A-12925
300
ESAB Fabricator® 252i
3-IN-1 Multi Process
Welding Systems
Operating
Manual
3163339
Révision : AA Issue Date: September 1, 2015 Manual No.: 0-5423
esab.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.esab.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
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 of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.
WARNING
!
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
ESAB Fabricator® 252i 3-in-1 Multi Process Welding Systems™
Operating Manual Number 0-5423
Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208
www.esab.com
Copyright 2015 by ESAB
All 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 for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.
Original Publication Date: September 1, 2015
Revision Date:
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be
used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service
advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
SECTION 1: SAFETY ........................................................................................ 1-1
1.0 Safety Precautions .......................................................................................... 1-1
SECTION 2:
SYSTEM INTRODUCTION .......................................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05 User Responsibility ......................................................................................... 2-1
2.06 Transportation Methods .................................................................................. 2-2
2.07 Packaged Items .............................................................................................. 2-2
2.08 Duty Cycle ....................................................................................................... 2-3
2.09 Specifications ................................................................................................. 2-4
SECTION 3: INSTALLATION OPERATION AND SETUP ................................................. 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Mains Supply Voltage Requirements .............................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-2
3.06 Power Source Controls, Indicators and Features ............................................ 3-3
3.07 Advanced Features Details .............................................................................. 3-6
3.08 Attaching the ESAB Fusion 250A MIG Gun ................................................... 3-13
3.09 Installing 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 Alignment ................................................................................... 3-16
3.14 Changing the Feed Roll ................................................................................. 3-17
3.15 Input And Output Wire Guide Installation ..................................................... 3-18
3.16 Wire Reel Brake ............................................................................................ 3-19
3.17 Shielding Gas Regulator Operating Instructions ........................................... 3-19
3.18 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire .......................... 3-22
3.19 Set-up for MIG (FCAW) Welding with Gasless MIG Wire .............................. 3-24
3.20 Set-up for LIFT TIG (GTAW) Welding ............................................................ 3-25
3.21 Set-up for STICK Metal Arc Welding (SMAW) ............................................... 3-26
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5
4.03 STICK (SMAW) Basic Welding Technique ....................................................... 4-8
4.04 STICK (SMAW) Welding Troubleshooting ..................................................... 4-15
4.05 TIG (GTAW) Basic Welding Technique .......................................................... 4-17
4.06 TIG (GTAW) Welding Problems ..................................................................... 4-19
TABLE OF CONTENTS
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS ............ 5-1
5.01 Power Source Problems ................................................................................. 5-1
5.02 Routine Service and Calibration Requirements ............................................... 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 Gun ........................................................................... 6-4
APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1
APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM .................................................. A-2
REVISION HISTORY ........................................................................................ A-4
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
ESAB FABRICATOR 252i
SECTION 1: SAFETY
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements
that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in
addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the
operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started 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, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinguishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its
implementation in accordance with national law, electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain information on approved
collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary cutting protection and accessories.
Manual 0-5423 1-1 SAFETY INSTRUCTIONS AND WARNINGS
ESAB FABRICATOR 252i
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from
your breathing zone and the general area.
ARC R AYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and
filter 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.
Arc welding and cutting can be injurious to yourself and others.
Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT-
ING.
PROTECT YOURSELF AND OTHERS!
Do not use the power source for thawing frozen pipes.
WARNING
CAUTION
CAUTION
Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.
This product is solely intended for metal removal. Any other use
may result in personal injury and / or equipment damage.
CAUTION
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5423
Read and understand the instruction manual before
installing or operating.
!
ESAB FABRICATOR 252i
SECTION 2:
SYSTEM INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part numbers
listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, DANGER,
and NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
NOTE!
An operation, procedure, or background
information which requires additional
emphasis or is helpful in efficient operation
of the system.
CAUTION
!
!
!
Additional copies of this manual may be purchased by contacting ESAB at the address and phone number in your area listed on
back cover of this manual. Include the Owner’s Manual number
and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the ESAB web site listed
below
http://www.esab.com
2.02 Equipment Identification
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
WARNING
Gives information regarding possible electrical shock injury. Warnings will be enclosed
in a box such as this.
