ESAB EMP 205ic AC/DC User manual

Service manual

0463 669 001 GB 20190517

Valid for: 814-xxx-xxxx

EMP 205ic AC/DC

TABLE OF CONTENTS

0463 669 001 © ESAB AB 2019

READ THIS FIRST.................................................................................... 4

BEFORE STARTING SERVICE................................................................ 5

Service aid .............................................................................................. 5

ESAB Tools ............................................................................................. 5

INTRODUCTION....................................................................................... 6

Equipment ............................................................................................... 6

ERROR CODES........................................................................................ 7

Error code fault isolation ....................................................................... 7

ERR 001 - TEMPERATURE FAULT..................................................... 7

ERR - 002 - TEMPERATURE FAULT................................................... 7

ERR - 003 - SYSTEM LOCKED POWER FAULT ................................ 8

ERR 004 - SYSTEM LOCKED VRD FAULT......................................... 9

ERR 005 - PS LOCAL FAULT SERVICE REQUIRED ......................... 10

ERR 006 - SET PCBA-20AP1 SW2.4 ON............................................ 10

ERR 007 - Reserved ............................................................................ 10

ERR 008 - VOLTAGE FAULT SERVICE REQUIRED........................... 11

ERR 009 - LOW INPUT........................................................................ 11

ERR 010 - Reserved ............................................................................ 11

ERR 011 - DEFAULT RESET UNCONFIRMED ................................... 12

ERR 012 - COMMUNICATION FAULT................................................. 12

ERR 013 - Reserved ............................................................................ 12

ERR 014 - SENSOR FAULT SERVICE REQUIRED............................ 12

ERR 015 – HARDWARE ERROR ........................................................ 12

ERR 016 – AC/DC TEMP TRIP............................................................ 13

ERR 017-019 – Reserved .................................................................... 13

ERR 020 – GRAPHICS ERROR .......................................................... 13

ERR 021 – GRAPHICS ERROR .......................................................... 13

ERR 022 – WRITE MEM Err ................................................................ 13

ERR 023 – READ MEM Err RETRIEVE FACTORY............................. 13

ERR 024-029 – Reserved .................................................................... 13

ERR 030 - FIRMWARE ERROR .......................................................... 13

ERR 031 – NVRAM CHECKSUM BAD................................................ 14

DIAGRAM ................................................................................................. 15

TECHNICAL DATA ................................................................................... 18

EMP 205ic AC/DC ................................................................................... 18

SOFTWARE UPDATE AND SYSTEM CALIBRATION ............................ 21

TROUBLESHOOTING .............................................................................. 22

Power-supply side component modules details ................................. 22

Service modules part numbers............................................................. 23

Design structure of the power supply circuit......................................... 23

TABLE OF CONTENTS

0463 669 001 © ESAB AB 2019

Block diagram....................................................................................... 24

Subassembly description, location, test points, removal .................. 26

User interface (UI) - PCB1/1AP1.......................................................... 26

UI disassembly .................................................................................. 26

Main power switch (SW1) and Thermal breaker (CB1)........................ 27

Main power switch (SW1) and Thermal breaker (CB1) disassembly 28

Main power board - PCB2/15AP1 ........................................................ 29

Main power board (PCB2/15AP1) disassembly ................................ 29

Control board - PCB3/20AP1 ............................................................... 31

Control board (PCB3/20AP1) disassembly ....................................... 33

Main transformer - T1........................................................................... 34

AC/DC module - PCB8/15AP3 ............................................................. 35

AC/DC module disassembly.............................................................. 35

Output inductor - L2.............................................................................. 39

IPS PCB assembly - PCB4/15AP2....................................................... 42

IPS board disassembly...................................................................... 42

HF starter PCB assembly - PCB9/15AP4 ............................................ 43

HF starter board disassembly ........................................................... 44

HF bypass board - PCB10/15AP5........................................................ 44

Current sensor - CT.............................................................................. 45

