Fabricator 252i

ESAB Fabricator® 252i
3-IN-1 Multi Process

Welding Systems
Operating
Manual
A-12925
3163339
300
Révision : AA Issue Date: September 1, 2015 Manual No.: 0-5423
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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.
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 install-
ing, 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 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!

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

Arc welding and cutting can be injurious to yourself and others.

WARNING Take precautions when welding and cutting. Ask for your employer's
safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with appli-
cable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet cloth-
ing.
- 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 RAYS - 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.
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
Class A equipment is not intended for use in residential locations
CAUTION 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 loca-
tions, due to conducted as well as radiated disturbances.
This product is solely intended for metal removal. Any other use
CAUTION may result in personal injury and / or equipment damage.
Read and understand the instruction manual before
CAUTION installing or operating. !
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5423

SECTION 2: 2.03 Receipt Of Equipment
SYSTEM INTRODUCTION When you receive the equipment, check it against the invoice to
make sure it is complete and inspect the equipment for pos-
sible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information
2.01 How To Use This Manual concerning damage claims or shipping errors to the location in
This Owner’s Manual applies to just specification or part numbers your area listed in the inside back cover of this manual.
listed on page i. Include all equipment identification numbers as described above
To ensure safe operation, read the entire manual, including the along with a full description of the parts in error.
chapter on safety instructions and warnings. Move the equipment to the installation site before un-crating
Throughout this manual, the words WARNING, CAUTION, DANGER, the unit. Use care to avoid damaging the equipment when using
and NOTE may appear. Pay particular attention to the information bars, hammers, etc., to un-crate the unit.
provided under these headings. These special annotations are
easily recognized as follows: 2.04 Description
NOTE! The ESAB Fabricator 252i is a self contained single phase multi
An operation, procedure, or background process welding power source that is capable of performing
information which requires additional MIG (GMAW/FCAW), STICK (SMAW) and Lift TIG (GTAW) welding
emphasis or is helpful in efficient operation processes. The Fabricator 252i is equipped with an integrated
of the system. wire feed unit, digital voltage / amperage meters, power factor
correction (PFC) with energy saving technology and a host of
CAUTION other features to satisfy the broad operating needs of the modern
! A procedure which, if not properly followed,

may cause damage to the equipment.
welding professional.
The Fabricator 252i is fully compliant to standard IEC 60974.1.
The Fabricator 252i MIG provides excellent welding performance
WARNING across a broad range of applications when used with the correct
! A procedure which, if not properly followed,
may cause injury to the operator or others
welding consumables and procedures. The following instructions
detail how to correctly and safely set up the machine and give
in the operating area. guidelines on gaining the best efficiency and quality from the
Power Source. Please read these instructions thoroughly before
WARNING using the unit.
Gives information regarding possible electri-
cal shock injury. Warnings will be enclosed 2.05 User Responsibility
in a box such as this. This equipment will perform as per the information contained
DANGER herein when installed, operated, maintained and repaired in
accordance with the instructions provided. This equipment must
! Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
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
Additional copies of this manual may be purchased by contact- recommended that such repairs be carried out by appropriately
ing ESAB at the address and phone number in your area listed on qualified persons approved by ESAB. Advice in this regard can be
back cover of this manual. Include the Owner’s Manual number obtained by contacting an Accredited ESAB Distributor.
and equipment identification numbers. This equipment or any of its parts should not be altered from
Electronic copies of this manual can also be downloaded at no standard specification without prior written approval of ESAB.
charge in Acrobat PDF format by going to the ESAB web site listed The user of this equipment shall have the sole responsibility for
below any malfunction which results from improper use or unauthorized
http://www.esab.com modification from standard specification, faulty maintenance,
damage or improper repair by anyone other than appropriately
2.02 Equipment Identification 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

2.06 Transportation Methods
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.
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
A-12953
Figure 2-2: Packaged Items
INTRODUCTION 2-2 Manual 0-5423

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 with-
out 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
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
Welding Current Max (amps) Art # A-10666
Figure 2-3: Fabricator 252i Duty Cycle with Upgraded Supply Lead and Plug

2.09 Specifications
Fabricator 252i MULTI PROCESS
Description
WELDING INVERTER
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
200A @ 60%, 24V
150A @ 100%, 21.5V
STICK (SMAW) Welding Output, 40°C, 10 min. 230A @ 40%,29.2V
200A @ 60%, 28V
150A @ 100%, 26V
TIG (GTAW) Welding Output, 40°C, 10 min. 250A @ 40%,20V
200A @ 60%, 18V
150A @ 100%, 16V
Table 2-1: Fabricator 252i Specification
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

SECTION 3: INSTALLATION 3.03 Ventilation
OPERATION AND SETUP
3.01 Environment
! WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
This unit is designed for use in environments with increased effectively ventilated.
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 3.04 Mains Supply Voltage
such areas. Requirements
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 ! CAUTION
The Mains supply voltage should be within ±
cramped (kneeling, sitting or lying) position with physi-
cal contact with conductive parts. 15% of the rated Mains supply voltage. Too low
2. In locations which are fully or partially limited by con- of a supply voltage may cause poor welding
ductive elements, and in which there is a high risk of performance or wirefeeder malfunction. Too
unavoidable or accidental contact by the operator. high of a supply voltage will cause components
3. In wet or damp hot locations where humidity or perspi- to overheat and possibly fail.
ration considerably reduces the skin resistance of the
human body and the insulation properties of accesso-
ries. WARNING
B. Environments with increased hazard of electric shock The Fabricator 252i must be electrically
do not include places where electrically conductive parts in the connected by a qualified electrical trades-
near vicinity of the operator, which can cause increased hazard, person. Damage to the PCA (Power Control
have been insulated. Assembly) could occur if 276 VAC or higher
is applied to the Primary Power Cable.
3.02 Location
Be sure to locate the welder according to the following guide-
lines: WARNING
A. In areas, free from moisture and dust. ELECTRIC SHOCK can kill; SIGNIFICANT DC
B. Ambient temperature between 32° F to 104° F. VOLTAGE is present after removal of input
C. In areas, free from oil, steam and corrosive gases. power. DO NOT TOUCH live electrical parts.
D. In areas, not subjected to abnormal vibration or shock.
E. In areas, not exposed to direct sunlight or rain. SHUT DOWN welding power source, disconnect input power em-
F. Place at a distance of 1 foot or more from walls or similar ploying lockout/tagging procedures. Lock-out/tagging procedures
that could restrict natural air flow for cooling. consist of padlocking line disconnect switch in open position,
G. The enclosure design of this power source meets the re- removing fuses from fuse box, or shutting OFF and red-tagging
quirements of IP23S as outlined in IEC60529. circuit breaker or other disconnecting device.
H. Precautions must be taken against the power source top- Electrical Input Requirements
pling over. The power source must be located on a suitable Operate the welding power source from a single-phase 50/60 Hz,
horizontal surface in the upright position when in use. AC power source. The Welding Power Source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local
WARNING regulations.
This equipment should be electrically con- • Connected to the correct size power point, fuse and primary
nected by a qualified electrician. supply lead based on Table 3-1.
WARNING
Any electrical work must be carried out by
a qualified Electrical Tradesperson.

50/60 Hz Primary Supply Minimum Primary Minimum Current & Duty Cycle
Single Phase Lead Size Current Circuit Plug Size MIG LIFT TIG STICK
Size (Vin/Iin)
Yes 10 AWG 208-230/50A 50A 40% @ 250A 40% @ 250A 40% @ 230A
Table 3-1: Input Power Source Leads for Fabricator 252i
3.05 Electromagnetic Compatibility 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

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

1 2
A-12927
6 8 9 7
Figure 3-1: Fabricator Control Panel
11
10 12
+ -
13 14
15 Art # A-10504
Figure 3-2: Fabricator Front Connections

5. Advanced Features Button
WARNING Advanced
DO NOT TOUCH the electrode wire while it is Features
being fed through the system. The electrode

wire will be at welding voltage potential.
Press and release the Advanced Features button to enter or exit
from the advanced programming mode. To exit, simply press
1. Power Indicator 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
The green power indicator will be illuminated when the
welder is turned ON and indicates the presence of power.
2. Fault Indicator 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
The yellow fault indicator will be illuminated when any of the approximately two (2) seconds. Once the Gas purge function has
faults are detected. ALL Faults will illuminate the indicator started, a countdown timer will show in the left alpha-numeric
display indicating the number of seconds remaining before the
3. Weld Process Selection Button
purge will be automatically terminated. You can stop the Gas
Process MIG purge any time during the 30 seconds by quickly pressing and
TIG releasing the button again.
STICK
6. Left Knob: Amperage Control (Wirespeed)
A
Press and release this button to change the selected weld pro-
cess mode from MIG to LIFT TIG to STICK. The weld process will
Left Knob
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.
WIRESPEED
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.

7. Right Knob: Multifunction Control - MIG Voltage / Arc 8. Left Digital Display
Control (Inductance) & STICK Arc Force
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 voltage 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.