DANGER
Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice to
make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information
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 a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when using
bars, hammers, etc., to un-crate the unit.
2.04 Description
The ESAB Fabricator 252i is a self contained single phase multi
process welding power source that is capable of performing
MIG (GMAW/FCAW), STICK (SMAW) and Lift TIG (GTAW) welding
processes. The Fabricator 252i is equipped with an integrated
wire feed unit, digital volt age / amperage meters, power factor
correction (PFC) with energy saving technology and a host of
other features to satisfy the broad operating needs of the modern
welding professional.
The Fabricator 252i is fully compliant to standard IEC 60974.1.
The Fabricator 252i MIG provides excellent welding performance
across a broad range of applications when used with the correct
welding consumables and procedures. The following instructions
detail how to correctly and safely set up the machine and give
guidelines on gaining the best efficiency and quality from the
Power Source. Please read these instructions thoroughly before
using the unit.
2.05 User Responsibility
This equipment will perform as per the information contained
herein when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must
be checked periodically. Defective equipment (including welding
leads) should not be used. Parts that are broken, missing, plainly
worn, distorted or contaminated, should be replaced immediately.
Should such repairs or replacements become necessary, it is
recommended that such repairs be carried out by appropriately
qualified persons approved by ESAB. Advice in this regard can be
obtained by contacting an Accredited ESAB Distributor.
This equipment or any of its parts should not be altered from
standard specification without prior written approval of ESAB.
The user of this equipment shall have the sole responsibility for
any malfunction which results from improper use or unauthorized
modification from standard specification, faulty maintenance,
damage or improper repair by anyone other than appropriately
qualified persons approved by ESAB.
The unit’s identification number (specification or part number),
model, and serial number usually appear on a data tag attached
to the rear panel. Equipment which does not have a data tag
such as torch and cable assemblies are identified only by the
specification or part number printed on loosely attached card or
the shipping container. Record these numbers on the bottom of
page i for future reference.
Manual 0-5423 2-1 INTRODUCTION
ESAB FABRICATOR 252i
A-12953
2.06 Transportation Methods
WARNING
Lift unit with integrated hand holds at the front and rear of the unit.
Use handcart or similar device of 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® Fusion 250 Amp MIG Gun
- Velocity Contact tips (1 each)
• .030" (0.8 mm)
• .035" (0.9 mm)
• .045" (1.2 mm)
- Victor® Argon Regulator / Gauge & 10 ft. (3M) Hose
-ESAB WeldSkill 200 Amp electrode holder with 13 ft. (4 M) lead
-ESAB WeldSkill 200 Amp ground clamp with 10 ft. (3 M) lead
-Drive Rolls:
• .035" / .045" (0.9 to 1.2 mm) V Grooved Lower & Flat Upper (Fitted)
• .045" (1.2 mm) Flux Cored Roll
- Operating Manual
- 9 ft. (2.75 M) Power cord & NEMA 6-50P 230V AC Plug
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors
from de-energized supply line before moving the welding power source.
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Figure 2-2: Packaged Items
INTRODUCTION 2-2 Manual 0-5423
ESAB FABRICATOR 252i
2.08 Duty Cycle
The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following
example is used. Suppose a Welding Power Source is designed to operate at a 40% duty 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 is 4 minutes). During the other 6 minutes of the 10 minute period the Welding Power Source must idle and
be allowed to cool.
With Factory Fitted Supply Cord and Plug
100
90
80
70
60
50
40
30
Duty Cycle (percentage)
20
10
0
0
Safe
Operating
Region
25 50 75
100
STICK (SMAW)
125 150 225 250
175
TIG (GTAW)
MIG (GMAW)
200
Welding Current Max (amps)
Art # A-10666
Figure 2-3: Fabricator 252i Duty Cycle with Upgraded Supply Lead and Plug
Manual 0-5423 2-3 INTRODUCTION
ESAB FABRICATOR 252i
2.09 Specifications
Description
Power Source Dimensions H 17.5" x W 10.25" x D 23.5"
Power Source Mass 65 lbs.
