ESAB FABRICATOR® 211i 3-IN-1 Multi Process Welding Systems Instruction manual
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FABRICATOR
®
211i
3-IN-1 Multi Process
Welding Systems
210
Operating
Manual
English
Canadien Français
Americas Español
3163339
Revision:
AJ
Issue Date:
April 24, 2015
Manual No.:
0-5157
Tweco.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Tweco product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.
We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.
For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.
YOU ARE IN GOOD COMPANY!
Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.
We strive to enhance your productivity, efficiency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at:
1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Tweco.com
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use.
Operating Manual Number 0-5157 for:
Tweco Fabricator 211i Portable System Package
Tweco Fabricator 211i Portable System with Cart
Tweco Fabricator 211i Power Source
Tweco Fabricator 211i Package w/Single Cylinder Cart
Published by:
Victor Technologies International, Inc.
16052 Swingley Ridge Road,
Suite 300 St, Louis, MO 63017
USA
Part Number: W1004201
Part Number: W1004202
Part Number: W1004200
Part Number: W1004203 www.victortechnologies.com
© Copyright 2012, 2013 by:
Victor Technologies International, Inc.
® 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.
Publication Date: May 4, 2012
Revision Date: April 24, 2015
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
____________________________________
____________________________________
____________________________________
TABLE OF CONTENTS
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............................................... 1-1
2.07 Fabricator 211i Portable System Package (Part No. W1004201) .................... 2-2
SECTION 3: INSTALLATION, OPERATION AND SETUP ................................................ 3-1
3.10 Fabricator 211i Power Source Controls, Indicators And Features ................... 3-9
3.11 Attaching the TWECO Fusion 220A MIG Gun ................................................ 3-16
3.15 Inserting Wire Into The Wire Feed Mechanism ............................................. 3-20
3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire .................... 3-22
3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire ................... 3-23
TABLE OF CONTENTS
3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire 3-25
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5
4.04 STICK (SMAW) Welding Troubleshooting ..................................................... 4-16
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS ............ 5-1
APPENDIX 1: FABRICATOR 211i CIRCUIT DIAGRAM ................................................. A-1
TWECO - LIMITED WARRANTY TERMS ............................................ INSIDE REAR COVER
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
This Page Intentionally Blank
SAFETY INSTRUCTIONS FABRICATOR 211i
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.
6. Turn OFF all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts at once.
3. Insulate yourself from work and ground using dry insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned ON accidentally.
13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
Manual 0-5157 1-1 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
SAFETY INSTRUCTIONS
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be hazardous to your health.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Process
Electrode Size in.
(mm)
Arc Current
(Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
Shielded Metal Arc Welding
(SMAW)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
Less than 60
60-160
160-250
250-550
7
8
10
11
-
10
12
14
Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding
(FCAW)
Gas Tungsten arc Welding
(GTAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
(Light)
(Heavy)
Less than 60
60-160
160-250
250-550
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
8
8
10
7
10
10
10
10
11
6
8
10
11
-
11
12
14
10
12
14
12
14
6 to 8
10
12
14
Plasma Arc Cutting (PAC)
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
8
9
10
6
8
4
5
9
12
14
6
8
4
5
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5157
SAFETY INSTRUCTIONS
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
FABRICATOR 211i
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long, possibly unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
Manual 0-5157 1-3 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
!
WARNING
Engines can be dangerous.
SAFETY INSTRUCTIONS
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving parts.
6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open flames.
3. Allow engine to cool before fuelling. If possible, check and add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely in place.
SAFETY INSTRUCTIONS AND WARNINGS 1-4
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.
The coolant in the radiator can be very hot and under pressure.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
Manual 0-5157
SAFETY INSTRUCTIONS
LEAD WARNING
WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology
Assessment, Biological Effects of Power Frequency
Electric & Magnetic Fields - Background Paper, OTA-
BP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding Power Source and cables as far away from body as practical.
B. Housekeeping
!
WARNING
NEVER allow oxygen to contact grease, oil, or other flam mable substances. Although oxygen by itself will not burn, these substances become highly explosive. They can ignite and burn violently in the presence of oxygen.
Keep ALL apparatus clean and free of grease, oil and other flammable substances.
ABOUT PACEMAKERS:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
FABRICATOR 211i
1.02 General Safety Information For
Victor CS Regulator
A. Fire Prevention
Welding and cutting operations use fire or combustion as a basic tool. The process is very useful when properly controlled. However, it can be extremely destructive if not performed cor rectly in the proper environment.
1. The work area must have a fireproof floor.
2. Work benches or tables used during welding or cutting operations must have fireproof tops.
3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring from sparks and hot metal.
4. Keep an approved fire extinguisher of the proper size and type in the work area. Inspect it regularly to ensure that it is in proper working order.
Know how to use the fire extin guisher.
5. Move combustible materials away from the work site. If you can not move them, protect them with fireproof covers.
!
WARNING
NEVER perform welding, heating, or cutting operations on a container that has held toxic, combustible or flammable liq uids, or vapors. NEVER perform welding, heating, or cutting operations in an area containing combustible vapors, flam mable liquids, or explosive dust.
Manual 0-5157 1-5 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
C. Ventilation
!
WARNING
Ade quately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concen trations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes.
Use respiratory protection equipment in these circumstances. When welding/brazing, read and understand the Material Safety Data
Sheet for the welding/brazing alloy.
D. Personal Protection
Gas flames produce infrared radiation which may have a harm ful effect on the skin and especially on the eyes.
Select goggles or a mask with tempered lenses, shaded
4 or darker, to protect your eyes from injury and provide good visibility of the work.
Always wear protective gloves and flame-resistant clothing to protect skin and clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned.
DO NOT roll up sleeves or cuff pants.
When working in a non-welding or cutting environment, always wear suitable eye protection or face shield.
!
WARNING
Practice the following safety and operation precautions EVERY TIME you use pressure regulation equipment. Deviation from the following safety and operation instructions can result in fire, explosion, damage to equipment, or injury to the operator.
E. Compressed Gas Cylinders
The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases used for welding or cutting operations.
1. Place the cylinder (Figure 1-1) where you will use it. Keep the cylinder in a vertical position.
Secure it to a cart, wall, work bench, post, etc.
Art # A-12127
Figure 1-1: Gas Cylinders
SAFETY INSTRUCTIONS AND WARNINGS 1-6
SAFETY INSTRUCTIONS
!
WARNING
Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or mis use of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, flames or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.
NOTE
CGA P-1 publication is available by writing the Compressed Gas Association, 4221
Walney Road, 5th Floor, Chantilly,VA 20151-
2923
2. Place the valve protection cap on the cylinder whenever mov ing it, placing it in storage, or not using it. Never drag or roll cylinders in any way.
Use a suitable hand truck to move cylin ders.
3. Store empty cylinders away from full cylinders.
Mark them “EMPTY” and close the cylinder valve.
4. NEVER use compressed gas cylinders without a pressure reducing regulator attached to the cylinder valve.
5. Inspect the cylinder valve for oil, grease, and damaged parts.
!
WARNING
DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition immediately.
6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve.
CAUTION
Open the cylinder valve slightly. If you open the valve too much, the cylinder could tip over. When cracking the cylinder valve, DO
NOT stand directly in front of the cylinder valve. Always perform cracking in a well ventilated area. If an acetylene cylinder sprays a mist when cracked, let it stand for
15 minutes. Then, try to crack the cylinder valve again. If this problem persists, contact your gas supplier.
Manual 0-5157
SAFETY INSTRUCTIONS
1.03 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
FABRICATOR 211i
Manual 0-5157 1-7 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
SAFETY INSTRUCTIONS
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Single Phase
Three Phase
Three Phase Static
Frequency Converter-
Transformer-Rectifier
Remote
X
%
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode t1 t Spot Time
Preflow Time t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.
t Burnback Time
IPM
Inches Per Minute
MPM Meters Per Minute
S See Note
See Note
Auxiliary Power
115V 15A Receptacle Rating-
Auxiliary Power
Variable Inductance
V
Voltage Input
Art # A-04130_AB when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5157
SAFETY INSTRUCTIONS
1.05 Precautions De Securite En Soudage A L’arc
FABRICATOR 211i
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA
MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDI-
AQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ
LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR
CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION,
D’ENTRETIEN ET D’ESSAI.
1.06 Dangers relatifs au soudage à l’arc
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.
Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension.
Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-
électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.
1. Ne touchez pas à des pièces sous tension.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
2. Portez des gants et des vêtements isolants, secs et non troués.
9. N’enroulez pas de câbles électriques autour de votre corps.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen de tapis isolants ou autres.
Manual 0-5157
10. N’utilisez qu’une bonne prise de masse pour la mise
à la terre de la pièce à souder.
1-9 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
SAFETY INSTRUCTIONS
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.
AWS F2.2 : 2001 (R2010), Modifié avec l’accord de l’American Welding Society (AWS), Miami, Florida
Guide de teinte des lentilles
Procédé
Taille de l’électrode en mm (po)
Courant
(ampères)
Gamme minimum
Numéro de teinte
(Confort)
Soudage à l’arc avec
électrode enrobée (procédé
SMAW)
Soudage à l’arc sous gaz avec fil plein (procédé
GMAW) et soudage avec fil fourré (procédé FCAW)
Soudage à l’électrode réfractaire (procédé GTAW)
Coupage à l’arc avec
électrode de carbone et jet d’air (procédé AAC)
Soudage à l’arc au plasma
(procédé PAW)
Coupage plasma (procédé
PAC)
Moins de 2,4 (3/32)
3/32-5/32 (2,4-4,0)
5/32-1/4 (4,0-6,4)
Plus de 1/4 (6,4)
(Clair)
(Sombre)
Moins de 60
60-160
160-250
250-550
Moins de 60
60-160
160-250
250-550
Moins de 50
50-150
150-500
Moins de
500 500-
1000
Moins de 20
20-100
100-400
400-800
Moins de 20
20-40
40-60
60-80
80-300
300-400
400-800
7
8
10
11
7
10
10
10
8
8
10
10
11
8
9
10
4
5
6
8
6
8
10
11
-
10
12
14
-
11
12
14
10
12
14
12
14
6 à 8
10
12
14
4
5
6
8
9
12
14
* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors du soudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante lumière jaune; il est préférable d’utiliser un filtre qui absorbe cette lumière jaune ou le sodium du spectre de la lumière visible.
Tableau 1-1
SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5157
SAFETY INSTRUCTIONS
2. Portez des lunettes de sécurité approuvées. Des
écrans latéraux sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont
été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air.
Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du soudage.
FABRICATOR 211i
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE
OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un
échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur
à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.
Manual 0-5157 1-11 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES
BLESSURES.
Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGE-
REUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEU-
VENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une
électrode de soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCEN-
DIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire démarrer le moteur.
SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT
CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLO-
SER UN ACCUMULATEUR; L’ELECTROLYTE
D’UN ACCUMU-LATEUR PEUT BRULER LA
PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROI-
DISSEMENT BRULANT SOUS PRESSION
PEUVENT BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de malformations fœtales ou d’autres problèmes de reproduction. Il faut se laver les mains après toute manipulation.
REMARQUE
Facteurs relatifs au soudage et aux effets des champs magnétiques et électriques de basse fréquence
Voici une citation tirée du chapitre des conclusions générales du document de base de l’Office of Technology
Assessment (bureau des évaluations technologiques) de l’U.S. Congress, « Biological Effects of Power
Frequency Electric & Magnetic Fields », OTA-BP-E-63
(Washington, DC : U.S. Government Printing Office, mai 1989) : « ... il existe de nos jours, un nombre très élevé de travaux scientifiques qui rapportent les résultats d’expériences menées au niveau cellulaire et d’études auprès d’homme et d’animaux qui établissent nettement le rapport entre les champs magnétiques de basse fréquence et les systèmes biologiques, soit par des interactions ou des modifications. Quoique la plupart de ces travaux soient de très bonne qualité, les résultats sont complexes. À la lumière des connaissances scientifiques actuelles, il nous est encore impossible d’interpréter les
évidences en un seul cadre de référence cohérent. La situation est toutefois très contrariante. En effet, il nous est aussi impossible de tirer des conclusions définitives quant aux risques éventuels ou de proposer des stratégies
Manual 0-5157 1-13 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i fondées sur des faits scientifiques visant à atténuer ou
éviter des risques potentiels ».
