Tweco 180 User Manual

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140

180

FABRICATOR

PORTABLE MIG WELDING MACHINE

Operating Manual

Version No: AC Issue Date: July 20, 2007 Manual No.: 0-4991 Operating Features:

Art # A-07923

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distr ibutor or service agency call 1-800-752-7621, or visit us on the web at www.thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety P hazards that may exist when working with this product.

recautions. They will help you to avoid potential

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Ar c is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgment, the Manufacturer assumes no liability for its use.

Fabricator 140 and 180 MIG Welding Machine Instruction Manual Number 0-4991 for: Fabricator 140 Catalog Number W1002500 Fabricator 180 Catalog Number W1002600

Published by: Thermadyne Industries 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

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: July 20, 2007 Revision AC Date: August 14, 2008

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 Principal Safety Standards ............................................................................. 1-4

1.03 Symbol Chart ................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc.................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole ................................................................................. 1-10

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 General ........................................................................................................... 2-2

2.05 Machine Specifications ................................................................................... 2-3

2.06 Volt - Amp Curves .......................................................................................... 2-4

2.07 Duty Cycle ...................................................................................................... 2-5

2.08 Fabricator 180A MIG Gun ............................................................................... 2-6

2.09 Installing a New Wire Liner ............................................................................ 2-7

2.10 MIG Gun Maintenance .................................................................................... 2-7

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Location ......................................................................................................... 3-1

3.02 Safety ............................................................................................................. 3-1

3.03 Grounding ...................................................................................................... 3-1

3.04 Electrical Input Requirements ........................................................................ 3-1

3.05 Requirements for Maximum Output ............................................................... 3-2

3.06 Installation of Shielding Gas (GMAW) Process .............................................. 3-2

3.07 Attaching the Gun and Cable Assembly to the Power Source ......................... 3-5

3.08 Polarity Changeover ....................................................................................... 3-6

3.09 Installing Wire Spool ...................................................................................... 3-7

3.10 Feedrolls ......................................................................................................... 3-8

3.11 Install Wir

3.12 Install Wire into the Welding Gun ................................................................. 3-11

e into the Feedhead ........................................................................ 3-9

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 General Safety Precautions ............................................................................ 4-1

4.02 Fabricator Controls ......................................................................................... 4-2

4.03 Gas Metal Arc Welding (GMAW) .................................................................... 4-4

4.04 Flux Cored Arc Welding (FCAW) ..................................................................... 4-4

4.05 Shutdown Procedures .................................................................................... 4-4

4.06 Basic Welding Technique................................................................................ 4-5

4.07 Welding Gun Positions ................................................................................... 4-6

4.08 MIG Welding (GMAW) Variables .................................................................... 4-7

4.09 Establishing the Arc and Making Weld Beads ................................................. 4-8

4.10 Pre-Weld Procedure ....................................................................................... 4-8

4.11 Welding Procedure ......................................................................................... 4-8

4.12 Reference Tables ............................................................................................ 4-9

4.13 Fabricator 140 Welding Setting Selection Guide ........................................... 4-10

4.14 Fabricator 180 Welding Setting Selection Guide ........................................... 4-12

4.15 Gas Selection for Gas Metal Arc Welding ..................................................... 4-14

SECTION 5:

MAINTENANCE & TROUBLESHOOTING .......................................................... 5-1

5.01 Cleaning of the Unit ........................................................................................ 5-1

5.02 Cleaning of the Feed Rolls .............................................................................. 5-1

5.03 Basic Troubleshooting .................................................................................... 5-1

5.04 Solving Problems Beyond the Welding Terminals .......................................... 5-1

5.05 Welding Problems .......................................................................................... 5-3

5.06 Power Source Problems .................................................................................5-5

APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1

APPENDIX 2: FABRICATOR 180 SYSTEM SCHEMATIC ............................................... A-2

APPENDIX 3: FABRICATOR 140 SYSTEM SCHEMATIC ............................................... A-4

APPENDIX 4: FEED ROLL KITS ........................................................................... A-6

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

SAFETY INSTRUCTIONS FABRICATOR 140, 180

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: 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.

SAFETY IN WELDING AND CUTTING. This publication and other

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.

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.

July 20, 2007 1-1 Manual 0-4991

15. Keep all panels and covers securely in place.

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.

FABRICATOR 140, 180 SAFETY INSTRUCTIONS

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

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.

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.

1. Keep your head out of the fumes. Do not breath 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 air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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.

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.

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen C utting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 P lasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

Manual 0-4991 1-2 July 20, 2007

SAFETY INSTRUCTIONS FABRICATOR 140, 180

2. If used in a closed area, vent engine exhaust outside and away

WARNING

from any building air intakes.

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

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

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

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

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.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

July 20, 2007 1-3 Manual 0-4991

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

FABRICATOR 140, 180 SAFETY INSTRUCTIONS

1.02 Principal Safety Standards

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.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et seq.)

NOTE

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 P1, 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.

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

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “...there is now a very large volume of scientific findings based

on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

ABOUT PACEMAKERS:

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

Manual 0-4991 1-4 July 20, 2007

SAFETY INSTRUCTIONS FABRICATOR 140, 180

1.03 Symbol Chart

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

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

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

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

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

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

July 20, 2007 1-5 Manual 0-4991

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

FABRICATOR 140, 180 SAFETY INSTRUCTIONS

1.04 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.

1.05 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.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

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

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. 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.

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.

Manual 0-4991 1-6 July 20, 2007

SAFETY INSTRUCTIONS FABRICATOR 140, 180

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

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.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

épais plus de 6 po. (150 mm) 5 ou 6

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

July 20, 2007 1-7 Manual 0-4991

FABRICATOR 140, 180 SAFETY INSTRUCTIONS

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.

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.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES 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.

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.

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.

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.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

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 piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

Manual 0-4991 1-8 July 20, 2007

SAFETY INSTRUCTIONS FABRICATOR 140, 180

4. N’utilisez pas une source de courant de soudage pour charger un

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.

accumulateur ou survolter momentanément un véhicule.

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

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.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction. Il faut se laver les mains après toute manipulation. (Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

1.06 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.

AVERTISSEMENT

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

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.

LATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

July 20, 2007 1-9 Manual 0-4991

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.

FABRICATOR 140, 180 SAFETY INSTRUCTIONS

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Sous Tension

Hors Tension

Tension dangereuse

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Fusible

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Distant

Facteur de Marche

Pourcentage

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

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

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

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Torch de

Purge Du Gaz

Mode Continu de Soudure

Soudure Par Point

Duréc du Pulse

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

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

Durée de Pré-Dèbit

Durée de Post-Dèbit

Soudage

Détente à 2-Temps

Détente à 4-Temps

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

115V 15A

Manual 0-4991 1-10 July 20, 2007

Classement de PriseSource Auxiliaire

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Probléme de Terre

Pouces Par Minute

Mètres Par Minute

Art # A-07639

INTRODUCTION FABRICATOR 140, 180

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or catalog numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the rear panel. In some cases, the nameplate may be attached to the control panel. Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

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.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Ther- mal Arc web site listed below and clicking on the Literature Library link:

http://www.thermalarc.com

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

July 20, 2007 2-1 Manual 0-4991

FABRICATOR 140, 180 INTRODUCTION

2.04 General

The Thermal Arc Fabricator 140 / 180 Machines are both single-phase input welding machine and come equipped with the following:

1. Built-in Wire Feeder and Wire Spool Hub

2. Quick Connect Welding Gun and Cable (10 Foot Length)

3. Work Cable and Clamp

4. Regulator/Flow Meter

5. Input Cord

6. Spare Parts Kit (4 contact tips)

7. Operational Manual

8. 0.5 lb Spool of Wire

The welding system is designed for use with the following processes:

1. GMAW – Gas metal arc welding (MIG). Requires the use of a shielding gas and regulator.

2. FCAW – Flux-cored arc welding – Does not require the use of a shielding gas.

As delivered from the factory, the Fabricator 140 is set up for .024" (0.6mm) diameter solid wire and the Fabricator 180 is set up for .030” (0.8mm) diameter solid wire.

The feed roll can be set up the Fabricator 140 for .030” (0.8mm) diameter solid wire and the Fabricator 180 for .024" (0.6mm) diameter solid wire.

Optional feedrolls, contact tips and gun liners are available to convert the gun and feed system to use the following wires.

1. .023” - .035" (0.6mm – 0.9mm) Solid Wire (Mild Steel and Stainless Steel)

2. .030" - .035” (0.8mm – 0.9mm) Self-Shielding Wire

3. .030" (0.8mm) Aluminum Wire

Refer to section 3.10 Feedrolls and Appendix 4 for more information.

reversed in either machine which will

Also refer to OPTIONAL EQUIPMENT LIST and 180A MIG Gun sections included in this manual.