Cooling Fan Cooled
Welder Type Multi Process Power Source
Standard IEC60974.1
Number of Phases Single Phase
Nominal Supply Voltage 208/230 VAC ± 15%
Supply Voltage Range 187 - 265 VAC
Nominal Supply Frequency 50/60Hz
Open Circuit Voltage 72 VDC
MIG Voltage Range 14-30 VDC
Wirefeeder Speed Range 67 - 700 ipm (1.7 - 17.8 M/min.)
Protection Class IP23S
Supply Lead & Plug Rating 50 Amps (10 AWG)
Welding Current Range (MIG 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 Generator Requirement 10 kVA
MIG (GMAW) Welding Output, 40°C, 10 min. 250A @ 40%,26.5V
STICK (SMAW) Welding Output, 40°C, 10 min. 230A @ 40%,29.2V
TIG (GTAW) Welding Output, 40°C, 10 min. 250A @ 40%,20V
Table 2-1: Fabricator 252i Specification
Fabricator 252i MULTI PROCESS
WELDING INVERTER
200A @ 60%, 24V
150A @ 100%, 21.5V
200A @ 60%, 28V
150A @ 100%, 26V
200A @ 60%, 18V
150A @ 100%, 16V
NOTE!
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all
capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities
and ratings in use and operation will depend upon correct installation, use, applications, maintenance and
service.
INTRODUCTION 2-4 Manual 0-5423
ESAB FABRICATOR 252i
SECTION 3: INSTALLATION
OPERATION AND SETUP
3.01 Environment
This unit is designed for use in environments with increased
hazard of electric shock as outlined in IEC 60974.1. Additional
safety precautions may be required when using unit in an
environment with increased hazard of electric shock. Please refer
to relevant local standards for further information prior to using in
such areas.
A. Examples of environments with increased hazard of electric
shock are:
1. In locations in which freedom of movement is restricted,
so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical contact with conductive parts.
2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator.
3. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the
human body and the insulation properties of accessories.
B. Environments with increased hazard of electric shock
do not include places where electrically conductive parts in the
near vicinity of the operator, which can cause increased hazard,
have been insulated.
3.02 Location
3.03 Ventilation
WARNING
!
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
3.04 Mains Supply Voltage Requirements
!
CAUTION
The Mains supply voltage should be within ±
15% of the rated Mains supply voltage. Too low
of a supply voltage may cause poor welding
performance or wirefeeder malfunction. Too
high of a supply voltage will cause components
to overheat and possibly fail.
WARNING
The Fabricator 252i must be electrically
connected by a qualified electrical tradesperson. Damage to the PCA (Power Control
Assembly) could occur if 276 VAC or higher
is applied to the Primary Power Cable.
Be sure to locate the welder according to the following guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 32° F to 104° F.
C. In areas, free from oil, steam and corrosive gases.
D. In areas, not subjected to abnormal vibration or shock.
E. In areas, not exposed to direct sunlight or rain.
F. Place at a distance of 1 foot or more from walls or similar
that could restrict natural air flow for cooling.
G. The enclosure design of this power 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 surface in the upright position when in use.
WARNING
This equipment should be electrically connected by a qualified electrician.
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power. DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging procedures
consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting OFF and red-tagging
circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz,
AC power source. The Welding Power Source must be:
• Correctly installed, if necessary, by a qualied electrician.
• Correctly earthed (electrically) in accordance with local
regulations.
• Connected to the correct size power point, fuse and primary
supply lead based on Table 3-1.
WARNING
Any electrical work must be carried out by
a qualified Electrical Tradesperson.
Manual 0-5423 3-1 INTRODUCTION
ESAB FABRICATOR 252i
50/60 Hz
Single Phase
Yes 10 AWG 208-230/50A 50A 40% @ 250A 40% @ 250A 40% @ 230A
3.05 Electromagnetic Compatibility
!
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.
Primary Supply
Lead Size
Minimum Primary
Current Circuit
Size (Vin/Iin)
Table 3-1: Input Power Source Leads for Fabricator 252i
WARNING
Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic situation.
NOTE!
