ESAB Fabricator 252i Operating Manual Download Page 1

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A-12925

300

3163339

Révision :

Issue Date:

September 1, 2015

Manual No.:

0-5423

Operating
Manual

ESAB Fabricator

252i

3-IN-1 Multi Process

Welding Systems

esab.com

Summary of Contents for Fabricator 252i

Page 1: ...A 12925 300 3163339 R vision AA Issue Date September 1 2015 Manual No 0 5423 Operating Manual ESAB Fabricator 252i 3 IN 1 Multi Process Welding Systems esab com...

Page 2: ...take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand...

Page 3: ...rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party f...

Page 4: ...reof contained in this manual and accom panying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked period...

Page 5: ...ing a 12 5 lb spool 8 diameter 3 13 3 10 Installing a Standard Spool 12 diameter 3 14 3 11 Inserting Wire into the Feed Mechanism 3 15 3 12 Feed Roller Pressure Adjustment 3 16 3 13 Feed Roller Alignm...

Page 6: ...rements 5 2 5 03 Cleaning the Welding Power Source 5 5 5 04 Cleaning the Feed Rolls 5 6 SECTION 6 KEY SPARE PARTS 6 1 6 01 Fabricator 252i Power Supply Replacement Panels 6 1 6 02 ESAB Fusion 250A MIG...

Page 7: ...arted up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment...

Page 8: ...lter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby...

Page 9: ...tion concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with...

Page 10: ...adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting 2 07 Packaged Items Fabricator 252i Part No W1004401 Fabricator 252i Power Supply 15 ft ESAB F...

Page 11: ...ty cycle 250 amperes at 26 5 volts This means that it has been designed and built to provide the rated amperage 250A for 4 minutes i e arc welding time out of every 10 minute period 40 of 10 minutes i...

Page 12: ...Mode 20 300 Amps Welding Current Range LIFT TIG Mode 5 300 Amps Welding Current Range STICK Mode 20 230 Amps Effective Input Current I1eff 22 4 Amps Maximum Input Current I1max 34 7 Amps Single Phase...

Page 13: ...wer source meets the re quirements of IP23S as outlined in IEC60529 H Precautions must be taken against the power source top pling over The power source must be located on a suitable horizontal surfac...

Page 14: ...itical equipment e g guarding of industrial equipment 5 The health of people around e g the use of pace makers and hearing aids 6 Equipment used for calibration and measurement 7 The time of day that...

Page 15: ...ere necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achie...

Page 16: ...om the advanced programming mode To exit simply press and release the button again Any changes made are saved The advanced programming menu items are described in detail for each welding mode in Secti...

Page 17: ...l meter is used to display the pre set preview Wirefeed Speed in Inches Per Minute IPM in MIG mode and actual welding amperage of the power source when welding At times of non welding the digital mete...

Page 18: ...ositive or negative output terminal allowing polarity reversal for different welding applications In general the polarity lead should be connected in to the positive welding terminal when using steel...

Page 19: ...ESAB Fusion 250A MIG Gun Refer to section 3 08 for the correct procedure for attaching the ESAB Fusion 250A MIG Gun 11 Remote Control Socket The 8 pin Remote Control Socket is used to connect remote...

Page 20: ...Pin Function A Voltage Pot Wiper B Wire Feed Motor C Wire Feed Motor D Trigger Switch Input E Wire Speed Pot Voltage Pot CW 10K ohm F Wiper Arm Speed Pot G Trigger Switch Input Solenoid H Wire Speed P...

Page 21: ...Range Press Advanced Button to Exit to Welding Mode LOCL REMT 0 1 5 0 S MPM IPM WFS UNIT 30 150 0 0 30 0 S 0 00 1 00 S 0 1 20 0 S FACT DFLT HR SPOT TIME 0 2 4 0 S 0 1 1 0 S 0 0 9999 9 NO YES Press Ad...

Page 22: ...Spot Time Only shown en abled if Spot ON SPOT TIME 2 0 S 0 1 20 0 S Spot Time is the time used for the Spot weld mode Stitch STCH OFF OFF ON Stitch is used to weld two or more components by stitch or...

Page 23: ...time specified before an arc is initiated Post Flow LIFT TIG Setting POST FLOW 10 0 S 0 0 30 S Shielding gas flows for the time specified after an arc has extinguished Down Slope DOWN SLPE 0 0 S 0 0 3...

Page 24: ...ator Controls STCK CNTL LOCL LOCL REMT LOCL Local control of the Amps with the machines controls REMT Remote control of the Amps with an acces sory device Hot Start HOT STRT ON OFF ON Hot Start is use...

Page 25: ...h the 8 pin receptacle to the right of the MIG Gun cable and plug them together Secure by turning the locking ring to the right clockwise Refer to Figure 3 8 NOTE When disconnecting the MIG Gun trigge...

