Fabricator 252i
Fabricator 252i
Fabricator 252i
Operating
Manual
A-12925
3163339
300
esab.com
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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.
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.
Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208
www.esab.com
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.
Where Purchased:__________________________________________
Purchase Date:_____________________________________________
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 equip-
ment, 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 accom-
panying 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 re-
pair 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!
ESAB can provide you with all necessary cutting protection and accessories.
WARNING
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.
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.
A-12953
90
80
TIG (GTAW)
70
MIG (GMAW)
Duty Cycle (percentage)
60
Safe
50
Operating
40
Region
30 STICK (SMAW)
20
10
0
0 25 50 75 100 125 150 175 200 225 250
Figure 2-3: Fabricator 252i Duty Cycle with Upgraded Supply Lead and Plug
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.
3.05 Electromagnetic Compatibility 7. The time of day that welding or other activities are to be
carried out.
WARNING 8. The immunity of other equipment in the environment: the
! Extra precautions for Electromagnetic
Compatibility may be required when this
user shall ensure that other equipment being used in the
environment is compatible: this may require additional
Welding Power Source is used in a domes- protection measures.
tic situation. 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
A. Installation and Use - Users Responsibility
of the premises.
The user is responsible for installing and using the welding
C. Methods of Reducing Electromagnetic Emissions
equipment according to the manufacturer’s instructions. If
electromagnetic disturbances are detected then it shall be the 1. Mains Supply
responsibility of the user of the welding equipment to resolve the
situation with the technical assistance of the manufacturer. In Welding equipment should be connected to the mains
some cases this remedial action may be as simple as earthing supply according to the manufacturer’s recommendations.
the welding circuit, see NOTE below. In other cases it could If interference occurs, it may be necessary to take
involve constructing an electromagnetic screen enclosing the additional precautions such as filtering of the mains supply.
Welding Power Source and the work, complete with associated Consideration should be given to shielding the supply cable
input filters. In all cases, electromagnetic disturbances shall be of permanently installed welding equipment in metallic
reduced to the point where they are no longer Troublesome. conduit or equivalent. Shielding should be electrically
continuous throughout its length. The shielding should
NOTE! be connected to the Welding Power Source so that good
The welding circuit may or may not be electrical contact is maintained between the conduit and
earthed for safety reasons. Changing the the Welding Power Source enclosure.
earthing arrangements should only be
authorized by a person who is competent to 2. Maintenance of Welding Equipment
assess whether the changes will increase The welding equipment should be routinely maintained
the risk of injury, e.g. by allowing parallel according to the manufacturer’s recommendations. All
welding current return paths which may access and service doors and covers should be closed
damage the earth circuits of other equip- and properly fastened when the welding equipment is in
ment. Further guidance is given in IEC operation. The welding equipment should not be modified in
60974-13 Arc Welding Equipment - Instal- any way except for those changes and adjustments covered
lation and use (under preparation). in the manufacturer’s instructions.
B. Assessment of Area 3. Welding Cables
Before installing welding equipment, the user shall make
The welding cables should be kept as short as possible and
an assessment of potential electromagnetic problems in the
should be positioned close together but never coiled and
surrounding area. The following shall be taken into account.
running at or close to the floor level.
1. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the welding equipment. 4. Equipotential Bonding
2. Radio and television transmitters and receivers. Bonding of all metallic components in the welding instal-
lation and adjacent to it should be considered. However,
3. Computer and other control equipment. metallic components bonded to the work piece will increase
4. Safety critical equipment, e.g. guarding of industrial the risk that the operator could receive a shock by touch-
equipment. ing the metallic components and the electrode at the same
time. The operator should be insulated from all such bonded
5. The health of people around, e.g. the use of pace-makers metallic components.
and hearing aids.
6. Equipment used for calibration and measurement.
INSTALLATION/SETUP 3-2 Manual 0-5423
A-12927
6 8 9 7
11
10 12
+ -
13 14
15 Art # A-10504
WARNING The amperage control knob adjusts the amount of welding cur-
When the Power light is lit, the machine is rent delivered by the power source. In STICK and LIFT TIG modes,
connected to the Mains supply voltage and the amperage control knob directly adjusts the power inverter
the internal electrical components are at to deliver the desired level of output current. In MIG mode, the
Mains voltage potential. 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 re-
4. 2T - 4T Trigger Latch Button quired is dependent on the type of welding application. The setup
chart on the inside of the wire feed compartment door provides a
Trigger
2T Normal brief summary of the required output settings for a basic range of
MIG welding applications. The value may also be adjusted while
4T Latch
a weld is in progress – if this occurs, the left display will briefly
Press and release the button to change the selected operat- switch to show the adjusted value as the knob is turned, and will
ing mode of the trigger. The selected mode can be either “2T” automatically revert back to showing the weld current measure-
(unlatched) or “4T” (latched) operation. The red indicator next to ments when the knob is not being turned.
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 acti-
vated again or the welding arc is broken to stop the welding arc.
