210
3163339
115V
208/230V
FABRICATOR® 211i
3-IN-1 Multi Process
Welding Systems
Operating
Manual
English
Canadien Français
Americas Español
Revision: AJ Issue Date: April 24, 2015 Manual No.: 0-5157
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 0-5157 for:
Tweco Fabricator 211i Portable System Package Part Number: W1004201
Tweco Fabricator 211i Portable System with Cart Part Number: W1004202
Tweco Fabricator 211i Power Source Part Number: W1004200
Tweco Fabricator 211i Package
w/Single Cylinder Cart Part Number: W1004203
Published by:
Victor Technologies International, Inc.
16052 Swingley Ridge Road,
Suite 300 St, Louis, MO 63017
USA
www.victortechnologies.com
© Copyright 2012, 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: May 4, 2012
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 .................................................................................. 2-2
2.06 User Responsibility ......................................................................................... 2-2
2.07 Fabricator 211i Portable System Package (Part No. W1004201) .................... 2-2
2.08 Duty Cycle ....................................................................................................... 2-3
2.09 Specifications ................................................................................................. 2-4
2.10 Optional Accessories ...................................................................................... 2-6
2.11 Volt-Ampere Curves ........................................................................................ 2-7
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 ........................................................................................... 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-4
3.06 Victor Regulator .............................................................................................. 3-5
3.07 Leak Testing The System ................................................................................ 3-8
3.08 When You Finish Using The Regulator ............................................................ 3-8
3.09 Storage Of The Regulator ............................................................................... 3-8
3.10 Fabricator 211i Power Source Controls, Indicators And Features ................... 3-9
3.11 Attaching the TWECO Fusion 220A MIG Gun ................................................ 3-16
3.12 Installing 33/44 lb Spool (12" diameter) ...................................................... 3-17
3.13 Installing 12.5 lb Spool ( 8" diameter) .......................................................... 3-18
3.14 Installing 1 lb Spool (4" diameter) ................................................................ 3-19
3.15 Inserting Wire Into The Wire Feed Mechanism ............................................. 3-20
3.16 Feed Roller Pressure Adjustment .................................................................. 3-21
3.17 Changing the Feed Roll ................................................................................. 3-21
3.18 Wire Reel Brake ............................................................................................ 3-22
3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire .................... 3-22
3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire ................... 3-23
TABLE OF CONTENTS
3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire 3-25
3.22 Setup For LIFT TIG (GTAW) Welding ............................................................. 3-26
3.23 Setup For STICK (SMAW) Welding .............................................................. 3-28
SECTION 4:
BASIC WELDING GUIDE ............................................................................. 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5
4.03 STICK (SMAW) Basic Welding Technique ....................................................... 4-8
4.04 Effects of Arc Welding Various Materials ........................................................ 4-8
4.04 STICK (SMAW) Welding Troubleshooting ..................................................... 4-16
4.05 TIG (GTAW) Basic Welding Technique .......................................................... 4-18
4.06 TIG (GTAW) Welding Problems ..................................................................... 4-20
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 ................................................................................... 5-6
SECTION 6: KEY SPARE PARTS .......................................................................... 6-1
6.01 Tweco Fusion 220A MIG Gun .......................................................................... 6-1
6.02 Power Source Spare Parts .............................................................................. 6-2
APPENDIX 1: FABRICATOR 211i CIRCUIT DIAGRAM ................................................. A-1
TWECO - LIMITED WARRANTY TERMS ............................................INSIDE REAR COVER
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
This Page Intentionally Blank
SAFETY INSTRUCTIONS FABRICATOR 211i
!
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training
in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
This publication and other guides to what you should learn before operating this equipment are listed at the
end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and
machine internal circuits are also live when
power is on. In semi-automatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned ON accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn OFF all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the ground
or the work surface. Do not touch holders connected
to two welding machines at the same time or touch
other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working
above floor level.
15. Keep all panels and covers securely in place.
Manual 0-5157 1-1 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
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)
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 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
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 travelling 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
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.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific
application; maintain them and associated parts in
good condition.
Manual 0-5157 1-3 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
!
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
WARNING
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. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases.
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. Allow engine to cool before fuelling. If possible,
check and add fuel to cold engine before beginning
job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
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.
SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5157
3. Allow pressure to escape before completely
removing cap.
SAFETY INSTRUCTIONS FABRICATOR 211i
!
!
1.02 General Safety Information For
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.
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.
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.
B. Housekeeping
Victor CS Regulator
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.
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.
ABOUT PACEMAKERS:
The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.
Manual 0-5157 1-5 SAFETY INSTRUCTIONS AND WARNINGS
Keep ALL apparatus clean and free of grease, oil and
other flammable substances.
FABRICATOR 211i SAFETY INSTRUCTIONS
!
!
!
!
C. Ventilation
WARNING
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.
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
D. Personal Protection
Gas flames produce infrared radiation which may have
a harm ful effect on the skin and especially on the eyes.
Select goggles or a mask with tempered lenses, shaded
4 or darker, to protect your eyes from injury and provide
good visibility of the work.
Always wear protective gloves and flame-resistant clothing
to protect skin and clothing from sparks and slag. Keep
collars, sleeves, and pockets buttoned. DO NOT roll up
sleeves or cuff pants.
When working in a non-welding or cutting environment,
always wear suitable eye protection or face shield.
WARNING
Practice the following safety and operation
precautions EVERY TIME you use pressure
regulation equipment. Deviation from the
following safety and operation instructions
can result in fire, explosion, damage to
equipment, or injury to the operator.
E. Compressed Gas Cylinders
The Department of Transportation (DOT) approves the
design and manufacture of cylinders that contain gases
used for welding or cutting operations.
CGA P-1 publication is available by writing
the Compressed Gas Association, 4221
Walney Road, 5th Floor, Chantilly,VA 201512923
2. Place the valve protection cap on the cylinder
whenever mov ing it, placing it in storage, or not
using it. Never drag or roll cylinders in any way.
Use a suitable hand truck to move cylin ders.
3. Store empty cylinders away from full cylinders.
Mark them “EMPTY” and close the cylinder valve.
4. NEVER use compressed gas cylinders without
a pressure reducing regulator attached to the
cylinder valve.
5. Inspect the cylinder valve for oil, grease, and
damaged parts.
WARNING
DO NOT use the cylinder if you find oil,
grease or damaged parts. Inform your gas
supplier of this condition immediately.
6. Momentarily open and close (called “cracking”)
the cylinder valve to dislodge any dust or dirt that
may be present in the valve.
1. Place the cylinder (Figure 1-1) where you will
use it. Keep the cylinder in a vertical position.
Secure it to a cart, wall, work bench, post, etc.
Art # A-12127
Figure 1-1: Gas Cylinders
SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5157
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.
CAUTION
SAFETY INSTRUCTIONS FABRICATOR 211i
1.03 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Manual 0-5157 1-7 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Hertz (cycles/sec)
Frequency
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
t2
Preflow Time
Postflow Time
2 Step Trigger
Operation
t1
Press to initiate wirefeed and
welding, release to stop.
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
115V 15A
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.
Receptacle RatingAuxiliary Power
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
V
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
IPM
MPM
S
S
4 Step Trigger
Operation
Burnback Time
Inches Per Minute
Meters Per Minute
See Note
See Note
Art # A-04130_AB
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
!
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.
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.
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.
Manual 0-5157 1-9 SAFETY INSTRUCTIONS AND WARNINGS
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.
FABRICATOR 211i SAFETY INSTRUCTIONS
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.
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER
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
Soudage à l’arc avec
électrode enrobée (procédé
SMAW)
Soudage à l’arc sous gaz
avec fil plein (procédé
GMAW) et soudage avec fil
fourré (procédé FCAW)
Soudage à l’électrode
réfractaire (procédé GTAW)
Coupage à l’arc avec
électrode de carbone et jet
d’air (procédé AAC)
Soudage à l’arc au plasma
(procédé PAW)
Coupage plasma (procédé
PAC)
* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite
progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors
dusoudage, 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.
