180
3163339
FABRICATOR® 181i
3-IN-1 Multi Process
Welding Systems
Operating
Manual
English
Canadien Français
Americas Español
Revision: AH Issue Date: April 24, 2015 Manual No.: 0-5191
Tweco.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Tweco product. We are proud to have you as our customer and
will strive to provide you with the best service and support in the industry. This product is backed by
our extensive warranty and world-wide service network.
We know you take pride in your work and we feel privileged to provide you with this high performance
product that will help you get the job done.
For more than 75 years Tweco has provided quality products you can trust, when your reputation is on
the line.
YOU ARE IN GOOD COMPANY!
Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish
ourselves from our competition through market-leading innovation and truly dependable products that
will stand the test of time.
We strive to enhance your productivity, efficiency and welding performance enabling you to excel in
your craft. We design products with the welder in mind delivering- advanced features, durability, ease
of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time to
read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Tweco product, please contact our friendly
and knowledgeable Customer Service Team at:
1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.Tweco.com
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment,
the Manufacturer assumes no liability for its use.
Operating Manual Number 0-5191 for:
Tweco Fabricator 181i Power Source Part Number: W1003180
Tweco Fabricator 181i Portable System Package Part Number: W1003181
Tweco Fabricator 181i Portable System Package with Cart Part Number: W1003182
Tweco Fabricator 181i Package w/Single Cylinder Cart Part Number: W1003183
Published by:
Victor Technologies International, Inc.
16052 Swingley Ridge Road,
Suite 300 St. Louis, MO 63017
USA
www.victortechnologies.com
Copyright © 2013 by
Victor Technologies International, Inc.
® All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results
from negligence, accident, or any other cause.
Publication Date: August 10, 2011
Revision Date: April 24, 2015
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 General Safety Information for Victor CS Regulator .......................................... 1-5
1.03 Principal Safety Standards .............................................................................. 1-7
1.04 Symbol Chart .................................................................................................. 1-8
1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-9
1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-9
1.07 Informations Générales de Sécurité .............................................................. 1-14
1.08 Principales Normes De Securite ................................................................... 1-16
1.09 Graphique de Symbole .................................................................................. 1-17
1.10 Declaration Of Conformity ............................................................................ 1-18
SECTION 2:
INTRODUCTION ..................................................................................... 2-1
2.01 How to Use This Manual ................................................................................. 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt of Equipment ...................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05 Transportation Methods .................................................................................. 2-1
2.06 User Responsibility ......................................................................................... 2-2
2.07 Fabricator 181i Portable System Package (Part No. W1003181) .................... 2-2
2.08 Duty Cycle ....................................................................................................... 2-3
2.09 Specifications ................................................................................................. 2-4
2.10 Options and Accessories ................................................................................ 2-5
SECTION 3:
INSTALLATION, OPERATION AND SETUP ........................................................ 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Electricity Supply Voltage .............................................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-3
3.06 Victor Regulator .............................................................................................. 3-4
3.07 Leak Testing the System ................................................................................. 3-6
3.08 When You Finish Using the Regulator ............................................................. 3-6
3.09 Storage of the Regulator ................................................................................. 3-6
3.10 Power Source Controls, Indicators and Features ............................................ 3-7
3.11 Attaching the Tweco Fusion 180A Gun .......................................................... 3-13
3.12 Torch Adapter Thumb Screw Replacement .................................................. 3-14
3.13 Installing 4" (100mm) Diameter Spool ......................................................... 3-16
3.14 Installing 8" (200mm) Diameter Spool .......................................................... 3-16
3.15 Inserting Wire into the Wire Feed Mechanism .............................................. 3-17
3.16 Feed Roller Pressure Adjustment .................................................................. 3-18
3.17 Changing the Feed Roll ................................................................................. 3-19
3.18 Wire Reel Brake ............................................................................................ 3-19
TABLE OF CONTENTS
3.19 Gas Regulator Operation ............................................................................... 3-20
3.20 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 3-21
3.21 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire .................... 3-22
3.22 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 3-24
3.23 Setup for LIFT TIG (GTAW) Welding ............................................................. 3-25
3.24 Setup for STICK (SMAW) Welding .............................................................. 3-27
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-6
4.03 Stick (SMAW) Basic Welding Technique ......................................................... 4-9
4.04 Effects of Stick Welding Various Materials ...................................................... 4-9
4.05 Stick (SMAW) Welding Troubleshooting ....................................................... 4-18
4.06 TIG (GTAW) Basic Welding Technique .......................................................... 4-20
4.07 TIG (GTAW) Welding Problems ..................................................................... 4-22
SECTION 5: Power Source PROBLEMS AND
ROUTINE SERVICE REQUIREMENTS .............................................................. 5-1
5.01 Power Source Problems ................................................................................. 5-1
5.02 Routine Service and Calibration Requirements ............................................... 5-2
5.03 Cleaning the Welding Power Source ............................................................... 5-5
5.04 Cleaning the Feed Rolls ................................................................................... 5-5
5.05 Volt-Ampere Curves ........................................................................................ 5-6
SECTION 6: KEY SPARE PARTS .......................................................................... 6-1
6.01 Tweco Fusion 180A MIG Gun Parts ................................................................ 6-1
6.02 Power Source ................................................................................................. 6-2
APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM .................................................... A-1
LIMITED WARRANTY TERMS ........................................................ INSIDE REAR COVER
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
This Page Intentionally Blank
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SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training
in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
This publication and other guides to what you should learn before operating this equipment are listed at the
end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is ON. The input power circuit and
machine internal circuits are also live when
power is ON. In semi-automatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned ON accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn OFF all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the ground
or the work surface. Do not touch holders connected
to two welding machines at the same time or touch
other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working
above floor level.
Manual 0-5191 1-1 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
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.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Process
Shielded Metal Arc Welding
(SMAW)
Electrode Size in.
(mm)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level
is high.
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
Arc Current
(Amperes)
Less than 60
60-160
160-250
250-550
Minimum
Protective
Shade
7
8
10
11
Suggested*
Shade No.
(Comfort)
10
12
14
Gas Metal Arc Welding (GMAW)
and Flux Cored Arc Welding
(FCAW)
Gas Tungsten arc Welding
(GTAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Plasma Arc Cutting (PAC)
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter
shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas
welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable
to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.
(Light)
(Heavy)
Less than 60
60-160
160-250
250-550
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
7
10
10
10
8
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
11
12
14
10
12
14
12
14
6 to 8
10
12
14
4
5
6
8
9
12
14
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5191
Fabricator 181iFabricator 181i
1. Keep your head out of the fumes. Do not breathe
the fumes.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing
injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapors to form highly toxic and
irritating gases.
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or
drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding current
from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental contact
of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike flammable
material.
3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
Manual 0-5191 1-3 SAFETY INSTRUCTIONS AND WARNINGS
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.
Fabricator 181i Fabricator 181i
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7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated
areas.
2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
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. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
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.
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.
STEAM AND PRESSURIZED HOT COOLANT
WARNING
can burn face, eyes, and skin.
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.
SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5191
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
!
!
WARNING: This product contains chemicals,
including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology
Assessment, Biological Effects of Power Frequency
Electric & Magnetic Fields - Background Paper, OTABP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume
of scientific findings based on experiments at the cellular level and from studies with animals and people
which clearly establish that low frequency magnetic
fields interact with, and produce changes in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the
evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite
conclusions about questions of possible risk or to offer
clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.
Fabricator 181iFabricator 181i
1.02 General Safety Information for Victor CS Regulator
A. Fire Prevention
Welding and cutting operations use fire or combustion
as a basic tool. The process is very useful when properly
controlled. However, it can be extremely destructive
if not performed cor rectly in the proper environment.
1. The work area must have a fireproof floor.
2. Work benches or tables used during welding or
cutting operations must have fireproof tops.
3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring
from sparks and hot metal.
4. Keep an approved fire extinguisher of the proper
size and type in the work area. Inspect it regularly to ensure that it is in proper working order.
Know how to use the fire extin guisher.
5. Move combustible materials away from the work
site. If you can not move them, protect them
with fireproof covers.
WARNING
NEVER perform welding, heating, or cutting
operations on a container that has held toxic,
combustible or flammable liq uids, or vapors.
NEVER perform welding, heating, or cutting
operations in an area containing combustible
vapors, flam mable liquids, or explosive dust.
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 0-5191 1-5 SAFETY INSTRUCTIONS AND WARNINGS
B. Housekeeping
WARNING
NEVER allow oxygen to contact grease, oil, or
other flam mable substances. Although oxygen by itself will not burn, these substances
become highly explosive. They can ignite
and burn violently in the presence of oxygen.
Keep ALL apparatus clean and free of grease, oil and
other flammable substances.
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C. Ventilation
WARNING
Ade quately ventilate welding, heating, and
cutting work areas to prevent accumulation of explosive or toxic concen trations
of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes.
Use respiratory protection equipment in
these circumstances. When welding/brazing,
read and understand the Material Safety Data
Sheet for the welding/brazing alloy.
D. Personal Protection
Gas flames produce infrared radiation which may have
a harm ful effect on the skin and especially on the eyes.
Select goggles or a mask with tempered lenses, shaded
4 or darker, to protect your eyes from injury and provide
good visibility of the work.
Always wear protective gloves and flame-resistant clothing
to protect skin and clothing from sparks and slag. Keep
collars, sleeves, and pockets buttoned. DO NOT roll up
sleeves or cuff pants.
When working in a non-welding or cutting environment,
always wear suitable eye protection or face shield.
Art # A-12127
Figure 1-1: Gas Cylinders
WARNING
Cylinders are highly pressurized. Handle
with care. Serious accidents can result from
improper handling or mis use of compressed
gas cylinders DO NOT drop the cylinder,
knock it over, or expose it to excessive heat,
flames or sparks. DO NOT strike it against
other cylinders. Contact your gas supplier
or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.
NOTE
CGA P-1 publication is available by writing
the Compressed Gas Association, 4221
Walney Road, 5th Floor, Chantilly,VA 201512923
WARNING
Practice the following safety and operation
precautions EVERY TIME you use pressure
regulation equipment. Deviation from the
following safety and operation instructions
can result in fire, explosion, damage to
equipment, or injury to the operator.
E. Compressed Gas Cylinders
The Department of Transportation (DOT) approves the
design and manufacture of cylinders that contain gases
used for welding or cutting operations.
1. Place the cylinder (Figure 1-1) where you will
use it. Keep the cylinder in a vertical position.
Secure it to a cart, wall, work bench, post, etc.
2. Place the valve protection cap on the cylinder
whenever mov ing it, placing it in storage, or not
using it. Never drag or roll cylinders in any way.
Use a suitable hand truck to move cylin ders.
3. Store empty cylinders away from full cylinders.
Mark them “EMPTY” and close the cylinder
valve.
4. NEVER use compressed gas cylinders without
a pressure reducing regulator attached to the
cylinder valve.
5. Inspect the cylinder valve for oil, grease, and
damaged parts.
WARNING
DO NOT use the cylinder if you find oil,
grease or damaged parts. Inform your gas
supplier of this condition immediately.
SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5191
6. Momentarily open and close (called “cracking”)
the cylinder valve to dislodge any dust or dirt that
may be present in the valve.
CAUTION
Open the cylinder valve slightly. If you open
the valve too much, the cylinder could tip
over. When cracking the cylinder valve, DO
NOT stand directly in front of the cylinder
valve. Always perform cracking in a well
ventilated area. If an acetylene cylinder
sprays a mist when cracked, let it stand for
15 minutes. Then, try to crack the cylinder
valve again. If this problem persists, contact
your gas supplier.
1.03 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Fabricator 181iFabricator 181i
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Manual 0-5191 1-7 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Art # A-04130_AB
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Meters Per Minute
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
S
See Note
See Note
S
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5191
Fabricator 181iFabricator 181i
!
1.05 Precautions De Securite En Soudage A L’arc
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA
MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ
LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR
CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages
au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne
prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques
doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi
un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent
les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les
pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser
cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION,
D’ENTRETIEN ET D’ESSAI.
1.06 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou
brûler gravement. L’électrode et le circuit
de soudage sont sous tension dès la mise
en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi
sous tension dès la mise en marche. En
soudage automatique ou semi-automatique
avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact
avec le fil de soudage sont sous tension.
Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et
non troués.
3 Isolez-vous de la pièce à souder et de la mise à la
terre au moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement
ou arrêtez le moteur avant de l’installer ou d’en faire
l’entretien. Bloquez le commutateur en circuit ouvert
ou enlevez les fusibles de l’alimentation afin d’éviter
une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à
la terre selon le manuel d’utilisation et les codes
nationaux, provinciaux et locaux applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou
inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne
jamais plonger les porte-électrodes dans l’eau pour
les refroidir. Ne jamais les laisser traîner par terre ou
sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
Manual 0-5191 1-9 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
9. N’enroulez pas de câbles électriques autour de votre
corps.
10. N’utilisez qu’une bonne prise de masse pour la mise
à la terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec
le circuit de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez
ou remplacez aussitôt les pièces endommagées.
LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
AVERTISSEMENT
brûler les yeux et la peau. Le bruit causé par
13. Dans des espaces confinés ou mouillés, n’utilisez
pas de source de courant alternatif, à moins qu’il
soit muni d’un réducteur de tension. Utilisez plutôt
une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en
hauteur.
15. Fermez solidement tous les panneaux et les capots.
AWS F2.2 : 2001 (R2010), Modifié avec l’accord de l’American Welding Society (AWS), Miami, Florida
Guide de teinte des lentilles
Procédé
Taille de l’électrode
en mm (po)
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire
de nuance appropriée (consultez la norme ANSI Z49
indiquée ci-après) pour vous protéger le visage et
les yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
Courant
d’arc
(ampères)
Gamme
d’intensité
minimum
Numéro de teinte
recommandée*
(Confort)
Soudage à l’arc avec
électrode enrobée (procédé
SMAW)
Soudage à l’arc sous gaz
avec fil plein (procédé
GMAW) et soudage avec fil
fourré (procédé FCAW)
Soudage à l’électrode
réfractaire (procédé GTAW)
Coupage à l’arc avec
électrode de carbone et jet
d’air (procédé AAC)
Soudage à l’arc au plasma
(procédé PAW)
Coupage plasma (procédé
PAC)
Moins de 2,4 (3/32)
3/32-5/32 (2,4-4,0)
5/32-1/4 (4,0-6,4)
Plus de 1/4 (6,4)
(Clair)
(Sombre)
Moins de 60
60-160
160-250
250-550
Moins de 60
60-160
160-250
250-550
Moins de 50
50-150
150-500
Moins de
500 500-
1000
Moins de 20
20-100
100-400
400-800
Moins de 20
20-40
40-60
60-80
80-300
300-400
400-800
7
8
10
11
7
10
10
10
8
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
10
12
14
11
12
14
10
12
14
12
14
6 à 8
10
12
14
4
5
6
8
9
12
14
* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite
progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors
du soudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante
lumière jaune; il est préférable d’utiliser un filtre qui absorbe cette lumière jaune ou le sodium du spectre
de la lumière visible.
SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5191
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 insatisfaisant, portez un respirateur à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes
du fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer
l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir avec des vapeurs
et former des gaz hautement toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au
plomb ou au cadmium que si les zones à souder ont
été grattées à fond, que si l’espace est bien ventilé;
si nécessaire portez un respirateur à adduction d’air.
Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au
moment du soudage.
Fabricator 181iFabricator 181i
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE
OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal
chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet
métallique peut provoquer des étincelles, un
échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules
volantes ou des projections peuvent atteindre des
matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon
de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes
par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur
à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut
enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir
ou un baril.
8. Connectez le câble de soudage le plus près possible
de la zone de soudage pour empêcher le courant de
suivre un long parcours inconnu, et prévenir ainsi
les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil
au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels
des gants en cuir, une chemise épaisse, un pantalon
revers, des bottines de sécurité et un casque.
Manual 0-5191 1-11 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES
BLESSURES.
8. Lisez et respectez les consignes relatives aux
bouteilles de gaz comprimé et aux équipements
connexes, ainsi que la publication P-1 de la CGA,
identifiée dans la liste de documents ci-dessous.
Le piquage et le meulage produisent des
particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats
de laitier.
1. Portez un écran facial ou des lunettes 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.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.
2. Si vous utilisez ces équipements dans un endroit
confiné, les fumées d’échappement doivent être
envoyées à l’extérieur, loin des prises d’air du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une
source d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de
faire le plein de carburant ou d’en vérifier le niveau
au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.
6. Ne placez pas le visage face à l’ouverture du robinet
de la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en
utilisation ou lorsque raccordé pour utilisation.
SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5191
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.
Fabricator 181iFabricator 181i
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION
PEUVENT BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur
peut être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.
2. Mettez des gants et posez un torchon sur le bouchon
pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.
4. Pour empêcher un démarrage accidentel pendant
l’entretien, débranchez le câble d’accumulateur à la
borne négative.
5. N’approchez pas les mains ou les cheveux de pièces
en mouvement; elles peuvent aussi accrocher des
vêtements amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez
les portes après des travaux d’entretien et avant de
faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE
D’UN ACCUMU-LATEUR PEUT BRULER LA
PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs
explosives.
1. Portez toujours un écran facial en travaillant sur un
accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler
sur un accumulateur.
4. N’utilisez pas une source de courant de soudage
pour charger un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
PLOMB AVERTISSEMENT
AVERTISSEMENT : Ce produit contient des
produits chimiques, notamment du plomb,
reconnu par l’État de la Californie pour
causer des malformations congénitales et
d’autres dommages touchant le système
reproductif. Se laver les mains après
manipulation.
REMARQUE
Facteurs relatifs au soudage et aux effets
des champs magnétiques et électriques de
basse fréquence
Voici une citation tirée du chapitre des conclusions
générales du document de base de l’Office of Technology
Assessment (bureau des évaluations technologiques)
del’U.S. Congress, « Biological Effects of Power
Frequency Electric & Magnetic Fields », OTA-BP-E-63
(Washington, DC : U.S. Government Printing Office,
mai 1989) : « ... il existe de nos jours, un nombre
très élevé de travaux scientifiques qui rapportent les
résultats d’expériences menées au niveau cellulaire et
d’études auprès d’homme et d’animaux qui établissent
nettement le rapport entre les champs magnétiques
de basse fréquence et les systèmes biologiques, soit
par des interactions ou des modifications. Quoique
la plupart de ces travaux soient de très bonne
qualité, les résultats sont complexes. Àla lumière
des connaissances scientifiques actuelles, il nous est
encore impossible d’interpréter les évidences en un seul
cadre de référence cohérent. La situation est toutefois
très contrariante. En effet, il nous est aussi impossible
Manual 0-5191 1-13 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
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de tirer des conclusions définitives quant aux risques
éventuels ou de proposer des stratégies fondées sur
des faits scientifiques visant à atténuer ou éviter des
risques potentiels ».
Pour atténuer les champs magnétiques sur les lieux
detravail, respectez les procédures qui suivent :
1. Maintenez les câbles l’un près de l’autre en les
entrelaçant ou les reliant ensemble au ruban.
2. Acheminez les câbles à un côté du soudeur, le
plus loin possible.
3. N’enroulez pas de câble autour du corps.
4. Maintenez le bloc d’alimentation du poste
desoudage et les câbles aussi loin que possible
du corps.
STIMULATEURS CARDIAQUES :
Les procédures décrites ci-dessus sont
habituellement celles recommandées pour
les porteurs de stimulateurs cardiaques.
Pour de plus amples renseignements,
consulter unmédecin.
AVERTISSEMENT
N’effectuez JAMAIS d’opérations de soudage
sur un récipient qui a contenu des liquides
ou vapeurs toxiques, combustibles ou
inflammables. N’effectuez JAMAIS d’opérations de soudage dans une zone contenant
des vapeurs combustibles, des liquides
inflammables ou des poussières explosives.
B. Entretien des Locaux
AVERTISSEMENT
Ne laissez jamais l’oxygène en contact avec
la graisse, l’huile ou d’autres substances
inflammables. Bien que l’oxygène elle même
ne brûle pas, ces substances peuvent devenir extrême ment explosives. Elles peuvent
prendre feu et brûler violem ment en présence d’oxygène.
Gardez TOUS les appareils propres et exempts de graisse,
huile ou autres substances inflammables.
1.07 Informations Générales de Sécurité
A. Prévention D’incendie
Les opérations de soudage utilisent le feu ou la combustion
comme outil de base. Ce processus est très utile quand il
est cor rectement contrôlé.
1. La zone doit comporter un sol ignifugé.
2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement
ignifuge.
3. Utilisez des écrans résistants à la chaleur ou en
matériau approuvé pour protéger les cloisons
proches ou le sol vul nérable des étincelles et du
métal chaud.
4. Gardez un extincteur approuvé du bon type et de
la bonne taille dans la zone de travail. Inspectez-le
régulièrement pour vous assurer qu’il est en état de
fonctionner. Apprenez à vous en servir.
5. Enlevez tous les matériaux combustibles de la
zone de travail. Si vous ne pouvez pas les enlever,
protégez-les avec une cou vre ignifuge.
C. Aération
AVERTISSEMENT
Ventilez les zones de soudage, chauffage et
découpage de façon adéquate pour éviter
l’accumulation de gaz explosifs ou toxiques.
Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques:
Utilisez un équipement de protection respiratoire dans ces circonstances. Si vous
soudez ou brasez, lisez et assimilez la fiche
technique de sécurité de matériau relative à
l’alliage de soudage/brasage.
D. Protection Personnelle
Les flammes de gaz produisent une radiation infrarouge
qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un
masque avec des verres trempés assombris au niveau 4
ou plus sombre, pour protéger vos yeux des dommages
et garder une bonne visibilité sur le travail.
Portez en permanence des gants de protection et des
vête ments ignifuges pour la protection de la peau et des
vêtements contre les étincelles et le laitier. Gardez col,
SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5191
Fabricator 181iFabricator 181i
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manches et poches boutonnés. Il ne faut pas remonter
vos manches ou les pantalons à revers.
Quand vous travaillez dans un environnement non
dédié au soudage ou découpage, portez toujours une
protection des yeux appropriées ou un masque facial.
AVERTISSEMENT
Mettez en pratique les procédures de
sécurité et de mode opératoire suivantes à
chaque fois que vous utilisez cet appareil
de régulation de pression. Si vous déviez de
ces procédures, cela peut entraîner incendie,
explosion, dégâts matériels et/ou blessures
corporelles pour l’opérateur.
E. Bouteilles de Gaz Comprimé
Le Département des Transports américain (DOT)
approuve la conception et la fabrication des bouteilles
qui contiennent les gaz utilisés pour les opérations de
soudage ou de découpage.
AVIS
Ce document CGA p. t peut être obtenu en
écrivant à “Compressed Gas Association”,
4221 Walney Roed, 5th Floor. Chantilly, VA
20151.2923, USA.
2. Placez le bouchon de protection de vanne sur
la bouteille à chaque fois que vous la déplacez
ou ne l’utilisez pas. Ne faites jamais glisser ou
rouler d’aucune manière les bouteilles. Utilisez
un diable approprié pour les déplacer.
3. Entreposez les bouteilles vides à l’écart des bouteilles pleines. Marquez-les “VIDE” et refermez
leur vanne.
4. N’utilisez JAMAIS des bouteilles de gaz comprimé
sans un régulateur de pression en série sur la
vanne de bouteille.
5. Inspectez la vanne de bouteille pour y détecter de l’huile ou de la graisse, ou dès pièces
endommagées.
1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale. Fixez-la sur un
chariot une cloison, un établi, etc.
Art # A-12127
Le schéma 1-1: Cylindres de gaz
AVERTISSEMENT
Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux
peuvent résulter d’une mauvaise manutention
ou d’un mauvais emploi des bouteilles de gaz
comprimé. NE faites PAS tomber la bouteille,
ne la cognez pas, ne l’exposez pas à une chaleur
excessive, aux flammes ou étincelles. NE la cognez
PAS contre d’autres bouteilles. Contactez votre
fournisseur de gaz ou reportez vous à la publication
CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur
l’utilisation et la manutention des bouteilles.
AVERTISSEMENT
N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces
endommagées. Informez immédiate ment
votre fournisseur de’ gaz de cet état.
6. Ouvrez et fermez momentanément la vanne de
la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour raient être présentes
dans la vanne.
MISE EN GARDE
Ouvrez la vanne de bouteille légèrement.
Si vous l’ouvrez trop en grand, la bouteille
pourrait se renverser. Quand vous ouvrez/
fermez rapidement la vanne de bouteille, ne
vous tenez pas directement devant. Opérez
toujours cette opération dans une zone bien
ventilée. Si une bouteille d’acétylène crache
un brouillard, laissez reposer pendant 15
minutes. Essayez de nouveau la vanne. Si
le problème persiste, con tactez votre fournisseur de gaz.
Manual 0-5191 1-15 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
1.08 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1,
American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, norme AWS F4.1, American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33128.
National Electrical Code, norme 70 NFPA, National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA
W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, norme ANSI Z87.1, American National
Standards Institute, 1430 Broadway, New York, NY
10018.
Cutting and Welding Processes, norme 51B NFPA,
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
SAFETY INSTRUCTIONS AND WARNINGS 1-16 Manual 0-5191
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Fabricator 181iFabricator 181i
SousTension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
X
%
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
Haute Température
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Torch de Soudage
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
Duréc du Pulse
t
t1
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
t2
Détente à 2-Temps
Détente à 4-Temps
Probléme de Terre
t
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
115V 15A
Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque conforme
à EN50192 lorsqu'utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à
l'hauteur de buse correctement installé.
Ne pas déposer avec les déchets ménagers.
Classement de PriseSource Auxiliaire
Force d'Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
V
IPM
MPM
S
Pouces Par Minute
Mètres Par Minute
Voir Note
Voir Note
Art # A-07639_AB
S
Manual 0-5191 1-17 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
1.10 Declaration Of Conformity
Declaration of Conformity
3163339
We Victor Technologies International Inc.
of 16052 Swingley Ridge Road
Suite 300
Chestereld, MO 63033 U.S.A.
in accordance with the following Directive(s):
•2006/95/EC The Low Voltage Directive
•2004/108/EC The Electromagnetic Compatibility (EMC) Directive
hereby declare that:
Equipment: Arc Welding Power Source
Model Name/Number: Fabricator 181i
Market Release Date: January 16, 2014
is in conformity with the applicable requirements of the following harmonized standards:
•EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility
(EMC) requirements
•EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
Classification: The equipment described in this document is Class A and intended for industrial use.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: November 18, 2014
Steve Ward
(Full Name)
V.P. Europe and General Manager
(Position)
(Signature)
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical power
is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5191
Fabricator 181iFabricator 181i
Classication:TheequipmentdescribedinthismanualisClassAandintendedforindustrialuse.
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There may be potential difculties in ensuring electromagnetic compatibility in those locations, due to conducted as well
as radiated disturbances.
Manual 0-5191 1-19 SAFETY INSTRUCTIONS AND WARNINGS
Fabricator 181i Fabricator 181i
This Page Intentionally Blank
SAFETY INSTRUCTIONS AND WARNINGS 1-20 Manual 0-5191
SECTION 2:
INTRODUCTION
Fabricator 181i
2.01 How to Use This Manual
This Manual usually applies to the part numbers listed
on page i. To ensure safe operation, read the entire
manual, including the chapter on safety instructions and
warnings. Throughout this manual, the word WARNING,
CAUTION and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as follows:
WARNING
Gives information regarding possible electrical shock injury. Warnings will be enclosed
in a box such as this.
!
WARNING
Gives information regarding possible personal injury. Warnings will be enclosed in a
box such as this.
CAUTION
Refers to possible equipment damage. Cautions will be shown in bold type.
NOTE
Offers helpful information concerning certain operating procedures. Notes will be
shown in italics.
You will also notice icons from the safety section appearing throughout the manual. These are to advise you of
specific types of hazards or cautions related to the portion of information that follows. Some may have multiple
hazards that apply and would look something like this:
2.03 Receipt of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage claims or shipping errors to the location in your area
listed in the inside back cover of this manual. Include
all equipment identification numbers as described above
along with a full description of the parts in error.
2.04 Description
The Tweco Fabricator 181i is a self contained single
phase multi process welding system that is capable of
performing MIG (GMAW/FCAW), STICK (SMAW) and
LIFT TIG (GTAW) welding processes. The Power Source
is equipped with an integrated wire feed unit, digital
voltage and amperage meters, and a host of other features in order to fully satisfy the broad operating needs
of the modern welding professional. The Power Source
is also fully compliant to Standard CSA E60974-1-00
and UL 60974.1.
The Fabricator 181i MIG provides excellent welding
performance across a broad range of applications when
used with the correct welding consumables and procedures. The following instructions detail how to correctly
and safely set up the machine and give guidelines on
gaining the best efficiency and quality from the Power
Source. Please read these instructions thoroughly before using this equipment.
2.05 Transportation Methods
!
Disconnect input power conductors from de-energized supply line before moving
the welding Power Source.
2.02 Equipment Identification
The Power Source's identification number (specification or part number), model, and serial number usually
appear on a nameplate attached to the machine. Equipment which does not have a nameplate attached to the
machine is identified only by the specification or part
number printed on the shipping container. Record these
numbers for future reference.
Manual 0-5191 2-1 INTRODUCTION
Lift Power Source with handle on top of case. Use
handcart or similar device of adequate capacity. If using
a fork lift vehicle, secure the Power Source on a proper
skid before transporting.
Fabricator 181i
2.06 User Responsibility
This equipment will perform as per the information contained herein when installed, operated, maintained and
repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective
equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted
or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is
recommended that such repairs be carried out by appropriately qualified persons approved by Tweco. Advice in
this regard can be obtained by contacting an Accredited Tweco Distributor.
This equipment or any of its parts should not be altered from standard specification without prior written approval
of Tweco. The user of this equipment shall have the sole responsibility for any malfunction which results from
improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper
repair by anyone other than appropriately qualified persons approved by Tweco.