Cooling fans - M2, M3 .......................................................................... 46

Cooling fans disassembly.................................................................. 46

Gas valves - SOL1, SOL2 .................................................................... 49

System fault troubleshooting................................................................ 49

Preliminary functional checks............................................................... 49

LED status......................................................................................... 52

POWER SOURCE DOES NOT POWER UP ....................................... 53

NO WELD OUTPUT............................................................................. 59

POOR WELDS ..................................................................................... 65

NO UI RESPONSE............................................................................... 68

UI Board test ..................................................................................... 68

User Interface (UI) does not respond or returns back to home/weld

mode screen......................................................................................

71

User Interface Main Encoder Knob press does not work .................. 76

NO GAS OUTPUT................................................................................ 76

REMOTE CONTROL OR TORCH TRIGGER CHECK ........................ 77

SPARE PARTS AND ACCESSORIES ..................................................... 79

Rights reserved to alter specifications without notice.

READ THIS FIRST

0463 669 001

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READ THIS FIRST

Maintenance and repair work must be performed by an experienced person, and electrical

work only by a trained electrician. Use only recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for

help in connection with fault-tracing and repair.

The circuit boards are divided into numbered blocks. Component names in the wiring

diagram are listed in the component description.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see the "SPARE PARTS" chapter

in this manual.

This manual contains details of design changes that have been made up to and including

February 2019.

The manual is valid for:

• EMP205icAC/DC with serial number 814-xxx-xxxx

NOTE!

The unit is tested by ESAB in a general set-up. The responsibility for safety and

function, of the specific set-up, lies with the integrator.

The EMP205ic AC/DC are designed and tested in accordance with the standards stated in

the instruction manual. On completion of service or repair work, it is the responsibility of the

person(s) performing the work to ensure that the product still complies with the requirements

of the involved standards.

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

BEFORE STARTING SERVICE

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BEFORE STARTING SERVICE

Service aid

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610×610mm /

24×24in)

• A 1.5m (3.28ft) long ground cable with

a crocodile clip

• An adjustable wrist strap and cable with

a built-in protective resistor

Antistatic service kit

ESAB Tools

Checkmaster 9000

Ordering no. 0740 505 880

Checkmaster 9000 DC - calibrated

Ordering no. 0740 505 881

0460 868 880

ESAB test box TB1

INTRODUCTION

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INTRODUCTION

The ESAB REBEL EMP 205ic AC/DC product 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.

The EMP 205ic AC/DC features a 4.3 in. (11 cm) color TFT (Thin Film Transistor) user

interface (UI) display which provides quick and easy selection of weld process and

parameters, suitable for both newly trained and intermediate-level users. For more advanced

users, any number of functions could be introduced and customized to give maximum

flexibility.

Equipment

The ESAB EMP 205ic AC/DC power source is supplied with:

• Tweco® Fusion™ 180 A MIG torch with Bonus Tweco® Contact Tips

• ESAB Heliarc HW 17 TIG Torch with Accessories

• ESAB 200 Amp Electrode Holder with Lead Cable

• Tweco® 200 Amp Earth Clamp with Lead Cable

• 120/230 V Power Adapter (USA ONLY)

• Victor® Flow Meter with 6 ft (2 m) Gas Hose

• Remote Amperage Foot Control

• ESAB sample spool .030" (0.8 mm) 70S–6 wire

• ESAB Atom Arc Acclaim 1/8" Premium Stick Electrodes 1# Sample Pack

• Drive Rolls for .023" (0.6 mm), .030" (0.8 mm) and .035" (0.9 mm) Wire Diameter

• Outlet Guides .023" -.045" (0.6 mm -1.2 mm)

• Thickness Gauge

• Welding chart (French)

• USB Stick Including Manuals

• Quick Start Guide

• Safety manual

ERROR CODES

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ERROR CODES

WARNING!

Bus voltage of 400 V DC will be present on the heatsinks of the main power board

while unit is on. Wait 40 seconds after removing power before handling.