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 3.07 Advanced Features Details
The positive welding terminal is used to connect the welding
output of the power source to the appropriate welding acces- NOTE!
sory such as the Fusion MIG Gun (via the MIG Gun polarity lead), The Local / Remote setting will only be
electrode holder lead or work lead. Positive welding current saved while in that welding process. Once
flows from the power source via this heavy duty bayonet type the welding process is changed the setting
terminal. It is essential, however, that the male plug is inserted will revert to the factory default.
and turned securely to achieve a sound electrical connection.
General Operation
Process MIG
! 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
output of the power source to the appropriate welding acces-

sory 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 Then press and release the Advanced Features button (Control
essential, however, that the male plug is inserted and turned No 5) to enter or exit from the Advanced Features programming
securely to achieve a sound electrical connection. function of the welder.
A
! CAUTION
Loose welding terminal connections can
Left Knob
WIRESPEED
15. MIG Gun Polarity Lead

The Advanced Features menu items are viewed by turning the
The polarity lead is used to connect the MIG Gun to the ap- left knob (Control No 6) to move forward or backward through
propriate positive or negative output terminal (allowing polarity the list. The function names in the menu will be displayed in
reversal for different welding applications). In general, the abbreviated form in the left alpha-numeric display. In the case of
polarity lead should be connected in to the positive welding two part names or abbreviations, the left display will alternately
terminal (+) when using steel, stainless steel or aluminum flash the first part of the function name and then the second part,
electrode wire. When using gasless wire, the polarity lead is followed by a brief “blank” interval. For each function, the right
generally connected to the negative welding terminal (-). If in alpha-numeric display will show its present value.
doubt, consult the manufacturer of the electrode wire for the
V
correct polarity. It is essential, however, that the male plug
is inserted and turned securely to achieve a sound electrical
connection.
Right Knob
! CAUTION
Loose welding terminal connections can ARC CONTROL

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 se-
lected 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
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
Figure 3-3: Remote Control Socket
Socket Pin Function

1 Not connected
2 Trigger Switch Input
3 Trigger Switch Input
4 Not connected
5 5k ohm (maximum) connection to 5k ohm remote control potentiometer.
6 Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper
7
arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.
8 Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Table 3-3
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.

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 con-
nections, align keyway, insert plug, and rotate threaded collar fully clockwise.
J
1
I
Peripheral
Resistor
D Trigger
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 -
Figure 3-4: Remote Control Socket
Socket Pin Function

A Voltage Pot. Wiper
B Wire Feed Motor (-)
C Wire Feed Motor (+)
D Trigger Switch Input
E Wire Speed Pot. & Voltage Pot. (+) CW 10K ohm
F Wiper Arm Speed Pot.
G Trigger Switch Input & Solenoid (-)
H Wire Speed Pot. & Voltage Pot. (-) ACW
I Solenoid (+)
J 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.

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 Advanced Menu - MIG Process MIG

Mode Options or Range TIG
MIG / CNTL LOCL REMT STICK
PRE- / FLOW 0.1 - 5.0 S

RUN- / IN 30 - 150%
POST / FLOW 0.0 - 30.0 S
BURN / BACK 0.00 - 1.00 S
WIRE / SHRP ON OFF
SPOT ON OFF
*SPOT / TIME 0.1-20.0 S
Advanced
STCH ON OFF Features
*STCH / TIME 0.2 - 4.0 S
DWEL / TIME 0.1 - 1.0 S
ARC- / TYPE AUTO CV
WFS- / UNIT MPM IPM
Wire Feed
HR Speed 0.0 - 9999.9
FACT / DFLT NO YES
Press Advanced Button Press Advanced Button

to Exit to Welding Mode to Exit to Welding Mode
Left Knob Selection 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

Right Display
Function Left Display (Factory Default Limits Comments
Values)
LOCL = Local control of the Wirespeed and Voltage with
MIG Operator the machines controls.
MIG/CNTL LOCL LOCL - REMT
Controls REMT = Remote control of the Wirespeed and Voltage
with an accessory device.
Pre Flow (MIG Shielding gas flows for the time specified before an arc
PRE-/FLOW 0.1 S 0.0 – 5 S
Setting) is initiated.
Wirespeed runs as a percentage of preview wirespeed
Run In RUN/IN 70% 30 – 150 %
until an arc is struck.
Post Flow (MIG Shielding gas flows for the time specified after an arc
POST/FLOW 0.5 S 0.0 – 30 S
Setting) has extinguished.
The time difference between turning the wire feed OFF
Burn Back BURN/BACK 0.15 S 0.00 – 1.00 S
before the voltage is turned OFF.
Wire Sharp adds a burst of current at the end of a weld
Wire Sharp WIRE/SHRP ON OFF – ON 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
Spot SPOT OFF OFF – ON
together to form a nugget between them. The weld
time is set by the Spot Time.
Spot Time
(Only shown/en- SPOT/TIME 2.0 S 0.1 – 20.0 S Spot Time is the time used for the Spot weld mode.
abled if Spot=ON)
Stitch is used to weld two or more components by
stitch or interval weld together.
Stitch STCH OFF OFF – ON
The weld time is set by the Stitch Time and the non
weld time is set by the Dwell Time.
Stitch Time
(Only shown/ Stitch Time is the time used for the weld time in Stitch
STCH/TIME 2.0 S 0.2 – 4.0 S
enabled if weld mode.
Stitch=ON)
Dwell Time
(Only shown/ Dwell Time is the time used for the non weld time in
DWEL/TIME 0.5 S 0.1 – 1.0 S
enabled if Stitch weld mode.
Stitch=ON)
Auto is an optimized arc control for dip transfer welding
with minimal spatter on mild steel with mixed shield-
Arc Type ARC-/TYPE AUTO AUTO – CV-M
ing gases. CV-M is the traditional constant-voltage arc
control for all other welding.
Wire Feed Speed MPM provides preview wirespeed in Meters Per Minute.
WFS/UNIT IPM MPM – IPM
Units IPM provides preview wirespeed in Inches Per Minute.
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.

LIFT TIG Mode Advanced Features Menu Map
Process MIG
Left Display Right Display
TIG
Advanced Menu - Advanced Menu - LIFT STICK
LIFT TIG Mode TIG Options or Range
TIG / CNTL LOCL REMT
PRE- / FLOW 0.0 - 5.0 S
POST / FLOW 0.0 - 30.0 S
DOWN / SLPE 0.0 - 30.0 S
Advanced
HR 0.0 - 9999.9 Features
FACT / DFLT NO YES

Art # A-10506_AB
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Figure 3-6: LIFT TIG Advanced Menu
Right Display
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.
HR 0.0 0.0 – 9999.9
reached.
Restore Factory
Defaults

STICK Mode Advanced Features
Left Display Right Display Process MIG
Advanced Menu - STICK Advanced Menu - STICK TIG
Mode Options or Range STICK
STCK / CNTL LOCL REMT
HOT- / START ON OFF
HS / TIME 0.0 - 2.0 S
HS / AMPS 75 - 200 %
HR 0.0 - 9999.9
Advanced
FACT / DFLT NO YES Features

Art # A-10507_AA
Left Display: Where (2) items shown, e.g. HOT- / STRT, the display will alternate (flash) between the (2) items
Figure 3-7: STICK Advanced Menu
Right Display
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
HR 0.0 0.0 – 9999.9
reached.
Restore Factory
Defaults

3.08 Attaching the ESAB Fusion 250A MIG Gun
1. Unscrew the Locking Screw in the MIG Gun Adapter located inside the Wire Feed Compartment.
2. Push the ESAB Fusion 250A MIG Gun into MIG Gun Adaptor firmly using a twisting action.
3. Lock the ESAB Fusion 250A MIG Gun into the MIG Gun Adaptor by turning the Locking Screw clockwise in the MIG Gun
Adapter within the Wire Feed Compartment to secure the ESAB Fusion 250A MIG Gun in position.
NOTE!
Failure to properly lock the ESAB Fusion 250A MIG Gun into the MIG Gun Adapter will result in the ESAB Fu-
sion 250A MIG Gun being pushed out of the MIG Gun Adapter by the MIG welding wire or lack of shielding
gas (porosity in the weld) at the weld zone.
Attach MIG Gun

and secure.
Art # A-10548
+ -
Remote Cable 8 pin connector
Figure 3-8: Mount Fusion MIG Gun Cable to Adapter Socket
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.
3.09 Installing a 12.5 lb spool (8" diameter)

In order to fit a 12.5 lb spool (8" diameter) assemble parts in the sequence shown in Figure 3-9.
Installation of wire spool.
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter
clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.
3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.
NOTE!
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section
3.16
CAUTION
! Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.