V
MIG Mode
This digital meter is used to display the pre-set (preview)
Right Knob
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
ARC CONTROL
(preview) value of Wirefeed Speed. This value can be adjusted by
varying the Left Knob (Control No 6).
MIG Voltage Control STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amper-
In this mode the control knob is used to adjust the output volt- age in STICK / LIFT TIG modes and actual welding amperage of
age of the power source. The welding voltage is increased by the power source when welding. At times of non-welding, the
turning the knob clockwise or decreased by turning the knob amperage meter will display a pre-set (preview) value in both
anti-clockwise. The optimum voltage level required is dependent STICK and LIFT TIG modes. This value can be adjusted by varying
on the type of welding application. The setup chart on the inside the Left Knob (Control No 6).
of the wire feed compartment door provides a brief summary When welding, this digital meter will display actual welding
of the required output settings for a basic range of MIG welding amperage in all modes.
applications. The value may also be adjusted while a weld is in At the completion of welding, the digital meter will hold the last
progress – if this occurs, the left display will briefly switch to recorded amperage value for a period of approximately 10 sec-
show the adjusted value as the knob is turned, and will automati- onds in all modes. The amperage meter will hold the value until;
cally revert back to showing the weld current measurements (1) any of the front panel controls are adjusted in which case the
when the knob is not being turned. unit will revert to preview mode, (2) welding is recommenced, in
V 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.
Right Knob
Knob
Right The display is also used for providing error messages to the user
and showing other information, which will be explained in Sec-
tion 5.
ARC CONTROL
9. Right Digital Display
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 func-
MIG Mode
tion, push inward on the right knob and hold it for approximately
This digital meter is used to display the pre-set (preview) Voltage
2 seconds. This feature can be accessed and adjusted during
in MIG mode and actual welding voltage of the power source
welding.
when welding. At times of non-welding, the digital meter will
When STICK Mode is Selected
display a pre-set (preview) value of Voltage. This value can be
In this mode the multifunction control knob is used to adjust
adjusted by varying the Right Knob (Control No 7).
arc force. Arc force control provides an adjustable amount of
STICK and LIFT TIG Modes
welding force (or “dig”) control. This feature can be particularly
This digital meter is used to display the Welding Output Terminal
beneficial in providing the operator the ability to compensate
Voltage in STICK / LIFT TIG modes during non-welding or welding.
for variability in joint fit-up in certain situations with particular
This value can not be adjusted by varying the Right Knob (Control
electrodes. In general increasing the arc force control toward
No 7).
‘100%’ (maximum arc force) allows greater penetration control
When welding, this digital meter will display actual welding volt-
to be achieved. Arc force is increased by turning the control knob
age in all modes.
clockwise or decreased by turning the knob anti-clockwise. This
At the completion of welding, the digital meter will hold the last
feature can be accessed and adjusted during welding.
recorded voltage value for a period of approximately 10 seconds
To access the Arc Control function, push inward on the right knob
in all modes. The voltage meter will hold the value until; (1) any
and hold it for approximately 2 seconds. This feature can be ac-
of the front panel controls are adjusted in which case the unit will
cessed and adjusted during welding.
revert to preview mode, (2) welding is recommenced, in which
The left display will change to show the Arc Control parameter
case actual welding amperage will be displayed, or (3) a period of
name that is in effect for the current MIG or STICK Modes and
10 seconds elapses following the completion of welding in which
the right display will show its present value. Use the right knob
case the unit will return to preview mode.
to change the value. When the desired value is selected, press
The display is also used for providing error messages to the user
inward again on the knob without turning it and release it to exit
and showing other information, which will be explained in Sec-
the Arc Control function and save the value.
tion 5.
! CAUTION
Loose welding terminal connections can
TIG
STICK
cause overheating and result in the male
plug being fused in the bayonet terminal.
Select the weld process (Control No 3) you wish to view Ad-
vanced Features for.
14. Negative Welding Output Terminal
Advanced
The negative welding terminal is used to connect the welding Features
! CAUTION
Loose welding terminal connections can
Left Knob
cause overheating and result in the male
plug being fused in the bayonet terminal.
WIRESPEED
! CAUTION
Loose welding terminal connections can ARC CONTROL
cause overheating and result in the male
plug being fused in the bayonet terminal.
1
2 (-)
Trigger Switch
3 M
2 1
4
(+) 24V DC
5 4 3 5 Remote Volts in
W V GMAW Mode
8 7 6 6
7
8
Remote Wirespeed in GMAW mode
A-09594_AB
Remote Amps in GTAW mode
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.
3
F E
G
G
J D
C
E 1
H
I
1
B
2 2
A
F
H 3 3
Wirespeed Voltage
Potentiometer Potentiometer
A
+
C M Motor
24V
Art # A-10813
B -
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.