Error code fault isolation

This section is for solving error codes appearing at power-up.

Faults resulting from user interaction or only during welding can be isolated using procedures

found in other sections identified below.

ERR 001 - TEMPERATURE FAULT

This section is to isolate a false digital temperature fault. This fault monitors the PFC

heatsink, main Inverter heatsink and main transformer.

Make sure that the system has at least 1 hour in un-powered state to cool down before

following these instructions.

A. With power applied, measure with DVMM the voltage between Control

Board 20AP1 CN19 pins 6 and 4 (ground). The voltage should be less

than 0.25VDC, if it is less than 0.25V replace Control Board 20AP1;

otherwise go to Step B.

B. (Hint: To prevent pin damage, use flat screwdriver to evenly remove wide

Control Board 20AP1 connectors).

Remove AC Mains power, remove Control Board 20AP1, and disconnect

15AP1 CN7 from Main Power board (PCB2/15AP1). Measure resistance

across CN7 plug. If it is not ~10K ohms, inspect plug connection or

replace Mains Transformer T1; If measurement is ~10K ohms, go to Step

C.

C. Inspect Control 20AP1 CN19 cable assembly and measure resistance for

continuity between pin 6 of each end of the cable, it should be ~0 ohms; If

cable reads 0 ohms, inspect for dust or replace faulty 15AP1 Main Power

board (PCB2/15AP1); Otherwise repair/replace the Cable.

ERR - 002 - TEMPERATURE FAULT

This section is to isolate a false output diode temperature fault.

Make sure that the system has at least 1 hour in un-powered state to cool down before

following these instructions.

ERROR CODES

0463 669 001

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A. With power applied, measure with DVMM at 20AP1 CN19 pin 3 to pin 4

(Ground). If between 1.0 - 2.0 Vdc, then replace 20AP1 Control PCB;

otherwise go to Step B.

B. Turn off power, unplug Rebel from AC mains power, disconnect CN28

on 15AP3 AC/DC Board, measure resistance across CN28 connector

leads on the AC/DC Board PCBA.

If measured value is 10K +/- 2K ohms, then there is a cable issue, go to

Step C.

If measured value is not 10K +/- 2K, replace 15AP3 AC/DC Board.

C. (Hint: To prevent pin damage, use flat screwdriver to evenly remove wide

Control Board 20AP1 connectors). Reconnect 15AP3 CN28, measure

continuity between 15AP3 CN28 PCBA connector leads on the PCB and

20AP1 CN19 connector plug pins 3 and pin 4. If the continuity is not good

for either the black and red wires, or the black and red are shorted

together, inspect both wire harness #13989 and #14028 for damage. If

the cabling is good, replace the Main Power board (PCB2/15AP1)

15AP1.

Figure 1. Reference for Err 001 and Err 002

ERR - 003 - SYSTEM LOCKED POWER FAULT

This section is to isolate a persistent low voltage fault at power up when the unit is in standby

or idle mode. This fault can temporarily happen under heavy load conditions, in which case,

is a warning that the 400VDC bus voltage has momentarily gone below 350VDC due to

input mains voltage sag caused by low AC input voltage, long line length or thin gauge

extension cords, causing a excessive voltage drop before reaching the Rebel. For the

service personnel having this fault continuously at power up follow the below procedure.

ERROR CODES

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A. Caution High Voltage Measurement: With power applied, measure on

15AP1 with DVMM the voltage between heat sink terminal at D50 and

R88 resistor lead. See Figure 2. - DC BUS Voltage Test Point on Power

Board. If voltage measured is 400 VDC +/- 10V go to Step B, if not go

section MACHINE DOES NOT POWER UP, (6) IPS CHECK.

B. With power applied measure between Control Board 20AP1 CN19 pins 5

and 4 (ground). The voltage should be less than 0.25VDC. If it is less

than 0.25V and the fault Error 4 persist, replace Control Board 20AP1;

otherwise go to Step C.