Taille de l’électrode
enmm (po)
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)
Tableau 1-1
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire
de nuance appropriée (consultez la norme ANSI Z49
indiquée ci-après) pour vous protéger le visage et
les yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
Courant
d’arc
(ampères)
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
Gamme
d’intensité
minimum
7
8
10
11
7
10
10
10
8
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
Numéro de teinte
recommandée*
(Confort)
10
12
14
11
12
14
10
12
14
12
14
6 à 8
10
12
14
4
5
6
8
9
12
14
SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
2. Portez des lunettes de sécurité approuvées. Des
écrans latéraux sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons
pour protéger les autres des coups d’arc ou de
l’éblouissement; avertissez les observateurs de ne
pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des
fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est
bien ventilée ou que les fumées et les vapeurs sont
aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes
du fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer
l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir avec des vapeurs
et former des gaz hautement toxiques et irritants.
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.
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.
Manual 0-5157 1-11 SAFETY INSTRUCTIONS AND WARNINGS
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.
FABRICATOR 211i SAFETY INSTRUCTIONS
8. Lisez et respectez les consignes relatives aux
bouteilles de gaz comprimé et aux équipements
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES
BLESSURES.
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
connexes, ainsi que la publication P-1 de la CGA,
identifiée dans la liste de documents ci-dessous.
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.
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
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 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT
CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent
couper doigts et mains, ou accrocher des
vêtements amples.
1. Assurez-vous que les portes, les panneaux, les
capots et les protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez
le moteur.
3. Seules des personnes qualifiées doivent démonter
des protecteurs ou des capots pour faire l’entretien
ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant
l’entretien, débranchez le câble d’accumulateur à la
borne négative.
5. N’approchez pas les mains ou les cheveux de pièces
en mouvement; elles peuvent aussi accrocher des
vêtements amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez
les portes après des travaux d’entretien et avant de
faire démarrer le moteur.
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.
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.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques,
comme le plomb, ou engendre des produits
chimiques, reconnus par l’état de Californie
comme pouvant être à l’origine de malformations fœtales ou d’autres problèmes de
reproduction. Il faut se laver les mains
après toute 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 de tirer des conclusions définitives
quant aux risques éventuels ou de proposer des stratégies
Manual 0-5157 1-13 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
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!
!
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.
1.07 Informations Générales de Sécurité
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.
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.
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.
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,
manches et poches boutonnés. Il ne faut pas remonter
vos manches ou les pantalons à revers.
SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
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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.
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.
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.
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.
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.
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.
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.
2. Placez le bouchon de protection de vanne sur
la bouteille à chaque fois que vous la déplacez
Manual 0-5157 1-15 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
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 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température
Force d’Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Tension dangereuse
Hors Tension
SousTension
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Distant
Facteur de Marche
Pourcentage
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
Classement de PriseSource Auxiliaire
Art # A-07639F_AC
115V 15A
t
t1
t2
%
X
IPM
MPM
t
Fusible
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Durée de Pré-Dèbit
Durée de Post-Dèbit
Duréc du Pulse
Soudure Par Point
Appuyez pour démarrer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Purge Du Gaz
Mode Continu de
Soudure
Pouces Par Minute
Mètres Par Minute
Torche de Soudage
Probléme de Terre
Maintenez appuyez pour pré-dèbit,
relailez pour initier l’arc. Appuyez
pour arrêter l’arc, et mainteuir pour
pré-dèbit.
Détente à 4-Temps
Détente à 2-Temps
V
S
S
Voir Note
Voir Note
Avis : 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.
Indication d’erreur
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Manual 0-5157 1-17 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
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 211i
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 19, 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 0-5157
SAFETY INSTRUCTIONS FABRICATOR 211i
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 0-5157 1-19 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i SAFETY INSTRUCTIONS
This Page Intentionally Blank
SAFETY INSTRUCTIONS AND WARNINGS 1-20 Manual 0-5157
INTRODUCTION FABRICATOR 211i
!
SECTION 2: INTRODUCTION
2.01 How To Use This Manual
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as follows:
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a
box such as this.
WARNING
A WARNING gives information regarding possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
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 211i 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 Tweco Fabricator 211i 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 the unit.
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the control panel. In some cases,
the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun
and cable assemblies is identified only by the specification or part number printed on the shipping container.
Record these numbers on the bottom of page i for future
reference.
Manual 0-5157 2-1 INTRODUCTION
FABRICATOR 211i INTRODUCTION
!
2.05 Transportation Methods
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line
before moving the welding power source.
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift Power Source with handles built into the top of the
front and rear molded panels.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure Power Source
on a proper skid before transporting.
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.
2.07 Fabricator 211i Portable System Package (Part No. W1004201)
• Fabricator 211i Power Source
• 12 ft. (3.6 m) Tweco® Fusion 220 Amp MIG Gun
• Victor Argon Regulator / Flowmeter
• Drive Rolls:
.023"/.030" (0.6/0.8 mm) "V" groove,
.023"/.035" (0.6/0.9 mm)"V" groove (fitted with .035"
groove lined up),
.030"/.035" (0.8/0.9 mm) "V" knurled for Flux Cored
Wire,
• Velocity Contact Tips (1 each)
.023"(0.6 mm), .030"(0.8 mm),
.035"(0.9 mm) (fitted)
.045"(1.2 mm)
• Electrode Holder with 13 ft. (4 m) lead
• Work Clamp with 10 ft. (3.1 m) lead
• Shielding Gas hose assembly
• 15A/20A Adapter Plug from 208/230V AC 50 Amps
to 115V Amps Circuits
• Tweco Cap
• Electrodes
• Large Spring
• Operating Manual
• DVD
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.
INTRODUCTION 2-2 Manual 0-5157
Figure 2-1: Fabricator 211i System Packaged W1004201
A-11187_AB
INTRODUCTION FABRICATOR 211i
Duty Cycle (PERCENTAGE)
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, 210 amperes at 24.5 volts. This means that it has been designed and built to provide the rated amperage (210A) 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 allowed to cool. The
thermal cut out will operate if the duty cycle is exceeded.
100
90
80
70
60
50
40
30
20
Duty Cycle (PERCENTAGE)
10
0
SAFE OPERATING REGION
(MIG, TIG & STICK)
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
0
Figure 2-2: Fabricator 211i Duty Cycle on 208/230V AC
100
90
80
70
Welding Current (AMPS)
STICK
FABRICATOR 211i
MIG
STICK / TIG
Art # A-11265
FABRICATOR 211i
TIG
60
50
40
30
20
10
Manual 0-5157 2-3 INTRODUCTION
SAFE OPERATING REGION
(MIG, TIG & STICK)
MIG
0
0102030405060708090100 110 120 130140 150
Welding Current (AMPS)
Art # A-11274
Figure 2-3: Fabricator 211i Duty Cycle on 115V AC
FABRICATOR 211i INTRODUCTION
2.09 Specifications
Description Fabricator 211i Multi Process 3 in 1 Welder
Power Source Part No. W1004200
Power Source Dimensions H17.12" x W10.47" x D 24.29" (435mm x 266mm x D617mm)
Power Source Mass 57.3lb (26kg)
Cooling Fan Cooled
Welder Type Multi Process Welding System
Applicable Standard CSA E60974-1-00 / UL60974-1 / IEC 60974-1
Number of Phases Single Phase
Nominal Supply Voltage 208/230 VAC ± 10% 115VAC± 10%
Nominal Supply Frequency 50/60Hz 50/60HZ
Welding Current Range
MIG Mode
STICK Mode
TIG Mode
Wirefeed Speed Range 100 - 600 IPM 100 - 400 IPM
MIG Welding Voltage Range 14.5 - 24.5V DC 14.5 - 19V DC
Nominal OCV 70V DC
Effective Input Current (I1eff)
for MIG (GMAW/FCAW)
for STICK (SMAW)
for LIFT TIG (GTAW)
Maximum Input Current (I1max)
for MIG (GMAW/FCAW)
for STICK (SMAW)
for LIFT TIG (GTAW)
Single Phase Generator Requirement 7.5 kVA *3.7 kVA
MIG (GMAW/FCAW) Welding Output, 104°F, 10 min. 210A @ 20%,24.5V
STICK (SMAW) Welding Output,1040°F, 10 min. 200A @ 25%,28.0V
TIG (GTAW) Welding Output, 104°F, 10 min. 200A @ 25%,18.0V
Open Circuit Voltage 70 V
Protection Class IP23S
Table 2-1: Fabricator 211i Specifications
10-210 Amps
10-200 Amps
10-200 Amps
14.4A/11.2A
16.8A/15.8A
11.7A/11.5A
32.2A/25.0A
33.6A/31.6A
23.3A/22.9A
122A @ 60%, 20.1V
95A @ 100%, 18.8V
130A @ 60%, 25.2V
101A @ 100%, 24.0V
130A @ 60%, 15.2V
101A @ 100%, 14.0V
10-140 Amps
10-110 Amps
10-150 Amps
15.5A
17.8A
17.4A
24.5A
30.1A
29.4A
110A @ 45%,19.5V
99A @ 60%, 19.0V
77A @ 100%, 17.9V
110A @ 35%,24.4V
90A @ 60%, 23.6V
70A @ 100%, 22.8V
150A @ 35%,16.0V
115A @ 60%, 14.6V
90A @ 100%, 13.6V
Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.
Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local require-
ments for your situation in this regard.
Note 3: Generator Requirements at the Maximum Output Duty Cycle.
* Some 115 VAC, 15 amp/20 amps electrical outlets fitted with GFCI (Ground Fault Circuit Interrupt) protection
against a nuisance trip with this equipment due to worn or out of tolerance components in the GFCI. In such cases
have the 115 VAC, 15 amp/20 amp FGCI electrical outlet replaced by a qualified electrical trades person.
INTRODUCTION 2-4 Manual 0-5157
INTRODUCTION FABRICATOR 211i
NOTE
The recommended time delay fuse or circuit breaker size for 115V is 30 amp. An individual branch circuit
capable of carrying 30 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 specifications 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 and conditions and local power
grid supply conditions.
.
Manual 0-5157 2-5 INTRODUCTION
FABRICATOR 211i INTRODUCTION
2.10 Optional Accessories
26V TIG Torch & Accessories (required for TIG welding) Part No. W4014603
12.5 ft cable length; 12.5 ft gas hose length; 8 pin control plug; 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
Tweco Spool Gun (required for aluminum MIG welding ) Part No. 1027-1390
160A, 12ft (3.6M) Length, suits 4" (100mm) spools
Professional 4 Wheel Cart, Dual Cylinder ................... Part No. W4015002
Professional 4 Wheel Cart, Single Cylinder ................ Part No. W4015001
Small Cart, Single Cylinder .......................................... Part No. W4014700
Roll Cage ...................................................................... Part No. W4015104
Foot Control ................................................................. Part No. 600285
For remote amperage control when TIG welding
Tweco Helmet (USA Only) ........................... Part No. 4100-1004
WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)
Drive Roll .023" - .030" (0.6/0.8mm ) V groove, (fitted) Part No. 7977036
Drive Roll .023" - .035" (0.6/0.9 mm) V groove . Part No. W4014800
Drive Roll .035"/.045" (0.9/1.2 mm) V groove .. Part No. 7977660
Drive Roll .030" - .035" (0.8/0.9 mm) U groove .. Part No. 7977731
Drive Roll .040" - 3/64" (1.0/1.2 mm) U groove . Part No. 7977264
Drive Roll .030" - .035" (0.8/0.9 mm) V knurled Part No. 7977732
Drive Roll .045"(1.2 mm) V knurled ............. Part No. 704277
Stick Lead, 200A, 13ft, 50mm Dinse ............. Part No. WS200E13
Ground Lead, 200A, 10Ft, 50mm Dinse .......... Part No. WS200G10
Victor Argon Regulator/ Flowgauge .................... Part No. 130781-4169
Accessory Kit for TIG Torch ................................... Part No. P062900010
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
INTRODUCTION 2-6 Manual 0-5157
INTRODUCTION FABRICATOR 211i
2.11 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.
Art # A-11297
Figure 2-4: Fabricator 211i Volt-Ampere Curves
Manual 0-5157 2-7 INTRODUCTION
FABRICATOR 211i INTRODUCTION
This Page Intentionally Blank
INTRODUCTION 2-8 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
!
SECTION 3: INSTALLATION, OPERATION AND SETUP
3.01 Environment
This Power Source is designed for use in environments
with increased hazard of electric shock. Additional
safety precautions may be required when using unit in
an environment with increased hazard of electric shock.
Please refer to relevant local standards for further
information prior to using in such areas.
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.
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 considerably 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.
H. Precautions must be taken against the power source
toppling over. The power source must be located on
a suitable horizontal surface in the upright position
when in use.
WARNING
This equipment should be electrically connected by a qualified electrician.
3.03 Ventilation
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
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 14° F (0° C) to 104° F
(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" (305mm) or more from
walls or similar that could restrict natural air flow for
cooling.
Manual 0-5157 3-1 INSTALLATION/SETUP
3.04 Electricity Supply
The Electricity Supply voltage
should be within 208/230V AC ± 10% or 115 V AC ±
10%. Too low a supply voltage may cause poor welding
performance in STICK mode such as the arc snuffing
out during welding. Too high a supply voltage will cause
components to overheat and possibly fail. The Welding
power Source must be:
• Correctly installed, if necessary, by a qualied electrician.
• Correctly earthed (electrically) in accordance with local
regulations.
• Connected to the correct size power point and fuse as
per the Specifications on page 2-4.
FABRICATOR 211i INSTALLATION/SETUP
WARNING
The Fabricator 211i 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.
Power Cords Included With Power Supply
Attached to the power supply is an input power cord with a 208/230Volt 50 Amp NEMA 6-50 P for plug. Supplied
adapter allow for connection of the power supply input cable plug to 115 V input power.
Art# A-11275
Figure 3-1: 115 VAC Adapter
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 supply whenever necessary to inspect or service the unit. The Welding Power Source must be:
Do not connect in input (WHITE or BLACK) conductor to the ground terminal.
Do not connect the ground (GREEN) conductor to an input line terminal.
• Correctly installed, if necessary, by a qualied electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point, fuse and primary supply lead based on Table 3-1.
Refer to Figure 3-1 and Table 3-1.
INSTALLATION/SETUP 3-2 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
WARNING
An electrical 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 208/230V AC 115V AC
Input Current at Maximum Output 32 Amps 30 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 Cord Size 12 AWG 12 AWG
Maximum Recommended Extension Cord Length 50 ft 25 ft
Minimum Recommended Grounding Conductor Size 12 AWG 12AWG
Table 3-1: Electrical Service Guide
50 Amps 30 Amps
50 Amps 30 Amps
CAUTION
The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.
208/230V, 50A,1Ø
115
20A,1Ø
The Adapter enable
connection to all these
power outlets
115 VAC Adapter
115V,V,
15A,1Ø
Primary Power Cable
Art# A-11240
Figure 3-2: Electrical Input Connections
Manual 0-5157 3-3 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
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
The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements
should only be authorized by a person who is competent to assess whether the changes will increase the
risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits
of other equipment.
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 pace-makers 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.
The size of the surrounding area to be considered will depend on the structure of the building and other activities that
are taking place. The surrounding area may extend beyond the boundaries of the premises.
C. Methods of Reducing Electromagnetic Emissions
1. Electricity Supply
Welding equipment should be connected to the Electricity Supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take additional precautions such as filtering of the Electricity Supply.
Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic
conduit or equivalent. Shielding should be electrically continuous throughout its 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.
INSTALLATION/SETUP 3-4 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
LOW PRESSURE
GAUGE (DELIVERY)
HIGH PRESSURE
GAUGE (SUPPLY)
INLET
CONNECTION
OUTLET
CONNECTION
PRESSURE
ADJUSTING
SCREW
A-09414_AB
!
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.
3. Welding Cables
The welding cables should be kept as short as possible and should be positioned close together but never coiled
and 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/grounding of the Work Piece
Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and
position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions
in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk
of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to
earth should be made by direct connection to the work piece, 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 3-3) attached to the cylinder valve reduce high cylinder pressures to suitable low working
pressures for welding, cutting, and other applications.
Figure 3-3: Victor CS Regulator
Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with
any other gas.
WARNING
Manual 0-5157 3-5 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
!
!
NOTE
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.
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 Pres-
sure 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 over-pressurization (i.e. system relief valve). Make sure the pressure
rating of the down stream equipment is compatible with the maximum delivery pressure of the regulator.
5. Be sure that the regulator has the correct pressure rating and gas service for the cylinder used.
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 3-4) to the cylinder valve. Tighten securely with a wrench.
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.
WARNING
WARNING
Art # A-09845
Figure 3-4: Regulator to Cylinder Valve
INSTALLATION/SETUP 3-6 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
!
!
!
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!
9. Slowly and carefully open the cylinder valve (Figure 3-5) until the maximum pressure shows on the high pressure gauge.