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
* 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
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Right Display
Function Left Display (Factory Default Limits Comments
Values)
LOCL = Local control of the Amps with the machines
LIFT TIG Operator controls
LIFT TIG/CNTL REMT LOCL - REMT
Controls REMT = Remote control of the Amps with an accessory
device
Pre Flow (LIFT TIG Shielding gas flows for the time specified before an arc
PRE-/FLOW 0.1 S 0.0 – 5 S
Setting) is initiated
Post Flow (LIFT TIG Shielding gas flows for the time specified after an arc
POST/FLOW 10.0 S 0.0 – 30 S
Setting) 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 sec-
onds).
In "4T" (latched), to enter down slope mode the trigger
Down Slope DOWN/SLPE 0.0 S 0.0 – 30 S
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
Arc Hour Accumu- welded. The number displayed is in hours and read
HR 0.0 0.0 – 9999.9
lated Runtime only. It will rollover to 0 once 10,000 hours have been
reached.
When YES is selected all the user adjustable values in
Restore Factory
FACT/DFLT NO NO – YES this table (except Arc Hour Accumulated Runtime) are
Defaults
reset to the Factory Default Values.
Left Display: Where (2) items shown, e.g. HOT- / STRT, the display will alternate (flash) between the (2) items
Right Display
Function Left Display (Factory Default Limits Comments
Values)
LOCL = Local control of the Amps with the machines
STICK Operator controls
STCK/CNTL LOCL LOCL - REMT
Controls REMT = Remote control of the Amps with an acces-
sory device
Hot Start is used to improve the start characteristics
Hot Start HOT/STRT ON OFF – ON
for STICK electrodes, e.g. low hydrogen electrodes.
Hot Start Time is the time that the Hot Start Amps is
Hot Start Time TIME/HS 0.5 S 0.0 - 2.0 S
applied.
Hot Start Amps sets the peak start current, e.g. 100A
Hot Start Amps AMPS/HS 140% 75 – 200%
at 140% = 140A
Provides Arc On Hours that the power source has
Arc Hour Accumu- welded. The number displayed is in hours and read
HR 0.0 0.0 – 9999.9
lated Runtime only. It will rollover to 0 once 10,000 hours have been
reached.
When YES is selected all the user adjustable values in
Restore Factory
FACT/DFLT NO NO – YES this table (except Arc Hour Accumulated Runtime) are
Defaults
reset to the Factory Default Values.
Art # A-10548
+ -
Remote Cable 8 pin connector
4. If equipped, align the keyways of the MIG Gun Switch connector pigtail with 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 trigger switch leads from the machine, DO NOT pull on the wires. Loosen
the locking ring and gently pull the plug out of the socket.
Fibre Washer
Retaining Clip
12.5lb / 8” Use inner holes on Pin
Wire Spool Spool Hub
Flat Washer
Wire Spool Large Hole
Hub Nut
Spool Hub
Flat Washer Keyed Washer
Small Hole Spring A-10670
Spool Hub
Retaining Clip
Fibre Washer
Use outer holes
33lb / 12” Pin
Wire Spool
Flat Washer
Wire Spool Large Hole
Hub Nut
WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before
proceeding. DO NOT reattach the input power until told to do so in these instructions.
1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure 3-11)
2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure 3-11)
3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire Guide and over
the 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 Fusion
250A MIG Gun as per Section 3.08 ensuring the MIG wire passes into the MIG Gun liner of the MIG Gun.)
5. Close the Pressure Roller Arm. (Figure 3-12)
6. Swing the Spring Pressure Adjusting Knob back into place. (Figure 3-12)
7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to Tighten and Counter Clockwise to loosen).
(Figure 3-12)
8. Figure 3-13 shows the result with wire installed. Continue to the next section for proper setting of tension.
1 2
3 4
Art # A-10030
5 7
Art # A-10031
The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise. The Tension Adjuster should be set
to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire out of the
MIG Gun reveals no deformation or wear, the conduit liner should be checked for kinks or clogging from metal flakes. If this is not the
cause of slipping, the feedroll pressure can be increased by rotating the Tension Adjusting knob clockwise. The use of excessive pres-
sure may cause rapid wear of the feed roller, motor shaft and motor bearings.
NOTE!
Genuine ESAB Velocity contact tips and liners should be used. Many non-genuine liners use inferior materi-
als which can cause wire feed problems.
2
Art # A-10415
Figure 3-13: Top View of Feed Plate with Pressure Arm Open
NOTE!
It may not be possible to align with both the inlet and outlet guide at the same time. The outlet guide is the
one that needs to be aligned to for best wire feeding.
NOTE!
Feedrolls often come with a rust prohibitive coating that needs to be cleaned off before installation.
A Feedroll consists of two different sized grooves. As delivered from the factory the drive roll is installed for .035" / .045" (0.9 / 1.2
mm).
The stamped marking on the feedroll refers to the groove furthest from the stamped marking. When mounted, that will be the groove
closest to the motor and the one to thread.
To ensure proper wire feed, the groove closest to the motor must match the electrode wire size being used.
.045” (1.2mm) Stamping
.045 .045
1.2 1.2
NOTE!
