TWECO FABRICATOR 252i 3-IN-1 Multi Process Welding Systems Instruction manual

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FABRICATOR

252i

3-IN-1 Multi Process Welding Systems

Operating Manual

Revision: AC Issue Date: November 12, 2014 Manual No.: 0-5193

Tweco.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efﬁciency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Tweco.com

WARNINGS

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

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

Operating Manual Number 0-5193 for:

Tweco Fabricator 252i Inverter Power Supply Part Number W1004406 Tweco Fabricator 252i Inverter System Part Number W1004408

Published by: Victor Technologies International, Inc. Europa Building Chorley Industrial Park Chorley, Lancaster, England, PR6 7BX

www.victortechnologies.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: February 1, 2012 Revision Date: November 12, 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 Declaration of Conformity ............................................................................... 1-8

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 Symbol Chart .................................................................................................. 2-2

2.05 Description ..................................................................................................... 2-3

2.06 User Responsibility ......................................................................................... 2-3

2.07 Transportation Methods .................................................................................. 2-3

2.08 Packaged Items .............................................................................................. 2-4

2.09 Duty Cycle ....................................................................................................... 2-5

2.10 Speciﬁcations ................................................................................................. 2-6

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 ............................................................................ 3-10

3.08 Attaching the MIG Gun (Euro) ...................................................................... 3-15

3.09 Installing a 5 kg (12.5 lb) spool 200mm (8") diameter ................................. 3-16

3.10 Installing a Standard Spool 300mm (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 ........................................... 3-22

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 (MMA) ................................................. 3-31

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 (MMA) Basic Welding Technique ......................................................... 4-7

4.04 STICK (MMA) Welding Troubleshooting ....................................................... 4-16

4.05 TIG (GTAW) Basic Welding Technique .......................................................... 4-18

4.06 TIG (GTAW) Welding Problems ..................................................................... 4-20

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

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

5.02 Routine Service and Calibration Requirements ............................................... 5-3

5.03 Cleaning the Welding Power Source ............................................................... 5-6

5.04 Cleaning the Feed Rolls ................................................................................... 5-7

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

6.01 Fabricator 252i Power Supply Replacement Panels ........................................ 6-1

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

APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM .................................................. A-2

TWECO - LIMITED WARRANTY TERMS ....................................................................2

LIMITED WARRANTY & WARRANTY SCHEDULE .........................................................3

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.

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FABRICATOR 252i SAFETY INSTRUCTIONS

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.

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. 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, ﬂame-resistant material (wool and leather) and foot protection.

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

Arc Current

(Amperes)

Less than 60

60-160 160-250 250-550

Minimum

Protective

Shade

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 10

10 11

8 10 11

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 0-5193

SAFETY INSTRUCTIONS FABRICATOR 252i

2. Do not weld where flying sparks can strike ﬂammable material.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not 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.

3. Remove all ﬂammables within 10.7 m (35 ft) 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.

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 galvanised, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause ﬂying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

WARNING

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.

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FABRICATOR 252i SAFETY INSTRUCTIONS

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.

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.

WARNING

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

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

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

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

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.

WARNING

2. Stop engine before disconnecting or connecting battery cables.

ENGINE FUEL can cause ﬁre or explosion.

3. Do not allow tools to cause sparks when working

Engine fuel is highly ﬂammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open ﬂames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overﬁll tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5193

on a battery.

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

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

SAFETY INSTRUCTIONS FABRICATOR 252i

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

WARNING

STEAM AND PRESSURISED 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.

NOTE

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

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, 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 minimise or avoid potential risks.”

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

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

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

4. Keep welding Power Source and cables as far away from body as practical.

ABOUT PACEMAKERS:

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

1.02 General Safety Information for Victor CS Regulator

A. Fire Prevention

Welding and cutting operations use ﬁre or combustion as a basic tool. The process is very useful when properly controlled. However, it can be extremely destructive if not performed cor rectly in the proper environment.

1. The work area must have a ﬁreproof ﬂoor.

2. Work benches or tables used during welding or cutting operations must have ﬁreproof tops.

3. Use heat resistant shields or other approved material to protect nearby walls or unprotected ﬂooring from sparks and hot metal.

4. Keep an approved ﬁre extinguisher of the proper size and type in the work area. Inspect it regularly to ensure that it is in proper working order. Know how to use the ﬁre extinguisher.