2.07 Fabricator 181i Portable System Package (Part No. W1003181)
A-12166
INTRODUCTION 2-2 Manual 0-5191
Fabricator 181i
A-10352
Duty Cycle (percentage)
Safe
Operating
Region
0
20 40 60
80
100
120 140 160 180
30
50
70
90
40
60
20
10
80 100
0
Welding Current (amps)
STICK (SMAW)
TIG (GTAW)
MIG (GMAW/FCAW)
2.08 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain
the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to
operate at a 20% duty cycle, 180 amperes at 23 volts. This means that it has been designed and built to provide
the rated amperage (180 A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes
is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be
allowed to cool.
Manual 0-5191 2-3 INTRODUCTION
Figure 2-1: Fabricator 181i Duty Cycle
Fabricator 181i
2.09 Specifications
DESCRIPTION FABRICATOR 181i MULTI PROCESS 3 IN 1 WELDER
Power Source Part No. W1003180
Power Source Dimensions H16.14" x W8.27" x D17.72" (410mm x 210mm x 450mm)
Power Source Mass 32.2lb(14.6kg)
Cooling Fan Cooled
Welder Type Multi Process Welding System
Output Terminal Type DinseTM 50
Standards CSA E60974-1-00 / UL60974-1 / IEC 60974-1
Number of Phases Single Phase
Nominal Supply Voltage 230V AC
Supply Voltage Range 208-265V AC
Supply Frequency 50/60Hz
Welding Current Range (MIG Mode) 10-180A
Wirefeed Speed Range 100 - 650 IPM
MIG Welding Voltage Range 14.5 - 23V DC
Nominal OCV 62V DC
Effective Input Current (I
for MIG (GMAW/FCAW)
for LIFT TIG (GTAW)
for STICK (SMAW)
Maximum Input Current (I
for MIG (GMAW/FCAW)
for LIFT TIG (GTAW)
for STICK (SMAW)
1eff
)
1max
15.9 Amps
14.3 Amps
17.2 Amps
)
35.6 Amps
28.6 Amps
35.7 Amps
Single Phase Generator Requirement 9 KVA
MIG (GMAW/FCAW) Welding Output at 104°F
(40°C)
180A @ 20%, 23V
113A @ 60%, 19.7V
88A @ 100%, 18.4V
STICK (SMAW) Welding Output at 104°F
(40°C).
175A @ 20%, 27V
101A @ 60%, 24V
78A @ 100%, 23.1V
LIFT TIG (GTAW) Welding Output at 104°F
(40°C).
175A @ 25%, 17V
113A @ 60%, 14.5V
88A @ 100%, 13.5V
Protection Class IP23S
Table 2-1: Fabricator 181i Specification
INTRODUCTION 2-4 Manual 0-5191
Fabricator 181i
NOTE
The recommended time delay fuse or circuit breaker size is 50 amp. An individual branch circuit capable
of carrying 50 amperes and protected by fuses or circuit breaker is recommended for this application.
Fuse size is based on not more than 200 percent of the rated input amperage of the welding Power
Source (Based on Article 630, National Electrical Code)
Tweco continuously strives to produce the best product possible and therefore reserves the right to
change, improve or revise the speci fications or design of this or any product without prior notice. Such
updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment
may differ from the above specifications due to in part, but not exclusively, to any one or more of the
following; variations or changes in manufactured components, installation location and conditions and
local power grid supply conditions.
The thermal protection switch is rated at 80°C.
2.10 Options and Accessories
DESCRIPTION PART NUMBER
Tweco Fusion 180A MIG Gun, 12ft (3.6m) Length
Tweco Spool Gun 160A,12ft (3.6M) Length, suits 4" (100mm) spools for aluminum welding
TIG Torch, 17V, 12.5 ft, 8 pin and accessory kit with 1/16", 3/32", 1/8" thoriated
tungstens; 1/16", 3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina
nozzle; short back cap; long back cap
Fabricator 141i-181i Carry Bag
Basic 4 Wheel Cart
Foot Control for remote amperage control when TIG welding
Tweco WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)
Drive Roll .023" - .035" (0.6-0.9mm) V groove for steel & stainless steel
Drive Roll .023"- .030" (0.6-0.8mm) V groove for steel & stainless steel wires [Fitted]
Drive Roll .035"/.045" (0.9/1.2mm) V groove for steel & stainless steel wires
Drive Roll .030"-.035" (0.8-0.9mm) U grooved for aluminum wires
Drive Roll .040"-.045" (1.0-1.2mm) U grooved for aluminum wires
Drive Roll .030"-.035" (0.8-0.9mm) V knurled groove for flux cored wires
Drive Roll .045" (1.2mm) V knurled groove for flux cored wire
F180TA-12-3035
SG160TA-12-3035
W4013802
W4015301
W4014700
600285
4100-1004
W4014800
7977036
7977660
7977731
7977264
7977732
704277
Stick Lead, 200A, 13ft, 50mm Dinse
Ground Lead, 200A,10ft, 50mm Dinse
Victor Argon Regulator/Flowgauge
Accessory Kit for TIG Torch with 1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8"
collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina nozzle; short back cap; long
back cap
Table 2-2: Fabricator 181i Options and Accessories List
Manual 0-5191 2-5 INTRODUCTION
WS200E13
WS200G10
0781-4169
P062900010
Fabricator 181i
This Page Intentionally Blank
INTRODUCTION 2-6 Manual 0-5191
SECTION 3:
!
INSTALLATION, OPERATION AND SETUP
Fabricator 181i
3.01 Environment
This Power Source is designed for use in environments
with increased hazard of electric shock.
A. Examples of environments with increased hazard of
electric shock are:
1. In locations in which freedom of movement
is restricted, so that the operator is forced to
perform the work in a cramped (kneeling, sitting
or lying) position with physical contact with
conductive parts.
2. In locations which are fully or partially limited
by conductive elements, and in which there is
a high risk of unavoidable or accidental contact
by the operator.
3. In wet or damp hot locations where humidity
or perspiration considerable reduces the skin
resistance of the human body and the insulation
properties of accessories.
B. Environments with increased hazard of electric shock
do not include places where electrically conductive
parts in the near vicinity of the operator, which can
cause increased hazard, have been insulated.
G. The enclosure design of this Power Source meets the
requirements of IP23S as outlined in EN 60529. This
provides adequate protection against solid objects
(greater than 1/2", 12mm), and direct protection
from vertical drops. Under no circumstances should
the Power Source be operated or connected in
a micro environment that will exceed the stated
conditions. For further information please refer to
EN 60529.
H. Precautions must be taken against the power source
toppling over. The power source must be located on
a suitable horizontal surface in the upright position
when in use.
WARNING
This equipment should be electrically
connected by a qualified electrician.
3.03 Ventilation
WARNING
3.02 Location
Be sure to locate the welder according to the following
guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 32 to 104° F (0 to
40° C).
C. In areas, free from oil, steam and corrosive gases.
D. In areas, not subjected to abnormal vibration or
shock.
E. In areas, not exposed to direct sunlight or rain.
F. Place at a distance of 12" (300mm) or more from
walls or similar that could restrict natural air flow
for cooling.
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
3.04 Electricity Supply Voltage
The Electricity Supply voltage
should be within 208-265V
AC. Too low a voltage may
cause poor welding performance in STICK mode. Too
high a supply voltage will cause components to overheat
and possibly fail.
The Welding Power Source must be:
• Correctly installed,if necessary,bya qualied
electrician.
• Correctlyearthed(electrically)inaccordancewith
local regulations.
• Connectedtothecorrectsizepowerpointandfuse
as per the Specifications on page 2-4.
Manual 0-5191 3-1 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
WARNING
The Fabricator 181i must be electrically connected by a qualified electrical trades-person. Damage to the
PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable.
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT
TOUCH live electrical parts.
SHUT DOWN welding Power Source, disconnect input power employing lockout/tagging procedures. Lock-out/
tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box,
or shutting OFF and red-tagging circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding Power Source from a single-phase 50/60 Hz, AC power supply. The input voltage must match
one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric
utility for information about the type of electrical service available, how proper connections should be made, and
inspection required. The line disconnect switch provides a safe and convenient means to completely remove all
electrical power from the welding power source whenever necessary to inspect or service the unit.
Do not connect an input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
• Correctlyinstalled,ifnecessary,byaqualiedelectrician.
• Correctlyearthed(electrically)inaccordancewithlocalregulations.
• Connectedtothecorrectsizepowerpoint,fuseandprimarysupplyleadbasedonTable3-1.
WARNING
An electric shock or fire hazard is probable if the following electrical service guide recommendations
are not followed. These recommendations are for a dedicated branch circuit sized for the rated output
and duty cycle of the welding Power Source.
50 / 60 Hz Single Phase Supply
Supply Voltage 230V AC
Input Current at Maximum Output 35.7 Amps
Maximum Recommended Fuse* or Circuit Breaker Rating
*Time Delay Fuse, UL class RK5. Refer to UL248
Maximum Recommended Fuse^ or Circuit Breaker Rating
^Normal Operating , UL class K5. Refer to UL248
Minimum Recommended Input Cable Size 12 AWG
Maximum Recommended Input Conductor Length 50 ft (15m)
Minimum Recommended Grounding Conductor Size 12 AWG
50 Amps
50 Amps
Table 3-1: Electrical Service Guide
NOTE
Welding arc outs may be experienced if an extension cord is used when STICK welding when operation
the Power Source on 208 VAC due to the lack of DC voltage at the STICK electrode.
INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5191
Fabricator 181i
Input Power
Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned ON, the inrush circuit
provides pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn ON after the
input capacitors have charged to operating voltage (after approximately 5 seconds)
NOTE
Damage to the PCA could occur if 265V AC or higher is applied to the Primary Power Cord.
Primary Supply
Model
Fabricator
181i
Cord Size
(Factory Fitted)
12 AWG (3.3mm²)
Table 3-2: Primary Circuit Sizes to Achieve Maximum Current
3.05 Electromagnetic Compatibility
WARNING
Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic
situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the
welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are
detected then it shall be the responsibility of the user
of the welding equipment to resolve the situation
with the technical assistance of the manufacturer.
In some cases this remedial action may be as
simple as earthing the welding circuit, see NOTE
below. In other cases it could involve constructing
an electromagnetic screen enclosing the Welding
Power Source and the work, complete with
associated input filters. In all cases, electromagnetic
disturbances shall be reduced to the point where
they are no longer troublesome.
NOTE
Minimum Primary
Current Circuit Size
(Vin/Amps)
208-230V/40A 180A @ 20% 175A @ 20%
208-230V/25A 175A @ 25%
MIG (GMAW/
FCAW)
B. Assessment of Area
Before installing welding equipment, the user shall
make an assessment of potential electromagnetic
problems in the surrounding area. The following
shall be taken into account
1. Other supply cables, control cables, signaling
and telephone cables; above, below and adjacent
to the welding equipment.
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of
industrial equipment.
5. The health of people around, e.g. the use of
pacemakers and hearing aids.
6. Equipment used for calibration and
measurement.
7. The time of day that welding or other activities
are to be carried out.
8. The immunity of other equipment in the
environment: the user shall ensure that other
equipment being used in the environment
is compatible: this may require additional
protection measures.
Current & Duty Cycle
STICK (SMAW)
LIFT TIG
(GTAW)
The welding circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorized by a person who is competent to
assess whether the changes will increase the
risk of injury, e.g. by allowing parallel welding
The size of the surrounding area to be considered
will depend on the structure of the building and other
activities that are taking place. The surrounding area
may extend beyond the boundaries of the premises.
C. Methods of Reducing Electromagnetic Emissions
current return paths which may damage the
earth circuits of other equipment. Further
1. Electricity Supply
guidance is given in EN 60974-13 Arc
Welding Equipment - Installation and use
(under preparation).
Manual 0-5191 3-3 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
LOW PRESSURE
GAUGE (DELIVERY)
HIGH PRESSURE
GAUGE (SUPPLY)
INLET
CONNECTION
OUTLET
CONNECTION
PRESSURE
ADJUSTING
SCREW
A-09414_AB
Welding equipment should be connected to the
Electricity Supply according to the manufacturer’s
recommendations. If interference occurs, it may
be necessary to take additional precautions
such as filtering of the Electricity Supply.
Consideration should be given to shielding the
supply cable of permanently installed welding
equipment in metallic conduit or equivalent.
Shielding should be electrically continuous
throughout it’s length. The shielding should be
connected to the Welding Power Source so that
good electrical contact is maintained between
the conduit and the Welding Power Source
enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely
maintained according to the manufacturer’s
recommendations. All access and service doors
and covers should be closed and properly
fastened when the welding equipment is in
operation. The welding equipment should not be
modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of
arc striking and stabilizing devices should
be adjusted and maintained according to the
manufacturer’s recommendations.
3. Welding Cables
The welding cables should be kept as short
as possible and should be positioned close
together, running at or close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the
welding installation and adjacent to it should
be considered. However. Metallic components
bonded to the work piece will increase the
risk that the operator could receive a shock
by touching the metallic components and the
electrode at the same time. The operator should
be insulated from all such bonded metallic
components.
5. Earthing of the Workpiece
Where the workpiece is not bonded to earth
for electrical safety, nor connected to earth
because of it’s size and position, e.g. ship’s hull
or building steelwork, a connection bonding
the workpiece to earth may reduce emissions
in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage
to other electrical equipment. Where necessary,
the connection of the workpiece to earth should
be made by direct connection to the workpiece,
but in some countries where direct connection is
not permitted, the bonding should be achieved
by suitable capacitance, selected according to
national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables
and equipment in the surrounding area may
alleviate problems of interference. Screening the
entire welding installation may be considered for
special applications.
3.06 Victor Regulator
Pressure regulator (Figure 3-1) attached to the cylinder valve reduce high cylinder pressures to suitable low working
pressures for welding, cutting, and other applications.
INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5191
Figure 3-1: Victor CS Regulator
!
!
!
Art # A-09845
!
!
Use the regulator for the gas and pressure
for which it is designed. NEVER alter a
regulator for use with any other gas.
Regulators purchased with open 1/8”, 1/4”,
3/8”, or 1/2” NPT ports must be assembled
to their intended system.
1. Note the maximum inlet pressure stamped
on the regulator. DO NOT attach the regulator
to a system that has a higher pressure than
the maximum rated pressure stamped on the
regulator.
2. The regulator body will be stamped “IN” or
“HP” at the inlet port. Attach the inlet port to
the system supply pressure connection.
WARNING
NOTE
Fabricator 181i
6. Carefully inspect the regulator for damaged
threads, dirt, dust, grease, oil, or other flammable
substances. Remove dust and dirt with a clean
cloth. Be sure the inlet swivel filter is clean and
in place. Attach the regulator (Figure 3-2) to the
cylinder valve. Tighten securely with a wrench.
WARNING
DO NOT attach or use the regulator if oil,
grease, flamma ble substances or damage is
present! Have a qualified repair technician
clean the regulator or repair any damage.
3. Wrap pipe threads with Teflon tape 1 1/2 to 2
turns to effect a seal. If other sealants are used,
they must be compatible with the gas that will
be used in the system.