C. (Hint: To prevent pin damage, use flat screwdriver to evenly remove wide

Control Board 20AP1 connectors).

Remove AC Mains power, remove Control Board 20AP1. With 20AP1

removed, check continuity of pins 4 and 5 end-to-end across cable

assembly #14028. If cable is good replace 15AP1 Main Power board

(PCB2/15AP1) otherwise repair/replace cable assembly.

Figure 2. DC BUS Voltage Test Point on Power Board

ERR 004 - SYSTEM LOCKED VRD FAULT

This section isolates failure of output (OKC) voltage being too high when VRD is enabled. It

applies to Australia Models only. VRD indication in MMA mode on other models indicate

improper dip switch settings. Please see figure 3A below for proper switch positions for

non-Australian models. See figure 3B for Australian models.

A. Check proper switch position (SW2), check latest software is loaded.

B. If Step A checks out OK, then replace 20AP1 Control Board.

ERROR CODES

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Figure 3. Control Board SW2 Positions

ERR 005 - PS LOCAL FAULT SERVICE REQUIRED

This section isolates Low Voltage of Internal Power Supply, IPS Error. This error code gets

set when the 24VDC supply is less than 22.5VDC. This can happen from overload from a

faulty peripheral, PCBA or wire feeder.

A. With power applied, measure with a DVMM 20AP1 CN2 between pins 1

and pins 7. If 23-24VDC is present replace 20AP1 Control PCB.

Otherwise go to step B.

B. Turn off power, disconnect the following 20AP1 connectors; CN7, CN9,

CN10, CN11, CN13, CN14. Reapply power, if the fault clears restore

connectors one at a time to isolate bad subassembly (fan, solenoid,

motor, etc). Otherwise go to Step C.

C. Turn off power, remove 20AP1 CN17 and CN19 of the Control PCB.

Reapply power, if the fault clears replace 20AP1 Control Board; otherwise

go to Step D.

D. Turn off power, remove 20AP1 CN2 of the Control PCB. Reapply power,

measure the voltage of plug sourcing 20AP1 CN2 between pins 1 and 7.

If the voltage is not ~24VDC replace 15AP2 IPS Board. Otherwise

replace 20AP1 Control Board.

ERR 006 - SET PCBA-20AP1 SW2.4 ON

This section isolates VRD Configuration Error. This Error happens when the VRD enable

switch 20AP1 S1.2 is enabled but VRD Capability switch 20AP1 S1.4 is disabled. Please see

"Control Board SW2 Positions", page10 for proper switch positions of S1 for non-VRD

use.

A. Check proper switch position (all off for non-Australian models), exercise

the switch leaving in proper positioin, check latest software is loaded.

B. If Step A checks good, replace 15AP1 Control Board.

ERR 007 - Reserved

ERROR CODES

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ERR 008 - VOLTAGE FAULT SERVICE REQUIRED

This error occurs when the OCK terminal voltage is not properly sensed when a voltage is

expected to be present, for instance when in MMA mode and the output is enabled. It takes

10 continuous second of no output to trip this fault. First attempt a software update to the

latest version before troubleshooting this fault.

A. Apply power, place unit in MMA mode, observe D33 on 20AP1 Control

Board (PCB3/20AP1) while enabling the output. Verify the green LED

flashes bright momentarily and remains on dimly. If the LED flashes or

stays on brightly go to Step B. If the LED does not flash replace 20AP1

Control Board.

B. With MMA enabled, measure the across OKC +/- terminals. If the voltage

is greater than 50VDC remove AC power with SW1 and perform the

following continuity cable checks: If voltage is ~0VDC go to section 'NO

WELD OUTPUT', step 9 to 13.

Check continuity of cable connection at PCB3/20AP1 CN1 pin 1 to XS1

(OKC+).

Check continuity of cable connection at PCB3/20AP1 CN1 pin 2 to

15AP3 TP39.

Check continuity of cable connection at 20AP1 CN15 pin 1 to XS2

(OKC-).