Manual 0-4991 2-2 July 20, 2007

INTRODUCTION FABRICATOR 140, 180

pply

y Cy

(

)

(

)

(

)

(

)

(

)

2.05 Machine Specifications

Description Fabricator 140 Fabricator 180 Package System Part Number W1002500 W1002600 Power Source Wei Power Source Dimensions HxWxD

Number of Phases Frequency Flexible S u Su Nominal In Rated Input Current ^ 15A ^ 21A Rated kVA @ 100% Dut Rated In Maximum In Generator Requirements # 6kVA # 8.5kVA Supply VA @ max. output # 5.1kVA # 7kVA O Out Duty Cycle Period Number of Output Voltage Values 4 6 Minimum Mains Circuit to suit factory fitted Plug & Lead Maximum Mains Circuit to suit factory fitted Plug & Lead (Weld Current @ Duty Cycle) Wire Size Range

Lead Plug Type 5-15P 6-50P

ut Current 15A (65A@40%) 21A

en Circuit Voltage Range 20.5 – 34V 19.5 – 38V

ut Current Range 30 – 140A 30 – 180A

Weld Current @ Duty Cycle

ht 64 lb (29 k

15.8 x 10.0 x 21.3”

400 x 255 x 540mm

1 Ø

60Hz

Cable Size 7 ft (2.3 m) 14AWG 8 ft (2.5 m) 12AWG

ut Voltage 120V AC 230V AC

cle 1kVA 1.9kVA

ut Current 24A (90A@20%

10 Minutes

(+) 15A (65A@40%) (+) 21A (130A@25%)

(+) 24A (90A@20%) (+) 31A (180A@15%)

Steel

Stainless Steel .023” - .030”

0.6 - 0.8mm

Flux Core .030” - .035”

(0.8 - 0.9mm)

Aluminum .030” - .035” (0.8 - 0.9mm)

.023” - .030” - .035"

0.6 - 0.8 - 0.9mm

80 lb (36 k

130A@25%)

31A (180A@15%)

.023” - .030” - .035"

0.6 - 0.8 - 0.9mm

.030” - .035” - .045"

(0.8 - 0.9 - 1.2mm)

^ The Rated Input Current should be used for the determination of cable size & supply requirements. + Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for

your situation in this regard.

# Generator Requirements at the Maximum Output Duty Cycle.

Table 2-1: Specifications

July 20, 2007 2-3 Manual 0-4991

FABRICATOR 140, 180 INTRODUCTION

[

]

2.06 Volt - Amp Curves

[V out]

Fabricator 140

34 32 30 28 26 24 22 20 18 16 14 12 10

8 6 4 2

I out

0 102030405060708090100110120130140150

Figure 2-1: Volt/Amp curves of the Fabricator 140

[V out]

38 36 34 32 30 28 26 24 22 20 18 16 14 12 10

8 6 4 2 0

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

FABRICATOR 180

[I out]

Art # A-07888

Figure 2-2: Volt/Amp curves of the Fabricator 180

Manual 0-4991 2-4 July 20, 2007

INTRODUCTION FABRICATOR 140, 180

2.07 Duty Cycle

Duty Cycle is the amount of arc-on time (actual welding time) during any 10 minute period that a machine can operate at it’s rated output without damaging internal components. For example, the Fabricator 180 is designed for 25% duty cycle at 130 amps. This means that it has been designed and built to provide the rated amperage, 130 amps, for 2.5 minutes out of every 10 minute period. During the other 7.5 minutes of the 10 minute period, the Fabricator 180 must idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.

The Fabricator 140 is designed for 20% duty cycle at 90 Amps. The Fabricator 180 is designed for 25% duty cycle at 130 Amps If the unit overheats and the thermostat opens, wait 15 minutes for unit to cool.

Fabricator 140 at Rated Duty Cycle

45678

Min utes

910

Art # A-07889

Fabricator 180 at Rated Duty Cycle

45678

Min utes

Figure 2-3: Duty Cycle of Fabricator 140 and Fabricator 180

July 20, 2007 2-5 Manual 0-4991

FABRICATOR 140, 180 INTRODUCTION

2.08 Fabricator 180A MIG Gun

The Fabricator 180A MIG Gun (Figure 2-4) fitted to the FABRICATOR 140 and 180 offers robust construction, unparalleled reliability and easy replacement of consumable parts. The Fabricator 180A MIG Gun has an operating capacity in

excess of the capacity of the FABRICATOR and can be expected to give trouble free service.

Item Description Part No. Size

1 Nozzle 21-50

11-23 .023” (0.6mm)

2 Contact Tip

3 Gas Diffuser 35-50

Conductor Tube

Assembly 180 Gun

5 Handle Torch Black W7004069

Switch Trigger

180Gun Cable Assembly,

180Gun

8 Wire Liner 35-40-15

11-30 .030” (0.8mm) 11-35 .040” (1.0mm)

W7004068

W7004070

W7004071

Art # A-07956_AB

9 Gas Inlet Nipple N/A

Guide, Outlet,

F140/180

11 Connector Plug N/A

12 Gun Switch Lead N/A

Connector 6-pin 180SG/180Gun

Figure 2-4: Exploded View of Fabricator 180A MIG Gun

W7004023

W7004067

Manual 0-4991 2-6 July 20, 2007

INTRODUCTION FABRICATOR 140, 180

2.09 Installing a New Wire Liner

1. Be sure that the Fabricator 180A MIG Gun cable is arranged in a straight line and free from twists when installing or removing a wire liner (8). Remove the old liner by first removing the gun’s nozzle (1), contact tip (2) and gas diffuser (3). Then remove the outlet guide (10) from the connector plug and pull the old wire liner out of the cable assembly from the connector plug end.

2. To install a new wire liner, first inspect the o-ring gas seal on the liner for cuts or damage. Start from the connector plug end of the assembly and begin pushing the liner through the connector plug, cable assembly (7), and into the gun handle (5). If the liner should lodge along the way, gently whip or work the cable assembly (7) to aid forward movement.

3. When the wire liner meets the end of the connector plug and the new raw end extends through the end of the conductor tube assembly (4), the outlet guide (10) in the connecto to prevent its backward movement.

NOTE

When the liner assembly is fully inserted into the cable assembly and the liner stop is firmly against the connector plug, the “raw end” of the liner will protrude out of the open end of the gun conductor tube. Trim the wire liner so that it protrudes past the end of the conductor tube assembly (4) by approximately the length of the gas diffuser (3); 1

/16" ± 1/16" (27mm ± 1.5mm). See Figure 2-5. The trimmed end which seats in the gas diffuser (3) must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed.

r plug must be securely tightened onto the liner

4. Replace gas diffuser (3), contact tip (2) and nozzle (1).

Gas Diffuser

Wire Liner

Figure 2-5: Trim Wire Liner to Length Of Gas Diffuser

x x

2.10 MIG Gun Maintenance

Remove dust and metallic particles from the gun conduit by forcing clean, dry compresses air into the conduit once a week. This will minimize wire feeding problems.

July 20, 2007 2-7 Manual 0-4991

FABRICATOR 140, 180 INTRODUCTION

Manual 0-4991 2-8 July 20, 2007

INSTALLATION FABRICATOR 140, 180

SECTION 3:

INSTALLATION

3.01 Location

For best operating characteristics and longest unit life, take care in selecting the installation site. Avoid locations exposed to high humidity, dust, high ambient temperature, or corrosive fumes. Moisture can condense on electrical components, causing corrosion or shorting of circuits. Dirt on components will retain this moisture and also increases wear on moving parts.

Adequate air circulation is needed at all times in order to assure proper operation. Provide a minimum of 12” (300mm) of free air space at both the front and rear of the unit. Make sure that the ventilation openings are not obstructed.

CAUTION

The Fabricator is not suitable for use in rain.

The Fabricator 180’s power cord is equipped with a NEMA 6-50P plug and will only connect to a NEMA 6-50P receptacle.

CAUTION

Consult the nameplate for proper input voltage and input amperage. The method of installation, conductor size, and over-current protection shall conform to the requirements of the local electrical code. All installation wiring and machine connection shall be done by a competent electrician.

The National Electrical Code (Article 630B) provides standards for amperage handling capability of supply conductors based on the duty cycle of the welding power source. The Fabricator 140 has a 20% duty cycle (2 minutes of every 10 minutes can be used for welding) and the Fabricator 180 has a 25% duty cycle. The power cords supplied with these units comply with these standards. Ensure that the building supply and receptacle comply with NEC standards and any additional state and local codes.

3.02 Safety

Refer to additional installation instructions under the SAFETY INSTRUCTIONS AND WARNINGS (Section 1) in this manual.

3.03 Grounding

The internal frame of this welding machine should be grounded for personal safety. Where grounding is mandatory under state or local codes, it is the

responsibility of the user to comply with all applicable rules and regulations. Where no state or local codes exist,

it is recommended that the National Electrical Code be followed.

3.04 Electrical Input Requirements

Plug the input cord into a properly grounded and protected (by fuse or circuit breaker) mains receptacle capable of handling a minimum of 20 Amperes. The Fabricator 140

requires a 120VAC supply voltage and the Fabricator 180 requires a 230VAC supply voltage.

The Fabricator 140’s power cord is equipped with a NEMA 5-15P plug and will only connect to a NEMA 5-15P receptacle.