4. If gauges are to be attached to the regulator
and the regu lator is stamped and listed by a
third party (i.e. “UL” or “ETL”). The following
requirements must be met:
a) Inlet gauges over 1000 PSIG (6.87 mPa)
shall conform with the requirements of UL
404, “Indicating Pressure Gauges for Compressed Gas Service.”
b) Low pressure gauges must be UL recognized
for the class of regulator they are being used
on according to UL252A.
DO NOT use a regulator that delivers
pressure exceeding the pressure rating
of the downstream equipment unless
pro visions are made to prevent overpressurization (i.e. system relief valve).
Make sure the pressure rating of the downstream equipment is compatible with the
maximum delivery pressure of the regulator.
5. Be sure that the regulator has the correct
pressure rating and gas service for the cylinder
used.
WARNING
Figure 3-2: Regulator to Cylinder Valve
7. Before opening the cylinder valve, turn the
regulator adjusting screw counterclockwise until
there is no pressure on the adjusting spring and
the screw turns freely.
8. Relief Valve (where provided): The relief valve is
designed to protect the low pressure side of the
regulator from high pres sures. Relief valves are
not intended to protect down stream equipment
from high pressures.
WARNING
DO NOT tamper with the relief valve or
remove it from the regulator.
WARNING
Stand to the side of the cylinder opposite the
regulator when opening the cylinder valve.
Keep the cylinder valve between you and the
regulator. For your safety, NEVER STAND
IN FRONT OF OR BEHIND A REGULATOR
WHEN OPENING THE CYLINDER VALVE!
Manual 0-5191 3-5 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
Art # A-09828
!
!
9. Slowly and carefully open the cylinder valve
(Figure 3-3) until the maximum pressure shows
on the high pressure gauge.
Figure 3-3: Open Cylinder Valve
10. On all cylinders, except acetylene, open the
valve completely to seal the valve packing. On
gaugeless regulators, the indicator will register
the cylinder contents open.
11. On acetylene cylinders, open the valve 3/4 of a
turn and no more than 1-1/2.
Acetylene delivery pressure must not exceed
15 PSIG (103 kPa) or 30 PSIG (207 kPa).
Acetylene can dissociate (decompose with
explosive violence) above these pressure
limits.
WARNING
a) If the high-pressure gauge reading drops,
there is a leak in the cylinder valve, inlet
fitting, or high-pressure gauge.
b) If the low-pressure gauge drops, there is a
leak in the down stream equipment, hose,
hose fitting, outlet fitting or low-pressure
gauge. Check for leaks using an approved
leak detector solution.
c) If the high-pressure gauge drops and the
low-pressure gauge increases at the same
time, there is a leak in the regulator seat.
d) If the regulator requires service or repair,
take it to a qualified repair technician.
5. Once leak testing has been performed and there
are no leaks in the system, slowly open the
cylinder valve and proceed.
If a leak has been detected anywhere in
the system, dis continue use and have
the system repaired. DO NOT use leaking
equipment. Do not attempt to repair a leaking
system while the system is under pressure.
WARNING
3.08 When You Finish Using the Regulator
1. Close the cylinder valve.
CAUTION
Keep the cylinder valve wrench, if one is
required, on the cylinder valve to turn OFF
the cylinder quickly, if necessary.
12. Attach the desired downstream equipment.
3.07 Leak Testing the System
Leak test the system before putting into operation.
1. Be sure that there is a valve in the downstream
equipment to turn OFF the gas flow.
2. With the cylinder valve open, adjust the regulator
to deliver the maximum required delivery
pressure.
3. Close the cylinder valve.
4. Turn the adjusting screw/knob counterclockwise
one turn.
INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5191
2. Open the valve on the downstream equipment.
This drains all pressure from the system.
3. Close the valve on the downstream equipment.
4. Turn the adjusting screw counterclockwise to
release the ten sion on the adjusting spring.
5. Check the gauges after a few minutes for
verification that the cylinder valve is closed
completely.
3.09 Storage of the Regulator
When the regulator is not in use and has been removed
from the cylinder, it should be stored in an area where
it will be pro tected from dust, oil, and grease. The inlet
and outlet should be capped to protect against internal
contamination and prevent insects from nesting.
3.10 Power Source Controls, Indicators and Features
18
Fabricator 181i
4
5
1
14
13
FAULT
2
44
33
3
22
11
WIRESPEED INDUCTANCE
WIRESPEED
POWER
A
V
66
77
88
22
11
99
10 10
10 10
DOWNSLOPE (S)
DOWNSLOPE(S)
ARC FORCE (%)
ARCFORCE(%)
99
2
2
SOFT
INDUCTANCE
MIG
MIG
LIFT TIG
STICK
STICK
2T
2T
4T
4T
4
6
6
8
8
-
HARD+ SOFT
HARD
12
11
10
15
16
17
9
8
7
6
Art #
A-12167
Figure 3-4: Front Panel
Figure 3-6: Wire Feed Compartment Control
Art #
A-10354
Figure 3-5: Rear Panel
19
20
21
Art #
A-10355
Manual 0-5191 3-7 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
1. Power Indicator
The power indicator is illuminated when the
Electricity Supply is applied to the Power Source
and when the ON/OFF switch located on the rear
panel is in the ON position.
2. Digital Wirespeed/Amperage Meter (Left Digital
Display)
This digital meter displays preview Wirespeed in
MIG mode only then actual amperage (weld current)
once an arc has been established. It also displays
preview amperage in both the STICK and LIFT TIG
modes only then actual amperage (weld current)
once an arc has been established.
At times of non-welding, the amperage meter will
display a preview value in both STICK and LIFT TIG
modes. This value can be adjusted by varying the
amperage potentiometer (Control No. 3). At times
of non-welding, the amperage meter will preview
a wirefeed speed value (Inches Per Minute) in
MIG mode only. This can be identified as preview
wirefeed speed by a decimal point at the lower right
hand side of the display.
When welding, the amperage meter will display
actual amperage (weld current) in all modes.
At the completion of welding, the amperage meter
will hold the last recorded amperage value for a
period of approximately 10 seconds in all modes.
The amperage meter will hold the value until; (1)
any of the front panel controls are adjusted in which
case the Power Source will revert to preview mode,
(2) welding is recommenced, in which case actual
welding amperage will be displayed, or (3) a period
of 10 seconds elapses following the completion of
welding in which case the Power Source will return
to preview mode.
NOTE
The preview functionality provided on this
power source is intended to act as a guide
only. Some differences may be observed
between preview values and actual welding
values due to factors including the mode of
welding, differences in consumables/gas
mixtures, individual welding techniques and
the transfer mode of the welding arc (ie dip
versus spray transfer). Where exact settings
are required (in the case of procedural
work), it is recommended that alternate
measurement methods be utilized to ensure
output values are accurate.
3. Wirespeed/Amperage Control
In MIG mode, the Wirespeed/Amperage control
knob adjusts the speed of the wire feed motor
(which in turn adjusts the output current by varying
the amount of MIG wire delivered to the welding
arc). The optimum wire speed depends upon the
material type and the welding application. The setup
chart on the inside of the wire feed compartment
door provides a brief summary of the required
settings for a basic range of MIG (GMAW/FCAW)
welding applications.
In STICK and LIFT TIG modes, the Wirespeed/
Amperage control knob adjusts the amount of
amperage (weld current) delivered to the welding
arc by the Power Source. It directly adjusts the
Power Source to deliver the desired level of weld
current.
4. MIG Gun Adaptor (Tweco Style)
The MIG Gun adaptor is the connection point for
the Tweco Fusion MIG Gun. Connect the MIG Gun
by pushing the MIG Gun connector into the brass
MIG Gun Adaptor firmly and screw the locking
screw in the MIG Gun Adapter within the Wire Feed
Compartment to secure the Tweco Fusion MIG Gun
in position. Failure to properly lock the MIG Gun
into the MIG Gun Adapter will result in the MIG Gun
being pushed out of the MIG Gun Adapter by the
MIG welding wire or lack of shielding gas (porosity
in the weld) at the weld zone.
5. Positive Welding Output Terminal
The positive welding terminal is used to connect
the welding output of the Power Source to the
appropriate welding accessory such as the MIG Gun
(via the MIG Gun polarity lead), electrode holder
lead or work lead. Positive welding current flows
from the Power Source via this heavy duty bayonet
type terminal. It is essential, however, that the male
plug is inserted and turned securely to achieve a
sound electrical connection.
CAUTION
Loose welding terminal connections can
cause overheating and result in the male
plug being fused in the bayonet terminal.
INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5191
Fabricator 181i
6. MIG Gun Polarity Lead
The polarity lead is used to connect the MIG Gun to the appropriate positive or negative output terminal (allowing
polarity reversal for different welding applications). In general, the polarity lead should be connected in to the
positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using flux
cored (gasless) wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt,
consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the male
plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
7. Negative Welding Output Terminal
The negative welding terminal is used to connect the welding output of the Power Source to the appropriate
welding accessory such as the MIG Gun (via the MIG Gun polarity lead), TIG Torch or work lead. Negative
welding current flows to the Power Source via this heavy duty bayonet type terminal. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
8. Remote Control and Spool Gun Socket
The 8 pin socket is used to connect the Tweco Fusion MIG Gun, remote control device or spool gun plug to
the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully
clockwise.
2
1
5
4
8
7
Art # A-10421_AC
1
2
3
3
6
4
5
6
7
8
Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Trigger Switch
WV
Remote Volts in
MIG (GMAW/FCAW)
Negative
Spool Gun Motor
Positive
Figure 3-7: Remote Control Socket
Socket Pin
1 Spool gun motor (0V)
2
3
4
Trigger Switch Input
Trigger Switch Input
Spool gun motor (+24V DC)
Function
5
6
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm potentiometer for the remote control of the Wirespeed in MIG mode.
7
Wiper arm connection to 5k ohm potentiometer for the remote control of the Amperage (Weld Current) in LIFT
TIG mode.
8
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Table 3-3
Manual 0-5191 3-9 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
Note that the Local/ Remote Switch (Control No. 18) located in the wirefeed compartment should be set to
Remote for remote amperage/voltage controls to operate.
9. Multifunction Control - Voltage, Down Slope & Arc Force
The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc
Force (STICK Mode) depending on the welding mode selected.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some
differences may be observed between preview values and actual welding values due to factors including
the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the
transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in
the case of procedural work), it is recommended that alternate measurement methods be utilized to
ensure output values are accurate.
When MIG Mode is Selected
In this mode the control knob is used to adjust the MIG welding voltage of the Power Source. The welding
voltage is increased by turning the knob clockwise or decreased by turning the knob counterclockwise. The
optimum voltage level required will depend on the type of welding application. The setup chart on the inside
of the wire feed compartment door provides a brief summary of the required output settings for a basic range
of MIG welding applications.
When STICK Mode is Selected
In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable
amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator
the ability to compensate for variability in joint fit-up in certain situations with particular electrodes. In general
increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be
achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob
counterclockwise.
When LIFT TIG Mode is Selected
In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to
select the ramp down time of the amperage at the completion of the weld. The main function of down slope
is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool
is given time to cool sufficiently.
Note that when in 2T normal mode (Control No. 11), the Power Source will enter down slope mode as soon
as the trigger switch is released (ie if the multifunction control knob is set to 5, the Power Source will ramp
down from the present welding current to zero over 5 seconds). If no down slope time is set then the welding
output will cease immediately. If the Power Source is set to 4T latch mode, to enter down slope mode the
trigger must be held in for the selected time period (ie press and release trigger to commence welding, then
press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope
phase (4T only), the output will cease immediately.
10. Arc Control (Inductance)
The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc
control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc
which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance.
11. Trigger Mode Control (MIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the of the MIG or TIG Trigger Switch between
2T (normal) and 4T (latch mode)
INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5191
Fabricator 181i
2T (Normal Mode)
In this mode, the MIG or TIG Trigger Switch must remain depressed for the welding output to be active. Press
and hold the MIG or TIG Trigger Switch to activate the Power Source (weld). Release the MIG or TIG Trigger
Switch to cease welding.
4T (Latch Mode)
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator
can press and release the MIG or TIG Trigger Switch and the output will remain active. To deactivate the Power
Source, the trigger switch must again be depressed and released, thus eliminating the need for the operator
to hold the MIG or TIG Trigger Switch
Note that when operating in LIFT TIG mode, the Power Source will remain activated until the selected Downslope
time has elapsed (refer Control No. 9).
12. Process Selection Control
The process selection control is used to select the desired welding mode. Three modes are available, MIG,
LIFT TIG and STICK modes. Refer to section 3.15 or 3.16 for MIG (GMAW/FCAW) set up details, section 3.17
for LIFT TIG (GTAW) set-up details or section 3.18 for STICK (SMAW) set-up details.
Note that when the Power Source is powered OFF the mode selection control will automatically default to MIG
mode. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the
Power Source and mistakenly be in contact with the work piece during power up.
13. Digital Voltage Meter (Right Digital Display)
The digital voltage meter is used to display the both the preview voltage (MIG mode only) and actual output
voltage (all modes) of the Power Source.
At times of non-welding, the voltage meter will display a preview value in MIG mode. This value can be
adjusted by varying the multifunction control knob (Control No. 9). Note that in STICK and LIFT TIG modes,
the voltage meter will not preview welding voltage but will display Open Circuit Voltage in STICK mode and
0V in LIFT TIG mode.
When welding, the voltage meter will display actual welding voltage in all modes.
At the completion of welding, the digital voltage meter will hold the last recorded voltage value for a period of
approximately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel
controls are adjusted in which case the Power Source will revert to preview mode, (2) welding is recommenced,
in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the
completion of welding in which case the Power Source will return to preview mode.
NOTE
The preview functionality provided on this power source is intended to act as a guide only. Some
differences may be observed between preview values and actual welding values due to factors including
the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the
transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in
the case of procedural work), it is recommended that alternate measurement methods be utilized to
ensure output values are accurate.
14. Thermal Overload Indicator
This welding Power Source is protected by a self resetting thermostat. The indicator will illuminate if the duty
cycle of the Power Source has been exceeded. Should the thermal overload indicator illuminate the output
of the Power Source will be disabled. Once the Power Source cools down this light will go OFF and the over
temperature condition will automatically reset. Note that the power switch should remain in the on position
such that the fan continues to operate thus allowing the Power Source to cool sufficiently. Do not switch the
Power Source OFF should a thermal overload condition be present.
Manual 0-5191 3-11 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
!
15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation)
The Gas Inlet connection is used to supply the appropriate MIG welding gas to the Power Source. Refer to
section 3.15 or 3.16 for MIG (FCAW/GMAW) set up details.
WARNING
Only Welding Shielding Gases specifically designed for arc welding applications should be used.
16. ON / OFF Switch
This switch is used to turn the Power Source ON/OFF.
WARNING
When the front digital displays are lit, the machine is connected to the Mains supply voltage and the
internal electrical components are at Mains voltage potential.
17. Intelligent Fan Control
The Fabricator 181i is designed with an intelligent fan control. It automatically switches the cooling fan OFF
when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize
the amount of contaminants such as dust that are drawn into the Power Source.
