Related Manuals for ESAB EMS 215ic
Summary of Contents for ESAB EMS 215ic
- Page 1 EMP 215ic, EMS 215ic, EM 215ic US Instruction manual Valid for: serial no. EMP215ic: 552-xxx-xxxx, EMS215ic: 612-xxx-xxxx, EM215ic: 623-xxx-xxxx...
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Page 2: Safety Precautions
1 SAFETY PRECAUTIONS SAFETY PRECAUTIONS Meaning of symbols As used throughout this manual: Means Attention! Be Alert! DANGER! Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. WARNING! Means potential hazards which could result in personal injury or loss of life. -
Page 3: Fires And Explosions
1 SAFETY PRECAUTIONS Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants, high-topped shoes, and a welding helmet or cap for personal protection; in order to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as additional protection against radiated heat and sparks. -
Page 4: Electric And Magnetic Fields
1 SAFETY PRECAUTIONS Make sure that all parts of your body are insulated from both the work piece and from the ground. Do not stand directly on metal or the ground while working in tight quarters or a damp area; stand on an effective insulation layer, such as dry boards, an insulating platform, and wear rubber-soled shoes. -
Page 5: Cylinder Handling
1 SAFETY PRECAUTIONS If you develop momentary eye, nose or throat irritation while operating, this is an indication that the ventilation is not adequate. Stop work and take the necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists. -
Page 6: Additional Safety Information
1 SAFETY PRECAUTIONS WARNING! FALLING EQUIPMENT CAN INJURE • Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any other accessories. • Use equipment of adequate capacity to lift and support unit. • If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. -
Page 7: User Responsibility
1 SAFETY PRECAUTIONS 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 or exceed the standard requirements that apply to this type of equipment. -
Page 8: Fire Hazard
For ordering information, contact your local ESAB dealer or visit us on our website. INTRODUCTION The ESAB EM, EMS and EMP product family is a new generation of MIG only (EM), MIG/Stick (EMS series) and Multi-Process (MIG/Stick/TIG) welding (EMP series) power sources. - Page 9 2 INTRODUCTION Exclusive to ESAB, sMIG provides users with excellent short circuit transfer arc characteristics. The EM, EMS and EMP family connects to 120 V – 230 V, 1 ~ 50/60 Hz input power supplies, supplied by mains or generator power. Incorporating a PFC (Power Factor Correction) circuit significantly increases power efficiency.
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Page 10: Technical Data
3 TECHNICAL DATA EMS series • ESAB EMS 215ic power source • Tweco Fusion™ 180 A MIG torch with 10 ft (3 m) cable / Tweco® pigtail with 0.023 in. (0.6 mm), 0.030 in. (0.8 mm), 0.035 in. (0.9 mm) contact tips and Operator manual all in one bag •... - Page 11 3 TECHNICAL DATA EMP 215ic SMAW - Stick 25 A Breaker 15 A: 20.8 A max. GMAW - MIG Breaker 20 A: 18.0 A eff. 14 A Breaker 15 A: 14.6 A GTAW - TIG 10 A Breaker 15 A: 14.7 A eff.
- Page 12 40 lb (18.2 kg) Operating temperature 14 to 104 °F (-10 to +40 °C) 14 to 104 °F (-10 to +40 °C) Enclosure class IP23S IP23S Application classification EMS 215ic Voltage 230 V, 1 ~ 50/60 Hz 120 V, 1 ~ 50/60 Hz Primary current GMAW - MIG Breaker 15 A: 20.3 A max.
- Page 13 3 TECHNICAL DATA EMS 215ic Stainless steel solid wire 0.030-0.035 in. (0.8-0.9 mm) 0.030-0.035 in. (0.8-0.9 mm) Flux cored wire 0.030–0.045 in. (0.8-1.1 mm) 0.030–0.045 in. (0.8-1.1 mm) Aluminum 0.030-3/64 in. (0.8-1.2 mm) 0.030-3/64 in. (0.8-1.2 mm) Bobbin size Ø 4– 8 in. (100–200 mm) Ø 4– 8 in. (100–200 mm) Dimensions l×w×h 23 × 9 × 16 in.