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
Figure 3-9: 12.5 lb 8" Spool Installation
3.10 Installing a Standard Spool (12" diameter)

As delivered from the factory, the unit is set for a 33 lb. or 12" spool.
Installation of wire spool. Refer to Figure 3-10.
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter
clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.
3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.
NOTE!
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section
3.16
CAUTION
! Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Spool Hub
Retaining Clip
Fibre Washer
Use outer holes
33lb / 12” Pin
Wire Spool
Flat Washer
Wire Spool Large Hole
Hub Nut
Flat Washer Keyed Washer

Small Hole Spring A-10671
Figure 3-10: Standard 33 lb 12" Spool Installation

3.11 Inserting Wire into the Feed Mechanism
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
Figure 3-11: Opening Pressure Arm and Inserting Wire
5 7
Art # A-10031
Figure 3-12: Closing Pressure Arm and Adjusting Tension

3.12 Feed Roller Pressure Adjustment
NOTE!
Before attempting to set the drive roller pressure you must select GMAW mode on the front panel. See
earlier in section 3 for information on how to select this feature. Once selected it will allow the activation of
the drive roll when the trigger on the MIG Gun is activated.
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.
3.13 Feed Roller Alignment

The bottom Feed Roll is adjustable in and out to provide for best alignment of wire as it feeds into the outlet guide. To adjust the roll do
the following and refer to Figure 3-13. Note, the welding wire is not shown in order to more clearly see the groove in the feed roll.
1. Place a wrench on the adjusting bolt (number 2) and hold in place while you loosen the locking screw (number 1) with a hex
wrench
2. With the locking screw loosened, turn the adjusting bolt right or left to align the feed roll (number 3) so the groove is aligned
with the outlet guide (number 4).
3. With the feed roll aligned, place a wrench on the adjusting bolt and hold it in place while tightening the locking screw with the
hex wrench. If the adjusting bolt moves before the locking screw is secured then the alignment will change.
3 4
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.

3.14 Changing the Feed Roll
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
.045” (1.2mm) Groove
Art: A-07150_AB The size that is visible when

fitting the feedroll is the groove
size in use.
Figure 3-14: Feedroll Example
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..

3.15 Input And Output Wire Guide Installation
NOTE!
.035" / .045" (0.9 / 1.2 mm) feed rolls and guides are installed from the factory. Other sizes need to be
purchased separately..
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
Input Wire Guide Output Wire Guide

Figure 3-15: Wire Guide Installation

3.16 Wire Reel Brake
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered neces-
sary, adjustment can be made by turning the tri-lobe nut inside the open end of the wire reel hub. Clockwise rotation will Tighten the
brake. (Refer to Figure 3-16).
Wheel Brake adjusting tri-lobe nut
Art # A-10508_AB
Pressure Adjustment
Knob
Figure 3-16: Wire Installed
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..
3.17 Shielding Gas Regulator Operating Instructions
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
Shielding Gas Regulator Safety

This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the
equipment using it.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users responsibility to prevent
such conditions. Before handing or using the equipment, understand and comply at all times with the safe practices prescribed in this
instruction.
SPECIFIC PROCEDURES for the use of regulators are listed below.
1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen a connection
or attempt to remove any part of a regulator until the gas pressure has been relieved. Under pressure, gas can dangerously
propel a loose part.
3. Do NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high
and low pressure chambers.

4. Do NOT use the regulator as a control valve. When downstream equipment is not in use for extended periods of time, shut OFF
the gas at the cylinder valve and release the gas from the equipment.
5. OPEN the cylinder valve SLOWLY. Close after use.
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
High Pressure Gauge

(Supply)
Flow Gauge
(Delivery) A-12957
Pressure
Adjusting
Screw
Figure 3-17: Adjusting Flow Rate
NOTE!
The regulator/flow meters used with argon based and carbon dioxide shielding gases are different. The
regulator/flow meter supplied is for argon based shielding gases. If carbon dioxide 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.

Ensure that the gas

cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.
Art # A-10549
Figure 3-18: Attach gas line to proper inlet
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
Figure 3-19: Adjust 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)

The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause turbulence
and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 28 - 35 CFH
- Outdoor welding: 35 - 46 CFH
Shutdown
Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes).
1. Close cylinder or upstream valve LIFT Tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition
source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.
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.
Ensure that the gas

upright position.
Connect MIG Gun Polarity

Terminal to +/Positive
(Dinse® type 50)
+ - Negative Output
Terminal
(Dinse® type 50)
Art # A-10550
Figure 3-20: MIG Gun Polarity Positive
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 ).

5. Connect the work lead to the negative 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. 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 3.06.3 for further information)
9. Remove the Fusion MIG Gun nozzle and contact tip.
10. Depress MIG Gun trigger to feed the MIG wire out. Then fit the contact tip on the MIG wire and hand tighten the nozzle in place.
11. Refer to the Weld 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.
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.

3.19 Set-up for MIG (FCAW) Welding with Gasless 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 gasless flux cored wire, you do not need to have an external gas source attached to the unit. For most Self Shielded Flux
Cored Wire, connect the Work Lead to the positive + terminal and connect the MIG Torch polarity lead to the negative - terminal. If in
doubt, consult the Flux Cored electrode wire manufacturer.
Connect MIG Torch Polarity

Terminal to -/Negative
(Dinse® type 50)
+ - Positive Output
Terminal
(Dinse® type 50)
Art # A-10551
Figure 3-21: MIG Gun Polarity Negative
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.

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.
3.20 Set-up for LIFT TIG (GTAW) Welding
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..
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.

2. Connect the work lead cable to the positive output terminal, and the LIFT TIG Torch cable to the negative output terminal.
Refer to Figure 3-23.
3. Connect the gas line/hose to the proper shielding gas source. Refer to Figure 3-23.
4. Slowly open the Argon Cylinder Valve to the fully open position.
5. Connect the work lead clamp to your work piece.
6. The tungsten must be ground to a blunt point (similar to a pencil) in order to achieve optimum welding results. See
illustration. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning. Grind at a 30 degree
angle and never to a sharp point.
2 to 2-1/2 Times
Electrode Diameter
Electrode
Art # A-00503_AB
Figure 3-22: Electrode sharpening

7. Install the tungsten with approximately 1/8" to 1/4"(3.2mm to 6.4mm) sticking out from the gas cup, ensuring you have
correct sized collet.
8. Tighten the back cap.
9. Turn the switch to the “ON” position. The power L.E.D. light should illuminate.
10. Set the welding process to LIFT TIG.
11. Set the Weld Current Control Knob to the desired amperage.

Art # A-10580
Ensure that the gas

+ - upright position.
Negative Output
Terminal
(Dinse® type 50)
Figure 3-23: Setup for LIFT TIG (GTAW) Welding

12. You are now ready to begin LIFT TIG Welding.
3.21 Set-up for STICK Metal Arc Welding (SMAW)
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)
Figure 3-24: Setup for STICK Welding reverse polarity shown.
3. Set the welding process to STICK.

4. Set the Weld Current Control Knob to the desired amperage.
5. Install a STICK electrode in the electrode holder.
6. You are now ready to begin STICK Welding.
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.

SECTION 4: Position of MIG Gun
The angle of MIG Gun to the weld has an effect on the width of
BASIC WELDING GUIDE the weld.
4.01 MIG (GMAW/FCAW) Basic Welding

Technique
Two different welding processes are covered in this section
(GMAW and FCAW), with the intention of providing the very basic
concepts in using the MIG mode of welding, where a MIG Gun Push Vertical Drag/Pull
is hand held, and the electrode (welding wire) is fed into a weld
puddle, and the arc is shielded by an inert welding grade shield- Art # A-07185_AB
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
FCAW Process Art # A-08992_AB
Figure 4-2
Manual 0-5423 4-1 BASIC WELDING

10° to 20° Longitudinal Primary Adjustable Variables
10° Angle
Longitudinal Angle These control the process after preselected variables have been
30° to 60° found. They control the penetration, bead width, bead height, arc
30° to 60°
Transverse Transverse stability, deposition rate and weld soundness. They are:
Angle Angle
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Direction of Travel Secondary Adjustable Variables
These variables cause changes in primary adjustable variables
Vertical Fillet Welds Art # A-08995
which in turn cause the desired change in the bead formation.
Figure 4-6 They are:
1. Sick-out (distance between the end of the contact tube
Direction of Travel (tip) and the end of the electrode wire). Maintain at
about 3/8" (10 mm) stick-out
2. Wire Feed Speed. Increase in wire feed speed increases
30° to 60°
weld current, Decrease in wire feed speed decreases
Transverse Angle 5° to 15° weld current.
Longitudinal
Angle
Gas Nozzle
Contact Tip (Tube)
Tip to Electrode Wire
Work Distance Actual Stick-out
Art # A-08996
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
BASIC WELDING 4-2 Manual 0-5423

Direction of Gun Travel Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas used de-
pends on the following:
• Thickness of the metal to be welded
• Type of joint
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.