The welding circuit may or may not be
earthed for safety reasons. Changing the
Minimum
Plug Size
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.
MIG LIFT TIG STICK
Current & Duty Cycle
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 equipment. Further guidance is given in IEC
60974-13 Arc Welding Equipment - Installation and use (under preparation).
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.
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.
INSTALLATION/SETUP 3-2 Manual 0-5423
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 touching the metallic components and the electrode at the same
time. The operator should be insulated from all such bonded
metallic components.
ESAB FABRICATOR 252i
1
5. Earthing/grounding of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g.
ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to
other electrical equipment. Where 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 achieved by suitable
capacitance, selected according to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference.
Screening the entire welding installation may be considered for special applications.
3.06 Power Source Controls, Indicators and Features
2
3
4
5
8
6
9
7
A-12927
Figure 3-1: Fabricator Control Panel
11
10
12
+
13 14
15
-
Art # A-10504
Figure 3-2: Fabricator Front Connections
Manual 0-5423 3-3 INTRODUCTION
ESAB FABRICATOR 252i
WARNING
DO NOT TOUCH the electrode wire while it is
being fed through the system. The electrode
wire will be at welding voltage potential.
1. Power Indicator
The green power indicator will be illuminated when the
welder is turned ON and indicates the presence of power.
5. Advanced Features Button
Advanced
Features
Press and release the Advanced Features button to enter or exit
from 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 Section 3.07.
Advanced
Features
2. Fault Indicator
The yellow fault indicator will be illuminated when any of the
faults are detected. ALL Faults will illuminate the indicator
3. Weld Process Selection Button
Process
MIG
TIG
STICK
Press and release this button to change the selected weld process mode from MIG to LIFT TIG to STICK. The weld process will
change to the next process in the sequence each time the button
is pressed and released. The red indicators next to the button
will illuminate to identify MIG or LIFT TIG or STICK process mode.
WARNING
When the Power light is lit, the machine is
connected to the Mains supply voltage and
the internal electrical components are at
Mains voltage potential.
4. 2T - 4T Trigger Latch Button
Trigger
2T Normal
4T Latch
Press and release the button to change the selected operating mode of the trigger. The selected mode can be either “2T”
(unlatched) or “4T” (latched) operation. The red indicator next to
the button will illuminate to identify which mode is selected (2T
or 4T). In the 4T mode once the weld has been started you can
release the trigger and continue welding until the trigger is activated again or the welding arc is broken to stop the welding arc.
Gas Purge. In addition, the Advanced Features Button is used
to initiate a 30 second gas line purge function to fill the gas line
with the shielding gas from the connected gas cylinder. To start
the gas purge function, simply press and hold the button for
approximately two (2) seconds. Once the Gas purge function has
started, a countdown timer will show in the left alpha-numeric
display indicating the number of seconds remaining before the
purge will be automatically terminated. You can stop the Gas
purge any time during the 30 seconds by quickly pressing and
releasing the button again.
6. Left Knob: Amperage Control (Wirespeed)
A
Left Knob
WIRESPEED
The amperage control knob adjusts the amount of welding current delivered by the power source. In STICK and LIFT TIG modes,
the amperage control knob directly adjusts the power inverter
to deliver the desired level of output current. In MIG mode, the
amperage knob adjusts the speed of the wire feed motor (which
in turn adjusts the output current by varying the amount of MIG
wire delivered to the welding arc). The optimum wire speed required is dependent on the type of welding application. The setup
chart on the inside of the wire feed compartment door provides a
brief summary of the required output settings for a basic range of
MIG welding applications. The value may also be adjusted while
a weld is in progress – if this occurs, the left display will briefly
switch to show the adjusted value as the knob is turned, and will
automatically revert back to showing the weld current measurements when the knob is not being turned.