NOTE

The supply wiring for the welding power source must be capable of handling a minimum of 20 amperes. The welding power source must be the only load connected to the supply circuit. Poor unit performance or fr equently opening line fuses or circuit breakers can result from an inadequate or improper supply.

CAUTION

Do not connect the Fabricator 140 to an input power supply with a rated voltage that is greater than 125 Volts. power cord ground prong.

Do not connect the Fabricator 180 to an input power supply with a rated voltage that is greater than 250 Volts. power cord ground prong.

Do not remove the

CAUTION

Do not remove the

July 20, 2007 3-1 Manual 0-4991

FABRICATOR 140, 180 INSTALLATION

3.05 Requirements for Maximum Output

In order to obtain the maximum output capability of the Fabricator 140, a branch circuit capable of 20 amperes at 115 to 125 Volts 60 Hz is required. In order to obtain the maximum output capability of the Fabricator 180, a branch circuit capable of 30 amperes at 230 to 250 Volts 60 Hz is required. This generally applies when welding steel that is equal to or greater than 12 gauge (0.105” 2.5mm) in thickness.

The rated output with this installation is 90 amperes, 18 Volt, 20% duty cycle (2 minutes out of every 10 minutes used for welding) for the Fabricator 140, and 130 amperes, 20 Volt, 25% duty cycle (2.5 minutes out of every 10 minutes used for welding) for the Fabricator 180.

3.06 Installation of Shielding Gas (GMAW) Process

Refer to Figure 3-1.

NOTE

Shielding Gas is not required if the unit is using self-shielded FCAW (flux cored arc welding) wires.

1. Cylinder Positioning: Chain the cylinder to a wall or

other support to prevent the cylinder from falling over. If an optional portable mounting arrangement is used, follow the instructions that are provided with it.

2. Remove Cylinder Cap: Remove the large metal cap

on top of the cylinder by rotating counter clockwise. Next remove the dust seal.

3. Cracking: Position yourself so the valve is pointed

away from you and quickly open and close the valve for a burst of gas. This is called “Cracking” and is done to blow out any foreign matter that may be lodged in the fitting.

CAUTION

KEEP FACE WELL AWAY FROM THE CYLINDER VALVE DURING “CRACKING” Never “crack” a fuel gas cylinder valve near other welding works, sparks or open flames. Ensure that the surrounding area is well ventilated.

4. Fit Regulator/Flowmeter to Cylinders:

Screw the regulator into the appropriate cylinder. The nuts on the regulator and hose connections are right hand (RH) threaded and need to be turned in a clockwise direction in order to tighten. Tighten with a wrench.

CAUTION

Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

5. Attach Supplied Gas Line: Attach supplied gas line

between the regulator output and the desired input at the rear of the power supply depending on Spool Gun or MIG Gun use.

Manual 0-4991 3-2 July 20, 2007

INSTALLATION FABRICATOR 140, 180

Cap

Shielding Gas

“Cracking”

Shielding Gas

Gas Hose

Regulator and Flow Meter

1 1/8”

Shielding Gas

Art # A-07965

Figure 3-1 Gas Cylinder Installation

July 20, 2007 3-3 Manual 0-4991

FABRICATOR 140, 180 INSTALLATION

Adjusting Regulator

Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-2 and data charts Approx. 20 CFH)

The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause turbulence and weld porosity.

Argon or argon based gas flow rates:

- Workshop welding: 20-30 CFH

- Outdoors welding: 30-40 CFH Helium based or CO2 gas flow rates:

- Workshop welding: 30-40 CFH

- Outdoors welding: 40-50 CFH

NOTE

All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.

Art # A-07280

Figure 3-2: Adjusting flow rate

Refer to section 4.15 for suggested gas / filler metal combinations.

NOTE

The regulator/flowmeters used with argon based and carbon dioxide shielding gases are different. The regulator/flow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/flow meter will need to be fitted.

Two types of gas are generally used with Gas Metal Arc Welding (GMAW) of thin gauge sheet steel. A mixture of 75% Argon and 25% Carbon Dioxide (CO2) is recommended, Carbon Dioxide (CO2) can also be used.

Manual 0-4991 3-4 July 20, 2007

INSTALLATION FABRICATOR 140, 180

3.07 Attaching the Gun and Cable Assembly to the Power Source

The Fabricator 140/180 is supplied with a 180A MIG gun. The 180A MIG gun is designed with an ergonomic handle and fewer parts to eliminate performance problems. The 180A MIG gun uses standard readily available TWECO consumable parts.

1. Open the door to the machine.

2. Connect the gun cable to the power source by first

routing the switch lead through the access hole in the front panel followed by the gun cable (see Figure 3-3).

NOTE:

Turn the cable end to align the gas hose nipple on the connector plug with the keyway located in the bottom of the front panel access hole.

Front Panel Access Hole

Gas Hose Nipple

Gas Nipple Keyway

3. Loosen the thumbscrew and insert the gun cable end as

far as it will go. Tighten thumbscrew (see Figure 3-3).

4. Insert the gun switch plug into the gun switch socket

(see Figure 3-3).

5. If shielding gas is being used, push the gas hose on

to the gas hose nipple and secure it with the hose clamp.

6. To remove the gun, simply reverse these directions.

CAUTION

When disconnecting gun switch leads from the machine, grab the connectors and pull. Do not pull on the wires.

Gun Switch Socket

Thumbscrew

Hose Clamp

Gas Hose

Gun Switch Plug

Figure 3-3: Attaching Gun and Cable

July 20, 2007 3-5 Manual 0-4991

FABRICATOR 140, 180 INSTALLATION

3.08 Polarity Changeover

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions

As delivered from the factory, the output polarity is connected as DCEP (reverse polarity). The output terminals are located on the interior panel of the welding power source.

CABLE CONNECTIONS PROCESS POLARITY

CABLE TO GUN CABLE TO WORK

1. GMAW* – Solid Wire & flux cored with shielding gas

2. FCAW* – Self-shielding Wire – no Shielding Gas

* Ex cept ion: Cont ac t y our filler met al s uppl i er for recommended polarit y.

1. DCEP – Reverse Polarity* 1. Connected to (+) Pos. output terminal

2. DCEN – Straight Polarity* 2. Connected to (-) Neg. output terminal

1. Connected to (-) Neg. output terminal

2. Connected to (+) Pos. output terminal

Table 3-1: Process Cable Connections

Connection for GMAW (reverse polarity DCEP)

1. Open the door to the machine.

2. Remove the polarity terminal knobs.

3. Set up the polarity (as per Table 3-1 above) by

removing the leads from the terminals and reversing them if necessary. Refer to Figure 3-4.

4. Replace the polarity terminal knobs.

NOTE

Ensure that the polarity terminal knobs are tightly secured and that there is no connection between positive and negative terminals.

Connection for FCAW (straight polarity DCEN)

1. Open the door to the machine.

2. Remove the polarity terminal knobs.

3. Set up the polarity (as per Table 3-1 above) by

removing the leads from the terminals and reversing them if necessary. Refer to Figure 3-5.

4. Replace the polarity terminal knobs.

NOTE

Ensure that polarity terminal knobs are tightly secured and that there is no connection between positive and negative terminals.

Polarity Termi nal Knobs

Polarity Termi nal Leads

Figure 3-4: Connection for GMAW (reverse polarity DCEP)

Polarity Termi nal Knobs

Polarity Termi nal Leads

Gas Hose Normally Connected

Gas Hose Normally Disconnected

Figure 3-5: Connection for FCAW (straight polarity DCEN)

Manual 0-4991 3-6 July 20, 2007

INSTALLATION FABRICATOR 140, 180

3.09 Installing Wire Spool

As delivered from the factory, the unit is set for an 4” (102mm) spool.

Installation of 4” (102mm) Spool

Assemble parts in sequence (shown in Figure 3-6 from right to left).

1. Spool 4” (102mm)

2. "D" Washer

3. Retaining Spring

4. Nut

NOTE

Nut is tightened until a slight force is required to turn the spool\

Art # A-07905

Figure 3-6: 4" Spool Installation

July 20, 2007 3-7 Manual 0-4991

FABRICATOR 140, 180 INSTALLATION

.030

0.8

Art # A-07963

Installation of 8” (203mm) spool

Assemble parts in sequence (shown in Figure 3-7).

1. Spool 8” (203mm)

2. "D" Washer

3. Retaining Spring

4. Nut

5. Spool Adapter Hub

6. Drive Pin

NOTE

Nut is tightened until a slight force is required to turn the spool

Art # A-07906

Figure 3-7: 8" Spool Installation

3.10 Feedrolls

A feedroll consists of two different sized grooves. As delivered from the factory, the drive roll is installed for .023” (0.6mm) for the Fabricator 140, and .030” / .035” (0.8mm / 0.9mm) for the Fabricator 180.

The groove size visible when fitting the feedroll is the groove size in˜use.

The groove closest to the motor is the one to thread. This also applies to optional feedrolls which are available

for this machine.

Manual 0-4991 3-8 July 20, 2007

Figure 3-8: Feedroll Example

INSTALLATION FABRICATOR 140, 180

3.11 Install Wire into the Feedhead

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions.