ESAB MIG, Lift TIG, Stick Wire Selection Chart
A-12928
Figure 4-11

4.02 MIG (GMAW/FCAW) Welding Troubleshooting
Solving Problems Beyond the Welding Terminals
The general approach to fix MIG (GMAW/FCAW) welding problems is to start at the wire spool then work through to the MIG Gun. There
are two main areas where problems occur with GMAW; Porosity and Inconsistent wire feed.
Problem 1 - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within
the molten weld pool which is in the process of escaping during solidification of the molten metal. Contaminants range from no gas
around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points.
FAULT/CONDITION CAUSE
1 Shielding gas cylinder contents Ensure that the shielding gas cylinder is not empty and the
and flow meter. flow meter is correctly adjusted to 31.75 CFH.
2 Gas leaks. Check for gas leaks between the regulator/cylinder connection
and in the gas hose to the Power Source.
3 Internal gas hose in the Power Ensure the hose from the solenoid valve to the MIG Gun
Source. adaptor has not fractured and that it is connected to the MIG
Gun adaptor.
4 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
5 Welding dirty, oily, painted, Clean contaminates off the work piece.
oxidized or greasy plate.
6 Distance between the MIG Gun Keep the distance between the MIG Gun nozzle and the work
nozzle and the work piece. piece to a minimum.
7 Maintain the MIG Gun in good A Ensure that the gas holes are not blocked and gas is exiting
working order. out of the torch nozzle.
B Do NOT restrict gas flow by allowing spatter to build up inside
the MIG Gun nozzle.
C Check that the MIG Gun O-rings are not damaged.
Table 4-1: MIG (GMAW / FCAW) Welding Troubleshooting
Problem 2 - Inconsistent Wire Feed
WARNING
! Disengage the feed roll when testing for gas flow by ear.

Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Feed roller driven by motor in the Wire spool brake is too tight.
cabinet slipped.
2 Wire spool unwound and tangled. Wire spool brake is too loose.
3 Worn or incorrect feed roller size. A Use a feed roller matched to the size you are welding.
B Replace feed roller if worn.
4 Wire rubbed against the misaligned Misalignment of inlet/outlet guides
guides and reduced wire feed ability.
5 Liner blocked with swarf. A Increased amounts of swarf are produced by the wire passing
through the feed roller when excessive pressure is applied to the
pressure roller adjuster.
B Swarf can also be produced by the wire passing through an
incorrect feed roller groove shape or size.
C Swarf is fed into the conduit liner where it accumulates thus
reducing wire feed ability.
6 Incorrect or worn contact tip. A The Velocity contact tip transfers the weld current to the electrode
wire. If the hole in the contact tip is too large then arcing may
occur inside the contact tip resulting in the wire jamming in the
contact tip.
B When using soft wire such as aluminum it may become jammed
in the contact tip due to expansion of the wire when heated. A
Velocity contact tip designed for soft wires should be used.
7 Poor work lead contact to work piece. If the work lead has a poor electrical contact to the work piece
then the connection point will heat up and result in a reduction of
power at the arc.
8 Bent liner. This will cause friction between the wire and the liner thus
reducing wire feed ability
Table 4-2: Wire Feeding Problems

Basic MIG (GMAW/FCAW) Welding Troubleshooting
FAULT CAUSE REMEDY

1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed.
B Incorrect MIG Gun angle B Adjust angle.
C Excessive heat input C Increase the MIG Gun travel speed and/or decrease
welding current by decreasing the voltage or
decreasing the wire feed speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed
speed and increasing voltage.
B Joint preparation too narrow B Increase joint angle or gap.
or gap too tight
C Shielding gas incorrect C Change to a gas which gives higher penetration.
3 Lack of fusion Voltage too low Increase voltage.
4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control.
B Voltage too low B Increase the voltage or decrease wirespeed.
5 Irregular weld shape A Incorrect voltage and current A Adjust voltage and current by adjusting the voltage
settings. Convex, voltage too control and the wirespeed control.
low. Concave, voltage too high.
B Wire is wandering. B Replace Velocity contact tip.
C Incorrect shielding gas C Check shielding gas.
D Insufficient or excessive heat D Adjust the wirespeed control or the voltage control.
input
6 Weld cracking A Weld beads too small A Decrease travel speed
B Weld penetration narrow and B Reduce current and voltage and increase MIG Gun
deep travel speed or select a lower penetration shielding gas.
C Excessive weld stresses C Increase weld metal strength or revise design.
D Excessive voltage D Decrease voltage.
E Cooling rate too fast E Slow the cooling rate by preheating part to be welded
or cool slowly.
7 Cold weld puddle A Loose welding cable connection. A Check all welding cable connections.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited ESAB Service Provider test then
replace the faulty component.
8 Arc does not have The MIG Gun has been Connect the MIG Gun to the positive (+) welding
a crisp sound that connected to the wrong terminal for solid wires and gas shielded flux cored
short arc exhibits voltage polarity on the front wires. Refer to the electrode wire manufacturer for
when the wirefeed panel. the correct polarity.
speed and voltage are
adjusted correctly.
9 Poor weld result Contact tip has arc marks in Replace the contact tip with only a Genuine ESAB
from setup chart the bore causing excessive Velocity contact tip.
parameters drag on the wire.
Table 4-3: MIG (GMAW /FCAW) Welding Problems

4.03 STICK (SMAW) Basic Welding Arc Welding Practice
Technique The techniques used for arc welding are almost identical regard-
less of what types of metals are being joined. Naturally enough,
Size of Electrode different types of electrodes would be used for different metals
The electrode size is determined by the thickness of metals being as described in the preceding section.
joined and can also be governed by the type of welding machine Welding Position
available. Small welding machines will only provide sufficient The electrodes dealt with in this publication can be used in most
current (amperage) to run the smaller size electrodes. positions, i.e. they are suitable for welding in flat, horizontal,
For thin sections, it is necessary to use smaller electrodes other- vertical and overhead positions. Numerous applications call for
wise the arc may burn holes through the job. A little practice will welds to be made in positions intermediate between these. Some
soon establish the most suitable electrode for a given application. of the common types of welds are shown in Figures 4-12 through
Storage of Electrodes 4-19.
Always store electrodes in a dry place and in their original
containers.
Electrode Polarity
Electrodes are generally connected to the ELECTRODE HOLDER
Art # A-07687
with the Electrode Holder connected positive polarity. The WORK
LEAD is connected negative polarity and is connected to the work
piece. If in doubt consult the electrode data sheet or your nearest Figure 4-12: Flat Position, Down Hand Butt Weld
Accredited ESAB Distributor.
Effects of Arc Welding Various Materials
A. High tensile and alloy steels
The two most prominent effects of welding these steels are
the formation of a hardened zone in the weld area, and, if suit-
Art # A-07688
able precautions are not taken, the occurrence in this zone of
under-bead cracks may result. Hardened zone and under-bead Figure 4-13: Flat Position, Gravity Fillet Weld
cracks in the weld area may be reduced by using the correct
electrodes, preheating, using higher current settings, using
larger electrodes sizes, short runs for larger electrode deposits
or tempering in a furnace.
Hydrogen controlled Electrodes must be used for this ap-
plication. Art # A-07689
B. Austenitic manganese steels

Figure 4-14: Horizontal Position, Butt Weld
The effect on manganese steel of slow cooling from high
temperatures is to embrittle it. For this reason it is absolutely
essential to keep manganese steel cool during welding by
quenching after each weld or skip welding to distribute the
heat.
C. Cast Iron Art # A-07690
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
Figure 4-16: Vertical Position, Butt Weld


Art # A-07692
Figure 4-17: Vertical Position, Fillet Weld
Art# A-07693
Figure 4-18: Overhead Position, Butt Weld
Art # A-07694
Figure 4-19: Overhead Position, Fillet Weld
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.

Open Square Butt Single Vee Butt Joint Not less than
70°
Joint 1/16” (1.6mm) max
Gap varies from
1/16” (1.6mm) to 3/16” (4.8mm)
depending on plate thickness
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
Lap Joint 1/16” (1.6mm)
Tee Joints
Fillet Joint (Fillet both sides of the
joint)
Corner Weld Edge Joint
Plug Weld Plug Weld
Art # A-10672
Figure 4-20: Typical Joint Designs for Arc Welding
Arc Welding Technique - A Word to Beginners

For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel
plate about 1/4" (6.4 mm) thick and a 1/8" (3.2 mm) electrode. Clean any paint, loose scale or grease off the plate and set it firmly on
the work bench so that welding can be carried out in the downhand position. Make sure that the work clamp is making good electrical
contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job,
otherwise a poor circuit will probably result.
The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting
down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will find that
the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worry-
ing then about being burnt or sparks setting alight to your clothes.
Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear
of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it
allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder
is not faulty, otherwise you are risking an electric shock.