Art # A-09828
Figure 3-5: 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.
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.
WARNING
CAUTION
Manual 0-5157 3-7 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
!
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.
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.
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.
INSTALLATION/SETUP 3-8 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
3.10 Fabricator 211i Power Source Controls, Indicators And Features
1
2
14
3
3A
4
5
13
16
12
11
15
10
21
6
7
Art # A-11241_AC
89
Figure 3-6: Front and Control Panel Figure 3-7: Rear Panel Connections
17
Art # A-10938
Figure 3-8: Wire Feed Compartment Control
Manual 0-5157 3-9 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
1. Power Indicator
The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/
OFF switch located on the rear panel is in the ON position.
2. Thermal Overload Indicator (Fault Indicator)
This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty
cycle of the power source has been exceeded. 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 mains power switch should remain in the on position such that
the fan continues to operate thus allowing the unit to cool sufficiently. Do not switch the unit OFF should a thermal
overload condition be present.
3. Digital Wirespeed/Amperage Meter (Left Digital Display)
MIG Mode
This digital meter is used to display the pre-set (preview) Wirefeed Speed in IPM (Inches per minute) in MIG mode
and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will
display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Amperage Control
Knob (4).
STICK and LIFT TIG Modes
The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding
amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set
(preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Amperage Control
Knob (4).
When welding, this digital meter will display actual welding amperage in all modes.
At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approxi-
mately 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 unit 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 unit 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.
3A Wirespeed Indicator
The Wirespeed Indicator illuminates when MIG mode is selected to identify that the Digital Wirespeed/Amperage
Meter is previewing Wirespeed in IPM (inches per minute).
The Wirespeed Indicator extinguishes when the user is MIG (GMAW/FCAW) welding or depressing the MIG gun
trigger and the Digital Wirespeed/Amperage Meter displays actual welding amperage of the power source.
INSTALLATION/SETUP 3-10 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
4. 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.
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.
5. MIG Gun Adapter (Tweco Style)
The MIG Gun adapter 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 Adapter 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
Tweco MIG Gun into the MIG Gun Adapter will result in the Tweco Fusion 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. To remove
the MIG gun simply reverse these directions.
6. 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 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.
7. MIG 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 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.
Manual 0-5157 3-11 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
8. 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 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.
9. Remote Control Socket
The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make
connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
2
5
4
8
7
Art # A-10421_AC
Socket Pin
1 Spool Gun Motor Negative
2
3
4
5
6
Trigger Switch Input
Trigger Switch Input
Spool Gun Motor (+24V DC)
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
1
2
1
3
6
3
4
5
6
7
8
WV
Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Figure 3-9: Remote Control Socket
Function
Trigger Switch
Remote Volts in
MIG (GMAW/FCAW)
Negative
Spool Gun Motor
Positive
7
8
Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper
arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer.
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Table 3- 2
Note that the local/ remote switch (item 18) located in the wirefeed compartment should be set to remote for the
amperage/voltage controls to be operative.
10. 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.
INSTALLATION/SETUP 3-12 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
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 output voltage of the unit. The welding voltage is increased by
turning the knob clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required
will dependent 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 anti-clockwise
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 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 (refer item 12), the unit will enter down slope mode as soon as the trigger
switch is released (ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding
current to zero over 5 seconds). If no down slope time is selected then the welding output will cease immediately.
If the unit 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.
11. 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.
12. Trigger Mode Control (MIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal) and
4T (latch mode)
2T (Normal Mode)
In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch
trigger to activate the power source (weld). Release the torch 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 torch trigger 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 torch trigger.
Note that when operating in LIFT TIG mode, the power source will remain activated until the selected downslope
time has elapsed (refer Item 10).
Manual 0-5157 3-13 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
!
13. Process Selection Control
The process selection control is used to select the desired welding mode. Three modes are available, MIG (GMAW/
FCAW), LIFT TIG (GTAW) and STICK (SMAW) modes. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set
up details, section 3.21 for LIFT TIG (GTAW) set-up details or section 3.22 for STICK (SMAW) set-up details.
Note that when the unit 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 unit and mistakenly
be in contact with the work piece during power up.
14. Digital Voltage Meter (Right Digital Display)
MIG Mode
This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the
power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of
Voltage. This value can be adjusted by varying the Multifunction Control Knob (10).
STICK and LIFT TIG Modes
This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during non-
welding or welding. This value cannot be adjusted by varying the Multifunction Control Knob (10).
When welding, this digital meter will display actual welding voltage in all modes.
At the completion of welding, the digital 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 unit 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 unit 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.
15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation)
The Gas Inlet connection,5/8-18 UNF female thread is used to supply the appropriate MIG welding gas to the
Power Source. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set up details
WARNING
Only Inert Shielding Gases specifically designed for welding applications should be used.
16. ON / OFF Switch
This Single Phase circuit breaker performs a dual function.
It is used to turn the unit ON/OFF and it will also trip in the event of a fault.
INSTALLATION/SETUP 3-14 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
WARNING
When the front digital displays are lit, the machine is connected to the Electricity Supply and the internal
electrical components are at Mains voltage potential.
17. Wiredrive Motor Circuit Breaker
The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload.
NOTE
If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit
by pressing the circuit breaker reset button
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 unit via the remote control socket (item 9). When the local/ remote switch is in the remote
position, the unit will detect a remote device and work accordingly. When in the local mode, the unit 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 unit 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 anti-clockwise.
To increase the burnback time (or shorten the amount of wire protruding from the torch at the completing of
welding), turn the Burnback Control knob clockwise.
20. MIG Gun & Spool Gun Switch
The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun functionality and Spool Gun
functionality
21. Cooling Fan
The Fabricator 211i is designed with an intelligent fan control. When the 211i is switched ON the cooling fan will
come ON for approximately 3 seconds then automatically switch the fan OFF. The cooling fan will remain OFF until
it is required for cooling purposes. 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 in STICK mode the fan operates continuously.
Manual 0-5157 3-15 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
3.11 Attaching the TWECO Fusion 220A MIG Gun
Fit the Fusion MIG gun to the power source by pushing the MIG gun connector into the MIG gun adapter and screwing
the plastic nut clockwise to secure the MIG gun to the MIG gun adapter.
Connect the 8 pin plug by aligning he keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded
collar fully clockwise to lock the plug into position.
MIG Gun Adapter
MIG Gun Connector
Wire Drive Tension Knob
Art # A-11242_AB
Inlet Guide
8 pin socket
8 pin plug
Pressure Arm
Outlet Guide
Figure 3-10: Attaching MIG Gun
Locking Screw
MIG Gun Connector
INSTALLATION/SETUP 3-16 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
3.12 Installing 33/44 lb Spool (12" diameter)
As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 33/44 lb. or 12" diameter.
Installation of wire spool, Refer to Figure 3-11.
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool
rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the
wire spool.
3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to Section 3.18
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Hub Nut
Flat Washer
Large Hole
Flat Washer
Small Hole
33/44 lb (12")
Wire Spool
Spring
Retaining Clip
Use inner holes on
Spool Hub
Keyed Washer
Figure 3-11: 33/44 lb (12") Spool Installation
Fiber Washer
Pin
Spool Hub
Art # A-11266
Manual 0-5157 3-17 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
3.13 Installing 12.5 lb Spool ( 8" diameter)
In order to fit a 12.5 lb spool (8" diameter) assemble parts in the sequence shown in Figure 3-9.
Installation of wire spool:
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool
rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the
wire spool.
3. Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool.
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section 3.18
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Hub Nut
Flat Washer
Large Hole
Flat Washer
Small Hole
12.5 lb (8")
Wire Spool
Spring
Retaining Clip
Use inner holes on
Spool Hub
Keyed Washer
Figure 3-12: 12.5lb (8") Spool Installation
Fiber Washer
Pin
Spool Hub
Art # A-11267
INSTALLATION/SETUP 3-18 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
3.14 Installing 1 lb Spool (4" diameter)
In order to fit a 1 lb spool (4" diameter) assemble parts in the sequence shown in Figure 3-13.
Installation of wire spool:
1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.
2. Place Fiber Washer and Large Spring onto the Shaft, then load the Wire Spool on the Shaft so that the wire
will feed off the bottom of the spool as spool rotates counter clockwise.
3. Then place Flat Washer Large Hole, Keyed Washer, Spring, Flat Washer Small Hole as shown in Figure 3-13.
Finally secure with Wire Spool Hub Nut.
