ESAB ES 95i User manual

A-13026
95
3163339
Révision : AA Issue Date: June 8, 2016 Manual No.: 0-5458
Operating
Manual
ESAB ES 95i
Inverter Arc Welder
esab.com

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to
provide you with the best service and reliability in the industry. This product is backed by our extensive
warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on
the web at www.esab.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB
product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions.They will help you to avoid potential
hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.

i
!
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 ES95i with Stick Kit
ESAB ES95i with Stick/TIG Kit
Operating Manual Number 0-5458
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.
For Printing Material Specification refer to document: 47x1909
Original Publication Date: June 8, 2016
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!

EU DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EU, entering into force 2 January 2013
Type of equipment
WELDING POWER SUPPLY
Type designation etc.
ESAB ES 95i
Brand name or trade mark
ESAB
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No:
ESAB Group Inc.
2800 Airport Rd
Denton TX 76207
Phone: [phone], FAX [phone]
The following harmonised standard in force within the EEA has been used in the design:
EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety re-
quirements stated above.
Date Signature Position
1 November 2015 Vice President,
Antonio Leon Brand Management
Manual Cutting Equipment
2016

TABLE OF CONTENTS
SECTION 1: SAFETY........................................................................................ 1-1
1.01 Safety Precautions.......................................................................................... 1-1
SECTION 2:
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 Transportation Methods.................................................................................. 2-2
2.06 Duty Cycle....................................................................................................... 2-2
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location.......................................................................................................... 3-1
3.03 Electrical Input Connections ........................................................................... 3-1
3.04 Electromagnetic Compatibility ........................................................................ 3-4
3.05 Setup for Welding........................................................................................... 3-5
3.06 SMAW (Stick) Setup ....................................................................................... 3-6
3.07 GTAW (Lift TIG) Setup .................................................................................... 3-7
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Front Panel ..................................................................................................... 4-1
4.02 SMAW Electrode Polarity ................................................................................ 4-2
4.03 Effects of SMAW (Stick) Welding Various Materials ....................................... 4-2
4.04 GTAW (Lift TIG) Electrode Polarity.................................................................. 4-3
4.05 Guide for Selecting Filler Wire ........................................................................ 4-3
4.06 Tungsten Electrode Current Ranges................................................................ 4-3
4.07 Shielding Gas Selection .................................................................................. 4-3
4.08 Tungsten Electrode Types ............................................................................... 4-3
4.09 GTAW (Lift TIG) Welding Parameters for Steel ............................................... 4-3
4.10 Arc Welding Practice....................................................................................... 4-4
4.11 Welding Position............................................................................................. 4-4
4.12 Joint Preparations........................................................................................... 4-5
4.13 Arc Welding Technique ................................................................................... 4-6
4.14 The Welder...................................................................................................... 4-6
4.15 Striking the Arc............................................................................................... 4-6
4.16 Arc Length ...................................................................................................... 4-6
4.17 Rate of Travel.................................................................................................. 4-6
4.18 Making Welded Joints..................................................................................... 4-6
4.19 Distortion........................................................................................................ 4-8
4.20 The Cause of Distortion .................................................................................. 4-8
4.21 Overcoming Distortion Effects ........................................................................ 4-9

TABLE OF CONTENTS
SECTION 5:
SERVICE............................................................................................... 5-1
5.01 Maintenance and Inspection ........................................................................... 5-1
5.02 SMAW (Stick) Welding Problems .................................................................. 5-2
5.03 GTAW (Lift TIG) Welding Problems ............................................................... 5-3
5.04 Power Source Problems ................................................................................ 5-4
APPENDIX 1: REPLACEMENT PARTS .................................................................... A-1
APPENDIX 2: OPTIONS AND ACCESSORIES............................................................ A-2
APPENDIX 3: system schematic ......................................................................... A-3
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER

ESAB ES 95i
Manual 0-5458 1-1 SAFETY INSTRUCTIONS AND WARNINGS
1.01 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.
SECTION 1: SAFETY

ESAB ES 95i
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5458
WARNING Arc welding and cutting can be injurious to yourself and others. Take
precautions when welding and cutting. Ask for your employer's safety
practices which should be based on manufacturers' hazard data.
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 clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your
breathing zone and the general area.
ARC 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 mate-
rials 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 OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING Do not use the power source for thawing frozen pipes.
CAUTION Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage
supply system. There may be potential difficulties in ensuring
electromagnetic compatibility of class A equipment in those loca-
tions, due to conducted as well as radiated disturbances.
CAUTION This product is solely intended for metal removal. Any other use may
result in personal injury and / or equipment damage.
CAUTION Read and understand the instruction manual before
installing or operating.
!

