TWECO FABRICATOR 252i 3-IN-1 Multi Process Welding Systems, FABRICATOR 252i Instruction manual
300
3163339
®
FABRICATOR
252i
3-IN-1 Multi Process
Welding Systems
Operating
Manual
English
Canadien Français
Americas Español
Português (Brasil)
Revision: AJ Issue Date: November 11, 2014 Manual No.: 0-5155
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:
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WARNINGS
Read and understand this entire Manual and your employer’s safety practices if applicable
before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment,
the Manufacturer assumes no liability for its use.
Operating Manual Number 0-5155 for:
Tweco Fabricator 252i Inverter Power Supply Part No. W1004400
Tweco Fabricator 252i Inverter System Part No. W1004401
Tweco Fabricator 252i Inverter System
w/Single Cylinder Cart Part No. W1004402
Tweco Fabricator 252i Inverter System
w/Dual Cylinder Cart/Deluxe Part No. W1004403
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.victortechnologies.com
Copyright 2011, 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: November 15, 2011
Revision Date: November 11, 2014
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 .............................................................. 1-13
1.08 Principales Normes De Securite ................................................................... 1-15
1.09 Graphique de Symbole .................................................................................. 1-16
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 User Responsibility ......................................................................................... 2-2
2.06 Transportation Methods .................................................................................. 2-2
2.07 Packaged Items .............................................................................................. 2-2
2.08 Duty Cycle ....................................................................................................... 2-3
2.09 Specifications ................................................................................................. 2-5
SECTION 3: INSTALLATION OPERATION AND SETUP ................................................. 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Mains Supply Voltage Requirements .............................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-2
3.06 Power Source Controls, Indicators and Features ............................................ 3-4
3.07 Advanced Features Details .............................................................................. 3-9
3.08 Attaching the Tweco Fusion 250A MIG Gun .................................................. 3-15
3.09 Installing a 12.5 lb spool (8" diameter) ......................................................... 3-16
3.10 Installing a Standard Spool (12" diameter) ................................................... 3-17
3.11 Inserting Wire into the Feed Mechanism ...................................................... 3-18
3.12 Feed Roller Pressure Adjustment .................................................................. 3-19
3.13 Feed Roller Alignment ................................................................................... 3-19
3.14 Changing the Feed Roll ................................................................................. 3-20
3.15 Input And Output Wire Guide Installation ..................................................... 3-21
3.16 Wire Reel Brake ............................................................................................ 3-22
3.17 Shielding Gas Regulator Operating Instructions ........................................... 3-23
3.18 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire .......................... 3-26
3.19 Set-up for MIG (FCAW) Welding with Gasless MIG Wire .............................. 3-27
3.20 Set-up for LIFT TIG (GTAW) Welding ............................................................ 3-29
3.21 Set-up for STICK Metal Arc Welding (SMAW) ............................................... 3-30
TABLE OF CONTENTS
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5
4.03 STICK (SMAW) Basic Welding Technique ....................................................... 4-7
4.04 STICK (SMAW) Welding Troubleshooting ..................................................... 4-15
4.05 TIG (GTAW) Basic Welding Technique .......................................................... 4-17
4.06 TIG (GTAW) Welding Problems ..................................................................... 4-20
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS
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
6.01 Fabricator 252i Power Supply Replacement Panels ........................................ 6-1
6.02 Tweco Fusion 250A MIG Gun .......................................................................... 6-4
APPENDIX 1: OPTIONS AND ACCESSORIES
APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM
TWECO - LIMITED WARRANTY TERMS
INTERNATIONAL CONTACT INFORMATION
.......................................................................... 6-1
............................................................ A-1
.................................................. A-2
............................................ INSIDE REAR COVER
................................................. REAR COVER
............ 5-1
This Page Intentionally Blank
SAFETY INSTRUCTIONS FABRICATOR 252i
!
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.
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.
Manual 0-5155 1-1 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 252i SAFETY INSTRUCTIONS
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.
3. Use protective screens or barriers to protect others from
flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flameresistant 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.
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)
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
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 0-5155
SAFETY INSTRUCTIONS FABRICATOR 252i
!
from the weld area, the area is well ventilated, and if
necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can
give off toxic fumes if welded.
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.
6. Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding
area as practical to prevent welding current from traveling
long, possibly unknown paths and causing electric shock
and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific application;
maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder
valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed in Safety Standards.
Engines can be dangerous.
WARNING
WARNING
WARNING
ENGINE EXHAUST GASES can kill.
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.
Manual 0-5155 1-3 SAFETY INSTRUCTIONS AND WARNINGS
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
FABRICATOR 252i SAFETY INSTRUCTIONS
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks
or open flames.
3. Allow engine to cool before fueling. If possible, check and
add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers
and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed
and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers
for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from
moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes and
skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a
battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
STEAM AND PRESSURIZED HOT COOLANT can
burn face, eyes, and skin.
The coolant in the radiator can be very hot and
under pressure.
1. Do not remove radiator cap when engine is hot. Allow
engine to cool.
2. Wear gloves and put a rag over cap area when removing
cap.
3. Allow pressure to escape before completely removing
cap.
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.
Considerations About Welding And The Effects
of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions
Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington,
DC: U.S. Government Printing Office, May 1989): “...there
is now a very large volume of scientific findings based on
experiments at the cellular level and from studies with animals
and people which clearly establish that low frequency magnetic fields interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the
results are complex. Current scientific understanding does
not yet allow us to interpret the evidence in a single coherent
framework. Even more frustrating, it does not yet allow us to
draw definite conclusions about questions of possible risk or
to offer clear science-based advice on strategies to minimize
or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
WARNING
LEAD WARNING
NOTE
3. Do not coil or drape cable around the body.
4. Keep welding Power Source and cables as far away
from body as practical.
SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5155
SAFETY INSTRUCTIONS FABRICATOR 252i
!
!
!
!
C. Ventilation
ABOUT PACEMAKERS:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
1.02 General Safety Information for Victor CS Regulator
A. Fire Prevention
Welding and cutting operations use fire or combustion
as a basic tool. The process is very useful when properly
controlled. However, it can be extremely destructive if not
performed cor rectly in the proper environment.
1. The work area must have a fireproof floor.
2. Work benches or tables used during welding or cutting operations must have fireproof tops.
3. Use heat resistant shields or other approved material
to protect nearby walls or unprotected flooring from
sparks and hot metal.
Ade quately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concen trations of gases. Certain
combinations of metals, coatings, and gases
generate toxic fumes. Use respiratory protection
equipment in these circumstances. When welding/brazing, read and understand the Material
Safety Data Sheet for the welding/brazing alloy.
D. Personal Protection
Gas flames produce infrared radiation which may have a
harm ful effect on the skin and especially on the eyes. Select
goggles or a mask with tempered lenses, shaded 4 or darker,
to protect your eyes from injury and provide good visibility
of the work.
Always wear protective gloves and flame-resistant clothing to
protect skin and clothing from sparks and slag. Keep collars,
sleeves, and pockets buttoned. DO NOT roll up sleeves or cuff
pants.
WARNING
4. Keep an approved fire extinguisher of the proper
size and type in the work area. Inspect it regularly
to ensure that it is in proper working order. Know
how to use the fire extin guisher.
5. Move combustible materials away from the work
site. If you can not move them, protect them with
fireproof covers.
WARNING
NEVER perform welding, heating, or cutting
operations on a container that has held toxic,
combustible or flammable liq uids, or vapors.
NEVER perform welding, heating, or cutting
operations in an area containing combustible
vapors, flam mable liquids, or explosive dust.
B. Housekeeping
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.
When working in a non-welding or cutting environment,
always wear suitable eye protection or face shield.
WARNING
Practice the following safety and operation precautions EVERY TIME you use pressure regulation equipment. Deviation from the following
safety and operation instructions can result in
fire, explosion, damage to equipment, or injury
to the operator.
E. Compressed Gas Cylinders
The Department of Transportation (DOT) approves the design
and manufacture of cylinders that contain gases used for
welding or cutting operations.
1. Place the cylinder (Figure 1-1) where you will use
it. Keep the cylinder in a vertical position. Secure it to a
cart, wall, work bench, post, etc.
Keep ALL apparatus clean and free of grease, oil and other
flammable substances.
Manual 0-5155 1-5 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 252i SAFETY INSTRUCTIONS
Art # A-12127
!
!
Figure 1-1: Gas Cylinders
WARNING
Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or misuse of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, flames
or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling
of Compressed Gases in Containers” publication.
NOTE
CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly,VA 20151-2923
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.
CAUTION
Open the cylinder valve slightly. If you open the valve too much, the cylinder could tip over. When cracking the
cylinder valve, DO NOT stand directly in front of the cylinder valve. Always perform cracking in a well ventilated
area. If an acetylene cylinder sprays a mist when cracked, let it stand for 15 minutes. Then, try to crack the cylinder
valve again. If this problem persists, contact your gas supplier.
SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5155
SAFETY INSTRUCTIONS FABRICATOR 252i
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 0-5155 1-7 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 252i 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
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5155
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
4 Step Trigger
Operation
Burnback Time
Inches Per Minute
Meters Per Minute
See Note
See Note
Pulse Welding
Art # A-10663_AB
SAFETY INSTRUCTIONS FABRICATOR 252i
!
1.05 Precautions De Securite En Soudage A L’arc
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT.
NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS
QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION
OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au
reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les
précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être
apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif
en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes
d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques
sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont
présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN
ET D’ESSAI.
1.06 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler
gravement. L’électrode et le circuit de soudage
sont sous tension dès la mise en circuit. Le
circuit d’alimentation et les circuits internes
de l’équipement sont aussi sous tension dès la
mise en marche. En soudage automatique ou
semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets
d’entrainement et toutes les pièces métalliques
en contact avec le fil de soudage sont sous
tension. Un équipement inadéquatement installé
ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non
troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre
au moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou
arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez
les fusibles de l’alimentation afin d’éviter une mise en
marche accidentelle.
Manual 0-5155 1-9 SAFETY INSTRUCTIONS AND WARNINGS
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 porte-électrodes raccordés
à deux sources de courant en même temps. Ne jamais
toucher quelqu’un d’autre avec l’électrode ou le porteélectrode.
8. N’utilisez pas de câbles électriques usés, endommagés,
mal épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre
corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la
terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le
circuit de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou
remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas
de source de courant alternatif, à moins qu’il soit muni
d’un réducteur de tension. Utilisez plutôt une source de
courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
FABRICATOR 252i SAFETY INSTRUCTIONS
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arc ou de l’éblouissement;
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES
YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de
nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux
lorsque vous soudez ou que vous observez l’exécution
d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans
latéraux sont recommandés.
AWS F2.2 : 2001 (R2010), Modifié avec l’accord de l’American Welding Society (AWS), Miami, Florida
Guide de teinte des lentilles
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.
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)
Taille de l’électrode
en mm (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)
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
* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite
progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors
du soudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante
lumière jaune; il est préférable d’utiliser un filtre qui absorbe cette lumière jaune ou le sodium du spectre
de la lumière visible.
SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5155
SAFETY INSTRUCTIONS FABRICATOR 252i
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. Assurezvous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage,
de nettoyage ou de pulvérisation. La chaleur et les rayons
de l’arc peuvent réagir avec des vapeurs et former des
gaz hautement toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou
au cadmium que si les zones à souder ont été grattées à
fond, que si l’espace est bien ventilé; si nécessaire portez
un respirateur à adduction d’air. Car ces revêtements et
tout métal qui contient ces éléments peuvent dégager des
fumées toxiques au moment du soudage.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre
côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un
baril.
8. Connectez le câble de soudage le plus près possible de
la zone de soudage pour empêcher le courant de suivre
un long parcours inconnu, et prévenir ainsi les risques
d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au
tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des
gants en cuir, une chemise épaisse, un pantalon revers,
des bottines de sécurité et un casque.
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.
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.
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la
peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles
font normalement partie du procédé de soudage,
traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou
à un cadre fixe pour les empêcher de tomber ou d’être
renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
4. Empêchez tout contact entre une bouteille et une électrode
de soudage.
Manual 0-5155 1-11 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 252i SAFETY INSTRUCTIONS
5. N’utilisez que des bouteilles de gaz protecteur, des
détendeurs, des boyauxs et des raccords conçus pour
chaque application spécifique; ces équipements et les
pièces connexes doivent être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de
la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles
de gaz comprimé et aux équipements connexes, ainsi
que la publication P-1 de la CGA, identifiée dans la liste
de documents ci-dessous.
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.
AVERTISSEMENT
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes
et bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné,
les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE
OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e carburant
ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire
le plein de carburant ou d’en vérifier le niveau au début
du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez
de l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez
tout carburant renversé avant de faire démarrer le moteur.