5. Move combustible materials away from the work site. If you can not move them, protect them with ﬁreproof covers.

Manual 0-5193 1-5 SAFETY INSTRUCTIONS AND WARNINGS

FABRICATOR 252i SAFETY INSTRUCTIONS

When working in a non-welding or cutting environment, always wear suitable eye protection or face

WARNING

NEVER perform welding, heating, or cutting operations on a container that has held toxic, combustible or ﬂammable liquids, or vapors. NEVER perform welding, heating, or cutting operations in an area containing combustible vapors, ﬂam mable liquids, or explosive dust.

B. Housekeeping

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.

WARNING

NEVER allow oxygen to contact grease, oil,

or other ﬂam mable substances. Although oxygen by itself will not burn, these substances become highly explosive. They can ignite and burn violently in the presence of oxygen.

Keep ALL apparatus clean and free of grease, oil and other ﬂammable substances.

C. Ventilation

WARNING

Ade quately ventilate welding, heating, and cutting work areas to prevent accumulation of explosive or toxic concen trations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. When welding/ brazing, read and understand the Material Safety Data Sheet for the welding/ brazing alloy.

D. Personal Protection

Gas ﬂames produce infrared radiation which may have a harm ful effect on the skin and especially on the eyes. Select goggles or a mask with tempered lenses, shaded 4 or darker, to protect your eyes from injury and provide good visibility of the work.

E. Compressed Gas Cylinders

The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases used for welding or cutting operations.

1. Place the cylinder (Figure 1-1) where you will use it. Keep the cylinder in a vertical position. Secure it to a cart, wall, work bench, post, etc.

Art # A-12127

Figure 1-1: Gas Cylinders

WARNING

Cylinders are highly pressurised. Handle with care. Serious accidents can result from improper handling or mis use of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, ﬂames or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.

NOTE

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.

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5193

CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly,VA 20151-2923

SAFETY INSTRUCTIONS FABRICATOR 252i

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.

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.

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FABRICATOR 252i SAFETY INSTRUCTIONS

1.04 Declaration of Conformity

Declaration of Conformity

We Victor Technologies International Inc.

of 16052 Swingley Ridge Road Suite 300 Chestereld, MO 63033 U.S.A.

in accordance with the following Directive(s):

 •2006/95/EC The Low Voltage Directive

 •2004/108/EC The Electromagnetic Compatibility (EMC) Directive

hereby declare that:

Equipment: Arc Welding Power Source

Model Name/Number: Fabricator 252i

Market Release Date: January 16, 2014

is in conformity with the applicable requirements of the following harmonized standards:

  • EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC) requirements

  •EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.

Classification: The equipment described in this document is Class A and intended for industrial use.

Manufacturer’s Authorized Representative

Steve Ward V.P. Europe and General Manager

Address:Victor Technologies International Inc.

Europa Building

Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Date: November 12, 2014

Steve Ward

V.P. Europe and General Manager

(Signature)

(Full Name)

(Position)

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difﬁculties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5193

SAFETY INSTRUCTIONS FABRICATOR 252i

Classication:TheequipmentdescribedinthismanualisClassAandintendedforindustrialuse.

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential

difculties in ensuring electromagnetic compatibility in those locations, due to conducted

as well as radiated disturbances.

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FABRICATOR 252i SAFETY INSTRUCTIONS

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SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5193

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 recgonised as follows:

WARNING

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

WARNING

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

CAUTION

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.

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 or 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 unboxing the unit. Use care to avoid damaging the equipment when using knives to un-box the unit.

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.

Manual 0-5193 2-1 INTRODUCTION

FABRICATOR 252i INTRODUCTION

2.04 Symbol Chart

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

OFF

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Hertz (cycles/sec)

Frequency

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

Preflow Time

Postflow Time

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

115V 15A

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Receptacle RatingAuxiliary Power

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Figure 2-1: Symbol chart

4 Step Trigger Operation

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

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

See Note

Pulse Welding

Art # A-10663_AB

INTRODUCTION 2-2 Manual 0-5193

INTRODUCTION FABRICATOR 252i

2.05 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 (MMA) 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.

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.

2.06 User Responsibility

2.07 Transportation Methods

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energised 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.

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 unauthorised modiﬁcation from standard speciﬁcation, faulty maintenance, damage or improper repair by anyone other than appropriately qualiﬁed persons approved by Tweco.