Note that the fan will only operate when required for cooling purposes and will automatically switch OFF when
not required.
Note in STICK mode the fan operates continuously.
18. Local / Remote Switch (located in wirefeed compartment)
The local/ remote switch is used only when a remote control device (such as a TIG Torch with remote current
control) is fitted to the Power Source via the remote control socket (Control No. 8). When the local/ remote
switch is in the remote position, the Power Source will detect a remote device and work accordingly. When in
the local mode, the Power Source will not detect the remote device and will operate from the Power Source
controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the
position of the local/ remote switch (ie in both local and remote modes).
Should a remote device be connected and the local/ remote switch set to remote, the maximum setting of
the Power Source will be determined by the respective front panel control, irrespective of the remote control
device setting. As an example, if the output current on the Power Source front panel is set to 50% and the
remote control device is set to 100%, the maximum achievable output from the Power Source will be 50%.
Should 100% output be required, the respective front panel control must be set to 100%, in which case the
remote device will then be able to control between 0-100% output.
19. Burnback Control (located in wirefeed compartment)
The Burnback control is used to adjust the amount of MIG wire that protrudes from the MIG Gun after the
completion of MIG welding (commonly referred to as stick-out). To decrease the Burnback time (or lengthen
the amount of wire protruding from the MIG Gun at the completing of welding), turn the Burnback control
knob counterclockwise . To increase the Burnback time (or shorten the amount of wire protruding from the
MIG Gun at the completing of welding), turn the Burnback Control knob clockwise.
INSTALLATION, OPERATION AND SETUP 3-12 Manual 0-5191
Fabricator 181i
Art #
A-10356_AB
MIG Gun Adaptor
MIG Gun Connector
MIG Gun Connector
Thumb Screw
8 pin socket
8 pin plug
20. MIG Gun & Spool Gun Switch
The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun functionality and Spool
Gun functionality
21. 10A Fuse
The 10A fuse is used to protect the spool gun motor.
3.11 Attaching the Tweco Fusion 180A Gun
Fit the Tweco Fusion MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adaptor
and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter.
Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded
collar fully clockwise to lock the plug into position.
Figure 3-8: Attaching MIG Gun
Manual 0-5191 3-13 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
Art # A-11482_AB
3.12 Torch Adapter Thumb Screw Replacement
1. Place unit on its back.
2. Remove 2 screws in bottom of the front panel. A securing block will become detached and fall free from
the front panel as you turn each screw out. Set these aside for reassembly. Leave screws sitting in the
pockets of the panel.
Screws
Art # A-11483
Securing Block
3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang
downwardly.
Tension Knob
Pressure Arm
Art # A-11484
INSTALLATION, OPERATION AND SETUP 3-14 Manual 0-5191
Fabricator 181i
4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed.
Thumb Screw
Fully Exposed
Art # A-11485_AB
5. Remove damaged thumb screw and replace with new one.
Art # A-11486
Push Upward
6. To reassemble, reverse steps 1 through 4.
Manual 0-5191 3-15 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
Art #
A-10357
Friction Washer
4”（100mm）
Diameter spool
Nut with
Nylon Insert
Spring
Plastic Spacer
Brass Flat
Washer
Flat Washer
3.13 Installing 4" (100mm) Diameter Spool
As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter
spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 3-9.
Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with
nylon insert tightens the brake. The brake is correctly adjusted when the spool stops within 4" (100mm) to 8"
(200mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without
becoming dislodged from the spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.
Figure 3-9: 4" (100mm)Diameter Spool Installation
3.14 Installing 8" (200mm) Diameter Spool
As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool.
In order to re-fit a 8" (200mm) spool assemble parts in the sequence shown below in Figure 3-10.
Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with
nylon insert tightens the brake. The Brake is correctly adjusted when the spool stops within 3/8" (10mm) to 3/4"
(20mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without
becoming dislodged from the spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.
Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 8" (200mm)
diameter spool.
This alignment pin can be removed by unscrewing in an counterclockwise direction and locating in the
appropriate position.
NOTE
INSTALLATION, OPERATION AND SETUP 3-16 Manual 0-5191
8” (200mm)
diameter spool
Spool Hub Nut
Alignment pin
Alternate
Alignment Pin
Position
Wire Spool Hub
Friction
Washer
Plastic Spacer
Spring
Flat Washer
Nut with
Nylon Insert
Brass Flat
Washer
Art #
A-10358
Figure 3-10: 8" (200mm) Diameter Spool Installation
Fabricator 181i
3.15 Inserting Wire into the Wire Feed Mechanism
Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in an
counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine
which releases the pressure roller arm (Figure 3-11). With the MIG welding wire feeding from the bottom of the
spool (Figure 3-12) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide
and into the MIG Gun.
Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly (Figure 3-11).
Remove the contact tip from the MIG Gun. With the MIG Gun lead reasonably straight, feed the wire through the
MIG Gun by depressing the trigger switch. Fit the appropriate Velocity contact tip.
WARNING
Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF.
The electrode wire will be at welding voltage potential while it is being fed through the system.
Keep MIG Gun away from eyes and face.
Manual 0-5191 3-17 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
MIG Welding Wire
Art #
A-10360
Art #
A-10359_AB
Wire Drive Tension Screw
Pressure Roller Arm
Outlet Guide
Inlet Guide
Figure 3-11: Wire Drive Assembly Components
Figure 3-12: MIG Welding Wire - Installation
3.16 Feed Roller Pressure Adjustment
The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These
devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If
slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit
liner should be checked for kinks and clogging by metal flakes and swarf. If it is not the cause of slipping, the feed
roll pressure can be increased by rotating the pressure screw clockwise.
Before changing the feed roller ensure that the Electricity Supply to the Power Source is switched OFF.
The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.
INSTALLATION, OPERATION AND SETUP 3-18 Manual 0-5191
WARNING
CAUTION
Fabricator 181i
GROOVE “B”GROOVE “A”
ZE
Art #
3.17 Changing the Feed Roll
To change feed roll remove the feed roll retaining screw by turning in an counterclockwise direction. Once the feed
roll is removed then to replace feed roll simply reverse these directions.
A dual groove feed roller is supplied as standard. It can accommodate 023"(0.6mm) -.030" (0.8mm) diameter hard
wires. Select the roller required with the chosen wire size marking facing outward.
GROOVE “B” SIZE
Figure 3-13: Dual Groove Feed Roller
Feed Roll
Retaining Screw
Feed Roll
Figure 3-14: Changing the Feed Roll
GROOVE “A” SI
A-09583
A-09584_AC
3.18 Wire Reel Brake
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is
considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise
to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 3/8"
(10mm) - 3/4" (20mm) after release of the trigger. The electrode wire should be slack without becoming dislodged
from wire spool.
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.
Manual 0-5191 3-19 INSTALLATION, OPERATION AND SETUP
CAUTION
Fabricator 181i
Wire Reel Brake Adjustment Nut
Art #
A-10361
Figure 3-15: Wire Reel Brake
3.19 Gas Regulator Operation
With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize
as follows:
1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure
surge may damage internal regulator parts.
2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is
recommended that testing for leaks at the regulator connection points be carried out using a suitable leak
detection solution or soapy water.
3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by
individually opening then closing the equipment control valves. Complete purging may take up to ten
seconds or more, depending upon the length and size of the hose being purged.
Adjusting Flow Rate
With the regulator ready for operation, adjust working flow rate as follows:
1. Adjust the gas flow rate. The recommended rate for MIG welding is 28-46 CFH. The recommended rate
for LIFT TIG welding is 10-28 CFH.
NOTE
It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence
due to back pressure present within shielding gas hose assembly.
Shutdown
Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes).
1. Close cylinder or upstream valve tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from
any ignition source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.
INSTALLATION, OPERATION AND SETUP 3-20 Manual 0-5191
Fabricator 181i
3.20 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire
A. Select MIG mode with the process selection control. (Refer to Section 3.10 for further information)
B. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the electrode
wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
C. Fit the MIG Gun to the Power Source. (Refer to section 3.07 Attaching the Tweco Fusion 180A MIG Gun).
D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
E. Fit the gas regulator/flow gauge to the shielding gas cylinder (refer to Section 3.14) then connect the shielding
gas hose from the rear of the Power Source to the regulator/flow gauge outlet.
F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.
G. Switch the LOCAL/REMOTE switch inside the wire feed
compartment to LOCAL to use the Power Sources Wirespeed and
Voltage controls.
H. Switch the MIG GUN/SPOOL GUN switch inside
the wire feed compartment to MIG GUN.
!
Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable
stationary support to prevent falling or tipping.
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
WARNING
Manual 0-5191 3-21 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
Art #
A-10362
Shielding Gas Hose Fitted
with 5/8"-18 UNF
connection
Primary Cord
Work Lead
Negative Welding
Terminal (-)
Positive Welding
Terminal (+)
MIG Gun
Polarity Lead
MIG Gun
8 pin Plug
Secure the gas cylinder
in an upright position
by chaining it to a
stationary support to
prevent falling or tipping.
Figure 3-16: Setup for MIG Welding with Gas Shielded MIG Wire
3.21 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire
A. Select MIG mode with the process selection control (refer to Section 3.10.12 for further information).
B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode
wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
C. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.
E. Switch the LOCAL/REMOTE switch inside the
wire feed compartment to LOCAL to use the
Power Sources Wirespeed and Voltage controls.
F. Switch the MIG GUN/SPOOL GUN switch inside
the wire feed compartment to MIG GUN.
WARNING
Before connecting the work clamp to the work make sure the Electricity Supply is switched OFF.
INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5191
Fabricator 181i
(+)
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
Positive Welding
Terminal
MIG Gun
Negative Welding
Terminal (-)
8 pin Plug
MIG Gun
Polarity Lead.
Work Lead
Figure 3-17: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire
A-09587_AD
Manual 0-5191 3-23 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
3.22 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire
Set the Process Selection Control to MIG for Spool Gun welding.
For setup and operation of the spool gun, please refer to the spool gun operations manual.
Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to SPOOL GUN.
Connect the shielding gas for the to the Shielding Gas Inlet on the rear panel of the Power
Source.
1. Make sure the welding power source is turned
OFF before connecting the welding gun.
2. Open side panel and loosen thumb screw.
Art #
A-10363
3. Insert the back end of the Spool gun into the gun
receiving bushing.
4. Tighten thumb screw and replace side panel.
5. Connect gas supply fitting and tighten with a
wrench.
6. Align Control Plug to panel fitting and tighten
securely.
INSTALLATION, OPERATION AND SETUP 3-24 Manual 0-5191
Fabricator 181i
3.23 Setup for LIFT TIG (GTAW) Welding
A. Select LIFT TIG mode with the process selection control (refer to Section 3.10.12 for further information).
B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the Power Source via
heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely
to achieve a sound electrical connection.
C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via
heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely
to achieve a sound electrical connection.
D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the Power Source as shown
below. The TIG torch will require a trigger switch to weld in LIFT TIG Mode.
NOTE
A Tweco 17V TIG torch with an 8 pin plug must be used to turn the weld current ON/OFF via the TIG
torch trigger switch to TIG weld OR a Tweco Foot Control with an 8 pin plug must be used to turn the
weld current ON/OFF as well as providing remote control of the weld current.
E. Fit the gas regulator/flow gauge to the shielding gas cylinder (refer to Section 3.14) then connect the shielding
gas hose from the TIG torch to the regulator/flow gauge outlet. Note that the TIG torch shielding gas hose is
connected directly to the regulator/flow gauge. The Power Source is not fitted with a shielding gas solenoid to
control the gas flow in LIFT TIG mode therefore the TIG torch will require a gas valve.
!
Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure
the Electricity Supply is switched OFF.
Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary
support to prevent falling or tipping.
WARNING
Manual 0-5191 3-25 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
Art #
A-10364
(+)
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
F. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use
the Power Sources Amperage control or REMOTE for remote amperage using a Foot
Control.
Positive welding
terminal
MIG Gun
polarity lead
not connected.
.
Work lead
Note: A Tweco 17V TIG torch with
an 8 pin plug must be used to turn the
weld current on/o via the TIG torch trigger
switch to TIG weld OR a Tweco Foot
Control with an 8 pin plug must be used to
TIG Torch
turn the weld current on/o as well as
providing remote control of the weld current.
Figure 3-18: Setup for TIG Welding
Connect to shielding gas
regulator/ow gauge.
Secure the gas cylinder
in an upright position by
chaining it to a stationary
support to prevent falling
or tipping.
Negative welding
terminal (-).
INSTALLATION, OPERATION AND SETUP 3-26 Manual 0-5191
Fabricator 181i
Art #
A-10365
Negative Welding
Terminal (-)
Positive Welding
Terminal
(+)
Work Lead
Electrode
Holder
MIG Gun
polarity lead
not connected.
3.24 Setup for STICK (SMAW) Welding
A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode
manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.
B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.
Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however,
that the male plug is inserted and turned securely to achieve a sound electrical connection.
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode holder
make sure the Electricity Supply is switched OFF.
CAUTION
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
C. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use
the Power Sources Amperage control or REMOTE for remote amperage control using a
Hand Pendant Control.
Figure 3-19: Setup for Manual Arc Welding.
Manual 0-5191 3-27 INSTALLATION, OPERATION AND SETUP
Fabricator 181i
This Page Intentionally Blank
INSTALLATION, OPERATION AND SETUP 3-28 Manual 0-5191
Fabricator 181i
Shielding Gas
SECTION 4:
BASIC WELDING GUIDE
4.01 MIG (GMAW/FCAW) Basic Welding Technique
Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the
very basic concepts in using the MIG mode of welding, where a welding MIG Gun is hand held, and the electrode
(welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert
welding grade shielding gas mixture.
GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO2 welding, Micro Wire Welding,
short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together
the parts to be welded by heating them with an arc between a solid continuous, consumable electrode and the
work. Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas
mixture. The process is normally applied semi automatically; however the process may be operated automatically
and can be machine operated. The process can be used to weld thin and fairly thick steels, and some non-ferrous
metals in all positions.
Shielding Gas
Molten Weld Metal
Solidified
Weld Metal
Nozzle
Electrode
Arc
Base Metal
GMAW Process
Art # A-8991_AB
Figure 4-1
FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to
be welded by heating them with an arc between a continuous flux filled electrode wire and the work. Shielding is
obtained through decomposition of the flux within the tubular wire. Additional shielding may or may not be obtained
from an externally supplied gas or gas mixture. The process is normally applied semi automatically; however the
process may be applied automatically or by machine. It is commonly used to weld large diameter electrodes in the
flat and horizontal position and small electrode diameters in all positions. The process is used to a lesser degree
for welding stainless steel and for overlay work.
Nozzle
(Optional)
Flux Cored
Electrode
Arc
Base Metal
Art # A-08992_AB
Slag
(Optional)
Molten Metal
Molten
Slag
Solidified
Weld Metal
FCAW Process
Figure 4-2
Manual 0-5191 4-1 BASIC WELDING GUIDE
Fabricator 181i
10° to 20° Longitudinal
Direction of Travel
Position of MIG Gun
The angle of MIG Gun to the weld has an effect on the width of the weld.
