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ESAB FABRICATOR 252i

INSTALLATION/SETUP                                                                       3-2                                                                           Manual 0-5423 

50/60 Hz 

Single Phase

Primary Supply 

Lead Size 

Minimum Primary 

Current Circuit 

Size  (Vin/Iin)

Minimum 

Plug Size

Current & Duty Cycle 

MIG

LIFT TIG 

STICK 

Yes

10 AWG

208-230/50A

50A

40% @ 250A

40% @ 250A

40% @ 230A

Table 3-1: Input Power Source Leads for Fabricator 252i

3.05  Electromagnetic Compatibility

!

  

WARNING

Extra precautions for Electromagnetic 
Compatibility may be required when this 
Welding Power Source is used in a domes-
tic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding 
equipment according to the manufacturer’s instructions. If 
electromagnetic disturbances are detected then it shall be the 
responsibility of the user of the welding equipment to resolve the 
situation with the technical assistance of the manufacturer. In 
some cases this remedial action may be as simple as earthing 
the welding circuit, see NOTE below. In other cases it could 
involve constructing an electromagnetic screen enclosing the 
Welding Power Source and the work, complete with associated 
input filters. In all cases, electromagnetic disturbances shall be 
reduced to the point where they are no longer Troublesome.

 

NOTE!

The welding circuit may or may not be 
earthed for safety reasons. Changing the 
earthing arrangements should only be 
authorized by a person who is competent to 
assess whether the changes will increase 
the risk of injury, e.g. by allowing parallel 
welding current return paths which may 
damage the earth circuits of other equip-
ment. Further guidance is given in IEC 
60974-13 Arc Welding Equipment - Instal-
lation and use (under preparation).

B. Assessment of Area

Before installing welding equipment, the user shall make 
an assessment of potential electromagnetic problems in the 
surrounding area. The following shall be taken into account.

1.  Other supply cables, control cables, signaling and telephone 

cables; above, below and adjacent to the welding equipment.

2.  Radio and television transmitters and receivers.

3.  Computer and other control equipment.

4.  Safety critical 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 welding or other activities are to be 

carried out. 

8.  The immunity of other equipment in the environment: the 

user shall ensure that other equipment being used in the 

environment is compatible: this may require additional 

protection measures.

The size of the surrounding area to be considered will depend on 
the structure of the building and other activities that are taking 
place. The surrounding area may extend beyond the boundaries 
of the premises.

C. Methods of Reducing Electromagnetic Emissions

1.  Mains Supply 

  Welding equipment should be connected to the mains 

supply according to the manufacturer’s recommendations. 

If interference occurs, it may be necessary to take 

additional precautions such as filtering of the mains supply. 

Consideration should be given to shielding the supply cable 

of permanently installed welding equipment in metallic 

conduit or equivalent. Shielding should be electrically 

continuous throughout its length. The shielding should 

be connected to the Welding Power Source so that good 

electrical contact is maintained between the conduit and 

the Welding Power Source enclosure.

2.  Maintenance of Welding Equipment 

 

The welding equipment should be routinely maintained 

according to the manufacturer’s recommendations. All 

access and service doors and covers should be closed 

and properly fastened when the welding equipment is in 

operation. The welding equipment should not be modified in 

any way except for those changes and adjustments covered 

in the manufacturer’s instructions. 

3.  Welding Cables

 

The welding cables should be kept as short as possible and 

should be positioned close together but never coiled and 

running at or close to the floor level.

4.  Equipotential Bonding

  Bonding of all metallic components in the welding instal-

lation and adjacent to it should be considered. However, 

metallic components bonded to the work piece will increase 

the risk that the operator could receive a shock by touch-

ing the metallic components and the electrode at the same 

time. The operator should be insulated from all such bonded 

metallic components.

Содержание Fabricator 252i

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 75: ......

Страница 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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