Manual 0-5193 2-3 INTRODUCTION

FABRICATOR 252i INTRODUCTION

2.08 Packaged Items

Fabricator 252i Part No. (W1004407)

- Fabricator 252i Power Supply

- 3M Tweco TWE2 250Amp MIG Gun

- Contact tip

• 1.0mm Fitted

-3M (9.8ft.) Gas Hose

-200 Amp electrode holder with 4M (13 ft.) lead

-200 Amp ground clamp with 3M (10 ft.) lead

-Drive Rolls:

• 0.9 / 1.2 mm (.035" / .045") V Grooved Lower & Flat Upper (Fitted)

• 0.6 / 0.9 mm (.023 / .035") V Grooved Roll

- Operating Manual

- 2.6M (8.5 ft) Power cord

A-12125

Figure 2-2: Packaged Items

INTRODUCTION 2-4 Manual 0-5193

INTRODUCTION FABRICATOR 252i

2.09 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 Input Lead

100

Duty Cycle (percentage)

Safe

Operating

Region

25 50 75

100

Stick (MMA)

125 150 225 250

175

TIG (GTAW)

MIG (GMAW)

200

Welding Current (amps)

Figure 2-3: Fabricator 252i Duty Cycle with Factory Fitted Supply Lead

With Upgraded Supply Cord

100

Duty Cycle (percentage)

25 50 75

Safe

Operating

Region

100

Welding Current Max (amps)

125 150 225 250

STICK (MMA)

175

200

Art # A-11213

TIG (GTAW) MIG (GMAW)

Art # A-11206

Figure 2-4: Fabricator 252i Duty Cycle with Upgraded Supply Lead

Manual 0-5193 2-5 INTRODUCTION

FABRICATOR 252i INTRODUCTION

2.10 Speciﬁcations

Description TRANSMIG 250i MULTI PROCESS WELDING INVERTER Power Source Dimensions H 440mm x W 260mm x D 600mm Power Source Mass 29.5kg Cooling Fan Cooled Welder Type Multi Process Inverter Power Source Australian Standard AS 60974.1-2006 / IEC60974.1 Number of Phases Single Phase Nominal Supply Voltage 220/230VAC ± 15% Nominal Supply Frequency 50/60Hz Open Circuit Voltage 72 VDC MIG Voltage Range 14-30 VDC Wirefeeder Speed Range 1.7-17.8 MPM Protection Class IP23S Supply Lead & Plug Rating "16 Amps (2.5mm²)

Ratings Below Applies to the

Factory Fitted Supply Lead"

Welding Current Range (MIG Mode) 20-180 Amps 20-300 Amps Welding Current Range (LIFT TIG Mode) 5-220 Amps 5-300 Amps Welding Current Range (STICK Mode) 20-160 Amps 20-230 Amps Effective Input Current (I1eff) 16 Amps 23.4 Amps Maximum Input Current (I1max) 22.9 Amps 36.2 Amps Single Phase Generator Requirement 6 kVA 10 kVA MIG (GMAW) Welding Output, 40°C, 10 min. 180A @ 51%, 23V

170A @ 60%, 22.5V

140A @ 100%, 21V

STICK (MMAW) Welding Output, 40°C, 10 min. 160A @ 49%, 26.4V

145A @ 60%, 25.8V

120A @ 100%, 24.8V

TIG (GTAW) Welding Output, 40°C, 10 min. 220A @ 51%, 18.8V

200A @ 60%, 18V

150A @ 100%, 16V

Table 2-1: Fabricator 252i Speciﬁcation

"25 Amps ( 4mm²)

[Ratings Below Applies to an

Upgraded 4mm² Supply Lead &

Plug Fitted]"

250A @ 40%,26.5V

200A @ 60%, 24V

150A @ 100%, 21.5V

230A @ 40%,29.2V

200A @ 60%, 28V

150A @ 100%, 26V

250A @ 40%,20V

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.

INTRODUCTION 2-6 Manual 0-5193

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. 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.

G. The enclosure design of this power source meets

the requirements of IP23S as outlined in EN 60529 / IEC 60529.

H. Precautions must be taken against the power source

toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

WARNING

This equipment should be electrically connected by a qualiﬁed electrician.

3.03 Ventilation

WARNING

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

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

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

A. In areas, free from moisture and dust.

B. Ambient temperature between 0° C to 40° C (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.

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 tradesperson. Damage to the PCA (Power Control Assembly) could occur if 276 VAC or higher is applied to the Primary Power Cable

Manual 0-5193 3-1 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

50/60 Hz

Single Phase

Yes

Yes 4mm

ELECTRIC SHOCK

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

Primary Supply

Lead Size

2.5mm² (Factory Fitted)

Table 3-1: Input Power Source Leads for Fabricator 252i

can kill;

Minimum

Primary Current

Circuit Size

(Vin/Iin)

220-230/15A 15A 51% @ 180A 51% @ 220A 49% @ 160A

220-230/25A 25A 40% @ 250A 40% @ 250A 40% @ 230A

SIGNIFICANT DC VOLTAGE

Maximum

Plug Size

WARNING

is present after removal of input power. DO NOT

Current & Duty Cycle

MIG LIFT TIG STICK

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 qualied 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.