Load the Wire Spool

Slide the wire spool onto the hub, loading it so that the wire will feed off the spool as the spool rotates counter- clockwise.

Make sure that the locating pin on the spool hub lines up with the hole in the spool. When the spool of wire is in place, replace the spool retaining pin.

NOTE

The hub tension has been pre-adjusted at the factory. However if adjustment is required, simply turn the spool nut counter-clockwise to reduce tension, and clockwise to increase tension.

CAUTION

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly and do not let go of it. Make sure that the end of the wire is free of any burrs and is straight.

Pressure Adjust Device Pressure Arm

Gun Cable End

Art # A-07911

Wire Spool Inlet Wire Guide Feedroll

Figure 3-9: Wire Feeder Components

July 20, 2007 3-9 Manual 0-4991

FABRICATOR 140, 180 INSTALLATION

Route the Wire Through the Feedhead

1. Loosen Pressure Adjust Device (Fig. 3-10).

Pressure Adjust Device

Pressure Arm

2. Open Pressure Adjust Device (Fig. 3-10).

3. Open Pressure Arm (Fig. 3-10).

4. Place the end of the wire into the Inlet Wire Guide, feeding it over the Feedroll. Make certain that the proper groove is being used (Fig. 3-11).

5. Pass the wire into the Gun Liner of the Gun Cable End (Fig. 3-11).

6. Close the Pressure Arm (Fig. 3-11).

7. Close the Pressure Adjust Device. Tighten it to a “snug” condition (Fig. 3-11).

8. Figure 3-12 shows the result with the wire installed.

Art # A-07912

Figure 3-10: Opening Pressure Arm

Pressure Adjust Device

Wire

Pressure Arm

Gun Cable End

Wire Spool Inlet Wire Guide

Figure 3-11: Inserting Wire

Figure 3-12: Wire Installed

Feedroll

Art # A-07913

Art # A-07915

Manual 0-4991 3-10 July 20, 2007

INSTALLATION FABRICATOR 140, 180

3.12 Install Wire into the Welding Gun

1. Plug the Welding Power Source into the 120VAC receptacle for the Fabricator 140, and into the 230VAC receptacle for the Fabricator 180.

WARNING

ELECTRIC SHOCK CAN KILL! With the gun switch (located on the gun) activated, welding power is applied to the output terminals, feedroll, ground clamp, gun cable connection and welding wire. Do not touch these parts with the gun switch activated.

2. Turn the welding machine ON with the front panel Voltage Control Switch set to "1".

OFF

4. Straighten the gun cable. Remove the nozzle and contact tip from the MIG welding gun (see Section

2.08).

WARNING

If ground connection clamp is in place on the workpiece the electrode wire is electrically “hot” when the gun switch is activated.

5. Activate the gun switch until the wire feeds out past the gun nozzle.

Nozzle

Contact Tip

Wire

Gun Switch

Figure 3--13: Power ON

3. Set the wire feed speed to half-way or "5".

Figure 3-14: Wire Speed Half-way

Figure 3-15: Feed Wire Through Gun

6. Deactivate the gun switch and replace the contact tip and nozzle. Cut the wire within ¼” (6mm) from the nozzle.

7. Set the Voltage Control Switch to "0 / OFF" and unplug the supply cord.

July 20, 2007 3-11 Manual 0-4991

FABRICATOR 140, 180 INSTALLATION

Manual 0-4991 3-12 July 20, 2007

OPERATION FABRICATOR 140, 180

SECTION 4:

OPERATION

4.01 General Safety Precautions

Read and understand the safety instructions at the beginning of this manual prior to operating this machine.

WARNING

Be sure to put on proper protective clothing and eye safeguards (welding coat, apron, gloves, and welding helmet, with proper lenses installed). See Safety Instructions and Warnings chapter included in this manual. Neglect of these precautions may result in personal injury.

WARNING

Make all connections to the power source including electrode and work cables, as well as remote control cables, with the power source turned off. These connections could be electrically live with the power switch ON.

WARNING

ELECTRIC SHOCK CAN KILL! Do not operate the machine with the door open.

CAUTION

Do not pull the machine with the gun. Damage can occur to the gun, gun liner and machine. Avoid bending the gun cable with a sharp radius. Damage can occur to the gun liner.

July 20, 2007 4-1 Manual 0-4991

FABRICATOR 140, 180 OPERATION

4.02 Fabricator Controls

Refer to Figure 4-1

(1) The Wire Speed Control knob controls the welding

current via the electrode wire feed rate (i.e. the speed of the wire feed motor).

(2) The Voltage Control Switch sets the voltage level to

the welding terminals as it is rotated in the clockwise direction. There are 4 positions available in the Fabricator 140 and 6 positions in the Fabricator 180. The OFF switch position disconnects the power from the controls.

CAUTION

The Voltage Control Switch MUST NOT BE SWITCHED during the welding process. Some internal electrical components are at Mains voltage potential with this switch in the OFF position.

(3) MIG Gun cable end and Gun Switch Leads are

routed through this opening.

(4) The Work Cable & Clamp connects to the item

being welded.

(5) The gas inlet nipple is used to connect the gas

hose to the gas regulator for GMAW or FCAW. Use the hose clamp to secure the has hose to the gas nipple.

NOTE

Genuine TWECO contact tips and liners should be used. Many non-genuine liners use inferior materials which can cause wire feed problems.

(9) The Gun Adaptor connects the MIG Gun to the

feedhead assembly.

(10) The Gun Switch Connector is provided for

connection of the Gun Switch Leads. (11) 32A Primary Circuit Breaker. (12) Negative (-) Welding Terminal. (13) Positive (+) Welding Terminal.

CAUTION

Loose welding terminal connections can cause overheating and result in the cables being fused to the welding terminals.

(14) The wire reel hub incorporates a friction brake

which is adjusted during manufactur e for

optimum braking. If it is considered necessary,

adjustment can be made by turning the large nut

inside the open end of the wire reel hub. Clockwise

rotation will tighten the brake. Correct adjustment

will result in the wire reel circumference continuing

no further than ¾” (20mm) after release of the

Torch Trigger Switch. The wire should be slack

without becoming dislodged from the reel.

(6) Main Power Cable (Fabricator 140 shown) (7) The FABRICATOR 180A MIG gun has an operating

capacity in excess of the capacity of the FABRICATOR and may be fitted to many different types of MIG welding power supplies.

(8)The moveable roller applies pressure to the

grooved roller via screw-adjustable spring pressure. The adjustable spring screw 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 clogging by metal flakes and slag. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the adjustable spring screw clockwise. The use of excessive pressure may cause rapid wear of the feed roller, motor shaft and motor bearings.

Manual 0-4991 4-2 July 20, 2007

kinks and

Excessive tension on the brake will cause rapid wear of mechanical wire feed par ts, overheating of electrical components and possibly an increased incidence of wire burnback into the contact tip.

CAUTION

OPERATION FABRICATOR 140, 180

F A B R I C A T O R

OFF

Weldskill

Art # A-07916

1213

Figure 4-1: Fabricator Controls

July 20, 2007 4-3 Manual 0-4991

FABRICATOR 140, 180 OPERATION

4.03 Gas Metal Arc Welding (GMAW)

See Welding Guidelines included in this manual. Make all necessary connections as instr ucted in the

INSTALLATION chapter. Place the WELD VOLTAGE RANGE SWITCH at the desired

setting.

CAUTION

Do not turn the WELD VOLTAGE RANGE SWITCH clockwise past position 4, as damage to the switch may occur.

Rotate the WIRE SPEED control to the desired setting. Plug the supply cord into a 120 VAC 20 Ampere receptacle

for the Fabricator 140, and into a 230 VAC 30 Ampere receptacle for the Fabricator 180.

Open the gas cylinder valve to supply shielding gas to the gun.

Connect the WORK CLAMP to the workpiece (material to be welded).

Travel at a speed necessary to maintain a bead width from

/8" to ¼" (3mm to 6mm) depending on the thickness of the material. For material that may require larger weldments, either change to a larger diameter filler wire or use multi pass beads. On some applications, it may be necessary to adjust the voltage range to stabilize the arc.

Upon completion of the weld, release the gun trigger switch, raise the welding helmet, and visually examine the weld.

NOTE

To help you overcome any problems that might arise, you will find useful information in section

4.08 Basic Welding Techniques.

4.04 Flux Cored Arc Welding (FCAW)

Follow the same general procedure as with the GMAW process above. Shielding gas is not required for self shielded type wires. For differences in the process see section 4.08 Basic Welding Techniques. Also included is information to solve any problem related to the FCAW process.

4.05 Shutdown Procedures

Extend wire from the gun, and cut to proper stick-out for that type of wire (when welding always maintain this distance).

Position gun to where it is at approximately right angles to the workpiece with proper wire stick-out. Lower your welding helmet and pull the gun trigger switch.

WARNING

Be sure to put on proper protective clothing and eye safeguards (welding coat, apron, gloves, and welding helmet with proper lenses installed). See Safety Instr uctions and Warnings chapter included in this manual. Neglect of these precautions may result in personal injury.

