across DC out of BR1/BR2) C 400 C 72 C 70...
  • Page 130 TROUBLESHOOTING DC out 535 Vdc – 680 Vdc (to Filter Caps C70, C72, C400 - DC + DC AC in 400V, 3 ɸ, 50/60 Hz (from EMI Board) CAUTION DO NOT CROSS-CONNECT PHASES. BE SURE TO RETURN ALL CONNECTIONS TO THEIR ORIGINAL LOCATION.

  • Page 131: Br1, Br2 Test Procedure

    TROUBLESHOOTING WARNING! Each pin on BR1 and BR2 connect to their identical pin on the other. DO NOT CROSS-CONNECT PHASES. FAILURE TO COMPLY WILL CAUSE IMMEDIATE DAMAGE AS SOON AS POWER IS APPLIED. Figure 9-53. Schematic of BR1 or BR2 9.13.2.1 BR1, BR2 Test Procedure As shown above in Figure 10-2, each bridge diode (BR1 and BR2) contains six diodes.
  • Page 132 TROUBLESHOOTING 4. Perform each of the tests in the Table: NOTE As soon as a failure is detected, stop this test procedure and replace BOTH BR1 and BR2. Figure 9-54. Terminal Identification of BR 1, BR 2 Table 9-4. BR1, BR2 Test Procedure Task Expected Meter Display Pass/Fail...

  • Page 133: Ips Board Test

    TROUBLESHOOTING 9.13.3 IPS Board Test WARNING! This test requires power to be ON. 400 VAC should be present where testing. Only a trained and certified technician should be performing any test on this unit when power is required to be ON. Failure to comply may result in injury or death. 1.

  • Page 134: Main Power Board Test

    TROUBLESHOOTING 9.13.4 Main Power Board Test 1. VR1 a. Visually Check. If burned/blown, the problem was caused from an over voltage from the Mains Power and further damage to the unit's power components is likely and is not eligible for warranty. Replace board. Figure 9-56.
  • Page 135 TROUBLESHOOTING IPS - Line - WHITE WIRE TO BR1, BR2 PIN 4 Figure 9-57. Test Points for Rl79, RY1 3. C 70, C72, C400 a. Disconnect WHITE wire from BR1 and BR2 (pin 4). Red wire may remain attached to pin 1. b.
  • Page 136 TROUBLESHOOTING REMOVE WHITE WIRE FROM PIN 4 OF BOTH BR1, BR2 LINE – WHITE WIRE LINE + RED WIRE RED WIRE MAY REMAIN CONNECTED Figure 9-58. Test Points for C70, C72, C400 4. Q3, 4, 6, 7 Test for Shorted Component NOTE The following transistors are in parallel with each other: Q3 with Q36...
  • Page 137 TROUBLESHOOTING LINE - TRANSF 2 Figure 9-59. Test Points for Q3, Q4, Q6, Q7 (1) With meter in diode setting, check for diode reading between Heatsink Terminals Q4 and Q7: (-) probe on Q4; (+) probe on Q. (2) With meter in diode setting, check for diode reading between Heatsink Terminals Q3 and Q6: (-) probe on Q3;...

  • Page 138: Control Board Test

    TROUBLESHOOTING 9.13.5 Control Board Test 1. Verify SW2 DIP Switch positions are correct (see Figure 9-60). Figure 9-60. SW2 Switch Positions 2. Check Control Board LEDs status as follows +15 Vdc OK ON +3.3 Vdc OK ON +24 Vdc LOW OFF +10.3 VDC OK ON +5 Vdc...
  • Page 139 TROUBLESHOOTING 5. Depress torch trigger (or place a short across two pins of CN3) and measure for 24 (21-23V) Vdc at connector CN13 between pins 1 & 2. If voltage is not present replace Control Board. Voltage should change to 0 V when trigger released (or short removed).

  • Page 140: Ui Board Test

    TROUBLESHOOTING a. Inspect LED D33 (Green LED) on Control Board to be at least dimly lit. PWM signal is present. b. If D33 is dark: Put Welder in MMA mode and while switching MMA mode from OFF to ON (use lower dial on UI to control ON/OFF display) observe that D33 blinks very briefly.

  • Page 141: Output Diode Board Test

    TROUBLESHOOTING UI CONNECTOR Figure 9-64. UI to Control Board Connection Locations 9.13.7 Output Diode Board Test Preliminary Visual Test: Visually verify that the Snubber Ring Ferrite Cores (mounted on the Main Transformer wires) are not missing or cracked. 1. Disconnect and isolate T1 Main Transformer wires from Terminals SEC1 & SEC2. 2.

  • Page 142: Current Sensor Test

    TROUBLESHOOTING LEAVE OUTPUT CABLES CONNECTED. VERIFY ZERO OHMS ACROSS TWO HEAT VERIFY ZERO OHMS SINKS ACROSS TWO HEAT SINKS EITHER MAIN TRANSFORMER SECONDARY OUTPUT LEAD DISCONNECTED (ONE IS SUFFICIENT.) TEST POINTS DIODE OUTPUT ASSEMBLY Figure 9-65. Diode Output Test Procedure Illustrated 4.

