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

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Rebel EMP 205ic AC/DC
Instruction manual
Valid for: Serial number: CD341YY-XXXXXX
0463 652 101 US 20240226

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

  • Page 1 Rebel EMP 205ic AC/DC Instruction manual Valid for: Serial number: CD341YY-XXXXXX 0463 652 101 US 20240226...

  • Page 2: Table Of Contents

    Welding with aluminum wire ..............Setting wire-feed pressure ..............Changing the feed/pressure rollers ............5.10 USER INTERFACE ..................How to navigate ..................Main menu ....................sMIG mode: Basic .................. sMIG mode: Advanced ................0463 652 101 © ESAB AB 2024...
  • Page 3 6.20 MAINTENANCE ................... Routine maintenance ................Wire-feeder assembly maintenance ............. 7.2.1 Wire-feeder assembly cleaning ............Rebel EMP 205ic AC/DC power side maintenance ......Torch liner maintenance ................ 7.4.1 Torch liner cleaning ................TROUBLESHOOTING ................. Preliminary checks ................. User interface error codes ..............

  • Page 4: Safety

    A flameproof apron may also be desirable as protection against radiated heat and sparks. 0463 652 101 - 4 - © ESAB AB 2024...
  • Page 5 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 652 101 - 5 - © ESAB AB 2024...
  • Page 6 When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. 0463 652 101 - 6 - © ESAB AB 2024...
  • Page 7 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 652 101 - 7 - © ESAB AB 2024...

  • Page 8: User Responsibility

    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 9 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 652 101 - 9 - © ESAB AB 2024...
  • Page 10 As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations. For further information contact the nearest ESAB dealer. 0463 652 101 - 10 - © ESAB AB 2024...

  • Page 11: California Proposition 65 Warning

    Wash hands after use. For more information, go to www.P65Warnings.ca.gov. 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. 0463 652 101 - 11 - ©...

  • Page 12: Introduction

    For more advanced users, any number of functions could be introduced and customized to give maximum flexibility. ESAB accessories for the product can be found in the "ACCESSORIES" chapter of this manual. Equipment The Rebel EMP 205ic AC/DC power source is supplied with:...

  • Page 13: Technical Data

    Breaker 15 A: 95 A/13.8 V 125 A/15.0 V 40% duty cycle* Breaker 15 A: 105 A/14.2 V — 25% duty cycle* — 205 A/18.2 V Setting range (DC) 10 – 130 A 10 - 205 A Permissible load at MMA/Stick/SMAW 100% duty cycle* 55 A/22.2 V 100 A/24 V 0463 652 101 - 13 - © ESAB AB 2024...
  • Page 14 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 652 101 - 14 - © ESAB AB 2024...

  • Page 15: Installation

    B. 8 in. (200 mm) C. 8 in. (200 mm) If permanent installation leave enough room to open door and access bobbin side. WARNING! Secure the equipment - particularly if the ground is uneven or sloping. 0463 652 101 - 15 - © ESAB AB 2024...

  • Page 16: High Frequency Interference

    4.2.1 User’s responsibility The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected, then it shall be the 0463 652 101 - 16 - © ESAB AB 2024...

  • Page 17: Assessment Of Area

    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 652 101 - 17 - © ESAB AB 2024...

  • Page 18: Main Supply

    S scmin NOTE! Use the welding power source in accordance with the relevant national regulations. 0463 652 101 - 18 - © ESAB AB 2024...

  • Page 19: Recommended Fuse Sizes And Minimum Cable Area For

    Mains supply cable 13 AWG (2.5 mm ) 13 AWG (2.5 mm Maximum recommended extension cord length 25 ft (8 m) 50 ft (15 m) Minimum recommended grounding conductor 13 AWG (2.5 mm ) 13 AWG (2.5 mm size 0463 652 101 - 19 - © ESAB AB 2024...

  • Page 20: Supply From Power Generators

    Generators with Automatic Voltage Regulation (AVR) or with equivalent or better type of regulation, with rated power of minimum 8 kW 1 phase, are recommended. 0463 652 101 - 20 - © ESAB AB 2024...