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section 3.18
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Hub Nut
1lb (4") Diameter
Wire Spool
Flat Washer
Large Hole
Flat Washer
Small Hole
Fiber
Washer
Large
Spring
Keyed Washer
Spring
Art # A-11298_AB
Figure 3-13: 1 lb (4") Spool Installation
Manual 0-5157 3-19 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
3.15 Inserting Wire Into The Wire Feed Mechanism
Release the tension from the pressure roller by turning the adjustable wire drive tension knob in an anti-clockwise
direction. Then to release the pressure roller arm push the tension screw toward the back of the machine which releases
the pressure roller arm (Figure 3-14). With the MIG welding wire feeding from the bottom of the spool (Figure 3-15)
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 3-14).
Remove the Velocity 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 feed through the system.
Keep MIG gun away from eyes and face.
Art # A-10426
Wire Drive Tension Screw
Pressure Roller Arm
Inlet Guide
Outlet Guide
Figure 3-14: Wire Drive Assembly Components
MIG Welding Wire
Art # A-10427_AB
Figure 3-15: MIG Welding Wire - Installation
INSTALLATION/SETUP 3-20 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
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.
WARNING
Before changing the feed roller ensure that the Electricity Supply to the power source is switched OFF.
CAUTION
The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.
3.17 Changing the Feed Roll
To change feed roll remove the feed roll retaining screw by turning in an anti-clockwise direction. Once the feed roll
is removed then to replace feed roll simply reverse these directions. Note: Be sure not to lose key that is located on
Drive Motor Shaft. This key must align with drive roll groove for proper operation.
A dual groove feed roller is supplied as standard. It can accommodate 0.6/0.8mm diameter hard wires. Select the
roller required with the chosen wire size marking facing outward.
GROOVE “B”GROOVE “A”
GROOVE “B” SIZE
GROOVE “A” SIZE
A-09583
Figure 3-16: Dual Groove Feed Roller
Feed Roll Retaining Screw
Art # A-10428
Figure 3-17: Changing the Feed Roll
Manual 0-5157 3-21 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
3.18 Wire Reel Brake
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking.
If it is considered necessary, adjustment can be made by turning the Thumb Screw 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 1/8"-3/16" (3-5mm) after release of the trigger. The electrode wire should be slack without becoming dislodged
from wire spool.
CAUTION
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip.
Spool Hub Tension
Thumb Screw
Art # A-10429
Figure 3-18: Wire Reel Brake
3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire
A. Select MIG mode with the process selection control. (Refer to Section 3.10.13 for further information)
B. Connect the MIG polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufac-
turer. 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 3.11 Attaching the TWECO Fusion 220A 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 welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.06) then
connect the shielding gas hose from the rear of the power source to the regulator/flowmeter 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.
INSTALLATION/SETUP 3-22 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
Shielding Gas Hose Fitted with Quick Connect
MIG Gun
!
WARNING
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.
Positive Welding
Terminal (+)
MIG Polarity Lead
8 pin plug
Negative Welding
Terminal (-)
Work Lead
Art # A-11244
Figure 3-19: Setup for MIG Welding with Gas Shielded MIG Wire
3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire
A. Select MIG mode with the process selection control (refer to Section 3.10.13 for further information).
B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufac-
turer. 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.
Manual 0-5157 3-23 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
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.
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.
MIG Gun
MIG Polarity Lead
Art # A-11245
Negative Welding
Terminal (-)
8 pin plug
Positive Welding
Terminal (+)
Work Lead
Figure 3-20: Setup for MIG Welding with Gasless MIG Wire
INSTALLATION/SETUP 3-24 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire
Select MIG mode with the Process Selection Control.
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.
Art #
1. Make sure the welding
power source is turned
OFF before connecting
the welding gun.
Thumb screw
2. Open side panel and
loosen thumb screw.
3. Insert the back end of the
Spool gun into the gun
receiving bushing.
A-11629
4. Tighten thumb screw and
replace side panel.
5. Connect gas supply fi tting
and tighten with a wrench.
6. Align Control Plug to
panel fi tting and tighten
securely.
!
WARNING
Before connecting the work clamp to the work make sure the main power 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.
Manual 0-5157 3-25 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
Shielding Gas Hose Fitted with Quick Connect
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in the
terminal.
Remove any packing material prior to use. Do not block the air vents at the front or rear of the Welding
Power Source.
Remote Control
Socket
Spool Gun Switch
Negative Welding
MIG polarity lead
Terminal (-)
Positive Welding
Terminal (+)
Spool Gun
Work Lead
Figure 3-21: Setup for Spool Gun Welding with Gas Shielded MIG Wire
Art # A-10576
3.22 Setup For LIFT TIG (GTAW) Welding
A. Select LIFT TIG mode with the process selection control (refer to Section 3.10.13 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 operate in LIFT TIG Mode.
NOTE
A Tweco 26V 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.
INSTALLATION/SETUP 3-26 Manual 0-5157
INSTALLATION/SETUP FABRICATOR 211i
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.06) then
connect the shielding gas hose from the TIG torch to the regulator/flowmeter outlet. Note that the TIG torch shielding gas hose is connected directly to the regulator/flowmeter. 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.
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.
WARNING
CAUTION
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.
Art # A-11246_AB
Positive Welding
Terminal (+)
Work Lead
TIG Torch
TIG Remote Control
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 (-)
Note: A Tweco 26V 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
turn the weld current on/o as well as
providing remote control of the weld current.
Figure 3-22: Setup for TIG Welding
Manual 0-5157 3-27 INSTALLATION/SETUP
FABRICATOR 211i INSTALLATION/SETUP
3.23 Setup For STICK (SMAW) Welding
A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufac-
turer. 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.
C. Select STICK mode with the process selection control (refer to Section 3.10.13 for further information).
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.
Positive Welding
Terminal (+)
Electrode Holder
Work Lead
Negative Welding
Terminal (-)
Art # A-11247
Figure 3-23: Setup for Manual Arc Welding.
INSTALLATION/SETUP 3-28 Manual 0-5157
BASIC WELDING FABRICATOR 211i
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 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
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
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 MIG 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.
GMAW Process
Figure 4-1
Art # A-8991_AB
Do NOT pull the MIG Gun back when the arc is
CAUTION
established. This will create excessive wire ex-
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
tension (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.
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
5° to 15°
Longitudinal
Angle
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
90°
Transverse
Angle
Direction of
Travel
welding stainless steel and for overlay work.
Art # A-08993
Figure 4-4
Manual 0-5157 4-1 BASIC WELDING
FABRICATOR 211i BASIC WELDING
10° to 20° Longitudinal
Direction of Travel
Electrode Stick-Out
Preselected Variables
Longitudinal Angle
10°
Longitudinal Angle
30° to 60°
Transverse
Angle
5° to 15°
Direction of
Travel
Figure 4-5
Direction of Travel
Vertical Fillet Welds
Figure 4-6
30° to 60°
Transverse Angle
Art # A-08994
Angle
Art # A-08995
30° to 60°
Transverse
Angle
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 for FCAW self shielding
wires)
• Gas flow rate (not applicable for FCAW self shielding
wires)
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
30° to 60°
Transverse Angle
5° to 15°
Longitudinal
Angle
Art # A-08996
Figure 4-7
Distance from the MIG Gun Nozzle to the Work Piece
The electrode wire stick out from the MIG Gun nozzle
should be between 3/8" - 3/4" (10 - 20 mm). 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 (GMAW) 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 .023 - 1/4" (0.6 mm - 6.4 mm) mild
sheet or plate. The applied techniques and end results
in the GMAW process are controlled by these variables.
These variables cause changes in primary adjustable
variables which in turn cause the desired change in the
bead formation. They are:
1. Sick-out (distance between the end of the contact tube (tip) and the end of the electrode wire).
Maintain at about 3/8" (10 mm) 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
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 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 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)
BASIC WELDING 4-2 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Transverse
Direction of Gun Travel
or leading (pushing). Whether the operator is left
handed or right handed has to be considered to
realize the effects of each angle in relation to the
direction of travel.
Angle
Longitudinal
Angle
Axis of Weld
Transverse and Longitudinal
Nozzle Axes
Art # A-08998_AB
Figure 4-9
Leading or “Pushing”
Angle
(Forward Pointing)
Nozzle Angle, Right Handed Operator
90°
Trailing or “Pulling”
Angle
(Backward Pointing)
Art # A-08999_AC
Setting of the Power Source
Power source 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 3.06.4) and the welding Voltage Control (refer
to section 3.06.10). 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
Figure 4-10
The choice of Electrode wire size and shielding gas used
depends on the following:
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.