Pour atténuer les champs magnétiques sur les lieux de travail, respectez les procédures qui suivent :
1. Maintenez les câbles l’un près de l’autre en les entrelaçant ou les reliant ensemble au ruban.
2. Acheminez les câbles à un côté du soudeur, le plus loin possible.
3. N’enroulez pas de câble autour du corps.
4. Maintenez le bloc d’alimentation du poste de soudage et les câbles aussi loin que possible du corps.
SAFETY INSTRUCTIONS
5. Enlevez tous les matériaux combustibles de la zone de travail. Si vous ne pouvez pas les enlever, protégez-les avec une cou vre ignifuge.
!
AVERTISSEMENT
N’effectuez JAMAIS d’opérations de soudage sur un récipient qui a contenu des liquides ou vapeurs toxiques, combustibles ou inflammables. N’effectuez JAMAIS d’opérations de soudage dans une zone contenant des vapeurs combustibles, des liquides inflammables ou des poussières explosives.
B Entretien des Locaux
STIMULATEURS CARDIAQUES :
Les procédures décrites ci-dessus sont habituellement celles recommandées pour les porteurs de stimulateurs cardiaques.
Pour de plus amples renseignements, consulter un médecin.
1.07 Informations Générales de
Sécurité
!
AVERTISSEMENT
Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres substances inflammables. Bien que l’oxygène elle même ne brûle pas, ces substances peuvent devenir extrême ment explosives. Elles peuvent prendre feu et brûler violem ment en présence d’oxygène.
Gardez TOUS les appareils propres et exempts de graisse, huile ou autres substances inflammables.
A Prévention D’incendie
Les opérations de soudage utilisent le feu ou la combustion comme outil de base. Ce processus est très utile quand il est cor rectement contrôlé.
1. La zone doit comporter un sol ignifugé.
2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement ignifuge.
3. Utilisez des écrans résistants à la chaleur ou en matériau approuvé pour protéger les cloisons proches ou le sol vul nérable des étincelles et du métal chaud.
4. Gardez un extincteur approuvé du bon type et de la bonne taille dans la zone de travail. Inspectez-le régulièrement pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir.
SAFETY INSTRUCTIONS AND WARNINGS
C Aération
1-14
!
AVERTISSEMENT
Ventilez les zones de soudage, chauffage et découpage de façon adéquate pour éviter l’accumulation de gaz explosifs ou toxiques.
Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques:
Utilisez un équipement de protection respiratoire dans ces circonstances. Si vous soudez ou brasez, lisez et assimilez la fiche technique de sécurité de matériau relative à l’alliage de soudage/brasage.
D Protection Personnelle
Les flammes de gaz produisent une radiation infrarouge qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un masque avec des verres trempés assombris au niveau 4 ou plus sombre, pour protéger vos yeux des dommages et garder une bonne visibilité sur le travail.
Portez en permanence des gants de protection et des vête ments ignifuges pour la protection de la peau et des vêtements contre les étincelles et le laitier. Gardez col, manches et poches boutonnés. Il ne faut pas remonter vos manches ou les pantalons à revers.
Manual 0-5157
SAFETY INSTRUCTIONS
Quand vous travaillez dans un environnement non dédié au soudage ou découpage, portez toujours une protection des yeux appropriées ou un masque facial.
!
AVERTISSEMENT
Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pression. Si vous déviez de ces procédures, cela peut entraîner incendie, explosion, dégâts matériels et/ou blessures corporelles pour l’opérateur.
E Bouteilles de Gaz Comprimé
Le Département des Transports américain (DOT) approuve la conception et la fabrication des bouteilles qui contiennent les gaz utilisés pour les opérations de soudage ou de découpage.
1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale. Fixez-la sur un chariot une cloison, un établi, etc.
FABRICATOR 211i ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez un diable approprié pour les déplacer.
3. Entreposez les bouteilles vides à l’écart des bouteilles pleines. Marquez-les “VIDE” et refermez leur vanne.
4. N’utilisez JAMAIS des bouteilles de gaz comprimé sans un régulateur de pression en série sur la vanne de bouteille.
5. Inspectez la vanne de bouteille pour y détecter de l’huile ou de la graisse, ou dès pièces endommagées.
!
AVERTISSEMENT
N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endommagées. Informez immédiate ment votre fournisseur de’ gaz de cet état.
6. Ouvrez et fermez momentanément la vanne de la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour raient être présentes dans la vanne.
Art # A-12127
Le schéma 1-1: Cylindres de gaz
!
AVERTISSEMENT
Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux peuvent résulter d’une mauvaise manutention ou d’un mauvais emploi des bouteilles de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez pas, ne l’exposez pas à une chaleur excessive, aux flammes ou étincelles. NE la cognez
PAS contre d’autres bouteilles. Contactez votre fournisseur de gaz ou reportez vous à la publication
CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur l’utilisation et la manutention des bouteilles.
AVIS
Ce document CGA p. t peut être obtenu en
écrivant à “Compressed Gas Association”,
4221 Walney Roed, 5th Floor. Chantilly, VA
20151.2923, USA.
MISE EN GARDE
Ouvrez la vanne de bouteille légèrement.
Si vous l’ouvrez trop en grand, la bouteille pourrait se renverser. Quand vous ouvrez/ fermez rapidement la vanne de bouteille, ne vous tenez pas directement devant. Opérez toujours cette opération dans une zone bien ventilée. Si une bouteille d’acétylène crache un brouillard, laissez reposer pendant 15 minutes. Essayez de nouveau la vanne. Si le problème persiste, con tactez votre fournisseur de gaz.
2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez
Manual 0-5157 1-15 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
1.08 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1,
American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, norme AWS F4.1, American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33128.
National Electrical Code, norme 70 NFPA, National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA
W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, norme ANSI Z87.1, American National
Standards Institute, 1430 Broadway, New York, NY
10018.
Cutting and Welding Processes, norme 51B NFPA,
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS AND WARNINGS 1-16 Manual 0-5157
SAFETY INSTRUCTIONS
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension Mono Phasé
FABRICATOR 211i
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Distant
Déroulement du Fil
Alimentation du Fil Vers la Pièce de Fabrication
Hors Tension
Torche de Soudage
Purge Du Gaz
Disjoncteur
Source AC Auxiliaire
X
%
Facteur de Marche
Pourcentage
Mode Continu de
Soudure
Soudure Par Point
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température t1 t
Duréc du Pulse
Durée de Pré-Dèbit t2
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour démarrer l’alimentation du fils et la soudure, le relâcher pour arrêter.
Détente à 4-Temps
Maintenez appuyez pour pré-dèbit, relailez pour initier l’arc. Appuyez pour arrêter l’arc, et mainteuir pour pré-dèbit. t Probléme de Terre
Terre de Protection
Indication d’erreur
IPM
Pouces Par Minute
Ligne Force d’Arc
MPM
Mètres Par Minute
Connexion de la Ligne
Amorçage de L’arc au
Contact (GTAW) S Voir Note
Source Auxiliaire Inductance Variable Voir Note
115V 15A Classement de Prise-
Source Auxiliaire
V
Tension
Art # A-07639F_AC
à EN50192 lorsqu’utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à l’hauteur de buse correctement installé.
Ne pas déposer avec les déchets ménagers.
Manual 0-5157 1-17 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
1.10 Declaration Of Conformity
Declaration of Conformity
SAFETY INSTRUCTIONS
We
Victor Technologies International Inc.
of
Suite 300
Chesterfield, MO 63033 U.S.A.
3163339
16052 Swingley Ridge Road
in accordance with the following Directive(s)
:
• 2006/95/EC The Low Voltage Directive
• 2004/108/EC The Electromagnetic Compatibility (EMC) Directive
hereby declare that
:
Equipment: Arc Welding Power Source
Model Name/Number: Fabricator 211i
Market Release Date: January 16, 2014
is in conformity with the applicable requirements of the following harmonized standards
:
• EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility
(EMC) requirements
• EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
Classification: The equipment described in this document is Class A and intended for industrial use.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.
Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: November 19, 2014
(Signature)
Steve Ward
(Full Name)
V.P. Europe and General Manager
(Position)
!
WARNING
This 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 in those locations, due to conducted as well as radiated disturbances.
SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
Classification: The equipment described in this manual is Class A and intended for industrial use.
!
WARNING
This 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 difficul ties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
Manual 0-5157 1-19 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
This Page Intentionally Blank
SAFETY INSTRUCTIONS AND WARNINGS 1-20 Manual 0-5157
INTRODUCTION FABRICATOR 211i
SECTION 2: INTRODUCTION
2.01 How To Use This Manual
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:
WARNING
Gives information regarding possible electrical shock injury. Warnings will be enclosed in a box such as this.
!
WARNING
A WARNING gives information regarding possible personal injury.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
A NOTE offers helpful information concerning certain operating procedures.
You will also notice icons from the safety section appearing throughout the manual. These are to advise you of specific types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim.
Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.
Include all equipment identification numbers as described above along with a full description of the parts in error.
2.04 Description
The Tweco Fabricator 211i is a self contained single phase multi process welding system that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and
LIFT TIG (GTAW) welding processes. The Power Source is equipped with an integrated wire feed unit, digital voltage and amperage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional. The Power Source is also fully compliant to Standard CSA E60974-1-00 and UL
60974.1.
The Tweco Fabricator 211i provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power
Source. Please read these instructions thoroughly before using the unit.
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container.
Record these numbers on the bottom of page i for future reference.
Manual 0-5157 2-1 INTRODUCTION
FABRICATOR 211i
2.05 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 Power Source with handles built into the top of the front and rear molded panels.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure Power Source on a proper skid before transporting.
2.06 User Responsibility
This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided.
This equipment must be checked periodically. Defective equipment (including welding leads) should not be used.
Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Tweco. Advice in this regard can be obtained by contacting an Accredited
Tweco Distributor.
This equipment or any of its parts should not be altered from standard specification without prior written approval of Tweco. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Tweco.
INTRODUCTION
2.07 Fabricator 211i Portable System
Package (Part No. W1004201)
• Fabricator 211i Power Source
• 12 ft. (3.6 m) Tweco ® Fusion 220 Amp MIG Gun
• Victor Argon Regulator / Flowmeter
• Drive Rolls:
.023"/.030" (0.6/0.8 mm) "V" groove,
.023"/.035" (0.6/0.9 mm)"V" groove (fitted with .035" groove lined up),
.030"/.035" (0.8/0.9 mm) "V" knurled for Flux Cored
Wire,
• Velocity Contact Tips (1 each)
.023"(0.6 mm), .030"(0.8 mm),
.035"(0.9 mm) (fitted)
.045"(1.2 mm)
• Electrode Holder with 13 ft. (4 m) lead
• Work Clamp with 10 ft. (3.1 m) lead
• Shielding Gas hose assembly
• 15A/20A Adapter Plug from 208/230V AC 50 Amps to 115V Amps Circuits
• Tweco Cap
• Electrodes
• Large Spring
• Operating Manual
• DVD
A-11187_AB
Figure 2-1: Fabricator 211i System Packaged W1004201
INTRODUCTION 2-2 Manual 0-5157
INTRODUCTION FABRICATOR 211i
2.08 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a
20% duty cycle, 210 amperes at 24.5 volts. This means that it has been designed and built to provide the rated amperage (210A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes is 2 minutes).