Striking the Arc A. Butt Welds
Practice this on a piece of scrap plate before going on to more Set up two plates with their edges parallel, as shown in Figure
exacting work. You may at first experience difficulty due to the tip 4-22, allowing 1/16" - 3/32" (1.6 mm - 2.4 mm) gap between
of the electrode "sticking" to the work piece. This is caused by them and tack weld at both ends. This is to prevent contraction
making too heavy a contact with the work and failing to withdraw stresses from the cooling weld metal pulling the plates out of
the electrode quickly enough. A low amperage will accentuate it. alignment. Plates thicker than 1/4" (6.4 mm) should have their
This freezing-on of the tip may be overcome by scratching the mating edges beveled to form a 70º to 90º included angle. This
electrode along the plate surface in the same way as a match is allows full penetration of the weld metal to the root. Using a
struck. As soon as the arc is established, maintain a 1/16" -1/8" 1/8" (3.2 mm) E7014 electrode at 100 amps, deposit a run of
(1.6 mm - 3.2 mm) gap between the burning electrode end and weld metal on the bottom of the joint.
the parent metal. Draw the electrode slowly along as it melts
Do not weave the electrode, but maintain a steady rate of
down.
travel along the joint sufficient to produce a well-formed
Another difficulty you may meet is the tendency, after the arc is
bead. At first you may notice a tendency for undercut to form,
struck, to withdraw the electrode so far that the arc is broken
but keeping the arc length short, the angle of the electrode at
again. A little practice will soon remedy both of these faults.
about 20º from vertical, and the rate of travel not too fast, will
20° help eliminate this. The electrode needs to be moved along
Art # A-10673
fast enough to prevent the slag pool from getting ahead of the
arc. To complete the joint in thin plate, turn the job over, clean
the slag out of the back and deposit a similar weld.
1/16” (1.6 mm) 20°-30°
Electrode Tack Weld
Figure 4-21: Striking an Arc

Arc Length
Tack Weld
The securing of an arc length necessary to produce a neat weld Art # A-07697_AB
soon becomes almost automatic. You will find that a long arc pro-
Figure 4-22: Butt Weld
duces more heat. A very long arc produces a crackling or splut-
tering noise and the weld metal comes across in large, irregular
blobs. The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained although
if it is too short there is the danger of it being blanketed by slag
and the electrode tip being solidified in. If this should happen,
give the electrode a quick twist back over the weld to detach it.
Contact or "touch-weld" electrodes such as E7014 do not stick Art # A-07698
in this way, and make welding much easier.
Rate of Travel
Figure 4-23: Weld Build up Sequence
After the arc is struck, your next concern is to maintain it, and
this requires moving the electrode tip towards the molten pool at
the same rate as it is melting away. At the same time, the elec- Heavy plate will require several runs to complete the joint.
trode has to move along the plate to form a bead. The electrode After completing the first run, chip the slag out and clean the
is directed at the weld pool at about 20º from the vertical. The weld with a wire brush. It is important to do this to prevent
rate of travel has to be adjusted so that a well-formed bead is slag being trapped by the second run. Subsequent runs are
produced. then deposited using either a weave technique or single beads
If the travel is too fast, the bead will be narrow and strung out laid down in the sequence shown in Figure 4-23. The width
and may even be broken up into individual globules. If the travel of weave should not be more than three times the core wire
is too slow, the weld metal piles up and the bead will be too diameter of the electrode. When the joint is completely filled,
large. the back is either machined, ground or gouged out to remove
slag which may be trapped in the root, and to prepare a suit-
Making Welded Joints able joint for depositing the backing run. If a backing bar is
Having attained some skill in the handling of an electrode, you used, it is not usually necessary to remove this, since it serves
will be ready to go on to make up welded joints. a similar purpose to the backing run in securing proper fusion
at the root of the weld.

B. Fillet Welds each side motion, pause for a moment to allow weld
metal to build up at the edges, otherwise undercut will
These are welds of approximately triangular cross-section form and too much metal will accumulate in the centre
made by depositing metal in the corner of two faces meeting of the weld. Figure 4-27 illustrates multi-run technique
at right angles. Refer to Figure 4-15. and Figure 4-28 shows the effects of pausing at the
A piece of angle iron is a suitable specimen with which to edge of weave and of weaving too rapidly.
begin, or two lengths of strip steel may be tacked together Art # A-07701
at right angles. Using a 1/8" (3.2 mm) E7014 electrode at
100 amps, position angle iron with one leg horizontal and
the other vertical. This is known as a horizontal-vertical (HV)
fillet. Strike the arc and immediately bring the electrode to a
position perpendicular to the line of the fillet and about 45º
from the vertical. Some electrodes require to be sloped about
20º away from the perpendicular position to prevent slag from
running ahead of the weld. Refer to Figure 4-24. Do not at-
tempt to build up much larger than 1/4" (6.4 mm) width with
a 1/8" (3.2 mm) electrode, otherwise the weld metal tends to
sag towards the base, and undercut forms on the vertical leg.
Multi-runs can be made as shown in Figure 4-25. Weaving in
HV fillet welds is undesirable. Figure 4-26: Single Run Vertical Fillet Weld
45° from
Art # A-07702
vertical
60° - 70° from line

of weld
Art # A-07699_AB
Figure 4-24: Electrode Position for HV Fillet Weld

Art # A-07700_AB
Figure 4-27: Multi Run Vertical Fillet Weld
6
3 5
1 2 4
Figure 4-25: Multi-runs in HV Fillet Weld

C. Vertical Welds Art # A-07703
1. Vertical Up Figure 4-28: Examples of Vertical Fillet Welds

Tack weld a three feet length of angle iron to your work
bench in an upright position. Use a 1/8" (3.2 mm) E7014 2. Vertical Down
electrode and set the current at 100 amps. Make your- The E7014 electrode makes welding in this position
self comfortable on a seat in front of the job and strike particularly easy. Use a 1/8" (3.2 mm) electrode at 100
the arc in the corner of the fillet. The electrode needs to amps. The tip of the electrode is held in light contact
be about 10º from the horizontal to enable a good bead with the work and the speed of downward travel is
to be deposited. Refer Figure 4-26. Use a short arc, and regulated so that the tip of the electrode just keeps
do not attempt to weave on the first run. When the first ahead of the slag. The electrode should point upwards
run has been completed de-slag the weld deposit and at an angle of about 45º.
begin the second run at the bottom. This time a slight
weaving motion is necessary to cover the first run and
obtain good fusion at the edges. At the completion of

3. Overhead Welds B. Expansion and Contraction of Parent Metal in the
Apart from the rather awkward position necessary, Fusion Zone:
overhead welding is not much more difficult that down- While welding is proceeding, a relatively small volume of the
hand welding. Set up a specimen for overhead welding adjacent plate material is heated to a very high temperature
by first tacking a length of angle iron at right angles to and attempts to expand in all directions. It is able to do this
another piece of angle iron or a length of waste pipe. freely at right angles to the surface of the plate (i.e., "through
Then tack this to the work bench or hold in a vice so the weld", but when it attempts to expand "across the weld"
that the specimen is positioned in the overhead position or "along the weld", it meets considerable resistance, and
as shown in the sketch. The electrode is held at 45º to to fulfill the desire for continued expansion, it has to deform
the horizontal and tilted 10º in the line of travel (Figure plastically, that is, the metal adjacent to the weld is at a high
4-29). The tip of the electrode may be touched lightly temperature and hence rather soft, and, by expanding, pushes
on the metal, which helps to give a steady run. A weave against the cooler, harder metal further away, and tends to
technique is not advisable for overhead fillet welds. Use bulge (or is "upset". When the weld area begins to cool, the
a 1/8" (3.2 mm) E6013 electrode at 100 amps, and de- "upset" metal attempts to contract as much as it expanded,
posit the first run by simply drawing the electrode along but, because it has been "upset" it does not resume its former
at a steady rate. You will notice that the weld deposit shape, and the contraction of the new shape exerts a strong
is rather convex, due to the effect of gravity before the pull on adjacent metal. Several things can then happen.
metal freezes.
The metal in the weld area is stretched (plastic deformation),
Art # A-07704 the job may be pulled out of shape by the powerful contraction
stresses (distortion), or the weld may crack, in any case, there
will remain "locked-up" stresses in the job. Figures 4-30 and
4- 31 illustrate how distortion is created.
Art # A-07705_AB Weld Upsetting
Expansion with
compression
Hot Hot Cool
Figure 4-29: Overhead Fillet Weld Figure 4-30: Parent Metal Expansion
Weld
Distortion Art # A-07706_AC Permanent Upset
Distortion in some degree is present in all forms of welding. In Contraction

many cases it is so small that it is barely perceptible, but in other with tension
cases allowance has to be made before welding commences for
the distortion that will subsequently occur. The study of distortion
is so complex that only a brief outline can be attempted hear. Figure 4-31: Parent Metal Contraction
The Cause of Distortion
Overcoming Distortion Effects
Distortion is caused by:
There are several methods of minimizing distortion effects.
A. Contraction of Weld Metal:
A. Peening
Molten steel shrinks approximately 11 per cent in volume on
cooling to room temperature. This means that a cube of molten This is done by hammering the weld while it is still hot. The
metal would contract approximately 2.2 per cent in each of weld metal is flattened slightly and because of this the tensile
its three dimensions. In a welded joint, the metal becomes stresses are reduced a little. The effect of peening is relatively
attached to the side of the joint and cannot contract freely. shallow, and is not advisable on the last layer.
Therefore, cooling causes the weld metal to flow plastically,
B. Distribution of Stresses
that is, the weld itself has to stretch if it is to overcome the
effect of shrinking volume and still be attached to the edge Distortion may be reduced by selecting a welding sequence
of the joint. If the restraint is very great, as, for example, in a which will distribute the stresses suitably so that they tend
heavy section of plate, the weld metal may crack. Even in cases to cancel each other out. See Figures 4-31 through 4-34 for
where the weld metal does not crack, there will still remain various weld sequences. Choice of a suitable weld sequence
stresses "Locked-up" in the structure. If the joint material is is probably the most effective method of overcoming distor-
relatively weak, for example, a butt joint in 5/64" (2.0 mm) tion, although an unsuitable sequence may exaggerate it.
sheet, the contracting weld metal may cause the sheet to Simultaneous welding of both sides of a joint by two welders
become distorted. is often successful in eliminating distortion.

