I bought the wrong welder...

[neil fraser]

for those interested page 24 & 28 contain all the infomation re the spool gun https://www.manualslib.com/manual/1244401/Esab-Emp-215ic.html

 

[hotponyshoes]

A quick look at the Aus manual does show that you should have an option on the left hand side of the screen (in s-mig or manual-mig mode) to switch between torch or spool gun.
This is on a machine with euro connector.
It looks like this is showing all the time (regardless of having a spell gun connected) so more than likely at least a software solution is required.

If yours is triggering the mig (presuming there are NOT 2 little pins inside the euro connector on the spool gun?) It would suggest at least some of the wiring on the 8pin is in place.
Get the wiring diagrams and see what's what.
Or, as earlier, plug the tig torch in and see if that will trigger the wire feed motor in mig mode. That will at least give you more of an idea on how it works.

 

[neil fraser]

A quick look at the Aus manual does show that you should have an option on the left hand side of the screen (in s-mig or manual-mig mode) to switch between torch or spool gun.
This is on a machine with euro connector.
It looks like this is showing all the time (regardless of having a spell gun connected) so more than likely at least a software solution is required.

If yours is triggering the mig (presuming there are NOT 2 little pins inside the euro connector on the spool gun?) It would suggest at least some of the wiring on the 8pin is in place.
Get the wiring diagrams and see what's what.
Or, as earlier, plug the tig torch in and see if that will trigger the wire feed motor in mig mode. That will at least give you more of an idea on how it works.

thanks Hotponyshoes, you can now see why I thought that it would just work, the machines look identical, and the spool gun said made for the rebel emp215ic, so I am sure it is just a software thing

 

[neil fraser]

There was never a spool gun option in the UK. That’s probably why it doesn’t work!

thanks Brad, helpful

but if you read the UK manual it tells you to weld Aluminium use a spool gun

 

[Munkul]

Why do you need a spool gun? Can you not set up a short 3m gun with an extended liner to the feed rolls?

 

[hotponyshoes]

thanks Hotponyshoes, you can now see why I thought that it would just work, the machines look identical, and the spool gun said made for the rebel emp215ic, so I am sure it is just a software thing

Probably. It will be interesting to see if there is anything you can do to sort that out though. I would think software etc. would be on the esab website if the end user could update it.
Dont remember seeing anything about it in the manual?

My uk manual does not say anything about a spool gun either. Just tells you about changing the roller and how to set up the roller pressure.

I buy a fair bit of welding kit and sill get caught out now and again, most manufacturers do seem to have errors or worldwide specifications on the main websites and you dont always get exactly what you are expecting or it can be pretty tricky to find out exactly what they are selling.
Best bet is to buy from a local dealer. That way you can demo it first and check it does what you need. Or, tell them what you need, then you can take it back if it turns out it does not do it.

I did buy the esab alloy kit for mine (roller/liner/3m torch) that I have never used,I would sell it if you wanted it but that's just chucking more money at the problem so see if you get anywhere with the spool gun first.

 

[willie.macleod]

The manual shows it is the small socket that the TIG torch switch plugs into that you need to wire the spool gun to, is that the connector your spool gun has?

 

[willie.macleod]

I wonder what the thinking was in not including spool gun for the UK market? Seems like a missed trick. Shame also that it appears to vulnerable to firmware upgrades.

 

[KemppiFrog]

Going back to the original , we have a 13ft 'Tinnie' built by a division of Crysler . All solid rivited, bit much thinner than the OPs at around 1mm. It does seep at the seams a bit, but, at over 60yrs old, no surprise. I do a bit..
Frankly, I would source some solid rivits and redo it as original. Mind you, I have quite a lot of experience on riviting aircraft together.
Tip: get a cheap air chisel and mod one of the bits to have a hollow end for the rounded heads. Worked for me on a serious rebuild on a Twin Piper.

 

[neil fraser]

had another little play with the spool gun

when connected and you pull the trigger the drive roller in the main unit activates , this continues to work when the Euro connector is not connected

when still connected in TIG mode then the wire speed dial on the spool gun alters the amps on the display

the 8 pin plug on the spool gun is actually wired as a 7 pin; pin 8 or 6 (I am not sure if the wiring diagram is a male or female) is missing

I am attaching a photo of the firmware on my system, it is a little strange as although there appears to be a scroll bar on the righthand side of the display you cant access it or scroll down.

in my view the best solution would be to update the firmware, does anyone know-how.

 

[hotponyshoes]

If it's in mig mode with the tig torch connected does the button on the tig torch activate the mig rollers?

I think there are only 7pins wired on the spool gun versions, 2 for switch, 2 motor and 3 for pot
If the tig torch is also activating the rollers it might be a hardware solution rather than firmware?

Edit: 8th pin looks like a resistor. Might be bringing the mig drive in as it can tell from that which gun is connected?
Try the tig torch switch in mig mode

 

[Munkul]

I don't understand why anyone in this day and age would make hardware that can't be simply flashed with a USB file etc.

 

[hotponyshoes]

I don't understand why anyone in this day and age would make hardware that can't be simply flashed with a USB file etc.

I don't think there is any need with welders.
You buy it, it works. End of.
There are welders out there that are missing features they were advertised with and some that could do with having newer synergic lines added so for somebody like me a welder that offered this would be a selling point.
I suppose in the op's position paying £100 (whatever) for a usb stick to add features would sell it to him?
Some higher end machines might already offer it but I can't see many users wanting it.

I have declined at least 3 free updates on my smart tv as it does what I want as it is.

 

[Munkul]

Like you say, there shoudn't be any need for normal CV or CC welding.

Synergic lines - can be a nice thing to have an upgrade path for exotic wires or gasses, maybe something that most people wouldn't be bothered about.

Upgrades like spool guns etc - in this case it would have worked well, if the firmware had been designed properly?

Pulse programs and other niche feedback-controlled programs - again, on high end machines it can work out well.

 

[hotponyshoes]

Upgrades like spool guns etc - in this case it would have worked well, if the firmware had been designed properly?

This is the issue the op is having.
In other markets his machine has a spool gun option so they obviously have a firmware version that works with it.
He is trying to update (actually replace) his firmware with another version.
I think he wants to check the hardware side first though as you might find it's an option that pops up in the menu with the correct hardware fitted.
Or get onto an Australian forum and ask somebody to post a photo of their firmware screen?