INSTALLATION/SETUP 3-4 Manual 0-5423
ESAB FABRICATOR 252i
7. Right Knob: Multifunction Control - MIG Voltage / Arc
Control (Inductance) & STICK Arc Force
V
Right Knob
ARC CONTROL
MIG Voltage Control
In this mode the control knob is used to adjust the output voltage of the power source. The welding voltage is increased by
turning the knob clockwise or decreased by turning the knob
anti-clockwise. The optimum voltage level required is dependent
on the type of welding application. The setup chart on the inside
of the wire feed compartment door provides a brief summary
of the required output settings for a basic range of MIG welding
applications. The value may also be adjusted while a weld is in
progress – if this occurs, the left display will briefly switch to
show the adjusted value as the knob is turned, and will automatically revert back to showing the weld current measurements
when the knob is not being turned.
V
Right Knob
Right Knob
ARC CONTROL
MIG Arc Control (Inductance)
The arc control operates in MIG mode only and is used to adjust
the intensity of the welding arc. To access the Arc Control function, push inward on the right knob and hold it for approximately
2 seconds. This feature can be accessed and adjusted during
welding.
When STICK Mode is Selected
In this mode the multifunction control knob is used to adjust
arc force. Arc force control provides an adjustable amount of
welding force (or “dig”) control. This feature can be particularly
beneficial in providing the operator the ability to compensate
for variability in joint fit-up in certain situations with particular
electrodes. In general increasing the arc force control toward
‘100%’ (maximum arc force) allows greater penetration control
to be achieved. Arc force is increased by turning the control knob
clockwise or decreased by turning the knob anti-clockwise. This
feature can be accessed and adjusted during welding.
To access the Arc Control function, push inward on the right knob
and hold it for approximately 2 seconds. This feature can be accessed and adjusted during welding.
The left display will change to show the Arc Control parameter
name that is in effect for the current MIG or STICK Modes and
the right display will show its present value. Use the right knob
to change the value. When the desired value is selected, press
inward again on the knob without turning it and release it to exit
the Arc Control function and save the value.
8. Left Digital Display
MIG Mode
This digital 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 meter will display a pre-set
(preview) value of Wirefeed Speed. This value can be adjusted by
varying the Left Knob (Control No 6).
STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding amperage of
the power source when welding. At times of non-welding, the
amperage meter will display a pre-set (preview) value in both
STICK and LIFT TIG modes. This value can be adjusted by varying
the Left Knob (Control No 6).
When welding, this digital meter will display actual welding
amperage in all modes.
At the completion of welding, the digital meter will hold the last
recorded amperage value for a period of approximately 10 seconds in all modes. The amperage meter will hold the value until;
(1) any of the front panel controls are adjusted in which case the
unit will revert to preview mode, (2) welding is recommenced, in
which case actual welding amperage will be displayed, or (3) a
period of 10 seconds elapses following the completion of welding
in which case the unit will return to preview mode.
The display is also used for providing error messages to the user
and showing other information, which will be explained in Section 5.
9. Right Digital Display
MIG Mode
This digital meter is used to display the pre-set (preview) Voltage
in MIG mode and actual welding voltage of the power source
when welding. At times of non-welding, the digital meter will
display a pre-set (preview) value of Voltage. This value can be
adjusted by varying the Right Knob (Control No 7).
STICK and LIFT TIG Modes
This digital meter is used to display the Welding Output Terminal
Voltage in STICK / LIFT TIG modes during non-welding or welding.
This value can not be adjusted by varying the Right Knob (Control
No 7).
When welding, this digital meter will display actual welding voltage in all modes.
At the completion of welding, the digital meter will hold the last
recorded voltage value for a period of approximately 10 seconds
in all modes. The voltage meter will hold the value until; (1) any
of the front panel controls are adjusted in which case the unit will
revert to preview mode, (2) welding is recommenced, in which
case actual welding amperage will be displayed, or (3) a period of
10 seconds elapses following the completion of welding in which
case the unit will return to preview mode.
The display is also used for providing error messages to the user
and showing other information, which will be explained in Section 5.
Manual 0-5423 3-5 INTRODUCTION
ESAB FABRICATOR 252i
Weld Modes Arc Control Function Left Display Right Display Limits
MIG Inductance INDU 25% (default) 0 – 100 %
STICK Arc Force ARC- / FRCE 50% (default) 0 – 100%
Table 3-2
13. Positive Welding Output Terminal
The positive welding terminal is used to connect the welding
output of the power source to the appropriate welding accessory such as the Fusion MIG Gun (via the MIG Gun polarity lead),
electrode holder lead or work lead. Positive welding current
flows from the power source via this heavy duty bayonet type
terminal. It is essential, however, that the male plug is inserted
and turned securely to achieve a sound electrical connection.