Push
Vertical
Drag/Pull
Art # A-07185_AB
Figure 4-3
The welding Gun should be held at an angle to the weld joint. (See Secondary Adjustment Variables below)
Hold the MIG Gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper
filter lenses and use the proper safety equipment.
CAUTION
Do not pull the welding MIG Gun back when the arc is established. This will create excessive wire
extension (stick-out) and make a very poor weld.
The electrode wire is not energized until the MIG Gun trigger switch is depressed. The wire may therefore be placed
on the seam or joint prior to lowering the helmet.
5° to 15°
Longitudinal
Angle
90°
Transverse
Angle
Direction of
Travel
10°
Longitudinal Angle
30° to 60°
Transverse
Angle
Angle
30° to 60°
Transverse
Angle
Direction of Travel
Art # A-08993
Butt & Horizontal Welds
Figure 4-4
5° to 15°
Longitudinal Angle
30° to 60°
Transverse Angle
Direction of
Travel
Art # A-08994
Horizontal Fillet Weld
Figure 4-5
BASIC WELDING GUIDE 4-2 Manual 0-5191
Transverse Angle
Vertical Fillet Welds
Figure 4-6
30° to 60°
Overhead Weld
Figure 4-7
Art # A-08995
5° to 15°
Longitudinal
Angle
Art # A-08996
Fabricator 181i
Distance from the MIG Gun Nozzle to the Work Piece
The electrode wire stick-out from the MIG Gun nozzle should be between 3/8" (10mm) to 3/4" (20.0mm). This
distance may vary depending on the type of joint that is being welded.
Travel Speed
The speed at which the molten pool travels influences the width of the weld and penetration of the welding run.
MIG Welding Variables
Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in
short-arc welding of 24 ga. (0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques and end results
in the MIG process are controlled by these variables.
Preselected Variables
Preselected variables depend upon the type of material being welded, the thickness of the material, the welding
position, the deposition rate and the mechanical properties. These variables are:
• Type of electrode wire
• Size of electrode wire
• Type of gas (not applicable to self shielding wires FCAW)
• Gas flow rate (not applicable to self shielding wires FCAW)
Primary Adjustable Variables
These control the process after preselected variables have been found. They control the penetration, bead width,
bead height, arc stability, deposition rate and weld soundness. They are:
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead
formation. They are:
1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain
at about 3/8" (10mm) stick-out
2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases
weld current.
Gas Nozzle
Tip to
Work Distance
Average Arc Length
Electrode Stick-Out
Contact Tip (Tube)
Electrode Wire
Actual Stick-out
Art # A-08997_AD
Figure 4-8
3. Nozzle Angle. This refers to the position of the welding MIG Gun in relation to the joint. The transverse
angle is usually one half the included angle between plates forming the joint. The longitudinal angle is
the angle between the centre line of the welding MIG Gun and a line perpendicular to the axis of the weld.
The longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading
(pushing). Whether the operator is left handed or right handed has to be considered to realize the effects
of each angle in relation to the direction of travel.
Manual 0-5191 4-3 BASIC WELDING GUIDE
Fabricator 181i
Transverse
Longitudinal
Angle
Angle
Direction of Gun Travel
Axis of Weld
Transverse and Longitudinal
Nozzle Axes
Figure 4-9
Art # A-08998_AB
Leading or “Pushing”
Angle
(Forward Pointing)
Nozzle Angle, Right Handed Operator
90°
Figure 4-10
Trailing or “Pulling”
Angle
(Backward Pointing)
Art # A-08999_AC
Establishing the Arc and Making Weld Beads
Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample
metal of the same material as that of the finished piece.
The easiest welding procedure for the beginner to experiment with MIG welding is the flat position. The equipment
is capable of flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 ga. (1.6mm) or 1/8" (3.2mm) mild steel plate 6” (150mm)
x 6” (150mm). Use 0.035” (0.9mm) gas shielded steel or gasless flux cored wire.
Setting of the Power Source
Power source and Wirefeeder setting requires some practice by the operator, as the welding plant has two control
settings that have to balance. These are the Wirespeed control (refer to section 3.06.3) and the welding Voltage
Control (refer to section 3.06.9). The welding current is determined by the Wirespeed control, the current will
increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen
the arc. Increasing the welding voltage hardly alters the current level, but lengthens the arc. By decreasing the
voltage, a shorter arc is obtained with a little change in current level.
When changing to a different electrode wire diameter, different control settings are required. A thinner electrode
wire needs more Wirespeed to achieve the same current level.
A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode
wire diameter and the dimensions of the work piece.
If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool
and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however,
the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The correct setting
of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.
Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas used depends on the following
• Thicknessofthemetaltobewelded
• Typeofjoint
• CapacityofthewirefeedunitandPowerSource
• Theamountofpenetrationrequired
• Thedepositionraterequired
• Thebeadproledesired
• Thepositionofwelding
• Costofthewire
BASIC WELDING GUIDE 4-4 Manual 0-5191
Tweco MIG, Lift TIG, Stick Wire Selection Chart
Art # A-10366_AB
Fabricator 181i
Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart
Manual 0-5191 4-5 BASIC WELDING GUIDE
Fabricator 181i
!
4.02 MIG (GMAW/FCAW) Welding Troubleshooting
Solving Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through
to the MIG Gun. There are two main areas where problems occur with MIG, Porosity and Inconsistent wire feed
Solving Problems Beyond the Welding Terminals - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some
contaminant within the molten weld pool which is in the process of escaping during solidification of the molten
metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can
be reduced by checking the following points.
FAULT CAUSE
1 Limited or no shielding gas flows
out of the MIG Gun nozzle.
2 Shielding gas cylinder contents
and flow gauge.
3 Gas leaks. Check for gas leaks between the regulator/cylinder connection and
4 Internal gas hose in the Power
Source.
5 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
6 Welding dirty, oily, painted,
oxidized or greasy plate.
7 Distance between the MIG Gun
nozzle and the work piece.
8 Maintain the MIG Gun in good
working order.
Check that the MIG Gun connection is fully engaged into the MIG
Gun Adapter. The o-rings in the MIG Gun connection must seal
the shielding gas within the MIG Gun Adapter so the shielding gas
flows into the MIG Gun and out thru the MIG Gun nozzle.
Ensure that the shielding gas cylinder is not empty and the flow
meter is correctly adjusted to workshop welding: 28-35 CFH or
outdoors welding: 35-46 CFH.
in the gas hose to the Power Source.
Ensure the hose from the solenoid valve to the MIG Gun adaptor
has not fractured and that it is connected to the MIG Gun adaptor.
Clean contaminates off the work piece.
Keep the distance between the MIG Gun nozzle and the work piece
to a minimum. Refer to section 2.03
A Ensure that the gas holes are not blocked and gas is exiting out of
the MIG Gun nozzle.
B Do not restrict gas flow by allowing spatter to build up inside the
MIG Gun nozzle.
C Check that the MIG Gun O-rings are not damaged.
Table 4-2: Solving Problems beyond the Welding Terminals-Porosity
WARNING
Disengage the feed roll when testing for gas flow by ear.
BASIC WELDING GUIDE 4-6 Manual 0-5191
Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
Fabricator 181i
1 Feed roller driven by motor in the
cabinet slipped.
2 Wire spool unwinds and tangles. Wire spool brake is too loose.
3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding.
4 Wire rubbed against the misaligned
guides and reduced wire feed-ability.
5 Liner blocked with swarf A Increased amounts of swarf are produced by the wire
6 Incorrect or worn contact tip A The Velocity contact tip transfers the weld current
Wire spool brake is too tight.
B Replace feed roller if worn.
Misalignment of inlet/outlet guides.
passing through the feed roller when excessive pressure is applied to the pressure roller adjuster.
B Swarf can also be produced by the wire passing
through an incorrect feed roller groove shape or size.
C Swarf is fed into the conduit liner where it accumu-
lates thus reducing wire feed-ability.
to the electrode wire. If the hole in the contact tip is
too large then arcing may occur inside the contact tip
resulting in the wire jamming in the contact tip
B When using soft wire such as aluminum it may be-
come jammed in the contact tip due to expansion of
the wire when heated. A Velocity contact tip designed
for soft wires should be used.
7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the
work piece then the connection point will heat up and
result in a reduction of power at the arc.
8 Bent liner This will cause friction between the wire and the liner
thus reducing wire feed-ability.
Table 4-3: Wire Feeding Problems
Manual 0-5191 4-7 BASIC WELDING GUIDE
Fabricator 181i
Basic MIG Welding Troubleshooting
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed
speed.
B Incorrect MIG Gun angle B Adjust angle.
C Excessive heat input C Increase the MIG Gun travel speed and/or
decrease welding current by decreasing the
voltage or decreasing the wire feed speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire
feed speed and increasing voltage.
B Joint preparation too narrow or
gap too tight
C Shielding gas incorrect C Change to a gas which gives higher penetration.
3 Lack of fusion Voltage too low Increase voltage.
4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed
B Voltage too low B Increase the voltage or decrease wirespeed.
5 Irregular weld shape A Incorrect voltage and current
settings. Convex, voltage too
low. Concave, voltage too high.
B Wire is wandering. B Replace Velocity contact tip.
C Incorrect shielding gas C Check shielding gas.
D Insufficient or excessive heat
input
6 Weld cracking A Weld beads too small A Decrease travel speed
B Weld penetration narrow and
deep
C Excessive weld stresses C Increase weld metal strength or revise design
B Increase joint angle or gap.
control.
A Adjust voltage and current by adjusting the
voltage control and the wirespeed control.
D Adjust the wirespeed control or the voltage
control.
B Reduce current and voltage and increase MIG Gun
travel speed or select a lower penetration shielding gas.
D Excessive voltage D Decrease voltage.
E Cooling rate too fast E Slow the cooling rate by preheating part to be
welded or cool slowly.
7 Cold weld puddle A Loose welding cable connection. A Check all welding cable connections.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited Tweco Service Provider to
test then replace the faulty component.
8 Arc does not have a crisp
sound that short arc exhibits when the wirefeed
speed and voltage are
adjusted correctly.
9 Poor weld result from
setup chart parameters
BASIC WELDING GUIDE 4-8 Manual 0-5191
The MIG Gun has been con-
nected to the wrong voltage
polarity on the front panel.
Contact tip has arc marks in the
bore causing excessive drag on
the wire
Table 4-4: MIG Welding Problems
Connect the MIG Gun to the positive (+) welding
terminal for solid wires and gas shielded
flux cored wires. Refer to the electrode wire
manufacturer for the correct polarity.
Replace the contact tip with only a Genuine
Tweco Velocity contact tip.
Fabricator 181i
4.03 Stick (SMAW) Basic Welding Technique
Size of Electrode
The electrode size is determined by the thickness of metals being joined and can also be governed by the type
of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the
smaller size electrodes.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A
little practice will soon establish the most suitable electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
Electrode Polarity
Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive
polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult
the electrode data sheet or your nearest Accredited Tweco Distributor.
4.04 Effects of Stick Welding Various Materials
High Tensile and Alloy Steels
The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and,
if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and underbead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current
settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.
Manganese Steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is
absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding
to distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally
cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart
malleable, due to the porosity caused by gas held in this type of iron.
Copper and Alloys
The most important factor is the high rate of heat conductivity of copper, making pre-heating of heavy sections
necessary to give proper fusion of weld and base metal.
Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on their applications. There are a great
number of electrodes used for specialized industrial purposes which are not of particular interest for everyday
general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large
diameter pipes, etc The range of electrodes dealt with in this publication will cover the vast majority of applications
likely to be encountered; are all easy to use.
Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined.
Naturally enough, different types of electrodes would be used for different metals as described in the preceding
section.
Manual 0-5191 4-9 BASIC WELDING GUIDE
Fabricator 181i
Art # A-07688
Art # A-07689
Art # A-07690
Welding Position
The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in
flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions
intermediate between these. Some of the common types of welds are shown in Figures 4-15 through 4-22.
Art # A-07687
Figure 4-11: Flat Position, Down Hand Butt Weld
Art A-07691
Figure 4-15: Vertical Position, Butt Weld
Figure 4-12: Flat Position, Gravity Fillet Weld
Figure 4-13: Horizontal Position, Butt Weld
Figure 4-14: Horizontal-Vertical (HV) Position
Art # A-07692
Figure 4-16: Vertical Position, Fillet Weld
Art# A-07693
Figure 4-17: Overhead Position, Butt Weld
Art # A-07694
Figure 4-18: Overhead Position, Fillet Weld
BASIC WELDING GUIDE 4-10 Manual 0-5191
Fabricator 181i
Open Square Butt
Single Vee Butt Joint
Not less than
Joint Preparations
In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and
for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to
ensure proper penetration of the weld metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed
from oxy-cut surfaces. Typical joint designs are shown in Figure 4-19.
Joint
Gap varies from
1/16" (1.6mm) to 3/16" (4.8mm)
depending on plate thickness
Single Vee Butt Joint
Lap Joint
Fillet Joint
Corner Weld
Not less than
45°
(Fillet both sides of the
1.6mm (1/16”)
Double Vee Butt Joint
1/16" (1.6mm)
Tee Joints
joint)
Edge Joint
70°
Not less than
70°
1/16" (1.6mm) max
1/16" (1.6mm) max
Plug Weld Plug Weld
Art # A-10367
Figure 4-19: Typical Joint Designs for Arc Welding
Arc Welding Technique - A Word to Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap
plate. Use mild steel plate about 1/4" (6.4mm) thick and a 1/8"(3.2mm) electrode. Clean any paint, loose scale
or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand
position. Make sure that the work clamp is making good electrical contact with the work, either directly or through
the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit
will probably result.
Manual 0-5191 4-11 BASIC WELDING GUIDE
Fabricator 181i
The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much
work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon
make you feel tired. Relax and you will find that the job becomes much easier. You can add much to your peace of
mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting
alight to your clothes.
Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder
lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down.
If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your
hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric
shock.
Striking the Arc
Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty
due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the
work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of
the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck.
As soon as the arc is established, maintain a 1/16"(1.6mm) to 1/8"(3.2mm) gap between the burning electrode
end and the parent metal. Draw the electrode slowly along as it melts down.
Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the
arc is broken again. A little practice will soon remedy both of these faults.
Art # A-10368
1/16" (1.6mm)
Figure 4-20: Striking an Arc
Arc Length
The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will find
that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal
comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential
if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag
and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld
to detach it. Contact or "touch-weld" electrodes such as E7014 Stick electrodes do not stick in this way, and make
welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the
molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to
form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the bead will be too large.
BASIC WELDING GUIDE 4-12 Manual 0-5191
Fabricator 181i
20°-30°
Making Welded Joints
Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1/16"(1.6mm) to 3/32"(2.4mm)
gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld
metal pulling the plates out of alignment. Plates thicker than 1/4" (6.4mm) should have their mating edges
beveled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using
a 1/8"(3.2mm) E7014 Stick electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a wellformed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the
angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this.
The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc.
To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.
Electrode
Tack Weld
Figure 4-21: Butt Weld
Tack Weld
Art # A-07698
Art # A-07697_AB
Figure 4-22: Weld Build up Sequence
Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and
clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run.
Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence
shown in Figure 4-22. The width of weave should not be more than three times the core wire diameter of the
electrode. When the joint is completely filled, the back is either machined, ground or gouged out to remove slag
which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing
bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in
securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-section made by depositing metal in the corner of two faces
meeting at right angles. Refer to Figure 4-14.
A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked
together at right angles. Using a 1/8"(3.2mm) E7014 Stick electrode at 100 amps, position angle iron with
one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet. Strike the arc and
immediately bring the electrode to a position perpendicular to the line of the fillet and about 45º from the vertical.
Some electrodes require to be sloped about 20º away from the perpendicular position to prevent slag from
running ahead of the weld. Refer to Figure 4-23. Do not attempt to build up much larger than 1/4"(6.4mm)width
with a 1/8"(3.2mm) electrode, otherwise the weld metal tends to sag towards the base, and undercut forms
on the vertical leg. Multi-runs can be made as shown in Figure 4-24. Weaving in HV fillet welds is undesirable.
Manual 0-5191 4-13 BASIC WELDING GUIDE
Fabricator 181i
45° from
vertical
60° - 70° from line
of weld
Art # A-07699_AB
6
3
1
5
2
4
Figure 4-24: Multi-runs in HV Fillet Weld
Art # A-07700_AB
Figure 4-23: Electrode Position for HV Fillet Weld
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 1/8"(3.2mm)
E7014 Stick electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the
job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the horizontal to
enable a good bead to be deposited. Refer Figure 4-25. Use a short arc, and do not attempt to weave on
the first run. When the first run has been completed de-slag the weld deposit and begin the second run at
the bottom. This time a slight weaving motion is necessary to cover the first run and obtain good fusion
at the edges. At the completion of each side motion, pause for a moment to allow weld metal to build up
at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld.
Figure 4-26 illustrates multi-run technique and Figure 4-27 shows the effects of pausing at the edge of
weave and of weaving too rapidly.
Art # A-07701
Figure 4-25: Single Run Vertical Fillet Weld
Art # A-07702
Art # A-07703
Figure 4-27: Examples of Vertical Fillet Welds
Figure 4-26: Multi Run Vertical Fillet Weld
BASIC WELDING GUIDE 4-14 Manual 0-5191
Fabricator 181i
2. Vertical Down
The E7014 Stick electrode makes welding in this position particularly easy. Use a 1/8"(3.2mm) electrode
at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward
travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point
upwards at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not much more difficult that
downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right
angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in
a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode
is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-28). The tip of the electrode may
be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for
overhead fillet welds. Use a 1/8"(3.2mm) E6013 Stick electrode at 100 amps, and deposit the first run by
simply drawing the electrode along at a steady rate. You will notice that the weld deposit is rather convex,
due to the effect of gravity before the metal freezes.
Art # A-07704
Figure 4-28: Overhead Fillet Weld
Distortion
Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible,
but in other cases allowance has to be made before welding commences for the distortion that will subsequently
occur. The study of distortion is so complex that only a brief outline can be attempted hear.
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a
cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded
joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes
the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking
volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy
section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still
remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint
in 5/64" (2.0mm) sheet, the contracting weld metal may cause the sheet to become distorted.
Manual 0-5191 4-15 BASIC WELDING GUIDE
Fabricator 181i
Upsetting
Weld
B. Expansion and Contraction of Parent Metal in the Fusion Zone:
While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very high
temperature and attempts to expand in all directions. It is able to do this freely at right angles to the surface
of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the weld", it
meets considerable resistance, and to fulfill the desire for continued expansion, it has to deform plastically, that
is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes
against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to
cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does
not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal.
Several things can then happen.
The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful
contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses
in the job. Figures 4-29 and 4- 30 illustrate how distortion is created.
Art # A-07705_AB
Weld
Art # A-07706_AC
Permanent Upset
Expansion with
compression
Hot
Hot
Cool
Figure 4-29: Parent Metal Expansion
Figure 4-30: Parent Metal Contraction
Contraction
with tension
Overcoming Distortion Effects
There are several methods of minimizing distortion effects.
A. Peening
This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable
on the last layer.
B. Distribution of Stresses
Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that
they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences. Choice of a
suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable
sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful
in eliminating distortion.
C. Restraint of Parts
Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack
welds are methods employed with this in view.
D. Presetting
It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to
calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the
components to be welded, constructional stresses can be made to pull the parts into correct alignment. A
simple example is shown in Figure 4-31.
E. Preheating
Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce
distortion. Figure 4-32 shows a simple application. By removing the heating source from b and c as soon as
welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.
BASIC WELDING GUIDE 4-16 Manual 0-5191
Fabricator 181i
Art # A-07707
Figure 4-31: Principle of Presetting
Art # A-07708
B
Dotted lines show effect if no preheat is used
Weld
C
PreheatPreheat
Figure 4-32: Reduction of Distortion by Preheating
Art # A-07709
Art # A-07710_AB
4
Art # A-07711_AB
Figure 4-35: Step back Sequence
1
2
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
3
Figure 4-34: Welding Sequence
1
2
3
Figure 4-33: Examples of Distortion
Art # A-07428_AB
Figure 4-36: Chain Intermittent Welding
Art # A-07713_AB
Figure 4-37: Staggered Intermittent Welding
Manual 0-5191 4-17 BASIC WELDING GUIDE
Fabricator 181i
Insufficient Gap
Incorrect Sequence
Art # A-05866_AC
4.05 Stick (SMAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Welding current
varying
2 A gap is left by
failure of the weld
metal to fill the
root of the weld.
3 Non-metallic par-
ticles are trapped
in the weld metal.
ARC FORCE control knob is
set at a value that causes the
welding current to vary excessively with the arc length.
Reduce the ARC FORCE control knob until welding
current is reasonably constant while prohibiting the
electrode from sticking to the work piece when you
“dig” the electrode into the workpiece.
A Welding current too low A Increase welding current.
B Electrode too large for joint. B Use smaller diameter electrode.
C Insufficient gap. C Allow wider gap.
A Non-metallic particles may
be trapped in undercut from
A If a bad undercut is present clean slag bout and
cover with a run from a smaller gauge electrode.
previous run.
B Joint preparation too re-
stricted.
C Irregular deposits allow slag
B Allow for adequate penetration and room for clean-
ing out the slag.
C If very bad, chip or grind out irregularities.
to be trapped.
D Lack of penetration with slag
trapped beneath weld bead.
D Use smaller electrode with sufficient current to give
adequate penetration. Use suitable tools to remove
all slag from comers.
E Rust or mill scale is prevent-
E Clean joint before welding.
ing full fusion.
F Wrong electrode for position
in which welding is done.
F Use electrodes designed for position in which
welding is done, otherwise proper control of slag is
difficult.
Figure 1 - Example of insufficient gap or incorrect sequence
4 A groove has been
A Welding current is too high. A Reduce welding current.
formed in the base
metal adjacent to
B Welding arc is too long. B Reduce the length of the welding arc.
the toe of a weld
and has not been
filled by the weld
metal (undercut).
C Angle of the electrode is
incorrect.
D Joint preparation does not
allow correct electrode angle.
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
E Electrode too large for joint. E Use smaller gauge electrode.
F Insufficient deposit time at
edge of weave.
G Power Source is set for MIG
F Pause for a moment at edge of weave to allow weld
metal buildup.
G Set Power Source to STICK (SMAW) mode.
(GMAW) welding.
BASIC WELDING GUIDE 4-18 Manual 0-5191
FAULT CAUSE REMEDY
Lack of fusion caused by dirt,
Fabricator 181i
5 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
6 Gas pockets or
voids in weld
metal (porosity)
A Small electrodes used on
A Use larger electrodes and preheat the plate.
heavy cold plate.
B Welding current is too low. B Increase welding current.
C Wrong electrode angle. C Adjust angle so the welding arc is directed more
into the base metal.
D Travel speed of electrode is
D Reduce travel speed of electrode.
too high.
E Scale or dirt on joint surface. E Clean surface before welding.
electrode angle incorrect,
rate of travel too high
Art # A-05867_AC
Lack of side fusion,
scale dirt, small electrode,
amperage too low
Lack of
inter-run fusion
Lack of root fusion
Figure 2: Example of Lack of Fusion
A High levels of sulfur in steel. A Use an electrode that is designed for high sulfur
steels.
B Electrodes are damp. B Dry electrodes before use.
C Welding current is too high. C Reduce welding current.
7 Crack occurring in
weld metal soon
after solidification
commences
D Surface impurities such as
D Clean joint before welding.
oil, grease, paint, etc.
E Welding in a windy environ-
E Shield the weld area from the wind.
ment.
F Electrode damaged ie flux
coating incomplete.
F Discard damaged electrodes and only use elec-
trodes with a complete flux coating.
A Rigidity of joint. A Redesign to relieve weld joint of severe stresses or
use crack resistance electrodes.
B Insufficient throat thickness. B Travel slightly slower to allow greater build up in
throat.
C Weld current is too high. C Decrease welding current.
Slag
trapped in
Not cleaned,
or incorrect
electrode
undercut
Art # A-05868_AC
Slag trapped in root
Figure 3: Example of Slag Inclusion
8 The Stick elec-
Manual 0-5191 4-19 BASIC WELDING GUIDE
trode is difficult to
run with multiple
arc-outs when
welding
The Stick electrode being
used is not suitable for use
with this machine.
Table 4-6: Welding Problems - Stick (SMAW)
Use E6013 or E7018 Stick electrodes for steel or
300 series stainless steel Stick electrodes for 300
series stainless steel.
Fabricator 181i
4.06 TIG (GTAW) Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process
in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable)
electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding
gas mixture which is generally Argon based. A filler metal may also be added manually in some circumstances
depending on the welding application.
Art # A-10369_AB
Gas Cup
Either Ceramic,
Work Piece
Can Be Any Commercial
Metal
Welds Made With or Without
Addition of Filler Metal
High Impact or
Water Cooled
Metal
Tungsten Electrode
Non-Consumable
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-38: TIG Welding Application Shot
Tungsten Electrode Current Ranges
Electrode Diameter DC Current (Amps)
0.040” (1.0mm) 30-60
1/16” (1.6mm) 60-115
3/32” (2.4mm) 100-165
1/8” (3.2mm) 135-200
5/32” (4.0mm) 190-280
3/16” (4.8mm) 250-340
Table 4-7: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
1/16” (1.6mm) 20-90
3/32” (2.4mm) 65-115
1/8” (3.2mm) 100-165
3/16” (4.8mm) 200-350
Table 4-8: Filler Wire Selection Guide
BASIC WELDING GUIDE 4-20 Manual 0-5191
Tungsten Electrode Types
Fabricator 181i
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Welding Application Features Color Code
DC welding of mild
steel, stainless steel
and copper
High quality AC welding of aluminum,
magnesium and their
alloys.
AC & DC welding of
mild steel, stainless
steel, copper, aluminum, magnesium and
their alloys
Excellent arc starting,
Long life, High current
carrying capacity
Self cleaning, Long
life, Maintains balled
end, High current carrying capacity.
Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.
Table 4-9
NOTE
The Fabricator 181i is not suited for AC TIG welding.
Red
White
Grey
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
1/4”
6.4mm
TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the
principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding
process is outside the scope of this Operating Manual. For further information please refer to www.thermalarc.
com or contact Tweco.
DC Current
for Mild
Steel
35-45
40-50
45-55
50-60
60-70
70-90
80-100
90-115
115-135
140-165
160-175
170-200
DC Current
for Stainless
Steel
20-30
25-35
30-45
35-50
40-60
50-70
65-85
90-110
100-125
125-150
135-160
160-180
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
Table 4-10
Filler Rod
Diameter (if
required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Argon Gas
Flow Rate
CFH
10-15 Butt/Corner
10-15 Butt/Corner
15 Butt/Corner
15 Butt/Corner
20 Butt/Corner
20 Butt/Corner
Joint Type
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Manual 0-5191 4-21 BASIC WELDING GUIDE
Fabricator 181i
4.07 TIG (GTAW) Welding Problems
FAULT CAUSE REMEDY
1 Excessive bead build up or
poor penetration or poor
fusion at edges of weld.
2 Weld bead too wide and
flat or undercut at edges
of weld or excessive burn
through.
3 Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
4 Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet
joint
6 Electrode melts or oxidizes
when an arc is struck.
Welding current is too
low
Welding current is too
high
Travel speed too fast Reduce travel speed.
Travel speed too slow Increase travel speed.
Wrong placement of
filler rod
A TIG Torch lead
connected to positive
welding terminal.
Increase weld current and/or faulty joint
preparation.
Decrease weld current.
Re-position filler rod.
A Connect TIG Torch lead to negative welding
terminal.
B No gas flowing to weld-
ing region.
C TIG Torch is clogged
with dust or dirt.
D
Gas hose is cut. D Replace gas hose.
E Gas passage contains
impurities.
F Gas regulator turned
OFF.
G TIG Torch valve is
turned OFF.
H The electrode is too
small for the welding
current.
I Power Source is set for
MIG welding.
B Turn TIG Torch gas valve ON. Check the gas
lines for kinks or breaks and gas cylinder
contents.
C Clean TIG Torch.
E Disconnect gas hose from the rear of Power
Source then raise gas pressure and blow out
impurities.
F Turn ON.
G Turn ON.
H Increase electrode diameter or reduce the
welding current.
I Set Power Source to LIFT TIG mode.
BASIC WELDING GUIDE 4-22 Manual 0-5191
FAULT CAUSE REMEDY
Fabricator 181i
7 Dirty weld pool A Electrode contaminated
by contact with work
piece or filler rod material.
B Work piece surface has
foreign material on it.
C Gas contaminated with
air.
8 Poor weld finish Inadequate shielding
gas.
9 Arc start is not smooth. A Tungsten electrode is
too large for the welding current.
B The wrong electrode
is being used for the
welding job.
C Gas flow rate is too
high.
A Clean the electrode by grinding off the con-
taminates.
B Clean surface.
C Check gas lines for cuts and loose fitting or
change gas cylinder.
Increase gas flow or check gas line for gas
flow problems.
A Select the right size electrode. Refer to Table
4-7 Current Ranges for Various Tungsten
Electrode Size.
B Select the right electrode type. Refer to Table
4-9 Tungsten Electrode Types.
C Select the right rate for the welding job. Refer
to Table 4-10.
10 Arc flutters during TIG
welding.
11 Tungsten blackens due to
lack of shielding gas
D Incorrect shielding gas
is being used.
E Poor work clamp con-
nection to work piece.
Tungsten electrode is
too large for the welding current.
A Gas valve on the TIG
Torch has not been
turned ON.
B Gas cylinder valve OFF
or TIG Torch hose not
connected to regulator
Table 4-11: TIG (GTAW) Welding Problems
D Select the right shielding gas.
E Improve connection to work piece.
Select the right size electrode. Refer to Table
4-7 Current Ranges for Various Electrode
Size.
A Turn ON TIG Torch gas valve before you
commence welding.
B Turn ON gas cylinder valve or connect TIG
Torch hose to regulator.