• Thickness of the metal to be welded
• Type of joint
• Capacity of the wire feed unit and Power Source
• The amount of penetration required
The 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 1/16"
or 3/16" (1.6 mm or 5.0 mm) mild steel plate 6" x 6" (150
• The deposition rate required
• The bead prole desired
• The position of welding
• Cost of the wire
mm x 150 mm). Use .035" (0.9 mm) flux cored gasless
wire or a solid wire with shielding gas.
Manual 0-5157 4-3 BASIC WELDING
FABRICATOR 211i BASIC WELDING
Tweco MIG, Lift TIG, Stick Wire Selection Chart
Art # A-11299_AC
Table 4-1
BASIC WELDING 4-4 Manual 0-5157
BASIC WELDING FABRICATOR 211i
4.02 MIG (GMAW/FCAW) Welding Troubleshooting
Solving Problems Beyond the Welding Terminals
The general approach to fix MIG (GMAW/FCAW) welding problems is to start at the wire spool then work through
to the MIG Gun. There are two main areas where problems occur with GMAW; 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/CONDITION CAUSE
1 Shielding gas cylinder contents
and flow meter.
2 Shielding gas cylinder contents
and flow gauge.
3
Gas leaks.
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.
Ensure that the shielding gas cylinder is not empty and the
flow meter is correctly adjusted to 31.75 CFH.
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.
Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Source.
Ensure the hose from the solenoid valve to the MIG Gun
adapter has not fractured and that it is connected to the MIG
Gun adapter.
Clean contaminates off the work piece.
Keep the distance between the MIG Gun nozzle and the work
piece to a minimum.
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
Manual 0-5157 4-5 BASIC WELDING
FABRICATOR 211i BASIC WELDING
!
Solving Probelms Beyond the Welding Terminals - Inconsistent Wire Feed
WARNING
Disengage the feed roll when testing for gas flow by ear.
Wire feeding problems can be reduced by checking the following points.
FAULT CAUSE
1 Feed roller driven by motor in the
cabinet slipped.
2 Wire spool unwound and tangled. 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
BASIC WELDING 4-6 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Basic MIG (GMAW/FCAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too
high.
B Incorrect MIG Gun angle B Adjust angle.
C Excessive heat input C Increase the MIG Gun travel speed and/or decrease welding
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed speed and
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 control.
B Voltage too low B Increase the voltage or decrease wirespeed.
A Decrease voltage or increase the wire feed speed.
current by decreasing the voltage or decreasing the wire feed
speed.
increasing voltage.
B Increase joint angle or gap.
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
D Excessive voltage D Decrease voltage.
E Cooling rate too fast E Slow the cooling rate by preheating part to be welded or cool
7 Cold weld puddle A Loose welding cable con-
nection.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited Tweco Service Provider test then replace
8 Arc does not have a
crisp sound that short
arc exhibits when the
wirefeed speed and
voltage are adjusted
correctly
The MIG Gun has been con-
nected to the wrong voltage
polarity on the front panel.
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.
slowly.
A Check all welding cable connections.
the faulty component.
Connect the MIG Polarity Cable to the positive (+) welding
terminal for solid wires and gas shielded flux cored wires.
Refer to the electrode wire manufacturer for the correct
polarity.
9 Poor weld result from
setup chart parameters
Contact tip has arc marks in
the bore causing excessive
drag on the wire.
Replace the contact tip with only a Genuine Tweco Velocity
contact tip.
Table 4-4: MIG (GMAW /FCAW) Welding Problems
Manual 0-5157 4-7 BASIC WELDING
FABRICATOR 211i BASIC WELDING
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 Arc Welding Various Materials
A. 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 may result. Hardened zone
and under-bead 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.
Hydrogen controlled Electrodes must be used for this application.
B. Austenitic 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.
C. 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.
D. Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections
necessary to give proper fusion of weld and base metal.
Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally
enough, different types of electrodes would be used for different metals as described in the preceding section.
Welding Position
The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat,
horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate
between these. Some of the common types of welds are shown in Figures 4-11 through 4-18.
BASIC WELDING 4-8 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Art # A-07688
Art # A-07689
Art # A-07690
Art # A-07687
Figure 4-11: Flat Position, Down Hand Butt Weld
Figure 4-12: Flat Position, Gravity Fillet Weld
Figure 4-13: Horizontal Position, Butt Weld
Art# A-07693
Figure 4-17: Overhead Position, Butt Weld
Art # A-07694
Figure 4-18: Overhead Position, Fillet Weld
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.
Figure 4-14: Horizontal-Vertical (HV) Position
Art A-07691
Figure 4-15: Vertical Position, Butt Weld
Art # A-07692
Figure 4-16: Vertical Position, Fillet Weld
Manual 0-5157 4-9 BASIC WELDING
FABRICATOR 211i BASIC WELDING
(
Open Square Butt
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°
Single Vee Butt Joint
1/16” (1.6mm)
Double Vee Butt Joint
Tee Joints
Fillet both sides of the
joint)
Edge Joint
1/16” (1.6mm)
Not less than
70°
Not less than
70°
1/16” (1.6mm) max
1/16” (1.6mm) max
Plug Weld Plug Weld
Art # A-10672
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" (6.4 mm) thick and a 1/8" (3.2 mm) 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.
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.
BASIC WELDING 4-10 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Art # A-07697_AB
Tack Weld
20°-30°
Electrode
Tack Weld
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" -1/8"
(1.6 mm - 3.2 mm) 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.
20°
Art # A-10673
1/16” (1.6 mm)
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 do not
stick in this way, and make welding much easier.
Rate of Travel
If the travel is too fast, the bead will be narrow and strung
out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the
bead will be too large.
Making Welded Joints
Having attained some skill in the handling of an electrode,
you will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown
in Figure 4-21, allowing 1/16" - 3/32" (1.6 mm - 2.4
mm) 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" (6.4 mm) 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" (3.2 mm) E7014 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
well-formed 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.
Figure 4-21: Butt Weld
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.
Manual 0-5157 4-11 BASIC WELDING
Figure 4-22: Weld Build up Sequence
Art # A-07698
FABRICATOR 211i BASIC WELDING
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 crosssection 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" (3.2 mm) E7014
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" (6.4 mm) width with a 1/8" (3.2 mm) electrode,
otherwise the weld metal tends to sag towards the
base, and undercut forms on the vertical leg. Multiruns can be made as shown in Figure 4-24. Weaving
in HV fillet welds is undesirable.
Art # A-07700_AB
6
3
1
5
2
4
Figure 4-24: Multi-runs in HV Fillet Weld
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your
work bench in an upright position. Use a 1/8"
(3.2 mm) E7014 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
45° from
vertical
60° - 70° from line
of weld
Figure 4-25: Single Run Vertical Fillet Weld
Art # A-07699_AB
Figure 4-23: Electrode Position for HV Fillet Weld
BASIC WELDING 4-12 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Art # A-07702
Figure 4-26: Multi Run Vertical Fillet Weld
Art # A-07703
Figure 4-27: Examples of Vertical Fillet Welds
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:
2. Vertical Down
The E7014 electrode makes welding in this
position particularly easy. Use a 1/8" (3.2 mm)
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" (3.2 mm)
E6013 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.
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" (2.0 mm) sheet,
the contracting weld metal may cause the sheet to
become distorted.
Manual 0-5157 4-13 BASIC WELDING
FABRICATOR 211i BASIC WELDING
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.
Hot
Weld
Hot
Expansion with
compression
Cool
Art # A-07705_AB
Figure 4-29: Parent Metal Expansion
Art # A-07706_AC
Permanent Upset
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.
Contraction
with tension
Art # A-07707
Figure 4-30: Parent Metal Contraction
Figure 4-31: Principle of Presetting
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.
BASIC WELDING 4-14 Manual 0-5157
BASIC WELDING FABRICATOR 211i
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
Figure 4-33: Examples of Distortion
1
2
3
4
Figure 4-35: Step back Sequence
Art # A-07428_AB
Figure 4-36: Chain Intermittent Welding
Art # A-07713_AB
1
Art # A-07710_AB
2
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-34: Welding Sequence
3
Figure 4-37: Staggered Intermittent Welding
Manual 0-5157 4-15 BASIC WELDING
FABRICATOR 211i BASIC WELDING
4.04 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 is set at a value that causes the welding
current to vary excessively
with the arc length.