All grooved feed 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 roll kit in the Appendix for the proper selection and ordering of feed roll kits. Kit includes drive rolls, an input wire guide
and an output wire guide for a specific wire type and size.
Feed rolls are removed by twisting the feed roll retainer cap and aligning the retaining knob splines/tabs with the drive gear splines.
Feedrolls are installed by putting the feedroll onto the drive gear splines and twisting the feedroll retainer cap so that the splines/tabs
rest against the face of the feedroll where they will click into place.
NOTE!
Installation of all styles of feed rolls for the Fabricator 252i are identical..
WARNING
The welding wire is electrically Hot if it is fed by depressing Fusion 250A MIG Gun switch. Electrode contact
to work piece will cause an arc with MIG Gun switch depressed..
Input Wire Guide - Install (the shorter one) by loosening the Input Guide Lock Screw and inserting the guide into the hole in the feed-
head assembly. Adjust the guide so that it is clear of the feed rolls and Tighten the Input Guide Lock Screw.
NOTE!
Before tightening the Input and Output Guide Lock Screws, install the 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 Lock Screw. Install the Output Wire Guide (the longer one) by inserting the conical end part way into the ESAB Adapter
from the front of the machine. Now install the MIG Gun pressing the output guide further in until the tip of the guide is as close to the
feed rolls as practical. Secure the MIG Gun. Tighten the MIG Adapter Lock Nut, then tighten the Output Guide Lock Screw.
Input Guide Lockscrew
Output Guide Lockscrew
MIG Gun
Lock
Screw
MIG Gun
Art # A-10555 Adapter Lock
Nut
Pressure Adjustment
Knob
CAUTION
! Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, over heat-
ing of electrical componentry and possibly an increased incidence of wire Burnback into the
contact tip.
NOTE!
Correct adjustment will result in the wire reel circumference continuing no further than 3/4" (19 mm) after
release of the MIG Gun trigger switch. The wire should be slack without becoming dislodged from the reel..
WARNING
! This equipment is designed for use with 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
User Responsibilities
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the
instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and re-
liable performance. Defective equipment should not be used. Parts that are broken, missing, obviously worn, distorted, or contaminated
should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper use, faulty main-
tenance, or by repair by anyone other than an accredited repairer.
CAUTION
! Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
Inlet Connection
Flow Gauge
(Delivery) A-12957
Pressure
Adjusting
Screw
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 is to be used a suitable
carbon dioxide regulator/flow meter will need to be fitted.
NOTE!
All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet
gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.
Installation
1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats
before connecting the regulator.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition. Wipe with a clean
lint free cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree and that the regula-
tor inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing
any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and Tighten it firmly but not excessively, with a suitable spanner.
4. Attach supplied gas line between the regulator output and the desired input at the rear of the power source. MIG Spool Gun
and LIFT TIG in the bottom fitting and regular Fusion MIG Gun in the top fitting.
Art # A-10549
5. To protect sensitive down-stream equipment a separate safety device may be necessary if the regulator is not fitted with a
pressure relief device.
Operation
With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:
1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage
internal regulator parts.
2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is recommended that test-
ing for leaks at the regulator connection points be carried out using a suitable leak detection solution or soapy water.
3. Purge air or other 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, depending upon the length
and size of the hose being purged.
Adjusting Flow Rate
With the regulator ready for operation, adjust working flow rate as follows:
1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.
NOTE!
It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence due
to back pressure present within shielding gas hose assembly.
2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator by opening the downstream valve.
Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw coun-
terclockwise, until the required flow rate is indicated on the gauge. Close downstream valve.
3. Adjust regulator pressure adjusting screw to the required flow rate, indicated on gauge dial. (Refer to Figure 3-19)
3.18 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire
The Fabricator 252i is supplied with a ESAB Fusion 250 AMP air-cooled MIG Gun. The ESAB Fusion 250A MIG Gun is designed with an
ergonomic handle and fewer parts to cause performance problems. The Fusion MIG 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 Work Lead to the negative - terminal and connect the MIG Gun polarity lead to the positive +
terminal. If in doubt, consult the MIG electrode wire manufacturer.
+ - Negative Output
Terminal
(Dinse® type 50)
Art # A-10550
1. Turn the Main ON/OFF switch OFF (located on the rear panel).
2. Check that the MIG wire size, contact tip, MIG Gun liner and drive roll groove are all the same size before fitting the MIG wire
into the Power Source.
3. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the MIG electrode wire manufactur-
er. Welding current flows from the Power Source via 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 wire spool and Fusion MIG Gun to the Power Source. (Refer to section 3.08 to 3.12 ).
WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched OFF.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary
support to prevent falling or tipping
CAUTION
! Loose welding terminal connections can cause overheating and result in the male plug being
fused in the terminal.
Remove any packaging material prior to use. DO NOT block the air vents at the front or rear of
the Welding Power Source.
NOTE!
Depending on the type of wire you will be using the MIG Gun polarity may need to be switched. Follow the
wire manufacturers recommendation.