  • Page 21: Operation

    Tighten the bobbin bolt to prevent it from sliding off the hub. WARNING! Rotating parts can cause injury, take great care. NOTE! When moving the equipment, use the handle. Never pull the cables. 0463 652 101 - 21 - © ESAB AB 2024...

  • Page 22: Connections

    5 OPERATION Connections Front & rear views: Model Rebel EMP 205ic AC/DC Encoder for current or wire-feed speed Polarity changeover cable adjustment Encoder for voltage adjustment Display Push button encoder (display Gas inlet for MIG/MAG/GMAW navigation) Gas outlet connection (TIG/GTAW)

  • Page 23: Connecting Welding And Return Cables

    [+] terminal and the return lead into the negative [-] terminal. Be sure that the connections are tight. Secure the work clamp to the work piece in a 0463 652 101 - 23 - © ESAB AB 2024...

  • Page 24: Shielding Gas

    ). Stainless steel can be welded with mixed gas (Ar + CO ) or trimix (He + Ar + CO ). Aluminum and silicon bronze use pure argon gas (Ar). 0463 652 101 - 24 - © ESAB AB 2024...

  • Page 25: Duty Cycle

    If installing aluminum wire, see "Welding with aluminum wire" section. The Rebel EMP 205ic AC/DC 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. 0463 652 101 - 25 - © ESAB AB 2024...

  • Page 26: Installing Wire

    Close the tension-arm onto the wire in its groove on the drive rolls. Re-connect the torch assembly to the unit being careful to insert the end of the wire protruding from the outlet guide into the torch connector. Power up the unit. 0463 652 101 - 26 - © ESAB AB 2024...

  • Page 27: Removing Wire

    Open the wire-bobbin side cover of the unit and observe how the wire feeds from the bobbin, through the wire feed assembly and into the torch connection. Path of wire through wire feed assembly Wire from bobbin Wire to torch Pressure arm Tension knob assembly 0463 652 101 - 27 - © ESAB AB 2024...
  • Page 28 5 OPERATION Locate the wire-feed assembly and its tension-knob. Wire-feed assembly part names Tension knob Inlet wire-guide Outlet wire-guide MIG/MAG/GMAW torch locking knob Wire-feed roller 0463 652 101 - 28 - © ESAB AB 2024...
  • Page 29 Pull the length of old wire out of the torch assembly from either end of the torch assembly. Remove the bobbin from the unit. 0463 652 101 - 29 - © ESAB AB 2024...

  • Page 30: Welding With Aluminum Wire

    If you hold the welding torch approximately 2 in. (50 mm) from the piece of wood, the wire should be fed out and bend. Check feed-roller for slip, indicating no over-pressure 0463 652 101 - 30 - © ESAB AB 2024...

  • Page 31: Changing The Feed/Pressure Rollers

    Three dual groove feed roller are supplied as standard. Change the feed roller to match the filler metal wire diameter. 0463 652 101 - 31 - © ESAB AB 2024...
  • Page 32 Visual indication on the face of the drive roll indicates the diameter of the groove on the outside of the drive roll and the groove that is in use for the selected wire diameter. 0463 652 101 - 32 - © ESAB AB 2024...
  • Page 33 5 OPERATION Wire-feed rollers offered in multiple sizes Labels 0463 652 101 - 33 - © ESAB AB 2024...

  • Page 34: User Interface

    MMA/Stick/SMAW mode DC TIG/GTAW mode AC TIG/GTAW mode Settings User manual Dialogue box sMIG mode: Basic Home screen selection Information Memory Material selection Wire-feed speed indication Material thickness indication Dialogue box 0463 652 101 - 34 - © ESAB AB 2024...

  • Page 35: Smig Mode: Advanced

    Information Memory Material selection Weld variables Wire-feed speed indication Voltage indication Dialogue box Flux cored wire mode: Basic Home screen selection Information Memory Wire-feed speed indication Voltage indication Dialogue box 0463 652 101 - 35 - © ESAB AB 2024...