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.
SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5155
SAFETY INSTRUCTIONS FABRICATOR 252i
!
1. Maintenez les câbles l’un près de l’autre en les
entrelaçant ou les reliant ensemble au ruban.
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
AVERTISSEMENT : Ce produit contient des pro-
duits chimiques, notamment du plomb, reconnu
par l’État de la Californie pour causer des malformations congénitales et d’autres dommages
touchant le système reproductif.
mains après manipulation.
Se laver les
2. Acheminez les câbles à un côté du soudeur, le plus
loin possible.
3. N’enroulez pas de câble autour du corps.
4. Maintenez le bloc d’alimentation du poste de soudage
et les câbles aussi loin que possible du corps.
STIMULATEURS CARDIAQUES :
Les procédures décrites ci-dessus sont
habituellement celles recommandées pour les
porteurs de stimulateurs cardiaques. Pour de
plus amples renseignements, consulter un
médecin.
1.07 Informations Générales de Sécurité
A. Prévention D’incendie
Les opérations de soudage utilisent le feu ou la combustion
comme outil de base. Ce processus est très utile quand il est
cor rectement contrôlé.
1. La zone doit comporter un sol ignifugé.
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) de l’U.S. Congress,
« Biological Effects of Power Frequency Electric & Magnetic
Fields », OTA-BP-E-63 (Washington, DC : U.S. Government
Printing Office, mai 1989) : « ... il existe de nos jours, un
nombre très élevé de travaux scientifiques qui rapportent les
résultats d’expériences menées au niveau cellulaire et d’études
auprès d’homme et d’animaux qui établissent nettement le
rapport entre les champs magnétiques de basse fréquence
et les systèmes biologiques, soit par des interactions ou des
modifications. Quoique la plupart de ces travaux soient de
très bonne qualité, les résultats sont complexes. À la lumière
des connaissances scientifiques actuelles, il nous est encore
impossible d’interpréter les évidences en un seul cadre de
référence cohérent. La situation est toutefois très contrariante.
En effet, il nous est aussi impossible de tirer des conclusions
définitives quant aux risques éventuels ou de proposer des
stratégies fondées sur des faits scientifiques visant à atténuer
ou éviter des risques potentiels ».
2. Les établis ou tables utilisés pendant les opérations
de soudage doivent avoir un revêtement ignifuge.
3. Utilisez des écrans résistants à la chaleur ou en matériau approuvé pour protéger les cloisons proches ou
le sol vul nérable des étincelles et du métal chaud.
4. Gardez un extincteur approuvé du bon type et de la bonne
taille dans la zone de travail. Inspectez-le régulièrement
pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir.
5. Enlevez tous les matériaux combustibles de la zone de
travail. Si vous ne pouvez pas les enlever, protégez-les
avec une cou vre ignifuge.
AVERTISSEMENT
N’effectuez
sur un récipient qui a contenu des liquides ou
vapeurs toxiques, combustibles ou inflammables.
N’effectuez
une zone contenant des vapeurs combustibles,
des liquides inflammables ou des poussières
explosives.
JAMAIS
d’opérations de soudage
JAMAIS
d’opérations de soudage dans
Pour atténuer les champs magnétiques sur les lieux de travail,
respectez les procédures qui suivent :
Manual 0-5155 1-13 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 252i SAFETY INSTRUCTIONS
!
!
!
Art # A-12127
!
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.
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 vêtements 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.
Quand vous travaillez dans un environnement non dédié au
soudage ou découpage, portez toujours une protection des
yeux appropriées ou un masque facial.
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.
Le schéma 1-1: Cylindres de gaz
AVERTISSEMENT
Les bouteilles sont sous haute pression. Manipulezles 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.
2. Placez le bouchon de protection de vanne sur la
bouteille à chaque fois que vous la déplacez ou
ne l’utilisez pas. Ne faites jamais glisser ou rouler
d’aucune manière les bouteilles. Utilisez un diable
approprié pour les déplacer.
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.
SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5155
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.
SAFETY INSTRUCTIONS FABRICATOR 252i
!
AVERTISSEMENT
N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endommagées. Informez
immédiate ment votre fournisseur de’ gaz de cet état.
6. Ouvrez et fermez momentanément la vanne de la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui
pour raient être présentes dans la vanne.
MISE EN GARDE
Ouvrez la vanne de bouteille légèrement. Si vous l’ouvrez trop en grand, la bouteille pourrait se renverser. Quand
vous ouvrez/fermez rapidement la vanne de bouteille, ne vous tenez pas directement devant. Opérez toujours
cette opération dans une zone bien ventilée. Si une bouteille d’acétylène crache un brouillard, laissez reposer
pendant 15 minutes. Essayez de nouveau la vanne. Si le problème persiste, con tactez votre fournisseur de gaz.
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, Washing-
ton, 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.
Manual 0-5155 1-15 SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 252i SAFETY INSTRUCTIONS
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
Sous Tension
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-10665
115V 15A
t
t1
t2
%
X
IPM
MPM
t
Fusible
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Durée de Pré-Dèbit
Durée de Post-Dèbit
Duréc du Pulse
Soudure Par Point
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Purge Du Gaz
Mode Continu de
Soudure
Pouces Par Minute
Mètres Par Minute
Torch de
Soudage
Probléme de Terre
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Détente à 4-Temps
Détente à 2-Temps
V
S
Voir Note
Voir Note
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
SAFETY INSTRUCTIONS AND WARNINGS 1-16 Manual 0-5155
INTRODUCTION FABRICATOR 252i
!
SECTION 2: INTRODUCTION
2.01 How to Use This Manual
This Operating Manual usually applies to the part numbers listed
on page i. To ensure safe operation, read the entire manual,
including the chapter on safety instructions and warnings.
Throughout this manual, the word WARNING, CAUTION and
NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.
WARNING
Gives information regarding possible personal
injury. Warnings will be enclosed in a box such
as this.
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.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when using
bars, hammers, etc., to un-crate the unit.
2.04 Description
The Tweco Fabricator 252i is a self contained single phase multi
process welding power source that is capable of performing
MIG (GMAW/FCAW), STICK (SMAW) and Lift TIG (GTAW)
welding processes. The Fabricator 252i is equipped with an
integrated wire feed unit, digital volt age / amperage meters,
power factor correction (PFC) with energy saving technology
and a host of other features to satisfy the broad operating needs
of the modern welding professional.
CAUTION
Refers to possible equipment damage. Cautions
will be shown in bold type.
NOTE
Offers helpful information concerning certain operating procedures. Notes will be shown in italics.
Additional copies of this manual may be purchased by contacting Tweco at the address and phone number for your location
listed in the inside back cover of this manual. Include the
Owner’s Manual number and equipment identification numbers.
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 machine. Equipment which does not have a
nameplate attached to the machine is identified only by the
specification or part number printed on the shipping container.
Record these numbers for future reference.
The Fabricator 252i is fully compliant to standard IEC 60974.1.
The Fabricator 252i MIG provides excellent welding performance across a broad range of applications when used with
the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the
machine and give guidelines on gaining the best efficiency and
quality from the Power Source. Please read these instructions
thoroughly before using the unit.
Manual 0-5155 2-1 INTRODUCTION
FABRICATOR 252i INTRODUCTION
2.05 User Responsibility
This equipment will perform as per the information contained
herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must
be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing,
plainly worn, distorted or contaminated, should be replaced
immediately. Should such repairs or replacements become
necessary, it is recommended that such repairs be carried out
by appropriately qualified persons approved by Tweco. Advice
in this regard can be obtained by contacting an Accredited
Tweco Distributor.
This equipment or any of its parts should not be altered from
standard specification without prior written approval of Tweco.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or
unauthorized modification from standard specification, faulty
maintenance, damage or improper repair by anyone other than
appropriately qualified persons approved by Tweco.
2.06 Transportation Methods
2.07 Packaged Items
Fabricator 252i Part No. (W1004401)
- Fabricator 252i Power Supply
- 15 ft Tweco® Fusion 250 Amp MIG Gun
- Velocity Contact tips (1 each)
• .030" (0.8 mm)
• .035" (0.9 mm)
• .045" (1.2 mm)
- Victor® Argon Regulator / Gauge & 10 ft. (3M) Hose
-Tweco WeldSkill 200 Amp electrode holder with 13 ft. (4
M) lead
-Tweco WeldSkill 200 Amp ground clamp with 10 ft. (3 M)
lead
-Drive Rolls:
• .035" / .045" (0.9 to 1.2 mm) V Grooved Lower & Flat
Upper (Fitted)
• .045" (1.2 mm) Flux Cored Roll
- Operating Manual
- 9 ft. (2.75 M) Power cord & NEMA 6-50P 230V AC Plug
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 unit with integrated hand holds at the front and rear of the
unit.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper
skid before transporting.
INTRODUCTION 2-2 Manual 0-5155
INTRODUCTION FABRICATOR 252i
A-12125
Figure 2-2: Packaged Items
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 40% duty cycle, 250 amperes at 26.5
volts. This means that it has been designed and built to provide the rated amperage (250A) for 4 minutes, i.e. arc welding time,
out of every 10 minute period (40% of 10 minutes is 4 minutes). During the other 6 minutes of the 10 minute period the Welding
Power Source must idle and be allowed to cool.
With Factory Fitted Supply Cord and Plug
100
90
80
70
60
50
40
30
Duty Cycle (percentage)
20
Safe
Operating
Region
STICK (SMAW)
TIG (GTAW)
MIG (GMAW)
10
0
0
25 50 75
100
Welding Current Max (amps)
125 150 225 250
175
200
Art # A-10666
Figure 2-3: Fabricator 252i Duty Cycle with Upgraded Supply Lead and Plug
Manual 0-5155 2-3 INTRODUCTION
FABRICATOR 252i INTRODUCTION
This Page Intentionally Blank
INTRODUCTION 2-4 Manual 0-5155
INTRODUCTION FABRICATOR 252i
2.09 Specifications
Description
Power Source Dimensions H 17.5" x W 10.25" x D 23.5"
Power Source Mass 65 lbs.
Cooling Fan Cooled
Welder Type Multi Process Power Source
Standard IEC60974.1
Number of Phases Single Phase
Nominal Supply Voltage 208/230 VAC ± 15%
Supply Voltage Range 187 - 265 VAC
Nominal Supply Frequency 50/60Hz
Open Circuit Voltage 72 VDC
MIG Voltage Range 14-30 VDC
Wirefeeder Speed Range 67 - 700 ipm (1.7 - 17.8 M/min.)
Protection Class IP23S
Supply Lead & Plug Rating 50 Amps (10 AWG)
Welding Current Range (MIG Mode) 20-300 Amps
Welding Current Range (LIFT TIG Mode) 5-300 Amps
Welding Current Range (STICK Mode) 20-230 Amps
Effective Input Current (I1eff) 22.4 Amps
Maximum Input Current (I1max) 34.7 Amps
Single Phase Generator Requirement 10 kVA
MIG (GMAW) Welding Output, 40°C, 10 min. 250A @ 40%,26.5V
STICK (SMAW) Welding Output, 40°C, 10 min. 230A @ 40%,29.2V
TIG (GTAW) Welding Output, 40°C, 10 min. 250A @ 40%,20V
Table 2-1: Fabricator 252i Specification
Fabricator 252i MULTI PROCESS
WELDING INVERTER
200A @ 60%, 24V
150A @ 100%, 21.5V
200A @ 60%, 28V
150A @ 100%, 26V
200A @ 60%, 18V
150A @ 100%, 16V
NOTE
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities,
measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and
operation will depend upon correct installation, use, applications, maintenance and service.
Manual 0-5155 2-5 INTRODUCTION
FABRICATOR 252i INTRODUCTION
This Page Intentionally Blank
INTRODUCTION 2-6 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
!
SECTION 3: INSTALLATION OPERATION AND SETUP
3.01 Environment
This unit is designed for use in environments with increased
hazard of electric shock as outlined in IEC 60974.1. 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.
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.
3.02 Location
3.03 Ventilation
WARNING
Since the inhalation of welding fumes can be
harmful, ensure that the welding area is effectively
ventilated.
3.04 Mains Supply Voltage Requirements
The Mains supply voltage should
be within ± 15% of the rated Mains supply voltage. Too low
of a supply voltage may cause poor welding performance or
wirefeeder malfunction. Too high of a supply voltage will cause
components to overheat and possibly fail.
WARNING
The Fabricator 252i must be electrically connected
by a qualified electrical trades-person. Damage to
the PCA (Power Control Assembly) could occur
if 276 VAC or higher is applied to the Primary
Power Cable.
Be sure to locate the welder according to the following guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 32° F to 104° F.
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 1 foot or more from walls or similar
that could restrict natural air flow for cooling.
G. The enclosure design of this power source meets the re-
quirements of IP23S as outlined in IEC60529.