+ - Positive Output
Terminal
(Dinse® type 50)
Art # A-10551
1. Turn the Main ON/OFF switch OFF (located on the rear panel).
2. Check that the MIG wire size, contact tip, MIG Gun liner and drive roll groove are all the same size before fitting the MIG wire
into the Power Source.
3. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the MIG electrode wire manufactur-
er. Welding current flows from the Power Source via 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 the Power Source. (Refer to section 3.08 to 3.12).
5. Connect the work lead to the positive welding terminal (+). If in doubt, consult the MIG electrode wire manufacturer. Weld-
ing current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is
inserted and turned securely to achieve a sound electrical connection.
6. If gasless MIG (FCAW) wire is fitted then shielding gas is not required for welding. Otherwise fit the welding grade shielding gas
regulator/flow gauge to the shielding gas cylinder (refer to Section 3.17) then connect the shielding gas hose from the rear of
the power source to the regulator/flow gauge outlet.
7. Turn the Main ON/OFF switch ON (located on the rear panel).
8. Select MIG mode with the process selection control. (Refer to Section 3.06.4 for further information)
9. Remove the 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 Guide located on the inside of the wire feed compartment door for further information on Voltage/Wirespeed
settings.
WARNING
Before connecting the work clamp to the work make sure the mains power supply is switched OFF.
WARNING
! Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
NOTE!
The following steps will assume that you have already set up the proper shielding gas as outlined in Sub
Section 3.17.
NOTE!
The following set up is known as Straight Polarity or DC Electrode Negative. This is commonly used for DC
LIFT TIG welding on most materials such as steel and stainless steel..
Electrode
Art # A-00503_AB
Art # A-10580
WARNING
! Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
NOTE!
The following set up is known as DC Electrode 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 STICK and Work Leads as shown in Figure 3-24.
Art # A-10553
+ -
Negative Output
Terminal
(Dinse® type 50)
NOTE!
To weld, gently strike the electrode on the work piece to generate a welding arc, and slowly move along the
work piece while holding a consistent arc length above base metal.
ing gas or inert welding grade shielding gas mixture. Figure 4-3
GAS METAL ARC WELDING (GMAW): This process, also known as The MIG Gun should be held at an angle to the weld joint. (See
MIG welding, CO2 welding, Micro Wire Welding, short arc welding, Secondary Adjustment Variables below)
dip transfer welding, wire welding etc., is an electric arc welding Hold the MIG Gun so that the welding seam is viewed at all times.
process which fuses together the parts to be welded by heat- Always wear the welding helmet with proper filter lenses and use
ing them with an arc between a solid continuous, consumable the proper safety equipment.
electrode and the work. Shielding is obtained from an externally
supplied welding grade shielding gas or welding grade shielding CAUTION
gas mixture. The process is normally applied semi automatically;
however the process may be operated automatically and can
! Do NOT pull the MIG Gun back when the arc
is established. This will create excessive
be machine operated. The process can be used to weld thin and wire extension (stick-out) and make a very
fairly thick steels, and some non-ferrous metals in all positions. poor weld.
Shielding Gas
Nozzle The electrode wire is not energized until the MIG Gun trigger
Molten Weld Metal Electrode switch is depressed. The wire may therefore be placed on the
Arc
seam or joint prior to lowering the helmet.
Solidified
Weld Metal Base Metal
5° to 15°
Longitudinal
GMAW Process Art # A-8991_AB
Angle
Figure 4-1
Direction of
FLUX CORED ARC WELDING (FCAW): This is an electric arc weld- 90° Travel
ing process which fuses together the parts to be welded by heat- Transverse
ing them with an arc between a continuous flux filled electrode Angle
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 Art # A-08993
mixture. The process is normally applied semi automatically; Figure 4-4
however the process may be applied automatically or by ma- Butt & Horizontal Welds
chine. It is commonly used to weld large diameter electrodes in
the flat and horizontal position and small electrode diameters in
5° to 15°
all positions. The process is used to a lesser degree for welding
Longitudinal Angle
stainless steel and for overlay work. 30° to 60°
Shielding Gas Transverse Angle
(Optional) Nozzle
(Optional)
Molten Metal
Flux Cored
Molten Electrode Direction of
Slag Travel
Slag
Arc Art # A-08994
Figure 4-5
Solidified Horizontal Fillet Weld
Weld Metal Base Metal
Figure 4-2
Manual 0-5423 4-1 BASIC WELDING
Overhead Weld
Figure 4-7 Average Arc Length
Art # A-08997_AD
Electrode Stick-Out
Distance from the MIG Gun Nozzle to the Work Piece Figure 4-8
The electrode wire stick out from the MIG Gun nozzle should
be between 3/8" - 3/4" (10 - 20 mm). This distance may vary 3. Nozzle Angle. This refers to the position of the MIG Gun
depending on the type of joint that is being welded. in relation to the joint. The transverse angle is usually
Travel Speed one half the included angle between plates forming the
joint. The longitudinal angle is the angle between the
The speed at which the molten pool travels influences the width
centre line of the MIG Gun and a line perpendicular to
of the weld and penetration of the welding run.
the axis of the weld. The longitudinal angle is generally
MIG Welding (GMAW) Variables called the Nozzle Angle and can be either trailing (pull-
Most of the welding done by all processes is on carbon steel. The ing) or leading (pushing). Whether the operator is left
items below describe the welding variables in short-arc weld- handed or right handed has to be considered to realize
ing of .023 - 1/4" (0.6 mm - 6.4 mm) mild sheet or plate. The the effects of each angle in relation to the direction of
applied techniques and end results in the GMAW process are travel.