  • Page 36: Flux Cored Wire Mode: Advanced

    "Hot/ON." 6.11 DC TIG/GTAW mode: Basic Home screen selection Information Memory Pulse ON/OFF section and pulse weld variables Amperage indication Dialogue box Cooler connected indicator Remote connected indicator 0463 652 101 - 36 - © ESAB AB 2024...

  • Page 37: Dc Tig/Gtaw Mode: Advanced

    Cooler connected indicator Remote connected indicator 6.14 AC TIG/GTAW mode: Advanced Home screen selection Information Memory Weld variables Amperage indication Balance indication Dialogue box Cooler connected indicator Remote connected indicator 0463 652 101 - 37 - © ESAB AB 2024...

  • Page 38: Settings

    A non-zero burn back setting will disable SCT. ICON MEANING ICON MEANING Home Spot time on/off selection Burn back time SCT Selection on Short Circuit display Termination 0463 652 101 - 38 - © ESAB AB 2024...
  • Page 39 Parameters Flux cored Parameters Manual MIG/MAG/GMAW Percent MMA/Stick/SMAW Pre-flow time Smart MIG/MAG/GMAW Post-flow time Lift TIG/GTAW Seconds Saving Settings Cancel Spool torch Remote connected indicator Settings Cooler connected indicator 0463 652 101 - 39 - © ESAB AB 2024...
  • Page 40 Downslope time Advanced Settings Hot start Basic Settings Arc dynamics Language selection Memory Stick electrode choice Upslope time Unit of Measure Wire diameter Concave bead profile DC TIG/GTAW Convex bead profile 0463 652 101 - 40 - © ESAB AB 2024...

  • Page 41: Dc Tig/Gtaw Pulse

    Pulse Peak Time 50% and Pulses per Second: 2. User will not be able to adjust these Pulse parameters, in order to adjust these parameters user has to go to advanced mode. Below picture illustration shows the navigation/setup of DC TIG/GTAW Pulse in basic mode (A-B-C-D). 0463 652 101 - 41 - © ESAB AB 2024...
  • Page 42 Lower encoder. Can be adjusted between 0.1 and 500. Below picture illustration shows the navigation/setup of DC TIG/GTAW Pulse in advanced mode (A-B-C-D-E-F-G-H-I-J). 0463 652 101 - 42 - © ESAB AB 2024...
  • Page 43 6 USER INTERFACE Below picture illustration shows an example of DC TIG/GTAW output current ideal waveforms in Basic and Advanced modes. 0463 652 101 - 43 - © ESAB AB 2024...

  • Page 44: Ac Tig/Gtaw Welding

    Balance = 70%. User will not be able to adjust these parameters, in order to adjust these parameters user has to be in advanced mode. Advanced Mode: In advanced mode user has the ability to adjust the AC TIG/GTAW settings as explained below. 0463 652 101 - 44 - © ESAB AB 2024...
  • Page 45 Offset gives the user ability to have a narrower bead with deeper penetration and no visible cleaning action or wider bead with less penetration and clear visible cleaning action based on which direction the Offset is adjusted. 0463 652 101 - 45 - © ESAB AB 2024...
  • Page 46 Another example; in the case of Offset set to +15 A with a user set current of 104 A, the weld current drives to EP = 119 A and EN = 89 A as shown in the pictures below. Below picture illustration shows the navigation/setup of AC TIG/GTAW Welding in advanced mode (A-B-C-D-E-F-G-H-I-J-K). 0463 652 101 - 46 - © ESAB AB 2024...
  • Page 47 6 USER INTERFACE Below picture illustration shows an example of AC TIG/GTAW output current ideal waveforms in Basic and Advanced modes. 0463 652 101 - 47 - © ESAB AB 2024...

  • Page 48: Lift Tig / Gtaw Welding

    The shielding gas will continue to flow in order to protect the weld and the tungsten electrode. A = Gas pre flow/arc start B = Slope up C = Slope down/arc end D = Gas post-flow 0463 652 101 - 48 - © ESAB AB 2024...
  • Page 49 The shielding gas will continue to flow in order to protect the weld and the tungsten electrode. A = Gas pre-flow C = Slope down B = Slope up D = Gas post-flow 0463 652 101 - 49 - © ESAB AB 2024...