If any are not ~0 ohms repair/replace cable assembly.

If the cables connections are good replace Control Board (PCB3/20AP1).

ERR 009 - LOW INPUT

This section isolates persistent Low Voltage Error. AC Mains voltage is monitored at the

Control Board. This fault can temporarily appear under heavy load conditions, in which case,

this is a warning and not a failure. Weld performance is affected by AC input voltage droop.

Long input power cords can result in significant voltage drop when under heavy output loads.

For service personnel having this fault continuously, and at power up, follow the below

procedure.

A. Apply power and check AC voltage at 20AP1 CN19 across pin 10 and pin

11 for:

When connected to 120VAC check monitor voltage of 7.85 AC Vrms +/-

0.4.

When connected to 230VAC check monitor voltage of 15.0 AC Vrms +/-

0.75V.

The conversion factor is (AC Vrms IN/15.25).

If the voltage is correct, replace the 20AP1 Control PCB; otherwise go to

step B.

B. Turn off power, disconnect from wall outlet, and remove PCB3/20AP1

Control Board. Check continuity of cable assembly #14028 end-to-end of

pins 10 and 11.

Repair/Replace if cable is faulty.

If cable is good replace Power board (PCB2/15AP1).

ERR 010 - Reserved

ERROR CODES

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ERR 011 - DEFAULT RESET UNCONFIRMED

This error happens when the 20AP1 does not report it has applied factory default values to

software. It is extremely rare to have this fault and difficult to isolate to component. Perform

the following steps in the event of this error.

A. Power up system navigate to the setup menu.

B. Attempt perform a factory reset.

If the error message continues to appear, attempt a full software update

to the latest version and repeat Steps A and B.

C. If step B does not clear the issue, replace 20AP1 Control PCB. Update to

the latest software and repeat Step A and B.

D. If step C does not correct the fault replace 1AP1 User Interface Board.

ERR 012 - COMMUNICATION FAULT

This fault happens when one side of the communication link has not responded for 5

seconds or more.

This can happen due to faulty cabling, high noise interference or faulty PCBs. Update to the

latest software version and recheck before troubleshooting hardware for this issue.

A. If the issue occurs during welding then check service bulletin to apply

Si180410.

B. If the issue occurs during idle state check cable assembly #10746G

continuity, if cable is good replace 1AP1 User Interface Board and do a

recheck.

C. If step B does not solve the issue replace 20AP1 Control Board and do a

recheck.

ERR 013 - Reserved

ERR 014 - SENSOR FAULT SERVICE REQUIRED

ERR 015 – HARDWARE ERROR

This section isolates fault occuring when the presence of AC/DC inverter board

(PCB8/15AP3) is not detected by the Control Board (PCB3/20AP1).

A. Check for physical connection of the wire harness between the Control

Board (PCB3/20AP1) CN14 connector and AC/DC Inverter Board

(PCB8/15AP3) CN3 connector.

B. Check for LED D28 illuminating solid Green on AC/DC Inverter Board

(PCB8/15AP3), if D28 ON go to Step C. Otherwise go to Step E.

C. Measure the DC voltage at 20AP1/PCB3 CN14 between pin 5 and pin 3

for ~12 Vdc +/-1V. If correct voltage is present replace Control Board

(PCB3/20AP1). Otherwise go to Step D.

D. Disconnect cable assembly #13619 from CN14 on Control Board

(PCB3/20AP1) and measure the DC Voltage on #13619 harness

(disconnected end) between pin 5 and pin 3 for ~12VDC +/-1V on

AC/DC Inverter board (PCB8/15AP3). If voltage is not present

replace/repair #13619 harness, otherwise go to Step E.

ERROR CODES

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E. Check for 24VDC voltage across CN1 connector on AC/DC Inverter

board (PCB8/15AP3). If voltage is present then replace AC/DC Inverter

board (PCB8/15AP3). Otherwise go to Step F.

