Tweco 141i User Manual

FABRICATOR® 141i

3163339

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

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 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.

Operating Manual Number 0-5145 for:
Tweco Fabricator 141i Portable System Package Part Number W1003141
Tweco Fabricator 141i Power Source Part Number W1003140
Tweco Fabricator 141i Portable System Package with Cart Part Number W1003142

Published by:
Victor Technologies, Inc.
16052 Swingley Ridge Road,
Suite 300 St. Louis, MO 63017
USA

www.victortechnologies.com

Copyright © 2013 by
Victor Technologies, 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: January 31, 2013
Revision Date: October 31, 2013

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

TABLE OF CONTENTS

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 General Safety Information for Victor CS Regulator .......................................... 1-5

1.03 Principal Safety Standards .............................................................................. 1-7

1.04 Symbol Chart .................................................................................................. 1-8

1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-9

1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-9

1.07 Informations Générales de Sécurité .............................................................. 1-14

1.08 Principales Normes De Securite ................................................................... 1-16

1.09 Graphique de Symbole .................................................................................. 1-17

1.10 Declaration Of Conformity ............................................................................ 1-18

SECTION 2: INTRODUCTION ............................................................................. 2-1

2.01 How to Use This Manual ................................................................................. 2-1

2.02 Equipment Identification ................................................................................. 2-1

2.03 Receipt of Equipment ...................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 Transportation Methods .................................................................................. 2-1

2.06 User Responsibility ......................................................................................... 2-2

2.07 Fabricator 141i Portable System Package (Part No. W1003141) .................... 2-2

2.08 Duty Cycle ....................................................................................................... 2-3

2.09 Specifications ................................................................................................. 2-4

2.10 Options and Accessories ................................................................................ 2-5

SECTION 3: INSTALLATION, OPERATION AND SETUP ................................................ 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location .......................................................................................................... 3-1

3.03 Ventilation ....................................................................................................... 3-1

3.04 Electricity Supply Voltage .............................................................................. 3-1

3.05 Electromagnetic Compatibility ........................................................................ 3-3

3.06 Victor Flowmeter/ Regulator ........................................................................... 3-4

3.07 Leak Testing the System ................................................................................. 3-6

3.08 When You Finish Using the Flowmeter/ Regulator ..........................................................3-6

3.09

3.10 Power Source Controls, Indicators and Features ............................................ 3-7

3.11 Attaching the Fusion 140A MIG Gun ............................................................. 3-14

3.12 Inserting Wire into the Wire Feed Mechanism .............................................. 3-15

3.13 Installing 4" (100mm) Diameter Spool ......................................................... 3-16

3.14 Installing 8" (200mm) Diameter Spool .......................................................... 3-17

3.15 Feed Roller Pressure Adjustment .................................................................. 3-18

3.16 Changing the Feed Roll ................................................................................. 3-18

3.17 Wire Reel Brake ............................................................................................ 3-19

3.18 Flowmeter/ Regulator Operation ................................................................... 3-20

3.19 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 3-21

3.20 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire .................... 3-23

3.21 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 3-25

3.22 Setup for LIFT TIG (GTAW) Welding ............................................................. 3-26

3.23 Setup for STICK (SMAW) Welding .............................................................. 3-28

3.24 Torch Adapter Thumb Screw Replacement ................................................... 3-29

Storage of the Flowmeter/ Regulator ..................................................................... 3-6

TABLE OF CONTENTS

SECTION 4: BASIC WELDING GUIDE .................................................................... 4-1

4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1

4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-7

4.03 Stick (SMAW) Basic Welding Technique ....................................................... 4-10

4.04 Effects of Stick Welding Various Materials .................................................... 4-10

4.05 Stick (SMAW) Welding Troubleshooting ....................................................... 4-21

4.06 TIG (GTAW) Basic Welding Technique .......................................................... 4-23

4.07 TIG (GTAW) Welding Problems ..................................................................... 4-25

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

5.01 Power Source Problems ................................................................................. 5-1

5.02 Routine Service............................................................................................... 5-3

5.03 Cleaning the Welding Power Source ............................................................... 5-4

5.04 Cleaning the Feed Rolls ................................................................................... 5-4

5.05 Volt-Ampere Curves ........................................................................................ 5-4

SECTION 6: KEY SPARE PARTS .......................................................................... 6-1

6.01 Tweco Fusion 140A MIG Gun Parts ................................................................ 6-1

6.02 Power Source ................................................................................................. 6-2

6.03 Hardware List ................................................................................................. 6-4

APPENDIX ................................................................................................... A-1

APPENDIX: FABRICATOR 141I CIRCUIT DIAGRAM .................................................... A-2

TWECO - LIMITED WARRANTY TERMS ............................................ INSIDE BACK COVER

This Page Intentionally Blank

Fabricator 141i

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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.

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.

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.

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 0-5145 1-1 SAFETY INSTRUCTIONS AND WARNINGS

Fabricator 141i

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.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Shielded Metal Arc Welding
(SMAW)

Electrode Size in.

(mm)

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)

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.

Arc Current

(Amperes)

Less than 60

60-160
160-250
250-550

Minimum

Protective

Shade

7

8
10
11

Suggested*

Shade No.

(Comfort)

­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)

Plasma Arc Cutting (PAC)

* 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.

(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

Less than 20

20-40
40-60
60-80

80-300
300-400
400-800

7
10
10
10

8

8
10

10
11

6

8
10
11

4

5

6

8

8

9
10

­11
12
14

10
12
14

12
14

6 to 8

10
12
14

4
5
6
8

9
12
14

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5145

Fabricator 141i

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.

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 traveling 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

WARNING

Shielding gas cylinders contain gas under

CYLINDERS can explode if damaged.

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.

Manual 0-5145 1-3 SAFETY INSTRUCTIONS AND WARNINGS

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.

6. Turn face away from valve outlet when opening
cylinder valve.

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.

WARNING

Engines can be dangerous.

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.

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

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.

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 fueling. 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.

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

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.

2. Stop engine before installing or connecting unit.

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5145

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WARNING: This product contains chemicals, including
lead, known to the State of California to cause birth
defects and other reproductive harm.

after handling.

NOTE

Considerations About Welding And The
Effects of Low Frequency Electric and Mag­netic Fields

WARNING

Wash hands

Fabricator 141i

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.

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, OTA­BP-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.

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.

B Housekeeping

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.

ABOUT PACEMAKERS:

The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.

Manual 0-5145 1-5 SAFETY INSTRUCTIONS AND WARNINGS

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.

WARNING

Fabricator 141i

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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

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 20151­2923

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.

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5145

Fabricator 141i

!

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.

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.

Manual 0-5145 1-7 SAFETY INSTRUCTIONS AND WARNINGS

Fabricator 141i

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)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating­Auxiliary Power

Art # A-04130_AB

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards
Workpiece With
Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld
Mode

Press to initiate wirefeed and
welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.

4 Step Trigger
Operation

2 Step Trigger
Operation

S

See Note

See Note

S

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.

1.04 Symbol Chart

Note that only some of these symbols will appear on your model.

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5145

Fabricator 141i

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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.

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

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

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.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et

non troués.

3 Isolez-vous de la pièce à souder et de la mise à la

terre au moyen de tapis isolants ou autres.

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.

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.

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 porte­électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endom­magés, mal épissés ou de section trop petite.

Manual 0-5145 1-9 SAFETY INSTRUCTIONS AND WARNINGS

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.

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

AVERTISSEMENT

brûler les yeux et la peau. Le bruit causé par

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.

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)

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.

Courant

d’arc

(ampères)

Gamme

d’intensité

minimum

Numéro de teinte

recommandée*

(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)

* 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.

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

6

8
10
11

4

5

6

8

8

9
10

­10
12
14

­11
12
14

10
12
14

12
14

6 à 8

10
12
14

4
5
6
8

9
12
14

SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5145

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 141i

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 0-5145 1-11 SAFETY INSTRUCTIONS AND WARNINGS

Fabricator 141i

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES
BLESSURES.

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.

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 protec-

2. Portez des vêtements appropriés pour protéger

.

trices approuvées. Des écrans latéraux sont
recommandés.

la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEU­VENT 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.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGE­REUX

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

LE CARBURANT PEUR CAUSER UN INCEN­DIE 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.

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.

SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5145

AVERTISSEMENT

Fabricator 141i

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

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

LA VAPEUR ET LE LIQUIDE DE REFROI­DISSEMENT 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.

!

AVERTISSEMENT: Ce produitcontient des produits
chimiques, notamment du plomb, reconnu par l’Étatde
la Californie pour causerdes malformations congé­nitaleset d’autresdommages touchant le système
reproductif.

Se laver les mains après manipulation.

