ESAB EMP 215ic User manual

Rebel EMP 215ic
Instruction manual
0463 789 001  US  20230714 Valid for: CD315-xxx-xxxx

TABLE OF CONTENTS
0463 789 001 -2- © ESAB AB 2023
1 SAFETY ...................................................................................................................................... 4
1.1 Meaning of symbols .................................................................................................... 4
1.2 Safety precautions ...................................................................................................... 4
1.3 User responsibility ...................................................................................................... 8
1.4 California proposition 65 warning ............................................................................. 10
2 INTRODUCTION ......................................................................................................................... 11
2.1 Equipment.................................................................................................................... 11
3 TECHNICAL DATA ..................................................................................................................... 12
4 INSTALLATION........................................................................................................................... 14
4.1 Location........................................................................................................................ 14
4.2 Lifting instructions ...................................................................................................... 14
4.3 Electrical supply.......................................................................................................... 15
4.3.1 Recommended fuse sizes and minimum cable area.......................................... 15
4.3.2 Connecting the power source to input supply .................................................... 16
5 OPERATION ............................................................................................................................... 17
5.1 Connections and control devices .............................................................................. 18
5.2 Connecting welding and return cables ..................................................................... 19
5.2.1 For GMAW (MIG) process.................................................................................. 19
5.2.2 For Stick (SMAW) process ................................................................................. 20
5.2.3 For GTAW process ............................................................................................. 20
5.3 Polarity change............................................................................................................ 20
5.4 Spool hub assembly ................................................................................................... 21
5.5 Inserting and replacing wire....................................................................................... 21
5.5.1 Installing wire...................................................................................................... 22
5.5.2 Removing wire.................................................................................................... 22
5.6 Welding with aluminum wire ...................................................................................... 23
5.7 Setting the wire feed pressure ................................................................................... 23
5.8 Changing the feed/pressure rollers ........................................................................... 24
5.9 Shielding gas ............................................................................................................... 24
5.10 Volt-Ampere curves..................................................................................................... 25
5.11 Duty cycle .................................................................................................................... 27
5.12 Overheating protection ............................................................................................... 28
6 USER INTERFACE ..................................................................................................................... 29
6.1 How to navigate........................................................................................................... 29
6.1.1 Home screen ...................................................................................................... 30
6.1.2 sMIG mode basic ............................................................................................... 30
6.1.3 Manual GMAW basic mode................................................................................ 31
6.1.4 Flux cored basic mode ....................................................................................... 32
6.1.5 Flux cored advanced mode ................................................................................ 33
6.1.6 Stick basic mode ................................................................................................ 33
6.1.7 LIFT-GTAW basic mode ..................................................................................... 35
6.1.8 DC-PULSE GTAW Basic mode .......................................................................... 36
6.1.9 Settings .............................................................................................................. 37
6.1.10 Reset mode ........................................................................................................ 37
6.1.11 User manual ....................................................................................................... 38
6.1.12 Icon reference guide........................................................................................... 39
6.2 LIFT GTAW welding ..................................................................................................... 43

TABLE OF CONTENTS
0463 789 001 -3- © ESAB AB 2023
6.3 DC PULSE GTAW......................................................................................................... 43
7 MAINTENANCE.......................................................................................................................... 51
7.1 Routine maintenance .................................................................................................. 51
7.2 Wire-feeder assembly maintenance .......................................................................... 52
7.3 Wire-feeder assembly cleaning.................................................................................. 52
7.4 Power side maintenance ............................................................................................ 53
7.5 Torch liner maintenance ............................................................................................. 53
7.6 Torch liner cleaning..................................................................................................... 53
8 TROUBLESHOOTING ................................................................................................................ 54
8.1 Preliminary checks...................................................................................................... 54
8.2 User interface (UI) software displayed error codes ................................................. 55
9 ORDERING SPARE PARTS ....................................................................................................... 57
MIG WELD PARAMETER CHART ........................................................................................................ 58
WIRING DIAGRAM ................................................................................................................................ 59
ORDERING NUMBERS ......................................................................................................................... 60
WEAR PARTS........................................................................................................................................ 61
ACCESSORIES ..................................................................................................................................... 63
REPLACEMENTS PARTS..................................................................................................................... 64

