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ESAB FABRICATOR 252i

Manual 0-5423                                                                             4-11                                                                            BASIC WELDING

Striking the Arc

Practice this on a piece of scrap plate before going on to more 
exacting work. You may at first experience difficulty due to the tip 

of the electrode "sticking" to the work piece. This is caused by 

making too heavy a contact with the work and failing to withdraw 
the electrode quickly enough. A low amperage will accentuate it. 
This freezing-on of the tip may be overcome by scratching the 
electrode along the plate surface in the same way as a match is 

struck. As soon as the arc is established, maintain a 1/16" -1/8" 

(1.6 mm - 3.2 mm) gap between the burning electrode end and 
the parent metal. Draw the electrode slowly along as it melts 
down.
Another difficulty you may meet is the tendency, after the arc is 
struck, to withdraw the electrode so far that the arc is broken 
again. A little practice will soon remedy both of these faults.

Art # A-10673

20°

1/16” (1.6 mm) 

Figure 4-21: Striking an Arc

Arc Length

The securing of an arc length necessary to produce a neat weld 
soon becomes almost automatic. You will find that a long arc pro-
duces more heat. A very long arc produces a crackling or splut-
tering noise and the weld metal comes across in large, irregular 
blobs. The weld bead is flattened and spatter increases. A short 
arc is essential if a high quality weld is to be obtained although 
if it is too short there is the danger of it being blanketed by slag 
and the electrode tip being solidified in. If this should happen, 
give the electrode a quick twist back over the weld to detach it. 

Contact or "touch-weld" electrodes such as E7014 do not stick 

in this way, and make welding much easier.

Rate of Travel

After the arc is struck, your next concern is to maintain it, and 
this requires moving the electrode tip towards the molten pool at 
the same rate as it is melting away. At the same time, the elec-
trode has to move along the plate to form a bead. The electrode 
is directed at the weld pool at about 20º from the vertical. The 
rate of travel has to be adjusted so that a well-formed bead is 
produced.
If the travel is too fast, the bead will be 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 skill in the handling of an electrode, you 
will be ready to go on to make up welded joints.

A.  Butt Welds

Set up two plates with their edges parallel, as shown in Figure 

4-22, allowing 1/16" - 3/32" (1.6 mm - 2.4 mm) gap between 

them and tack weld at both ends. This is to prevent contraction 
stresses from the cooling weld metal pulling the plates out of 

alignment. Plates thicker than 1/4" (6.4 mm) should have their 

mating edges beveled to form a 70º to 90º included angle. This 
allows full penetration of the weld metal to the root. Using a 

1/8" (3.2 mm) E7014 electrode at 100 amps, deposit a run of 

weld metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady rate of 
travel along the joint sufficient to produce a well-formed 
bead. At first you may notice a tendency for undercut to form, 
but keeping the arc length short, the angle of the electrode at 
about 20º from vertical, and the rate of travel not too fast, will 
help eliminate this. The electrode needs to be moved along 
fast enough to prevent the slag pool from getting ahead of the 
arc. To complete the joint in thin plate, turn the job over, clean 
the slag out of the back and deposit a similar weld.

Art # A-07697_AB

Tack Weld

20°-30°

Electrode

Tack Weld

Figure 4-22: Butt Weld

Art # A-07698

Figure 4-23: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. 
After completing the first run, chip the slag out and clean the 
weld with a wire brush. It is important to do this to prevent 
slag being trapped by the second run. Subsequent runs are 
then deposited using either a weave technique or single beads 
laid down in the sequence shown in Figure 4-23. The width 
of weave should not be more than three times the core wire 
diameter of the electrode. When the joint is completely filled, 
the back is either machined, ground or gouged out to remove 
slag which may be trapped in the root, and to prepare a suit-
able joint for depositing the backing run. If a backing bar is 
used, it is not usually necessary to remove this, since it serves 
a similar purpose to the backing run in securing proper fusion 
at the root of the weld.

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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