AVERTISSEMENT

REMARQUE

Facteurs relatifs au soudage et aux effets
des champs magnétiques et électriques de
basse fréquence

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLO­SER UN ACCUMULATEUR; L’ELECTROLYTE
D’UN ACCUMU-LA

TEUR PEUT BRULER LA

PEAU ET LES YEUX.
Les accumulateurs contiennent de l’élec-

trolyte 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.

Manual 0-5145 1-13 SAFETY INSTRUCTIONS AND WARNINGS

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 fondées sur

Fabricator 141i

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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.

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

AVERTISSEMENT

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

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.

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.

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.

C Aération

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
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,

ou brasez, lisez et assimilez la fiche

SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5145

Fabricator 141i

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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.

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.

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. 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.

3. Entreposez les bouteilles vides à l’écart des bou­teilles pleines. Marquez-les “VIDE” et refermez
leur vanne.

4. N’utilisez
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.

JAMAIS des bouteilles de gaz comprimé

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.

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.

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.

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.

Manual 0-5145 1-15 SAFETY INSTRUCTIONS AND WARNINGS

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.
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 AND WARNINGS 1-16 Manual 0-5145

1.09 Graphique de Symbole

Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)

Decoupe Arc Carbone
(CAC-A)

Courant Constant

Tension Constante
Ou Potentiel Constant

Haute Température

Force d'Arc

Amorçage de L’arc au
Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur
Transformateur-Redresseur

Tension dangereuse

Hors Tension

SousTension

Panneau/Local

Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)

Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de Prise­Source Auxiliaire

Art # A-07639_AB

115V 15A

t

t1

t2

%

X

IPM

MPM

t

Fusible

Déroulement du Fil

Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.

Purge Du Gaz

Mode Continu de
Soudure

Pouces Par Minute

Mètres Par Minute

Torch de

Soudage

Probléme de Terre

Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.

Détente à 4-Temps

Détente à 2-Temps

V

S

S

Voir Note

Voir Note

Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque conforme
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.

Seulement certains de ces symboles apparaîtront sur votre modèle.

Fabricator 141i

Manual 0-5145 1-17 SAFETY INSTRUCTIONS AND WARNINGS

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.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.

National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CSAE60974-1,UL60974-1andIEC60974-1applicabletoweldingequipmentandassociatedaccessories.

•

2002/95/EC RoHS directive

• Extensiveproductdesignvericationisconductedatthemanufacturingfacilityaspartoftheroutinedesign

and manufacturing process. This is to ensure the product is safe, when used according to instructions in
this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into
the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence
in our area of manufacture.

Manufacturers responsible representative:

Tom Wermert
Senior Brand Manager Tweco
Victor Technologies International, Inc
16052 Swingley Ridge Road
Chesterfield, MO 63017, USA

SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5145

SECTION 2: INTRODUCTION

Fabricator 141i

2.01 How to Use This Manual

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. These
special annotations are easily recognized as follows:

!

WARNING

Gives information regarding possible per­sonal injury. Warnings will be enclosed in a
box such as this.

CAUTION

Refers to possible equipment damage. Cau­tions will be shown in bold type.

NOTE

Offers helpful information concerning cer­tain operating procedures. Notes will be
shown in italics

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 141i 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 Fabricator 141i MIG 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 this equipment.

2.05 Transportation Methods

2.02 Equipment Identification

The Power Source's identification number (specifica­tion or part number), model, and serial number usually
appear on a nameplate attached to the machine. Equip­ment which does not have a nameplate attached to the
machine is identified only by the specification or part
number printed on the shipping container. Record these
numbers for future reference.

Manual 0-5145 2-1 INTRODUCTION

!

Disconnect input power con­ductors from de-energized supply line before moving
the welding Power Source.

Lift Power Source with handle on top of case. Use
handcart or similar device of adequate capacity. If using
a fork lift vehicle, secure the Power Source on a proper
skid before transporting.

Fabricator 141i

Art # A-11575_AD

• Fabricator 141i Power Source

• 140 Amp MIG Gun

• Victor Argon Regulator/Flowmeter & Hose

• Tweco Electrode Holder & Ground Clamp

• Drive Rolls & Contact Tips

• Sample Electrodes & Shoulder Strap

• 20A to 15A Power Cord Adapter

• Operator Manual & CD

Comes Complete With

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.

2.07 Fabricator 141i Portable System Package (Part No. W1003141)

INTRODUCTION 2-2 Manual 0-5145

Fabricator 141i

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. This means that it has been designed and built to provide
the rated amperage (100 A) 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 be
allowed to cool.

100

90

80

70

60

50

40

30

Duty Cycle (percentage)

20

10

0

0102030405060708090100 110120 130140 150

Safe

Operating

Region

STICK (SMAW)/ MIG (GMAW/ FCAW)

TIG (GTAW)

Art # A-11276_AB

Welding Current (amps)

Figure 2-1: Fabricator 141i Duty Cycle

Manual 0-5145 2-3 INTRODUCTION

Fabricator 141i

2.09 Specifications

DESCRIPTION FABRICATOR 141i MULTI PROCESS 3 IN 1 WELDER

Power Source Part No. W1003140
Power Source Dimensions H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm)

Power Source Weight 32.2lb(14.6kg)
Cooling Fan Cooled
Welder Type Multi Process Welding System

TM

Output Terminal Type Dinse
Standards CSA E60974-1-00 / UL60974-1 / IEC 60974-1
Number of Phases Single Phase

Nominal Supply Voltage 115V AC
Supply Voltage Range 95-140V AC
Supply Frequency 50/60Hz
Welding Current Range (MIG Mode) 10- 90A

Welding Current Range (LIFT TIG Mode) 10- 140A
Welding Current Range (STICK Mode) 10- 90A
Wirefeed Speed Range 95-390 IPM

MIG Welding Voltage Range 10-19V DC

25

Nominal OCV 53V DC

Breaker Size 20A 30A

(Requires updated Power Cord and Plug)

Effective Input Current (I
MIG (GMAW/FCAW)
STICK (SMAW)
TIG (GTAW)

Maximum Input Current (I
MIG (GMAW/FCAW)
STICK (SMAW)
TIG (GTAW)

1eff

)

1max

16.8A

16.8A

11.0A

16.1A*

11.8A*

14.3A*

)

26.2A

28.4A

24.7A

41.5A*

30.5A*
37A*

Single Phase Generator Requirement 5 KW 6 KW*
MIG (GMAW/FCAW) Welding Output 90A@20%, 18.5V

60A@60%, 17.0V

45A@100%, 16.25V

STICK (SMAW) Welding Output 80A@35%, 23.2V

60A@60%, 22.4V

45A@100%, 21.8V

LIFT TIG (GTAW) Welding Output 100A@20%, 14.0V

60A@60%, 12.4V

45A@100%, 11.8V

140A@15%, 19V*

60A@60%, 17.6V*

45A@100%, 16.8V*

90A@15%, 23.0V*
60A@60%, 22.8V*

45A@100%, 22.2V*
140A@15%, 15.6V*

60A@60%, 12.8V*

45A@100%, 12.2V*

Protection Class IP23S

Table 2-1: Fabricator 141i Specification

NOTE

* indicates data tested by Victor Technologies International, Inc.

INTRODUCTION 2-4 Manual 0-5145

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.
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 speci fications 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 correspond

ing 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 location and conditions and
local power grid supply conditions.

The thermal protection switch is rated at 80°C.

2.10 Options and Accessories

DESCRIPTION PART NUMBER

Fusion 140A MIG Gun, 10ft (3.0m) Length
Tweco Spool Gun 160A,12ft (3.6M) Length, suits 4" (100mm) spools for

aluminium welding
TIG Torch, 17V, 12.5 ft, 8 pin and accessory kit with 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

Fabricator 141i- 181i Carry Bag
Basic 4 Wheel Cart
Foot Control for remote amperage control when TIG welding
Tweco WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)

Drive Roll .023" - .035" (0.6-0.9mm) V groove for steel & stainless steel
Drive Roll .023"- .030" (0.6-0.8mm) V groove for steel & stainless steel wires

[Fitted]
Drive Roll .035"/.045" (0.9/1.2mm) V groove for steel & stainless steel wires
Drive Roll .030"-.035" (0.8-0.9mm) U grooved for aluminum wires
Drive Roll .040"-.045" (1.0-1.2mm) U grooved for aluminum wires
Drive Roll .030"-.035" (0.8-0.9mm) V knurled groove for flux cored wires
Drive Roll .045" (1.2mm) V knurled groove for flux cored wire
STICK KIT, 25mm DINSE

WTL ground clamp with 16 mm
WTL electrode clamp with 16 mm

2

lead and 25 mm2 dinse, 10ft (3.1m) long

2

lead and 25 mm2 dinse, 13ft (4m) long

F140TA-10-3035 1017-1321

SG160TA-12-3035 1027-1390

W4013802

W4015301
W4014700

600285
4100-1004
W4014800

7977036

7977660

7977731
7977264
7977732

704277
W4009401

Victor Argon Flowmeter/ Regulator
Accessory Kit for TIG Torch with 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

Power Adapter, 115V, 20A- 15A

Table 2-2: Fabricator 141i Options and Accessories List

Manual 0-5145 2-5 INTRODUCTION

0781-4169

P062900010

W4013300

This Page Intentionally Blank

Fabricator 141i

SECTION 3: INSTALLATION, OPERATION AND SETUP

3.01 Environment

This Power Source is designed for use in environments
with increased hazard of electric shock.