F. Disconnect cable assembly #13999 from CN1 connector on AC/DC

Inverter board (PCB8/15AP3) and measure voltage across disconnected

end of cable #13999 for ~24VDC +/- 1VDC. If voltage is not present

replace/repair #13999 harness.

ERR 016 – AC/DC TEMP TRIP

This section isolates faults occuring when the AC/DC inverter board (PCB8/15AP3) is

tripping the temperature fault.

A. Check for physical connection of the wire harness of cable assembly

#13619 between the Control Board (PCB3/20AP1) CN14 connector and

AC/DC Inverter Board (PCB8/15AP3) CN3 connector.

B. Measure the DC voltage at 20AP1/PCB3 CN14 between pin 5 and pin 3

for ~12 to 13VDC. If correct voltage is present replace Control Board

(PCB3/20AP1). Otherwise go to Step C.

C. Disconnect cable assembly #13619 from CN14 on Control Board

(PCB3/20AP1) and measure the DC Voltage on #13619 harness

(disconnected end) between pin 5 and pin 3 on AC/DC Inverter board

(PCB8/15AP3). If ~15VDC +/-0.5VDC or ~10 +/- 0.5VDC voltage is

present replace AC/DC Inverter Board (PCB8/15AP3).

ERR 017-019 – Reserved

ERR 020 – GRAPHICS ERROR

This section isolates an error related to memory on the UI panel. When this error occurs, it is

indication the software image library file was corrupted or not present or the memory device

has failed on the Display PCAB.

A. Attempt to update the system with the latest software. If that does not

correct the issue replace User Interface Board (PCB1/1AP1) and update

to the latest software.

ERR 021 – GRAPHICS ERROR

Follow Err 20 procedure to isolate this fault.

ERR 022 – WRITE MEM Err

Follow Err 20 procedure to isolate this fault.

ERR 023 – READ MEM Err RETRIEVE FACTORY

Follow Err 20 procedure to isolate this fault.

ERR 024-029 – Reserved

ERR 030 - FIRMWARE ERROR

This error is a result of the control software self-check failed. This can happen during

software update if poor cables are used or high noise environment. If it happens outside of a

software upgrade, it could be a Control Board (PCB3/20AP1) failure.

A. Attempt to update the system with latest software. If unable to load new

software or failure returns replace Control Board (PCB3/20A1).

ERROR CODES

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ERR 031 – NVRAM CHECKSUM BAD

Use ERR 030 procedure to trouble shoot this error.

DIAGRAM

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DIAGRAM

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System wiring diagram

DIAGRAM

0463 669 001

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Functional block diagram

TECHNICAL DATA

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TECHNICAL DATA

• Due to variations that can occur in manufactured products, claimed performance,

voltages, ratings, all capabilities, measurements, dimensions and weights quoted are

approximate only. Achievable capacities and ratings in use and operation will depend

upon correct installation, use, applications, maintenance and service.

• The Effective Input Current should be used for the determination of cable size and

supply requirements.

• Motor start fuses, or thermal circuit breakers are recommended for this application.

Check local requirements for your situation in this regard.

• Generator Requirements at the Maximum Output Cycle.

• Due to large variations in performance and specifications of different brands and types

of generators, ESAB cannot guarantee full welding output power or duty cycle on every

brand or type of generator. ESAB recommends that when selecting a generator, that

the power source/generator combination be adequately tested to ensure the

combination performs to the user’s expectations without notice.

EMP 205ic AC/DC

EMP205icAC/DC

Voltage 230V, 1ph, 50/60Hz 120V, 1ph, 50/60Hz

Primary current

I

max.

GMAW – MIG 29.6A Breaker 20A: 27.1A

Breaker 15A: 20.2A

I

max.

GTAW – DC TIG 24.0A Breaker 15A: 20.7A

I

max.

GTAW – AC TIG 26.5A Breaker 15A: 21.4A

I

max.

SMAW – Stick 28.3A Breaker 15A: 20.5A

I

eff.