Close the cylinder valve (GMAW process only). Press gun switch to vent gas line (GMAW process only). Place the POWER ON/OFF SWITCH in the OFF position.

WARNING

After releasing the gun switch, the electrode wire will remain electrically “hot” for several seconds.

Manual 0-4991 4-4 July 20, 2007

OPERATION FABRICATOR 140, 180

Base Metal

Arc

Electrode

Nozzle

Shielding Gas

Weld Metal Solidiﬁed Weld Metal

Art: A-05103

4.06 Basic Welding Technique

General

Two different welding processes are covered in this section, with the intention of providing the very basic concepts in using the semi-automatic mode of welding. In this mode, the welding gun is hand-held. The electrode (welding wire) is then fed into a weld puddle and the arc is shielded by a gas or gas mixture.

Setting of the Power Supply

The settings of the Fabricator requires some practice by the operator in that the welding Power Supply has two control settings that need to balance. These are the Wire Speed control and the Voltage Control switches. The welding current is determined by the Wire Speed control (i.e., the current will increase with increased wire speed, resulting in a shorter arc). Slower wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alte lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding current.

rs the welding current level, but

GAS METAL ARC WELDING (GMAW)

This process, also known as MIG welding, CO

welding,

Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid, continuous, consumable electrode and the work. Shielding is obtained from an externally supplied gas or 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.

Figure 4-2: GMAW Process

When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more wire speed to achieve the same current level.

A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the work piece.

If the wire speed 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 electrode wire, causing spatter. The correct setting of voltage and wire speed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.

FLUX CORED ARC WELDING (FCAW)

This process also known as Dual-Shielded, Innershield, FAB Shield, FabCO, etc., 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.

Molten Metal

Solid Weld Metal

Slag

Gas (optional)

Molten Slag

Nozzle (optional)

Flux Cored Electrode

Arc

Art: A-05104

Figure 4-3: FCAW Process

July 20, 2007 4-5 Manual 0-4991

FABRICATOR 140, 180 OPERATION

WARNING

Follow these instructions only after referring to the Safety Instructions and Warnings chapter of this manual, and the instructions in the Installation chapter

Check List Before Starting

POLARITY – DCEP (Direct Current Electrode Positive) or DCEN (Direct Current Electrode Negative) WIRE FEED SPEED – 1 to 10 VOLTAGE RANGE SWITCH SETTING – 1 to 4 GAS FLOW RATE – 15 to 25 CFH ELECTRODE WIRE STICK-OUT – approx 3/8” (10mm)

4.07 Welding Gun Positions

The welding gun should be held at an angle to the weld joint (see Secondary Adjustment Variables in Section 4.08). Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses.

CAUTION

Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stickout) and make a very poor weld.

The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed on the seam or joint prior to lowering the helmet.

5º to 15º Longitudinal Angle

90º Tra nsverse Angle

Art: A-05105

Figure 4-4: Butt and Horizontal Welds

10º Longitudinal Angle

30 to 60º Tra nsverse Angle

Direction of Travel

10 to 20º Longitudinal Angle

to 60º

30º

Tra nsverse Angle

5 to 15º Longitudinal Angle

Direction of Travel

30 to 60º Tra nsverse Angle

Art: A-05107

Figure 4-6: Horizontal Fillet Weld

Direction of Travel

30 to 60º Tra nsverse Angle

Art: A-05108

5 to 15º Longitudinal Angle

Direction of Travel

Art: A-05106

Figure 4-7: Overhead

Figure 4-5: Vertical Weld

Manual 0-4991 4-6 July 20, 2007

OPERATION FABRICATOR 140, 180

4.08 MIG Welding (GMAW) Variables

Most of the welding done by all processes is on carbon steel. The following items describe the welding variables in short-arc welding of 24 gauge (0.024”, 0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.

Pre-selected Variables

Pre-selected 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:

1. Type of electrode wire

2. Size of electrode wire

3. Type of gas (not applicable to self-shielding wires FCAW)

4. Gas flow rate (not applicable to self-shielding wires FCAW)

Primary Adjustable Variables

These control the process after Pre-selected Variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness. They are:

2. Wire Feed Speed. Increase in wire feed speed increases weld current. Decrease in wire feed speed decreases weld current.

3. Nozzle Angle. (Figures 4-9 and 4-10) This refers to the position of the welding 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 center line of the welding 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.

Tra nsverse Angle

Longitudinal Angle

Axis of Weld

1. Arc Voltage

2. Welding Current (wire feed speed)

3. Travel Speed

Secondary Adjustable Variables

These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are:

1. Stickout—distance between the end of the contact tube (tip) and the end of the electrode wire. Keep this at about 3/8” (10mm) stickout (as shown in Figure 4-8).

Gas Nozzle

Tip to Work Distance

Average Arc Length

Contact Tip (Tube) Electrode Wire

Actual Stickout

Art: A-05109

Figure 4-8: Electrode Stick-Out

Art: A-05110

Figure 4-9: Transverse and Longitudinal Nozzle Axes

Direction of Gun Travel

Art # A-05111

Leading or "Pushing" Angle (Forehand)

90º

Trailing or "Pulling" Angle (Backhand)

Figure 4-10: Nozzle Angle, Right-Handed Operator

July 20, 2007 4-7 Manual 0-4991

FABRICATOR 140, 180 OPERATION

4.09 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 MIG welding procedure for the beginner to experiment with, is the flat position. This equipment is capable of flat, vertical and overhead positions.

For practicing MIG welding, secure some pieces of 16 or 18 gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel plate 6” x 6” (150 x 150mm). Use 0.024” (0.6mm) wire and CO

shielding gas.

4.10 Pre-Weld Procedure

1. Check the OPERATION chapter of this manual for details on this equipment.

2. Set the welding voltage range switch at position 1 or 2.

3. Set the wire feed speed control to about the 2.5 setting. Readjust as necessary.

4. Adjust the gas flow rate to about 20 cubic feet per hour (15 - 20 lpm).

5. Review standard safe practice procedures in ventilation, eye and face protection, fire, compressed gas and preventative maintenance. See Safety Instructions and Warnings chapter included in this manual.

4.11 Welding Procedure

1. Maintain the tip to work distance (stickout) at 5/16” to 3/8” (8 to 9mm) at all times.

2. For transverse and longitudinal nozzle angles, see section 4.07 Welding Gun Positions.

3. Hold the gun about 3/8” (9mm) from the work, lower the helmet by shaking your head and squeeze the trigger to start the wire feeding, and establish the arc.

NOTE

Get in the habit of shaking the helmet down, rather than using the hands. One hand must hold the gun, and the other is often needed to hold pieces to be tacked or positioned.

4. Make a single down-hand (pulling) stringer weld bead.

5. Practice welding beads. Start at one edge and weld across the plate to the opposite edge.

NOTE

When the equipment is properly adjusted, a rapidly cracking or hissing sound of the arc is

a good indicator of correct arc length.

6. Practice stopping in the middle of the plate, restarting into the existing weld crater and continuing the weld bead across the plate.

NOTE

When the gun trigger is released after welding, the electrode forms a ball on the end. To the new operator, this may present a problem in obtaining the penetration needed at the start of the next weld. This can be corrected by cutting the ball off with wire cutters.

Manual 0-4991 4-8 July 20, 2007

OPERATION FABRICATOR 140, 180

4.12 Reference Tables

The following tables are provided as user aids when performing MIG or FLUX CORED welding.

Type of Gas Typical Mixtures Primary Uses Carbon Dioxide (CO2) Mild and low alloy steels

Argon (Ar) - Carbon Dioxide (CO2) 75% Ar – 25% CO2 Mild and low alloy steels, Stainless Steel Argon (Ar)

Aluminum

Result Desired

Voltage

Deeper

Penetration

Shallower

Penetration

Larger Bead

Smaller Bead

Higher

Decreas

Narrower Bead

Flatter Wider

Increase

Bead

Faster

Deposition Rate

Arc

Welding Current

(wire speed)

Increase

Decrease

Increase 2Decrease

Decrease 2Increase

Increase

Welding Variable

Travel

Nozzle Angle Stick out Wi r e

Speed

3Trailing Max

Gas

25°

size

2Decrease 5Smalle r

(*)

Type

4CO

3Leading 2Increase 5Larger 4Ar CO

mix

3Increase

(*)

3Decrease

(*)

Trailing 3Increase

290° or

3Decrease

Leading

2Increase

3Smalle r

(*)

Slower

Deposition Rate

Key: (1) First Choice, (2) Second Choice, (3) Third Choice, (4) Fourth Choice, (5) Fifth Choice

* When these variables are changed, the wire feed speed must be adjusted so that the welding current remains constant. See DEPOSITION RATE in the WELDING VARIABLES section. This change is especially helpful on materials of 20 gauge (.04” 1mm approximately) and smaller in thickness.