A. Examples of environments with increased hazard of

electric shock are:

1. In locations in which freedom of movement
is restricted, so that the operator is forced to
perform the work in a 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.

3. In wet or damp hot locations where humidity
or perspiration considerable 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 have been insulated.

3.02 Location

Be sure to locate the welder according to the following
guidelines:

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.

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.

WARNING

This equipment should be electrically
connected by a qualified electrician.

3.03 Ventilation

!

WARNING

Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.

A. In areas, free from moisture and dust.

3.04 Electricity Supply Voltage

B. Ambient temperature between 32 to 104° F (0 to

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"(300mm) or more from

walls or similar that could restrict natural air flow

for cooling.

Manual 0-5145 3-1 INSTALLATION, OPERATION AND SETUP

poor welding performance in STICK mode. 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 qualied

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.

The Electricity Supply voltage
should be within 95-140V AC.
Too low a voltage may cause

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. Lock-out/

tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box,
or shutting off and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirements

Operate the welding Power Source from a single-phase 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 source whenever necessary to inspect or service the unit.

Do not connect an input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.

• 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Table

3-1.

WARNING

An electric 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.

50 / 60 Hz Single Phase Supply
Supply Voltage 115V AC
Input Current at Maximum Output 28.4 Amps

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

30 Amps

30 Amps

Single Phase Generator Requirement 5 KW
Minimum Recommended Input Cable Size 12AWG
Maximum Recommended Input Cable Length 10ft (3m)
Minimum Recommended Grounding Cable Size 12AWG

Table 3-1: Electrical Service Guide

INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5145

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. 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 140V AC or higher is applied to the Primary Power Cord.

Model

Fabricator
141i

Primary Supply

Cord Size

(Factory Fitted)

12AWG (3.3mm

10AWG (5mm

2

Table 3-2: Primary Circuit Sizes to Achieve Maximum Current

2

) 115V/30A 140A@15% 90A@15% 140A@15%

Minimum Primary

Current Circuit Size

(Vin/Amps)

) 115V/20A 90A@20% 80A@35% 100A@20%

3.05 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic
situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the

welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the user
of the welding equipment to resolve the situation
with the technical assistance of the manufacturer.
In some cases this remedial action may be as
simple as earthing the welding circuit, see NOTE
below. In other cases it could involve constructing
an electromagnetic screen enclosing the Welding
Power Source and the work, complete with
associated input filters. In all cases, electromagnetic
disturbances shall be reduced to the point where
they are no longer troublesome.

Current & Duty Cycle

MIG (GMAW/

FCAW)

STICK (SMAW)

LIFT TIG

(GTAW)

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. Further
guidance is given in EN 60974-13 Arc
Welding Equipment - Installation and use
(under preparation).

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
pacemakers and hearing aids.

6. Equipment used for calibration and measurement.

Manual 0-5145 3-3 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

LOW PRESSURE
GAUGE (DELIVERY)

HIGH PRESSURE
GAUGE (SUPPLY)

INLET

CONNECTION

OUTLET

CONNECTION

PRESSURE

ADJUSTING

SCREW

A-09414_AB

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. 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 it’s length. The shielding should be
connected to the Welding Power Source so that
good electrical contact is maintained between
the conduit and the Welding Power Source
enclosure.

2. Maintenance of Welding Equipment

be considered. However. Metallic components
bonded to the work piece will increase the
risk that the operator could receive a shock
by touching the metallic components and the
electrode at the same time. The operator should
be insulated from all such bonded metallic
components.

5. Earthing of the Workpiece
Where the workpiece is not bonded to earth

for electrical safety, nor connected to earth
because of it’s size and position, e.g. ship’s hull
or building steelwork, a connection bonding
the workpiece to earth may reduce emissions
in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage
to other electrical equipment. Where necessary,
the connection of the workpiece to earth should
be made by direct connection to the workpiece,
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.

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

3.06 Victor Flowmeter/ Regulator

Flowmeter/ Regulator (Figure 3-1) attached to the
cylinder valve reduces high cylinder pressures to
suitable low working pressures for welding, cutting,
and other applications.

modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of
arc striking and stabilizing devices should
be adjusted and maintained according to the
manufacturer’s recommendations.

3. Welding Cables

The welding cables should be kept as short

as possible and should be positioned close
together, running at or close to the floor level.

Figure 3-1: Victor CS Flowmeter/ Regulator

4. Equipotential Bonding

Bonding of all metallic components in the

welding installation and adjacent to it should

INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5145

Fabricator 141i

!

!

!

!

4. Be sure that the flowmeter/ regulator has the
correct pressure rating and gas service for the

WARNING

cylinder used.

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.

NOTE

Flowmeters/ Regulators supplied with
5/8" -18 standard inert gas connections.
Flowmeters/ 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 flowmeter/ regulator. DO NOT attach
the flowmeter/ regulator to a system that has
a higher pressure than the maximum rated
pressure stamped on the flowmeter/ regulator.

2. The flowmeter/ regulator body will be stamped
“IN” or “HP” at the inlet port. Attach the inlet
port to the system supply pressure connection.

3. If gauges are to be attached to the flowmeter/
regulator and the flowmeter/ regulator 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 flowmeter/ regulator they are
being used on according to UL252A.

DO NOT use a flowmeter/ 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
flowmeter/ regulator.

WARNING

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. Attach the flowmeter/
regulator (Figure 3-2) to the cylinder valve.
Tighten securely with a wrench.

WARNING

DO NOT attach or use the flowmeter/
regulator if oil, grease, flamma ble substances
or damage is present! Have a qualified repair
technician clean the flowmeter/ regulator or
repair any damage.

Art # A-09845

Figure 3-2: Flowmeter/ Regulator to Cylinder

Valve

6. Before opening the cylinder valve, turn
the flowmeter/ regulator adjusting screw
counterclockwise until there is no pressure on
the adjusting spring and the screw turns freely.

7. Relief Valve (where provided): The relief valve is
designed to protect the low pressure side of the
flowmeter/ 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 flowmeter/ regulator.

Manual 0-5145 3-5 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

!

Art # A-09828

!

WARNING

a) If the high-pressure gauge reading drops,

there is a leak in the cylinder valve, inlet
fitting, or high-pressure gauge.

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.
For your safety, NEVER STAND IN FRONT OF
OR BEHIND A FLOWMETER/ REGULATOR
WHEN OPENING THE CYLINDER VALVE!

8. Slowly and carefully open the cylinder valve
(Figure 3-3) until the maximum pressure shows
on the high pressure gauge.

Figure 3-3: Open Cylinder Valve

9. On all cylinders, open the valve completely to
seal the valve packing. On gaugeless flowmeters/
regulators, the indicator will register the cylinder
contents open.

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 flowmeter/ regula­tor seat.

d) If the flowmeter/ 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.

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.

WARNING

3.08 When You Finish Using the Flowmeter/ Regulator

CAUTION

Keep the cylinder valve wrench, if one is
required, on the cylinder valve to turn off
the cylinder quickly, if necessary.

10. Attach the desired downstream equipment.

3.07 Leak Testing the System

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
Flowmeter/ regulator to deliver the maximum
required delivery pressure.

3. Close the cylinder valve.

4. Turn the adjusting screw/knob counterclockwise
one turn.

INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5145

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

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.

Storage of the Flowmeter/ Regulator

3.10 Power Source Controls, Indicators and Features

Art #

A-10354

16

17

15

18

19

20

21

Art #

A-10355

Fabricator 141i

4

5

1

14

13

FAULT

2

44

33

3

22

11

WIRESPEED INDUCTANCE

WIRESPEED

POWER

A

V

66

77

88

22

11

99

10 10

10 10

DOWNSLOPE (S)

DOWNSLOPE(S)

ARC FORCE (%)

ARCFORCE(%)

99

2

2

SOFT

INDUCTANCE

MIG

MIG

LIFT TIG

STICK

STICK

2T

2T

4T

4T

4

6

6

8

8

-

HARD+ SOFT

HARD

12

11

10

9

8

7

6

Art #

A-11509_AC

Figure 3-4: Front Panel

Figure 3-5: Rear Panel

Figure 3-6: Wire Feed Compartment Control

Manual 0-5145 3-7 INSTALLATION, OPERATION AND SETUP

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. 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.
This value can be adjusted by varying the Wire speed / Amperage potentiometer (Control No. 3). At times of
non-welding, the amperage meter will preview a wirefeed speed value (Inches Per Minute) in MIG mode only.
This can be identified as preview wirefeed speed by a decimal point at the lower right hand side of the display.