1  SAFETY
0463 789 001 -4- © ESAB AB 2023
1 SAFETY
1.1 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.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and
follow all labels, employer's safety practices and Safety Data
Sheets (SDSs).
1.2 Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarize precautionary information
from the references listed in the Additional Safety Information section. Before performing any
installation or operating procedures, be sure to read and follow the safety precautions listed
below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require ear
protection. The arc, like the sun, emits ultraviolet (UV) and other radiation
and can injure the skin and eyes. Hot metal can cause burns. Training in the
proper use of the processes and equipment is essential to prevent
accidents. Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when
welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields
and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck and
ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not
to look at the arc and not to expose themselves to the rays of the electric-arc or hot metal.
4. Wear flameproof gauntlet-type gloves, heavy long-sleeve shirt, cuffless pants, high-topped shoes,
and a welding helmet or cap for protection, to protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars
should be kept buttoned and open pockets eliminated from the front of the clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or
curtains.
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can
fly for long distances. Bystanders should also wear goggles over safety glasses.

1  SAFETY
0463 789 001 -5- © ESAB AB 2023
FIRES AND EXPLOSIONS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause
fires and explosions. Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Move all combustible materials well away from the work area or cover the materials with a
protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and
gas fuels, solvents, paints, and coating paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a
hidden smoldering fire or fires on the floor below. Make certain that such openings are protected
from hot sparks and metal.
4. Do not weld, cut, or perform other hot work until the work piece has been completely cleaned so
that there are no substances on the work piece which might produce flammable or toxic vapors. Do
not perform hot work on closed containers, they may explode.
5. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand
bucket, or portable fire extinguisher. Be sure you are trained in its use.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable can overheat
and create a fire hazard.
7. 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.
ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury or
death. DO NOT use AC welding current in damp areas, if movement is
confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the earth system of the input power.
2. Connect the workpiece to a good electrical earth.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to
a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source.
6. Make sure that all parts of your body are insulated from both the work piece and from the ground.
7. Do not stand directly on metal or the ground while working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. 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.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding and cutting current
creates EMF around welding cables and welding machines. Therefore:

1  SAFETY
0463 789 001 -6- © ESAB AB 2023
1. Welders with 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) Route the electrode and work cables together. Secure them with tape when possible.
b) Never coil the torch or work cable around your body.
c) Do not place your body between the torch and work cables. Route cables on the same side of
your body.
d) Connect the work cable to the workpiece as close as possible to the area being welded.
e) Keep the welding power source and cables as far away from your body as possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Shielding gases can cause asphyxiation. Therefore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld,
cut or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead beryllium or
cadmium unless positive mechanical ventilation is provided. Do not breathe in the fumes from these
materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.
4. 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.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases which contain
chemicals known to the State of California to cause birth defects and in some cases cancer
(California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A sudden
rupture of cylinder valve or relief device can injure or kill. Therefore:
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not use adapters. Maintain hoses and fittings in good
condition. Follow the manufacturer's operating instructions for mounting a regulator to a
compressed gas cylinder.
3. Always secure cylinders in an upright position, by chain or strap, to suitable hand trucks,
undercarriages, benches, wall, post or racks. Never secure cylinders to work tables or fixtures
where they may become part of an electrical circuit.
4. 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.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause injury.
Therefore:
1. Keep all doors, panels, guards, and covers closed and securely in place.
2. Stop the engine or drive systems before installing or connecting a unit.
3. Have only qualified people remove covers for maintenance and troubleshooting as necessary

1  SAFETY
0463 789 001 -7- © ESAB AB 2023
4. To prevent accidental starting of equipment during service, disconnect negative (-) battery cable
from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before starting engine.
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.
• Keep cables and cords away from moving vehicles when working from an aerial location.
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting and maintenance
work. Do not perform any electrical work unless you are qualified to perform such work.
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 any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such
as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres
and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting equipment,
ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging,” Form 52-529.
The following publications are recommended:
• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
• AWS SP - “Safe practices” - Reprint, Welding Handbook
• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of Containers
That Have Held Hazardous Substances”
• OSHA 29 CFR 1910 - "Safety and health standards"
• CSA W117.2 - "Code for safety in welding and cutting"
• NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot Work"
• CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”
• ANSI Z87.1, "Occupational and Educational Personal Eye and Face Protection Devices"