  • Page 50: Maintenance

    NOTE! There are no user serviceable parts inside of the power supply side of the 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 51: Wire-Feeder Assembly Maintenance

    Inspect if the input wire-feed guides and the feed rollers for wear and need replacement. NOTE! When removing the roller be careful not to lose the drive-shaft key on the motor shaft. 0463 652 101 - 51 - © ESAB AB 2024...

  • Page 52: Rebel Emp 205Ic Ac/Dc Power Side Maintenance

    There are no user-serviceable parts on the power-side. In dusty environments, the power-side should be checked periodically for any dust/debris accumulation because of the fan forced-air cooling used on this side. Any maintenance on this side should be done by an authorized ESAB service technician. 0463 652 101 - 52 - ©...

  • Page 53: Torch Liner Maintenance

    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 652 101 - 53 - © ESAB AB 2024...

  • Page 54: Troubleshooting

    Make sure you are using the correct polarity. The electrode basic welding holder is usually connected to the positive polarity and the work problems lead to the negative polarity. Consult the electrode data sheet. 0463 652 101 - 54 - © ESAB AB 2024...
  • Page 55 Make sure that you have not exceeded the recommended duty protection trips cycle for the weld current being used. frequently. • Make sure the air inlets or outlets are not blocked. • Make sure fans are operating when welding. 0463 652 101 - 55 - © ESAB AB 2024...

  • Page 56: User Interface Error Codes

    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 652 101 - 56 - © ESAB AB 2024...

  • Page 57: Ordering Spare 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 58: Diagram

    DIAGRAM DIAGRAM Functional block diagram 0463 652 101 - 58 - © ESAB AB 2024...

  • Page 59: Ordering Numbers

    ORDERING NUMBERS ORDERING NUMBERS Ordering no. Description Note 0558 102 553 Rebel EMP 205ic AC/DC Bobbin size 4–8 in. (100–200 mm) 0463 661 001 Spare Parts List 0463 652 101 - 59 - © ESAB AB 2024...

  • Page 60: Wear Parts

    0.023" (0.6 mm) 0.035" (0.9 mm) 7977036 Drive roll “V" groove Fe/SS 0.024" (0.6 mm) 0.030" (0.8 mm) 7977732 Drive roll "Flux cored V" Fe/SS 0.030" (0.8 mm) groove 0.035" (0.9 mm) 0558 102 329 Locking knob 0463 652 101 - 60 - © ESAB AB 2024...
  • Page 61 WEAR PARTS Item Ordering no. Description Wire type Wire dimensions 0558 102 331 Pressure arm assembly 0558 102 331 Screw 0558 102 333 MIG torch locking knob 0463 652 101 - 61 - © ESAB AB 2024...

  • Page 62: Accessories

    Accommodates 1 × 9 in. (228.6 mm) diameter cylinder 0558 103 000 Rebel dual cylinder cart Accomodates maximum 9 in. diameter cylinder with accessory drawer and a parts storage box. 0700 300 872 Rebel two wheel trolley 0463 652 101 - 62 - © ESAB AB 2024...
  • Page 63 ACCESSORIES 0447 888 880 CoolMini 2 Cooler 0700 500 084 MMA 4 Analogue remote control including 33 ft. (10 m) cable and 8-pin connector 0463 652 101 - 63 - © ESAB AB 2024...

  • Page 64: Replacements Parts

    ESAB Heliarc SR-17 TIG Torch, gas-cooled, 12.5 ft (4 m) 0700 026 611 ESAB Heliarc SR-17 TIG Torch, gas-cooled, 25 ft (8 m) 0558 102 667 ESAB 200 A electrode holder & lead assembly, 13 ft (4 m), 2 in. (50 mm) dinse WS200G10 Tweco® 200 A ground clamp & lead assembly, 10 ft (3 m), 2 in.
  • Page 65 REPLACEMENTS PARTS 0463 652 101 - 65 - © ESAB AB 2024...
  • Page 66 For contact information visit esab.com ESAB Corporation, 2800 Airport Road Denton, TX 76207, USA, Phone +1 800 378 8123 manuals.esab.com...

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