  • Page 143: Remote Control Trigger Test

    TROUBLESHOOTING 4. Measure voltage from Pin 4 to Pin 3. Voltage with no current flow should measure 0VDC. 5. Measure voltage from Pin 4 to Pin 3. When weld current is flowing, the voltage measured should be approx. 0.5VDC per 100A output. Use an external ammeter to verify actual current flow as a reference.

  • Page 144: Calibration

    Remote-Control Connector J1 with harness. 9.14 CALIBRATION NOTE CALIBRATION IS DONE USING ESAB REBEL SERVICE GUI. The Control Board will require calibration when: The Control Board has been replaced, The Wire Feed Motor M1 has been replaced, The Output current sensor CS1 has been replaced.

  • Page 145: Section 10 Ordering Spare Parts

    Repair work should be done by an authorized ESAB service technician. Use only ESAB parts. The EMP 255ic and the EMP 320ic 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 146 EMP 255ic Can hold: Bobbin Size 100–300 mm (4–12 in.) Comes with: Euro Connector 0700 300 991 EMP 320ic Can hold: Bobbin Size 100–300 mm (4–12 in.) Comes with: Euro Connector 0463 606 001 EMP 255ic/EMP 320ic spare parts list 10-2...

  • Page 147: Wear Parts

    ORDERING SPARE PART 10.2 WEAR PARTS Certain mechanical parts on the wire-feed assembly are subject to more frequent use hence may wear more frequently. These are exhibited here. Figure 10-2. Wire-Feed Assembly, Wear-Parts Table 10-2. Reference for Figure 9-2 Wire-Feed Assembly, Wear-Parts PART # DESCRIPTION 0558102591...

  • Page 148: Accessories

    ORDERING SPARE PART 10.3 ACCESSORIES Table 10-3. Accessories Part # Description 0458 401 880 MIG Torch: PSF 305, 3 m 0458 401 881 MIG Torch: PSF 305, 4.5 m TIG Torch: TXH™ 202, 4 m (12 ft.) TIG 0700 300 857 torch c/w 8-pin plug W4014450 Foot control: Contactor on/off and...

  • Page 149: Replacements Parts

    ORDERING SPARE PART 10.4 REPLACEMENTS PARTS Table 10-4. Replacement Parts Part # Description 0349 312 105 Gas hose, 4.5 m (15 ft.) 0700 006 901 Return welding cable kit, 3 m (10 ft.) 0700 006 900 MMA welding cable kit, 3 m (10 ft.) 10-5...

  • Page 150: Functional Block Diagram

    DIAGRAMS A.1 Functional Block Diagram DESCRIPTION Main Power Switch EMI Filter Board Primary Rectifier on Power Board Primary Inverter on Power Board Main Transformer Ferrite Cores Output Diode Assembly Current Sensor Output Inductor 10 Internal Power Supply Board 11 Control Board 12 User Interface (UI) 13 Wire Feeder 14 Gas Valves...

  • Page 151: Schematic

    SCHEMATIC Block Diagram EMP 320ic/255ic...

  • Page 152: Lift-Tig Welding

    Lift-TIG Welding 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. 1. The electrode is touched on to the work piece. 2. The trigger switch is pressed, and a low current starts to flow. 3.
  • Page 153 2 STROKE 2 STROKE Gas pre-flow Slope Slope down Gas post- flow 4 STROKE 4 STROKE Gas pre-flow Slope Slope down Gas post- flow...

  • Page 154: Roller & Wire-Guide Selection

    Roller & Wire-Guide Selection D.1 Roller Selection ITEM PART # DESCRIPTION COMMENT (Values = Wire Diameter) FEED ROLLER FOR STEEL WIRE 0369557003 ROLLER, .040 (1.0) - .045 (1.2), V-SOLID DEFAULT* 0369557002 ROLLER, .030 (.8) - .040 (1.0), V-SOLID ACCESSORY** 0369557001 ROLLER, .024 (.6) - .030 (.8), V-SOLID OPTIONAL FOR PURCHASE 0369557013...
  • Page 155 GLOSSARY NOTE For an extensive listing of standard welding terms and definitions the following publication is recommended. ESAB Glossary of Technical Terms See: http://www.esabna.com/us/en/support/documentation/downloads.cfm (or see) http://online.fliphtml5.com/zitj/zqen/ ESAB Multi Process FCAW Flux Core Arc Welding GMAW Gas Metal Arc Welding...
  • Page 156 (Intentionally Blank)
  • Page 157 ESAB Subsidiaries and Representative Offices ITALY SWITZERLAND INDONESIA Europe ESAB Saldatura S.p.A. Bareggio ESAB Europe GmbH Baar P.T. ESABindo AUSTRIA Tel: +41 1 741 25 25 (Mi) Pratama Jakarta ESAB Ges.m.b.H Fax: +41 1 740 30 55 Tel: +39 02 97 96 8.1...

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