1  SAFETY
0463 789 001 -8- © ESAB AB 2023
1.3 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.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
Incorrect operation of the equipment may lead to hazardous situations, which could result in injury to
the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
• its operation
• the location of emergency stops
• its function
• the relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
• no unauthorized person is within the working area of the equipment when it is started up
• no-one is unprotected when the arc is struck or work is started with the equipment
3. The workplace must:
• be suitable for the purpose
• be free from drafts
4. Personal safety equipment:
• Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves
• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns
5. General precautions:
• Make sure the return cable is connected securely
• Work on high voltage equipment may only be carried out by a qualified electrician
• Appropriate fire extinguishing equipment must be clearly marked and close at hand
• Lubrication and maintenance must not be carried out on the equipment during operation
WARNING!
Wire feeders are intended to be used in GMAW (MIG/MAG) mode only.
If used in any other welding mode, such as SMAW (Stick), the welding cable between wire
feeder and power source must be disconnected, or else the wire feeder becomes live or
energized.
If equipped with ESAB cooler
Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize
product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.
For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
WARNING!
Arc welding and cutting may cause injury to yourself and others. Take precautions when
welding and cutting.

1  SAFETY
0463 789 001 -9- © ESAB AB 2023
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves, or wet
clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders with pacemakers fitted should consult their doctor before welding. EMF
may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to EMF:
○ Route the electrode and work cables together on the same side of your body.
Secure them with tape when possible. Do not place your body between the torch
and work cables. Never coil the torch or work cable around your body. Keep the
welding power source and cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the area being
welded.
FUMES AND GASES - Can be dangerous to health
• 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 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.
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only qualified
people remove covers for maintenance and troubleshooting as necessary. Reinstall
panels or covers and close doors when service is finished and before starting
engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause a fire. Therefore, make sure that there are no
inflammable materials nearby
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to prevent
burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!

1  SAFETY
0463 789 001 - 10 - © ESAB AB 2023
CAUTION!
This product is solely intended for arc welding.
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.
1.4 California proposition 65 warning
WARNING!
Welding or cutting equipment produces fumes or gases which contain chemicals known in the
State of California to cause birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
WARNING!
This product can expose you to chemicals including lead, which are known to the state of
California to cause cancer and birth defects or other reproductive harm. Wash hands after use.
For more information, go to www.P65Warnings.ca.gov.

2  INTRODUCTION
0463 789 001 - 11 - © ESAB AB 2023
2 INTRODUCTION
The RebelEMP215ic product family is a new generation of Multi-Process (GMAW/Stick/GTAW)
welding (EMP series) power sources.
The new series of 215ic 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 RebelEMP215ic family features a 4.3 in. (11 cm) color TFT user interface 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 a number of functions could be introduced and
customized to give maximum flexibility.
Exclusive to ESAB, sMIG provides users with excellent short circuit transfer arc characteristics.
The RebelEMP215ic 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.
Key features:
• Excellent GMAW/Stick characteristics
• Excellent multi-process welding capabilities
• Automatic recognition of input power with PFC (120 V – 230 V)
• Large 4.3 in. (11 cm) high resolution customizable user interface
• Rugged case design and internal hardware
• Portable
• High grade cast aluminum wire drive system provides excellent control of drive roll geometry
ensuring smooth, precise wire feeding
• Professional high grade accessories
2.1 Equipment
Package consists of the following:
RebelEMP215ic full package
• Power source
• TwecoFusion™ 180 GMAW gun with 10ft (3m) cable, 0.023in (0.6mm), 0.030in (0.8mm),
0.035in (0.9mm), Tips & Allen Key
• ESAB Heliarc 17V GTAW torch with accessories
• Victor® Flow Meter with 10ft (3m), gas hose
• Tweco® 200 A electrode holder and lead assembly
• Tweco® 200 A work clamp and lead assembly
• OK AristoRod 12.50 0.030in. (0.8mm), 1kg
• Feed roll 0.023in./0.030in. (0.6/0.8mm), V fitted
• Feed roll 0.023in./0.035in. (0.6/0.9mm), V (Spare)
• Feed roll 0.030in./0.035in. (0.8/0.9mm), VK (Spare)
• Thickness gauge
• Power adapter (230V – 120V, 15A)
• Safety manual
• USB stick including manuals
• Weld parameter chart
• Quick start guide