When welding, the amperage meter will display actual amperage (weld current) in all modes.
At the completion of welding, the amperage 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 Power Source 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 Power Source 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.

3. Wirespeed/Amperage Control

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.

4. MIG Gun Adapter (Tweco Style)

The MIG Gun adapter is standard Tweco connection with an 8 pin gun trigger for the 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 Fusion MIG Gun in position.
Failure to properly lock the Fusion MIG Gun into the MIG Gun Feedplate will result in the MIG Gun being
pushed out of the MIG Gun Feedplate by the MIG welding wire or lack of shielding gas (porosity in the weld)
at the weld zone.

INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5145

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.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in
the Dinse connector.

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 (-). If in doubt,
consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the Dinse
adapter and male plug are 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 Dinse connector.

7. Negative Welding Output Terminal

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 Gun polarity lead), TIG Torch or work lead. Negative
welding current flows to 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.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in
the Dinse connector.

8. Remote Control and Spool Gun Socket

The 8 pin socket is used to connect the Fusion MIG Gun, remote control device or spool gun plug to the welding
Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Manual 0-5145 3-9 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

Socket Pin

1 Spool gun motor (0V)
2

3
4
5
6

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.

2

1

5

4

8

7

Art # A-10421_AC

1
2
3
4

3

6

5
6
7
8

Remote Wirespeed in MIG (GMAW/FCAW) mode

Remote Amps in LIFT TIG (GTAW) mode

Trigger Switch

WV

Figure 3-7: Remote Control Socket

Function

Negative

Spool Gun Motor

Positive

Remote Volts in
MIG (GMAW/FCAW)

Wiper arm connection to 5k ohm potentiometer for the remote control of the Wirespeed in MIG mode.

7

Wiper arm connection to 5k ohm potentiometer for the remote control of the Amperage (Weld Current)
in LIFT TIG mode.

8

Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.

Table 3-3

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. 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 MIG welding voltage of the Power Source. The welding
voltage is increased by turning the knob clockwise or decreased by turning the knob counterclockwise. The
optimum voltage level required will depend 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.

INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5145

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. Arc force is increased by turning the control knob clockwise or decreased by turning the knob
counterclockwise.

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 of the amperage 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 (Control No. 11), the Power Source will enter down slope mode as soon
as the trigger switch is released (ie if the multifunction control knob is set to 5, the Power Source will ramp
down from the present welding current to zero over 5 seconds). If no down slope time is set then the welding
output will cease immediately. If the Power Source 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.

10. 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.

11. Trigger Mode Control (MIG and LIFT TIG Mode only)

The trigger mode control is used to switch the functionality of the of the MIG or TIG Trigger Switch between
2T (normal) and 4T (latch mode)

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. To deactivate the Power
Source, the trigger switch must again be depressed and released, thus eliminating the need for the operator
to hold the MIG or TIG Trigger Switch

Note that when operating in LIFT TIG mode, the Power Source will remain activated until the selected Downslope
time has elapsed (refer Control No. 9).

12. Process Selection Control

The process selection control is used to select the desired welding mode. Three modes are available, MIG,
LIFT TIG and STICK modes. Refer to section 3.20 or 3.21 for MIG (GMAW/FCAW) set up details, section 3.22
for LIFT TIG (GTAW) set-up details or section 3.23 for STICK (SMAW) set-up details.

Note that when the Power Source 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
Power Source and mistakenly be in contact with the work piece during power up.

Manual 0-5145 3-11 INSTALLATION, OPERATION AND SETUP

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). Note that in STICK and LIFT TIG modes,
the voltage meter will not preview welding voltage but will display Open Circuit Voltage in STICK mode and
0V in LIFT TIG mode.

When welding, the voltage meter will display actual welding voltage in all modes.

At the completion of welding, the digital voltage 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 Power Source 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 Power Source 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.

14. 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 or if a fault is detected in the Inverter. Should the Fault 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 power switch should remain
in the on position such that the fan continues to operate thus allowing the Power Source to cool sufficiently.
Do not switch the Power Source off should a thermal overload condition be present. If the fault condition
does not extinguish, then the Power Supply will need to be taken to an authorized repair center for analysis.

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 3.19 to 3.20 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.

WARNING

When the front digital displays are lit, the machine is connected to the Mains supply voltage and the
internal electrical components are at Mains voltage potential.

INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5145

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. When set to
Stick mode, fan will turn on immediately and will not turn off until welding has ceased and Power Supply is
at proper operating temperature.

Note in STICK mode the fan operates continuously.

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 Power Source via the remote control socket (8 Pin Remote Socket). When the local/
remote switch is in the remote position, the Power Source will detect a remote device and work accordingly.
When in the local mode, the Power Source 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 Power Source 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 counterclockwise. To increase the Burnback time (or shorten the amount of wire protruding from the
MIG Gun 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 function and Spool Gun
function.

21. 10A Fuse

The 10A fuse is used to protect both the spool gun motor and internal motor.

Manual 0-5145 3-13 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

Art #

A-10356_AB

MIG Gun Adaptor

MIG Gun Connector

MIG Gun Connector

Thumb Screw

8 pin socket

8 pin plug

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.

INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5145

Figure 3-8: Attaching MIG Gun

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. With the MIG welding wire feeding from the bottom of the spool (Figure
3-10) 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 3-9). Remove the nozzle and 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 contact tip.

WARNING

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so
premature arcing will not occur.

The electrode wire will be at welding voltage potential while it is being fed through the system.
Keep MIG Gun away from eyes and face.

Art #

A-10359

Wire Drive Tension Screw

Pressure Roller Arm

Outlet Guide

Inlet Guide

Figure 3-9: Wire Drive Assembly Components

Art #

MIG Welding Wire

A-10360

Figure 3-10: MIG Welding Wire - Installation

Manual 0-5145 3-15 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

Art #

A-10357

Friction Washer

4”（100mm）
Diameter spool

Nut with
Nylon Insert

Spring

Plastic Spacer

Brass Flat
Washer

Flat Washer

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. The brake is correctly adjusted when the spool stops within 4" (100mm) to 8"
(200mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without
becoming dislodged from the spool.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.

Figure 3-11: 4" (100mm)Diameter Spool Installation

INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5145

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. The Brake is correctly adjusted when the spool stops within 3/8" (10mm) to 3/4"
(20mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without
becoming dislodged from the spool.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.

Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 8" (200mm)
diameter spool.

NOTE

This alignment pin can be removed by unscrewing in an counterclockwise direction and locating in the
appropriate position.

Alignment pin

8” (200mm)
diameter spool

Spool Hub Nut

Alternate
Alignment Pin
Position

Plastic Spacer

Figure 3-12: 8" (200mm) Diameter Spool Installation

Spring

Nut with
Nylon Insert

Wire Spool Hub

Friction
Washer

Flat Washer

Brass Flat
Washer

Art #

A-10358

Manual 0-5145 3-17 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

Art #

A-09584_AC

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. 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.

3.16 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.

GROOVE “B”GROOVE “A”

GROOVE “B” SIZE

GROOVE “A” SIZE

A-09583

Figure 3-13: Dual Groove Feed Roller

Feed Roll

Retaining Screw

Feed Roll

Figure 3-14: Changing the Feed Roll

INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5145

Fabricator 141i

Wire Reel Brake Adjustment Nut

Art #

A-10361

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.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.

Figure 3-15: Wire Reel Brake

Manual 0-5145 3-19 INSTALLATION, OPERATION AND SETUP

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.
It is recommended that testing for leaks at the flowmeter/ regulator connection points be carried out using
a suitable leak detection solution or soapy water.

3. Purge air or other unwanted welding grade shielding gas from equipment connected to the flowmeter/
regulator by individually opening then closing the equipment control valves. Complete purging may take
up to ten seconds or more, depending upon the length and size of the hose being purged.

Adjusting Flow Rate

With the flowmeter/ regulator ready for operation, adjust working flow rate as follows:

1. Adjust the gas flow rate. The recommended rate for MIG welding is 15-25 CFH. The recommended rate
for LIFT TIG welding is 10-25 CFH.

NOTE

It may be necessary to re-check the shielding gas flowmeter/ regulator flow rate following the first weld
sequence due to back pressure present within shielding gas hose assembly.

Shutdown

Close cylinder valve whenever the flowmeter/ regulator is not in use. To shut down for extended periods (more
than 30 minutes).

1. Close cylinder or upstream valve tightly.

2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from
any ignition source.

3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.

4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove flowmeters/
regulators. Put caps on all cylinders that do not have flowmeters/ regulators on them.

