Name: ESAB EMP 255ic
Brand: ESAB
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PART # 0463 617 001 © ESAB AB 2018

SERVICE MANUAL

MODEL EMP 255ic & EMP 320ic

Valid for: serial nos. 730-xxx-xxxx, 735-xxx-xxxx

Rights

reserved

to alter

specifications

without

notice.

Table of Contents5
Section 1 Welcome to Esab15
How to Use this Manual15
Equipment Identification15
Receipt of Equipment15
Description15
Section 2 Safety16
Meaning of Symbols16
Safety Guidance and Information16
Safety Precautions16
Fires and Explosions18
Electrical Shock19
Electric and Magnetic Fields19
Fumes and Gases20
Cylinder Handling21
Moving Parts22
Malfunction22
Equipment Maintenance22
Falling Equpment23
User Responsibility24
Esd (Electrostatic Discharge)26
Section 3 Introduction28
Key Features28
Equipment28
Emp 255Ic Series28
Emp 320Ic Series28
Section 4 Technical Specifications30
Emp 255Ic Specifications30
Emp 320Ic Specifications32
Section 5 Installation34
Location34
High Frequency Interference35
Lifting Instructions37
Mains Supply37
Recommended Electrical-Supply Specifications39
Supply from Power Generators39
Section 6 Operation41
User Connections and Controls42
Connection of Welding and Return Cables43
For Mig/Mma Process43
For Tig Process43
Polarity Change44
Shielding Gas44
Volt-Ampere Curves44
MAW (Stick) 400 V45
Gmaw (Mig) 400 V45
Gtaw (Tig) 400 V46
Duty Cycle46
Removing/Installing Bobbin48
Removing/Installing Wire50
Removing Wire51
Installling Wire54
Welding with Aluminum Wire54
Setting Wire-Feed Pressure55
Removing/Installing Wire-Feed Rollers57
Removing Wire-Feed Rollers57
Installing Wire-Feed Rollers59
Removing/Installing/Adjusting Wire-Guides60
Output Wire-Guide Removal/Installation62
Center Wire-Guide Removal/Installation63
Adjusting Wire Guides63
Overheating Protection65
Short Circuit Protection While Welding65
Section 7 Control Panel66
How to Navigate66
Main Menu66
Smig Mode: Basic67
Smig Mode: Advanced67
Manual Mig Mode: Basic67
Manual Mig Mode: Advanced68
Flux Cored Wire Mode: Basic68
Flux Cored Wire Mode: Advanced68
Mma Mode: Basic69
Mma Mode: Advanced69
Lift-Tig Mode: Basic69
Lift-Tig Mode: Advanced70
Settings70
User Manual Information70
Icon Reference Guide71
Section 8 Maintenance74
Routine Maintenance75
Wire-Side Maintenance76
Wire-Feeder Assembly Cleaning76
Emp-Unit Power-Side Maintenance79
Torch Liner Maintenance79
Torch Liner Cleaning80
Section 9 Troubleshooting81
Preliminary Checks81
Using Generators or Extension Cords83
Interconnections83
Wire-Feed Problems83
User Interface (Ui) Software-Displayed Fault Codes84
The Power Source Side86
Design of the Power Source86
Main Power Switch86
EMI Filter Board87
Main Power Board93
Internal Power Supply (IPS) Board98
Control Board101
DIP Switch Settings103
Main Transformer106
Output Diode Assembly108
Output Inductor110
Current Sensor112
Cooling Fans113
OKC Capacitor Board114
Gas Valves115
Testing Procedures116
Initial Set up Conditions116
Power-UP Procedure117
Power up Faults119
Mains Power Fuses Blow/ Breaker Trips When SW1 Is Turned on119
Unit Is Completely Inactive, Front Panel Display Is Off, no Output Voltage119
Smaw Process Test121
SMAW Process Test: LED Status121
SMAW Process Test Problems122
Gtaw Lift Tig Process Test123
GTAW LIFT TIG Process Test: LED Status123
GTAW LIFT TIG Process Test Problems124
Gmaw Mig Process Test125
GMAW Process Test: LED Status125
GMAW Process Test Problems125
Component, Sub-Assembly Tests128
Power Cord/Plug, Power Switch, and EMI Board Test128
Primary Rectifier Test129
BR1, BR2 Test Procedure131
IPS Board Test133
Main Power Board Test134
Control Board Test138
UI Board Test140
Output Diode Board Test141
Current Sensor Test142
Remote Control Trigger Test143
Calibration144
Section 10 Ordering Spare Parts145
Spare Parts145
Wear Parts147
Accessories148
Replacements Parts149
Functional Block Diagram150
Schematic151
Lift-TIG Welding152
2-Stroke and 4-Stroke Welding Process Illustrated152
Roller & Wire-Guide Selection154
Roller Selection154
Wire-Guide Selection154

Brand	ESAB
Model	EMP 255ic
Category	Welding System
Language	English

ESAB EMP 255ic Service Manual

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