C. Restraint of Parts 3
2
1
Forcible restraint of the components being welded is often
used to prevent distortion. Jigs, positions, and tack welds are
methods employed with this in view.
Art # A-07710_AB
D. Presetting Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
It is possible in some cases to tell from past experience or to
find by trial and error (or less frequently, to calculate) how much Figure 4-35: Welding Sequence
distortion will take place in a given welded structure. By correct 1
pre-setting of the components to be welded, constructional 2
3
stresses can be made to pull the parts into correct alignment. 4
A simple example is shown in Figure 4-32.
E. Preheating
Suitable preheating of parts of the structure other than the Art # A-07711_AB
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-07707 Art # A-07428_AB
Figure 4-37: Chain Intermittent Welding

Art # A-07713_AB
Figure 4-32: Principle of Presetting
Art # A-07708
B C
Preheat Preheat
Weld
Figure 4-38: Staggered Intermittent Welding
Dotted lines show effect if no preheat is used

Figure 4-33: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-34: Examples of Distortion

Electrode Selection Chart
METAL BEING JOINED ELECTRODE COMMENTS
Mild Steel E6010 This electrode is used for all-position welding or for welding on rusty, dirty, less-
than-new metal. It has a deep, penetrating arc and is used for pipe and repair
welding.
Mild Steel E6011 This electrode is used for all-position welding on sheet metal or for welding on
plated, dirty, painted or greasy steel. It has a deep, penetrating arc and is often
the first choice for repair or maintenance work.
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
4.04 STICK (SMAW) Welding Troubleshooting

FAULT CAUSE REMEDY
1 Welding current ARC FORCE is set at a value Reduce the ARC FORCE until welding current is
varying that causes the welding reasonably constant while prohibiting the electrode
current to vary excessively from sticking to the work piece when you “dig” the
with the arc length. electrode into the workpiece.
2 A gap is left by A Welding current too low A Increase welding current.
failure of the weld
B Electrode too large for joint. B Use smaller diameter electrode.
metal to fill the root
of the weld. C Insufficient gap. C Allow wider gap.
3 Non-metallic A Non-metallic particles may A If a bad undercut is present clean slag out and cover
particles are trapped be trapped in undercut from with a run from a smaller gauge electrode.
in the weld metal. previous run.
B Joint preparation too B Allow for adequate penetration and room for cleaning
restricted. out the slag.
C Irregular deposits allow slag C If very bad, chip or grind out irregularities.
to be trapped.
D Lack of penetration with slag D Use smaller electrode with sufficient current to give
trapped beneath weld bead. adequate penetration. Use suitable tools to remove all
slag from comers.
E Rust or mill scale is E Clean joint before welding.
preventing full fusion.
F Wrong electrode for position F Use electrodes designed for position in which welding
in which welding is done. is done, otherwise proper control of slag is difficult.

Incorrect sequence
Insufficient
gap
Art # A-04273
Figure 4-39: Example of insufficient gap or incorrect sequence

Table 4-5a:
FAULT CAUSE REMEDY
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.
E Electrode too large for joint. E Use smaller gauge 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.
D Travel speed of electrode is D Reduce travel speed of electrode.

too high.
E Scale or dirt on joint surface. E Clean surface before welding.
Lack of fusion caused by dirt, Art # A-04274_AB

electrode angle incorrect,
rate of travel too high
Lack of inter-run fusion
Lack of side fusion, scale Lack of Root Fusion

dirt, small electrode,
amperage too low
Figure 4-40: Example of Lack of Fusion
Table 4-5b: STICK (SMAW) metal welding trouble shooting

4.05 TIG (GTAW) Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is
produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is
obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based. A filler metal may
also be added manually in some circumstances depending on the welding application.
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
Figure 4-41: TIG (GTAW) Welding Application Shot
Tungsten Electrode Current Ranges
Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30-60
1/16” (1.6mm) 60-115
3/32” (2.4mm) 100-165
1/8” (3.2mm) 135-200
5/32” (4.0mm) 190-280
3/16” (5mm) 250-340
Table 4-6: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm) 20-90
3/32” (2.4mm) 65-115
1/8” (3.2mm) 100-165
3/16” (5mm) 200-350
Table 4-7: Filler Wire Selection Guide

Tungsten Electrode Types
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.
TIG Welding Filler Rods
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
1/16” 60-70 40-60 1/16” 1/16” 15 Butt/Corner
1/8” 80-100 65-85 1/16” 3/32” 15 Butt/Corner
3/16” 115-135 100-125 3/32” 1/8” 20 Butt/Corner
1/4” 160-175 135-160 1/8” 5/32” 20 Butt/Corner
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.

4.06 TIG (GTAW) Welding Problems
FAULT CAUSE REMEDY
1 Excessive beard build up Welding current is too Increase weld current and/or faulty joint
or poor penetration or poor low preparation.
fusion at edges of weld.
2 Weld bead too wide and Welding current is too Decrease weld current.
flat or undercut at edges high
of weld or excessive burn
through.
3 Weld bead too small or Travel speed too fast Reduce travel speed.
insufficient penetration or
ripples in bead are widely
spaced apart.
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.
C TIG Torch is clogged C Clean TIG Torch.

with dust or dirt.
D Gas hose is cut. D Replace gas hose.
E Gas passage contains E Disconnect gas hose from the rear of
impurities. Power Source then raise gas pressure
and blow out impurities.
F Gas regulator turned F Turn ON.
OFF.
G TIG Torch valve is G Turn ON.
turned OFF.
H The electrode is too H Increase electrode diameter or reduce the
small for the welding welding current.
current.
I Power source is set for I Set Power Source to LIFT TIG mode.
MIG welding.

FAULT CAUSE REMEDY
7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the
by contact with work contaminates.
piece or filler rod
material.
B Work piece surface has B Clean surface.
foreign material on it.
C Gas contaminated with C Check gas lines for cuts and loose fitting
air. or change gas cylinder.
8 Poor weld finish Inadequate shielding Increase gas flow or check gas line for
gas. gas flow problems.
9 Arc start is not smooth. A Tungsten electrode A Select the right size electrode. Refer to
is too large for the Table 4-6 ESAB Electrode Selection Chart.
welding current.
B The wrong electrode B Select the right electrode type. Refer to
is being used for the Table 4-8 ESAB Electrode Selection Chart.
welding job.
C Gas flow rate is too C Select the right rate for the welding job.
high. Refer to Table 4-10.
D Incorrect shielding gas D Select the right shielding gas.
is being used.
E Poor work clamp E Improve connection to work piece.
connection to work
piece.
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

SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE
REQUIREMENTS
5.01 Power Source Problems
Error Code CAUSE REMEDY
ERR 01 Over Temperature Fault OverTemp signal from Power board A. Decrease duty cycle of welding activity
indicates Over temperature fault B. Ensure that air vents are not blocked/obstructed
condition of power components C. Consult an Accredited ESAB Service Provider.
ERR 02 Input Power Fault Signal from Power board indicates A. Check input power connections and cables for
input power voltage is out of range damage or improper insertion
(too high or too low) B. Verify input voltage levels meet product
requirements
ERR 03 VBIAS Voltage Low Fault Controller board circuit monitor Consult an Accredited ESAB Service Provider.
indicates 15 volt supply is too low
(< 13.7 VDC)
ERR 04 Ground Fault Excessive current detected on A. Isolate welder chassis from work piece. Check
Ground wire of power connection workpiece ground connection.
B. Check for MIG wire feed problem in spool/feedplate.
Verify wire is not contacting chassis.
ERR 08 Input Sensor Fault Unexpected reading of voltage or A. Inspect ribbon cable between power supply and
current sensor during power-up display board.
self test B. Consult an accredited ESAB service provider.
ERR 09 Fan Fault Cooling Fan Failure detected on A. Examine fan vents for potential obstruction.
Inverter board B. Consult an Accredited ESAB Service Provider.
ERR 10 Inverter Output Fault Substandard output voltage Consult an Accredited ESAB Service Provider.
condition detected by controller
before weld started
ERR 14 Trigger Fault Fault occurred detecting trigger A. Trigger may be already activated when MIG
state/condition process mode is selected - verify that trigger is not
accidentally activated
B. Trigger may be faulty and/or dirty, test and replace
MIG Gun/trigger device
ERR 15 Wirefeed Fault Welder detects prolonged open A. Inspect MIG wire spool and feedplate for improper
circuit during MIG weld tension or 'bird's nest'.
B. Inspect MIG Gun and cable for damage or
obstruction
C. Consult an Accredited ESAB Service Provider.
ERR 23 Weld Fault Welder detected a fault during the Consult an Accredited ESAB Service Provider if
weld process symptom recurs frequently.
ERR 24 Code Memory Fault Welder detected a fault in program Firmware image is corrupted. Consult an Accredited
flash memory ESAB Service Provider.
ERR 25 Nonvolatile Memory Welder detected a fault in A. Welding may still be possible, but no weld setting
Fault parameter NVROM. changes can be saved.
B. Consult an Accredited ESAB Service Provider.
ERR 26 Unknown PCB Fault Welder control board cannot Consult an Accredited ESAB Service Provider.
identify an attached inverter board
and/or determine its own identity
ERR 30 Service Mode Switch SERVICE DIP switch is enabled Welding is disabled while SERVICE Mode DIP switch
Fault is enabled. Disable SERVICE Mode switch to resume
welding.
Manual 0-5423 5-1 PROBLEMS AND ROUTINE SERVICE