H. Precautions must be taken against the power source top-
pling 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.
Manual 0-5155 3-1 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
50/60 Hz
Single Phase
Yes 10 AWG 208-230/50A 50A 40% @ 250A 40% @ 250A 40% @ 230A
Primary Supply
Lead Size
Minimum Primary
Current Circuit
Size (Vin/Iin)
Table 3-1: Input Power Source Leads for Fabricator 252i
Minimum
Plug Size
WARNING
MIG LIFT TIG STICK
Current & Duty Cycle
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live
electrical parts.
SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging procedures
consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting OFF and red-tagging
circuit breaker or other disconnecting device.
Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power source. 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, fuse and primary supply lead based on Table 3-1.
WARNING
Any electrical work must be carried out by a qualified Electrical Tradesperson.
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. Further guidance is given in IEC 60974-13 Arc Welding Equipment - Installation and use (under preparation).
B. Assessment of Area
Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding
area. The following shall be taken into account.
INSTALLATION/SETUP 3-2 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
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. Mains Supply
Welding equipment should be connected to the mains
supply according to the manufacturer’s recommendations.
If interference occurs, it may be necessary to take
additional precautions such as filtering of the mains 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.
4. Equipotential Bonding
Bonding of all metallic components in the welding instal-
lation 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.
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.
Manual 0-5155 3-3 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.06 Power Source Controls, Indicators and Features
1
6
9
8
2
3
4
5
Art # A-10503_AB
7
Figure 3-1: Fabricator Control Panel
11
10
+
13 14
15
-
Art # A-10504
12
Figure 3-2: Fabricator Front Connections
WARNING
DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding
voltage potential.
INSTALLATION/SETUP 3-4 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
1. Power Indicator
The green power indicator will be illuminated when the welder
is turned ON and indicates the presence of power.
2. Fault Indicator
The yellow fault indicator will be illuminated when any of the
faults are detected. ALL Faults will illuminate the indicator
3. Weld Process Selection Button
Process
MIG
TIG
STICK
Press and release this button to change the selected weld process mode from MIG to LIFT TIG to STICK. The weld process
will change to the next process in the sequence each time the
button is pressed and released. The red indicators next to
the button will illuminate to identify MIG or LIFT TIG or STICK
process mode.
5. Advanced Features Button
Advanced
Features
Press and release the Advanced Features button to enter or exit
from the advanced programming mode. To exit, simply press
and release the button again. Any changes made are saved.
The advanced programming menu items are described in detail
for each welding mode in Section 3.07.
Advanced
Features
Gas Purge.
In addition, the Advanced Features Button is used to initiate a
30 second gas line purge function to fill the gas line with the
shielding gas from the connected gas cylinder. To start the
gas purge function, simply press and hold the button for approximately two (2) seconds. Once the Gas purge function has
started, a countdown timer will show in the left alpha-numeric
display indicating the number of seconds remaining before the
purge will be automatically terminated. You can stop the Gas
purge any time during the 30 seconds by quickly pressing and
releasing the button again.
6. Left Knob: Amperage Control (Wirespeed)
WARNING
When the Power light is lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage
potential.
4. 2T - 4T Trigger Latch Button
Trigger
2T Normal
4T Latch
Press and release the button to change the selected operating
mode of the trigger. The selected mode can be either “2T”
(unlatched) or “4T” (latched) operation. The red indicator
next to the button will illuminate to identify which mode is
selected (2T or 4T). In the 4T mode once the weld has been
started you can release the trigger and continue welding until
the trigger is activated again or the welding arc is broken to
stop the welding arc.
A
Left Knob
WIRESPEED
The amperage control knob adjusts the amount of welding
current delivered by the power source. In STICK and LIFT TIG
modes, the amperage control knob directly adjusts the power
inverter to deliver the desired level of output current. In MIG
mode, the amperage 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 required is 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. The value may
also be adjusted while a weld is in progress – if this occurs, the
left display will briefly switch to show the adjusted value as the
knob is turned, and will automatically revert back to showing the
weld current measurements when the knob is not being turned.
Manual 0-5155 3-5 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
7. Right Knob: Multifunction Control - MIG Voltage / Arc Control (Inductance) & STICK Arc Force
V
Right Knob
ARC CONTROL
MIG Voltage Control
In this mode the control knob is used to adjust the output voltage of the power source. The welding voltage is increased by turning
the knob clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required is 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. The value may also be adjusted while a weld is in progress – if this
occurs, the left display will briefly switch to show the adjusted value as the knob is turned, and will automatically revert back to
showing the weld current measurements when the knob is not being turned.
V
Right Knob
Right Knob
ARC CONTROL
MIG Arc Control (Inductance)
The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. To access the Arc Control function,
push inward on the right knob and hold it for approximately 2 seconds. This feature can be accessed and adjusted during welding.
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 ‘100%’ (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. This feature can be accessed and adjusted during welding.
To access the Arc Control function, push inward on the right knob and hold it for approximately 2 seconds. This feature can be
accessed and adjusted during welding.
The left display will change to show the Arc Control parameter name that is in effect for the current MIG or STICK Modes and
the right display will show its present value. Use the right knob to change the value. When the desired value is selected, press
inward again on the knob without turning it and release it to exit the Arc Control function and save the value.
Weld Modes Arc Control Function Left Display Right Display Limits
MIG Inductance INDU 25% (default) 0 – 100 %
STICK Arc Force ARC- / FRCE 50% (default) 0 – 100%
Table 3-2
8. Left Digital Display
MIG Mode
This digital meter is used to display the pre-set (preview) Wirefeed Speed in Inches Per Minute (IPM) 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 Left Knob (Control No 6).
INSTALLATION/SETUP 3-6 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
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 Left Knob (Control No 6).
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 approximately 10 seconds
in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the 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.
The display is also used for providing error messages to the user and showing other information, which will be explained in Section 5.
9. 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 Right Knob (Control No 7).
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 can not be adjusted by varying the Right Knob (Control No 7).
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.
The display is also used for providing error messages to the user and showing other information, which will be explained in Section 5.
10. MIG Gun Adaptor
The MIG Gun Adapter is the connection point for the Tweco Fusion 250A MIG Gun. Refer to section 3.08 for the correct procedure
for attaching the Tweco Fusion 250A MIG Gun.
11. 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.
1
5
A-09594_AC
2
1
2
3
4
8
6
7
3
4
5
6
7
8
Remote Wirespeed in GMAW mode
Remote Amps in GTAW mode
Trigger Switch
W
V
Remote Volts in
GMAW Mode
Figure 3-3: Remote Control Socket
Manual 0-5155 3-7 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
Socket Pin
Function
1 Not connected
2
3
4
5
6
7
8
Trigger Switch Input
Trigger Switch Input
Not connected
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm 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 3-3
NOTE
The remote local setting on the control panel should be set to remote for the remote wire feeder amperage/voltage
controls to be operative.
12. 10 Pin Accessories Socket
The 10 pin Accessories Socket is used to connect remote devices such as a spool gun to the welding power source. To make
connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
J
1
I
D
Trigger
1
Peripheral
Resistor
G
H
Art # A-10813
F
E
D
J
I
C
B
A
G
E
F
H
1
2
Wirespeed
Potentiometer
3 3
1
2
Voltage
Potentiometer
3
A
+
C
B
Figure 3-4: Remote Control Socket
Motor
M
24V
-
INSTALLATION/SETUP 3-8 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
Socket Pin
A Voltage Pot. Wiper
B
C
D
E
F
G
H
I
J
Wire Feed Motor (-)
Wire Feed Motor (+)
Trigger Switch Input
Wire Speed Pot. & Voltage Pot. (+) CW 10K ohm
Wiper Arm Speed Pot.
Trigger Switch Input & Solenoid (-)
Wire Speed Pot. & Voltage Pot. (-) ACW
Solenoid (+)
Peripheral Program Resistor
13. 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 Fusion MIG Gun (via the MIG Gun
polarity lead), electrode holder lead or work lead. Positive
welding current flows from the power source via this heavy
duty bayonet type terminal. It is essential, however, that
the male plug is inserted and turned securely to achieve a
sound electrical connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being fused
in the bayonet terminal.
14. Negative Welding Output Terminal
The negative welding terminal is used to connect the welding output of the power source to the appropriate welding
accessory such as the MIG Gun (via the MIG Gun polarity
lead), LIFT 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.
Function
Table 3-4
15. MIG Gun Polarity Lead
The polarity lead is used to connect the MIG Gun to the
appropriate positive or negative output terminal (allowing
polarity reversal for different welding applications). In
general, the polarity lead should be connected in to the
positive welding terminal (+) when using steel, stainless
steel or aluminum electrode wire. When using 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.
3.07 Advanced Features Details
NOTE
The Local / Remote setting will only be saved
while in that welding process. Once the welding
process is changed the setting will revert to the
factory default.
General Operation
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being fused
Process
MIG
TIG
STICK
in the bayonet terminal.
Select the weld process (Control No 3) you wish to view Advanced Features for.
Manual 0-5155 3-9 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
Advanced
Features
Then press and release the Advanced Features button (Control
No 5) to enter or exit from the Advanced Features programming
function of the welder.
A
Left Knob
WIRESPEED
The Advanced Features menu items are viewed by turning the
left knob (Control No 6) to move forward or backward through
the list. The function names in the menu will be displayed in
abbreviated form in the left alpha-numeric display. In the case of
two part names or abbreviations, the left display will alternately
flash the first part of the function name and then the second
part, followed by a brief “blank” interval. For each function, the
right alpha-numeric display will show its present value.
V
Process
MIG
TIG
STICK
If the welder is in Advanced Features mode and the Weld Process Selection button (Control No 3) is pressed, the welder
will exit Advanced Features mode, saving any change made,
and change to the next weld process function in the sequence:
MIG, LIFT TIG, STICK. (See previous note) If you wish to view
the Advanced Features for the next process you will need to
enter the Advanced Features function again.
V
Right Knob
Right Knob
ARC CONTROL
If the welder is in Advanced Features mode and the right knob
(Control No 7) is pressed for one (1) second (to enter Arc
Control Function) the welder will exit Advanced Features mode,
saving any change made, and enter the Arc Control Function
for the currently selected weld process.
Right Knob
ARC CONTROL
To change the value of that parameter, simply turn the right knob
(Control No 7) to change it. If the setting has been changed
from its previous value the welder will save the new value when
the left knob is turned to view the next parameter, or if the
user activates a control to cause the welder to exit Advanced
Features mode as described earlier. Once the beginning or end
of the menu list is reached, additional turning of the left knob
in that direction will not result in any change of the displayed
parameter.
The Advanced Features control functions are in order with the
user’s process steps when setting up to operate the welder in
the selected welding process modes (MIG, LIFT TIG, STICK).
The menu functions shown in Advanced Features Mode are
mostly dependent on the currently selected weld process mode
of the machine.
INSTALLATION/SETUP 3-10 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
MIG (GMAW/FCAW)Mode Advanced Features Menu Map
Left Display Right Display
Advanced Menu – MIG
Mode
MIG / CNTL
PRE- / FLOW
RUN- / IN
POST / FLOW
BURN / BACK
WIRE / SHRP
SPOT
*SPOT / TIME
STCH
*STCH / TIME
DWEL / TIME
ARC- / TYPE
Wire Feed Speed
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection
* SPOT TIME and STCH TIME are only active when SPOT or STCH are “ON”.
Note “SPOT” and “STCH” are MUTUALLY EXCLUSIVE functions. If the user enables either function and the system
detects that the OTHER function is already ON, the system will automatically turn the OTHER conflicting function OFF.
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Advanced Menu - MIG
Options or Range
LOCL REMT
0.1 - 5.0 S
30 - 150%
0.0 - 30.0 S
0.00 - 1.00 S
ON OFF
ON OFF
0.1-20.0 S
ON OFF
0.2 - 4.0 S
0.1 - 1.0 S
AUTO CV
MPM IPMWFS- / UNIT
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Right Knob Selection
Process
MIG
TIG
STICK
Advanced
Features
Art # A-10505_AB
Figure 3-5: MIG Advanced Menu
Right Display
Function Left Display
(Factory Default
Limits Comments
Values)
MIG Operator
Controls
Pre Flow (MIG
Setting)
MIG/CNTL LOCL LOCL - REMT
PRE-/FLOW 0.1 S 0.0 – 5 S
Run In RUN/IN 70% 30 – 150 %
Post Flow (MIG
Setting)
POST/FLOW 0.5 S 0.0 – 30 S
Burn Back BURN/BACK 0.15 S 0.00 – 1.00 S
Wire Sharp WIRE/SHRP ON OFF – ON
Spot SPOT OFF OFF – ON
LOCL = Local control of the Wirespeed
and Voltage with the machines controls.
REMT = Remote control of the Wirespeed and Voltage
with an accessory device.