!
CAUTION
Loose welding terminal connections can
cause overheating and result in the male
plug being fused in the bayonet terminal.
14. Negative Welding Output Terminal
The negative welding terminal is used to connect the welding
output of the power source to the appropriate welding accessory such as the MIG Gun (via the MIG Gun polarity lead), LIFT
TIG torch or work lead. Negative welding current flows to the
power source via this heavy duty bayonet type terminal. It is
essential, however, that the male plug is inserted and turned
securely to achieve a sound electrical connection.
3.07 Advanced Features Details
NOTE!
The Local / Remote setting will only be
saved while in that welding process. Once
the welding process is changed the setting
will revert to the factory default.
General Operation
Process
Select the weld process (Control No 3) you wish to view Advanced Features for.
Then press and release the Advanced Features button (Control
No 5) to enter or exit from the Advanced Features programming
function of the welder.
Advanced
Features
MIG
TIG
STICK
!
CAUTION
Loose welding terminal connections can
cause overheating and result in the male
plug being fused in the bayonet terminal.
15. MIG Gun Polarity Lead
The polarity lead is used to connect the MIG Gun to the appropriate positive 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, stainless steel or aluminum
electrode wire. When using gasless wire, the polarity lead is
generally connected to the negative welding terminal (-). If in
doubt, consult the manufacturer of the electrode wire for the
correct polarity. It is essential, however, that the male plug
is inserted and turned securely to achieve a sound electrical
connection.
!
CAUTION
Loose welding terminal connections can
cause overheating and result in the male
plug being fused in the bayonet terminal.
A
Left Knob
WIRESPEED
The Advanced Features menu items are viewed by turning the
left knob (Control No 6) to move forward or backward through
the list. The function names in the menu will be displayed in
abbreviated form in the left alpha-numeric display. In the case of
two part names or abbreviations, the left display will alternately
flash the first part of the function name and then the second part,
followed by a brief “blank” interval. For each function, the right
alpha-numeric display will show its present value.
V
Right Knob
ARC CONTROL
INSTALLATION/SETUP 3-6 Manual 0-5423
ESAB FABRICATOR 252i
To change the value of that parameter, simply turn the right knob (Control No 7) to change it. If the setting has been changed from
its previous value the welder will save the new value when the left knob is turned to view the next parameter, or if the user activates
a control to cause the welder to exit Advanced Features mode as described earlier. Once the beginning or end of the menu list is
reached, additional turning of the left knob in that direction will not result in any change of the displayed parameter.
The Advanced Features control functions are in order with the user’s process steps when setting up to operate the welder in the selected welding process modes (MIG, LIFT TIG, STICK). The menu functions shown in Advanced Features Mode are mostly dependent on
the currently selected weld process mode of the machine.
10. MIG Gun Adaptor
The MIG Gun Adapter is the connection point for the 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 control devices to the welding power source. To make connections, align
keyway, insert plug, and rotate threaded collar fully clockwise.
1
5
8
A-09594_AB
2
1
2
3
4
6
7
3
4
5
6
7
8
Remote Wirespeed in GMAW mode
Remote Amps in GTAW mode
Trigger Switch
W
V
Remote Volts in
GMAW Mode
(-)
M
(+) 24VDC
Socket Pin
1 Not connected
2
3
4
5
6
7
8
Trigger Switch Input
Trigger Switch Input
Not connected
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper
arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
NOTE!
The remote local setting on the control panel should be set to remote for the remote wire feeder amperage/
voltage controls to be operative.