During the other 8 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.
50
40
70
60
30
20
100
90
80
10
0
0
SAFE OPERATING REGION
(MIG, TIG & STICK)
FABRICATOR 211i
STICK / TIG
MIG
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
Welding Current (AMPS)
Art # A-11265
Figure 2-2: Fabricator 211i Duty Cycle on 208/230V AC
50
40
30
20
10
0
100
90
80
70
60
STICK
SAFE OPERATING REGION
(MIG, TIG & STICK)
FABRICATOR 211i
MIG
TIG
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Welding Current (AMPS)
Art # A-11274
Figure 2-3: Fabricator 211i Duty Cycle on 115V AC
Manual 0-5157 2-3 INTRODUCTION
FABRICATOR 211i INTRODUCTION
2.09 Specifications
Description
Power Source Part No.
Power Source Dimensions
Power Source Mass
Cooling
Welder Type
Applicable Standard
Number of Phases
Nominal Supply Voltage
Nominal Supply Frequency
Welding Current Range
MIG Mode
STICK Mode
TIG Mode
Wirefeed Speed Range
MIG Welding Voltage Range
Nominal OCV
Effective Input Current (I
1eff
)
for MIG (GMAW/FCAW)
for STICK (SMAW)
for LIFT TIG (GTAW)
Maximum Input Current (I
1max
)
for MIG (GMAW/FCAW)
for STICK (SMAW)
for LIFT TIG (GTAW)
Single Phase Generator Requirement
MIG (GMAW/FCAW) Welding Output, 104°F, 10 min.
STICK (SMAW) Welding Output,1040°F, 10 min.
TIG (GTAW) Welding Output, 104°F, 10 min.
Fabricator 211i Multi Process 3 in 1 Welder
W1004200
H17.12" x W10.47" x D 24.29" (435mm x 266mm x D617mm)
57.3lb (26kg)
Fan Cooled
Multi Process Welding System
CSA E60974-1-00 / UL60974-1 / IEC 60974-1
Single Phase
208/230 VAC ± 10%
50/60Hz
115VAC± 10%
50/60HZ
10-210 Amps
10-200 Amps
10-200 Amps
100 - 600 IPM
14.5 - 24.5V DC
14.4A/11.2A
16.8A/15.8A
11.7A/11.5A
32.2A/25.0A
33.6A/31.6A
23.3A/22.9A
7.5 kVA
210A @ 20%,24.5V
122A @ 60%, 20.1V
95A @ 100%, 18.8V
200A @ 25%,28.0V
130A @ 60%, 25.2V
101A @ 100%, 24.0V
200A @ 25%,18.0V
130A @ 60%, 15.2V
101A @ 100%, 14.0V
70V DC
10-140 Amps
10-110 Amps
10-150 Amps
100 - 400 IPM
14.5 - 19V DC
15.5A
17.8A
17.4A
24.5A
30.1A
29.4A
*3.7 kVA
110A @ 45%,19.5V
99A @ 60%, 19.0V
77A @ 100%, 17.9V
110A @ 35%,24.4V
90A @ 60%, 23.6V
70A @ 100%, 22.8V
150A @ 35%,16.0V
115A @ 60%, 14.6V
90A @ 100%, 13.6V
Open Circuit Voltage
Protection Class
70 V
IP23S
Table 2-1: Fabricator 211i Specifications
Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.
Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.
Note 3: Generator Requirements at the Maximum Output Duty Cycle.
* Some 115 VAC, 15 amp/20 amps electrical outlets fitted with GFCI (Ground Fault Circuit Interrupt) protection against a nuisance trip with this equipment due to worn or out of tolerance components in the GFCI. In such cases have the 115 VAC, 15 amp/20 amp FGCI electrical outlet replaced by a qualified electrical trades person.
INTRODUCTION 2-4 Manual 0-5157
INTRODUCTION FABRICATOR 211i
NOTE
The recommended time delay fuse or circuit breaker size for 115V is 30 amp. An individual branch circuit capable of carrying 30 amperes and protected by fuses or circuit breaker is recommended for this application. Fuse 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)
Tweco continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items .
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation and conditions and local power grid supply conditions.
Manual 0-5157 2-5 INTRODUCTION
FABRICATOR 211i
2.10 Optional Accessories
26V TIG Torch & Accessories (required for TIG welding)
12.5 ft cable length; 12.5 ft gas hose length; 8 pin control plug; 1/16", 3/32", 1/8" thoriated tungstens; 1/16",
3/32", 1/8" collets; 1/16", 3/32",1/8:" collet bodies; No.
5, 6, 7 Alumina nozzle; short back cap; long back cap
Tweco Spool Gun (required for aluminum MIG welding
160A, 12ft (3.6M) Length, suits 4" (100mm) spools
Professional 4 Wheel Cart, Dual Cylinder ...................
Professional 4 Wheel Cart, Single Cylinder ................
Small Cart, Single Cylinder ..........................................
Roll Cage ......................................................................
Foot Control .................................................................
For remote amperage control when TIG welding
Tweco Helmet (USA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . .
WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)
Drive Roll .023" - .030" (0.6/0.8mm ) V groove, (fitted)
Part No. W4014603
INTRODUCTION
)
Part No.
W4015002
Part No. W4015001
Part No. W4014700
Part No. W4015104
Part No. 1027-1390
Part No. 600285
Part No. 4100-1004
Part No. 7977036
Drive Roll .023" - .035" (0.6/0.9 mm) V groove . Part No. W4014800
Drive Roll .035"/.045" (0.9/1.2 mm) V groove . . Part No. 7977660
Drive Roll .030" - .035" (0.8/0.9 mm) U groove . . Part No. 7977731
Drive Roll .040" - 3/64" (1.0/1.2 mm) U groove .
Drive Roll .030" - .035" (0.8/0.9 mm) V knurled
Part No. 7977264
Part No. 7977732
Drive Roll .045"(1.2 mm) V knurled . . . . . . . . . . . . . Part No. 704277
Stick Lead, 200A, 13ft, 50mm Dinse . . . . . . . . . . . . . Part No. WS200E13
Ground Lead, 200A, 10Ft, 50mm Dinse . . . . . . . . . . Part No. WS200G10
Victor Argon Regulator/ Flowgauge .................... Part No. 130781-4169
Accessory Kit for TIG Torch ...................................
1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32",
1/8" collets; 1/16", 3/32",1/8:" collet bodies; No. 5,
6, 7 Alumina nozzle; short back cap; long back cap
Part No. P062900010
INTRODUCTION 2-6 Manual 0-5157
INTRODUCTION FABRICATOR 211i
2.11 Volt-Ampere Curves
Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.
Manual 0-5157
Art # A-11297
Figure 2-4: Fabricator 211i Volt-Ampere Curves
2-7 INTRODUCTION
FABRICATOR 211i
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INTRODUCTION
INTRODUCTION 2-8 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
SECTION 3: INSTALLATION, OPERATION AND SETUP
3.01 Environment
This Power Source is designed for use in environments with increased hazard of electric shock. Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock.
Please refer to relevant local standards for further information prior to using in such areas.
G. The enclosure design of this Power Source meets the requirements of IP23S as outlined in EN 60529. This provides adequate protection against solid objects
(greater than 1/2", 12mm) and direct protection from vertical drops. Under no circumstances should the
Power Source be operated or connected in a micro environment that will exceed the stated conditions.
For further information please refer to EN 60529.
A. Examples of environments with increased hazard of electric shock are:
H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.
1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts.
2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator.
WARNING
This equipment should be electrically connected by a qualified electrician.
3.03 Ventilation
3. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.
B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.
!
WARNING
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
3.04 Electricity Supply 3.02 Location
Be sure to locate the welder according to the following guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 14° F (0° C) to 104° F
(40° C).
C. In areas, free from oil, steam and corrosive gases.
D. In areas, not subjected to abnormal vibration or shock.
E. In areas, not exposed to direct sunlight or rain.
F. Place at a distance of 12" (305mm) or more from walls or similar that could restrict natural air flow for cooling.
The Electricity Supply voltage should be within 208/230V AC ± 10% or 115 V AC ±
10%. Too low a supply voltage may cause poor welding performance in STICK mode such as the arc snuffing out during welding. Too high a supply voltage will cause components to overheat and possibly fail. The Welding power Source must be:
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point and fuse as per the Specifications on page 2-4.
Manual 0-5157 3-1 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
WARNING
The Fabricator 211i must be electrically connected by a qualified electrical trades-person. Damage to the
PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable.
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT
TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting
OFF and red-tagging circuit breaker or other disconnecting device.
Power Cords Included With Power Supply
Attached to the power supply is an input power cord with a 208/230Volt 50 Amp NEMA 6-50 P for plug. Supplied adapter allow for connection of the power supply input cable plug to 115 V input power.
Art# A-11275
Figure 3-1: 115 VAC Adapter
Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical 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. The Welding Power Source must be:
Do not connect in input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
• Correctly installed, if necessary, by a qualified electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point, fuse and primary supply lead based on Table 3-1.
Refer to Figure 3-1 and Table 3-1.
INSTALLATION/SETUP 3-2 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
WARNING
An electrical shock or fire hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source.
Supply Voltage
Input Current at Maximum Output
Maximum Recommended Fuse* or Circuit Breaker Rating
* Time Delay Fuse, UL class RK5. Refer to UL248
Maximum Recommended Fuse^ or Circuit Breaker Rating
^Normal Operating, UL class K5. Refer to UL248
Minimum Recommended Cord Size
Maximum Recommended Extension Cord Length
Minimum Recommended Grounding Conductor Size
50 / 60 Hz Single Phase Supply
208/230V AC
32 Amps
50 Amps
50 Amps
12 AWG
50 ft
12 AWG
Table 3-1: Electrical Service Guide
115V AC
30 Amps
30 Amps
30 Amps
12 AWG
25 ft
12AWG
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.
208/230V, 50A, 1Ø
Manual 0-5157
115 V, 20A, 1Ø
The Adapter enable connection to all these power outlets
115 VAC Adapter
115 V, 15A, 1Ø
Primary Power Cable
Art# A-11240
Figure 3-2: Electrical Input Connections
3-3 INSTALLATION/SETUP
FABRICATOR 211i
3.05 Electromagnetic Compatibility
INSTALLATION/SETUP
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 Troublesome.
NOTE
The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.
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. Electricity Supply
Welding equipment should be connected to the Electricity Supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take additional precautions such as filtering of the Electricity 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.
INSTALLATION/SETUP 3-4 Manual 0-5157
INSTALLATION/SETUP
2. Maintenance of Welding Equipment
FABRICATOR 211i
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.
3. Welding Cables
The welding cables should be kept as short as possible and should be positioned close together but never coiled and running at or close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the welding 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/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 Victor Regulator
Pressure regulator (Figure 3-3) attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding, cutting, and other applications.
LOW PRESSURE
GAUGE (DELIVERY)
HIGH PRESSURE
GAUGE (SUPPLY)
INLET
CONNECTION
OUTLET
CONNECTION
PRESSURE
ADJUSTING
SCREW
A-09414_AB
Figure 3-3: Victor CS Regulator
!
WARNING
Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with any other gas.
Manual 0-5157 3-5 INSTALLATION/SETUP
FABRICATOR 211i
NOTE
INSTALLATION/SETUP
Regulators purchased with open 1/8”, 1/4”, 3/8”, or 1/2” NPT ports must be assembled to their intended system.
1. Note the maximum inlet pressure stamped on the regulator. DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator.
2. The regulator body will be stamped “IN” or “HP” at the inlet port. Attach the inlet port to the system supply pressure connection.
3. Wrap pipe threads with Teflon tape 1 1/2 to 2 turns to effect a seal. If other sealants are used, they must be compatible with the gas that will be used in the system.