ERR 31 Controller Fault Welder control board has detected Consult an Accredited ESAB Service Provider if
a hardware fault on itself symptom recurs frequently.
ERR 33 Calibration Fault An output (current, voltage, or A. Check integrity of welder cables, MIG Gun or
motor) fault was detected while electrode holder and retry calibration.
attempting a calibration process B. Check MIG wire spool, feedplate area for wire feed
issues, correct and retry calibration
ERR 34 User Calibration Abort User-initiated abort/interruption Restart/reselect calibration process and retry
of an active calibration process calibration when ready.
occurred (usually, release of trigger
too early)
ERR 35 Parameter Fault Welder control board has detected System Parameter re-initialization has been
a parameter out of range automatically performed or is required (Factory
Default Reset)
Note 1: If the left display is alternate flashing "Err" and "Code" this is indicating that the fault was detected but has either
stopped occurring or is in the process of clearing itself. If this is the case, the flashing error message will return to normal
display functionality within 10 seconds unless another fault occurs. If the left display shows a steady "Err" this is indicating that
the fault is persistent and is still being detected.
Note 2: Flashing Amperage and Voltage displays (when welding) indicates that the machines maximum output power rating
(300A x 26.7V = 8kVA) is being exceeded and the system is automatically reducing the output. If welding is ceased while the
displays are flashing, the last values will be displayed for 10 seconds or until controls are adjusted.
Table 5-1: Power Source Problems
5.02 Routine Service and Calibration Requirements

WARNING
! There are extremely dangerous voltage and power levels present inside this Inverter Power Source.
Do NOT attempt to open or repair unless you are an accredited ESAB Service Provider. Disconnect the
Welding Power Source from the Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
A. Testing Schedule
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of
the most recent inspection.
A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in
which it is operated.
B. Insulation Resistance
Minimum insulation resistance for in-service ESAB Inverter Power Sources shall be measured at a voltage of 500V between the
parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be
withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.
PROBLEMS AND ROUTINE SERVICE 5-2 Manual 0-5423

Minimum Insulation
Components to be Tested
Resistance (MΩ)
Input circuit (including any connected control circuits) to welding circuit 5
(including any connected control circuits)
All circuits to exposed conductive parts 2.5
Welding circuit (including any connected control circuits) to any auxiliary 10

circuit which operates at a voltage exceeding extra low voltage
Welding circuit (including any connected control circuits) to any auxiliary 1
circuit which operates at a voltage not exceeding extra low voltage
Separate welding circuit to separate welding circuit 1
Table 5-2: Minimum Insulation Resistance Requirements: ESAB Inverter Power Sources
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.

B. Calibration Requirements
Where applicable, the tests outlined in Table 5-4 below shall be conducted by an accredited ESAB service agent.
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.

5.03 Cleaning the Welding Power Source
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of Visual check of torch

regulator and pressure Consumable parts
Weekly
Visually inspect the torch

body and consumables Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all Clean

broken parts exterior
of power supply
6 Months
Bring the unit to an authorized

Tweco Service Provider
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-10502_AB
Figure 5-1: Routine Cleaning

5.04 Cleaning the Feed Rolls
Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on
the upper feed roll. After cleaning, tighten the feed roll retaining knobs.
CAUTION
! Do NOT use compressed air to clean the Welding Power Source. Compressed air can 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.

SECTION 6: KEY SPARE PARTS
6.01 Fabricator 252i Power Supply Replacement Panels
4
5
6
3
Art # A-10784_AB
8
1
Figure 6-1
FABRICATOR 252i POWER SOURCE SPARE PARTS (Panels/Sheet Metal)

ITEM PART NUMBER DESCRIPTION
1 W7005323 Latch, Slide
2 W7005438 Door, 252i
3 W7005385 Panel, Rear, 252i
4 W7005439 Panel, Side, 252i
5 W7005303 Bkt, Spool Support, 252i
6 W7005300 Panel, Center, 252i
7 W7005437 Panel, Front 252i
8 831596 Door chart label
Table 6-1
Manual 0-5423 6-1 REPLACEMENT PARTS

7
3 6
12
4 11
9 Art # 10332_AD
5
10
2
8
Figure 6-2
FABRICATOR 252i POWER SOURCE SPARE PARTS (LEFT SIDE)

1 W7005311 Spool Hub Assembly
2 W7005353 Wire Drive Assembly, 250i. (Does not include motor)
3 375838-002 Guide, Inlet 0.6-1.6mm
4 See Appendix 1 Roll, Pressure No Groove
5 See Appendix 1 Roll, Feed Dual V
6 W6000801 Guide, Outlet 0.9-1.2mm
7 W7005354 Motor, Wire Drive, RH, 20VDC.
8 W7005361 Retainer, Drive Gear, 2R
9 871001PKD Idler Gear
10 870560PKD Drive Gear
11 W7005379 Black Plastic Spacer
12 831508 Clear Mylar Sheet
Table 6-3
REPLACEMENT PARTS 6-2 Manual 0-5423

1
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
Figure 6-3: Right side and Front Replacement Parts

FABRICATOR 252i POWER SOURCE SPARE PARTS (RIGHT SIDE AND FRONT)
1 W7005330 PCB, 252i Main Power
2 W7005318 Circuit Breaker, 50A (On Off Switch)
3 W7005316 Fan, 92x38 HS 24V
4 W7005317 Fan, 92x25 LS 24V
5 W7005322 Shroud, Heatsink Tunnel
6 W7005331 PCB, Mov/Bridge, 250A
7 W7005302 Transformer, Main, 252i
8 W7005315 Solenoid,24V,0-0.8MPa
9 W7005301 Inductor, 252i
10 W7005355 Circuit Breaker, PB, 8A
11 W7005354 Motor, Wire Drive, RH, 20VDC
12 W7005357 Socket 10 pin (Note: 10 pin Control Plug Part# is W7005358)
13 W7005381 Dinse, Socket Panel, 50mm
14 W7003036 Socket 8 pin (Note: 8 pin Control Plug Part# is UOA706900)
15 W7005308 Assy, Polarity Cable, 252i
16 W7005335 Knob, 15/64", D Shaft, Snap Fit
17 W7005436 Panel, Control, 252i (w/label)
18 W7005381 PCB, Control Assy, 252i
19 W7005352 Ribbon Cable
20 W7005362 Panel Mounted Gas Fitting
21 W7005305 Wiring Harness, with plugs
22 W7005324 Current Transformer
Table 6-3

6.02 ESAB Fusion 250A MIG Gun
Torch Part No: FV215TA-3545
Art# A-11673_AB
Figure 6-4: ESAB Fusion 250 A MIG Gun

Item Item
Description Part No. Description Part No.
No. No.
VNS-50 Cablehoz Assembly – 10 ft (3 m) MS210
VNS-50F Cablehoz Assembly – 12 ft (4 m) MS212
VNS-62 Cablehoz Assembly – 15 ft (5 m) MS210
1 Velocity Nozzle* VNS-62F Cablehoz Assembly – 25 ft (8 m) MS225
VNS-37 NS Cablehoz Assembly, Euro-Kwik MS212X
– 12 ft (4 m)
VNS-37F
Cablehoz Assembly, Euro-Kwik
VNS-75FAS MS215X
– 15 ft (5 m)
8
VTS-23 Cablehoz Assembly, Euro-Kwik MS225X
– 25 ft (8 m)
VTS-30
Cablehoz Front Mechanical
VTS-35 8A MS102-RK
Connector Replacement Kit
VTS-40 Cablehoz Rear Mechanical
8B MS172-RK
VTS-45 Connector Replacement Kit
2 Velocity Contact Tip*
VTSA-364 Cablehoz Front Mechanical
8C Connector Replacement Kit for 172X-M
VTS-52 Euro-Style
VTS-116 9A Miller® Rear Connector 350-174MH
9 ®
VTSA-116 9B Miller Control Wire & Plug WM354-M
®
VTS-564 10A ESAB Rear Connector 350-174H
Velocity 45˚ Conductor Tube FVCT-S45 10 10B ESAB Control Wire & Plug 35K-350-1
3
Velocity 60˚ Conductor Tube FVCT-S60 10C ESAB Control Wire & Plug WS-354-TA-LC
®
4 Handle Halves w/screws F84 11A Lincoln Rear Connector 350-174HXL
11 ®
5 Trigger – Standard ELC84 11B Lincoln Control Wire & Plug WM354-M
6 Trigger Blade Assembly ELC94-BL 12A Euro-Kwik Connection Assembly 174EX-1
7 Gun Hanger 152 12 12B Euro-Kwik Nut 174X-2
12C Euro-Kwik Connector Case X6RC
13 Conduit Assembly** **
Table 6-4: ESAB Fusion 250 A MIG Gun Parts
* 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.