Transverse
controlled by these variables. Angle
Preselected Variables
Preselected variables depend upon the type of material being
welded, the thickness of the material, the welding position, the
deposition rate and the mechanical properties. These variables Longitudinal
are: Angle
• Type of electrode wire
• Size of electrode wire
Axis of Weld
• Type of gas (not applicable for FCAW self shielding wires)
• Gas flow rate (not applicable for FCAW self shielding wires) Art # A-08998_AB
Transverse and Longitudinal
Nozzle Axes
Figure 4-9
90°
• Capacity of the wire feed unit and Power Source
Leading or “Pushing” Trailing or “Pulling”
Angle Angle • The amount of penetration required
(Forward Pointing) (Backward Pointing)
• The deposition rate required
Nozzle Angle, Right Handed Operator Art # A-08999_AC
• The bead profile desired
Figure 4-10
• The position of welding
Establishing the Arc and Making Weld Beads • Cost of the wire
Before attempting to weld on a finished piece of work, it is
recommended that practice welds be made on a sample metal of
the same material as that of the finished piece.
The easiest welding procedure for the beginner to experiment
with MIG welding is the flat position. The equipment is capable of
flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 1/16" or
3/16" (1.6 mm or 5.0 mm) mild steel plate 6" x 6" (150 mm x
150 mm). Use .035" (0.9 mm) flux cored gasless wire or a solid
wire with shielding gas.
Setting of the Power Source
Power source and Wirefeeder setting requires some practice by
the operator, as the welding plant has two control settings that
have to balance. These are the Wirespeed control (refer to section
3.06.4) and the welding Voltage Control (refer to section 3.06.10).
The welding current is determined by the Wirespeed control, the
current will increase with increased Wirespeed, resulting in a
shorter arc. Less wire speed will reduce 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 current level.
When changing to a different electrode wire diameter, different
control settings are required. A thinner electrode wire needs
more Wirespeed to achieve the same current level.
A satisfactory weld cannot be obtained if the Wirespeed and Volt-
age settings are not adjusted to suit the electrode wire diameter
and the dimensions of the work piece.
If the Wirespeed is too high for the welding voltage, “stubbing”
will occur as the wire dips into the molten pool and does not
melt. Welding in these conditions normally produces a poor
weld due to lack of fusion. If, however, the welding voltage is too
high, large drops will form on the end of the wire, causing spat-
ter. The correct setting of voltage and Wirespeed can be seen
in the shape of the weld deposit and heard by a smooth regular
arc sound. Refer to the Weld Guide located on the inside of the
wirefeed compartment door for setup information.
Figure 4-11
WARNING
! Disengage the feed roll when testing for gas flow by ear.
Most types of cast iron, except white iron, are weldable. White
iron, because of its extreme brittleness, generally cracks when Figure 4-15: Horizontal-Vertical (HV) Position
attempts are made to weld it. Trouble may also be experienced
when welding white-heart malleable, due to the porosity
caused by gas held in this type of iron.
D. Copper and alloys
The most important factor is the high rate of heat conductivity
of copper, making preheating of heavy sections necessary to
give proper fusion of weld and base metal.
Art A-07691
Art # A-07692
Art# A-07693
Art # A-07694
Joint Preparations
In many cases, it will be 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 to ensure proper penetration of the weld
metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut sur-
faces. Typical joint designs are shown in Figure 4-19.
1/16” (1.6mm)
Not less than
Single Vee Butt Joint 45° Double Vee Butt Joint Not less than
70°
1/16” (1.6mm) max
Tee Joints
Fillet Joint (Fillet both sides of the
joint)
Art # A-10672
Art # A-07699_AB
6
3 5
1 2 4
Expansion with
compression
Figure 4-29: Overhead Fillet Weld Figure 4-30: Parent Metal Expansion
Weld
Distortion Art # A-07706_AC Permanent Upset
area to be welded can be sometimes used to reduce distor- Figure 4-36: Step back Sequence
tion. Figure 4-33 shows a simple application. By removing the
heating source from b and c as soon as welding is completed,
the sections b and c will contract at a similar rate, thus reduc-
ing distortion.
Art # A-07708
B C
Preheat Preheat
Weld
Figure 4-38: Staggered Intermittent Welding
Mild Steel E6013 This all-position, electrode is used for welding clean, new sheet metal. Its soft
arc has minimal spatter, moderate penetration and an easy-to-clean slag.