Reduce the ARC FORCE 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
B Use smaller diameter electrode.
joint.
C Insufficient gap. C Allow wider gap.
A Non-metallic particles may
be trapped in undercut
A If a bad undercut is present clean slag out and
cover with a run from a smaller gauge electrode.
from previous run.
B
Joint preparation too
restricted.
C Irregular deposits allow
B Allow for adequate penetration and room for
cleaning out the slag.
C If very bad, chip or grind out irregularities.
slag 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 pre-
E Clean joint before welding.
venting full fusion.
F Wrong electrode for posi-
tion in which welding is
done.
Art # A-04273
F Use electrodes designed for position in which
welding is done, otherwise proper control of slag
is difficult.
Incorrect sequence
Insufficient
gap
Figure
4-38: Example of insufficient gap or incorrect sequence
Table 4-5a:
BASIC WELDING 4-16 Manual 0-5157
BASIC WELDING FABRICATOR 211i
FAULT CAUSE REMEDY
4 A groove has been
formed in the base
metal adjacent to
the toe of a weld
and has not been
filled by the weld
metal (undercut).
5 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.
A Welding current is too
A Reduce welding current.
high.
B Welding arc is too long. B Reduce the length of the welding arc.
C Angle of the electrode is
incorrect.
D Joint preparation does not
allow correct electrode
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
angle.
E Electrode too large for
E Use smaller gauge electrode.
joint.
F Insufficient deposit time at
edge of weave.
G Power source is set for
F Pause for a moment at edge of weave to allow
weld metal buildup.
G Set power source to STICK (SMAW) mode.
MIG (GMAW) welding.
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
D Reduce travel speed of electrode.
is too high.
E Scale or dirt on joint
E Clean surface before welding.
surface.
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Lack of inter-run fusion
Art # A-04274_AB
Lack of Root Fusion
Figure 4-39: Example of Lack of Fusion
Table 4-5b: STICK (SMAW) metal welding trouble shooting
Manual 0-5157 4-17 BASIC WELDING
FABRICATOR 211i BASIC WELDING
4.05 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-09658_AC
Gas Cup
Either Ceramic,
Work Piece
Can Be Any Commercial
Metal
Welds Made With or Without
Addition of Filler Metal
High-lmpact or
Water Cooled
Metal
Tungsten Electrode
Non-Consumable
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-40: TIG (GTAW) 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” (5mm) 250-340
Table 4-6: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
1/16” (1.6mm) 20-90
3/32” (2.4mm) 65-115
1/8” (3.2mm) 100-165
3/16” (5mm) 200-350
Table 4-7: Filler Wire Selection Guide
BASIC WELDING 4-18 Manual 0-5157
BASIC WELDING FABRICATOR 211i
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
Welding Application Features Color Code
DC welding of mild
steel, stainless steel
and copper
High quality AC welding of aluminum,
magnesium and their
alloys.
AC & DC welding of
mild steel, stainless
steel, copper, aluminum, magnesium and
their alloys
Excellent arc starting,
Long life, High current
carrying capacity
Self cleaning, Long
life, Maintains balled
end, High current carrying capacity.
Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.
Table 4-8
NOTE
The Fabricator 211i Inverter is not suited for AC TIG welding.
Red
White
Grey
TIG Welding Filler Rods
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.
DC Current
for Mild
Steel
35-45
40-50
45-55
50-60
60-70
70-90
80-100
90-115
115-135
140-165
160-175
170-200
DC Current
for Stainless
Steel
20-30
25-35
30-45
35-50
40-60
50-70
65-85
90-110
100-125
125-150
135-160
160-180
Tungsten
Electrode
Diameter
0.040”
1.0mm
0.040”
1.0mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
Table 4-9
Filler Rod
Diameter (if
required)
1/16”
1.6mm
1/16”
1.6mm
1/16”
1.6mm
3/32”
2.4mm
1/8”
3.2mm
5/32”
4.0mm
Argon Gas
Flow Rate
CFH
10-15 Butt/Corner
10-15 Butt/Corner
15 Butt/Corner
15 Butt/Corner
20 Butt/Corner
20 Butt/Corner
Joint Type
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Lap/Fillet
Manual 0-5157 4-19 BASIC WELDING
FABRICATOR 211i BASIC WELDING
4.06 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 connect-
ed 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 weld-
ing 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 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 4-20 Manual 0-5157
BASIC WELDING FABRICATOR 211i
FAULT CAUSE REMEDY
7 Dirty weld pool A Electrode contaminated
by contact with work
piece or filler rod material.
B Work piece surface has
foreign material on it.
C Gas contaminated with
air.
8 Poor weld finish Inadequate shielding
gas.
9 Arc start is not smooth. A Tungsten electrode is
too large for the welding current.
B The wrong electrode
is being used for the
welding job.
C Gas flow rate is too
high.
A Clean the electrode by grinding off the
contaminates.
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
Tweco Electrode Selection Chart.
B Select the right electrode type. Refer to
Tweco Electrode Selection Chart.
C Select the right rate for the welding job.
Refer to Table 4-9.
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 4-10: TIG (GTAW) Welding Problems
D Select the right shielding gas.
E Improve connection to work piece.
Select the right size electrode. Refer to
Tweco Electrode Selection Chart.
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 0-5157 4-21 BASIC WELDING
FABRICATOR 211i BASIC WELDING
This Page Intentionally Blank
BASIC WELDING 4-22 Manual 0-5157
PROBLEMS/SERVICE FABRICATOR 211i
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 unit will not
commence welding when
the torch trigger switch is
depressed.
A Power source is not in the
correct mode of operation.
B Faulty torch trigger. B Repair or replace torch trigger
A Set the power source to the cor-
rect mode of operation with the
process selection switch.
switch/lead.
2 Fault Indicator is illumi-
nated and unit will not
commence welding when
the torch trigger switch is
depressed.
3 Unit 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 Internal fault in power
source
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.
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 Have an Accredited Tweco
Service Provider investigate the
fault.
A Change the trigger mode selec-
tion switch from 4T latch mode
to 2T normal mode.
switch/lead.
A Connect the MIG gun polar-
ity lead to either the positive
welding output terminal or the
negative welding output terminal
as required.
B Poor or no work lead
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 con-
duit liner
Manual 0-5157 5-1 PROBLEMS AND ROUTINE SERVICE
B Clean work clamp area and en-
sure good electrical contact.
C Reduce brake tension on spool
hub
D Clean or replace conduit liner
FABRICATOR 211i PROBLEMS/SERVICE
FAULT CAUSE REMEDY
7 No gas flow in MIG mode. A Gas hose is damaged. A Replace or repair.
B Gas passage contains
impurities.
C Gas regulator turned OFF. C Turn ON regulator.
D Empty gas cylinder. D Replace gas cylinder.
8 Gas flow continues after
the trigger switch has been
released (MIG mode).
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.
Gas valve has jammed open
due to impurities in the gas
or the gas line.
The Electricity Supply 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: Power Source Problems
5.02 Routine Service and Calibration Requirements
B Disconnect gas hose from the
rear of power source and blow
out impurities.
Have an accredited Tweco service provider repair or replace
gas valve.
Ensure that the Electricity Supply is within 115V ± 10% or
208/230VAC ± 10%.
Connect the TIG torch to the (-)
VE terminal.
Select the correct size of tungsten electrode. Refer to Table
4-7.
WARNING
There are extremely dangerous voltage and power levels present inside this Inverter 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 before disassembling.
Routine Inspection, Testing & Maintenance
The inspection and testing of the power source and associated accessories shall be carried out by a licensed
electrician. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is
compliant with Tweco's original specifications.
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.
B. Insulation Resistance
Minimum insulation resistance for in-service Tweco Inverter Power Sources shall be measured at a voltage
of 500V between the parts referred to in Table 5-2 below. 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.
PROBLEMS AND ROUTINE SERVICE 5-2 Manual 0-5157
PROBLEMS/SERVICE FABRICATOR 211i
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 Inverter 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 0-5157 5-3 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i PROBLEMS/SERVICE
Power Source Calibration
A. Schedule
Output testing of all Tweco Inverter 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.
B. Calibration Requirements
Where applicable, the tests outlined in Table 5-3 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.