Shielding gas flows for the time specified before an
arc is initiated.
Wirespeed runs as a percentage of preview wirespeed
until an arc is struck.
Shielding gas flows for the time specified after an arc
has extinguished.
The time difference between turning the wire feed OFF
before the voltage is turned OFF.
Wire Sharp adds a burst of current at the end of a
weld to remove the ball at the end of the wire. This
improves the restart of the next weld.
Spot is used to weld two thin plates together at a
desired location by melting the top & bottom plates
together to form a nugget between them. The weld
time is set by the Spot Time.
Manual 0-5155 3-11 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
Right Display
Function Left Display
Spot Time
(Only shown/en-
abled if Spot=ON)
Stitch STCH OFF OFF – ON
Stitch Time
(Only shown/
enabled if
Stitch=ON)
Dwell Time
(Only shown/
enabled if
Stitch=ON)
Arc Type ARC-/TYPE AUTO AUTO – CV-M
Wire Feed Speed
Units
Arc Hour Accumulated Runtime
Restore Factory
Defaults
SPOT/TIME 2.0 S 0.1 – 20.0 S Spot Time is the time used for the Spot weld mode.
STCH/TIME 2.0 S 0.2 – 4.0 S
DWEL/TIME 0.5 S 0.1 – 1.0 S
WFS/UNIT IPM MPM – IPM
HR 0.0 0.0 – 9999.9
FACT/DFLT NO NO – YES
(Factory Default
Values)
Limits Comments
Stitch is used to weld two or more components by
stitch or interval weld together.
The weld time is set by the Stitch Time and the non
weld time is set by the Dwell Time.
Stitch Time is the time used for the weld time in Stitch
weld mode.
Dwell Time is the time used for the non weld time in
Stitch weld mode.
Auto is an optimized arc control for dip transfer welding with minimal spatter on mild steel with mixed
shielding gases. CV-M is the traditional constantvoltage arc control for all other welding.
MPM provides preview wirespeed in Meters Per
Minute.
IPM provides preview wirespeed in Inches Per
Minute.
Provides Arc On Hours that the power source has
welded. The number displayed is in hours and read
only. It will rollover to 0 once 10,000 hours have been
reached.
When YES is selected all the user adjustable values
in this table (except Arc Hour Accumulated Runtime)
are reset to the Factory Default Values.
INSTALLATION/SETUP 3-12 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
LIFT TIG Mode Advanced Features Menu Map
Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (flash) between the (2) items
Function Left Display
LIFT TIG Operator
Controls
Pre Flow (LIFT TIG
Setting)
Post Flow (LIFT
TIG Setting)
PRE-/FLOW 0.1 S 0.0 – 5 S
POST/FLOW 10.0 S 0.0 – 30 S
Left Display Right Display
Advanced Menu -
LIFT TIG Mode
TIG / CNTL
PRE- / FLOW
POST / FLOW
DOWN / SLPE
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Left Knob Selection Right Knob Selection
Advanced Menu - LIFT
TIG Options or Range
LOCL REMT
0.0 - 5.0 S
0.0 - 30.0 S
0.0 - 30.0 S
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Figure 3-6: LIFT TIG Advanced Menu
Right Display
(Factory Default
Limits Comments
Values)
LIFT TIG/
CNTL
REMT LOCL - REMT
Process
LOCL = Local control of the Amps with the machines controls
REMT = Remote control of the Amps with an accessory device
Shielding gas flows for the time specified before an
arc is initiated
Shielding gas flows for the time specified after an arc
has extinguished
In “2T” (unlatched), the unit will enter down slope
mode as soon as the trigger switch is released (ie if
Down Slope is set to 5.0 S, the unit will ramp down
from the present welding current to zero over 5
seconds).
MIG
TIG
STICK
Advanced
Features
Art # A-10506_AB
Down Slope DOWN/SLPE 0.0 S 0.0 – 30 S
In "4T" (latched), to enter down slope mode the trigger
switch must be held in for the selected time period
(ie press and release trigger switch to commence
welding, then press and hold trigger switch again to
enter down slope mode). Should the trigger switch
be released during the down slope time, the output
will cease immediately in "4T" only.
Provides Arc On Hours that the power source has
Arc Hour Accumulated Runtime
HR 0.0 0.0 – 9999.9
welded. The number displayed is in hours and read
only. It will rollover to 0 once 10,000 hours have been
reached.
Restore Factory
Defaults
Manual 0-5155 3-13 INSTALLATION/SETUP
FACT/DFLT NO NO – YES
When YES is selected all the user adjustable values
in this table (except Arc Hour Accumulated Runtime)
are reset to the Factory Default Values.
FABRICATOR 252i INSTALLATION/SETUP
STICK Mode Advanced Features
Left Display Right Display
Advanced Menu - STICK
Mode
STCK / CNTL
HOT- / START
HS / TIME
HS / AMPS
HR
FACT / DFLT
Press Advanced Button
to Exit to Welding Mode
Advanced Menu - STICK
Options or Range
LOCL REMT
ON OFF
0.0 - 2.0 S
75 - 200 %
0.0 - 9999.9
NO YES
Press Advanced Button
to Exit to Welding Mode
Process
MIG
TIG
STICK
Advanced
Features
Left Knob Selection
Left Display: Where (2) items shown, e.g. HOT- / STRT, the display will alternate (flash) between the (2) items
Right Knob Selection
Figure 3-7: STICK Advanced Menu
Right Display
Function Left Display
(Factory Default
Limits Comments
Values)
STICK Operator
Controls
STCK/CNTL LOCL LOCL - REMT
Hot Start HOT/STRT ON OFF – ON
Hot Start Time TIME/HS 0.5 S 0.0 - 2.0 S
Hot Start Amps AMPS/HS 140% 75 – 200%
Arc Hour Accumulated Runtime
Restore Factory
Defaults
HR 0.0 0.0 – 9999.9
FACT/DFLT NO NO – YES
Art # A-10507_AA
LOCL = Local control of the Amps with the machines controls
REMT = Remote control of the Amps with an accessory device
Hot Start is used to improve the start characteristics
for STICK electrodes, e.g. low hydrogen electrodes.
Hot Start Time is the time that the Hot Start Amps
is applied.
Hot Start Amps sets the peak start current, e.g. 100A
at 140% = 140A
Provides Arc On Hours that the power source has
welded. The number displayed is in hours and read
only. It will rollover to 0 once 10,000 hours have
been reached.
When YES is selected all the user adjustable values
in this table (except Arc Hour Accumulated Runtime)
are reset to the Factory Default Values.
INSTALLATION/SETUP 3-14 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
3.08 Attaching the Tweco Fusion 250A MIG Gun
1. Unscrew the Locking Screw in the MIG Gun Adapter located inside the Wire Feed Compartment.
2. Push the Tweco Fusion 250A MIG Gun into MIG Gun Adaptor firmly using a twisting action.
3. Lock the Tweco Fusion 250A MIG Gun into the MIG Gun Adaptor by turning the Locking Screw clockwise in the MIG
Gun Adapter within the Wire Feed Compartment to secure the Tweco Fusion 250A MIG Gun in position.
NOTE
Failure to properly lock the Tweco Fusion 250A MIG Gun into the MIG Gun Adapter will result in the Tweco Fusion
250A 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.
Attach MIG Gun
and secure.
Art # A-10548
+
-
Remote Cable 8 pin connector
Figure 3-8: Mount Fusion MIG Gun Cable to Adapter Socket
4. If equipped, align the keyways of the MIG Gun Switch connector pigtail with the 8 pin receptacle to the right of the MIG
Gun cable and plug them together. Secure by turning the locking ring to the right (clockwise ). Refer to Figure 3-8.
NOTE
When disconnecting the MIG Gun trigger switch leads from the machine, DO NOT pull on the wires. Loosen the
locking ring and gently pull the plug out of the socket.
Manual 0-5155 3-15 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.09 Installing a 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 3.16
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
12.5lb / 8”
Wire Spool
Spring
Fibre Washer
Retaining Clip
Use inner holes on
Spool Hub
Keyed Washer
Pin
Spool Hub
Figure 3-9: 12.5 lb 8" Spool Installation
A-10670
INSTALLATION/SETUP 3-16 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
3.10 Installing a Standard Spool (12" diameter)
As delivered from the factory, the unit is set for a 33 lb. or 12" spool.
Installation of wire spool. Refer to Figure 3-10.
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 3.16
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
Small Hole
33lb / 12”
Wire Spool
Flat Washer
Large Hole
Spring
Retaining Clip
Use outer holes
Keyed Washer
Spool Hub
Fibre Washer
Pin
Figure 3-10: Standard 33 lb 12" Spool Installation
A-10671
Manual 0-5155 3-17 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.11 Inserting Wire into the Feed Mechanism
WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before proceeding.
DO NOT reattach the input power until told to do so in these instructions.
1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure 3-11)
2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure 3-11)
3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire Guide and
over the Feedroll. Make certain the proper groove is being used. (Second part of Figure 3-11)
4. Pass the MIG wire over the drive roll groove, through the outlet guide and out past the MIG Gun Adaptor. Then fit the
Fusion 250A MIG Gun as per Section 3.08 ensuring the MIG wire passes into the MIG Gun liner of the MIG Gun.)
5. Close the Pressure Roller Arm. (Figure 3-12)
6. Swing the Spring Pressure Adjusting Knob back into place. (Figure 3-12)
7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to Tighten and Counter Clockwise to
loosen). (Figure 3-12)
8. Figure 3-13 shows the result with wire installed. Continue to the next section for proper setting of tension.
1
Art # A-10030
2
3
4
Figure 3-11: Opening Pressure Arm and Inserting Wire
5
7
6
Art # A-10031
Figure 3-12: Closing Pressure Arm and Adjusting Tension
INSTALLATION/SETUP 3-18 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
3.12 Feed Roller Pressure Adjustment
NOTE
Before attempting to set the drive roller pressure you must select GMAW mode on the front panel. See earlier in
section 3 for information on how to select this feature. Once selected it will allow the activation of the drive roll when
the trigger on the MIG Gun is activated.
The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise. The Tension Adjuster should
be set to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the
wire out of the MIG Gun reveals no deformation or wear, the conduit liner should be checked for kinks or clogging from metal
flakes. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the Tension Adjusting knob clockwise.
The use of excessive pressure may cause rapid wear of the feed roller, motor shaft and motor bearings.
NOTE
Genuine TWECO Velocity contact tips and liners should be used. Many non-genuine liners use inferior materials which
can cause wire feed problems.
3.13 Feed Roller Alignment
The bottom Feed Roll is adjustable in and out to provide for best alignment of wire as it feeds into the outlet guide. To adjust the
roll do the following and refer to Figure 3-13. Note, the welding wire is not shown in order to more clearly see the groove in the
feed roll.
1. Place a wrench on the adjusting bolt (number 2) and hold in place while you loosen the locking screw (number 1) with
a hex wrench
2. With the locking screw loosened, turn the adjusting bolt right or left to align the feed roll (number 3) so the groove is
aligned with the outlet guide (number 4).
3. With the feed roll aligned, place a wrench on the adjusting bolt and hold it in place while tightening the locking screw with
the hex wrench. If the adjusting bolt moves before the locking screw is secured then the alignment will change.
3
1
Figure 3-13: Top View of Feed Plate with Pressure Arm Open
4
2
Art # A-10415
NOTE
It may not be possible to align with both the inlet and outlet guide at the same time. The outlet guide is the one that
needs to be aligned to for best wire feeding.
Manual 0-5155 3-19 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.14 Changing the Feed Roll
NOTE
Feedrolls often come with a rust prohibitive coating that needs to be cleaned off before installation.
A Feedroll consists of two different sized grooves. As delivered from the factory the drive roll is installed for .035" / .045" (0.9 /
1.2 mm).
The stamped marking on the feedroll refers to the groove furthest from the stamped marking. When mounted, that will be the
groove closest to the motor and the one to thread.
To ensure proper wire feed, the groove closest to the motor must match the electrode wire size being used.
.045” (1.2mm) Stamping
.045
1.2
.045
1.2
.045” (1.2mm) Groove
Art: A-07150_AB
The size that is visible when
fitting the feedroll is the groove
size in use.
Figure 3-14: Feedroll Example
NOTE
All grooved feed rolls have their wire size or range stamped on the side of the roll. On rolls with different size grooves,
the outer (visible when installed) stamped wire size indicates the groove in use.
Refer to feed roll kit in the Appendix for the proper selection and ordering of feed roll kits. Kit includes drive rolls, an input wire
guide and an output wire guide for a specific wire type and size.
Feed rolls are removed by twisting the feed roll retainer cap and aligning the retaining knob splines/tabs with the drive gear splines.
Feedrolls are installed by putting the feedroll onto the drive gear splines and twisting the feedroll retainer cap so that the splines/
tabs rest against the face of the feedroll where they will click into place.
