Multi-Process Welding with Groundbreaking Operator Interface

ESAB Welding & Cutting Products (Florence, SC) has introduced the Rebel EMP 215ic, a 120V-230V, CC/CV welding system that offers true multi-process arc performance, location flexibility, lightweight portability and a groundbreaking operator interface. A unique sMIG (“smart MIG”) function enables users to begin MIG welding – with an extremely stable arc – just by setting metal thickness and wire diameter. Unlike competitive units, there is no need to enter information for shielding gas mix. The Rebel provides an industrial quality arc for MIG, flux-cored, Lift TIG and Stick welding, including excellent performance with difficult-to-weld E6010 electrodes. In fact, ESAB encourages side-by-side weld test comparisons and believes that this welding system will provide a superior experience for welders of all skill levels.

The Rebel has two operating modes, Basic and Advanced, that make welding easy for beginners or lets those with more experience fine tune parameters. Operators interact with the welding system using a unique control that combines traditional weld parameter adjustments with the functionality of a smart phone (in fact, the 4.3 in color display uses the same thin-film transistor (TFT) LCD technology found in smart phones). No other welder combines this level of simplicity, performance and control. The unit accepts 4 in and 8 in diameter wire spools, runs .023 in to .035 in diameter wires and enables users to switch from 230V to 120V primary power simply by connecting the supplied adapter plug. The welding system weighs 40 lb, measures 23 in x 9 in x 16 in and features a five-handle roll cage and unibody construction that integrates the front, back and top panels to provide superior durability for protecting internal components.

When connected to 230V primary, the unit provides a MIG output of 20 amps to 220 amps, a Stick output of 30 amps to 160 amps and a TIG output of 5 amps to 240 amps. When connected to 120V primary, the unit provides a MIG output of 15 amps to 130 amps, a Stick output of 5 amps to 110 amps and a TIG output of 5 amps to 140 amps. Applications include auto repair and restoration, maintenance and repair, mechanical contractors, light construction, farm and ranch, training facilities and sheet metal/HVAC. The unit comes ready-to-weld for all welding processes. Included are a professional-grade Tweco® Fusion™ 180 MIG gun, a Tweco stick electrode holder, a Victor® gas regulator, a TIG torch (an item not included by competitors), all required hoses and cables, and a sample of general purpose electrodes and a 2 lb spool of Weld ER70S-6 solid wire. An optional spool gun provides MIG aluminum capabilities.

“No other small, integrated welder can run a E6010 electrode, much less run it well on 120V,” says Doug Smith, the product business manager for arc equipment at ESAB. “The Rebel offers outstanding all-process arc performance because we enhanced the control algorithms from our industrial systems, such as the Warrior™ and Aristo®, gathered input from real world welders, and then incorporated that knowledge into this design.” Available in the North American market, the Rebel’s interface can be set for English, Spanish and French. The control display incorporates a built-in user manual with graphics and text to help with weld process set up, such as for connecting the work and ground leads to the correct terminals, as well as for ordering parts. The display lets users select the welding mode, as well as set and control all functions.

With the sMIG function, users begin MIG welding by setting metal thickness and selecting wire diameter. The Rebel will automatically adapt to any popular steel, stainless, chrome-moly or aluminum filler metal/gas combination and provide a stable MIG arc. The sMIG mode enables users to weld thicker or thinner metal by increasing or decreasing wire feed speed, as well as to raise or flatten the bead profile (“crown”) by increasing or decreasing voltage (“trim”). Welders can also adjust inductance to fine tune arc stability and control spatter. As users adjust one parameter, sMIG automatically adjusts others to keep the MIG arc stable.

Using an exclusive, built-in algorithm, sMIG monitors the operator’s technique and continuously adapts the MIG output to provide a stable arc and superior, repeatable welds. “sMIG takes smart to a level never-before-seen in the industry,” adds Smith. “Experienced welders become productive more quickly, and novice welders start producing quality welds in less time. The sMIG feature takes away the doubt of welding with incorrect settings and so users can focus on good gun technique. This welding system gives users confidence to weld anywhere with a ready-to-weld package.” For those welders who prefer traditional MIG and flux-cored welding, the Rebel enables users to pre-set and adjust wire feed speed and voltage, as well as set run-in speed, adjust burn-back control and program timers for spot and stitch welding. When welding, the control shifts to display amperage and voltage.

Because different types of Stick electrodes require different controls, this welding system lets users optimize performance by selecting from one of two settings: Cellulosic Electrodes (E6010, E6011) or all other Electrodes (E70XX, E308, E309, E316). To further fine tune performance, the unit features adjustable arc force and hot start control. With TIG welding (as well as MIG), users can select either 2T/4T trigger control; 2T for standard operation and 4T to provide a hold function that reduces hand fatigue. Operators can adjust gas pre- and post-flow, as well as adjust upslope and downslope to help them establish the weld puddle and prevent crater cracking, respectively.

Three models are available: the full-featured Rebel EMP 215ic offers all of the capabilities noted above. The Rebel EMS 215ic provides all of the same capabilities, features and functions, except that it does not have a TIG output. The Rebel EM 215ic provides MIG, sMIG and flux-cored welding outputs and features a more traditional interface with digital meters.

ESAB Welding & Cutting Products, PO Box 100545, 411 South Ebenezer Road, Florence, SC 29501-0545, 843-669-4411, Fax: 843-664-4258, www.esab.com.