ESAB ES 95i
Manual 0-5458 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part numbers
listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, DANGER,
and NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
NOTE!
An operation, procedure, or background
information which requires additional em-
phasis or is helpful in efficient operation of
the system.
!
CAUTION
A procedure which, if not properly followed,
may cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
WARNING
Gives information regarding possible electri-
cal shock injury. Warnings will be enclosed
in a box such as this.
!
DANGER
Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
Additional copies of this manual may be purchased by contacting
ESAB at the address and phone number in your area listed on
back cover of this manual. Include the Owner’s Manual number
and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the ESAB web site
listed below
http://www.esab.com
2.02 Equipment Identification
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.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice to
make sure it is complete and inspect the equipment for possible
damage due to shipping. If there is any damage, notify the carrier
immediately to file a claim. Furnish complete information con-
cerning damage claims or shipping errors to the location in your
area listed in the inside back cover of this manual.
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Move the equipment to the installation site before un-crating the
unit. Use care to avoid damaging the equipment when using bars,
hammers, etc., to un-crate the unit.
2.04 Description
This compact inverter welding machine has infinitely adjustable
welding current from 5 to 95 amps. It uses standard general
purpose SMAW 3/32” (2.5mm) electrodes for light gauge work,
generally less than 1/8” (3.2mm) thick. The unit also has a
GTAW (Lift TIG) welding mode that offers stable TIG welding
characteristics when used with a suitable TIG torch and shielding
gas.

ESAB ES 95i
INTRODUCTION 2-2 Manual 0-5458
2.05 Transportation Methods
!
CAUTION
ELECTRIC SHOCK can kill. DO NOT TOUCH live electric 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 handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place secure unit on
a proper skid before transporting.
2.06 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output
without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the
following example is used. Suppose a Welding Power Source is designed to operate at a 40% duty cycle, 75 amperes at 23 volts. This
means that it has been designed and built to provide the rated amperage (75A) 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 allowed to cool.

ESAB ES 95i
Manual 0-5458 3-1 INSTALLATION
3.01 Environment
These units are designed for use in environments with increased
hazard of electric shock. Examples of environments with
increased hazard of electric shock are:
A. In locations in which freedom of movement is restricted, so
that the operator is forced to perform the work in a cramped
(kneeling, sitting or lying) position with physical contact
with conductive parts.
B. In locations which are fully or partially limited by conductive
elements, and in which there is a high risk of unavoidable
or accidental contact by the operator.
C. In wet or damp hot locations where humidity or perspiration
considerably reduces the skin resistance of the human body
and the insulation properties of accessories.
Environments with increased hazard of electric shock do not
include places where electrically conductive parts in the near
vicinity of the operator, which can cause increased hazard, have
been insulated.
3.02 Location
Be sure to locate the welder according to the following guide-
lines:
• In areas, free from moisture and dust.
• Ambient temperature between 32°F (0°C) to 104° F (40°
C).
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 12” (300mm) or more from walls or
similar that could restrict natural air flow for cooling
!
WARNING
ESAB advises that this equipment be elec-
trically connected by a qualified electrician.
SECTION 3:
INSTALLATION
3.03 Electrical Input Connections
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power em-
ploying lockout/tagging procedures. Lock-out/tagging procedures
consist of padlocking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and red-tagging
circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding power source from a single-phase 60 Hz, AC
power supply. The input voltage must match one of the electri-
cal input voltages shown on the input data label on the unit
nameplate. Contact the local electric utility for information about
the type of electrical service available, how proper connections
should be made, and inspection required. The line disconnect
switch provides a safe and convenient means to completely
remove all electrical power from the welding power supply
whenever necessary to inspect or service the unit.
Do not connect an input (WHITE or BLACK) conductor to the
ground terminal.
Do not connect the ground (GREEN) conductor to an input line
terminal.

ESAB ES 95i
INSTALLATION 3-2 Manual 0-5458
Figure 3-1: Electrical Input Connections
!
CAUTION
The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.
The recommended time-delay fuses or circuit breaker size is 20 amperes. Fuse/circuit breaker size is
based on not more than 200 percent of the rated input amperage of the welding power source (Based on
Article 630, National Electrical Code).
An individual branch circuit capable of carrying 20 amperes and time-delay fuses or circuit breaker protec-
tion is recommended for this application.
Art #: A-08473_AB
Welding Power Supply
Primary Power Cable
120 V, 20A, 1Ø
Refer to Figure 3-1:
1. Connect end of ground (GREEN or GREEN/YELLOW) conductor to a suitable ground. Use a grounding method that complies
with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.
3. Use Table 3-1 as a guide to select line fuses for the disconnect switch.
Input Voltage Fuse Size
115V 20 Amps
Table 3-1: Fuse Guide

ESAB ES 95i
Manual 0-5458 3-3 INSTALLATION
Input Power
Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the
input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to operating voltage
(after approximately 5 seconds)
NOTE!
Damage to the PCA could occur if 133 VAC or higher is applied to the Primary Power Cable.
Table 3-2: Primary Circuit Sizes to Achieve Maximum Current
Model
Primary Supply Lead Size
(Factory Fitted)
Minimum Primary
Current Circuit Size
(Vin/Amps)
Current & Duty Cycle
GTAW (Lift TIG) SMAW (Stick)
ESAB ES95i 12 AWG (3.3mm²) 115V/20A - 75A / 23V @ 40%
115V/21A 95A / 13.8V @ 20% -