NOTE
Installation of all styles of feed rolls for the Fabricator 252i are identical.
WARNING
The welding wire is electrically Hot if it is fed by depressing Fusion 250A MIG Gun switch. Electrode contact to work
piece will cause an arc with MIG Gun switch depressed.
INSTALLATION/SETUP 3-20 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
3.15 Input And Output Wire Guide Installation
NOTE
.035" / .045" (0.9 / 1.2 mm) feed rolls and guides are installed from the factory. Other sizes need to be purchased
separately.
Input Wire Guide - Install (the shorter one) by loosening the Input Guide Lock Screw and inserting the guide into the hole in the
feedhead assembly. Adjust the guide so that it is clear of the feed rolls and Tighten the Input Guide Lock Screw.
NOTE
Before tightening the Input and Output Guide Lock Screws, install the drive roll to help in the alignment of the wire
guides.
Output Wire Guide - With the Fusion 250A MIG Gun removed, loosen the MIG Adapter Lock Nut. This will aid with alignment.
Then loosen Output Guide Lock Screw. Install the Output Wire Guide (the longer one) by inserting the conical end part way into
the Tweco Adapter from the front of the machine. Now install the MIG Gun pressing the output guide further in until the tip of the
guide is as close to the feed rolls as practical. Secure the MIG Gun. Tighten the MIG Adapter Lock Nut, then tighten the Output
Guide Lock Screw.
Input Guide Lockscrew
Output Guide Lockscrew
MIG Gun
Lock
Screw
Input Wire Guide
MIG Gun
Art # A-10555
Output Wire Guide
Adapter Lock
Nut
Figure 3-15: Wire Guide Installation
Manual 0-5155 3-21 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.16 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 tri-lobe nut inside the open end of the wire reel hub. Clockwise rotation will
Tighten the brake. (Refer to Figure 3-16).
Wheel Brake adjusting tri-lobe nut
Art # A-10508_AB
Pressure Adjustment
Knob
Figure 3-16: Wire Installed
CAUTION
Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, over heating of electrical componentry and possibly an increased incidence of wire Burnback into the contact tip.
NOTE
Correct adjustment will result in the wire reel circumference continuing no further than 3/4" (19 mm) after release of
the MIG Gun trigger switch. The wire should be slack without becoming dislodged from the reel.
INSTALLATION/SETUP 3-22 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
3.17 Shielding Gas Regulator Operating Instructions
!
WARNING
This equipment is designed for use with welding grade (Inert) shielding gases only.
NOTE
Shielding Gas is not required if the unit is used with self shielded FCAW (flux cored arc welding) wires
Shielding Gas Regulator Safety
This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required
for the equipment using it.
If the equipment is improperly used, hazardous conditions are created that may cause accidents. It is the users responsibility
to prevent such conditions. Before handing or using the equipment, understand and comply at all times with the safe practices
prescribed in this instruction.
SPECIFIC PROCEDURES for the use of regulators are listed below.
1. NEVER subject the regulator to inlet pressure greater than its rated inlet pressure.
2. NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been relieved. Under pressure, gas can
dangerously propel a loose part.
3. Do NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator
high and low pressure chambers.
4. Do NOT use the regulator as a control valve. When downstream equipment is not in use for extended periods of time,
shut OFF the gas at the cylinder valve and release the gas from the equipment.
5. OPEN the cylinder valve SLOWLY. Close after use.
User Responsibilities
This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the
instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe
and reliable performance. Defective equipment should not be used. Parts that are broken, missing, obviously worn, distorted, or
contaminated should be replaced immediately.
The user of this equipment will generally have the sole responsibility for any malfunction, which results from improper use, faulty
maintenance, or by repair by anyone other than an accredited repairer.
CAUTION
Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a
cylinder containing any other gas.
Manual 0-5155 3-23 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
INLET
CONNECTION
OUTLET
CONNECTION
FLOW GAUGE (DELIVERY)
PRESSURE
ADJUSTING
SCREW
HIGH PRESSURE
GAUGE (SUPPLY)
Art # A-12126
Figure 3-17: Adjusting Flow Rate
NOTE
The regulator/flow meters used with argon based and carbon dioxide shielding gases are different. The regulator/flow
meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/
flow meter will need to be fitted.
NOTE
All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge. (Welding
power source must be triggered) Close the valves after the pressure has been set.
Installation
1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage
seats before connecting the regulator.
Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition. Wipe with
a clean lint free cloth.
2. Match regulator to cylinder. Before connecting, check that the regulator label and cylinder marking agree and that the
regulator inlet and cylinder outlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder
containing any other gas.
3. Connect the regulator inlet connection to cylinder or pipeline and Tighten it firmly but not excessively, with a suitable
spanner.
4. Attach supplied gas line between the regulator output and the desired input at the rear of the power source. MIG Spool
Gun and LIFT TIG in the bottom fitting and regular Fusion MIG Gun in the top fitting.
Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.
Art # A-10549
Figure 3-18: Attach gas line to proper inlet
5. To protect sensitive down-stream equipment a separate safety device may be necessary if the regulator is not fitted with
a pressure relief device.
INSTALLATION/SETUP 3-24 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
Operation
With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:
1. Stand to one side of regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage
internal regulator parts.
2. With valves on downstream equipment closed, adjust regulator to approximate working pressure. It is recommended that
testing for leaks at the regulator connection points be carried out using a suitable leak detection solution or soapy water.
3. Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by individually
opening then closing the equipment control valves. Complete purging may take up to ten seconds or more, depending
upon the length and size of the hose being purged.
Adjusting Flow Rate
Figure 3-19: Adjust Flow Rate
With the regulator ready for operation, adjust working flow rate as follows:
1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.
NOTE
It may be necessary to re-check the shielding gas regulator flow rate following the first weld sequence due to back
pressure present within shielding gas hose assembly.
2. To reduce flow rate, allow the welding grade shielding gas to discharge from regulator by opening the downstream valve.
Bleed welding grade shielding gas into a well ventilated area and away from any ignition source. Turn adjusting screw
counterclockwise, until the required flow rate is indicated on the gauge. Close downstream valve.
3. Adjust regulator pressure adjusting screw to the required flow rate, indicated on gauge dial. (Refer to Figure 3-19)
The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause
turbulence and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 28 - 35 CFH
- Outdoor welding: 35 - 46 CFH
Shutdown
Close cylinder valve whenever the regulator is not in use. To shut down for extended periods (more than 30 minutes).
1. Close cylinder or upstream valve LIFT Tightly.
2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition
source.
3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.
4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.
Manual 0-5155 3-25 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.18 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire
The Fabricator 252i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Gun. The Tweco Fusion 250A MIG Gun is designed
with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Gun uses standard readily available
Tweco Velocity consumable parts.
When using a non shielded wire, you need to have an external gas source attached to the unit.
For most Non Shielded Wire, connect the Work Lead to the negative - terminal and connect the MIG Gun polarity lead to the posi-
tive + terminal. If in doubt, consult the MIG electrode wire manufacturer.
Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.
Connect MIG Gun Polarity
Terminal to +/Positive
(Dinse® type 50)
+
-
Negative Output
Terminal
(Dinse® type 50)
Art # A-10550
Figure 3-20: MIG Gun Polarity Positive
1. Turn the Main ON/OFF switch OFF (located on the rear panel).
2. Check that the MIG wire size, contact tip, MIG Gun liner and drive roll groove are all the same size before fitting the MIG
wire into the Power Source.
3. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the MIG 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.
4. Fit the MIG wire spool and Fusion MIG Gun to the Power Source. (Refer to section 3.08 to 3.12 ).
5. Connect the work lead to the negative welding terminal (-). If in doubt, consult the MIG 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.
6. Fit the welding grade shielding gas regulator/flow gauge to the shielding gas cylinder (refer to Section 3.17) then connect
the shielding gas hose from the rear of the power source to the regulator/flow gauge outlet.
7. Turn the Main ON/OFF switch ON (located on the rear panel).
8. Select MIG mode with the process selection control. (Refer to Section 3.06.3 for further information)
9. Remove the Fusion MIG Gun nozzle and contact tip.
10. Depress MIG Gun trigger to feed the MIG wire out. Then fit the contact tip on the MIG wire and hand tighten the nozzle
in place.
11. Refer to the Weld Guide located on the inside of the wire feed compartment door for further information on Voltage/
Wirespeed settings.
INSTALLATION/SETUP 3-26 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
WARNING
Before connecting the work clamp to the work make sure the mains 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.
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.
NOTE
Depending on the type of wire you will be using the MIG Gun polarity may need to be switched. Follow the wire
manufacturers recommendation.
3.19 Set-up for MIG (FCAW) Welding with Gasless MIG Wire
The Fabricator 252i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Gun. The Tweco Fusion 250A MIG Gun is designed
with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Gun uses standard readily available
Tweco Velocity consumable parts.
When using a gasless flux cored wire, you do not need to have an external gas source attached to the unit. For most Self Shielded
Flux Cored Wire, connect the Work Lead to the positive + terminal and connect the MIG Torch polarity lead to the negative - terminal. If in doubt, consult the Flux Cored electrode wire manufacturer.
Connect MIG Torch Polarity
Terminal to -/Negative
®
(Dinse
+
-
Positive Output
type 50)
Terminal
®
(Dinse
Figure 3-21: MIG Gun Polarity Negative
type 50)
Art # A-10551
Manual 0-5155 3-27 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
1. Turn the Main ON/OFF switch OFF (located on the rear panel).
2. Check that the MIG wire size, contact tip, MIG Gun liner and drive roll groove are all the same size before fitting the MIG
wire into the Power Source.
3. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the MIG 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.
4. Fit the MIG (FCAW) wire spool and MIG Gun to the Power Source. (Refer to section 3.08 to 3.12).
5. Connect the work lead to the positive welding terminal (+). If in doubt, consult the MIG 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.
6. If gasless MIG (FCAW) wire is fitted then shielding gas is not required for welding. Otherwise fit the welding grade shielding
gas regulator/flow gauge to the shielding gas cylinder (refer to Section 3.17) then connect the shielding gas hose from
the rear of the power source to the regulator/flow gauge outlet.
7. Turn the Main ON/OFF switch ON (located on the rear panel).
8. Select MIG mode with the process selection control. (Refer to Section 3.06.4 for further information)
9. Remove the MIG Gun nozzle and contact tip.
10. Depress MIG Gun trigger to feed the MIG wire out. Then fit the contact tip on the MIG wire and hand tighten the nozzle
in place.
11. Refer to the Weld Guide located on the inside of the wire feed compartment door for further information on Voltage/
Wirespeed settings.
WARNING
Before connecting the work clamp to the work make sure the mains power 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.
NOTE
Depending on the type of wire you will be using the MIG Gun polarity may need to be switched. Follow the wire
manufacturers recommendation.
INSTALLATION/SETUP 3-28 Manual 0-5155
INSTALLATION/SETUP FABRICATOR 252i
+
-
Art # A-10580
Negative Output
Terminal
(Dinse® type 50)
Ensure that the gas
cylinder is secured to
a building pillar, wall
bracket or otherwise
securely fixed in an
upright position.
3.20 Set-up for LIFT TIG (GTAW) Welding
!
WARNING
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
NOTE
The following steps will assume that you have already set up the proper shielding gas as outlined in Sub Section 3.17.
NOTE
The following set up is known as Straight Polarity or DC Electrode Negative. This is commonly used for DC LIFT
TIG welding on most materials such as steel and stainless steel.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Connect the work lead cable to the positive output terminal, and the LIFT TIG Torch cable to the negative output terminal.
Refer to Figure 3-23.
3. Connect the gas line/hose to the proper shielding gas source. Refer to Figure 3-23.
4. Slowly open the Argon Cylinder Valve to the fully open position.
5. Connect the work lead clamp to your work piece.
6. The tungsten must be ground to a blunt point (similar to a pencil) in order to achieve optimum welding results. See
illustration. It is critical to grind the tungsten electrode in the direction the grinding wheel is turning. Grind at a 30 degree
angle and never to a sharp point.
2 to 2-1/2 Times
Electrode Diameter
Electrode
Art # A-00503_AB
Figure 3-22: Electrode sharpening
7. Install the tungsten with approximately 1/8" to 1/4"(3.2mm to 6.4mm) sticking out from the gas cup, ensuring you have
correct sized collet.
8. Tighten the back cap.
9. Turn the switch to the “ON” position. The power L.E.D. light should illuminate.
10. Set the welding process to LIFT TIG.
11. Set the Weld Current Control Knob to the desired amperage.
Figure 3-23: Setup for LIFT TIG (GTAW) Welding
12. You are now ready to begin LIFT TIG Welding.
Manual 0-5155 3-29 INSTALLATION/SETUP
FABRICATOR 252i INSTALLATION/SETUP
3.21 Set-up for STICK Metal Arc Welding (SMAW)
!