4. If gauges are to be attached to the regulator and the regu lator is stamped and listed by a third party (i.e. “UL” or “ETL”). The following requirements must be met: a) Inlet gauges over 1000 PSIG (6.87 mPa) shall conform with the requirements of UL 404, “Indicating Pressure Gauges for Compressed Gas Service.” b) Low pressure gauges must be UL recognized for the class of regulator they are being used on according to UL252A.
!
WARNING
DO NOT use a regulator that delivers pressure exceeding the pressure rating of the downstream equipment unless pro visions are made to prevent over-pressurization (i.e. system relief valve). Make sure the pressure rating of the down stream equipment is compatible with the maximum delivery pressure of the regulator.
5. Be sure that the regulator has the correct pressure rating and gas service for the cylinder used.
6. Carefully inspect the regulator for damaged threads, dirt, dust, grease, oil, or other flammable substances.
Remove dust and dirt with a clean cloth. Be sure the inlet swivel filter is clean and in place. Attach the regulator
(Figure 3-4) to the cylinder valve. Tighten securely with a wrench.
!
WARNING
DO NOT attach or use the regulator if oil, grease, flamma ble substances or damage is present! Have a qualified repair technician clean the regulator or repair any damage.
INSTALLATION/SETUP
Art # A-09845
Figure 3-4: Regulator to Cylinder Valve
3-6 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
7. Before opening the cylinder valve, turn the regulator adjusting screw counterclockwise until there is no pressure on the adjusting spring and the screw turns freely.
8. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the regulator from high pres sures. Relief valves are not intended to protect down stream equipment from high pressures.
!
WARNING
DO NOT tamper with the relief valve or remove it from the regulator.
!
WARNING
Stand to the side of the cylinder opposite the regulator when opening the cylinder valve. Keep the cylinder valve between you and the regulator. For your safety, NEVER STAND IN FRONT OF OR BEHIND A REGULA-
TOR WHEN OPENING THE CYLINDER VALVE!
9. Slowly and carefully open the cylinder valve (Figure 3-5) until the maximum pressure shows on the high pressure gauge.
Art # A-09828
Figure 3-5: Open Cylinder Valve
10. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless regulators, the indicator will register the cylinder contents open.
11. On acetylene cylinders, open the valve 3/4 of a turn and no more than 1-1/2.
!
WARNING
Acetylene delivery pressure must not exceed 15 PSIG (103 kPa) or 30 PSIG (207 kPa). Acetylene can dissociate (decompose with explosive violence) above these pressure limits.
CAUTION
Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn OFF the cylinder quickly, if necessary.
12. Attach the desired downstream equipment.
Manual 0-5157 3-7 INSTALLATION/SETUP
FABRICATOR 211i
3.07 Leak Testing The System
INSTALLATION/SETUP
Leak test the system before putting into operation.
1. Be sure that there is a valve in the downstream equipment to turn OFF the gas flow.
2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure.
3. Close the cylinder valve.
4. Turn the adjusting screw/knob counterclockwise one turn. a) If the high-pressure gauge reading drops, there is a leak in the cylinder valve, inlet fitting, or high-pressure gauge. b) If the low-pressure gauge drops, there is a leak in the down stream equipment, hose, hose fitting, outlet fitting or low-pressure gauge. Check for leaks using an approved leak detector solution. c) If the high-pressure gauge drops and the low-pressure gauge increases at the same time, there is a leak in the regulator seat. d) If the regulator requires service or repair, take it to a qualified repair technician.
5. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed.
!
WARNING
If a leak has been detected anywhere in the system, dis continue use and have the system repaired. DO
NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pressure.
3.08 When You Finish Using The Regulator
1. Close the cylinder valve.
2. Open the valve on the downstream equipment. This drains all pressure from the system.
3. Close the valve on the downstream equipment.
4. Turn the adjusting screw counterclockwise to release the ten sion on the adjusting spring.
5. Check the gauges after a few minutes for verification that the cylinder valve is closed completely.
3.09 Storage Of The Regulator
When the regulator is not in use and has been removed from the cylinder, it should be stored in an area where it will be pro tected from dust, oil, and grease. The inlet and outlet should be capped to protect against internal contamination and prevent insects from nesting.
INSTALLATION/SETUP 3-8 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
3.10 Fabricator 211i Power Source Controls, Indicators And Features
1 2 14
4
3
3A
13
16
12
11
10
15
5
21
6
7
Art # A-11241_AC
9 8
Figure 3-6: Front and Control Panel Figure 3-7: Rear Panel Connections
17
Manual 0-5157
Art # A-10938
Figure 3-8: Wire Feed Compartment Control
3-9 INSTALLATION/SETUP
FABRICATOR 211i
1. Power Indicator
INSTALLATION/SETUP
The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/
OFF switch located on the rear panel is in the ON position.
2. Thermal Overload Indicator (Fault Indicator)
This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled. Once the power source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not switch the unit OFF should a thermal overload condition be present.
3. Digital Wirespeed/Amperage Meter (Left Digital Display)
MIG Mode
This digital meter is used to display the pre-set (preview) Wirefeed Speed in IPM (Inches per minute) in MIG mode and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Amperage Control
Knob (4).
STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set
(preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Amperage Control
Knob (4).
When welding, this digital meter will display actual welding amperage in all modes.
At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.
3A Wirespeed Indicator
The Wirespeed Indicator illuminates when MIG mode is selected to identify that the Digital Wirespeed/Amperage
Meter is previewing Wirespeed in IPM (inches per minute).
The Wirespeed Indicator extinguishes when the user is MIG (GMAW/FCAW) welding or depressing the MIG gun trigger and the Digital Wirespeed/Amperage Meter displays actual welding amperage of the power source.
INSTALLATION/SETUP 3-10 Manual 0-5157
INSTALLATION/SETUP
4. Wirespeed/Amperage Control
FABRICATOR 211i
In MIG mode, the Wirespeed/Amperage control 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 depends upon the material type and the welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required settings for a basic range of MIG (GMAW/FCAW) welding applications.
In STICK and LIFT TIG modes, the Wirespeed/Amperage control knob adjusts the amount of amperage (weld current) delivered to the welding arc by the Power Source. It directly adjusts the Power Source to deliver the desired level of weld current.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.
5. MIG Gun Adapter (Tweco Style)
The MIG Gun adapter is the connection point for the Tweco Fusion MIG Gun. Connect the MIG Gun by pushing the
MIG Gun connector into the brass MIG Gun Adapter firmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment to secure the Tweco Fusion MIG Gun in position. Failure to properly lock the
Tweco MIG Gun into the MIG Gun Adapter will result in the Tweco Fusion 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. To remove the MIG gun simply reverse these directions.
6. Positive Welding Output Terminal
The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG gun (via the MIG polarity lead), electrode holder lead or work lead. Positive welding current flows from the power source via this heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.
7. MIG Polarity Lead
The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using gasless wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt, consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.
Manual 0-5157 3-11 INSTALLATION/SETUP
FABRICATOR 211i
8. Negative Welding Output Terminal
INSTALLATION/SETUP
The negative welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG gun (via the MIG polarity lead), TIG torch or work lead. Negative welding current flows to the power source via this heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.
9. 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.
5
8
2
4
7
1
3
6
5
6
7
8
3
4
1
2
W
Trigger Switch
V
Negative
Spool Gun Motor
Positive
Remote Volts in
MIG (GMAW/FCAW)
Art # A-10421_AC
Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Figure 3-9: Remote Control Socket
Socket Pin
1
2
3
4
5
6
7
8
Function
Spool Gun Motor Negative
Trigger Switch Input
Trigger Switch Input
Spool Gun Motor (+24V DC)
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Table 3- 2
Note that the local/ remote switch (item 18) located in the wirefeed compartment should be set to remote for the amperage/voltage controls to be operative.
10. Multifunction Control - Voltage, Down Slope & Arc Force
The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc Force
(STICK Mode) depending on the welding mode selected.
INSTALLATION/SETUP 3-12 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.
When MIG Mode is Selected
In this mode the control knob is used to adjust the output voltage of the unit. The welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required will dependent on the type of welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications.
When STICK Mode is Selected
In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved.
Arc force is increased by turning the control knob clockwise or decreased by turning the knob anti-clockwise
When LIFT TIG Mode is Selected
In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufficiently.
Note that when in 2T normal mode (refer item 12), the unit will enter down slope mode as soon as the trigger switch is released (ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding current to zero over 5 seconds). If no down slope time is selected then the welding output will cease immediately.
If the unit is set to 4T latch mode, to enter down slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output will cease immediately.
11. Arc Control (Inductance)
The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance.
12. Trigger Mode Control (MIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal) and
4T (latch mode)
2T (Normal Mode)
In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.
4T (Latch Mode)
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and released, thus eliminating the need for the operator to hold the torch trigger.
Note that when operating in LIFT TIG mode, the power source will remain activated until the selected downslope time has elapsed (refer Item 10).
Manual 0-5157 3-13 INSTALLATION/SETUP
FABRICATOR 211i
13. Process Selection Control
INSTALLATION/SETUP
The process selection control is used to select the desired welding mode. Three modes are available, MIG (GMAW/
FCAW), LIFT TIG (GTAW) and STICK (SMAW) modes. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set up details, section 3.21 for LIFT TIG (GTAW) set-up details or section 3.22 for STICK (SMAW) set-up details.
Note that when the unit is powered OFF the mode selection control will automatically default to MIG mode. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up.
14. Digital Voltage Meter (Right Digital Display)
MIG Mode
This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of
Voltage. This value can be adjusted by varying the Multifunction Control Knob (10).
STICK and LIFT TIG Modes
This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during nonwelding or welding. This value cannot be adjusted by varying the Multifunction Control Knob (10).
When welding, this digital meter will display actual welding voltage in all modes.
At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.
15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation)
The Gas Inlet connection,5/8-18 UNF female thread is used to supply the appropriate MIG welding gas to the
Power Source. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set up details
!
WARNING
Only Inert Shielding Gases specifically designed for welding applications should be used.
16. ON / OFF Switch
This Single Phase circuit breaker performs a dual function.
It is used to turn the unit ON/OFF and it will also trip in the event of a fault.
INSTALLATION/SETUP 3-14 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
WARNING
When the front digital displays are lit, the machine is connected to the Electricity Supply and the internal electrical components are at Mains voltage potential.
17. Wiredrive Motor Circuit Breaker
The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload.
NOTE
If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button .
18. Local / Remote Switch (located in wirefeed compartment)
The local/ remote switch is used only when a remote control device (such as a TIG torch with remote current control) is fitted to the unit via the remote control socket (item 9). When the local/ remote switch is in the remote position, the unit will detect a remote device and work accordingly. When in the local mode, the unit will not detect the remote device and will operate from the power source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local/ remote switch (ie in both local and remote modes).
Should a remote device be connected and the local/ remote switch set to remote, the maximum setting of the power source will be determined by the respective front panel control, irrespective of the remote control device setting.
As an example, if the output current on the power source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output from the unit will be 50%. Should 100% output be required, the respective front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output.
19. Burnback Control (located in wirefeed compartment)
The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG gun after the completion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG gun at the completing of welding), turn the burnback control knob anti-clockwise.
To increase the burnback time (or shorten the amount of wire protruding from the torch at the completing of welding), turn the Burnback Control knob clockwise.
20. MIG Gun & Spool Gun Switch
The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun functionality and Spool Gun functionality
21. Cooling Fan
The Fabricator 211i is designed with an intelligent fan control. When the 211i is switched ON the cooling fan will come ON for approximately 3 seconds then automatically switch the fan OFF. The cooling fan will remain OFF until it is required for cooling purposes. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the power source.
Note in STICK mode the fan operates continuously.
Manual 0-5157 3-15 INSTALLATION/SETUP
FABRICATOR 211i
3.11 Attaching the TWECO Fusion 220A MIG Gun
INSTALLATION/SETUP
Fit the Fusion MIG gun to the power source by pushing the MIG gun connector into the MIG gun adapter and screwing the plastic nut clockwise to secure the MIG gun to the MIG gun adapter.