Figure 3-3: Remote Control Socket
Function
Table 3-3
Manual 0-5423 3-7 INTRODUCTION
ESAB FABRICATOR 252i
12. 10 Pin Accessories Socket
The 10 pin Accessories Socket is used to connect remote devices such as a spool gun to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
J
1
I
D
Trigger
1
Peripheral
Resistor
F
E
G
H
Art # A-10813
I
D
J
C
B
A
Socket Pin
A Voltage Pot. Wiper
B
C
D
E
Wire Feed Motor (-)
Wire Feed Motor (+)
Trigger Switch Input
Wire Speed Pot. & Voltage Pot. (+) CW 10K ohm
G
E
F
H
1
2
3 3
Wirespeed
Potentiometer
A
C
B
Figure 3-4: Remote Control Socket
Function
1
2
Voltage
Potentiometer
3
+
Motor
M
24V
-
F
G
H
I
J
Wiper Arm Speed Pot.
Trigger Switch Input & Solenoid (-)
Wire Speed Pot. & Voltage Pot. (-) ACW
Solenoid (+)
Peripheral Program Resistor
Table 3-4
Process
MIG
TIG
STICK
If the welder is in Advanced Features mode and the Weld Process Selection button (Control No 3) is pressed, the
welder will exit Advanced Features mode, saving any change made, and change to the next weld process function in the sequence:
MIG, LIFT TIG, STICK. (See previous note) If you wish to view the Advanced Features for the next process you will need to enter the
Advanced Features function again.
INSTALLATION/SETUP 3-8 Manual 0-5423
ESAB FABRICATOR 252i
V
Right Knob
Right Knob
ARC CONTROL
If the welder is in Advanced Features mode and the right knob (Control No 7) is pressed for one (1) second (to enter Arc Control
Function) the welder will exit Advanced Features mode, saving any change made, and enter the Arc Control Function for the currently
selected weld process.
MIG (GMAW/FCAW)Mode Advanced Features Menu Map
Left Display Right Display
Advanced Menu – MIG
Mode
MIG / CNTL
PRE- / FLOW
RUN- / IN
POST / FLOW
BURN / BACK
WIRE / SHRP
SPOT
*SPOT / TIME
STCH
*STCH / TIME
DWEL / TIME
ARC- / TYPE
Advanced Menu - MIG
Options or Range
LOCL REMT
0.1 - 5.0 S
30 - 150%
0.0 - 30.0 S
0.00 - 1.00 S
ON OFF
ON OFF
0.1-20.0 S
ON OFF
0.2 - 4.0 S
0.1 - 1.0 S
AUTO CV
Process
MIG
TIG
STICK
Advanced
Features
MPM IPMWFS- / UNIT
Wire Feed Speed
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Right Knob Selection
Art # A-10505_AB
* SPOT TIME and STCH TIME are only active when SPOT or STCH are “ON”.
Note “SPOT” and “STCH” are MUTUALLY EXCLUSIVE functions. If the user enables either function and the system
detects that the OTHER function is already ON, the system will automatically turn the OTHER conflicting function OFF.
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Figure 3-5: MIG Advanced Menu
Manual 0-5423 3-9 INTRODUCTION
ESAB FABRICATOR 252i
Right Display
Function Left Display
MIG Operator
Controls
Pre Flow (MIG
Setting)
Run In RUN/IN 70% 30 – 150 %
Post Flow (MIG
Setting)
Burn Back BURN/BACK 0.15 S 0.00 – 1.00 S
Wire Sharp WIRE/SHRP ON OFF – ON
Spot SPOT OFF OFF – ON
Spot Time
(Only shown/enabled if Spot=ON)
Stitch STCH OFF OFF – ON
Stitch Time
(Only shown/
enabled if
Stitch=ON)
Dwell Time
(Only shown/
enabled if
Stitch=ON)
Arc Type ARC-/TYPE AUTO AUTO – CV-M
Wire Feed Speed
Units
Arc Hour Accumulated Runtime
Restore Factory
Defaults
MIG/CNTL LOCL LOCL - REMT
PRE-/FLOW 0.1 S 0.0 – 5 S
POST/FLOW 0.5 S 0.0 – 30 S
SPOT/TIME 2.0 S 0.1 – 20.0 S Spot Time is the time used for the Spot weld mode.