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Page 14: Installation
4 INSTALLATION EM 215ic Dimensions l×w×h 23 × 9 × 16 in. 23 × 9 × 16 in. (548 × 229 × 406 mm) (548 × 229 × 406 mm) Weight 40 lb (18.2 kg) 40 lb (18.2 kg) Operating temperature 14 to 104 °F (-10 to +40 °C) 14 to 104 °F (-10 to +40 °C) Enclosure class IP23S IP23S Application classification Duty cycle The duty cycle refers to the time as a percentage of a ten-minute period that you can weld at a certain current without overheating. -
Page 15: Lifting Instructions
4 INSTALLATION Lifting instructions The power source can be lifted using any of the handles. Secure the equipment - particularly if the ground is uneven or sloping. Electrical supply The supply voltage should be 230 V AC ±10% or 120 V ±10%. Too low supply voltage may cause poor welding performance. - Page 16 4 INSTALLATION Rating plate with supply connection data 4.3.1 Recommended fuse sizes and minimum cable area 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.
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Page 17: Operation
5 OPERATION 4.3.2 Connecting the power source to input supply Use one of the supplied adapters to connect the power source to mains. OPERATION General safety regulations for handling the equipment can be found in the "SAFETY PRECAUTIONS" chapter of this manual. Read it through before you start using the equipment! NOTE! When moving the equipment, use the intended handle. - Page 18 5 OPERATION WARNING! Make sure that the side covers are closed during operation. WARNING! Tighten the spool locking nut in order to prevent it from sliding off the hub. 4 in. (100 mm) 8 in. (200 mm)
- Page 19 5 OPERATION Connections Front and rear: Knob for current or wire feed speed Torch connection selection (EMP/EMS) Display (EMP/EMS) Mains cable Knob for voltage selection (EMP/EMS) Mains supply switch ON/OFF Main knob for menu navigation Gas valve inlet female 5/8 - 18 UNF (EMP/EMS) Torch/Remote control connection Knob for voltage selection (EM)
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Page 20: Connecting Welding And Return Cables
The polarity can be changed by moving the polarity changeover cable to suit the applicable welding process. Inserting and replacing wire EMS 215ic, EMP 215ic and EM 215ic will handle bobbin sizes of 4 in. (100 mm) and 8 in. (200 mm). See TECHNICAL DATA chapter for suitable wire dimensions for each wire type. - Page 21 5 OPERATION WARNING! Do not place or point the torch near the face, hand, or body as this may result in personal injury. WARNING! Risk of crushing or pinching when replacing the wire spool! Do not use safety gloves when inserting the welding wire between the feed rollers. NOTE! Make sure the correct feed/pressure rollers are used.
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Page 22: Setting The Wire Feed Pressure
5 OPERATION Welding with aluminium wire In order to weld with aluminium wire use optional spool gun. Refer to Instruction manual for spool gun for set up. Setting the wire feed pressure Piece of wood Start by making sure that the wire moves smoothly through the wire guide. Then set the pressure of the wire feeder's pressure rollers. -
Page 23: Shielding Gas
5 OPERATION Open the side cover. Remove the feed roll retaining screw by turning it in a counter-clockwise direction. Change the feed roll. Tighten the feed roll retaining screw by turning it to clockwise position. Close the side cover. NOTE! The visual wire stamp designates the wire diameter groove in use. -
Page 24: Volt-Ampere Curves
5 OPERATION Volt-Ampere curves The curves below show the maximum voltage and amperage output capabilities of the power source for three common welding process settings. Other settings result in curves that fall between these curves. A=Welding current (AMPS), V=Output voltage SMAW (Stick) 230 V SMAW (Stick) 120 V GMAW (MIG) 230 V... - Page 25 5 OPERATION GMAW (MIG) 120 V GTAW (TIG) 230 V GTAW (TIG) 120 V...