This Page Intentionally Blank

APPENDIX 1: OPTIONS AND ACCESSORIES
Description Part Number
ESAB Fusion 250A MIG Gun, 15ft 1023-1097
26 TIG torch 12.5ft (3.8m); accessory kit with 1/16”, 3/32”, 1/8”
thoriated tungstens with collets, collet bodies No.5,6,7 Alumina
W4013600
Nozzle - Gas Hose 9” (230mm) long with 5/8” 18 UNF male
fitting, Torch switch & remote current control with 8 pin plug
Gas Hose,12.5ft,Male 5/8-18UNF W4013900
Roll Cage, 252i W4015101
Large HD Cart,Single Cylinder,211i-252i W4015001
Large HD Cart, Dual Cylinder, 211i-252i W4015002
Basic Utility Cart, Single Cylinder, 211i-252i W4014700
Adapter Cable for Miller® Spool Gun SG200M30AJC
Accessory Kit P062900010
Table A-1: Options and Accessories
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
Figure A-1: Drive Roll Chart
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
Manual 0-5423 A-1 APPENDIX

APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM
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
APPENDIX A-2 Manual 0-5423

4 5 6
CHASSIS GND NOTE 1

AC IN AC IN
A
BRIDGE + BRIDGE -
COMMON MODE CHOKE
BRIDGE / MOV BOARD
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
Manual 0-5423 A-3 APPENDIX

REVISION HISTORY
Date Rev Description
09/01/2015 AA Manual release
APPENDIX A-4 Manual 0-5423

ESAB subsidiaries and representative offices
Europe NORWAY North and South America SOUTH KOREA
AUSTRIA AS ESAB ESAB SeAH Corporation
Larvik ARGENTINA Kyungnam
ESAB Ges.m.b.H Tel: +47 33 12 10 00 CONARCO Tel: +82 55 269 8170
Vienna-Liesing Fax: +47 33 11 52 03 Buenos Aires Fax: +82 55 289 8864
Tel: +43 1 888 25 11 Tel: +54 11 4 753 4039
Fax: +43 1 888 25 11 85 POLAND Fax: +54 11 4 753 6313 UNITED ARAB EMIRATES
BELGIUM ESAB Sp.zo.o. ESAB Middle East FZE
Katowice BRAZIL Dubai
S.A. ESAB N.V. Tel: +48 32 351 11 00 ESAB S.A. Tel: +971 4 887 21 11
Heist-op-den-Berg Fax: +48 32 351 11 20 Contagem-MG Fax: +971 4 887 22 63
Tel: +32 70 233 075 Tel: +55 31 2191 4333
Fax: +32 15 257 944 PORTUGAL Fax: +55 31 2191 4440 Africa
BULGARIA ESAB Lda
Lisbon CANADA EGYPT
ESAB Kft Representative Office Tel: +351 8 310 960 ESAB Group Canada Inc. ESAB Egypt
Sofia Fax: +351 1 859 1277 Missisauga, Ontario Dokki-Cairo
Tel/Fax: +359 2 974 42 88 Tel: +1 905 670 02 20 Tel: +20 2 390 96 69
ROMANIA Fax: +1 905 670 48 79
THE CZECH REPUBLIC Fax: +20 2 393 32 13
ESAB Romania Trading SRL
ESAB VAMBERK s.r.o. Bucharest MEXICO SOUTH AFRICA
Vamberk Tel: +40 316 900 600 ESAB Mexico S.A. ESAB Africa Welding & Cutting
Tel: +420 2 819 40 885 Fax: +40 316 900 601 Monterrey Ltd
Fax: +420 2 819 40 120 Tel: +52 8 350 5959 Durbanvill 7570 - Cape Town
RUSSIA Fax: +52 8 350 7554
DENMARK Tel: +27 (0)21 975 8924
LLC ESAB
Aktieselskabet ESAB Moscow USA
Herlev Tel: +7 (495) 663 20 08 ESAB Welding & Cutting Products Distributors
Tel: +45 36 30 01 11 Fax: +7 (495) 663 20 09 Florence, SC For addresses and phone num-
Fax: +45 36 30 40 03 Tel: +1 843 669 44 11
SLOVAKIA bers to our distributors in other
FINLAND Fax: +1 843 664 57 48 countries, please visit our home
ESAB Slovakia s.r.o.
ESAB Oy Bratislava Asia/Pacific page
Helsinki Tel: +421 7 44 88 24 26
Tel: +358 9 547 761 www.esab.eu
Fax: +421 7 44 88 87 41 AUSTRALIA
Fax: +358 9 547 77 71 ESAB South Pacific
SPAIN
FRANCE Archerfield BC QLD 4108
ESAB Ibérica S.A. Tel: +61 1300 372 228
ESAB France S.A. Alcalá de Henares (MADRID)
Cergy Pontoise Fax: +61 7 3711 2328
Tel: +34 91 878 3600
Tel: +33 1 30 75 55 00 Fax: +34 91 802 3461 CHINA
Fax: +33 1 30 75 55 24 Shanghai ESAB A/P
SWEDEN
GERMANY Shanghai
ESAB Sverige AB Tel: +86 21 2326 3000
ESAB GmbH Gothenburg
Solingen Fax: +86 21 6566 6622
Tel: +46 31 50 95 00
Tel: +49 212 298 0 Fax: +46 31 50 92 22 INDIA
Fax: +49 212 298 218 ESAB international AB ESAB India Ltd
GREAT BRITAIN Gothenburg Calcutta
ESAB Group (UK) Ltd Tel: +46 31 50 90 00 Tel: +91 33 478 45 17
Waltham Cross Fax: +46 31 50 93 60 Fax: +91 33 468 18 80
Tel: +44 1992 76 85 15 SWITZERLAND INDONESIA
Fax: +44 1992 71 58 03 ESAB AG P.T. ESABindo Pratama
ESAB Automation Ltd Dietikon Jakarta
Andover Tel: +41 1 741 25 25 Tel: +62 21 460 0188
Tel: +44 1264 33 22 33 Fax: +41 1 740 30 55 Fax: +62 21 461 2929
Fax: +44 1264 33 20 74
UKRAINE JAPAN
HUNGARY
ESAB Ukraine LLC ESAB Japan
ESAB Kft Kiev Tokyo
Budapest Tel: +38 (044) 501 23 24 Tel: +81 45 670 7073
Tel: +36 1 20 44 182 Fax: +38 (044) 575 21 88 Fax: +81 45 670 7001
Fax: +36 1 20 44 186
MALAYSIA
ITALY
ESAB (Malaysia) Snd Bhd
ESAB Saldatura S.p.A. USJ
Bareggio (Mi) Tel: +603 8023 7835
Tel: +39 02 97 96 8.1 Fax: +603 8023 0225
Fax: +39 02 97 96 87 01
SINGAPORE
THE NETHERLANDS
ESAB Asia/Pacific Pte Ltd
ESAB Nederland B.V. Singapore
Amersfoort Tel: +65 6861 43 22
Tel: +31 33 422 35 55 Fax: +65 6861 31 95
Fax: +31 33 422 35 44
www.esab.eu
©2015 ESAB Welding and Cutting Products Printed in China


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3-IN-1 Multi Process

Révision : AA Issue Date: September 1, 2015 Manual No.: 0-5423

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Plasma Cutting Power Supply

Copyright 2015 by ESAB

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the

Original Publication Date: September 1, 2015

Record the following information for Warranty purposes:

Power Supply Serial #:______________________________________

Torch Serial #:______________________________________________

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SECTION 1: SAFETY......................................................................................... 1-1

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SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS............. 5-1

APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM................................................... A-2

REVISION HISTORY......................................................................................... A-4

INTERNATIONAL CONTACT INFORMATION.................................................. REAR COVER

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Dispose of electronic equipment at the recycling facility!

Manual 0-5423 1-1 SAFETY INSTRUCTIONS AND WARNINGS

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Arc welding and cutting can be injurious to yourself and others.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT-

PROTECT YOURSELF AND OTHERS!

Do not use the power source for thawing frozen pipes.

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5423

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! A procedure which, if not properly followed,

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2.07 Packaged Items

- Fabricator 252i Power Supply

Figure 2-2: Packaged Items

INTRODUCTION 2-2 Manual 0-5423

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With Factory Fitted Supply Cord and Plug

Welding Current Max (amps) Art # A-10666

Manual 0-5423 2-3 INTRODUCTION

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INTRODUCTION 2-4 Manual 0-5423

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Manual 0-5423 3-1 INTRODUCTION

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6. Screening and Shielding

3.06 Power Source Controls, Indicators and Features

Figure 3-1: Fabricator Control Panel

Figure 3-2: Fabricator Front Connections

Manual 0-5423 3-3 INTRODUCTION

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being fed through the system. The electrode

INSTALLATION/SETUP 3-4 Manual 0-5423

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Manual 0-5423 3-5 INTRODUCTION

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output of the power source to the appropriate welding acces-

15. MIG Gun Polarity Lead