INSTALLATION, OPERATION AND SETUP 3-20 Manual 0-5145

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. Fit the MIG Gun to the Power Source. (Refer to Section 3.11 Attaching the Fusion 140A 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 Dinse style connectors. It is essential, however, that the

male plug is inserted and turned securely to achieve a sound electrical connection.
E. Fit the flowmeter/ regulator 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 flowmeter/ regulator 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.

!

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so
premature arcing will not occur.

Secure the 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.

WARNING

Manual 0-5145 3-21 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

MIG Gun

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 (+)

8 pin Plug

Shielding Gas Hose Fitted
with 5/8"-18 UNF

connection

Negative Welding

MIG Gun
Polarity Lead

Work Lead

Terminal (-)

Primary Cord

Figure 3-16: Setup for MIG Welding with Gas Shielded MIG Wire

INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5145

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. 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 Dinse style connectors. 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.
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.

WARNING

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so
premature arcing will not occur.

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.

Manual 0-5145 3-23 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

(+)

Positive Welding
Terminal

MIG Gun

Negative Welding
Terminal (-)

8 pin Plug

Work Lead

MIG Gun
Polarity Lead.

A-09587_AD

Figure 3-17: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire

INSTALLATION, OPERATION AND SETUP 3-24 Manual 0-5145

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.

Art #

1. Make sure the welding
power source is turned
OFF before connecting
the welding gun.

2. Open side panel and
loosen thumb screw.

3. Insert the back end of the
Spool gun into the gun
receiving bushing.

A-10363

4. Tighten thumb screw and
replace side panel.

5. Connect gas supply fitting
and tighten with a wrench.

6. 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.

Manual 0-5145 3-25 INSTALLATION, OPERATION AND SETUP

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. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via

Dinse style 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. The TIG

torch will require a trigger switch to weld in LIFT TIG Mode.

NOTE

A Tweco 17V 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. Please refer to "2.10 Options
and Accessories".

E. Fit the flowmeter/ regulator to the shielding gas cylinder (refer to Section 3.06) then connect the shielding

gas hose from the TIG torch to the flowmeter/ regulator outlet. Note that the TIG torch shielding gas hose is
connected directly to the flowmeter/ regulator. 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.

!

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so
premature arcing will not occur.

Secure the shielding gas cylinder in an upright position by chaining it to a stationary support to prevent
falling or tipping.

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.

WARNING

CAUTION

INSTALLATION, OPERATION AND SETUP 3-26 Manual 0-5145

Art # A-11576_AB

Positive Welding
Terminal (+)

Fabricator 141i

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.

MIG Torch
polarity lead
not connected

Work Lead

TIG Torch

Figure 3-18: Setup for TIG Welding

Negative welding terminal (-)

50mm- 25mm Adaptor

Note: A Tweco 17V 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.

Manual 0-5145 3-27 INSTALLATION, OPERATION AND SETUP

Fabricator 141i

Art #

A-10365

Negative Welding
Terminal (-)

Positive Welding
Terminal

(+)

Work Lead

Electrode
Holder

MIG Gun
polarity lead
not connected.

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.

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.

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.

Figure 3-19: Setup for Stick Welding(SMAW)

INSTALLATION, OPERATION AND SETUP 3-28 Manual 0-5145

3.24 Torch Adapter Thumb Screw Replacement

WARNING

All power to unit should be removed.

1. Place unit on its back.

Fabricator 141i

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

Art # A-11483

Securing Block

Manual 0-5145 3-29 INSTALLATION, OPERATION AND SETUP

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.

Thumb Screw
Fully Exposed

Art # A-11485_AB

5. Remove damaged thumb screw and replace with new one.

Art # A-11486

Push Upward

6. To reassemble, reverse steps 1 through 4.

INSTALLATION, OPERATION AND SETUP 3-30 Manual 0-5145

Fabricator 141i

Shielding Gas

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 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.

GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO

welding, Micro Wire Welding,

2

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

Solidified
Weld Metal

GMAW Process

Nozzle

Electrode

Arc

Base Metal

Art # A-8991_AB

Figure 4-1

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.

Nozzle
(Optional)

Flux Cored
Electrode

Arc

Base Metal

Art # A-08992_AB

Slag

(Optional)

Molten Metal

Molten
Slag

Solidified
Weld Metal

FCAW Process

Figure 4-2

Manual 0-5145 4-1 BASIC WELDING GUIDE

Fabricator 141i

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. 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

Direction of

90°

Transverse

Angle

Travel

Art # A-08993

Butt & Horizontal Welds

Figure 4-4

5° to 15°

Longitudinal Angle

30° to 60°

Transverse Angle

Direction of

Travel

Horizontal Fillet Weld

Figure 4-5

BASIC WELDING GUIDE 4-2 Manual 0-5145

Art # A-08994

Fabricator 141i

10° to 20° Longitudinal

Direction of Travel

10°

Longitudinal Angle

30° to 60°
Transverse

Angle

30° to 60°

Transverse Angle

Direction of Travel

Vertical Fillet Welds

Figure 4-6

Figure 4-7

Angle

30° to 60°
Transverse

Angle

Art # A-08995

5° to 15°
Longitudinal
Angle

Art # A-08996

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. The items below describe the welding variables in
short-arc welding of 24 ga. (0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques and end results
in the MIG process are controlled by these variables.

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 to self shielding wires FCAW)

• Gas flow rate (not applicable to self shielding wires FCAW)

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

Manual 0-5145 4-3 BASIC WELDING GUIDE

Fabricator 141i

Transverse

Direction of Gun Travel

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.

Gas Nozzle

Tip to

Work Distance

Average Arc Length

Electrode Stick-Out

Contact Tip (Tube)

Electrode Wire

Actual Stick-out

Art # A-08997_AD

Figure 4-8

3. Nozzle Angle. This refers to the position of the welding 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 welding 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) 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.

Angle

Longitudinal
Angle

Axis of Weld

Transverse and Longitudinal
Nozzle Axes

Art # A-08998_AB

Figure 4-9

Leading or “Pushing”

Angle

(Forward Pointing)

Nozzle Angle, Right Handed Operator

90°

Trailing or “Pulling”

Angle

(Backward Pointing)

Art # A-08999_AC

Figure 4-10

BASIC WELDING GUIDE 4-4 Manual 0-5145

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" (3.2mm) mild steel plate 6” (150mm)
x 6” (150mm). Use 0.035” (0.9mm) gas shielded steel or gasless flux cored wire.

Setting of the Power Source

Power source and Wirefeeder setting requires some practice by the operator, as the welding plant has two control
settings that have to balance. These are the Wirespeed control (refer to section 3.10.3) and the welding Voltage
Control (refer to section 3.10.9). 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proledesired

• Thepositionofwelding

• Costofthewire

Manual 0-5145 4-5 BASIC WELDING GUIDE

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. 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 CAUSE

1 Limited or no shielding gas flows

out of the MIG Gun nozzle.

2 No shielding gas flow. Ensure that the shielding gas cylinder is not empty and the flow

3 Gas leaks. Check for gas leaks between the regulator/cylinder connection and

4 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
5 Welding dirty, oily, painted,

oxidized or greasy plate.

6 Distance between the MIG Gun

nozzle and the work piece.

7 Maintain the MIG Gun in good

working order.

Check that the MIG Gun connection is fully engaged into the MIG
Gun Adapter. The o-rings in the MIG Gun connection must seal
the shielding gas within the MIG Gun Adapter so the shielding gas
flows into the MIG Gun and out thru the MIG Gun nozzle.

meter is correctly adjusted to workshop welding: 15-25 CFH or
outdoors welding: 35-46 CFH.

in the gas hose to the Power Source.

Clean contaminates off the work piece.

Keep the distance between the MIG Gun nozzle and the work piece
to a minimum. Refer to section 4.01

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

WARNING

Disengage the feed roll when testing for gas flow by ear.

Manual 0-5145 4-7 BASIC WELDING GUIDE

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

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

4 Wire rubbed against the mis-aligned

guides and reduced wire feedability.

5 Liner blocked with debris A Increased amounts of debris are produced by the wire

6 Incorrect or worn contact tip A The contact tip transfers the weld current to the elec-

Wire spool brake is too tight or drive roll tension not
tight enough.

matched to the size you are welding.

B Replace feed roller if worn.

Mis-alignment of inlet/outlet guides

passing through the feed roller when excessive pres­sure is applied to the pressure roller adjuster.

B Debris can also be produced by the wire passing

through an incorrect feed roller groove shape or size.

C Debris is fed into the conduit liner where it accumu-

lates thus reducing wire feedability.

trode 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 be-

come jammed in the contact tip due to expansion of
the wire when heated. A Velocity contact tip designed
for soft wires should be used.

7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the

work piece then the connection point will heat up and
result in a reduction of power at the arc.