3  TECHNICAL DATA
0463 789 001 - 12 - © ESAB AB 2023
3 TECHNICAL DATA
RebelEMP 215ic
Voltage 120 V, 1 ~ 50/60 Hz 230 V, 1 ~ 50/60 Hz
Primary current
Imax. GMAW - MIG Breaker 20 A: 28.6 A
Breaker 15 A: 20.8 A 30 A (27.6A at 25% duty cycle)
Imax. GTAW - TIG Breaker 15 A: 20.8 A 19 A
Imax. SMAW - Stick Breaker 15 A: 20.8 A 25A
Ieff. GMAW - MIG Breaker 20 A: 18.0 A
Breaker 15 A: 14.7 A 14A
Ieff. GTAW - TIG Breaker 15 A: 14.7 A 10A
Ieff. SMAW - Stick Breaker 15 A: 14.7 A 13A
Permissible load at GMAW - MIG
100% duty cycle Breaker 15 A: 75 A / 17.75 V
Breaker 20 A: 90 A / 18.5 V
110 A / 19.5 V
60% duty cycle Breaker 15 A: 90 A / 18.5 V
Breaker 20 A: 110 A / 19.5 V
125 A / 20.25 V
40% duty cycle Breaker 15 A: 100 A / 19 V 150 A / 21.5 V
25% duty cycle - 205 A / 24.25 V
20% duty cycle Breaker 20 A: 130 A / 20.5 V -
15% duty cycle - 235A / 26A
Setting range (DC) 15 A / 14.75 V – 130A/20.5V 15 A / 14.75 V – 235A/26.0V
Permissible load at GTAW - TIG
100% duty cycle 100 A / 14 V 110 A / 14.4 V
60% duty cycle 120 A / 14.8 V 125 A / 15 V
40% duty cycle 130 A / 15.2 V -
30% duty cycle - 180 A / 17.2 V
20% duty cycle - 200A / 18V
Setting range (DC) 5 A / 10.2 V – 130A/15.2V 5 A / 10.2 V – 200A/18V
Permissible load at SMAW - Stick
100% duty cycle 65 A / 22.6 V 100 A / 24 V
60% duty cycle 80 A / 23.2 V 125 A / 25 V
40% duty cycle 85A / 23.4V -
25% duty cycle - 180 A / 27.2 V
20% duty cycle 130A / 25.2V -
Setting range (DC) 6 A / 20.6 V – 130A/25.2V 16 A / 20.6 V – 180A/27.2V
Open circuit voltage (OCV)
VRD deactivated 52 V 52 V

3  TECHNICAL DATA
0463 789 001 - 13 - © ESAB AB 2023
RebelEMP 215ic
VRD activated 35V 35V
Efficiency 84% 86%
Power factor 0.99 0.98
Wire feed speed 80–475 in./min (2–12.1m/min) 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) 0.023–0.035in. (0.6–0.9mm)
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)
Spool size Ø 4– 8in. (100–200 mm) Ø 4– 8in. (100–200 mm)
Dimensions l×w×h 23×9×16in.
(548×229×406mm)
23×9×16in.
(548×229×406mm)
Weight 42 lb (19.1 kg) 42 lb (19.1 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 or cut at a
certain load without overloading. The duty cycle is valid for 104°F (40°C) or below.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water.
Equipment marked IP23S is intended for indoor and outdoor use; however, it 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.

4  INSTALLATION
0463 789 001 - 14 - © ESAB AB 2023
4 INSTALLATION
4.1 Location
Position the power source so that its cooling air inlets and outlets are not obstructed.
1. 4in. (100 mm) 2. 4in. (100 mm)
4.2 Lifting instructions
The power source can be lifted using any of the handles.
Secure the equipment - particularly if the ground is uneven or
sloping.