PROBLEMS AND ROUTINE SERVICE 5-4 Manual 0-5157
PROBLEMS/SERVICE FABRICATOR 211i
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 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.
Warning!
Disconnect input power before maintaining.
Maintain more often if used under severe conditions
Each Use
Visual check of
regulator and pressure
Visually inspect the torch
body and consumables
Replace all
broken parts
Visual check of torch
Consumable parts
Weekly
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
Tweco Service Provider
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-10502_AB
Manual 0-5157 5-5 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i PROBLEMS/SERVICE
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 these parts and their eventual failure.
PROBLEMS AND ROUTINE SERVICE 5-6 Manual 0-5157
REPLACEMENT PARTS FABRICATOR 211i
SECTION 6: KEY SPARE PARTS
6.01 Tweco Fusion 220A MIG Gun
Torch Part No: F220TA-12-3035
Figure 6-1
Art# A-11672_AB
Item
No.
1 Velocity Nozzle**
Velocity Contact Tip**
2
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.
Table 6-1: Tweco Fusion 220A MIG Gun Parts
** Patent Pending
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
* Refer to Tweco Catalog No. 64-2103 for additional
options.
Manual 0-5157 6-1 REPLACEMENT PARTS
FABRICATOR 211i REPLACEMENT PARTS
6.02 Power Source Spare Parts
810
11
15
26
4
3
29
9
2
1
Art # A-11250
16
25
24
23
12
32
33
17
19
18
30
31
35
34
Figure 6-2
20
14
22
13
36
5
7
6
REPLACEMENT PARTS 6-2 Manual 0-5157
REPLACEMENT PARTS FABRICATOR 211i
Item Part Number Description
1 W7005621 PCB Power, Fab 211i
2 W7005638 PCB Control, Fab 211i
3 W7005602 PCB Display, Fab 211i
4 W7005607 PCB Spool Gun, Fab 211i
5 W7005603 Wiredrive Assembly, Fab 211i
6 W7004906 Thumbscrew,Feedroll Positioner
7 W4014800 DRIVE RL2 Roll, .023/.035 “V”
8 W7005622 Fan Assembly, Fab 211i UL/CSA
9 W7003010 Rectifier Bridge,1000V,50A
10 W7003033 Gas Solenoid Valve Assy
11 W7003215 Gas Inlet Fitting
12 W7004909 Connector Socket,50 Dinse
13 W7004955 Connector Plug,50 Dinse
14 W7003242 Socket,8 Pin,w/ Harness
15 W7005623 Switch CB,Main On-Off
16 W7004911 CT, Output
17 W7005617 Spool Hub Assembly
18 W7005608 Washer,Friction,Spool Hub
19 W7005609 Spool Hub
20 W7004966 Adapter,Tweco 4,141i-211i
21 W7005619 Guide,Inlet,.023-.045 (not shown)
22 W7004967 Guide,Outlet,.023-.045
23 W7005557 Front, Panel, Fab 211i UL/CSA
24 W7005610 Panel, Base, Fab 211i
25 W7005625 Center Panel, Fab 211i
26 W7005556 Rear, Panel, Fab 211i UL/CSA
27 W7005560 Panel, Cover, Fab 211i (not shown)
28 W7005559 Panel, Door, Fab 211i (not shown)
29 W7005558 Panel,Control,Fab 211i
30 W7004972 Knob,1/4” IDx1” ODx0.9” H
31 W7005630 Knob,1/4” IDx1.25” ODx.9” H
32 W7005629 Circuit Breaker,4A
33 W7004943 Switch,250V/2A
34 870734 Knob,1/4” IDx.72” ODx.9” H
35 W7004940 PCB, Burnback Potentiometer
36 W7005632 Shroud, WF Motor, 211i
37 W7005561 Label, Identification, Fab 211i (not shown)
38 W7005562 Setup chart English version (not shown)
39
40
7978044PKD Large Spring, for One Pound Spool (not shown)
W7005635 Latch, Door, Slide (not shown)
Table 6-2: Fabricator 211i Parts
Manual 0-5157 6-3 REPLACEMENT PARTS
FABRICATOR 211i REPLACEMENT PARTS
This Page Intentionally Blank
REPLACEMENT PARTS 6-4 Manual 0-5157
APPENDIX FABRICATOR 211i
ACOUT
DC -
DC +
RED
BLACK
+15V 1
IGBT Driver A 2
IGBT Driver B 3
GND 7
Over Current Signal 6
OT2
Funs
RED
Main Power PCB1
Control PCB2
4 GND
1 +15V
2 -15V
3 Current Feedback
Current Sensor
CONNECTOR LAYOUT DIAGRAM
MWPBFI
FunsDRIVE
ON
1
FAN
PFC CIRCUIT
GUN
MB
BLACK
POS
NEG
+
-
BLACK
WVIN
OT1
DRIVE
IFB
RED
YELLOW
GRAY
WHITE
IN
1
IGBT Driver B 4
IGBT Driver A 5
1 +15V
2 IGBT Driver A
3 IGBT Driver B
7 GND
6 Over Current Signal
4 IGBT Driver B
5 IGBT Driver A
1
1
1
+24VDC 1
-24VDC 3
GND 2
1 +24VDC
2 GND
3 -24VDC
DY2
SOURCE
1
+
1
1
MOTOR PWM CONTROL
CIRCUIT
PWM
PWM
1 PWM RETURN
2 PWM (MOTOR DRIVER 5VDC PEAK)
1
1
1
1
1
ACOUT
SHEETMETAL COVER
VR
BR1
BR2
+++
+
1
1
1
GAS
SOLENOID
1
1
1
1
1
Wirefeeder
Power
Fault
MIG
LIFT TIG
STICK
2T Normal
4T Latch
Process
Trigger
Wirefeed / Amps
Volts
Down Slope / Arc Force(%)
Arc Control
Amps / Wirefeed Display
Volts Display
12
3456
78
Front View
8A/250V
Fuse
MIG GUN
SPOOL GUN
1
1
K1
L1
L2
GND
OT1
OT2
CR
SOURCE
QF / DY
WVIN
JC
1
2
MB
1
POT1
1
CR
JC
QF / DY
GND
+24VDC
3 POT MAX (+5VDC)
2 WIPER
1 POT MIN
RED
BLK
YEL
1 +24VDC
1
1 - OUTPUT
3 + OUTPUT
8 Pin Remote Control
Spool Gun
1
SPOOL GUN (0V) 1
TORCH SWITCH (+24V) 2
TORCH SWITCH RIN (0VDC) 3
SPOOL GUN (+24VDC) 4
5
REMOTE CONTROL IN (+15V ) 6
(REMOVE VOLTAGE) POT WIPER 8
(REMOVE AMPS/WIRESPEED) POT WIPER 7
1
LOCAL
REMOTE
-15VDC
1
1
GUN
+24VDC 1
GND
1
1 +15VDC
1 +15VDC
GND
DISPLAY DATA &EPROM (D-IN) 1
SEIAL DISPLAY DATA (LOAD) 2
SEIAL DISPLAY DATA (CLK) 3
2T/4T PUSHBUTTON 4
SERIAL DISPLAY DATA (EPROM) 5
STICK 6
+15VDC 9
PROCESS PUSHBUTTON 8
POT3 B 11
POT2 WIPER 12
POT3 A (PANEL DEMAND) 13
POT1 WIPER 14
+15VDC 15
GND
1
1
RED
WHITE
YELLOW
RED
BLACK
1 +24CDC
GND
+24CDC 1
N/A 2
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
WHITE
RED
JC
2 +5VDC
1
INPUT 230V/115V
OUTPUT CONTROL SIGNAL
1
SPOOL GUN PCB3
PP
15V
FUSE
SGM
Display PCB4
DY1
QF/FJ
GUN
MT
75
ć
75
ć
RED
RED
BLACK
BLACK
RED
BLACK
CON3
FJ
BURN BACK PCB 5
RED
YELLOW
RED
BLACK
INPUT 115/208/230VAC
50/60Hz50/60Hz50/60Hz
MD
RED
YELLOW
1
R-G
remote15V
SGM
1
1
Art#A-11249_AC
APPENDIX 1: FABRICATOR 211i CIRCUIT DIAGRAM
Manual 0-5157 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 NONAUTHORIZED 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
Rawang, Malaysia
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
Shanghai, China
Sales Office
Ph +86 21-64072626
Fax: +86 21-64483032
Singapore
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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