July 20, 2007 4-9 Manual 0-4991

Decrease

Same adjustment is required for wire feed speed

NOTE

2Decrease

(*)

3Larger

FABRICATOR 140, 180 OPERATION

4.13 Fabricator 140 Welding Setting Selection Guide

Material Type Wire Type Shielding Gas

and Flow Rate

100%

25cfh

Solid

Steel

(or hard)

ER70S-6

75% Ar

25%

25cfh

Wire Size

(Diameter)

.023” (0.6mm)

.030” (0.8mm) .035” (0.9mm)

.023” (0.6mm)

.030” (0.8mm) .035” (0.9mm)

Art # A-07960

Flux Core

Steel

Aluminum Aluminum

***

E71T-GS

Stainless

Steel

ER 308L

None

Required

100% Ar

25cfh

75% Ar

25%CO

25cfh

90% He

7.5% Ar

2.5 CO

35cfh

.030” (0.8mm)

.035” (0.9mm)

.030” (0.8mm) .035” (0.9mm)

.023” (0.6mm)

.030” (0.8mm) .023” (0.6mm)

.030” (0.8mm)

Manual 0-4991 4-10 July 20, 2007

OPERATION FABRICATOR 140, 180

4.13 Fabricator 140 Welding Setting Selection Guide (con't)

OFF ARRÊT

22 ga. (0.8mm)

20 ga. (0.9mm)

1.5

1.4

1.5

Voltage Step

Wire Speed

18 ga. (1.2mm)

1/16” (1.6mm)

234

1.5 2 3 5

1.4

1.5

3.5

1.5

1.4

1/8” (3mm)

4 4

THICKNESS

3/16” (4.5mm)

2.2

3.5

2.2

5.5

3.5

1.2

2 2 2

1.2

2.5

1.3

1.5

1.4

3.2

2.4

3 3

2.5

1.7

2.5

2 2.5

3.2

443

2.71.7

2.7

443

4.54

5.2

234

2 3.5 6

3.52.51.81.8

73.5

1.5

July 20, 2007 4-11 Manual 0-4991

1.5

2.3

3.5

FABRICATOR 140, 180 OPERATION

4.14 Fabricator 180 Welding Setting Selection Guide

Material Type Wire Type Shielding Gas

and Flow Rate

100%CO

25cfh

Solid

Steel

(or hard)

ER70S-6

75% Ar

25%

25cfh

92% Ar

Wire Size

(Diameter)

.023” (0.6mm)

.030” (0.8mm) .035” (0.9mm)

.023” (0.6mm)

.030” (0.8mm) .035” (0.9mm)

.035” (0.9mm)

Art # A-07959

Flux Core

Steel

E71T-GS

Aluminum Aluminum

Stainless

Steel

ER 308L

None

Required

100% Ar

25cfh

90% He

7.5% Ar

2.5 CO

35cfh

.030” (0.8mm)

.035” (0.9mm) .045” (1.2mm)

.030” (0.8mm) .035” (0.9mm)

.025” (0.6mm)

.030” (0.8mm) .035” (0.9mm)

Manual 0-4991 4-12 July 20, 2007

OPERATION FABRICATOR 140, 180

4.14 Fabricator 180 Welding Setting Selection Guide (con't)

OFF

ARRÊT

Voltage Step

Wire Speed

THICKNESS

22 ga. (0.8mm)

20 ga. (0.9mm)

1.6

1.4

1.6

1.5

18 ga. (1.2mm)

1/16” (1.6mm)

1/8” (3mm)

3/16” (4.5mm)

1355

1.6 1.9 3.5 6.5 10

1.4

1.2

1.6

1.5

1.3

1.5

1.4

1.5

1.4

3 3

3 2

2.3

1.7

3.5 2

1.6

4 4

4 3

2.4

5.5

2.5 2

5.3 7.4

3.5

5.5

4.3

3.3

4.2

145

1.6

1.9 4.3 6

1/4” (6.4mm)

3.7

4.5

4.2

1.4

2 3

3 3

1.6

1.8

3.5

4.5

4.7

5.5

2.5

6.2

2245

2.6 3 3.6 5.7

3.5

6.2

5.7

3.72.522

July 20, 2007 4-13 Manual 0-4991

32.52

FABRICATOR 140, 180 OPERATION

4.15 Gas Selection for Gas Metal Arc Welding

Metal Type

Carbon

Steel

Low Alloy

and

High Alloy

Steel

Base Plate

Thickness

Greater than

22 gauge

(.030”)

Greater than

22 gauge

(.030”)

Greater than

22 gauge

(.030”)

Greater than

10 gauge (1/8”)

Greater than

22 gauge

(.030”)

Greater than

22 gauge

(.030”)

Filler

Metal

Transfer

Mode

ER70S-X Short

Circuit

ER70S-X Short

Circuit

ER70S-X Short

Circuit

ER70S-X Spray

Transfer

See Note 1 Short

Circuit

Globular

See Note 1 Short

Circuit

Suggested

Shielding Gas

Welding

Positions

100% CO2 All Position

Welding

75% Argon

25% CO

92% Argon

8% CO

92% Argon

8% CO

75% Argon

25% CO

92% Argon

8% CO

All Position

Welding

All Position

Welding

Flat & HV

Fillet

All Position

Welding

All Position

Welding

Comments

High welding speeds. Good penetration and pool control.

Suitable for high-current and highspeed welding.

Higher deposition rates without meltthrough. Minimum distortion and spatter. Good pool control for out-of- position welding.

Good arc stability, weld soundness, and increasing width of fusion.

High welding speeds. Good penetration and pool control. Applicable for out-of-position welds. Suitable for high-current and highspeed welding.

Good coalescence and bead contour. Good mechanical properties.

Stainless

Steel

Greater than

3/32”

Greater than

14 gauge

(.075”)

Greater than

22 gauge

(.030”)

Greater than

3/32”

See Note 1 Spray

transfer

See Note 1 Short

Circuit

ER308-X ER309-X

Short

Circuit

ER316-X

ER308-X ER309-X

Spray

Transfer

ER316-X

92% Argon

8% CO

98% Argon

2% CO

90% Helium

7.5% Argon

2.5% CO or

81% Argon

18% Helium

1 % CO

90% Helium

7.5% Argon

2.5% CO or

81% Argon

18% Helium

1 % CO

Flat & HV

Fillet

All Position

Welding

All Position

Welding

Flat & HV

Fillet

Reduces undercutting. Higher deposition rates and improved bead wetting. Deep penetration and good mechanical properties.

Good control of melt-through and distortion. Used also for spray arc welding. Pool fluidity sometimes sluggish depending on the base alloy.

Low CO

percentages in Helium mix

minimizes carbon pickup, which can cause intergranular corrosion with some alloys. Helium improves wetting action and contour. CO

percentages

above 5% should be used with caution on some alloys.

Good arc stability. Produces a fluid but controllable weld pool, good coalescence, and bead contour. Minimizes undercutting on heavier thickness.

Aluminum Greater than

18 gauge

(.045”)

ER4043 ER5356

Spray

Transfer

Argon All Position

Welding

Excellent cleaning action. Provides more stable arc than helium-rich mixtures.

Note 1: Contact your Filler Metal Supplier for recommended filler metal for the base metal to be welded.

Manual 0-4991 4-14 July 20, 2007

MAINTENANCE FABRICATOR 140, 180

SECTION 5:

MAINTENANCE & TROUBLESHOOTING

5.01 Cleaning of the Unit

Periodically remove the right side panel (after disconnecting the supply cord from the receptacle) and blow out the interior with clean, dry, compressed air of not more than 25 PSI air pressure. Do not strike any components with the air hose nozzle.

5.02 Cleaning of the Feed Rolls

Clean the wire groove on the feed roll at frequent intervals. This cleaning operation can be done by using a small wire brush. To clean the wire groove, loosen the pressure device and lift the feedroll pressure arm. Remove all wire from the feedhead. Wipe off the bearing roll (the “top” roll in the feedhead).

5.03 Basic Troubleshooting

The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and without removing the covers from the Power Source.

If major components are faulty, then the Power Source should be returned to an Accredited THERMAL ARC Service Agent for repair.

5.04 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 torch. There are two main areas where problems occur with GMAW:

1. 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:

1. Gas cylinder contents and flow meter.

a. Ensure that the gas cylinder is not empty and

the flow meter is correctly adjusted to 20CFM (15 liters per minute).

2. Gas leaks

a. Check for gas leaks between the regulator/

cylinder connection and in the gas hose to the Power Source.

3. Internal gas hose in the Power Source.

a. Ensure the hose from the solenoid valve to the

MIG torch adaptor has not fractured and that it is connected to the MIG torch adaptor.

4. Welding in a windy environment.

a. Shield the weld area from the wind or increase

the gas flow.

5. Welding dirty, oily, painted, oxidized or greasy plate.

a. Clean contaminates off the plate.

6. Distance between the MIG torch nozzle and the work piece.

a. Keep the distance between the MIG torch nozzle

and the work piece to a minimum.

July 20, 2007 5-1 Manual 0-4991

FABRICATOR 140, 180 MAINTENANCE

7. Maintain the MIG torch in good working order.

a. Ensure that the gas holes are not blocked and

gas is exiting out of the torch nozzle. Refer to WARNING below.

b. Do not restrict gas flow by allowing spatter to

build up inside the MIG torch nozzle.