Page 26: ...at the wire will feed off the bottom of the spool as the spool rotates counter clockwise Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire...

Page 27: ...Feedroll Make certain the proper groove is being used Second part of Figure 3 11 4 Pass the MIG wire over the drive roll groove through the outlet guide and out past the MIG Gun Adaptor Then fit the F...

Page 28: ...AB Velocity contact tips and liners should be used Many non genuine liners use inferior materi als which can cause wire feed problems 3 13 Feed Roller Alignment The bottom Feed Roll is adjustable in a...

Page 29: ...rolls have their wire size or range stamped on the side of the roll On rolls with different size grooves the outer visible when installed stamped wire size indicates the groove in use Refer to feed ro...

Page 30: ...drive roll to help in the alignment of the wire guides Output Wire Guide With the Fusion 250A MIG Gun removed loosen the MIG Adapter Lock Nut This will aid with alignment Then loosen Output Guide Loc...

Page 31: ...th welding grade Inert shielding gases only NOTE Shielding Gas is not required if the unit is used with self shielded FCAW flux cored arc welding wires Shielding Gas Regulator Safety This regulator is...

Page 32: ...Flow Rate NOTE The regulator flow meters used with argon based and carbon dioxide shielding gases are different The regulator flow meter supplied is for argon based shielding gases If carbon dioxide...

Page 33: ...her unwanted welding grade shielding gas from equipment connected to the regulator by individually opening then closing the equipment control valves Complete purging may take up to ten seconds or more...

Page 34: ...Gun uses standard readily available ESAB Velocity consumable parts When using a non shielded wire you need to have an external gas source attached to the unit For most Non Shielded Wire connect the W...

Page 35: ...ove the Fusion MIG Gun nozzle and contact tip 10 Depress MIG Gun trigger to feed the MIG wire out Then fit the contact tip on the MIG wire and hand tighten the nozzle in place 11 Refer to the Weld Gui...

Page 36: ...ia heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 4 Fit the MIG FCAW wire spool and MIG Gun to th...

Page 37: ...OFF Switch located on the rear panel to OFF 2 Connect the work lead cable to the positive output terminal and the LIFT TIG Torch cable to the negative output terminal Refer to Figure 3 23 3 Connect t...

Page 38: ...trode Positive or reverse polarity Please consult with the STICK electrode manufacturer for specific polarity recommendations 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Attach the S...

Page 39: ...illed electrode wire and the work Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding may or may not be obtained from an externally supplied gas or gas...

Page 40: ...hielding wires Primary Adjustable Variables These control the process after preselected variables have been found They control the penetration bead width bead height arc stability deposition rate and...

Page 41: ...duce the current and lengthen the arc Increasing the welding voltage hardly alters the current level but lengthens the arc By decreasing the voltage a shorter arc is obtained with a little change in c...

Page 42: ...ESAB FABRICATOR 252i BASIC WELDING 4 4 Manual 0 5423 ESAB MIG Lift TIG Stick Wire Selection Chart A 12928 Figure 4 11...

Page 43: ...ty and the flow meter is correctly adjusted to 31 75 CFH 2 Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Source 3 Internal gas hose in the Po...

Page 44: ...ced by the wire passing through an incorrect feed roller groove shape or size C Swarf is fed into the conduit liner where it accumulates thus reducing wire feed ability 6 Incorrect or worn contact tip...

Page 45: ...heck shielding gas D Insufficient or excessive heat input D Adjust the wirespeed control or the voltage control 6 Weld cracking A Weld beads too small A Decrease travel speed B Weld penetration narrow...

Page 46: ...gen controlled Electrodes must be used for this ap plication B Austenitic manganese steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is...

Page 47: ...possible to weld steel sections without any special preparation For heavier sections and for repair work on castings etc it will be necessary to cut or grind an angle between the pieces being joined...

Page 48: ...l contact with the work either directly or through the work table For light gauge material always clamp the work lead directly to the job otherwise a poor circuit will probably result The Welder Place...

Page 49: ...narrow and strung out and may even be broken up into individual globules If the travel is too slow the weld metal piles up and the bead will be too large Making Welded Joints Having attained some ski...

Page 50: ...ack weld a three feet length of angle iron to your work bench in an upright position Use a 1 8 3 2 mm E7014 electrode and set the current at 100 amps Make your self comfortable on a seat in front of t...

Page 51: ...mple a butt joint in 5 64 2 0 mm sheet the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a r...

Page 52: ...ing of parts of the structure other than the area to be welded can be sometimes used to reduce distor tion Figure 4 33 shows a simple application By removing the heating source from b and c as soon as...