8 Bent liner This will cause friction between the wire and the liner

thus reducing wire feedability

Table 4-3: Wire Feeding Problems

Basic MIG Welding Troubleshooting

FAULT CAUSE REMEDY

1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed

speed.
B Incorrect MIG Gun angle B Adjust angle.
C Excessive heat input C Increase the MIG Gun travel speed and/or

decrease welding current by decreasing the
voltage or decreasing the wire feed speed.

BASIC WELDING GUIDE 4-8 Manual 0-5145

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FAULT CAUSE REMEDY

2 Lack of penetration A Welding current too low A Increase welding current by increasing wire

feed speed and increasing voltage.

B Joint preparation too narrow or

gap too tight

C Shielding gas incorrect C Change to a gas which gives higher penetration.

3 Lack of fusion Welding current too low Increase welding current.
4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed

B Voltage too low B Increase the voltage or decrease wirespeed.

5 Irregular weld shape A Incorrect voltage and travel

speed settings. Convex, voltage
too low. Concave, voltage too
high.

B Wire is wandering. B Check to see if it is near the end of the roll

C Incorrect shielding gas C Check shielding gas.
D Insufficient or excessive heat

input

B Increase joint angle or gap.

control.

A Adjust voltage and travel speed by adjusting the

voltage control and the wirespeed control.

of wire and replace when necessary. If the
problem continues, tighten the nozzle to see
if this corrects the problem. Then replace
contact tip.

D Adjust the wirespeed control or the voltage

control.

E Incorrect gun manipulation or

angle

6 Weld cracking A Weld high carbon steel without

pre/post heat treatment

B Incompatible filler metal used

to the base metal
C Weld beads too small C Decrease travel speed.
D Weld penetration narrow and

deep

E Excessive weld stresses E Increase weld metal strength or revise design
F Excessive voltage F Decrease voltage.

G Cooling rate too fast G Slow the cooling rate by preheating part to be

7 Cold weld puddle A Welding voltage too high A Decrease voltage or increase the wirespeed

B Loose welding cable connec-

tion
C Low primary voltage C Contact supply authority.

E Manipulate the gun correctly or place it in

correct angle.

A Have sufficient pre/post heat treatment before

welding high carbon steel.

B Use correct filler metal.

D Reduce current and voltage and increase MIG

Gun travel speed or select a lower penetration
shielding gas.

welded or cool slowly.

control.

B Check all welding cable connections.

D Fault in power source D Have an Accredited Tweco Service Provider to

test then replace the faulty component.

Manual 0-5145 4-9 BASIC WELDING GUIDE

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.

9 Poor weld result from

setup chart parameters

The MIG Gun has been con­nected to the wrong voltage
polarity on the front panel

A Incorrect welder setup, polar-

ity, shielding gas, wire type and
size

B Contact tip has arc marks in the

bore causing excessive drag on
the wire

Table 4-4: MIG Welding Problems

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.

A Check to make sure that the welder is set up

correctly; also check polarity, shielding gas,
wire type and size.

B Replace the contact tip with only a Genuine

Velocity contact tip.

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 Stick Welding Various Materials

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. Hardened zone and under­bead 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.

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.

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.

BASIC WELDING GUIDE 4-10 Manual 0-5145

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Art # A-07688

Art # A-07689

Art # A-07690

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. These include some low hydrogen types for high tensile steel, cellulose types for welding large
diameter pipes, etc The range of electrodes dealt with in this publication will cover the vast majority of applications
likely to be encountered; are all easy to use.

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.

Art # A-07687

Figure 4-11: Flat Position, Down Hand Butt Weld

Figure 4-12: Flat Position, Gravity Fillet Weld

Figure 4-13: Horizontal Position, Butt Weld

Figure 4-14: Horizontal-Vertical (HV) Position

Manual 0-5145 4-11 BASIC WELDING GUIDE

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

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Open Square Butt

Single Vee Butt Joint

Not less than

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.

Joint

Gap varies from
1/16" (1.6mm) to 3/16" (4.8mm)
depending on plate thickness

Single Vee Butt Joint

Lap Joint

Fillet Joint

Corner Weld

Not less than

45°

(Fillet both sides of the

1.6mm (1/16”)

Double Vee Butt Joint

1/16" (1.6mm)

Tee Joints

joint)

Edge Joint

70°

Not less than

70°

1/16" (1.6mm) max

1/16" (1.6mm) max

Plug Weld Plug Weld

Art # A-10367

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" (6.4mm) thick and a 1/8"(3.2mm) 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.

Manual 0-5145 4-13 BASIC WELDING GUIDE

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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"(1.6mm) to 1/8"(3.2mm) 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.

Art # A-10368

1/16" (1.6mm)

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 Stick electrodes 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.

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"(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" (6.4mm) 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"(3.2mm) E7014 Stick 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 well­formed 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.

BASIC WELDING GUIDE 4-14 Manual 0-5145

Fabricator 141i

20°-30°

Art # A-07699_AB

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. 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 cross-section 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"(3.2mm) E7014 Stick 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"(6.4mm)width
with a 1/8"(3.2mm) electrode, otherwise the weld metal tends to sag towards the base, and undercut forms
on the vertical leg. Multi-runs can be made as shown in Figure 4-24. Weaving in HV fillet welds is undesirable.

45° from
vertical

60° - 70° from line
of weld

Figure 4-23: Electrode Position for HV Fillet Weld

Manual 0-5145 4-15 BASIC WELDING GUIDE

Fabricator 141i

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"(3.2mm)

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. 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-07702

Figure 4-26: Multi Run Vertical Fillet Weld

BASIC WELDING GUIDE 4-16 Manual 0-5145

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. 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"(3.2mm) E6013 Stick 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.

Art # A-07704

Figure 4-28: Overhead Fillet Weld

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Upsetting

Weld

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" (2.0mm) sheet, the contracting weld metal may cause the sheet to become distorted.

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.

Hot

Weld

Hot

Expansion with
compression

Cool

Art # A-07705_AB

Figure 4-29: Parent Metal Expansion

Art # A-07706_AC

Permanent Upset

Contraction
with tension

Figure 4-30: Parent Metal Contraction

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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. 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 4-31 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

Art # A-07708

B

Weld

C

PreheatPreheat

Dotted lines show effect if no preheat is used

Figure 4-32: Reduction of Distortion by Preheating

Manual 0-5145 4-19 BASIC WELDING GUIDE

Fabricator 141i

Art # A-07709

Figure 4-33: Examples of Distortion

Art # A-07710_AB

4

Art # A-07711_AB

Figure 4-35: Step back Sequence

1

2

Block Sequence.
The spaces between the welds are
filled in when the welds are cool.

3

Figure 4-34: Welding Sequence

1

2

3

Art # A-07428_AB

Figure 4-36: Chain Intermittent Welding

Art # A-07713_AB

Figure 4-37: Staggered Intermittent Welding

BASIC WELDING GUIDE 4-20 Manual 0-5145

4.05 Stick (SMAW) Welding Troubleshooting

Insufficient Gap

Incorrect Sequence

Art # A-05866_AC

FAULT CAUSE REMEDY

Fabricator 141i

1 Welding current

varying

2 A gap is left by

failure of the weld
metal to fill the
root of the weld.

3 Non-metallic par-

ticles are trapped
in the weld metal.

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.

A Welding current too low A Increase welding current.

B Electrode too large for joint. B Use smaller diameter electrode.

C Insufficient gap. C Allow wider gap.

A Non-metallic particles may

be trapped in undercut from

A If a bad undercut is present clean slag bout and

cover with a run from a smaller gauge electrode.

previous run.

B Joint preparation too re-

stricted.

C Irregular deposits allow slag

B Allow for adequate penetration and room for clean-

ing out the slag.

C If very bad, chip or grind out irregularities.

to be trapped.

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 Rust or mill scale is prevent-

E Clean joint before welding.

ing 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.

Figure 1- Example of insufficient gap or incorrect sequence

4 A groove has been

A Welding current is too high. A Reduce welding current.
formed in the base
metal adjacent to

B Welding arc is too long. B Reduce the length of the welding arc.
the toe of a weld
and has not been
filled by the weld
metal (undercut).

C Angle of the electrode is

incorrect.

D Joint preparation does not

allow correct electrode angle.

C Electrode should not be inclined less than 45° to

the vertical face.

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

G Set Power Source to STICK (SMAW) mode.

(GMAW) welding.

Manual 0-5145 4-21 BASIC WELDING GUIDE

Fabricator 141i

Lack of fusion caused by dirt,

Not cleaned,
or incorrect
electrode

Slag
trapped in
undercut

Slag trapped in root

Art # A-05868_AC

FAULT CAUSE REMEDY

5 Portions of the

weld run do not
fuse to the surface
of the metal or
edge of the joint.

electrode angle incorrect,
rate of travel too high

Art # A-05867_AC

Lack of side fusion,
scale dirt, small electrode,
amperage too low

6 Gas pockets or

voids in weld
metal (porosity)

A Small electrodes used on

A Use larger electrodes and preheat the plate.

heavy cold 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

D Reduce travel speed of electrode.

too high.
E Scale or dirt on joint surface. E Clean surface before welding.