WARNING

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

2. Inconsistent wire feed

Wire feeding problems can be reduced by checking the following points:

1. Wire spool brake is too tight.

a. Feed roller driven by motor in the cabinet will

slip.

6. Incorrect or worn contact tip.

a. The contact tip transfers the weld current to

the electrode wire. If the hole in the contact tip is too large, then arcing may occur inside the contact tip resulting in the electrode wire jamming in there. When using soft electrode wire such as aluminum, the wire may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft electrode wires should be used.

7. Poor work lead contact to work piece.

a. 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.

a. This will cause friction between the wire and

the liner thus reducing wire feedability

2. Wire spool brake is too loose.

a. Wire spool can unwind and tangle.

3. Worn or incorrect feed roller size.

a. Use ‘U’ groove drive feed roller matched to the

aluminum wire size you are welding. Use ‘V’ groove drive feed roller matched to the steel wire size you are welding. Use ‘knurled V’ groove drive feed roller matched to the flux cored wire size you are welding.

4. Misalignment of inlet/outlet guides.

a. Wire will rub against the misaligned guides and

reduces wire feedability.

5. Liner blocked with slag.

a. Slag is produced by the wire passing through

the feed roller, if excessive pressure is applied to the pressure roller adjuster. Slag can also be produced by the wire passing through an incorrect feed roller groove shape or size. Slag is fed into the liner where it accumulates, thus reducing wire feedability.

Manual 0-4991 5-2 July 20, 2007

MAINTENANCE FABRICATOR 140, 180

5.05 Welding Problems

FAULT CAUSE REMEDY

1 Undercut. A Welding arc voltage

too high.

B Incorrect torch

angle

C Excessive heat input C Increase the torch travel speed and/or

2 Lack of penetration. A Welding current too

low

B Joint preparation

too narrow or gap

A Reduce voltage by reducing the voltage

selection switch position or increase the wire feed speed.

B Adjust angle

reduce welding current by reducing the voltage selection switch position or reducing the wire feed speed.

A Increase welding current by increasing

wire feed speed and increasing voltage selection switch position.

B Increase joint angle or gap

C Shielding gas

incorrect

3 Lack of fusion. Voltage too low Increase voltage by increasing voltage

4 Excessive spatter. A Voltage too high A Lower voltage by reducing the voltage

B Voltage too low B Raise voltage by increasing the voltage

5 Irregular weld shape. A Incorrect voltage

and current settings. Convex = voltage too low. Concave = voltage too high.

B Wire is wandering B Replace contact tip

C Incorrect shielding

gas

D Insufficient or

excessive heat input

C Change to a gas which gives higher

penetration

selection switch position.

selection switch or increase wirespeed control.

selection switch or reduce wirespeed control.

A Adjust voltage and current by adjusting

the voltage selection switch and the wirespeed control.

C Check shielding gas

D Adjust the wirespeed control or the

voltage selection switch

Table 5-1a: Welding Problems

July 20, 2007 5-3 Manual 0-4991

FABRICATOR 140, 180 MAINTENANCE

FAULT

6 Weld cracking A Weld beads too small A Decrease travel speed

7 Cold weld puddle A Faulty rectifier unit A Have an Accredited THERMAL ARC Service

C Low Primary Voltage C Contact supply authority

8 Arc does not have a crisp

sound that short arc exhibits when the wir

efeed speed and voltage are adjusted correctly.

CAUSE REMEDY

B Weld penetration

narrow and deep

C Excessive weld

stresses

D Excessive voltage D Decrease voltage by reducing the voltage

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

B Loose welding cable

connection.

The MIG torch has been

connected to the wrong voltage polarity on the front panel.

B Reduce current and voltage and increase MIG

torch travel speed or select a lower penetration shielding gas.

C Increase weld metal strength or revise design

selection switch.

welded or cool slowly.

Agent to test then replace the faulty component.

B Check all welding cable connections.

Connect the MIG torch to the positive (+)

welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

Table 5-1b: Welding Problems Continued

Manual 0-4991 5-4 July 20, 2007

MAINTENANCE FABRICATOR 140, 180

5.06 Power Source Problems

FAULT CAUSE REMEDY

1 Primary line voltage is

ON. Welding arc can not be established.

2 Primary line voltage is

ON but when the MIG Gun trigger switch is depressed nothing happens.

3 Primary line voltage is

ON, no wire feed but gas flows from the MIG Gun when the torch trigger switch is depressed.

4 Wire feeds when the MIG

Gun trigger switch is depressed but arc can not be established.

5 Jerky wire feed A Worn or dirty contact tip A Replace

B Worn feed roller.BReplace C Excessive back tension from

D Worn, kinked or dirty conduit

6 No gas flow A Gas hose is cut. A Replace or repair.

B Gas passage contains

C Gas regulator turned off. C Turn on.

7 Gas flow continues after

the MIG Gun trigger switch has been released.

A Primary fuse is blown. A Replace primary fuse.

BBroken connection in primary

circuit.

MIG Gun trigger switch leads

are disconnected.

AElectrode wire stuck in wire

liner or contact tip (burn-back jam).

B Faulty control PCB B Have an Accredited THERMAL ARC Service Agent

Poor or no work lead connection.

wire reel hub.

liner

impurities.

Gas valve has jammed open

due to impurities in the gas or the gas line.

B Have an Accredited THERMAL ARC Service Agent check

primary circuit.

Reconnect.

A Check fo

contact tip. Replace faulty component(s).

investigate the fault. Clean work clamp area and ensure good electrical contact.

C Reduce brake tension on spool hub

DClean or replace conduit liner

B Disconnect gas hose from the rear of FABRICATOR then

raise gas pressure and blow out the impurities.

Have an Accredited THERMAL ARC Service Agent repair or

replace gas valve.

r clogged / kinked MIG Gun wire liner or worn

Table 5-2: Power Source Problems

July 20, 2007 5-5 Manual 0-4991

FABRICATOR 140, 180 MAINTENANCE

Manual 0-4991 5-6 July 20, 2007

APPENDIX FABRICATOR 140, 180

APPENDIX 1: OPTIONS AND ACCESSORIES

• Contact your Thermal Arc distributor to order options and accessories. For assistance in locating a Thermal Arc distributor, contact the Thermadyne office listed in the inside rear cover that is nearest to you.

• Note the model and specification number shown on the equipment nameplate.

For T weco/V ictor Inquiries and Orders: Call 1-800-318-6819 Consumable Parts Management Group

EQUIPMENT OPTIONS PART NO Description

GUNS

Tweco® WeldSkill 10ft W4011400

ACCESSORIES

Victor Regulator/Flowmeter Mixed Gases 0781-2723 Victor Regulator/Flowmeter CO2 0781-2725 Medalist™ 1400 Series, HRF Flowmeter Regulator, CO2 gas

CONSUMABLES Feedroll Kits Feedroll .023”-.030”/.035” (0.6-0.8/0.9mm) 7977036 V grooved for hard wire Feedroll .035”-.045” (0.9-1.2mm) 7977660 V grooved for hard wire Feedroll .030”-.035” (0.8-0.9mm) 7977731 U grooved for soft wire Feedroll .040”-.045” (1.0-1.2mm) 7977264 U grooved for soft wire Feedroll .030”-.035” (0.8-0.9mm) 7977732 V grooved knurl for cored wire Feedroll .045”-.1/16” (1.2-1.6mm) 704277 V grooved knurl for cored wire Contact Tips 11-23 .023” (0.6mm) 11-30 .030” (0.8mm) 11-35 .035” (.09mm) 11-40 .040” (1.0mm) 11-45 .045” (1.2mm) Nozzles

21-50 1/2” (12.7mm)

21.62 5/8” (16mm) Wire Liners 42-23-15 .023”, 15 ft.(7.6m) 42-3035-15 .030-.035”, 15ft. (4.5m) 42-4045-15 .040-.045”, 15ft. (4.5m) 42N-3545-15 .035-3/64”, 15ft. (4.5m) Gas Diffuser 51

21-37

Gun Assembly with 10ft cable (supplied with package), 180 Amp @ 30%

Medalist™ 1400 Series, HRF Flowmeter Regulator, Argon- Argon/CO2 mix gases

3/8” (9.5mm)

July 20, 2007 A-1 Manual 0-4991

FABRICATOR 140, 180 APPENDIX

APPENDIX 2: FABRICATOR 180 SYSTEM SCHEMATIC

230 VAC 1PH 60Hz

GNDGND

JFMJFM

T1T1

J1J1

R/L1

SW1SW1

S/L2

SOL1SOL1

M1M1

FAN

J2J2

1 2 3

4 5

1 2 3

4 5

CB1CB1

J4J4

L1L1

L2L2

SW1

J3J3

PCB1

F1F1

V+ V M+ M TS1 COM COM GUN SW

OVERTEMPOVERTEMP

YELLOW

ACAC

GREEN

WIRE SPEEDWIRE SPEED

J5J5

1 2 3 4 5 6 7 8

TS1 (DIODE HEATSINK)3TS1 (DIODE HEATSINK)3

Art # A-7918

TS1 (T1)TS1 (T1)