ESAB ES 95i
INSTALLATION 3-4 Manual 0-5458
3.04 Electromagnetic Compatibility
!
WARNING
Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is
used in a domestic situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic
disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the
technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see
NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work,
complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer
Trouble-some.
B. Assessment of Area
Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area.
The following shall be taken into account.
1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment.
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of industrial equipment.
5. The health of people around, e.g. the use of pace-makers and hearing aids.
6. Equipment used for calibration and measurement.
7. The time of day that welding or other activities are to be carried out.
8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment
is compatible: this may require additional protection measures.
The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place.
The surrounding area may extend beyond the boundaries of the premises.
C. Methods of Reducing Electromagnetic
Emissions
1. Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference
occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given
to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should
be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good
electrical contact is maintained between the conduit and the Welding Power Source enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and
service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding
equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according
to the manufacturer’s recommendation
3. Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or close to the
floor level.

ESAB ES 95i
Manual 0-5458 3-5 INSTALLATION
4. Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic
components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic
components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
5. Earthing 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.
3.05 Setup for Welding
NOTE!
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead
directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the de-
sign ensure that the Welding Power Source will withstand short-term overload without adverse effects. The
welding current range values should be used as a guide only. Current delivered to the arc is dependent on
the welding arc voltage, and as welding arc voltage varies between different classes of electrodes, welding
current at any one setting would vary according to the type of electrode in use. The operator should use the
welding current range values as a guide then fine tune the welding current to suit the application.
!
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder make
sure the Primary power supply is switched off.
!
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.

ESAB ES 95i
INSTALLATION 3-6 Manual 0-5458
SMAW (Stick) Mode Sequence of Operation
!
CAUTION
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the ground clamp cable to the negative output terminal, and the electrode holder cable to the positive output terminal.
NOTE!
This set up is known as DC Electrode Positive or reverse polarity. Please consult with the stick electrode
manufacturer for specific polarity recommendations.
3. Connect the ground clamp to your workpiece.
4. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D light should
illuminate.
5. Set the “Process Selection Switch” to SMAW (Stick)
6. Set the weld current control knob to the desired amperage.
7. Install a stick electrode in the electrode holder.
8. You are now ready to begin SMAW (Stick) Welding
NOTE!
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.
Figure 3-2: Setup for SMAW (Stick) Welding
3.06 SMAW (Stick) Setup
200A
Set Welding Current
as specified by the
Electrode Manufacturer.
Set Process Selection
Switch to SMAW (Stick)
Positive Output
Terminal
(Dinse™ 25)
Negative Output
Terminal
(Dinse™ 25)
Art #: A-08602_AC

ESAB ES 95i
Manual 0-5458 3-7 INSTALLATION
3.07 GTAW (Lift TIG) Setup
Figure 3-3: Setup for GTAW (Lift TIG) Welding
GTAW (Lift TIG) Sequence of Operation
!
CAUTION
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the ground clamp cable to positive output terminal, and the TIG torch cable to the negative output terminal.
NOTE!
This set up is known as Straight Polarity or DC Electrode Negative. This is commonly used for DC TIG weld-
ing on most materials such as steel and stainless steel.
3. Using a secured Argon cylinder, slowly crack open then close the cylinder valve while standing off to the side of the valve.
This will remove any debris that may be around the valve & regulator seat area.
4. Install the regulator and tighten with a wrench.
5. Connect the gas hose to the outlet of the Argon regulator, and tighten with a wrench.
6. Be sure the gas valve on the torch is closed, and slowly open the Argon Cylinder Valve to the fully open position.
7. Connect the ground clamp to your work piece.
Set Process Selection
Switch to GTAW (Lift TIG).
Positive Output
Terminal
(Dinse™ 25)
Negative
Output
Terminal
(Dinse™ 25)
Art #: A-08603_AC
Set Welding Current
as specified by the
Electrode Manufacturer.
Secure the gas cylinder in an
upright position by chaining it
to a stationary support to prevent
falling or tipping.

ESAB ES 95i
INSTALLATION 3-8 Manual 0-5458
8. Plug the power cable into the appropriate outlet, and turn the switch to the “ON” position. The power L.E.D. light should
illuminate.
9. Set the “Process Selection Switch” to GTAW (Lift TIG)
10. Set the weld current control knob to the desired amperage.
11. The tungsten must be ground to a blunt point in order to achieve optimum welding results. It is critical to grind the tungsten
electrode in the direction the grinding wheel is turning.
12. Install the tungsten with approximately 1/8” to ¼” sticking out from the gas cup, ensuring you have correct sized collet.
13. Tighten the back cap.
14. You are now ready to begin TIG Welding
NOTE!
Open the gas valve on TIG torch handle, and adjust the pressure of regulator to 15-25 cubic feet per hour.
This gas flow should be sufficient for most TIG welding applications.
ii. Touch the tungsten to the work piece. This closes the welding circuit, and the arc starts by slowly
LIFTING the torch off the base metal. Keep a consistent arc length of about 1/8-1/4”.
iii. If necessary re-adjust the amperage setting to an appropriate level.
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