Connect the 8 pin plug by aligning he keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position.
MIG Gun Adapter
MIG Gun Connector
8 pin plug
8 pin socket
Wire Drive Tension Knob
Pressure Arm
Locking Screw
MIG Gun Connector
Art # A-11242_AB
Inlet Guide
Outlet Guide
Figure 3-10: Attaching MIG Gun
INSTALLATION/SETUP 3-16 Manual 0-5157
INSTALLATION/SETUP
3.12 Installing 33/44 lb Spool (12" diameter)
FABRICATOR 211i
As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 33/44 lb. or 12" diameter.
Installation of wire spool, Refer to Figure 3-11.
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 3.18
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.
Wire Spool
Hub Nut
33/44 lb (12")
Wire Spool
Flat Washer
Large Hole
Retaining Clip
Use inner holes on
Spool Hub
Pin
Fiber Washer
Flat Washer
Small Hole Spring
Keyed Washer
Spool Hub
Figure 3-11: 33/44 lb (12") Spool Installation
Art # A-11266
Manual 0-5157 3-17 INSTALLATION/SETUP
FABRICATOR 211i
3.13 Installing 12.5 lb Spool ( 8" diameter)
INSTALLATION/SETUP
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 3.18
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.
Wire Spool
Hub Nut
12.5 lb (8")
Wire Spool
Retaining Clip
Use inner holes on
Spool Hub
Flat Washer
Large Hole
Pin
Fiber Washer
Flat Washer
Small Hole Spring
Keyed Washer
Spool Hub
Figure 3-12: 12.5lb (8") Spool Installation
Art # A-11267
INSTALLATION/SETUP 3-18 Manual 0-5157
INSTALLATION/SETUP
3.14 Installing 1 lb Spool (4" diameter)
FABRICATOR 211i
In order to fit a 1 lb spool (4" diameter) assemble parts in the sequence shown in Figure 3-13.
Installation of wire spool:
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Fiber Washer and Large Spring onto the Shaft, then load the Wire Spool on the Shaft so that the wire will feed off the bottom of the spool as spool rotates counter clockwise.
3. Then place Flat Washer Large Hole, Keyed Washer, Spring, Flat Washer Small Hole as shown in Figure 3-13.
Finally secure with Wire Spool Hub Nut.
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section 3.18
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.
1lb (4") Diameter
Wire Spool
Fiber
Washer
Wire Spool
Hub Nut
Flat Washer
Large Hole
Flat Washer
Small Hole Spring
Keyed Washer
Large
Spring
Figure 3-13: 1 lb (4") Spool Installation
Art # A-11298_AB
Manual 0-5157 3-19 INSTALLATION/SETUP
FABRICATOR 211i
3.15 Inserting Wire Into The Wire Feed Mechanism
INSTALLATION/SETUP
Release the tension from the pressure roller by turning the adjustable wire drive tension knob in an anti-clockwise direction. Then to release the pressure roller arm push the tension screw toward the back of the machine which releases the pressure roller arm (Figure 3-14). With the MIG welding wire feeding from the bottom of the spool (Figure 3-15) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the MIG gun.
Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly (Figure 3-14).
Remove the Velocity contact tip from the MIG gun. With the MIG gun lead reasonably straight, feed the wire through the MIG gun by depressing the trigger switch. Fit the appropriate Velocity contact tip.
WARNING
Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF.
The electrode wire will be at welding voltage potential while it is being feed through the system.
Keep MIG gun away from eyes and face.
Wire Drive Tension Screw
Pressure Roller Arm
Art # A-10426
Inlet Guide
Outlet Guide
Figure 3-14: Wire Drive Assembly Components
MIG Welding Wire
INSTALLATION/SETUP
Art # A-10427_AB
Figure 3-15: MIG Welding Wire - Installation
3-20 Manual 0-5157
INSTALLATION/SETUP
3.16 Feed Roller Pressure Adjustment
FABRICATOR 211i
The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf. If it is not the cause of slipping, the feed roll pressure can be increased by rotating the pressure screw clockwise.
WARNING
Before changing the feed roller ensure that the Electricity Supply to the power source is switched OFF.
CAUTION
The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.
3.17 Changing the Feed Roll
To change feed roll remove the feed roll retaining screw by turning in an anti-clockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions. Note: Be sure not to lose key that is located on
Drive Motor Shaft. This key must align with drive roll groove for proper operation.
A dual groove feed roller is supplied as standard. It can accommodate 0.6/0.8mm diameter hard wires. Select the roller required with the chosen wire size marking facing outward.
GROOVE “A” GROOVE “B”
GROOVE “B” SIZE GROOVE “A” SIZE
A-09583
Figure 3-16: Dual Groove Feed Roller
Manual 0-5157
Feed Roll Retaining Screw
Art # A-10428
Figure 3-17: Changing the Feed Roll
3-21 INSTALLATION/SETUP
FABRICATOR 211i
3.18 Wire Reel Brake
INSTALLATION/SETUP
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking.
If it is considered necessary, adjustment can be made by turning the Thumb Screw inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 1/8"-3/16" (3-5mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip.
Spool Hub Tension
Thumb Screw
Art # A-10429
Figure 3-18: Wire Reel Brake
3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire
A. Select MIG mode with the process selection control. (Refer to Section 3.10.13 for further information)
B. Connect the MIG polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. 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.
C. Fit the MIG gun to the power source. (Refer to section 3.11 Attaching the TWECO Fusion 220A MIG gun).
D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
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.
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.06) then connect the shielding gas hose from the rear of the power source to the regulator/flowmeter outlet.
F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.
G. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the
Power Sources Wirespeed and Voltage controls.
H. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to MIG GUN.
INSTALLATION/SETUP 3-22 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
!
WARNING
Before connecting the work clamp to the work make sure the Electricity 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.
Shielding Gas Hose Fitted with Quick Connect
Positive Welding
Terminal (+)
MIG Gun
MIG Polarity Lead
8 pin plug
Negative Welding
Terminal (-)
Work Lead
Art # A-11244
Figure 3-19: Setup for MIG Welding with Gas Shielded MIG Wire
3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire
A. Select MIG mode with the process selection control (refer to Section 3.10.13 for further information).
B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. 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.
C. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
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.
D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.
Manual 0-5157 3-23 INSTALLATION/SETUP
FABRICATOR 211i
E. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the
Power Sources Wirespeed and Voltage controls.
F. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to MIG GUN.
INSTALLATION/SETUP
WARNING
Before connecting the work clamp to the work make sure the Electricity 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.
INSTALLATION/SETUP
MIG Gun
8 pin plug
Positive Welding
Terminal (+)
Work Lead
Negative Welding
Terminal (-)
MIG Polarity Lead
Art # A-11245
Figure 3-20: Setup for MIG Welding with Gasless MIG Wire
3-24 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire
Select MIG mode with the Process Selection Control .
For setup and operation of the spool gun, please refer to the spool gun operations manual.
Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to SPOOL GUN.
Connect the shielding gas for the to the Shielding Gas Inlet on the rear panel of the Power Source.
Art # A-11629
1. Make sure the welding power source is turned
OFF before connecting the welding gun.
Thumb screw
2. Open side panel and loosen thumb screw.
3. Insert the back end of the
Spool gun into the gun receiving bushing.
4. Tighten thumb screw and replace side panel.
5. Connect gas supply fi tting and tighten with a wrench.
6. Align Control Plug to panel fi tting and tighten securely.
!
WARNING
Before connecting the work clamp to the work make sure the main 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.
Manual 0-5157 3-25 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.
Remove any packing material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.
Shielding Gas Hose Fitted with Quick Connect
Spool Gun Switch
MIG polarity lead
Spool Gun
Negative Welding
Terminal (-)
Positive Welding
Terminal (+)
Work Lead
Art # A-10576
Figure 3-21: Setup for Spool Gun Welding with Gas Shielded MIG Wire
3.22 Setup For LIFT TIG (GTAW) Welding
A. Select LIFT TIG mode with the process selection control (refer to Section 3.10.13 for further information).
B. Connect the TIG Torch to the negative welding terminal (-). 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.
C. Connect the work lead to the positive welding terminal (+). 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.
D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below.
The TIG torch will require a trigger switch to operate in LIFT TIG Mode.
NOTE
A Tweco 26V TIG torch with an 8 pin plug must be used to turn the weld current ON/OFF via the TIG torch trigger switch to TIG weld OR a Tweco Foot Control with an 8 pin plug must be used to turn the weld current ON/OFF as well as providing remote control of the weld current.
INSTALLATION/SETUP 3-26 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.06) then connect the shielding gas hose from the TIG torch to the regulator/flowmeter outlet. Note that the TIG torch shielding gas hose is connected directly to the regulator/flowmeter. The power source is not fitted with a shielding gas solenoid to control the gas flow in LIFT TIG mode therefore the TIG torch will require a gas valve.
!
WARNING
Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure the
Electricity Supply is switched OFF.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.
Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.
F. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the
Power Sources Amperage control or REMOTE for remote amperage using a Foot Control.
Art # A-11246_AB
Positive Welding
Terminal (+)
Work Lead
TIG Remote Control
TIG Torch
Connect to shielding gas regulator/flow gauge.
Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.
Negative Welding
Terminal (-)
Note: A Tweco 26V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Tweco Foot
Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.
Figure 3-22: Setup for TIG Welding
Manual 0-5157 3-27 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
3.23 Setup For STICK (SMAW) Welding
A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. 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.
B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer. 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.
C. Select STICK mode with the process selection control (refer to Section 3.10.13 for further information).
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Electricity 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.
C. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources
Amperage control or REMOTE for remote amperage control using a Hand Pendant Control.
INSTALLATION/SETUP
Positive Welding
Terminal (+)
Electrode Holder Negative Welding
Terminal (-)
Work Lead
Art # A-11247
Figure 3-23: Setup for Manual Arc Welding.
3-28 Manual 0-5157
BASIC WELDING
SECTION 4:
BASIC WELDING GUIDE
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 is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO
2
welding, Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable electrode and the work.
Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture. The process is normally applied semi automatically; however the process may be operated automatically and can be machine operated. The process can be used to weld thin and fairly thick steels, and some non-ferrous metals in all positions.
Shielding Gas
Molten Weld Metal
Nozzle
Electrode
Arc
Solidified
Weld Metal Base Metal
Shielding Gas
(Optional)
Slag
Molten Metal
Molten
Slag
Solidified
Weld Metal
FABRICATOR 211i
FCAW Process
Figure 4-2
Nozzle
(Optional)
Flux Cored
Electrode
Arc
Base Metal
Art # A-08992_AB
Position of MIG Gun
The angle of MIG Gun to the weld has an effect on the width of the weld.
Push Vertical Drag/Pull
Art # A-07185_AB
Figure 4-3
The MIG Gun should be held at an angle to the weld joint.
(See Secondary Adjustment Variables below)
Hold the MIG Gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment.
GMAW Process
Figure 4-1
Art # A-8991_AB
FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous flux filled electrode wire and the work. Shielding is obtained through decomposition of the flux within the tubular wire. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. The process is normally applied semi automatically; however the process may be applied automatically or by machine. It is commonly used to weld large diameter electrodes in the flat and horizontal position and small electrode diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay work.
CAUTION
Do NOT pull the MIG Gun back when the arc is established. This will create excessive wire extension (stick-out) and make a very poor weld.
The electrode wire is not energized until the MIG Gun trigger switch is depressed. The wire may therefore be placed on the seam or joint prior to lowering the helmet.