WARNING
Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment.
NOTE
The following set up is known as DC Electrode Positive or reverse polarity. Please consult with the STICK electrode
manufacturer for specific polarity recommendations.
1. Switch the ON/OFF Switch (located on the rear panel) to OFF.
2. Attach the STICK and Work Leads as shown in Figure 3-24.
Art # A-10553
+
Figure 3-24: Setup for STICK Welding reverse polarity shown.
3. Set the welding process to STICK.
4. Set the Weld Current Control Knob to the desired amperage.
5. Install a STICK electrode in the electrode holder.
6. You are now ready to begin STICK Welding.
To weld, gently strike the electrode on the work piece to generate a welding arc, and slowly move along the work
piece while holding a consistent arc length above base metal.
-
NOTE
Negative Output
Terminal
(Dinse® type 50)
INSTALLATION/SETUP 3-30 Manual 0-5155
BASIC WELDING FABRICATOR 252i
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
GMAW Process
Nozzle
Electrode
Arc
Base Metal
Art # A-8991_AB
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.
Figure 4-1
FLUX CORED ARC WELDING (FCAW): This is an electric arc
welding process which fuses together the parts to be welded
by heating them with an arc between a continuous flux filled
electrode wire and the work. Shielding is obtained through
decomposition of the flux within the tubular wire. Additional
shielding may or may not be obtained from an externally supplied gas or gas mixture. The process is normally applied semi
automatically; however the process may be applied automatically or by machine. It is commonly used to weld large diameter
electrodes in the flat and horizontal position and small electrode
diameters in all positions. The process is used to a lesser degree
for welding stainless steel and for overlay work.
CAUTION
Do NOT pull the MIG Gun back when the arc is established. This will create excessive wire extension
(stick-out) and make a very poor weld.
The electrode wire is not energized until the MIG Gun trigger
switch is depressed. The wire may therefore be placed on the
seam or joint prior to lowering the helmet.
5° to 15°
Longitudinal
Angle
Direction of
90°
Travel
Transverse
Angle
Figure 4-4
Manual 0-5155 4-1 BASIC WELDING
FABRICATOR 252i BASIC WELDING
10° to 20° Longitudinal
Direction of Travel
5° to 15°
Longitudinal Angle
30° to 60°
Transverse Angle
Direction of
Travel
Art # A-08994
Figure 4-5
10°
Longitudinal Angle
30° to 60°
Transverse
Angle
Direction of Travel
Vertical Fillet Welds
Angle
30° to 60°
Transverse
Angle
Art # A-08995
Figure 4-6
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.
30° to 60°
Transverse Angle
5° to 15°
Longitudinal
Angle
Art # A-08996
Overhead Weld
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
2. Wire Feed Speed. Increase in wire feed speed increases
weld current, Decrease in wire feed speed decreases
weld current.
Preselected Variables
Preselected variables depend upon the type of material being
welded, the thickness of the material, the welding position, the
deposition rate and the mechanical properties. These variables
are:
• Type of electrode wire
• Size of electrode wire
• Type of gas (not applicable 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
These variables cause changes in primary adjustable variables
which in turn cause the desired change in the bead formation.
They are:
Gas Nozzle
Tip to
Work Distance
Average Arc Length
Electrode Stick-Out
Contact Tip (Tube)
Electrode Wire
Actual Stick-out
Art # A-08997_AD
Figure 4-8
3. Nozzle Angle. This refers to the position of the 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) 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.
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
BASIC WELDING 4-2 Manual 0-5155
BASIC WELDING FABRICATOR 252i
Transverse
Direction of Gun Travel
Angle
Longitudinal
Angle
Axis of Weld
Transverse and Longitudinal
Nozzle Axes
Art # A-08998_AB
Figure 4-9
Leading or “Pushing”
Angle
(Forward Pointing)
Nozzle Angle, Right Handed Operator
90°
Trailing or “Pulling”
Angle
(Backward Pointing)
Art # A-08999_AC
Figure 4-10
Establishing the Arc and Making Weld Beads
Before attempting to weld on a finished piece of work, it is
recommended that practice welds be made on a sample metal
of the same material as that of the finished piece.
The easiest welding procedure for the beginner to experiment
with MIG welding is the flat position. The equipment is capable
of flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 1/16" or
3/16" (1.6 mm or 5.0 mm) mild steel plate 6" x 6" (150 mm x
150 mm). Use .035" (0.9 mm) flux cored gasless wire or a solid
wire with shielding gas.
Setting of the Power Source
Power source and Wirefeeder setting requires some practice
by the operator, as the welding plant has two control settings
that have to balance. These are the Wirespeed control (refer
to section 3.06.4) 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
The choice of Electrode wire size and shielding gas used de-
pends on the following:
• Thickness of the metal to be welded
• Type of joint
• Capacity of the wire feed unit and Power Source
• The amount of penetration required
• The deposition rate required
• The bead prole desired
• The position of welding
• Cost of the wire
Manual 0-5155 4-3 BASIC WELDING
FABRICATOR 252i BASIC WELDING
Tweco MIG, Lift TIG, Stick Wire Selection Chart
A-12128
Figure 4-11
BASIC WELDING 4-4 Manual 0-5155
BASIC WELDING FABRICATOR 252i
!
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.
Problem 1 - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant
within the molten weld pool which is in the process of escaping during solidification of the molten metal. Contaminants range
from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points.
FAULT/CONDITION CAUSE
1
Shielding gas cylinder contents
and flow meter.
2
Gas leaks. Check for gas leaks between the regulator/cylinder connection
3
Internal gas hose in the Power
Source.
4
Welding in a windy environment. Shield the weld area from the wind or increase the gas flow.
Ensure that the shielding gas cylinder is not empty and the
flow meter is correctly adjusted to 31.75 CFH.
and in the gas hose to the Power Source.
Ensure the hose from the solenoid valve to the MIG Gun
adaptor has not fractured and that it is connected to the MIG
Gun adaptor.
5
Welding dirty, oily, painted,
Clean contaminates off the work piece.
oxidized or greasy plate.
6
Distance between the MIG Gun
nozzle and the work piece.
7
Maintain the MIG Gun in good
working order.
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 torch 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 4-1: MIG (GMAW / FCAW) Welding Troubleshooting
Problem 2 - 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.
Manual 0-5155 4-5 BASIC WELDING
FABRICATOR 252i BASIC WELDING
FAULT CAUSE
1
Feed roller driven by motor in the
cabinet slipped.
2
Wire spool unwound and tangled. Wire spool brake is too loose.
Wire spool brake is too tight.
3
Worn or incorrect feed roller size.
4
Wire rubbed against the misaligned
guides and reduced wire feed ability.
5
Liner blocked with swarf.
6
Incorrect or worn contact tip.
7
Poor work lead contact to work piece.
A
Use a feed roller matched to the size you are welding.
B
Replace feed roller if worn.
Misalignment of inlet/outlet guides
A
Increased amounts of swarf are produced by the wire 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 accumulates thus
reducing wire feed ability.
A
The Velocity contact tip transfers the weld current to the electrode
wire. If the hole in the contact tip is too large then arcing may
occur inside the contact tip resulting in the wire jamming in the
contact tip.
B
When using soft wire such as aluminum it may become jammed
in the contact tip due to expansion of the wire when heated. A
Velocity contact tip designed for soft wires should be used.
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 4-2: Wire Feeding Problems
Basic MIG (GMAW/FCAW) Welding Troubleshooting
FAULT CAUSE REMEDY
1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed.
B Incorrect MIG Gun angle B Adjust angle.
C Excessive heat input C Increase the MIG Gun travel speed and/or decrease
welding current by decreasing the voltage or
decreasing the wire feed speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed
speed and increasing voltage.
B Joint preparation too narrow
B Increase joint angle or gap.
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.
BASIC WELDING 4-6 Manual 0-5155
BASIC WELDING FABRICATOR 252i
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.
5 Irregular weld shape A Incorrect voltage and current
settings. Convex, voltage too
A Adjust voltage and current by adjusting the voltage
control and the wirespeed control.
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
D Adjust the wirespeed control or the voltage control.
input
6 Weld cracking A Weld beads too small A Decrease travel speed
B Weld penetration narrow and
deep
B Reduce current and voltage and increase MIG Gun
travel speed or select a lower penetration shielding gas.
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 slowly.
7 Cold weld puddle A Loose welding cable connection. A Check all welding cable connections.
B Low primary voltage B Contact supply authority.
C Fault in power source C Have an Accredited Tweco Service Provider test then
replace the faulty component.
8 Arc does not have
a crisp sound that
short arc exhibits
when the wirefeed
The MIG Gun has been
connected to the wrong
voltage polarity on the front
panel.
speed and voltage are
adjusted correctly.
9 Poor weld result
from setup chart
parameters
Contact tip has arc marks in
the bore causing excessive
drag on the wire.
Table 4-3: MIG (GMAW /FCAW) Welding Problems
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.
Connect the MIG Gun to the positive (+) welding
terminal for solid wires and gas shielded flux cored
wires. Refer to the electrode wire manufacturer for
the correct polarity.
Replace the contact tip with only a Genuine Tweco
Velocity contact tip.
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.
Manual 0-5155 4-7 BASIC WELDING
FABRICATOR 252i BASIC WELDING
Art # A-07688
Art # A-07689
Art # A-07690
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
Figure 4-13: Flat Position, Gravity Fillet Weld
Figure 4-14: Horizontal Position, Butt Weld
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 regard-
less 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 4-12
through 4-19.
Figure 4-15: Horizontal-Vertical (HV) Position
Art A-07691
Figure 4-16: Vertical Position, Butt Weld
Art # A-07692
Figure 4-17: Vertical Position, Fillet Weld
Art # A-07687
Figure 4-12: Flat Position, Down Hand Butt Weld
Art# A-07693
Figure 4-18: Overhead Position, Butt Weld
BASIC WELDING 4-8 Manual 0-5155
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(
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
Art # A-07694
Figure 4-19: Overhead Position, Fillet Weld
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.
of the weld metal and to produce sound joints.
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 4-20: 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.
Manual 0-5155 4-9 BASIC WELDING
FABRICATOR 252i BASIC WELDING
20°-30°
The Welder
Place yourself in a comfortable position before beginning to
weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude
of mind and a tensed body will soon make you feel tired. Relax
and you will find that the job becomes much easier. You can
add much to your peace of mind by wearing a leather apron
and gauntlets. You won't be worrying then about being burnt
or sparks setting alight to your clothes.
Place the work so that the direction of welding is across, rather
than to or from, your body. The electrode holder lead should
be clear of any obstruction so that you can move your arm
freely along as the electrode burns down. If the lead is slung
over your shoulder, it allows greater freedom of movement and
takes a lot of weight off your hand. Be sure the insulation on
your cable and electrode holder is not faulty, otherwise you are
risking an electric shock.
Striking the Arc
Practice this on a piece of scrap plate before going on to more
exacting work. You may at first experience difficulty due to the
tip of the electrode "sticking" to the work piece. This is caused
by making too heavy a contact with the work and failing to
withdraw the electrode quickly enough. A low amperage will
accentuate it. This freezing-on of the tip may be overcome by
scratching the electrode along the plate surface in the same
way as a match is struck. As soon as the arc is established,
maintain a 1/16" -1/8" (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
Rate of Travel
After the arc is struck, your next concern is to maintain it,
and this requires moving the electrode tip towards the molten
pool at the same rate as it is melting away. At the same time,
the electrode has to move along the plate to form a bead. The
electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed
bead is produced.
If the travel is too fast, the bead will be narrow and strung out
and may even be broken up into individual globules. If the travel
is too slow, the weld metal piles up and the bead will be too large.
Making Welded Joints
Having attained some skill in the handling of an electrode, you
will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in
Figure 4-22, 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.
1/16” (1.6 mm)
Figure 4-21: Striking an Arc
Arc Length
The securing of an arc length necessary to produce a neat weld
Tack Weld
Electrode
Figure 4-22: Butt Weld
Tack Weld
Art # A-07697_AB
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.
Figure 4-23: Weld Build up Sequence
Art # A-07698
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BASIC WELDING FABRICATOR 252i
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
4-23. The width of weave should not be more than three
times the core wire diameter of the electrode. When the
joint is completely filled, the back is either machined,
ground or gouged out to remove slag which may be trapped
in the root, and to prepare a suitable joint for depositing
the backing run. If a backing bar is used, it is not usually
necessary to remove this, since it serves a similar purpose
to the backing run in securing proper fusion at the root
of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-section
made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-15.
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
4-24. 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. Multi-runs can be made as shown
in Figure 4-25. Weaving in HV fillet welds is undesirable.
45° from
vertical
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 4-26. 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 4-27 illustrates
multi-run technique and Figure 4-28 shows the effects
of pausing at the edge of weave and of weaving too
rapidly.