Mild Steel E7014 All positional, easy to use electrode for use on thicker steel than E6013.
Especially suitable for sheet metal lap joints and fillet welds, general purpose
plate welding.
Mild Steel E7018 A low-hydrogen, all-position electrode used when quality is an issue or for hard-
to-weld metals. It has the capability of producing more uniform weld metal,
which has better impact properties at low temperatures.
Cast Iron ENi-Cl Suitable for joining all cast irons except white cast iron.
Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc.
Table 4-4: ESAB Electrode Selection Chart
Incorrect sequence
Insufficient
gap
Art # A-04273
4 A groove has been A Welding current is too high. A Reduce welding current.
formed in the base
metal adjacent to
the toe of a weld B Welding arc is too long. B Reduce the length of the welding arc.
and has not been
filled by the weld C Angle of the electrode is C Electrode should not be inclined less than 45° to the
metal (undercut). incorrect. vertical face.
D Joint preparation does not D Allow more room in joint for manipulation of the
allow correct electrode angle. electrode.
F Insufficient deposit time at F Pause for a moment at edge of weave to allow weld
edge of weave. metal buildup.
G Power source is set for MIG G Set power source to STICK (SMAW) mode.
(GMAW) welding.
5 Portions of the weld A Small electrodes used on A Use larger electrodes and preheat the plate.
run do not fuse to heavy cold plate.
the surface of the
metal or edge of the B Welding current is too low. B Increase welding current.
joint. C Wrong electrode angle. C Adjust angle so the welding arc is directed more into
the base metal.
Art # A-09658_AC
Gas Cup
Either Ceramic,
Work Piece High-lmpact or
Can Be Any Commercial Water Cooled
Metal Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Inert Gas
Addition of Filler Metal
Shields Electrode
and Weld Puddle
Electrode Type
Welding Application Features Color Code
(Ground Finish)
DC welding of mild Excellent arc starting,
Thoriated 2% steel, stainless steel Long life, High current Red
and copper carrying capacity
High quality AC Self cleaning, Long
welding of aluminum, life, Maintains balled
Zirconated 1% White
magnesium and their end, High current
alloys. carrying capacity.
AC & DC welding
Longer life, More
of mild steel,
stable arc, Easier
stainless steel,
Ceriated 2% starting, Wider current Grey
copper, aluminum,
range, Narrower more
magnesium and their
concentrated arc.
alloys
Table 4-8
NOTE!
The Fabricator 252i Inverter is not suited for AC TIG welding.
Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type
Thickness for Mild for Stainless Electrode Diameter (if Flow Rate
Steel Steel Diameter required) CFH
0.040” 35-45 20-30 0.040” 1/16” 10-15 Butt/Corner
1.0mm 40-50 25-35 1.0mm 1.6mm Lap/Fillet
0.045” 45-55 30-45 0.040” 1/16” 10-15 Butt/Corner
1.2mm 50-60 35-50 1.0mm 1.6mm Lap/Fillet
1/16” 60-70 40-60 1/16” 1/16” 15 Butt/Corner
1.6mm 70-90 50-70 1.6mm 1.6mm Lap/Fillet
1/8” 80-100 65-85 1/16” 3/32” 15 Butt/Corner
3.2mm 90-115 90-110 1.6mm 2.4mm Lap/Fillet
3/16” 115-135 100-125 3/32” 1/8” 20 Butt/Corner
4.8mm 140-165 125-150 2.4mm 3.2mm Lap/Fillet
1/4” 160-175 135-160 1/8” 5/32” 20 Butt/Corner
6.4mm 170-200 160-180 3.2mm 4.0mm Lap/Fillet
Table 4-9
TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in
the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operat-
ing Manual.
4 Weld bead too wide or Travel speed too slow Increase travel speed.
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet Wrong placement of Re-position filler rod.
joint filler rod
6 Electrode melts or oxidizes A TIG Torch lead A Connect TIG Torch lead to negative
when an arc is struck. connected to positive welding terminal.
welding terminal.
B No gas flowing to B Check the gas lines for kinks or breaks
welding region. and gas cylinder contents.
10 Arc flutters during TIG Tungsten electrode Select the right size electrode. Refer to
welding. is too large for the Table 4-6 ESAB Electrode Selection Chart.
welding current.
Table 4-10: TIG (GTAW) Welding Problems
C. Earthing/Grounding
The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -
1. The earth terminal of a fixed power source; or
2. The earth terminal of the associated plug of a transportable power source
Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying ESAB welding
power sources should be inspected by a licensed electrical worker in accordance with the requirements below -
1. For outlets/wiring and 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. General Maintenance Checks
Welding equipment should be regularly checked by an accredited ESAB Service Provider to ensure that:
1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in
good condition.
2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.
3. The Welding System is clean internally, especially from metal filing, slag, and loose material.
E. Accessories
Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least
monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall
not be used.
F. Repairs
If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited ESAB Service Provider.
