FABRICATOR 141i ® 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Art # A-11510_AC Revision: AF Issue Date: October 31, 2013 Manual No.: 0-5145 3163339 Tweco.
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.
! WARNINGS Read and understand this entire Manual and your employer’s safety practices if applicable 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.
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 Arc Welding Hazards........................................................................................ 1-1 General Safety Information for Victor CS Regulator........................................... 1-5 Principal Safety Standards............................................................................... 1-7 Symbol Chart...............
TABLE OF CONTENTS SECTION 4: BASIC WELDING GUIDE ..................................................................... 4-1 4.01 4.02 4.03 4.04 4.05 4.06 4.07 MIG (GMAW/FCAW) Basic Welding Technique................................................ 4-1 MIG (GMAW/FCAW) Welding Troubleshooting................................................ 4-7 Stick (SMAW) Basic Welding Technique........................................................ 4-10 Effects of Stick Welding Various Materials.............................
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Fabricator 141i 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.
Fabricator 141i 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. 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. 5.
Fabricator 141i 1. Keep your head out of the fumes. Do not breathe the fumes. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 7. Do not weld on closed containers such as tanks or drums. 3. If ventilation is poor, use an approved air-supplied respirator. 8.
Fabricator 141i 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. ! 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.
Fabricator 141i ! 1.02 General Safety Information for Victor CS Regulator WARNING 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 correctly in the proper environment. 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 1.
Fabricator 141i C 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. Ventilation ! WARNING Adequately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concentrations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances.
Fabricator 141i 1.03 Principal Safety Standards 5. Inspect the cylinder valve for oil, grease, and damaged parts. ! Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. WARNING Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition immediately.
Fabricator 141i 1.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
Fabricator 141i 1.05 Precautions De Securite En Soudage A L’arc ! 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 CARDIAQUE (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.
Fabricator 141i 9. N’enroulez pas de câbles électriques autour de votre corps. 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder. 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.
Fabricator 141i 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.
Fabricator 141i 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. AVERTISSEMENT Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.
Fabricator 141i 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES. AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX. 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.
Fabricator 141i 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 : 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. 1.
Fabricator 141i manches et poches boutonnés. Il ne faut pas remonter vos manches ou les pantalons à revers. Quand vous travaillez dans un environnement non dédié au soudage ou découpage, portez toujours une protection des yeux appropriées ou un masque facial. ! 2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez un diable approprié pour les déplacer.
Fabricator 141i 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.
Fabricator 141i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.
Fabricator 141i 1.10 Declaration Of Conformity Manufacturer: Victor Technologies International, Inc. Address: 16052 Swingley Ridge Road, Suite 300 St. Louis, MO 63017 The equipment described in this manual has been designed to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive.
SECTION 2: INTRODUCTION Fabricator 141i 2.01 How to Use This Manual 2.03 Receipt of Equipment This Manual usually applies to the part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the word WARNING, CAUTION and NOTE may appear. Pay particular attention to the information provided under these headings.
Fabricator 141i 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.
Fabricator 141i 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, 100 amperes at 19 volts.
Fabricator 141i 2.09 Specifications DESCRIPTION Power Source Part No. Power Source Dimensions FABRICATOR 141i MULTI PROCESS 3 IN 1 WELDER W1003140 H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm) Power Source Weight 32.2lb(14.
Fabricator 141i NOTE The recommended time delay fuse or circuit breaker size is 20 amp. An individual branch circuit capable of carrying 20 amperes and protected by fuses or circuit breaker is recommended for this application.
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Fabricator 141i SECTION 3: INSTALLATION, OPERATION AND SETUP 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. 3.
Fabricator 141i WARNING The Fabricator 141i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 140 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.
Fabricator 141i NOTE Welding arc outs may be experienced if an extension cord is used when STICK welding when operating the Power Source on 95 VAC due to the lack of DC voltage at the STICK electrode. Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors.
Fabricator 141i 7. The time of day that welding or other activities are to be carried out. 8. The compatibility 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.
Fabricator 141i ! 4. Be sure that the flowmeter/ regulator has the correct pressure rating and gas service for the cylinder used. WARNING Use the flowmeter/ regulator for the gas and pressure for which it is designed. NEVER alter a flowmeter/ regulator for use with any other gas. 5. Carefully inspect the flowmeter/ 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.
Fabricator 141i ! a) If the high-pressure gauge reading drops, there is a leak in the cylinder valve, inlet fitting, or high-pressure gauge. WARNING Stand to the side of the cylinder opposite the flowmeter/ regulator when opening the cylinder valve. Keep the cylinder valve between you and the flowmeter/ regulator.
Fabricator 141i 3.
Fabricator 141i 1. Power Indicator The power indicator is illuminated when the Electricity Supply is applied to the Power Source and when the ON/OFF switch located on the rear panel is in the ON position. 2. Digital Wirespeed/Amperage Meter (Left Digital Display) This digital meter displays preview Wirespeed in MIG mode only then actual amperage (weld current) once an arc has been established.
Fabricator 141i 5. 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 Gun polarity lead), electrode holder lead or work lead. Positive welding current flows from the Power Source via 25mm Dinse style connector. It is essential, however, that the Dinse adapter and male plug are inserted and turned securely to achieve a sound electrical connection.
Fabricator 141i 1 2 2 3 4 1 5 4 3 8 7 6 Negative Trigger Switch Spool Gun Motor Positive 5 W 6 V Remote Volts in MIG (GMAW/FCAW) 7 8 Remote Wirespeed in MIG (GMAW/FCAW) mode Remote Amps in LIFT TIG (GTAW) mode Art # A-10421_AC Figure 3-7: Remote Control Socket Socket Pin Function 1 Spool gun motor (0V) 2 Trigger Switch Input 3 Trigger Switch Input 4 Spool gun motor (+24V DC) 5 5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Fabricator 141i 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.
Fabricator 141i 13. Digital Voltage Meter (Right Digital Display) The digital voltage meter is used to display the both the preview voltage (MIG mode only) and actual output voltage (all modes) of the Power Source. At times of non-welding, the voltage meter will display a preview value in MIG mode. This value can be adjusted by varying the multifunction control knob (Control No. 9).
Fabricator 141i 17. Intelligent Fan Control When Power Supply is first turned on it will default in MIG Mode. The Fan will operate for approximately 10 seconds, then shut down. When triggered in MIG mode, fan will not turn on until Power Supply reaches temperatures in which cooling is required. When in Lift TIG mode, as soon as output is enabled, the fan will come on immediately and will not shut down until welding has ceased and Power Supply is at proper operating temperature.
Fabricator 141i 3.11 Attaching the Fusion 140A MIG Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter. Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position.
Fabricator 141i 3.12 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in a counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm.
Fabricator 141i 3.13 Installing 4" (100mm) Diameter Spool As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 3-11. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake.
Fabricator 141i 3.14 Installing 8" (200mm) Diameter Spool As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool. In order to re-fit a 8" (200mm) spool assemble parts in the sequence shown below in Figure 3-12. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake.
Fabricator 141i 3.15 Feed Roller Pressure Adjustment 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 wire feed 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 debris.
Fabricator 141i 3.17 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut 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 3/8" (10mm) - 3/4" (20mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.
Fabricator 141i 3.18 Flowmeter/ Regulator Operation With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal parts. 2. With valves on downstream equipment closed, adjust flowmeter/ regulator to approximate working pressure.
Fabricator 141i 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 for further information) B. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C.
Fabricator 141i Art # A-10362 Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.
Fabricator 141i 3.20 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 3.10.12 for further information). B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C.
Fabricator 141i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead.
Fabricator 141i 3.21 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire Set the Process Selection Control to MIG for Spool Gun welding. 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 Argon shielding gas to the Shielding Gas Inlet on the rear panel of the Power Source. 1. Make sure the welding power source is turned OFF before connecting the welding gun.
Fabricator 141i 3.22 Setup for LIFT TIG (GTAW) Welding A. Select LIFT TIG mode with the process selection control (refer to Section 3.10.12 for further information). B. Using the supplied 50mm to 25mm DINSE adapter, connect the TIG torch to the negative welding terminal (-). Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. C.
Fabricator 141i Art # A-11576_AB 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.
Fabricator 141i 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 Dinse style connectors. 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.
Fabricator 141i 3.24 Torch Adapter Thumb Screw Replacement WARNING All power to unit should be removed. 1. Place unit on its back. Art # A-11482_AB 2. Remove 2 screws in bottom of the front panel. A securing block will become detached and fall free from the front panel as you turn each screw out. Set these aside for reassembly. Leave screws sitting in the pockets of the panel.
Fabricator 141i 3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang downwardly. Tension Knob Pressure Arm Art # A-11484 4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed. Push Upward Thumb Screw Fully Exposed Art # A-11485_AB 5. Remove damaged thumb screw and replace with new one. Art # A-11486 6. To reassemble, reverse steps 1 through 4.
SECTION 4: BASIC WELDING GUIDE Fabricator 141i 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 welding 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.
Fabricator 141i Position of MIG Gun The angle of MIG Gun to the weld has an effect on the width of the weld. Vertical Push Drag/Pull Art # A-07185_AB Figure 4-3 The welding 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. CAUTION Do not pull the welding MIG Gun back when the arc is established.
Fabricator 141i 10° to 20° Longitudinal Angle 10° Longitudinal Angle 30° to 60° Transverse 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 5° to 15° Longitudinal Angle Art # A-08996 Overhead Figure Weld 4-7 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" (10mm) to 3/4" (20.0mm).
Fabricator 141i 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. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 3/8" (10mm) stick-out 2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases weld current.
Fabricator 141i 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 16 ga. (1.6mm) or 1/8" (3.
Fabricator 141i Tweco MIG, Lift TIG, Stick Wire Selection Chart Art # A-11577_AD Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart BASIC WELDING GUIDE 4-6 Manual 0-5145
Fabricator 141i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG Gun. There are two main areas where problems occur with MIG, 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.
Fabricator 141i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the cabinet slipped Wire spool brake is too tight or drive roll tension not tight enough. 2 Wire spool unwinds and tangles Wire spool brake is too loose. 3 Wire slipping A Worn or incorrect feed roller size. Use a feed roller matched to the size you are welding. B Replace feed roller if worn.
Fabricator 141i FAULT 2 Lack of penetration CAUSE REMEDY A Welding current too low A Increase welding current by increasing wire feed speed and increasing voltage. B Joint preparation too narrow or B Increase joint angle or gap. gap too tight C Shielding gas incorrect 3 Lack of fusion 4 Excessive spatter 5 Irregular weld shape 6 Weld cracking 7 Cold weld puddle Manual 0-5145 C Change to a gas which gives higher penetration. Welding current too low Increase welding current.
Fabricator 141i FAULT CAUSE REMEDY 8 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly. The MIG Gun has been connected to the wrong voltage polarity on the front panel Connect the MIG Gun to the positive (+) welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.
Fabricator 141i Copper and Alloys The most important factor is the high rate of heat conductivity of copper, making pre-heating of heavy sections necessary to give proper fusion of weld and base metal. Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work.
Fabricator 141i Art A-07691 Figure 4-15: Vertical Position, Butt Weld Art # A-07692 Figure 4-16: Vertical Position, Fillet Weld Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld BASIC WELDING GUIDE 4-12 Manual 0-5145
Fabricator 141i 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.
Fabricator 141i 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.
Fabricator 141i 20°-30° Electrode Tack Weld Tack Weld Art # A-07697_AB Figure 4-21: Butt Weld Art # A-07698 Figure 4-22: Weld Build up Sequence 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.
Fabricator 141i Art # A-07700_AB 6 3 5 1 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"(3.2mm) E7014 Stick 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.
Fabricator 141i Art # A-07703 Figure 4-27: Examples of Vertical Fillet Welds 2. Vertical Down The E7014 Stick electrode makes welding in this position particularly easy. Use a 1/8"(3.2mm) 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.
Fabricator 141i 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.
Fabricator 141i 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. B.
Fabricator 141i Art # A-07709 Figure 4-33: Examples of Distortion 3 2 1 Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool.
Fabricator 141i 4.05 Stick (SMAW) Welding Troubleshooting FAULT CAUSE 1 Welding current varying REMEDY ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length. 2 A gap is left by A Welding current too low failure of the weld B Electrode too large for joint. metal to fill the root of the weld. C Insufficient gap. 3 Non-metallic par- A Non-metallic particles may ticles are trapped be trapped in undercut from previous run. in the weld metal.
Fabricator 141i FAULT CAUSE REMEDY 5 Portions of the A Small electrodes used on weld run do not heavy cold plate. fuse to the surface B Welding current is too low. of the metal or edge of the joint. C Wrong electrode angle. A Use larger electrodes and preheat the plate. B Increase welding current. C Adjust angle so the welding arc is directed more into the base metal. D Travel speed of electrode is too high. D Reduce travel speed of electrode. E Scale or dirt on joint surface.
Fabricator 141i 4.06 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based.
Fabricator 141i Tungsten Electrode Types Electrode Type (Ground Finish) Welding Application Features Color Code Thoriated 2% DC welding of mild steel, stainless steel and copper Excellent arc starting, Long life, High current carrying capacity Red Zirconated 1% High quality AC welding of aluminum, magnesium and their alloys. Self cleaning, Long life, Maintains balled end, High current carrying capacity.
Fabricator 141i 4.07 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or poor penetration or poor fusion at edges of weld. Welding current is too low Increase weld current and/or faulty joint preparation. 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through. Welding current is too high Decrease weld current. 3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart.
Fabricator 141i FAULT 7 Dirty weld pool CAUSE REMEDY A Electrode contaminated A Clean the electrode by grinding off the conby contact with work taminates. piece or filler rod material. B Work piece surface has B Clean surface. foreign material on it. C Gas contaminated with C Check gas lines for cuts and loose fitting or air. change gas cylinder. 8 Poor weld finish 9 Arc start is not smooth. Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems.
Fabricator 141i SECTION 5: Power Source PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Primary Power Supply is A Power Source is not in the correct A Set the Power Source to the correct ON, power indicator is illumode of operation. mode of operation with the process minated however the Power selection switch. Source will not commence B Welding leads, or polarity cable B Connect welding leads or polarity welding when the torch trignot connected. cable.
Fabricator 141i FAULT 6 Inconsistent wire feed. CAUSE A Fouled contact tip. REMEDY A Replace Velocity contact tip if necessary. B Drive roll tension not tight enough. B Tighten drive roll tension. C Worn feed roll. C Replace. D Excessive brake tension on wire reel hub. D Reduce brake tension on spool hub E Worn, kinked or dirty conduit liner. E Clean or replace conduit liner 7 No gas flow in MIG mode. A Gas hose is damaged. A Replace or repair. B Gas passage contains debris.
Fabricator 141i 5.02 Routine Service WARNING There are extremely dangerous voltage and power levels present inside this 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 Voltage before disassembling.
Fabricator 141i 5.03 Cleaning the Welding Power Source 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 Voltage before disassembling. 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.
Fabricator 141i SECTION 6: KEY SPARE PARTS 6.01 Tweco Fusion 140A MIG Gun Parts Torch Part No: 1017-1321 Item No. Description Art# A-11672_AB 1 2 5 Part No.
Fabricator 141i 31 Art # A-11811_AB 6.
Fabricator 141i FABRICATOR 141i POWER SOURCE SPARE PARTS ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Manual 0-5145 PART NUMBER W7006216 W7006227 W7003033 W7006226 W7006209 W7004906 7977036 W7004947 W7003010 W7003215 W7006210 W7004983 W7006224 W7004942 W7003053 W7004911 W7004912 W7006220 W7006223 W7004922 W7006222 W7004966 W7004925 W7004967 W7006221 W7006208 870734 W7004972 W7006211 W7004953 OTWAK/1S W7004961 W7004940 W7006214 W7
Fabricator 141i 6.03 Hardware List ITEM DESCRIPTION WHERE USED Qty 1 Nut Lock, M20 25mm Dinse 2 2 Screw Hexagon, M10 × 1.5-20 ST ZP 25mm Dinse 2 3 Washer, M4, ET Lock Handle 2 Side Panel 3 Handle 2 Rear Panel 2 Front Panel 3 Side Panel 3 Door Assy 2 Front Panel 2 Rear Moulding 2 8 Pin Remote Socket 2 Front PCB 4 4 5 6 SC PHCR M4 × 0.7-10 ST ZP SC PHCR M4 × 0.7-16 ST BK SC PHCR ST 6G × 3/8 STBK 7 Nut Hexagon M4 × 0.7 ST ZP Fan 4 8 SC PHSL M4 × 0.
Fabricator 141i 4 1 3 1 4 1 4 1 3 1 4 1 4 1 6 4 4 1 8 4 7 4 4 1 SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL 6 2 5 2 SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL 2 2 1 2 9 1 4 1 3 1 4 1 3 1 4 1 17 1 3 1 15 1 12 1 11 1 10 1 13 2 5 2 SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL 4 1 4 1 14 2 SCREW ITEM 4, 2 OFF USED TO SECURE DOOR ASSY TO BASE PANEL 16 1 Art # A-11932_AB Figure 6-3 Manual 0-5145 6-5 KEY SPARE PARTS
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Fabricator 141i APPENDIX: FABRICATOR 141i CIRCUIT DIAGRAM I 8 APPENDIX 2 Manual 0-5145
Fabricator 141i Art # A-11792 _AB Manual 0-5145 3 APPENDIX
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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.
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.
THE AMERICAS Denton, TX USA U.S.