Page 53: ...ESAB Electrode Selection Chart 4 04 STICK SMAW Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current varying ARC FORCE is set at a value that causes the welding current to vary excessively wit...

Page 54: ...t deposit time at edge of weave F Pause for a moment at edge of weave to allow weld metal buildup G Power source is set for MIG GMAW welding G Set power source to STICK SMAW mode 5 Portions of the wel...

Page 55: ...he welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Electrode a...

Page 56: ...Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate CFH Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0mm 1 1...

Page 57: ...l speed 5 Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidizes when an arc is struck A TIG Torch lead connected to positive welding term...

Page 58: ...ectrode is too large for the welding current A Select the right size electrode Refer to Table 4 6 ESAB Electrode Selection Chart B The wrong electrode is being used for the welding job B Select the ri...

Page 59: ...amine fan vents for potential obstruction B Consult an Accredited ESAB Service Provider ERR 10 Inverter Output Fault Substandard output voltage condition detected by controller before weld started Con...

Page 60: ...2 Flashing Amperage and Voltage displays when welding indicates that the machines maximum output power rating 300A x 26 7V 8kVA is being exceeded and the system is automatically reducing the output If...

Page 61: ...associated accessories supplying transportable equipment at least once every 3 months and 2 For outlets wiring and associated accessories supplying fixed equipment at least once every 12 months D Gen...

Page 62: ...of wire drive motors to be checked to ensure it falls within required ESAB power source wire feeder specifications Accuracy of digital meters to be checked to ensure it falls within applicable ESAB p...

Page 63: ...ly inspect the torch body and consumables Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Bring the unit to an authori...

Page 64: ...Also wipe off or clean the grooves on the upper feed roll After cleaning tighten the feed roll retaining knobs CAUTION Do NOT use compressed air to clean the Welding Power Source Compressed air can f...

Page 65: ...7 6 Art A 10784_AB 8 Figure 6 1 FABRICATOR 252i POWER SOURCE SPARE PARTS Panels Sheet Metal ITEM PART NUMBER DESCRIPTION 1 W7005323 Latch Slide 2 W7005438 Door 252i 3 W7005385 Panel Rear 252i 4 W70054...

Page 66: ...Hub Assembly 2 W7005353 Wire Drive Assembly 250i Does not include motor 3 375838 002 Guide Inlet 0 6 1 6mm 4 See Appendix 1 Roll Pressure No Groove 5 See Appendix 1 Roll Feed Dual V 6 W6000801 Guide O...

Page 67: ...PCB Mov Bridge 250A 7 W7005302 Transformer Main 252i 8 W7005315 Solenoid 24V 0 0 8MPa 9 W7005301 Inductor 252i 10 W7005355 Circuit Breaker PB 8A 11 W7005354 Motor Wire Drive RH 20VDC 12 W7005357 Socke...

Page 68: ...ESAB FABRICATOR 252i REPLACEMENT PARTS 6 4 Manual 0 5423 6 02 ESAB Fusion 250A MIG Gun Torch Part No FV215TA 3545 Art A 11673_AB Figure 6 4 ESAB Fusion 250 A MIG Gun...

Page 69: ...Replacement Kit MS102 RK 8B Cablehoz Rear Mechanical Connector Replacement Kit MS172 RK 8C Cablehoz Front Mechanical Connector Replacement Kit for Euro Style 172X M 9 9A Miller Rear Connector 350 174...

Page 70: ...ESAB FABRICATOR 252i REPLACEMENT PARTS 6 6 Manual 0 5423 This Page Intentionally Blank...

Page 71: ...Options and Accessories Top Drive Roll Bottom Drive Roll HARD 023 035 FLUX CORED 030 035 FLUX CORED 045 1 16 SOFT 035 3 64 Art A 10669 Figure A 1 Drive Roll Chart Wire Size Wire Type Top Drive Roll B...

Page 72: ...LD OUTPUT 1 WELD OUTPUT 1 2 3 4 CURRENT SENSOR INDUCTOR BREAKER LINE LOAD TRIG_RETURN WFSPOT1 N C VPOT1 N C TRIG1 POT_RETURN VBIAS 1 2 3 4 5 6 7 8 J I H G F E D C B A TRIG_SOL_RTN SOL VBIAS VIDENT WFS...

Page 73: ...ary to Victor Technologies Title Not for release reproduction or distribution without written consent 7 12 2011 Date Printed Date Revised 7 12 2011 00 PROTOTYPE GAC 07 12 2011 1 50 1 2 3 4 5 6 7 8 9 1...

Page 74: ...ESAB FABRICATOR 252i APPENDIX A 4 Manual 0 5423 REVISION HISTORY Date Rev Description 09 01 2015 AA Manual release...

Page 75: ......

Page 76: ...x 46 31 50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501...

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