5° to 15°
Longitudinal
Angle
90°
Transverse
Angle
Direction of
Travel
Art # A-08993
Manual 0-5157 4-1 BASIC WELDING
FABRICATOR 211i
5° to 15°
Longitudinal Angle
10°
Longitudinal Angle
30° to 60°
Transverse
Angle
Direction of Travel
Vertical Fillet Welds
Art # A-08995
Figure 4-6
Direction of Travel
30° to 60°
Transverse Angle
Distance from the MIG Gun Nozzle to the Work Piece
The electrode wire stick out from the MIG Gun nozzle should be between 3/8" - 3/4" (10 - 20 mm). This distance may vary depending on the type of joint that is being welded.
Travel Speed
The speed at which the molten pool travels influences the width of the weld and penetration of the welding run.
MIG Welding (GMAW) Variables
Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in short-arc welding of .023 - 1/4" (0.6 mm - 6.4 mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.
BASIC WELDING
Direction of
Travel
30° to 60°
Transverse Angle
Art # A-08994
10° to 20° Longitudinal
Angle
30° to 60°
Transverse
Angle
5° to 15°
Longitudinal
Angle
Art # A-08996
4-2
BASIC WELDING
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 are:
• Type of electrode wire
• Size of electrode wire
• Type of gas (not applicable for FCAW self shielding wires)
• Gas flow rate (not applicable for FCAW self shielding wires)
Primary Adjustable Variables
These control the process after preselected variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness.
They are:
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are:
1. Sick-out (distance between the end of the contact tube (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 weld current, Decrease in wire feed speed decreases weld current.
Gas Nozzle
Tip to
Work Distance
Contact Tip (Tube)
Electrode Wire
Actual Stick-out
Average Arc Length
Electrode Stick-Out Art # A-08997_AD
Figure 4-8
3. Nozzle Angle. This refers to the position of the MIG
Gun in relation to the joint. The transverse angle is usually one half the included angle between plates forming the joint. The longitudinal angle is the angle between the centre line of the MIG Gun and a line perpendicular to the axis of the weld.
The longitudinal angle is generally called the
Nozzle Angle and can be either trailing (pulling)
Manual 0-5157
BASIC WELDING or leading (pushing). Whether the operator is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel.
Transverse
Angle
Longitudinal
Angle
Axis of Weld
Transverse and Longitudinal
Nozzle Axes
Figure 4-9
Direction of Gun Travel
Leading or “Pushing”
Angle
(Forward Pointing)
90°
Trailing or “Pulling”
Angle
(Backward Pointing)
Nozzle Angle, Right Handed Operator Art # A-08999_AC
Figure 4-10
Art # A-08998_AB
Establishing the Arc and Making Weld Beads
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.
FABRICATOR 211i
Setting of the Power Source
Power source 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 Voltage 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 spatter. 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.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas used depends on the following:
• Thickness of the metal to be welded
• Type of joint
• Capacity of the wire feed unit and Power Source
• The amount of penetration required
• The deposition rate required
• The bead profile desired
• The position of welding
• Cost of the wire
Manual 0-5157 4-3 BASIC WELDING
FABRICATOR 211i
Tweco MIG, Lift TIG, Stick Wire Selection Chart
BASIC WELDING
BASIC WELDING
Table 4-1
4-4 Manual 0-5157
BASIC WELDING
4.02 MIG (GMAW/FCAW) Welding Troubleshooting
FABRICATOR 211i
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.
Solving Problems Beyond the Welding Terminals - 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
1 Shielding gas cylinder contents and flow meter.
2 Shielding gas cylinder contents and flow gauge.
3 Gas leaks.
4 Internal gas hose in the Power
Source.
CAUSE
Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to 31.75 CFH.
Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to workshop welding: 28-35
CFH or outdoors welding: 35-46 CFH.
Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Source.
Ensure the hose from the solenoid valve to the MIG Gun adapter has not fractured and that it is connected to the MIG
Gun adapter.
Shield the weld area from the wind or increase the gas flow.
Clean contaminates off the work piece.
5 Welding in a windy environment.
6 Welding dirty, oily, painted, oxidized or greasy plate.
7 Distance between the MIG Gun nozzle and the work piece.
8 Maintain the MIG Gun in good working order.
Keep the distance between the MIG Gun nozzle and the work piece to a minimum.
A Ensure that the gas holes are not blocked and gas is exiting out of the MIG Gun 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 4-2: Solving Problems beyond the Welding Terminals - Porosity
Manual 0-5157 4-5 BASIC WELDING
FABRICATOR 211i BASIC WELDING
Solving Probelms Beyond the Welding Terminals - Inconsistent Wire Feed
!
Disengage the feed roll when testing for gas flow by ear.
WARNING
Wire feeding problems can be reduced by checking the following points.
FAULT
1 Feed roller driven by motor in the cabinet slipped.
2 Wire spool unwound and tangled.
3 Worn or incorrect feed roller size
CAUSE
Wire spool brake is too tight.
Wire spool brake is too loose.
A Use a feed roller matched to the size you are welding.
B Replace feed roller if worn.
Misalignment of inlet/outlet guides 4 Wire rubbed against the misaligned guides and reduced wire feed ability.
5 Liner blocked with swarf
6 Incorrect or worn contact tip
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.
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
8 Bent liner
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.
This will cause friction between the wire and the liner thus reducing wire feed ability
Table 4-3: Wire Feeding Problems
BASIC WELDING 4-6 Manual 0-5157
BASIC WELDING
Basic MIG (GMAW/FCAW) Welding Troubleshooting
FABRICATOR 211i
FAULT
1 Undercut
2 Lack of penetration
3 Lack of fusion
4 Excessive spatter
CAUSE
A Welding arc voltage too high.
B Incorrect MIG Gun angle
REMEDY
A Decrease voltage or increase the wire feed speed.
B Adjust angle.
C Excessive heat input
A Welding current too low
C Increase the MIG Gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed.
A Increase welding current by increasing wire feed speed and increasing voltage.
B Joint preparation too narrow or gap too tight
B Increase joint angle or gap.
C Shielding gas incorrect C Change to a gas which gives higher penetration.
Voltage too low Increase voltage.
A Voltage too high A Decrease voltage or increase the wirespeed control.
B Voltage too low
5 Irregular weld shape A Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high.
B Wire is wandering.
C Incorrect shielding gas
B Increase the voltage or decrease wirespeed.
A Adjust voltage and current by adjusting the voltage control and the wirespeed control.
B Replace Velocity contact tip.
C Check shielding gas.
6 Weld cracking
7 Cold weld puddle
8 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly
9 Poor weld result from setup chart parameters
D Insufficient or excessive heat input
A Weld beads too small
B Weld penetration narrow and deep
C Excessive weld stresses
D Excessive voltage
E Cooling rate too fast
D Decrease voltage.
E Slow the cooling rate by preheating part to be welded or cool slowly.
A Check all welding cable connections.
A Loose welding cable connection.
B Low primary voltage
C Fault in power source
The MIG Gun has been connected to the wrong voltage polarity on the front panel.
B Contact supply authority.
C Have an Accredited Tweco Service Provider test then replace the faulty component.
Connect the MIG Polarity Cable to the positive (+) welding terminal for solid wires and gas shielded flux cored wires.
Refer to the electrode wire manufacturer for the correct polarity.
Contact tip has arc marks in the bore causing excessive drag on the wire.
D Adjust the wirespeed control or the voltage control.
A Decrease travel speed
B Reduce current and voltage and increase MIG Gun travel speed or select a lower penetration shielding gas.
C Increase weld metal strength or revise design
Replace the contact tip with only a Genuine Tweco Velocity contact tip.
Table 4-4: MIG (GMAW /FCAW) Welding Problems
Manual 0-5157 4-7 BASIC WELDING
FABRICATOR 211i BASIC WELDING
4.03 STICK (SMAW) Basic Welding Technique
Size of Electrode
The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
Electrode Polarity
Electrodes are generally connected to the ELECTRODE HOLDER 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 Accredited Tweco Distributor.
4.04 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 suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result. Hardened zone and under-bead 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 application.
B. Austenitic manganese steels
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
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when 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.
Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.
Welding Position
The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-11 through 4-18.
BASIC WELDING 4-8 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Art # A-07687
Figure 4-11: Flat Position, Down Hand Butt Weld
Art# A-07693
Figure 4-17: Overhead Position, Butt Weld
Art # A-07688
Figure 4-12: Flat Position, Gravity Fillet Weld
Art # A-07689
Figure 4-13: Horizontal Position, Butt Weld
Art # A-07690
Figure 4-14: Horizontal-Vertical (HV) Position
Art # A-07694
Figure 4-18: 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 surfaces. Typical joint designs are shown in Figure 4-19.
Art A-07691
Figure 4-15: Vertical Position, Butt Weld
Figure 4-16: Vertical Position, Fillet Weld
Manual 0-5157
Art # A-07692
4-9 BASIC WELDING
FABRICATOR 211i
Open Square Butt
Joint
Gap varies from
1/16” (1.6mm) to 3/16” (4.8mm)
depending on plate thickness
Single Vee Butt Joint
Not less than
45 °
BASIC WELDING
Single Vee Butt Joint
Not less than
70 °
1/16” (1.6mm) max
1/16” (1.6mm)
Double Vee Butt Joint
Not less than
70 °
1/16” (1.6mm) max
Lap Joint
Fillet Joint
Corner Weld
Tee Joints
(Fillet both sides of the joint)
1/16” (1.6mm)
Edge Joint
Plug Weld Plug Weld
Art # A-10672
Figure 4-19: 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 worrying 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.
BASIC WELDING 4-10 Manual 0-5157
BASIC WELDING
Striking the Arc
Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty due to the tip of the electrode "sticking" to the work piece.
This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough.
A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck.
As soon as the arc is established, maintain a 1/16" -1/8"
(1.6 mm - 3.2 mm) gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.
Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.
20°
Art # A-10673
1/16” (1.6 mm)
Figure 4-20: Striking an Arc
Arc Length
The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld to detach it.
Contact or "touch-weld" electrodes such as E7014 do not stick in this way, and make welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.
FABRICATOR 211i
If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the bead will be too large.
Making Welded Joints
Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1/16" - 3/32" (1.6 mm - 2.4 mm) gap between them and tack weld at both ends.
This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment.
Plates thicker than 1/4" (6.4 mm) should have their mating edges beveled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 1/8" (3.2 mm) E7014 electrode at
100 amps, deposit a run of weld metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a well-formed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.
20°-30°
Electrode Tack Weld
Tack Weld
Figure 4-21: Butt Weld
Art # A-07697_AB
Art # A-07698
Figure 4-22: Weld Build up Sequence
Manual 0-5157 4-11 BASIC WELDING
FABRICATOR 211i
Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-22. The width of weave should not be more than three times the core wire diameter of the electrode. When the joint is completely filled, the back is either machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular crosssection made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-14.
A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together 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
4-23. Do not attempt 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. Multiruns can be made as shown in Figure 4-24. Weaving in HV fillet welds is undesirable.
45° from vertical
60° - 70° from line of weld
BASIC WELDING
Art # A-07700_AB
6
3
1
5
2 4
Figure 4-24: Multi-runs in HV Fillet Weld
C. Vertical Welds
1. Vertical Up
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 electrode and set the current at
100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Figure 4-25. Use a short arc, and do not attempt to weave on the first run. When the first run has been completed de-slag the weld deposit and 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 each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 4-26 illustrates multi-run technique and Figure 4-27 shows the effects of pausing at the edge of weave and of weaving too rapidly.
Art # A-07701
Figure 4-25: Single Run Vertical Fillet Weld
Art # A-07699_AB
Figure 4-23: Electrode Position for HV Fillet Weld
BASIC WELDING 4-12 Manual 0-5157
BASIC WELDING
Art # A-07702
FABRICATOR 211i
Art # A-07704
Figure 4-28: Overhead Fillet Weld
Figure 4-26: Multi Run Vertical Fillet Weld
Art # A-07703
Figure 4-27: Examples of Vertical Fillet Welds
2. Vertical Down
The E7014 electrode makes welding in this position particularly easy. Use a 1/8" (3.2 mm) electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel
(Figure 4-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead fillet welds. Use a 1/8" (3.2 mm)
E6013 electrode at 100 amps, and deposit the first run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex, due to the effect of gravity before the metal freezes.