Lack of
inter-run fusion

Lack of root fusion

Figure 2: Example of Lack of Fusion

A High levels of sulfur in steel. A Use an electrode that is designed for high sulfur

steels.
B Electrodes are damp. B Dry electrodes before use.
C Welding current is too high. C Reduce welding current.

7 Crack occurring in

weld metal soon
after solidification
commences

D Surface impurities such as

D Clean joint before welding.

oil, grease, paint, etc.

E Welding in a windy environ-

E Shield the weld area from the wind.

ment.

F Electrode damaged ie flux

coating incomplete.

F Discard damaged electrodes and only use elec-

trodes with a complete flux coating.
A Rigidity of joint. A Redesign to relieve weld joint of severe stresses or

use crack resistance electrodes.
B Insufficient throat thickness. B Travel slightly slower to allow greater build up in

throat.
C Weld current is too high. C Decrease welding current.

Figure 3: Example of Slag Inclusion

8 The Stick elec-

BASIC WELDING GUIDE 4-22 Manual 0-5145

trode is difficult to
run with multiple
arc-outs when
welding

The Stick electrode being
used is not suitable for use
with this machine.

Table 4-5: Welding Problems - Stick (SMAW)

Use E6013 or E7018 Stick electrodes for steel or

300 series stainless steel Stick electrodes for 300

series stainless steel.

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. A filler metal may also be added manually in some circumstances
depending on the welding application.

Art # A-10369_AB

Gas Cup

Either Ceramic,

Work Piece

Can Be Any Commercial

Metal

Welds Made With or Without

Addition of Filler Metal

High Impact or

Water Cooled

Metal

Tungsten Electrode

Non-Consumable

Inert Gas

Shields Electrode

and Weld Puddle

Figure 4-38: TIG Welding Application Shot

Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30-60
1/16” (1.6mm) 60-115
3/32” (2.4mm) 100-165

1/8” (3.2mm) 135-200
5/32” (4.0mm) 190-280
3/16” (4.8mm) 250-340

Table 4-6: Current Ranges for Various Tungsten Electrode Sizes

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1/16” (1.6mm) 20-90
3/32” (2.4mm) 65-115

1/8” (3.2mm) 100-165
3/16” (4.8mm) 200-350

Table 4-7: Filler Wire Selection Guide

Manual 0-5145 4-23 BASIC WELDING GUIDE

Fabricator 141i

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

Welding Application Features Color Code

DC welding of mild
steel, stainless steel
and copper

High quality AC weld­ing of aluminum,
magnesium and their
alloys.

AC & DC welding of
mild steel, stainless
steel, copper, 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.

Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.

Table 4-8

NOTE

The Fabricator 141i is not suited for AC TIG welding.

Red

Brown

Grey

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

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. For further information please refer to www.
victortechnologies.com or contact Tweco.

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

Argon Gas
Flow Rate

CFH

10-15 Butt/Corner

10-15 Butt/Corner

15 Butt/Corner

15 Butt/Corner

20 Butt/Corner

20 Butt/Corner

Joint Type

Lap/Fillet

Lap/Fillet

Lap/Fillet

Lap/Fillet

Lap/Fillet

Lap/Fillet

BASIC WELDING GUIDE 4-24 Manual 0-5145

4.07 TIG (GTAW) Welding Problems

FAULT CAUSE REMEDY

Fabricator 141i

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.

4 Weld bead too wide or

excessive bead build up or
excessive penetration in
butt joint.

5 Uneven leg length in fillet

joint

6 Electrode melts or oxidizes

when an arc is struck.

Welding current is too
low

Welding current is too
high

Travel speed too fast Reduce travel speed.

Travel speed too slow Increase travel speed.

Wrong placement of
filler rod

A TIG Torch lead

connected to positive
welding terminal.

Increase weld current and/or faulty joint
preparation.

Decrease weld current.

Re-position filler rod.

A Connect TIG Torch lead to negative welding

terminal.

B No gas flowing to weld-

ing region.

C TIG Torch is clogged

with dust or dirt.
D Gas hose is cut. D Replace gas hose.
E Gas passage contains

impurities.

F Gas regulator turned off

or cylinder shut off.
G TIG Torch valve is

turned off.
H The electrode is too

small for the welding

current.

I Power Source is set for

MIG welding.

B Turn TIG Torch gas valve ON. Check the gas

lines for kinks or breaks and gas cylinder
contents.

C Clean TIG Torch.

E Disconnect gas hose from the rear of Power

Source then raise gas pressure and blow out
impurities.

F Turn on.

G Turn on.

H Increase electrode diameter or reduce the

welding current.

I Set Power Source to LIFT TIG mode.

Manual 0-5145 4-25 BASIC WELDING GUIDE

Fabricator 141i

FAULT CAUSE REMEDY

7 Dirty weld pool A Electrode contaminated

by contact with work
piece or filler rod mate­rial.

B Work piece surface has

foreign material on it.

C Gas contaminated with

air.

8 Poor weld finish Inadequate shielding

gas.

9 Arc start is not smooth. A Tungsten electrode is

too large for the weld­ing current.

B The wrong electrode

is being used for the
welding job.

C Gas flow rate is too

high.

A Clean the electrode by grinding off the con-

taminates.

B Clean surface.

C Check gas lines for cuts and loose fitting or

change gas cylinder.

Increase gas flow or check gas line for gas
flow problems.

A Select the right size electrode. Refer to Table

4-7 Current Ranges for Various Tungsten
Electrode Size.

B Select the right electrode type. Refer to Table

4-9 Tungsten Electrode Types.

C Select the right rate for the welding job. Refer

to Table 4-10.

10 Arc flutters during TIG

welding.

11 Tungsten blackens due to

lack of shielding gas or
wrong shield gas.

D Incorrect shielding gas

is being used.

E Poor work clamp con-

nection to work piece.

F Tungsten not properly

sharpened.

Tungsten electrode is
too large for the weld­ing current.

A Gas valve on the TIG

Torch has not be turned
on.

B Gas cylinder valve off

or TIG Torch hose not
connected to regulator

C Incorrect shielding gas

is being used.

Table 4-10: TIG (GTAW) Welding Problems

D Select the right shielding gas.

E Improve connection to work piece.

F Grind tungsten to proper shape.

Select the right size electrode. Refer to Table
4-7 Current Ranges for Various Electrode
Size.

A Turn on TIG Torch gas valve before you

commence welding.

B Turn on gas cylinder valve or connect TIG

Torch hose to regulator.

C Select the right shielding gas.

BASIC WELDING GUIDE 4-26 Manual 0-5145

POWER SOURCE PROBLEMS AND ROUTINE SERVICE

5.01 Power Source Problems

FAULT CAUSE REMEDY

1 Primary Power Supply is

ON, power indicator is illu­minated however the Power
Source will not commence
welding when the torch trig­ger switch is depressed.

A Power Source is not in the correct

mode of operation.

B Welding leads, or polarity cable

not connected.

C Faulty torch trigger. C Repair or replace torch trigger

Fabricator 141i

SECTION 5:

REQUIREMENTS

A Set the Power Source to the correct

mode of operation with the process
selection switch.

B Connect welding leads or polarity

cable.

switch/lead.

2 Fault Indicator is illuminat-

ed and the Power Source
will not commence weld­ing when the torch trigger
switch is depressed.

3 The Power Source will not

feed wire in MIG mode.

4 Welding wire continues to

feed when torch trigger is
released.

Duty cycle of Power Source has
been exceeded.

A Electrode wire stuck in conduit

liner or contact tip (burn-back
jam).

B 8 pin gun connector not con-

nected.

C MIG GUN/SPOOL GUN switch is

switched to SPOOL GUN.

D Faulty torch trigger. D Repair or replace torch trigger.
E Wire tension too loose. E Tighten wire tension.

F Brake tension too tight. F Loosen brake tension.

A Trigger mode selection switch is in

4T latch mode.

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, loose nozzle or worn
contact tip. Replace faulty compo­nents.

B Connect 8 pin gun connector.

C Switch the MIG GUN/SPOOL GUN

switch to MIG GUN.

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.

5 Welding arc cannot be

established in MIG mode.

Manual 0-5145 5-1 TROUBLE SHOOTING AND SERVICE

A MIG Gun polarity lead is not

connected into a welding output
terminal.

B Poor or no work lead contact. B Clean work clamp area and ensure

A Connect the MIG Gun polarity lead

to either the positive welding output
terminal or the negative welding
output terminal as required.

good electrical contact.

Fabricator 141i

FAULT CAUSE REMEDY

6 Inconsistent wire feed. A Fouled contact tip. 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

D Reduce brake tension on spool hub

reel 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. B Disconnect gas hose from the rear

of Power Source and blow out
debris.