Manual 0-5191 4-23 BASIC WELDING GUIDE
Fabricator 181i
This Page Intentionally Blank
BASIC WELDING GUIDE 4-24 Manual 0-5191
SECTION 5: POWER SOURCE PROBLEMS AND
ROUTINE SERVICE REQUIREMENTS
5.01 Power Source Problems
FAULT CAUSE REMEDY
1 Electricity Supply is ON,
power indicator is illuminated however the Power
Source will not commence
welding when the torch trigger switch is depressed.
A Power Source is not in the cor-
B Faulty torch trigger. B Repair or replace torch trigger
rect mode of operation.
Fabricator 181i
A Set the Power Source to the correct
mode of operation with the process
selection switch.
switch/lead.
2 Fault Indicator is illuminat-
ed and the Power Source
will not commence welding when the torch trigger
switch is depressed.
3 The Power Source will not
feed wire in MIG mode.
4 Welding wire continues to
feed when torch trigger is
released.
5 Welding arc cannot be
established in MIG mode.
Duty cycle of Power Source has
been exceeded.
A Electrode wire stuck in conduit
liner or contact tip (burn-back
jam).
B MIG GUN/SPOOL GUN switch
is switched to SPOOL GUN.
A Trigger mode selection switch
is in 4T latch mode.
B Torch trigger leads shorted. B Repair or replace torch trigger
A MIG Gun polarity lead is not
connected into a welding output terminal.
B Poor or no work lead contact. B Clean work clamp area and ensure
Leave the Power Source switched
ON and allow it to cool. Note that
fault indicator must be extinguished
prior to commencement of welding.
A Check for clogged / kinked MIG Gun
conduit liner or worn contact tip.
Replace faulty components.
B Switch the MIG GUN/SPOOL GUN
switch to MIG GUN.
A Change the trigger mode selection
switch from 4T latch mode to 2T
normal mode.
switch/lead.
A Connect the MIG Gun polarity lead
to either the positive welding output
terminal or the negative welding
output terminal as required.
good electrical contact.
6 Inconsistent wire feed. A Worn or dirty contact tip. A Replace if necessary.
B Worn feed roll. B Replace.
C Excessive brake tension on wire
reel hub.
D Worn, kinked or dirty conduit
liner
7 No gas flow in MIG mode. A Gas hose is damaged. A Replace or repair.
B Gas passage contains impuri-
ties.
C Gas regulator turned OFF. C Turn ON regulator.
D Empty gas cylinder. D Replace gas cylinder.
Manual 0-5191 5-1 TROUBLE SHOOTING AND SERVICE
C Reduce brake tension on spool hub
D Clean or replace conduit liner
B Disconnect gas hose from the rear
of Power Source and blow out
impurities.
Fabricator 181i
FAULT CAUSE REMEDY
8 Gas flow continues after
the torch trigger switch has
been released (MIG mode).
Gas valve has jammed open
due to impurities in the gas or
the gas line.
Have an accredited Tweco service
provider repair or replace gas valve.
9 Power indicator will not
illuminate and welding arc
cannot be established.
10 TIG electrode melts when
arc is struck.
11 Arc flutters during TIG
welding.
The Electricity Supply voltage
has exceeded voltage limits of
the Power Source.
TIG Torch is connected to the
(+) VE terminal.
Tungsten electrode is too large
for the welding current.
Table 5-1
Ensure that the Electricity Supply
voltage is within 208-265 VAC.
Connect the TIG Torch to the (-) VE
terminal.
Select the correct size of tungsten
electrode. Refer to Table 4-7.
5.02 Routine Service and Calibration Requirements
WARNING
There are extremely dangerous voltage and power levels present inside this Power Source. Do not attempt to open or repair unless you are an accredited Tweco Service Provider. Disconnect the Welding
Power Source from the Electricity Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the Power Source and associated accessories shall be carried out in accordance
with Section 5 of EN 60974-1: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation
resistance test and an earthing test to ensure the integrity of the Power Source is compliant with Tweco's original
specifications.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in
EN 60974-1, then the above tests should be carried out prior to entering this location.
A. Testing Schedule
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.
A transportable Power Source is deemed to be any equipment that is not permanently connected and fixed in
the position in which it is operated.
NOTE
Please refer to local guidelines for further information.
B. Insulation Resistance
Minimum insulation resistance for in-service Tweco Power Sources shall be measured at a voltage of 500V
between the parts referred to in Table 6-1below. Power Sources that do not meet the insulation resistance
requirements set out below shall be withdrawn from service and not returned until repairs have been performed
such that the requirements outlined below are met.
TROUBLE SHOOTING AND SERVICE
5-2 Manual 0-5191
Fabricator 181i
Components to be Tested
Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)
All circuits to exposed conductive parts
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage exceeding extra low voltage
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage not exceeding extra low voltage
Separate welding circuit to separate welding circuit
Table 5-2: Minimum Insulation Resistance Requirements: Tweco Power Sources
C. Earthing
The resistance shall not exceed 1Ω between any metal of a Power Source where such metal is required to be
earthed, and -
1. The earth terminal of a fixed Power Source; or
2. The earth terminal of the associated plug of a transportable Power Source
Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Tweco welding Power Sources should be inspected by a licensed electrical worker in accordance with
the requirements below -
Minimum Insulation
Resistance (MΩ)
5
2.5
10
1
1
1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every
3 months; and
2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12
months.
D. General Maintenance Checks
Welding equipment should be regularly checked by an accredited Tweco Service Provider to ensure that:
1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly
connected and in good condition.
2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short
circuit.
3. The Welding System is clean internally, especially from metal filing, slag, and loose material.
E. Accessories
Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be
inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable
condition. All unsafe accessories shall not be used.
F. Repairs
If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited
Tweco Service Provider.
Manual 0-5191 5-3 TROUBLE SHOOTING AND SERVICE
Fabricator 181i
Power Source Calibration
A. Schedule
Output testing of all Tweco Power Sources and applicable accessories shall be conducted at regular intervals
to ensure they fall within specified levels. Calibration intervals shall be as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined
in EN 60974-1, then the above tests should be carried out prior to entering this location.
B. Calibration Requirements
Where applicable, the tests outlined in Table 6-3 below shall be conducted by an accredited Tweco service agent.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable Tweco Power Source specifications
Output Voltage (V) to be checked to ensure it falls within applicable Tweco Power Source specifications
Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Tweco Power Source
/ wire feeder specifications
Accuracy of digital meters to be checked to ensure it falls within applicable Tweco Power Source specifica-
tions
Table 5-3: Calibration Parameters
Periodic calibration of other parameters such as timing functions are not required unless a specific fault has
been identified.
C. Calibration Equipment
All equipment used for Power Source calibration shall be in proper working condition and be suitable for
conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized.
TROUBLE SHOOTING AND SERVICE
5-4 Manual 0-5191
Fabricator 181i
5.03 Cleaning the Welding Power Source
WARNING
There are dangerous voltage and power levels present inside this product. Do not attempt to open or
repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from
the Electricity Supply Voltage before disassembling.
To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated
dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign
material may reduce the welders output welding current.
5.04 Cleaning the Feed Rolls
Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or
clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs.
CAUTION
Do not use compressed air to clean the Welding Power Source. Compressed air can force metal particles
to lodge between live electrical parts and earthed metal parts within the Welding Power Source. This
may result in arcing between this parts and their eventual failure.
Manual 0-5191 5-5 TROUBLE SHOOTING AND SERVICE
Fabricator 181i
5.05 Volt-Ampere Curves
Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source.
Curves of other settings fall between curves shown.
TROUBLE SHOOTING AND SERVICE
Art # A-11296
Figure 5-1: Fabricator 181i Volt-Ampere Curves
5-6 Manual 0-5191
SECTION 6: KEY SPARE PARTS
6.01 Tweco Fusion 180A MIG Gun Parts
Fabricator 181i
Torch Part No: F180TA-12-3035
Art# A-11672_AB
Item
No.
1 Velocity Nozzle**
2 Velocity Contact Tip**
3 Handle / Trigger Repair Kit F80
4 Conduit Assembly* WS42-3035-15
5A Tweco Rear Connector 350-174H
5
5B Tweco Control Wire 35K-350-1
5C Tweco Control Wire & Plug WS-354-TA-LC
Description Part No.
VNS-50
VNS-50F
VNS-62
VNS-62F
VNS-37
VNS-37F
VNS-75FAS
VTS-23
VTS-30
VTS-35
VTS-40
VTS-45
VTS-364
VTSA-364
VTS-52
VTS-116
VTSA-116
VTS-564
Table 6-1: Tweco Fusion 180A MIG Gun Parts
Figure 6-1
** Patent Pending
* Refer to Tweco Catalog No. 64-2103 for additional
options.
Manual 0-5191 6-1 KEY SPARE PARTS
Fabricator 181i
6.02 Power Source
A-11243_AC
Art #
Figure 6-2
31
KEY SPARE PARTS 6-2 Manual 0-5191
FABRICATOR 181i POWER SOURCE SPARE PARTS
ITEM PART NUMBER DESCRIPTION
1 W7004962 PCB,Power,181i
2 W7004963 PCB,Control,181i
3 W7003033 Solenoid,Valve,24VDC
4 W7004970 PCB,Display,181i
5 W7004969 PCB,Remote Interface,181i
6 W7004905 Wiredrive Assy,w/ Motor,181i
7 W7004906 Feedroll retaining thumb screw
8 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed
9 W7004947 Fan,24VDC,4.75"x4.75"x1",181i
10 W7003010 Rectifier Bridge,1000V,50A
11 W7003215 Connector,Gas Inlet,5/8"-18UNF
12 W7004909 Dinse,Socket,181i
13 W7004955 Connector,Dinse,181i
14 W7004942 Socket,8 Pin,w/ Harness
15 W7003053 Switch,On/Off,250V
16 W7004911 CT Sensor,Output,181i
17 W7004912 Wire Hub Assy,181i
18 W7005552 Panel, Front
19 W7005555 Panel, Rear
20 W7004922 Handle,181i
21 W7005554 Side and Top Panels (not shown)
22 W7004966 Adapter,Tweco 4,181i
23 W7004925 Guide,Inlet,.023-.045,181i
24 W7004967 Guide,Inlet,.023-.045,181i
25 W7005553 Panel,Door (not shown)
26 W7004928 Panel,Base,181i
27 870734 Knob,1/4" IDx.72" ODx.9" H
28 W7004972 Knob,1/4" IDx1" ODx0.9" H
29 W7004957 Panel,Front Control,181i
30 W7004953 Push Button Actuator
31 OTWAK/1S Screw,Locking,MIG Gun
32 W7004961 Thermistor,NTC,K45 47K,181i
33 W7004940 PCB Burnback Potentiometer
34 W7004968 PCB,Spool Gun,181i
35 W7004979 Fuse Holder,181i
36 W7004982 Fuse,10 Amp
37 9-0025 Power Cord,12AWG,NEMA 6-50P (not shown)
38 W7005550 Label,Setup Chart,181i,English (not shown)
39 W7005551 Label,Setup Chart,181i,French (not shown)
40 W7004960 Inductor,181i (not shown)
41 W7004951 Spool Hub,181i
42 W7004943 Switch,250V/2A,181i
43 W7004983 Shoulder strap, 181i (not shown)
Table 6-2
Fabricator 181i
Manual 0-5191 6-3 KEY SPARE PARTS
Fabricator 181i
This Page Intentionally Blank
KEY SPARE PARTS 6-4 Manual 0-5191
CONNECTOR LAYOUT DIAGRAM
DRIE
M
I
N
I
M
OURCE
GUN
DY
OT
UN
CRNTC
ON
Art # A-11230_AC
1 SPOOL GUN (0V)
2 TORCH SWITCH (+24VDC)
3 TORCH SWITCH RIN (0VDC)
4 SPOOL GUN (+24VDC)
5
6 REMOTE CONTROL IN (+15VDC)
7 (REMOTE AMPS/WIRESPEED) POT WIPER
8 (REMOTE VOLTAGE) POT WIPER
FUSE
BLACK
RED
OT
1
RED
BLK
YEL
BURN BACK PCB 5
3 +24VDC1
1 +12VDC
2 RETURN
Current Sensor
1
Fabricator 181i
APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM
Manual 0-5191 A-1
APPENDIX
This Page Intentionally Blank
This Page Intentionally Blank
TWECO - LIMITED WARRANTY TERMS
LIMITED WARRANTY: Tweco ®, Inc, A Victor Technologies Company, warrants to customers of its authorized
distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should
any failure to conform to this warranty appear within the time period applicable to the Tweco products as stated
below, Tweco shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized
standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects
by suitable repair or replacement, at Tweco’s sole option, of any components or parts of the product determined
by Tweco to be defective.
TWECO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU
OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: TWECO SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco with respect to
any contract, or anything done in connection therewith such as the performance or breach thereof, or from the
manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Tweco whether arising out
of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided
herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of
Tweco is authorized to change this warranty in any way or grant any other warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE
USED WHICH IN TWECO’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY TWECO
PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers
the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more
than the time stated plus one year from the date Tweco delivered the product to the authorized distributor.
WARRANTY SCHEDULE
5 Years Parts* / 3 Years Labor
ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster
Portafeed, Ultrafeed, Ultima 150, WC 100B
* 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards.
* 3 years on Power Supply Components
2 Years Parts and Labor Unless specified
Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy
Victor Regulator for Fabricator 181i (No labor)
1 Years Parts and Labor Unless specified
95S, Water recirculators
All Plasma Welding consols (i.e WC-1 Controller, WT Timer,
WF-100 Capstain Feeder, etc)
180 days parts and Labor Unless specified
Plasma Welding Torch and leads packages
Gas Regulators "Supplied with power sources" (No Labor)
90 days parts / No Labor
Remote Controls
MIG and TIG Torches (Supplied with power sources)
Replacement repair parts
30 days parts / No Labor
MIG Torch for Fabricator 181i
5-2-1 years Parts / No Labor
FirePower® Welders
5 Years Parts / No Labor
Victor® Professional
Victor Technologies limited warranty shall not apply to:
Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due
normal wear
* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Victor Technologies repair facility
within thirty (30) days of the repair.
* No employee, agent, or representative of Victor Technologies is authorized to change this warranty in any way or grant any other warranty,
and Victor Technologies shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein,
constitutes fulfillment of Victor Technologies’s obligations to purchaser with respect to the product.
* This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Victor
Technologies's sole judgment, impaired the safety or performance of any Victor Technologies product. Purchaser’s rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada
Canada Customer Care
Ph 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph +44 1257-261755
Fax: +44 1257-224800
Milan, Italy
Customer Care
Ph +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph 6221-8990-6095
Fax: 6221-8990-6096
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Customer Care
Ph +603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph 1300-654-674 (tollfree)
Ph 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph 61-3-9474-7508
Fax: 61-3-9474-7488
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Sales Office
Ph +86 21-64072626
Fax: +86 21-64483032
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Sales Office
Ph +65 6832-8066
Fax: +65 6763-5812
INNOVATION TO SHAPE THE WORLD
U.S. Customer Care: 800-426-1888 / FAX 800-535-0557
Canada Customer Care: 905-827-4515 / FAX 800-588-1714
International Customer Care: 940-381-1212 / FAX 940-483-8178
© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in China
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