4  INSTALLATION
0463 789 001 - 15 - © ESAB AB 2023
4.3 Electrical supply
The supply voltage should be 120VAC±10% or 230V±10%. Too low of supply voltage may cause
poor welding performance. Too high of welding supply voltage will cause components to overheat and
possibly fail. Contact the local electric utility for information about the type of electrical service
available, how proper connections should be made, and inspection required.
The Welding power source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly grounded (electrically) in accordance with local regulations.
• Connected to the correct size power point and fuse as indicated in table below.
WARNING!
Do not connect an input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN/YELLOW) conductor to an input line terminal.
NOTE!
Use the welding power source in accordance with the relevant national regulations.
CAUTION!
Disconnect input power and secure employing 'Lock-out' / 'Tagging' procedures. Ensure input
power line disconnect switch is locked (Lock-out/Tagging) in the 'Open' position BEFORE
removing input power fuses. Connection/Disconnect should be carried out by competent
persons.
1. 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.
120 – 230 V, 1 ~ 50/60 Hz
Supply voltage 120VAC 230VAC
Input current at maximum output 30A 30A
Maximum recommended fuse* or circuit breaker rating
*Time delay fuse UL class RK5, refer to UL 248
30A 30A
Maximum recommended fuse* or circuit breaker rating
*Normal operating UL class K5, refer to UL 248
50A 50A

4  INSTALLATION
0463 789 001 - 16 - © ESAB AB 2023
120 – 230 V, 1 ~ 50/60 Hz
Minimum recommended cord size 12AWG(4mm2) 12AWG(4mm2)
Maximum recommended extension cord length 25ft(8m) 50ft (15m)
Minimum recommended grounding conductor size 12AWG(4mm2) 12AWG(4mm2)
Supply from power generators
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 8 kW rated
power, are recommended.
4.3.2 Connecting the power source to input supply
Use one of the supplied adapters to connect the power source to mains.

5  OPERATION
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5 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 handle. Never pull on the cables.
WARNING!
Rotating parts can cause injury, take great care.
WARNING!
Electric shock! Do not touch the workpiece or the welding head during operation!
WARNING!
Make sure that the side covers are closed during operation.

5  OPERATION
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5.1 Connections and control devices
1. Knob for current or wire feed speed selection 7. Positive output [+]
2. Knob for voltage selection 8. Polarity changeover cable
3. Main knob for menu navigation 9. Display
4. Torch/remote control connection 10. Gas inlet for GMAW
5. Torch connection 11. Main power switch ON/OFF
6. Negative output [-] 12. Main power cable

5  OPERATION
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Drive system diagram
1. Spool hub assembly 3. GMAW Solenoid gas assembly
2. Circuit breaker 4. Wire feeder mechanism
5.2 Connecting welding and return cables
The power source has two outputs for connecting welding and return cables: a negative [-] terminal (6)
and a positive [+] terminal (7), see "Connections and control devices" section.
The polarity changeover cable is used to select the correct polarity for the weld output. The correct
polarity is determined by the wire that has been selected to complete the weld.
To configure the machine to operate with electrode positive, see the following instructions.
1) Insert and secure the polarity changeover cable into the positive [+] terminal.
2) Insert and secure the return lead into the negative [-] terminal.
3) Make sure that the connections are tight.
4) Secure the work clamp to the work piece in a clean, debris-free location.
5.2.1 For GMAW (MIG) process
For GMAW process, the output to which the welding cable is connected depends on type of electrode
(solid wire/flux cored).
Solid wire - Connect the polarity changeover cable to positive OKC.
Flux cored - Connect the polarity changeover cable to negative OKC.

5  OPERATION
0463 789 001 - 20 - © ESAB AB 2023
NOTE!
The backside of the door on the spool side displays a GMAW parameter chart for initial
selection of welding controls. This is intended as a guide for setting parameters on this
equipment.
5.2.2 For Stick (SMAW) process
For Stick process, the output to which the welding cable is connected depends on type of electrode.
Refer to electrode packaging for information relating to the correct electrode polarity.
Disconnect the polarity changeover cable from the terminals, connect the electrode holder to OKC
positive and return cable to OKC negative. Secure the return cable's contact clamp to the work piece
and ensure that there is good electrical contact.
5.2.3 For GTAW process
For GTAW process, connect the GTAW torch power cable to the negative [-] terminal (7), see
illustration. Connect the work return lead to the return-cable terminal positive output [+](7). Connect
the torch connector to the negative output [-] (6) (see "Connections and control devices" section).
5.3 Polarity change
Polarity changeover connections
1. Polarity changeover cable (not connected in
Stick or GTAW modes)
Check the recommended polarity for the welding wire you want to use. Refer to electrode packaging
for information relating to the correct electrode polarity. The polarity can be changed by moving the
polarity changeover cable to suit the applicable welding process.