GMAW – MIG 14.8A Breaker 20A: 15.8A

Breaker 15A: 14.5A

I

eff.

GTAW – DC TIG 12.0A Breaker 15A: 14.3A

I

eff.

GTAW – AC TIG 13.3A Breaker 15A: 14.9A

I

eff.

SMAW – Stick 14.1A Breaker 15A: 14.4A

Permissible load at GMAW – MIG

100% duty cycle* 110A (V

out

= 19.5V) Breaker 15A: 65A

(V

out

= 17.25V)

Breaker 20A: 70A

(V

out

= 17.5V)

60% duty cycle* 125A (V

out

= 20.25V) Breaker 15A: 85A

(V

out

= 18.25V)

Breaker 20A: 90A

(V

out

= 18.5V)

40% duty cycle* 150A (V

out

= 21.5V) Breaker 15A: 90A

(V

out

= 18.5V)

TECHNICAL DATA

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EMP205icAC/DC

25% duty cycle* 205A (V

out

= 24.25V) —

20% duty cycle* — Breaker 20A: 115A

(V

out

= 19.75V)

Setting range (DC) 15A (V

out

= 14.75V) –

235A (V

out

= 26.0V)

15A (V

out

= 14.75V) –

130A (V

out

= 20.5V)

Permissible load at GTAW – DC TIG

100% duty cycle* 110A (V

out

= 14.4V) Breaker 15A: 80A

(V

out

= 13.2V)

60% duty cycle* 125A (V

out

= 15.0V) Breaker 15A: 100A

(V

out

= 14.0V)

40% duty cycle* — Breaker 15A: 110A

(V

out

= 14.4V)

25% duty cycle* 205A (V

out

= 18.2V) —

Setting range (DC) 5A (V

out

= 10.2V) –

205A (V

out

= 18.2V)

5A / 10.2V – 130A

(V

out

= 15.2V)

Permissible load at GTAW

–AC TIG

100% duty cycle* 110A (V

out

= 14.4V) Breaker 15A: 75A

(V

out

= 13.0V)

60% duty cycle* 125A (V

out

= 15.0V) Breaker 15A: 95A

(V

out

= 13.8V)

40% duty cycle* — Breaker 15A: 105A

(V

out

= 14.2V)

25% duty cycle* 205A (V

out

= 18.2V) —

Setting range (DC) 10A (V

out

= 10.4V) –

205A (V

out

= 18.2V)

10A / 10.4V – 130A

(V

out

= 15.2V)

Permissible load at SMAW – STICK

100% duty cycle* 100A (V

out

= 24V) 55A (V

out

= 22.2V)

60% duty cycle* 125A (V

out

= 25V) 70A (V

out

= 22.8V)

40% duty cycle* — 75A (V

out

= 23.0V)

25% duty cycle* 170A (V

out

= 26.8V) —

Setting range (DC) 16A (V

out

= 20.6V) –

180A (V

out

= 27.2V)

16A (V

out

= 20.6V) –

130A (V

out

= 25.2V)

Open circuit voltage (OCV)

VRD deactivated 68V

VRD activated 35V

TECHNICAL DATA

0463 669 001

- 20 -

EMP205icAC/DC

Efficiency 78%

Power factor 0.98

Wire feed speed 80–475in./min (2–12.1m/min)

Wire diameter

Mild steel solid wire 0.023–0.035in. (0.6–0.9mm)

Stainless steel solid wire 0.030–0.035in. (0.8–0.9mm)

Flux-cored wire 0.030–0.045in. (0.8–1.1mm)

Aluminum 0.030–3/64in. (0.8–1.2mm)

Bobbin size 4–8in. (100–200mm)

Dimensions l×w×h 23×9×16in. (548×229×406mm)

Weight 50lb. (22.7kg)

Operating temperature 14 to 104°F (-10 to +40°C)

Enclosure class** IP23S

Application class***

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C(104°F).

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

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.

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ESAB EMP 205ic AC/DC User manual

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