Art # A-07701
Figure 4-26: Single Run Vertical Fillet Weld
Art # A-07702
60° - 70° from line
of weld
Art # A-07699_AB
Figure 4-24: Electrode Position for HV Fillet Weld
Art # A-07700_AB
Figure 4-27: Multi Run Vertical Fillet Weld
6
3
1
Figure 4-25: Multi-runs in HV Fillet Weld
Manual 0-5155 4-11 BASIC WELDING
5
2
4
FABRICATOR 252i BASIC WELDING
Upsetting
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.
Art # A-07703
Figure 4-28: Examples of Vertical Fillet Welds
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 4-29). 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.
Art # A-07704
Figure 4-29: Overhead Fillet Weld
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume
on cooling to room temperature. This means that a cube
of molten metal would contract approximately 2.2 per
cent in each of its three dimensions. In a welded joint, the
metal becomes attached to the side of the joint and cannot
contract freely. Therefore, cooling causes the weld metal
to flow plastically, that is, the weld itself has to stretch if
it is to overcome the effect of shrinking volume and still
be attached to the edge of the joint. If the restraint is very
great, as, for example, in a heavy section of plate, the weld
metal may crack. Even in cases where the weld metal does
not crack, there will still remain stresses "Locked-up" in
the structure. If the joint material is relatively weak, for
example, a butt joint in 5/64" (2.0 mm) sheet, the contracting weld metal may cause the sheet to become distorted.
B. Expansion and Contraction of Parent Metal in the
Fusion Zone:
While welding is proceeding, a relatively small volume of
the adjacent plate material is heated to a very high temperature and attempts to expand in all directions. It is able
to do this freely at right angles to the surface of the plate
(i.e., "through the weld", but when it attempts to expand
"across the weld" or "along the weld", it meets considerable
resistance, and to fulfill the desire for continued expansion,
it has to deform plastically, that is, the metal adjacent to the
weld is at a high temperature and hence rather soft, and, by
expanding, pushes against the cooler, harder metal further
away, and tends to bulge (or is "upset". When the weld
area begins to cool, the "upset" metal attempts to contract
as much as it expanded, but, because it has been "upset"
it does not resume its former shape, and the contraction
of the new shape exerts a strong pull on adjacent metal.
Several things can then happen.
The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful
contraction stresses (distortion), or the weld may crack, in
any case, there will remain "locked-up" stresses in the job.
Figures 4-30 and 4- 31 illustrate how distortion is created.
Art # A-07705_AB
Weld
Expansion with
compression
Cool
Hot
Hot
Figure 4-30: Parent Metal Expansion
BASIC WELDING 4-12 Manual 0-5155
BASIC WELDING FABRICATOR 252i
Weld
Art # A-07706_AC
Permanent Upset
Contraction
with tension
Figure 4-31: Parent Metal Contraction
Overcoming Distortion Effects
There are several methods of minimizing distortion effects.
A. Peening
This is done by hammering the weld while it is still hot.
The weld metal is flattened slightly and because of this the
tensile stresses are reduced a little. The effect of peening
is relatively shallow, and is not advisable on the last layer.
B. Distribution of Stresses
Distortion may be reduced by selecting a welding sequence
which will distribute the stresses suitably so that they tend
to cancel each other out. See Figures 4-31 through 4-34
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 4-32.
Art # A-07708
B
Dotted lines show effect if no preheat is used
Weld
C
PreheatPreheat
Figure 4-33: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-34: Examples of Distortion
3
Art # A-07710_AB
1
2
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-35: Welding Sequence
3
2
4
Art # A-07711_AB
1
Figure 4-36: Step back Sequence
E. Preheating
Suitable preheating of parts of the structure other than the
area to be welded can be sometimes used to reduce distortion. Figure 4-33 shows a simple application. By removing
the heating source from b and c as soon as welding is
completed, the sections b and c will contract at a similar
rate, thus reducing distortion.
Art # A-07707
Figure 4-32: Principle of Presetting
Figure 4-37: Chain Intermittent Welding
Art # A-07713_AB
Figure 4-38: Staggered Intermittent Welding
Art # A-07428_AB
Manual 0-5155 4-13 BASIC WELDING
FABRICATOR 252i BASIC WELDING
Electrode Selection Chart
Metal Being Joined Electrode Comments
Mild Steel E6010 This electrode is used for all-position welding or for welding on rusty, dirty,
less-than-new metal. It has a deep, penetrating arc and is used for pipe and
repair welding.
Mild Steel E6011 This electrode is used for all-position welding on sheet metal or for welding
on plated, dirty, painted or greasy steel. It has a deep, penetrating arc and
is often the first choice for repair or maintenance work.
Mild Steel E6013 This all-position, electrode is used for welding clean, new sheet metal. Its
soft arc has minimal spatter, moderate penetration and an easy-to-clean
slag.
Mild Steel E7014 All positional, easy to use electrode for use on thicker steel than E6013.
Especially suitable for sheet metal lap joints and fillet welds, general
purpose plate welding.
Mild Steel E7018 A low-hydrogen, all-position electrode used when quality is an issue or for
hard-to-weld metals. It has the capability of producing more uniform weld
metal, which has better impact properties at low temperatures.
Cast Iron ENi-Cl Suitable for joining all cast irons except white cast iron.
Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc.
Table 4-4: Tweco Electrode Selection Chart
BASIC WELDING 4-14 Manual 0-5155
BASIC WELDING FABRICATOR 252i
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
particles are
trapped in the
weld metal.
ARC FORCE is set at a
value that causes the
welding current to vary
excessively with the arc
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.
length.
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
E Clean joint before welding.
preventing full fusion.
F Wrong electrode for
position in which welding
is done.
Art # A-04273
Figure 4-39: Example of insufficient gap or incorrect sequence
F Use electrodes designed for position in which
welding is done, otherwise proper control of slag
is difficult.
Incorrect sequence
Insufficient
gap
Table 4-5a:
Manual 0-5155 4-15 BASIC WELDING
FABRICATOR 252i BASIC WELDING
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 inter-run fusion
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Figure 4-40: Example of Lack of Fusion
Table 4-5b: STICK (SMAW) metal welding trouble shooting
Art # A-04274_AB
Lack of Root Fusion
BASIC WELDING 4-16 Manual 0-5155
BASIC WELDING FABRICATOR 252i
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
Tungsten Electrode Current Ranges
Table 4-6: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
Figure 4-41: TIG (GTAW) Welding Application Shot
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
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
Manual 0-5155 4-17 BASIC WELDING
FABRICATOR 252i BASIC WELDING
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Zirconated 1%
Ceriated 2%
The Fabricator 252i Inverter is not suited for AC TIG welding.
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
Red
White
Grey
BASIC WELDING 4-18 Manual 0-5155
BASIC WELDING FABRICATOR 252i
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
Joint Type
Flow Rate
CFH
10-15 Butt/Corner
Lap/Fillet
10-15 Butt/Corner
Lap/Fillet
15 Butt/Corner
Lap/Fillet
15 Butt/Corner
Lap/Fillet
20 Butt/Corner
Lap/Fillet
20 Butt/Corner
Lap/Fillet
Manual 0-5155 4-19 BASIC WELDING
FABRICATOR 252i BASIC WELDING
4.06 TIG (GTAW) Welding Problems
FAULT CAUSE
1 Excessive beard build up
or poor penetration or poor
fusion at edges of weld.
2 Weld bead too wide and
flat or undercut at edges
of weld or excessive burn
through.
3 Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
4 Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
5 Uneven leg length in fillet
joint
6 Electrode melts or oxidizes
when an arc is struck.
Welding current is too
low
Welding current is too
high
Travel speed too fast Reduce travel speed.
Travel speed too slow Increase travel speed.
Wrong placement of
filler rod
A TIG Torch lead
connected to positive
welding terminal.
Increase weld current and/or faulty joint
preparation.
Decrease weld current.
Re-position filler rod.
A Connect TIG Torch lead to negative
welding terminal.
REMEDY
B No gas flowing to
welding 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 0-5155
BASIC WELDING FABRICATOR 252i
FAULT CAUSE
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.
REMEDY
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 Table 4-6 Tweco Electrode Selection
Chart.
B Select the right electrode type. Refer
to Table 4-8 Tweco Electrode Selection
Chart.
C Select the right rate for the welding job.
Refer to Table 4-10.
10 Arc flutters during TIG
welding.
D Incorrect shielding gas
is being used.
E Poor work clamp
connection to work
piece.
Tungsten electrode
is too large for the
welding current.
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 Table 4-6 Tweco Electrode Selection
Chart.
Manual 0-5155 4-21 BASIC WELDING
FABRICATOR 252i BASIC WELDING
This Page Intentionally Blank
BASIC WELDING 4-22 Manual 0-5155
PROBLEMS/SERVICE FABRICATOR 252i
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE
REQUIREMENTS
5.01 Power Source Problems
Error Code CAUSE REMEDY
ERR
01
ERR
02
ERR 03VBIAS Voltage Low
ERR
04
ERR
08
ERR
09
ERR 10Inverter Output Fault Substandard output voltage
ERR
14
ERR
15
ERR
23
ERR 24Code Memory Fault Welder detected a fault in
ERR 25Nonvolatile Memory
ERR 26Unknown PCB Fault Welder control board cannot
Over Temperature
Fault
Input Power Fault Signal from Power board
Fault
Ground Fault Excessive current detected on
Input Sensor Fault Unexpected reading of voltage or
Fan Fault Cooling Fan Failure detected on
Trigger Fault Fault occurred detecting trigger
Wirefeed Fault Welder detects prolonged open
Weld Fault Welder detected a fault during
Fault
OverTemp signal from Power
board indicates Over temperature
fault condition of power
components
indicates input power voltage is
out of range (too high or too low)
Controller board circuit monitor
indicates 15 volt supply is too
low
(< 13.7 VDC)
Ground wire of power connection
current sensor during power-up
self test
Inverter board
condition detected by controller
before weld started
state/condition
circuit during MIG weld
the weld process
program flash memory
Welder detected a fault in
parameter NVROM.
identify an attached inverter
board and/or determine its own
identity
A. Decrease duty cycle of welding activity
B. Ensure that air vents are not blocked/obstructed
C. Consult an Accredited Tweco Service Provider.
A. Check input power connections and cables for
damage or improper insertion
B. Verify input voltage levels meet product
requirements
Consult an Accredited Tweco Service Provider.
A. Isolate welder chassis from work piece. Check
workpiece ground connection.
B. Check for MIG wire feed problem in spool/
feedplate. Verify wire is not contacting chassis.
A. Inspect ribbon cable between power supply and
display board.
B. Consult an accredited Tweco service provider.
A. Examine fan vents for potential obstruction.
B. Consult an Accredited Tweco Service Provider.
Consult an Accredited Tweco Service Provider.
A. Trigger may be already activated when MIG
process mode is selected - verify that trigger is not
accidentally activated
B. Trigger may be faulty and/or dirty, test and
replace MIG Gun/trigger device
A. Inspect MIG wire spool and feedplate for
improper tension or 'bird's nest'.
B. Inspect MIG Gun and cable for damage or
obstruction
C. Consult an Accredited Tweco Service Provider.
Consult an Accredited Tweco Service Provider if
symptom recurs frequently.
Firmware image is corrupted. Consult an
Accredited Tweco Service Provider.
A. Welding may still be possible, but no weld
setting changes can be saved.
B. Consult an Accredited Tweco Service Provider.
Consult an Accredited Tweco Service Provider.
Manual 0-5155 5-1 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 252i PROBLEMS/SERVICE
!
ERR 30Service Mode Switch
Fault
ERR
31
ERR
33
ERR 34User Calibration Abort User-initiated abort/interruption
ERR
35
Note 1: If the left display is alternate flashing "Err" and "Code" this is indicating that the fault was detected but has either
stopped occurring or is in the process of clearing itself. If this is the case, the flashing error message will return to
normal display functionality within 10 seconds unless another fault occurs. If the left display shows a steady "Err" this is
indicating that the fault is persistent and is still being detected.
Note 2: Flashing Amperage and Voltage displays (when welding) indicates that the machines maximum output power
rating (300A x 26.7V = 8kVA) is being exceeded and the system is automatically reducing the output. If welding is ceased
while the displays are flashing, the last values will be displayed for 10 seconds or until controls are adjusted.
Controller Fault Welder control board has
Calibration Fault An output (current, voltage, or
Parameter Fault Welder control board has
SERVICE DIP switch is enabled Welding is disabled while SERVICE Mode DIP
switch is enabled. Disable SERVICE Mode switch
to resume welding.
Consult an Accredited Tweco Service Provider if
detected a hardware fault on
itself
motor) fault was detected while
attempting a calibration process
of an active calibration process
occurred (usually, release of
trigger too early)
detected a parameter out of
range
Table 5-1: Power Source Problems
symptom recurs frequently.