STCH/TIME 2.0 S 0.2 – 4.0 S
DWEL/TIME 0.5 S 0.1 – 1.0 S
WFS/UNIT IPM MPM – IPM
HR 0.0 0.0 – 9999.9
FACT/DFLT NO NO – YES
(Factory Default
Values)
Limits Comments
LOCL = Local control of the Wirespeed and Voltage with
the machines controls.
REMT = Remote control of the Wirespeed and Voltage
with an accessory device.
Shielding gas flows for the time specified before an arc
is initiated.
Wirespeed runs as a percentage of preview wirespeed
until an arc is struck.
Shielding gas flows for the time specified after an arc
has extinguished.
The time difference between turning the wire feed OFF
before the voltage is turned OFF.
Wire Sharp adds a burst of current at the end of a weld
to remove the ball at the end of the wire. This improves
the restart of the next weld.
Spot is used to weld two thin plates together at a
desired location by melting the top & bottom plates
together to form a nugget between them. The weld
time is set by the Spot Time.
Stitch is used to weld two or more components by
stitch or interval weld together.
The weld time is set by the Stitch Time and the non
weld time is set by the Dwell Time.
Stitch Time is the time used for the weld time in Stitch
weld mode.
Dwell Time is the time used for the non weld time in
Stitch weld mode.
Auto is an optimized arc control for dip transfer welding
with minimal spatter on mild steel with mixed shielding gases. CV-M is the traditional constant-voltage arc
control for all other welding.
MPM provides preview wirespeed in Meters Per Minute.
IPM provides preview wirespeed in Inches Per Minute.
Provides Arc On Hours that the power source has
welded. The number displayed is in hours and read
only. It will rollover to 0 once 10,000 hours have been
reached.
When YES is selected all the user adjustable values in
this table (except Arc Hour Accumulated Runtime) are
reset to the Factory Default Values.
INSTALLATION/SETUP 3-10 Manual 0-5423
LIFT TIG Mode Advanced Features Menu Map
Left Display Right Display
Advanced Menu -
LIFT TIG Mode
TIG / CNTL
PRE- / FLOW
POST / FLOW
DOWN / SLPE
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection Right Knob Selection
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Advanced Menu - LIFT
TIG Options or Range
Press Advanced Button
to Exit to Welding Mode
Figure 3-6: LIFT TIG Advanced Menu
Right Display
Function Left Display
(Factory Default
Limits Comments
Values)
LIFT TIG Operator
Controls
Pre Flow (LIFT TIG
Setting)
Post Flow (LIFT TIG
Setting)
LIFT TIG/CNTL REMT LOCL - REMT
PRE-/FLOW 0.1 S 0.0 – 5 S
POST/FLOW 10.0 S 0.0 – 30 S
Down Slope DOWN/SLPE 0.0 S 0.0 – 30 S
Arc Hour Accumulated Runtime
Restore Factory
Defaults
HR 0.0 0.0 – 9999.9
FACT/DFLT NO NO – YES
LOCL REMT
0.0 - 5.0 S
0.0 - 30.0 S
0.0 - 30.0 S
0.0 - 9999.9
NO YES
LOCL = Local control of the Amps with the machines
controls
REMT = Remote control of the Amps with an accessory
device
Shielding gas flows for the time specified before an arc
is initiated
Shielding gas flows for the time specified after an arc
has extinguished
In “2T” (unlatched), the unit will enter down slope
mode as soon as the trigger switch is released (ie if
Down Slope is set to 5.0 S, the unit will ramp down
from the present welding current to zero over 5 seconds).
In "4T" (latched), to enter down slope mode the trigger
switch must be held in for the selected time period (ie
press and release trigger switch to commence welding,
then press and hold trigger switch again to enter down
slope mode). Should the trigger switch be released
during the down slope time, the output will cease im-
mediately in "4T" only.
Provides Arc On Hours that the power source has
welded. The number displayed is in hours and read
only. It will rollover to 0 once 10,000 hours have been
reached.
When YES is selected all the user adjustable values in
this table (except Arc Hour Accumulated Runtime) are
reset to the Factory Default Values.
ESAB FABRICATOR 252i
Process
MIG
TIG
STICK
Advanced
Features
Art # A-10506_AB
Manual 0-5423 3-11 INTRODUCTION
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