C Shielding gas cylinder valve shut

C Turn on the cylinder.

off.

D Flowmeter/ Regulator turned off. D Turn on flowmeter/ regulator.
E Empty gas cylinder. E Replace gas cylinder.

8 Gas flow continues after

the torch trigger switch has

Gas valve has jammed open due to
debris in the gas or the gas line.

Have an accredited Tweco service
provider repair or replace gas valve.

been released (MIG mode).

9 Power indicator will not

illuminate and welding arc

The Electricity supply is inad­equate.

Ensure that the Electricity Supply
voltage is within 95-140 VAC.

cannot be established.

10 TIG electrode melts when

arc is struck.

TIG Torch is connected to the (+)
polarity terminal.

Connect the TIG Torch to the (-)
polarity terminal.

11 Arc flutters during TIG

welding.

Tungsten electrode is too large for
the welding current.

Table 5-1

Select the correct size of tungsten
electrode. Refer to Table 4-7.

TROUBLE SHOOTING AND SERVICE

5-2 Manual 0-5145

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.

Routine Inspection, Testing & Maintenance

The inspection and testing of the Power Source and associated accessories shall be carried out in accordance
with Section 5 of EN 60974-1: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation
resistance test and an earthing test to ensure the integrity of the Power Source is compliant with Tweco's original
specifications.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in
EN 60974-1, then the above tests should be carried out prior to entering this location.

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.

NOTE

Please refer to local guidelines for further information.

B. 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.

C. 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.

D. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited
Tweco Service Provider.

Manual 0-5145 5-3 TROUBLE SHOOTING AND SERVICE

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. 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 this parts and their eventual failure.

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.

60

50

40

30

20

Output Voltage (Volts)

10

0

0102030405060708090 100 110 120 130 140 150

MIG (GMAW/ FCAW)

Fabricator 141i

STICK (SMAW)

Welding Current (Amps)

TIG (GTAW)

Art # A-11807

Figure 5-1: Fabricator 141i Volt-Ampere Curves

TROUBLE SHOOTING AND SERVICE

5-4 Manual 0-5145

SECTION 6: KEY SPARE PARTS

6.01 Tweco Fusion 140A MIG Gun Parts

Fabricator 141i

Torch Part No: 1017-1321

Art# A-11672_AB

Item

No.

1 Velocity Nozzle**

2

3

4 Conduit Assembly* WS42-3035-15 1420-1140

5

Description Part No.

VNS-50 1220-1201

VNS-50F 1220-1200

VNS-62 1220-1203

VNS-62F 1220-1202

VNS-37 1220-1206

VNS-37F 1220-1204

VNS-75FAS 1220-1205

VTS-23 1110-1308
VTS-30 1110-1309
VTS-35 1110-1310
VTS-40 1110-1311

Velocity Contact
Tip**

Handle / Trigger
Repair Kit

Tweco Rear

5A

Connector
Tweco Control Wire

5B

& Plug

5C Tweco Control Wire WS-354-TA-LC 2060-2141

VTS-45 1110-1312
VTS-52 1110-1314

VTS-116 1110-1315
VTSA-116 1110-1317
VTSA-364 1110-1313

VTS-564 1110-1316

F8 2020-2025

350-174H 2035-2110

35K-350-1 2000-2352

Table 6-1: Tweco Fusion 140A MIG Gun Parts

Figure 6-1

** Patent Pending

* Refer to Tweco Catalog No. 64-2103 for additional
options.

Manual 0-5145 6-1 KEY SPARE PARTS

Fabricator 141i

6.02 Power Source

A-11811_AB

Art #

31

KEY SPARE PARTS 6-2 Manual 0-5145

Figure 6-2

FABRICATOR 141i POWER SOURCE SPARE PARTS

ITEM PART NUMBER DESCRIPTION

1 W7006216 PCB,Power,141i
2 W7006227 PCB,Control,141i
3 W7003033 Solenoid,Valve,24VDC
4 W7006226 PCB, Remote Interface Integrated with Display, 141i
5 W7006209 Wiredrive Assy,w/ Motor,141i
6 W7004906 Feedroll retaining thumb screw
7 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed
8 W7004947 Fan,24VDC,4.75"x4.75"x1",141i

9 W7003010 Rectifier Bridge,1000V,50A
10 W7003215 Connector,Gas Inlet,5/8"-18UNF
11 W7006210 Dinse,Socket,141i
12 W7004983 Shoulder strap, 141i (not shown)
13 W7006224 Input Power Cable (not shown)
14 W7004942 Socket,8 Pin,w/ Harness
15 W7003053 Switch,On/Off,250V
16 W7004911 CT Sensor,Output,141i
17 W7004912 Wire Hub Assy,141i
18 W7006220 Panel, Front
19 W7006223 Panel, Rear
20 W7004922 Handle,141i
21 W7006222 Side and Top Panels (not shown)
22 W7004966 Adapter,Tweco 4,141i
23 W7004925 Guide,Inlet,.023-.045,141i
24 W7004967 Guide,Outlet,.023-.045,141i
25 W7006221 Panel,Door (not shown)
26 W7006208 Panel,Base,141i
27 870734 Knob,1/4" IDx.72" ODx.9" H
28 W7004972 Knob,1/4" IDx1" ODx0.9" H
29 W7006211 Panel,Front Control,141i
30 W7004953 Push Button Actuator
31 OTWAK/1S Screw,Locking,MIG Gun
32 W7004961 Thermistor,NTC,K45 47K,141i
33 W7004940 PCB Burnback Potentiometer
34 W7006214 PCB,Spool Gun,141i
35 W7004979 Fuse Holder,141i
36 W7006217 Fuse,10 Amp
37 W7006218 Label,Setup Chart,141i,English (not shown)
38 W7006219 Label,Setup Chart,141i,French (not shown)
39 W7006212 Inductor,141i (not shown)
40 W7004951 Spool Hub,141i
41 W7004943 Remote/Local and MIG/ Spool Gun Switch
42 W4017500 Dinse Adapter, 50mm- 25mm (not shown)

Table 6-2

Fabricator 141i

Manual 0-5145 6-3 KEY SPARE PARTS

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

4 SC PHCR M4 × 0.7-10 ST ZP Handle 2

5 SC PHCR M4 × 0.7-16 ST BK Front Panel 2

6 SC PHCR ST 6G × 3/8 STBK 8 Pin Remote Socket 2

Side Panel 3

Rear Panel 2
Front Panel 3
Side Panel 3
Door Assy 2

Rear Moulding 2

Front PCB 4

7 Nut Hexagon M4 × 0.7 ST ZP Fan 4

8 SC PHSL M4 × 0.7-30 ST ZP Fan 4

9 Nut Hexagon M12 × 1.75 ST ZP Gas Adaptor Inlet 1

10 Washer Flat, 7.91 D (M8) Wirefeeder Plate 2

11 Washer Spring, 7.91 D Wirefeeder Plate 2

12 Screw Hexagon M8 × 1.25-30 ST ZP Wirefeeder Plate 2

13 Nut Hexagon M8 × 1.25 ST ZP Wirefeeder Plate 2

14 Screw Hexagon HD 9/32 × 16 ×19 Wirefeeder Plate 2

15 Screw Skt Set M4 × 0.7 Tweco No. 4 Torch Adaptor 1

16 Screw Hexagon M6 × 1.0-10 ST ZP Tweco No. 4 Torch Adaptor 1

17 Nut Hexagon M10 × 1. 5 ST ZP Tweco No. 4 Torch Adaptor 1

Table 6-3

NOTE

All the hardware can be purchased from local store.

KEY SPARE PARTS 6-4 Manual 0-5145

4
1

4
1

4
1

SCREW ITEM 4, OFF
USED TO SECURE
MOULDING TO INTERNAL
PANEL

SCREW ITEM 5, OFF USED

5

TO SECURE MOULDING TO

2

BASE PANEL

Fabricator 141i

4
1

3

4

1

1

3

4

1

1

6
4

8
4

7
4

6
2

2

1

2

2

9
1

3

4

1

1

3

4

1

1

4
1

3

4

1

1

5
2

SCREW ITEM 5, 2 OFF USED
TO SECURE REAR MOULDING
TO BASE PANEL

SCREW ITEM 4, 2 OFF USED
TO SECURE DOOR ASSY TO
BASE PANEL

17

1

12

1111101

13

2

4
1

4
1

14

2

16

1

Art # A-11932_AB

15

1

Figure 6-3

Manual 0-5145 6-5 KEY SPARE PARTS

Fabricator 141i

This Page Intentionally Blank

KEY SPARE PARTS 6-6 Manual 0-5145

APPENDIX

Fabricator 141i

This Page Intentionally Blank.

Manual 0-5145 1

APPENDIX

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

Fabricator 141i

This Page Intentionally Blank.

APPENDIX

4 Manual 0-5145