Manual 0-5157 4-13
Distortion
Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other 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.
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions.
In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to flow plastically, 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 of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in 5/64" (2.0 mm) sheet, the contracting weld metal may cause the sheet to become distorted.
BASIC WELDING
FABRICATOR 211i
B. Expansion and Contraction of Parent Metal in the Fusion Zone:
While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or
"along the weld", it meets considerable resistance, and to fulfill the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset".
When the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen.
The metal in the weld area is stretched (plastic deformation), 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 4-29 and 4- 30 illustrate how distortion is created.
Art # A-07705_AB
Weld Upsetting
Expansion with compression
Cool Hot Hot
Figure 4-29: Parent Metal Expansion
Art # A-07706_AC
Weld
Permanent Upset
Contraction with tension
Figure 4-30: Parent Metal Contraction
Overcoming Distortion Effects
There are several methods of minimizing distortion effects.
A. Peening
This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.
BASIC WELDING 4-14
BASIC WELDING
B. Distribution of Stresses
Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences.
Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it.
Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion.
C. Restraint of Parts
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.
D. Presetting
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 distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment.
A simple example is shown in Figure 4-31.
E. Preheating
Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-32 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 reducing distortion.
Art # A-07707
Figure 4-31: Principle of Presetting
Manual 0-5157
BASIC WELDING
Preheat
B
Weld
C
Art # A-07708
Preheat
Dotted lines show effect if no preheat is used
Figure 4-32: Reduction of Distortion by Preheating
Art # A-07709
4
3
2
FABRICATOR 211i
1
Art # A-07711_AB
Figure 4-35: Step back Sequence
Art # A-07428_AB
Figure 4-36: Chain Intermittent Welding
Art # A-07713_AB Figure 4-33: Examples of Distortion
2
3
1
Art # A-07710_AB
Block Sequence.
The spaces between the welds are filled in when the welds are cool.
Figure 4-34: Welding Sequence
Figure 4-37: Staggered Intermittent Welding
Manual 0-5157 4-15 BASIC WELDING
FABRICATOR 211i
4.04 STICK (SMAW) Welding Troubleshooting
FAULT
1 Welding current varying
CAUSE
ARC FORCE is set at a value that causes the welding current to vary excessively with the arc length.
BASIC WELDING
REMEDY
Reduce the ARC FORCE until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you
“dig” the electrode into the workpiece.
2 A gap is left by failure of the weld metal to fill the root of the weld.
A Welding current too low
B Electrode too large for joint.
C Insufficient gap.
A Increase welding current.
B Use smaller diameter electrode.
C Allow wider gap.
3 Non-metallic particles are trapped in the weld metal.
A Non-metallic particles may be trapped in undercut from previous run.
A If a bad undercut is present clean slag out and cover with a run from a smaller gauge electrode.
B Joint preparation too restricted.
C Irregular deposits allow slag to be trapped.
B Allow for adequate penetration and room for cleaning out the slag.
C If very bad, chip or grind out irregularities.
D Lack of penetration with slag trapped beneath weld bead.
D Use smaller electrode with sufficient current to give adequate penetration. Use suitable tools to remove all slag from comers.
E Clean joint before welding.
E Rust or mill scale is preventing full fusion.
F Wrong electrode for position in which welding is done.
F Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult.
Incorrect sequence
Insufficient gap
Art # A-04273
Figure
4-38: Example of insufficient gap or incorrect sequence
Table 4-5a:
BASIC WELDING 4-16 Manual 0-5157
BASIC WELDING FABRICATOR 211i
FAULT CAUSE
4 A groove has been formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut).
A Welding current is too high.
C Angle of the electrode is incorrect.
A Reduce welding current.
B Welding arc is too long.
B Reduce the length of the welding arc.
C Electrode should not be inclined less than 45° to the vertical face.
D Joint preparation does not allow correct electrode angle.
D Allow more room in joint for manipulation of the electrode.
E Electrode too large for joint.
E Use smaller gauge electrode.
F Insufficient deposit time at edge of weave.
F Pause for a moment at edge of weave to allow weld metal buildup.
G Power source is set for
MIG (GMAW) welding.
G Set power source to STICK (SMAW) mode.
5 Portions of the weld run do not fuse to the surface of the metal or edge of the joint.
A Small electrodes used on heavy cold plate.
A Use larger electrodes and preheat the plate.
B Welding current is too low. B Increase welding current.
C Wrong electrode angle.
C Adjust angle so the welding arc is directed more into the base metal.
D Travel speed of electrode is too high.
E Scale or dirt on joint surface.
REMEDY
D Reduce travel speed of electrode.
E Clean surface before welding.
Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high
Art # A-04274_AB
Lack of inter-run fusion
Lack of side fusion, scale dirt, small electrode, amperage too low
Lack of Root Fusion
Figure 4-39: Example of Lack of Fusion
Table 4-5b: STICK (SMAW) metal welding trouble shooting
Manual 0-5157 4-17 BASIC WELDING
FABRICATOR 211i
4.05 TIG (GTAW) Basic Welding Technique
BASIC WELDING
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
Work Piece
Can Be Any Commercial
Metal
Gas Cup
Either Ceramic,
High-lmpact or
Water Cooled
Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Addition of Filler Metal
Inert Gas
Shields Electrode and Weld Puddle
Figure 4-40: TIG (GTAW) Welding Application Shot
Tungsten Electrode Current Ranges
Electrode Diameter
0.040” (1.0mm)
1/16” (1.6mm)
3/32” (2.4mm)
DC Current (Amps)
30-60
60-115
100-165
1/8” (3.2mm)
5/32” (4.0mm)
135-200
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)
3/32” (2.4mm)
20-90
65-115
1/8” (3.2mm) 100-165
3/16” (5mm) 200-350
Table 4-7: Filler Wire Selection Guide
BASIC WELDING 4-18 Manual 0-5157
BASIC WELDING
Tungsten Electrode Types
Electrode Type
(Ground Finish)
FABRICATOR 211i
Thoriated 2%
Zirconated 1%
Welding Application Features
DC welding of mild steel, stainless steel and copper
High quality AC welding of aluminum, magnesium and their alloys.
Excellent arc starting,
Long life, High current carrying capacity
Self cleaning, Long life, Maintains balled end, High current carrying capacity.
Color Code
Red
White
Ceriated 2%
AC & DC welding of mild steel, stainless steel, copper, aluminum, magnesium and their alloys
Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.
Table 4-8
NOTE
The Fabricator 211i Inverter is not suited for AC TIG welding.
TIG Welding Filler Rods
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
1/4”
6.4mm
DC Current for Mild
Steel
35-45
40-50
45-55
50-60
60-70
70-90
80-100
90-115
115-135
140-165
160-175
170-200
DC Current for Stainless
Steel
20-30
25-35
30-45
35-50
40-60
50-70
65-85
90-110
100-125
125-150
135-160
160-180
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
Table 4-9
Filler Rod
Diameter (if required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Grey
Argon Gas
Flow Rate
CFH
10-15
10-15
15
15
20
20
Joint Type
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
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 Operating Manual.
Manual 0-5157 4-19 BASIC WELDING
FABRICATOR 211i
4.06 TIG (GTAW) Welding Problems
FAULT
1 Excessive bead build up or poor penetration or poor fusion at edges of weld.
2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through.
3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.
CAUSE
Welding current is too low
Welding current is too high
Travel speed too fast
BASIC WELDING
REMEDY
Increase weld current and/or faulty joint preparation.
Decrease weld current.
Reduce travel speed.
4 Weld bead too wide or excessive bead build up or excessive penetration in butt joint.
5 Uneven leg length in fillet joint
Travel speed too slow Increase travel speed.
Wrong placement of filler rod
Re-position filler rod.
6 Electrode melts or oxidizes when an arc is struck.
A TIG Torch lead connected to positive welding terminal.
A Connect TIG Torch lead to negative welding terminal.
B No gas flowing to welding region.
B Check the gas lines for kinks or breaks and gas cylinder contents.
C TIG Torch is clogged with dust or dirt.
D Gas hose is cut.
C Clean TIG Torch.
D Replace gas hose.
E Gas passage contains impurities.
E Disconnect gas hose from the rear of
Power Source then raise gas pressure and blow out impurities.
F Turn ON.
F Gas regulator turned
OFF.
G TIG Torch valve is turned OFF.
G Turn ON.
H The electrode is too small for the welding current.
H Increase electrode diameter or reduce the welding current.
I Power source is set for
MIG welding.
I Set Power Source to LIFT TIG mode.
BASIC WELDING 4-20 Manual 0-5157
BASIC WELDING
FAULT
7 Dirty weld pool
8 Poor weld finish
9 Arc start is not smooth.
FABRICATOR 211i
CAUSE REMEDY
A Electrode contaminated by contact with work piece or filler rod material.
A Clean the electrode by grinding off the contaminates.
B Work piece surface has foreign material on it.
B Clean surface.
C Gas contaminated with air.
C Check gas lines for cuts and loose fitting or change gas cylinder.
Inadequate shielding gas.
A Tungsten electrode is too large for the welding current.
Increase gas flow or check gas line for gas flow problems.
A Select the right size electrode. Refer to
Tweco Electrode Selection Chart.
B The wrong electrode is being used for the welding job.
B Select the right electrode type. Refer to
Tweco Electrode Selection Chart.
C Gas flow rate is too high.
C Select the right rate for the welding job.
Refer to Table 4-9.
D Incorrect shielding gas is being used.
D Select the right shielding gas.
E Poor work clamp connection to work piece.
E Improve connection to work piece.
10 Arc flutters during TIG welding.
11 Tungsten blackens due to lack of shielding gas
Tungsten electrode is too large for the welding current.
Select the right size electrode. Refer to
Tweco Electrode Selection Chart.
A Gas valve on the TIG
Torch has not been turned ON.
B Gas cylinder valve OFF or TIG Torch hose not connected to regulator.
A Turn ON TIG Torch gas valve before you commence welding.
B Turn ON gas cylinder valve or connect TIG
Torch hose to regulator.
Table 4-10: TIG (GTAW) Welding Problems
Manual 0-5157 4-21 BASIC WELDING
FABRICATOR 211i BASIC WELDING
This Page Intentionally Blank
BASIC WELDING 4-22 Manual 0-5157
PROBLEMS/SERVICE FABRICATOR 211i
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE
REQUIREMENTS
5.01 Power Source Problems
FAULT
1 Electricity Supply is ON, power indicator is illuminated however unit will not commence welding when the torch trigger switch is depressed.
2 Fault Indicator is illuminated and unit will not commence welding when the torch trigger switch is depressed.
3 Unit will not feed wire in
MIG mode.
4 Welding wire continues to feed when torch trigger is released.
5 Welding arc cannot be established in MIG mode.
6 Inconsistent wire feed.
CAUSE
A Power source is not in the correct mode of operation.
B Faulty torch trigger.
Duty cycle of power source has been exceeded.
A Electrode wire stuck in conduit liner or contact tip
(burn-back jam).
REMEDY
A Set the power source to the correct mode of operation with the process selection switch.
B Repair or replace torch trigger switch/lead.
Leave the power source switched ON and allow it to cool.
Note that fault indicator must be extinguished prior to commencement of welding.
A Check for clogged / kinked MIG gun conduit liner or worn contact tip. Replace faulty components.
B Internal fault in power source
B Have an Accredited Tweco
Service Provider investigate the fault.
A Trigger mode selection switch is in 4T latch mode.
A Change the trigger mode selection switch from 4T latch mode to 2T normal mode.
B Torch trigger leads shorted. B Repair or replace torch trigger switch/lead.
A MIG gun polarity lead is not connected into a welding output terminal.