A. Check integrity of welder cables, MIG Gun or
electrode holder and retry calibration.
B. Check MIG wire spool, feedplate area for wire
feed issues, correct and retry calibration
Restart/reselect calibration process and retry
calibration when ready.
System Parameter re-initialization has been
automatically performed or is required (Factory
Default Reset)
5.02 Routine Service and Calibration Requirements
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 Mains Supply Voltage before disassembling.
Routine Inspection, Testing & Maintenance
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 0-5155
PROBLEMS/SERVICE FABRICATOR 252i
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/Grounding
The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -
Minimum Insulation
Resistance (MΩ)
5
2.5
10
1
1
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 -
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.
Power Source Calibration
A. Schedule
Output testing of all Tweco Power Sources and applicable accessories shall be conducted at regular intervals to ensure
they fall within specified levels. Calibration intervals shall be as outlined below -
1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
Manual 0-5155 5-3 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 252i PROBLEMS/SERVICE
B. Calibration Requirements
Where applicable, the tests outlined in Table 5-4 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 (Inches Per Minute) 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
specifications
Table 5-4: 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 0-5155
PROBLEMS/SERVICE FABRICATOR 252i
5.03 Cleaning the Welding Power Source
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
Figure 5-1: Routine Cleaning
Manual 0-5155 5-5 PROBLEMS AND ROUTINE SERVICE
FABRICATOR 252i 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 0-5155
REPLACEMENT PARTS FABRICATOR 252i
1
SECTION 6: KEY SPARE PARTS
6.01 Fabricator 252i Power Supply Replacement Panels
4
3
2
Figure 6-1
5
6
7
8
Art # A-10784_AB
FABRICATOR 252i POWER SOURCE SPARE PARTS (Panels/Sheet Metal)
ITEM PART NUMBER DESCRIPTION
1 W7005323 Latch, Slide
2 W7005438 Door, 252i
3 W7005385 Panel, Rear, 252i
4 W7005439 Panel, Side, 252i
5 W7005303 Bkt, Spool Support, 252i
6 W7005300 Panel, Center, 252i
7 W7005437 Panel, Front 252i
8 831596 Door chart label
Table 6-1
Manual 0-5155 6-1 REPLACEMENT PARTS
FABRICATOR 252i REPLACEMENT PARTS
1
2
4
5
7
3
6
Art # 10332_AD
8
10
9
11
12
Figure 6-2
FABRICATOR 252i POWER SOURCE SPARE PARTS (LEFT SIDE)
ITEM PART NUMBER DESCRIPTION
1 W7005311 Spool Hub Assembly
2 W7005353 Wire Drive Assembly, 250i. (Does not include motor)
3 375838-002 Guide, Inlet 0.6-1.6mm
4 See Appendix 1 Roll, Pressure No Groove
5 See Appendix 1 Roll, Feed Dual V
6 W6000801 Guide, Outlet 0.9-1.2mm
7 W7005354 Motor, Wire Drive, RH, 20VDC.
8 W7005361 Retainer, Drive Gear, 2R
9 871001PKD Idler Gear
10 870560PKD Drive Gear
11 W7005379 Black Plastic Spacer
12 831508 Clear Mylar Sheet
REPLACEMENT PARTS 6-2 Manual 0-5155
Table 6-3
REPLACEMENT PARTS FABRICATOR 252i
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Art # A-10668_AB
19
20
21
22
Figure 6-3: Right side and Front Replacement Parts
FABRICATOR 252i POWER SOURCE SPARE PARTS (RIGHT SIDE AND FRONT)
ITEM PART NUMBER DESCRIPTION
1 W7005330 PCB, 252i Main Power
2 W7005318 Circuit Breaker, 50A (On Off Switch)
3 W7005316 Fan, 92x38 HS 24V
4 W7005317 Fan, 92x25 LS 24V
5 W7005322 Shroud, Heatsink Tunnel
6 W7005331 PCB, Mov/Bridge, 250A
7 W7005302 Transformer, Main, 252i
8 W7005315 Solenoid,24V,0-0.8MPa
9 W7005301 Inductor, 252i
10 W7005355 Circuit Breaker, PB, 8A
11 W7005354 Motor, Wire Drive, RH, 20VDC
12 W7005357 Socket 10 pin (Note: 10 pin Control Plug Part# is W7005358)
13 W7005381 Dinse, Socket Panel, 50mm
14 W7003036 Socket 8 pin (Note: 8 pin Control Plug Part# is UOA706900)
15 W7005308 Assy, Polarity Cable, 252i
16 W7005335 Knob, 15/64", D Shaft, Snap Fit
17 W7005436 Panel, Control, 252i (w/label)
18 W7005381 PCB, Control Assy, 252i
19 W7005352 Ribbon Cable
20 W7005362 Panel Mounted Gas Fitting
21 W7005305 Wiring Harness, with plugs
22 W7005324 Current Transformer
Manual 0-5155 6-3 REPLACEMENT PARTS
Table 6-3
FABRICATOR 252i REPLACEMENT PARTS
6.02 Tweco Fusion 250A MIG Gun
Torch Part No: FV215TA-3545
Art# A-11673_AB
Figure 6-4: Tweco Fusion 250 A MIG Gun
REPLACEMENT PARTS 6-4 Manual 0-5155
REPLACEMENT PARTS FABRICATOR 252i
Item
No.
1 Velocity Nozzle*
2 Velocity Contact Tip*
Velocity 45˚ Conductor Tube
3
Velocity 60˚ Conductor Tube
4 Handle Halves w/screws F84
5 Trigger – Standard ELC84
6 Trigger Blade Assembly ELC94-BL
7 Gun Hanger 152
Description Part No.
VNS-50
VNS-50F
VNS-62
VNS-62F
VNS-37
VNS-37F
VNS-75FAS
VTS-23
VTS-30
VTS-35
VTS-40
VTS-45
VTSA-364
VTS-52
VTS-116
VTSA-116
VTS-564
FVCT-S45
FVCT-S60
Item
No.
Cablehoz Assembly – 10 ft (3 m) MS210
Cablehoz Assembly – 12 ft (4 m) MS212
Cablehoz Assembly – 15 ft (5 m) MS210
Cablehoz Assembly – 25 ft (8 m) MS225
NS
Cablehoz Assembly, Euro-Kwik
– 12 ft (4 m)
Cablehoz Assembly, Euro-Kwik
8
9
10
11
12
– 15 ft (5 m)
Cablehoz Assembly, Euro-Kwik
– 25 ft (8 m)
Cablehoz Front Mechanical
8A
Connector Replacement Kit
Cablehoz Rear Mechanical
8B
Connector Replacement Kit
Cablehoz Front Mechanical
8C
Connector Replacement Kit for
Euro-Style
9A Miller® Rear Connector 350-174MH
9B Miller® Control Wire & Plug WM354-M
10A Tweco® Rear Connector 350-174H
10B Tweco Control Wire & Plug 35K-350-1
10C Tweco Control Wire & Plug WS-354-TA-LC
11A Lincoln® Rear Connector 350-174HXL
11B Lincoln® Control Wire & Plug WM354-M
12A Euro-Kwik Connection Assembly 174EX-1
12B Euro-Kwik Nut 174X-2
12C Euro-Kwik Connector Case X6RC
13 Conduit Assembly** **
Description Part No.
MS102-RK
MS172-RK
Table 6-4: Tweco Fusion 250 A MIG Gun Parts
MS212X
MS215X
MS225X
172X-M
* Patent Pending
** Refer to Tweco Catalog No. for specific parts.
MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN is a registered trademark of LINCOLN Electric
Co.; The aforementioned registered trademarks are no way affiliated with Tweco Products, Inc. or Victor Technologies. Tweco is a registered trademark of Victor
Technologies.
Manual 0-5155 6-5 REPLACEMENT PARTS
FABRICATOR 252i REPLACEMENT PARTS
This Page Intentionally Blank
REPLACEMENT PARTS 6-6 Manual 0-5155
APPENDIX FABRICATOR 252i
APPENDIX 1: OPTIONS AND ACCESSORIES
Description Part Number
Tweco Fusion 250A MIG Gun, 15ft 1023-1097
26 TIG torch 12.5ft (3.8m); accessory kit with 1/16”, 3/32”, 1/8”
thoriated tungstens with collets, collet bodies No.5,6,7 Alumina
Nozzle - Gas Hose 9” (230mm) long with 5/8” 18 UNF male
fitting, Torch switch & remote current control with 8 pin plug
Gas Hose,12.5ft,Male 5/8-18UNF W4013900
Roll Cage, 252i W4015101
Large HD Cart,Single Cylinder,211i-252i W4015001
Large HD Cart, Dual Cylinder, 211i-252i W4015002
Basic Utility Cart, Single Cylinder, 211i-252i W4014700
Adapter Cable for Miller® Spool Gun SG200M30AJC
Accessory Kit P062900010
Table A-1: Options and Accessories
W4013600
FLUX
CORED
.045”, 1/16”
SOFT
.035”, 3/64”
Art # A-10669
Top
Drive
Roll
Bottom
Drive
Roll
HARD
.023”, .035”
FLUX
CORED
.030”, .035”
Figure A-1: Drive Roll Chart
Wire Size Wire Type Top Drive Roll Bottom Drive Roll Inlet Guide Outlet Guide
.023" (0.6mm) Hard 407002-001 407002-002 375407-001 W6000803
.030" (0.8mm) Hard 407002-001 407002-009 375407-001 W6000804
.035" (0.9mm) Hard 407002-001 407002-009 375407-001 W6000804
.045" (1.2mm) Hard 407002-001 407002-009 375407-001 W6000804
.030" (0.8mm) Flux Cored 375832 407002-009 375407-001 W6000804
.035" (0.9mm) Flux Cored 375832 407002-009 375407-001 W6000804
.045" (1.2mm) Flux Cored 170924-010 170924-010 375407-001 W6000804
1/16" (1.6mm) Flux Cored 170924-001 170924-001 375407-001 W6000805
.035" (0.9mm) Soft 408023-001 408023-001 375647 W6000804
3/64" (1.2mm) Soft 408023-002 408023-002 375647 W6000804
Table A-2: Wire, Drive Roll and Guide Recommended Combinations
Manual 0-5155 A-1 APPENDIX
FABRICATOR 252i APPENDIX
APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM
1
L1
L2
GND
GND
A
FRONT PANEL
J
VIDENT
SOL+
WFSPOT2
VBIAS
TRIG2
MOTOR+
MOTOR-
VPOT2
VPOT1
WFSPOT1
VBIAS
N/C
TRIG1
N/C
I
E
G
F
H
D
C
B
A
8
7
6
5
4
3
2
1
1
2
3
4
5
POT_RETURN
TRIG_SOL_RTN
POT_RETURN
B
TRIG_RETURN
LINE
BREAKER
LOAD
CONTROL BOARD
NOTE 1
FERRITE
AUX TRIG
FRONT PANEL
2
EMI BOARD
1
P2
50
3
C
D
WELD OUTPUT +
WELD OUTPUT -
1
1
FRONT PANEL
NOTES:
1. EMI ASSEMBLY, COMMON MODE CHOKE AND FERRITE (IF USED)
Art # A-10334
1
CURRENT SENSOR
1
2
3
4
INDUCTOR
Rev
2
Revision
3
Date
By
APPENDIX A-2 Manual 0-5155
APPENDIX FABRICATOR 252i
4
123456789
1
CHASSIS GND
BRIDGE + BRIDGE -
BRIDGE / MOV BOARD
P1 P2 P3
NI CANI CA
123456789
123
4
10
5
NOTE 1
COMMON MODE CHOKE
MOTOR
12341324121
101112
P8
GAS SOL
TIG SOL
BREAKER
FAN
FAN
2
P4
P6P5
DC+
6
A
B
1
2
P7
Rev
Revision
00 PROTOTYPE
P12
50
2
1
1
2
3
4
5
6
P9
P10
HI-POT
TEMP SW
P11
P13
SECSEC CT
TRANSFORMER
PRI PRI
P14
HI-POT
1
2
GND PRI
C
Art # A-10334_AB
Date
By
GAC 07/12/2011
The information contained here in is proprietary to Victor Technologies.
Not for release, reproduction or distribution without written consent.
Title
T ECH N O L O GIE S
SCHEMATIC
™
SCH, SYS, NEXT GEN WELDER
4
5
Victor Technologies, Inc.
16052 Swingley Ridge Road, Suite 300
St Louis, Missouri 63017 USA
Date Printed
Drawn
Size
Drawing Number
7/12/2011
GAC
B
Date Revised
7/12/2011
Date
02/14/2011
Sheet
1 1
of
42X500100
6
D
Manual 0-5155 A-3 APPENDIX
FABRICATOR 252i APPENDIX
This Page Intentionally Blank
APPENDIX A-4 Manual 0-5155
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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