Power Source Calibration
A. Schedule
Output testing of all ESAB Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall
within specified levels. Calibration intervals shall be as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable ESAB power source specifications
Output Voltage (V) to be checked to ensure it falls within applicable ESAB power source specifications
Motor Speed (Inches Per Minute) 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 power source
specifications
Table 5-4: Calibration Parameters
Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified.
C. Calibration Equipment
All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measure-
ment in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized.
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Weekly
3 Months
6 Months
Art # A-10502_AB
CAUTION
! Do NOT use compressed air to clean the Welding Power Source. Compressed air can force metal par-
ticles to lodge between live electrical parts and earthed metal parts within the Welding Power Source.
This may result in arcing between these parts and their eventual failure.
Art # A-10784_AB
8
1
Figure 6-1
7
3 6
12
4 11
9 Art # 10332_AD
5
10
2
8
Figure 6-2
2
Art # A-10668_AB
20
3
21
4
19
18 5 6
17
10
14
8
11
16 12 22
15 7
13 9
Art# A-11673_AB
* Patent Pending
** Refer to ESAB Catalog No. for specific parts.
MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a regis-
tered trademark of ESAB AB; LINCOLN is a registered trademark of LINCOLN
Electric Co.; The aforementioned registered trademarks are no way affiliated with ESAB Products, Inc. or Victor Technologies. ESAB is a registered trademark of Victor
Technologies.
FLUX FLUX
HARD CORED SOFT
CORED
.023”, .035” .030”, .035” .045”, 1/16” .035”, 3/64”
Top
Drive
Roll
Bottom
Drive Art # A-10669
Roll
Wire Size Wire Type Top Drive Roll Bottom Drive Roll Inlet Guide Outlet Guide
.023" (0.6mm) Hard 407002-001 407002-002 375407-001 W6000803
.030" (0.8mm) Hard 407002-001 407002-009 375407-001 W6000804
.035" (0.9mm) Hard 407002-001 407002-009 375407-001 W6000804
.045" (1.2mm) Hard 407002-001 407002-009 375407-001 W6000804
.030" (0.8mm) Flux Cored 375832 407002-009 375407-001 W6000804
.035" (0.9mm) Flux Cored 375832 407002-009 375407-001 W6000804
.045" (1.2mm) Flux Cored 170924-010 170924-010 375407-001 W6000804
1/16" (1.6mm) Flux Cored 170924-001 170924-001 375407-001 W6000805
.035" (0.9mm) Soft 408023-001 408023-001 375647 W6000804
3/64" (1.2mm) Soft 408023-002 408023-002 375647 W6000804
Table A-2: Wire, Drive Roll and Guide Recommended Combinations
1 2 3
L1
NOTE 1
L2
LINE
GND
BREAKER
GND FERRITE
EMI BOARD
LOAD
A
FRONT PANEL
VIDENT J
SOL+ I
POT_RETURN E
TRIG_SOL_RTN G
WFSPOT2 F
VBIAS H
TRIG2 D
MOTOR+ C
MOTOR- B
VPOT2 A
AUX TRIG
VPOT1 8
WFSPOT1 7
POT_RETURN 6
B VBIAS 5
N/C 4
TRIG_RETURN 3
TRIG1 2
N/C 1
FRONT PANEL
1
2
P2
3
4
5
50
CONTROL BOARD
1 CURRENT SENSOR
WELD OUTPUT +
1
2
3
4
INDUCTOR
1
WELD OUTPUT -
FRONT PANEL
Rev Revision By Date
D NOTES:
1. EMI ASSEMBLY, COMMON MODE CHOKE AND FERRITE (IF USED)
Art # A-10334
1 2 3
4 5 6
BREAKER
GAS SOL
MOTOR
TIG SOL
FAN
FAN
B
10
10
11
12
1
2
3
4
5
6
7
8
9
1
2
3
4
1
2
3
4
5
6
7
8
9
1
2
3
4
1
3
2
4
1
2
1
2
1
2
P8 P5 P6 P7
P1 P2 P3 P4
1 DC+
P12 P9
P10
50 HI-POT GND PRI
TEMP SW
2 P11
P14
1
P13
1
2
HI-POT
3 C
4
5
6
2
1
SEC CT SEC
TRANSFORMER
PRI PRI
Art # A-10334_AB
Rev Revision By Date
Victor Technologies, Inc.
00 PROTOTYPE GAC 07/12/2011 16052 Swingley Ridge Road, Suite 300
St Louis, Missouri 63017 USA
D
Date Printed Date Revised
7/12/2011 7/12/2011
TECHNOLOGIES ™
Drawn
GAC
Date
02/14/2011
The information contained herein is proprietary to Victor Technologies.
Size Sheet
Not for release, reproduction or distribution without written consent. B 1 of 1
Title Drawing Number
SCHEMATIC
SCH, SYS, NEXT GEN WELDER 42X500100
4 5 6
REVISION HISTORY
Date Rev Description
09/01/2015 AA Manual release
www.esab.eu