A Connect the MIG gun polarity lead to either the positive welding output terminal or the negative welding output terminal as required.
B Poor or no work lead contact.
B Clean work clamp area and ensure good electrical contact.
A Worn or dirty contact tip.
A Replace if necessary.
B Worn feed roll.
C Excessive brake tension on wire reel hub.
D Worn, kinked or dirty conduit liner
B Replace.
C Reduce brake tension on spool hub
D Clean or replace conduit liner
Manual 0-5157 5-1 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i
FAULT CAUSE
7 No gas flow in MIG mode.
A Gas hose is damaged.
B Gas passage contains impurities.
PROBLEMS/SERVICE
REMEDY
A Replace or repair.
B Disconnect gas hose from the rear of power source and blow out impurities.
8 Gas flow continues after the trigger switch has been released (MIG mode).
C Gas regulator turned OFF.
C Turn ON regulator.
D Empty gas cylinder.
D Replace gas cylinder.
Gas valve has jammed open due to impurities in the gas or the gas line.
Have an accredited Tweco service provider repair or replace gas valve.
9 Power indicator will not illuminate and welding arc cannot be established.
10 TIG electrode melts when arc is struck.
11 Arc flutters during TIG welding.
The Electricity Supply has exceeded voltage limits of the power source.
TIG torch is connected to the (+) VE terminal.
Tungsten electrode is too large for the welding current.
Table 5-1: Power Source Problems
Ensure that the Electricity Supply is within 115V ± 10% or
208/230VAC ± 10%.
Connect the TIG torch to the (-)
VE terminal.
Select the correct size of tungsten electrode. Refer to Table
4-7.
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 Tweco Service Provider. Disconnect the
Welding Power Source from the Electricity Supply before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Tweco's original specifications.
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 Tweco 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 0-5157
PROBLEMS/SERVICE FABRICATOR 211i
Components to be Tested
Minimum Insulation
Resistance (M Ω )
Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)
All circuits to exposed conductive parts
Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage exceeding extra low voltage
5
2.5
10
Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage not exceeding extra low voltage
1
Separate welding circuit to separate welding circuit 1
Table 5-2: Minimum Insulation Resistance Requirements: Tweco Inverter Power Sources
C. Earthing
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 Tweco 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 Tweco 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
Tweco Service Provider.
Manual 0-5157 5-3 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i
Power Source Calibration
PROBLEMS/SERVICE
A. Schedule
Output testing of all Tweco Inverter 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 5-3 below shall be conducted by an accredited Tweco service agent.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable Tweco power source specifications
Output Voltage (V) to be checked to ensure it falls within applicable Tweco power source specifications
Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Tweco power source / wire feeder specifications
Accuracy of digital meters to be checked to ensure it falls within applicable Tweco power source specifications
Table 5-3: 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 measurement in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized.
PROBLEMS AND ROUTINE SERVICE 5-4 Manual 0-5157
PROBLEMS/SERVICE
5.03 Cleaning the Welding Power Source
FABRICATOR 211i
WARNING
There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Electricity Supply before disassembling.
To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current.
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of regulator and pressure
Visual check of torch
Consumable parts
Weekly
Manual 0-5157
Art # A-10502_AB
Visually inspect the torch body and consumables
3 Months
Visually inspect the cables and leads.
Replace as needed
Replace all broken parts
Clean 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.
5-5 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i PROBLEMS/SERVICE
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 particles 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.
PROBLEMS AND ROUTINE SERVICE 5-6 Manual 0-5157
REPLACEMENT PARTS
SECTION 6: KEY SPARE PARTS
6.01 Tweco Fusion 220A MIG Gun
Torch Part No: F220TA-12-3035
Figure 6-1
Art# A-11672_AB
FABRICATOR 211i
5
Item
No.
Description Part No.
1
2
Velocity Nozzle**
Velocity Contact Tip**
3
4
Handle / Trigger Repair Kit
Conduit Assembly*
5A Tweco Rear Connector
5B Tweco Control Wire
VNS-50
VNS-50F
VNS-62
VNS-62F
VNS-37
VNS-37F
VNS-75FAS
VTS-23
VTS-30
VTS-35
VTS-40
VTS-45
VTS-364
VTSA-364
VTS-52
VTS-116
VTSA-116
VTS-564
F80
WS42-3035-15
350-174H
35K-350-1
5C Tweco Control Wire & Plug WS-354-TA-LC
Table 6-1: Tweco Fusion 220A MIG Gun Parts
** Patent Pending
* Refer to Tweco Catalog No. 64-2103 for additional
options.
Manual 0-5157 6-1 REPLACEMENT PARTS
FABRICATOR 211i
6.02 Power Source Spare Parts
REPLACEMENT PARTS
REPLACEMENT PARTS
Figure 6-2
6-2 Manual 0-5157
REPLACEMENT PARTS
29
30
31
32
33
24
25
26
27
28
19
20
21
22
23
14
15
16
17
18
38
39
40
34
35
36
37
11
12
13
8
9
6
7
10
3
4
5
Item
1
2
FABRICATOR 211i
W7005610
W7005625
W7005556
W7005560
W7005559
W7005558
W7004972
W7005630
W7005629
W7004943
W7003242
W7005623
W7004911
W7005617
W7005608
W7005609
W7004966
W7005619
W7004967
W7005557
870734
W7004940
W7005632
W7005561
Part Number
W7005621
W7005638
W7005602
W7005607
W7005603
W7004906
W4014800
W7005622
W7003010
W7003033
W7003215
W7004909
W7004955
Description
PCB Power, Fab 211i
PCB Control, Fab 211i
PCB Display, Fab 211i
PCB Spool Gun, Fab 211i
Wiredrive Assembly, Fab 211i
Thumbscrew,Feedroll Positioner
DRIVE RL2 Roll, .023/.035 “V”
Fan Assembly, Fab 211i UL/CSA
Rectifier Bridge,1000V,50A
Gas Solenoid Valve Assy
Gas Inlet Fitting
Connector Socket,50 Dinse
Connector Plug,50 Dinse
Socket,8 Pin,w/ Harness
Switch CB,Main On-Off
CT, Output
Spool Hub Assembly
Washer,Friction,Spool Hub
Spool Hub
Adapter,Tweco 4,141i-211i
Guide,Inlet,.023-.045 (not shown)
Guide,Outlet,.023-.045
Front, Panel, Fab 211i UL/CSA
Panel, Base, Fab 211i
Center Panel, Fab 211i
Rear, Panel, Fab 211i UL/CSA
Panel, Cover, Fab 211i (not shown)
Panel, Door, Fab 211i (not shown)
Panel,Control,Fab 211i
Knob,1/4” IDx1” ODx0.9” H
Knob,1/4” IDx1.25” ODx.9” H
Circuit Breaker,4A
Switch,250V/2A
Knob,1/4” IDx.72” ODx.9” H
PCB, Burnback Potentiometer
Shroud, WF Motor, 211i
Label, Identification, Fab 211i (not shown)
W7005562
7978044PKD
Setup chart English version (not shown)
Large Spring, for One Pound Spool (not shown)
W7005635 Latch, Door, Slide (not shown)
Table 6-2: Fabricator 211i Parts
Manual 0-5157 6-3 REPLACEMENT PARTS
FABRICATOR 211i REPLACEMENT PARTS
This Page Intentionally Blank
REPLACEMENT PARTS 6-4 Manual 0-5157
APPENDIX FABRICATOR 211i
APPENDIX 1: FABRICATOR 211i CIRCUIT DIAGRAM
Manual 0-5157
BLACK
1 +24VDC
BLACK
RED
+24CDC 1
N/A 2
+
MD
+24VDC
INPUT 230V/115V
OUTPUT CONTROL SIGNAL
+24VDC 1
GND 2
-24VDC 3
+15V 1
IGBT Driver A 2
IGBT Driver B 3
IGBT Driver B 4
IGBT Driver A 5
Over Current Signal 6
GND 7
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
RED
YELLOW
RED
BLACK
2 +5VDC
1
2 PWM (MOTOR DRIVER 5VDC PEAK)
1 PWM RETURN
1 +24VDC
2 GND
3 -24VDC
1 +15V
2 IGBT Driver A
3 IGBT Driver B
4 IGBT Driver B
5 IGBT Driver A
6 Over Current Signal
7 GND
JC
WVIN
QF / DY
GUN
BLACK
RED
GRAY
YELLOW
WHITE
RED
1 - OUTPUT
3 + OUTPUT
1 +15V
2 -15V
3 Current Feedback
4 GND
GUN
MB
1
1
1 +15VDC
1
1 +15VDC
LOCAL
REMOTE
(REMOVE VOLTAGE) POT WIPER 8
(REMOVE AMPS/WIRESPEED) POT WIPER 7
REMOTE CONTROL IN (+15V ) 6
5
SPOOL GUN (+24VDC) 4
TORCH SWITCH RIN (0VDC) 3
TORCH SWITCH (+24V) 2
SPOOL GUN (0V) 1
1
-15VDC
Amps / Wirefeed Display
Power Fault
Display PCB4
Process MIG
LIFT TIG
STICK
Trigger
Volts Display
2T Normal
4T Latch
Wirefeed / Amps
Volts
Down Slope / Arc Force(%) Arc Control
Art#A-11249_AC
A-1 APPENDIX
This Page Intentionally Blank
This Page Intentionally Blank
TWECO - LIMITED WARRANTY TERMS
LIMITED WARRANTY: Tweco ®, Inc, A Victor Technologies Company, warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Tweco products as stated below, Tweco shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Tweco’s sole option, of any components or parts of the product determined by Tweco to be defective.
TWECO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: TWECO SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT
OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION.
The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Tweco whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Tweco is authorized to change this warranty in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED
WHICH IN TWECO’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY TWECO PRODUCT.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-
AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Tweco delivered the product to the authorized distributor.
WARRANTY SCHEDULE
5 Years Parts* / 3 Years Labor
ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster
Portafeed, Ultrafeed, Ultima 150, WC 100B
* 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards.
* 3 years on Power Supply Components
2 Years Parts and Labor Unless specified
Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy
Victor Regulator for Fabricator 181i (No labor)
1 Years Parts and Labor Unless specified
95S, Water recirculators
All Plasma Welding consols (i.e WC-1 Controller, WT Timer,
WF-100 Capstain Feeder, etc)
180 days parts and Labor Unless specified
Plasma Welding Torch and leads packages
Gas Regulators "Supplied with power sources" (No Labor)
90 days parts / No Labor
Remote Controls
MIG and TIG Torches (Supplied with power sources)
Replacement repair parts
30 days parts / No Labor
MIG Torch for Fabricator 181i
5-2-1 years Parts / No Labor
FirePower® Welders
5 Years Parts / No Labor
Victor® Professional
Victor Technologies limited warranty shall not apply to:
Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due normal wear
* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Victor Technologies repair facility within thirty (30) days of the repair.
* No employee, agent, or representative of Victor Technologies is authorized to change this warranty in any way or grant any other warranty, and Victor Technologies shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of Victor Technologies’s obligations to purchaser with respect to the product.
* This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Victor
Technologies's sole judgment, impaired the safety or performance of any Victor Technologies product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada
Canada Customer Care
Ph 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph +44 1257-261755
Fax: +44 1257-224800
Milan, Italy
Customer Care
Ph +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph 6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
Customer Care
Ph +603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph 1300-654-674 (tollfree)
Ph 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph 61-3-9474-7508
Fax: 61-3-9474-7488
Shanghai, China
Sales Office
Ph +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph +65 6832-8066
Fax: +65 6763-5812
I N N O V A T I O N T O S H A P E T H E W O R L D ™
U.S. Customer Care: 800-426-1888 / FAX 800-535-0557
Canada Customer Care: 905-827-4515 / FAX 800-588-1714
International Customer Care: 940-381-1212 / FAX 940-483-8178
© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in China
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