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Page 26: Duty Cycle
5 OPERATION Duty cycle The EMS 215ic, EMP 215ic and EM 215ic all have 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. -
Page 27: Overheating Protection
6 CONTROL PANEL Duty cycle on 230 V AC Welding current (A) 5.10 Overheating protection The welding power source has overheating protection that operates if the internal temperature becomes too high. When this occurs the welding current is interrupted and an overheating symbol appears in the display (EMP and EMS), or the overtemperature indicator is illuminated (EM). - Page 28 EMP 215ic sMIG mode Manual MIG mode Flux cored wire mode Stick/MMA mode Lift-TIG mode Settings User manual information Dialogue box EMS 215ic sMIG mode Manual MIG mode Flux cored wire mode Stick/MMA mode Settings User manual information Dialogue box 6.1.2...
- Page 29 6 CONTROL PANEL 6.1.3 Manual MIG mode Home screen Information Memory MIG/Spool gun selection Parameter Wire feed speed Voltage Dialogue box 6.1.4 Flux cored wire mode Home screen Information Memory Parameter Wire feed speed Voltage Dialogue box 6.1.5 Stick mode Home screen Information Memory...
- Page 30 6 CONTROL PANEL 6.1.6 LIFT-TIG mode (EMP 215ic only) Home screen Information Memory Parameter Amperage Dialogue box 6.1.7 Settings Reset mode Inch/Metric Basic/Advanced Language Information Home screen Dialogue box 6.1.8 User manual information Maintenance information Wear & Spare parts Operation information Home screen Dialogue box 6.1.9...
- Page 31 6 CONTROL PANEL Parameters Flux cored Parameters Manual MIG Percent Settings Preflow The time the shielding gas stays on Smart MIG before the welding arc is started Postflow The time the shielding gas stays on after Cancel the welding arc is stopped Saving welding programs for Seconds a specific application when in...
- Page 32 6 CONTROL PANEL Arc force On stick welding-increasing amps when the arc length is Trim bar Changing the weld shortened to reduce or bead profile from flat to convex eliminate the freezing of the or flat to concave stick electrode in the weld puddle Downslope Sloping the current down over a period...
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Page 33: How To Navigate - Em 215Ic
6 CONTROL PANEL How to navigate - EM 215ic Spool gun indication: Symbol illuminates when spool gun is connected. Over temperature indication: Symbol illuminates when product is overheated. Volt/Amp display: LED displays the Volts and Amps values during welding. It holds the last used parameter. -
Page 34: Routine Maintenance
7 MAINTENANCE MAINTENANCE NOTE! Regular maintenance is important for safe and reliable operation. CAUTION! Only persons with the appropriate electrical knowledge (authorized personnel) may remove the cover of the product or carry out service, maintenance or repair work on the welding equipment. CAUTION! The product is covered by manufacturer's warranty. -
Page 35: Torch And Liner Maintenance
7 MAINTENANCE Power source and wire feeder cleaning procedure NOTE! Always were safety gloves during cleaning. Disconnect the power source from the mains socket. Open the lid and release the tension from the pressure roller by turning the tension screw (1) counter-clockwise and then pull it toward you. Remove the wire and the wire spool. -
Page 36: Troubleshooting
8 TROUBLESHOOTING TROUBLESHOOTING Try these checks and inspections before sending for an authorized service technician. Type of fault Corrective action Porosity within the weld • Check that the correct gas is connected and the correct metal gas flow is used. •... -
Page 37: 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 EM 215ic, EMS 215ic, and EMP 215ic are designed and tested in accordance with international standards IEC 60974-1, IEC 60974-5, Canadian and US standards CAN/CSA-E60974-1:12 and US standards ANSI/IEC 60974-1:2008.