Manual 0-4991 A-2 July 20, 2007

APPENDIX FABRICATOR 140, 180

GAS / NO GAS POLARITY CHANGE OVER

POS

D2D2

D1D1

D5D5

D3D3

D4D4

RV1RV1

D6D6

D8D8

D7D7

+C1+

+C2+

R1R1

INDUCTOR

NEG

M2M2

WFM

Last Modified:

CONTROL RECEPTACLE

J6 RECEPTACLE FRONT VIEW

Tuesday, July 24, 2007

Tuesday, July 24, 2007 15:02:51

15:02:51

MIG GUN PLUG

J6J6

1 2 3 4 5 6

P6P6

1 2 3 4 5 6

SW3SW3

SPOOL GUN PLUG

P6P6

1 2 3 4 5 6

SW4SW4

M3M3

PCB No:

DateByRevisionsRev

A THERMADYNE COMPANY

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent. NOTE: UNLESS OTHERWISE SPECIFIED -

NOTE: UNLESS OTHERWISE SPECIFIED -

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

TITLE:

SCHEMATIC,

FABRICATOR 180

INDUSTRIAL PARK #2

WEST LEBANON, NH 03784

(603) 298-5711

PCB No: Assy No:

Assy No:

Assy No: References

References

Monday, July 23, 2007

Chk: App:

Chk: App: Size

Size

DWG No:

SupersedesScale

Date:Drawn:

Date:Drawn: Sheet

Sheet

July 20, 2007 A-3 Manual 0-4991

FABRICATOR 140, 180 APPENDIX

APPENDIX 3: FABRICATOR 140 SYSTEM SCHEMATIC

120 VAC 60Hz

GNDGND

J1J1

JFMJFM

J2J2

T1T1

1 2 3 4

R/L1

1 2 3 4

SOL1SOL1

M1M1

FAN

CB1CB1 SW1SW1

J4J4

BLK

WHT

GRN

A1 A

SW1

B1 B

J3J3

L1L1

L2L2

PCB1

F1F1

V+ V M+ M TS1 COM COM GUN SW

OVERTEMPOVERTEMP

YELLOW GREEN

ACAC

WIRE SPEEDWIRE SPEED

J5J5

1 2 3 4 5 6 7 8

TS1 (DIODE HEATSINK)TS1 (DIODE HEATSINK)

Art # A-7919

Manual 0-4991 A-4 July 20, 2007

APPENDIX FABRICATOR 140, 180

GAS / NO GAS POLARITY CHANGE OVER

POS

D1D1

D2D2

D3D3

D4D4

RV1RV1

D7D7

D6D6

D5D5

D8D8

+C1+

+C2+

R1R1

INDUCTOR

NEG

M2M2

WFM

Last Modified:

CONTROL RECEPTACLE

J6 RECEPTACLE FRONT VIEW

Tuesday, July 24, 2007

15:56:58

MIG GUN PLUG

J6J6

1 2 3 4 5 6

P6P6

1 2 3 4 5 6

SW3SW3

SPOOL GUN PLUG

P6P6

1 2 3 4 5 6

SW4SW4

M3M3

PCB No:

DateByRevisionsRev

A THERMADYNE COMPANY

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS OTHERWISE SPECIFIED -

1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.

2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).

TITLE:

SCHEMATIC,

FABRICATOR 140

INDUSTRIAL PARK #2

WEST LEBANON, NH 03784

(603) 298-5711

PCB No: Assy No:

Assy No:

Assy No: References

References

Monday, July 16, 2007

Chk: App:

Chk: App: Size

Size

DWG No:

SupersedesScale

Date:Drawn:

Date:Drawn: Sheet

Sheet

July 20, 2007 A-5 Manual 0-4991

FABRICATOR 140, 180 APPENDIX

APPENDIX 4: FEED ROLL KITS

FEED ROLL INSTALLATION & PARTS GUIDE

.030

0.8

Size visible when fitting the feedroll is the groove size in use

Part No.

7977036 Feed Roll .023/.030” (0.6 / 0.8mm) Hard Wire 7977660 Feed Roll .035/.045” (0.9 / 1.2mm) Hard Wire 7977731 Feed Roll .030/.035” (0.8 / 0.9mm) Soft Wire 7977732 Feed Roll .030/.035” (0.8 / 0.9mm) Cored Wire 7977264 704277 Feed Roll .045/1/16” (1.2 / 1.6mm) Cored Wire W7004022

Feed Roll .040/.045” (1.0-1.2mm) Soft Wire

Guide, Inlet, 023-035

Description

Manual 0-4991 A-6 July 20, 2007

LIMITED WARRANTY

This information applies to Thermal Arc products that were purchased in the USA and Canada.

July 2007

LIMITED WARRANTY: Thermal Arc warrants to customers of authorized distributors ("Purchaser") that its products will be free of defects in workmanship or material. Should any failure to conform to this warrant appear within the warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc's specifications, instructions, recommendat ions and recogn ized standard ind ustry practice, and not subjec t to misuse, repair, neglect, alteration, or damage, correct such defects by suitable repair o replacement, at Thermal Arc's sole option, of any components or parts of the produc determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o merchantability, fitness for any particular purpose, or other warranty o quality, whether express, implied, or statutory.

Limitation of liability: The rmal Arc shall no t under any circum stances be liable for sp ecial, indirect, incidental, or consequential damag es, including but not limited to lost profits and business interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe arising out of contract, tort, including n egligence or strict liability, or under an y warranty, or otherwise, shall not exceed the price of the goods u pon which such liability is based.

, Inc., A Thermadyne Company ("Thermal Arc"),

No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound b any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the product.

This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the safety or performance of any Thermal Arc product. Purchaser’s rights under this warrant are void if the product is sold to purchaser by unauthorized persons.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Ar c delivered the product to the authorized distributor.

Warranty repairs or replacement claims under this limited warranty mu st be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any kind under this warranty. Transpor tation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All return ed goods shall be at the Purchaser's risk and expense. This warranty dated July 1 supersedes all previous Thermal Arc warranties. Thermal Arc

is a Registered

2007

Trademark of Thermal Arc, Inc.

WARRANTY SCHEDULE

This information applies to Thermal Arc products that were purchased in the USA and Canada.

July 2007

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout, Raider, Explorer

Original Main Power Stators and Inductors.................................................................................. 3 years

Origina l Main Power Rectifiers, Control P.C. Boards.......................................................... ......... 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine Manufactures Warranty for

Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 140; 180; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045. Wire Feeders; Ultrafeed, P ortafeed

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

All other original c ircuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

All other original c ircuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

Welding Console, Weld Controller, W eld Timer................ ........................................................... 3 years 3 years

All other original c ircuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ...............................1 year

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR Dragster 85

Original Main Power Magnetics.....................................................................................................1 year 1 year

Original Main Power Rectifiers, Control P.C. Boards ....................................................................1 year 1 year

All other original c ircuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

160S, 300S, 400S

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years 3 years

All other original c ircuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators.......................................... .............................................................................1 year 1 year

Plasma Welding Torches............................................................................ .................................180 days 180 days

Gas Regulators (Supplied with power sources) ..........................................................................180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts......................................................................................................... ....90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years 3 years

1 year

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017

Telephone: (636) 728-3000 FAX:

(636) 728-3010

Email: sales@thermalarc.com

www.thermalarc.com

Tweco 180 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 General

2.05 Machine Specifications

2.06 Volt - Amp Curves

2.07 Duty Cycle

2.09 Installing a New Wire Liner

2.10 MIG Gun Maintenance

3.01 Location

3.02 Safety

3.03 Grounding

3.04 Electrical Input Requirements

3.05 Requirements for Maximum Output

3.06 Installation of Shielding Gas (GMAW) Process

3.07 Attaching the Gun and Cable Assembly to the Power Source

3.08 Polarity Changeover

3.09 Installing Wire Spool

3.10 Feedrolls

3.11 Install Wire into the Feedhead

3.12 Install Wire into the Welding Gun

4.01 General Safety Precautions

4.02 Fabricator Controls

4.03 Gas Metal Arc Welding (GMAW)

4.04 Flux Cored Arc Welding (FCAW)

4.05 Shutdown Procedures

4.06 Basic Welding Technique

4.07 Welding Gun Positions

4.08 MIG Welding (GMAW) Variables

4.09 Establishing the Arc and Making Weld Beads

4.10 Pre-Weld Procedure

4.11 Welding Procedure

4.12 Reference Tables

4.13 Fabricator 140 Welding Setting Selection Guide

4.14 Fabricator 180 Welding Setting Selection Guide

4.15 Gas Selection for Gas Metal Arc Welding

5.01 Cleaning of the Unit

5.02 Cleaning of the Feed Rolls

5.03 Basic Troubleshooting

5.04 Solving Problems Beyond the Welding Terminals

5.05 Welding Problems

5.06 Power Source Problems

APPENDIX 1: OPTIONS AND ACCESSORIES

APPENDIX 2: FABRICATOR 180 SYSTEM SCHEMATIC

APPENDIX 3: FABRICATOR 140 SYSTEM SCHEMATIC

APPENDIX 4: FEED ROLL KITS

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION