FABRICATOR 181i ® 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Revision: AF Issue Date: June 12, 2013 Manual No.: 0-5191 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 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................................................ 4-6 Stick (SMAW) Basic Welding Technique.......................................................... 4-9 Effects of Stick Welding Various Materials.....................
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Fabricator 181i 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 181i 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 181i 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 181i 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 181i 1.02 General Safety Information for Victor CS Regulator LEAD 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 181i C Ventilation ! 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. 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 181i ! Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. WARNING DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition immediately. 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.
Fabricator 181i 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 181i 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 181i 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 181i 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 181i 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 181i AVERTISSEMENT AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES. 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. Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression. 1.
Fabricator 181i de tirer des conclusions définitives quant aux risques éventuels ou de proposer des stratégies 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.
Fabricator 181i 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. ! 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. 2.
Fabricator 181i 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 181i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.
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 181i 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 181i 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 181i 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, 180 amperes at 23 volts.
Fabricator 181i 2.09 Specifications DESCRIPTION FABRICATOR 181i MULTI PROCESS 3 IN 1 WELDER Power Source Part No. W1003180 Power Source Dimensions H16.14" x W8.27" x D17.72" (410mm x 210mm x 450mm) Power Source Mass 32.2lb(14.
Fabricator 181i NOTE The recommended time delay fuse or circuit breaker size is 50 amp. An individual branch circuit capable of carrying 50 amperes and protected by fuses or circuit breaker is recommended for this application.
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SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment Fabricator 181i 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.
Fabricator 181i WARNING The Fabricator 181i 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.
Fabricator 181i Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned ON, the inrush circuit provides pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn ON after the input capacitors have charged to operating voltage (after approximately 5 seconds) NOTE Damage to the PCA could occur if 265V AC or higher is applied to the Primary Power Cord.
Fabricator 181i 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.
Fabricator 181i ! 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 3-2) to the cylinder valve. Tighten securely with a wrench. WARNING Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with any other gas.
Fabricator 181i 9. Slowly and carefully open the cylinder valve (Figure 3-3) until the maximum pressure shows on the high pressure gauge. 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 downstream equipment, hose, hose fitting, outlet fitting or low-pressure gauge. Check for leaks using an approved leak detector solution.
Fabricator 181i 3.
Fabricator 181i 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. It also displays preview amperage in both the STICK and LIFT TIG modes only then actual amperage (weld current) once an arc has been established. At times of non-welding, the amperage meter will display a preview value in both STICK and LIFT TIG modes.
Fabricator 181i 6. MIG Gun 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 flux cored (gasless) wire, the polarity lead is generally connected to the negative welding terminal (-).
Fabricator 181i Note that the Local/ Remote Switch (Control No. 18) located in the wirefeed compartment should be set to Remote for remote amperage/voltage controls to operate. 9. 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. NOTE The preview functionality provided on this power source is intended to act as a guide only.
Fabricator 181i 2T (Normal Mode) In this mode, the MIG or TIG Trigger Switch must remain depressed for the welding output to be active. Press and hold the MIG or TIG Trigger Switch to activate the Power Source (weld). Release the MIG or TIG 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 MIG or TIG Trigger Switch and the output will remain active.
Fabricator 181i 15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation) The Gas Inlet connection is used to supply the appropriate MIG welding gas to the Power Source. Refer to section 3.15 or 3.16 for MIG (FCAW/GMAW) set up details. ! WARNING Only Welding Shielding Gases specifically designed for arc welding applications should be used. 16. ON / OFF Switch This switch is used to turn the Power Source ON/OFF.
Fabricator 181i 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. 10A Fuse The 10A fuse is used to protect the spool gun motor. 3.11 Attaching the Tweco Fusion 180A Gun Fit the Tweco Fusion MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adaptor and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter.
Fabricator 181i 3.12 Torch Adapter Thumb Screw Replacement 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. Screws Securing Block Art # A-11483 3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang downwardly.
Fabricator 181i 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. 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.
Fabricator 181i Spring Plastic Spacer Friction Washer 4”（100mm） Diameter spool Brass Flat Washer Flat Washer Nut with Nylon Insert Art # A-10357 Figure 3-9: 4" (100mm)Diameter Spool Installation 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 3-10. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake.
Fabricator 181i Alignment pin Alternate Alignment Pin Position Brass Flat Washer Wire Spool Hub 8” (200mm) diameter spool Friction Washer Plastic Spacer Spring Flat Washer Spool Hub Nut Nut with Nylon Insert Art # A-10358 Figure 3-10: 8" (200mm) Diameter Spool Installation 3.15 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in an counterclockwise.
Fabricator 181i Wire Drive Tension Screw Pressure Roller Arm Outlet Guide Inlet Guide Art # A-10359 Figure 3-11: Wire Drive Assembly Components MIG Welding Wire Art # A-10360 Figure 3-12: MIG Welding Wire - Installation 3.16 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 WIREFEED without slippage.
Fabricator 181i 3.17 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an counterclockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions. A dual groove feed roller is supplied as standard. It can accommodate 023"(0.6mm) -.030" (0.8mm) diameter hard wires. Select the roller required with the chosen wire size marking facing outward.
Fabricator 181i Wire Reel Brake Adjustment Nut Art # A-10361 Figure 3-15: Wire Reel Brake 3.19 Gas Regulator Operation With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator parts. 2. With valves on downstream equipment closed, adjust regulator to approximate working pressure.
Fabricator 181i 3.20 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 heavy duty bayonet type terminals.
Fabricator 181i Art # A-10362 Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. Positive Welding Terminal (+) Shielding Gas Hose Fitted with 5/8"-18 UNF connection MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead Primary Cord Work Lead Figure 3-16: Setup for MIG Welding with Gas Shielded MIG Wire 3.21 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A.
Fabricator 181i 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. Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead.
Fabricator 181i 3.22 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 shielding gas for the to the Shielding Gas Inlet on the rear panel of the Power Source. 1.
Fabricator 181i 3.23 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. 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 (+).
Fabricator 181i Art # A-10364 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. Positive welding terminal (+). MIG Gun polarity lead not connected. Work lead Negative welding terminal (-).
Fabricator 181i 3.24 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.
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SECTION 4: BASIC WELDING GUIDE Fabricator 181i 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 181i 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 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 181i 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). 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 Variables Most of the welding done by all processes is on carbon steel.
Fabricator 181i Transverse Angle Direction of Gun Travel Longitudinal Angle Axis of Weld Transverse and Longitudinal Nozzle Axes Leading or “Pushing” Angle (Forward Pointing) Art # A-08998_AB 90° Trailing or “Pulling” Angle (Backward Pointing) Nozzle Angle, Right Handed Operator Art # A-08999_AC Figure 4-10 Figure 4-9 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 materi
Fabricator 181i Tweco MIG, Lift TIG, Stick Wire Selection Chart Art # A-10366_AB Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart Manual 0-5191 4-5 BASIC WELDING GUIDE
Fabricator 181i 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 181i 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. 2 Wire spool unwinds and tangles. Wire spool brake is too loose. 3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding. B Replace feed roller if worn.
Fabricator 181i Basic MIG Welding Troubleshooting FAULT 1 Undercut 2 Lack of penetration CAUSE REMEDY A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed. B Incorrect MIG Gun angle B Adjust angle. C Excessive heat input C Increase the MIG Gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed. A Welding current too low A Increase welding current by increasing wire feed speed and increasing voltage.
Fabricator 181i 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.
Fabricator 181i 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 4-15 through 4-22.
Fabricator 181i 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 181i 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.
Fabricator 181i 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"(1.6mm) to 3/32"(2.4mm) 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.
Fabricator 181i Art # A-07700_AB 45° from vertical 6 60° - 70° from line of weld 3 5 1 2 4 Figure 4-24: Multi-runs in HV Fillet Weld Art # A-07699_AB Figure 4-23: Electrode Position for 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.
Fabricator 181i 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 181i 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.
Fabricator 181i 3 2 1 Art # A-07707 Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool.
Fabricator 181i 4.05 Stick (SMAW) Welding Troubleshooting FAULT 1 Welding current varying CAUSE REMEDY ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length. Reduce the ARC FORCE control knob until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.
Fabricator 181i 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 181i 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 181i 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 181i 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 181i 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.
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Fabricator 181i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Electricity Supply is ON, A Power Source is not in the cor- A Set the Power Source to the correct power indicator is illumirect mode of operation. mode of operation with the process nated however the Power selection switch. Source will not commence B Faulty torch trigger. B Repair or replace torch trigger welding when the torch trigswitch/lead. ger switch is depressed.
Fabricator 181i FAULT CAUSE REMEDY 8 Gas flow continues after the torch trigger switch has been released (MIG mode). 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. The Electricity Supply voltage has exceeded voltage limits of the Power Source. Ensure that the Electricity Supply voltage is within 208-265 VAC.
Fabricator 181i Components to be Tested Minimum Insulation Resistance (MΩ) Input circuit (including any connected control circuits) to welding circuit (including any connected control circuits) 5 All circuits to exposed conductive parts 2.
Fabricator 181i Power Source Calibration A. Schedule Output testing of all Tweco 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.
Fabricator 181i 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. 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.
Fabricator 181i 5.05 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.
Fabricator 181i SECTION 6: KEY SPARE PARTS 6.01 Tweco Fusion 180A MIG Gun Parts Item No. Torch Part No: F180TA-12-3035 Description Art# A-11672_AB Part No.
Fabricator 181i Art # A-11243_AC 6.
Fabricator 181i FABRICATOR 181i 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 43 Manual 0-5191 PART NUMBER W7004962 W7004963 W7003033 W7004970 W7004969 W7004905 W7004906 7977036 W7004947 W7003010 W7003215 W7004909 W7004955 W7004942 W7003053 W7004911 W7004912 W7005552 W7005555 W7004922 W7005554 W7004966 W7004925 W7004967 W7005553 W7004928 870734 W7004972 W7004957 W7004953 OTWAK/1S W7004961 W7004940 W70049
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Fabricator 181i APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM CONNECTOR LAYOUT DIAGRAM IFB J18 J1 DRIVE J16 J3 SOURCE PWM J5 CR J19 J7 FUNS MB J8 NTCS QF/DY OT GUN WVIN 1 2 3 4 ON J15 Art # A-11230 APPENDIX 1 Manual 0-5191 J13 J24 J10
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.