INSTALLATION/SETUP 3-2 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in EN 60974-13 / IEC 60974-13.

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account.

1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment.

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.

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.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

4. Equipotential Bonding

Bonding of all metallic components in the welding

installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could

5. The health of people around, e.g. the use of pacemakers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

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

Manual 0-5193 3-3 INSTALLATION/SETUP

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.

FABRICATOR 252i INSTALLATION/SETUP

3.06 Power Source Controls, Indicators and Features

Art # A-10503_AB

Figure 3-1: Fabricator Control Panel

13 14

Art # A-10504

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 0-5193

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.

5. Advanced Features Button

Advanced Features

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.

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.

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

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.

Manual 0-5193 3-5 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

6. Left Knob: Amperage Control (Wirespeed)

Left Knob

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.

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.

7. Right Knob: Multifunction Control - MIG Voltage / Arc Control (Inductance) & STICK Arc Force

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 anticlockwise. This feature can be accessed and adjusted during welding.

ARC CONTROL

To access the Arc Control function, push inward on the right knob and hold it for approximately 2 seconds. This

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

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.

the required output settings for a basic range of MIG

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

INSTALLATION/SETUP 3-6 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

8. Left Digital Display

MIG Mode

This digital meter is used to display the pre-set (preview) Wirefeed Speed in Metres Per Minute (MPM) 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).

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.

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 nonwelding 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 display is also used for providing error messages to the user and showing other information, which will be explained in Section 5.

Manual 0-5193 3-7 INSTALLATION/SETUP

The MIG Gun Adapter is the connection point for the Tweco MIG Gun. Refer to section 3.08 for the correct procedure for attaching the MIG Gun.

FABRICATOR 252i INSTALLATION/SETUP

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.

A-09594_AC

5 6

7 8

Remote Wirespeed in GMAW mode

Remote Amps in GTAW mode

Figure 3-3: Remote Control Socket

Trigger Switch

Remote Volts in GMAW Mode

Socket Pin

Function

1 Not connected

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.

INSTALLATION/SETUP 3-8 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

Trigger

Peripheral

Resistor

Art # A-10813

Socket Pin

A Voltage Pot. Wiper

Wire Feed Motor (-)

Wire Feed Motor (+)

Trigger Switch Input

Wire Speed Pot. & Voltage Pot. (+) CW 10K ohm

Wirespeed

Potentiometer

3 3

Figure 3-4: Remote Control Socket

Function

Voltage

Potentiometer

Motor

24V

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 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.

Table 3-4

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.

CAUTION

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

Manual 0-5193 3-9 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

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 aluminium 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.

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.

Left Knob

WIRESPEED

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

Process

Select the weld process (Control No 3) you wish to view Advanced Features for.

or exit from the Advanced Features programming function of the welder.

Advanced Features

MIG

TIG

STICK

Then press and release the Advanced Features button (Control No 5) to enter

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.

Process

MIG

TIG

STICK

INSTALLATION/SETUP 3-10 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

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.

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.

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

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

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

Manual 0-5193 3-11 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

Right

Display

Function Left Display

MIG Operator Controls

Pre Flow (MIG Setting)

Run In RUN/IN 70% 30 – 150 %

Post Flow (MIG Setting)

Burn Back BURN/BACK 0.15 S 0.00 – 1.00 S

Wire Sharp WIRE/SHRP ON OFF – ON

Spot SPOT OFF OFF – ON

Spot Time

(Only shown/ enabled 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

MIG/CNTL LOCL LOCL - REMT

PRE-/FLOW 0.1 S 0.0 – 5 S

POST/FLOW 0.5 S 0.0 – 30 S

SPOT/TIME 2.0 S 0.1 – 20.0 S

STCH/TIME 2.0 S 0.2 – 4.0 S

DWEL/TIME 0.5 S 0.1 – 1.0 S

WFS/UNIT MPM MPM – IPM

(Factory

Default

Values)

Limits Comments

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.

Spot Time is the time used for the Spot weld mode.

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 optimised arc control for dip transfer welding with minimal spatter on mild steel with mixed shielding gases. CV-M is the traditional constant-voltage arc control for all other welding.

MPM provides preview wirespeed in Metres Per Minute. IPM provides preview wirespeed in Inches Per Minute.

INSTALLATION/SETUP 3-12 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

Right Dis-

play

Function Left Display

Arc Hour Accumulated Run-

HR 0.0 0.0 – 9999.9

time

Restore Factory Defaults

FACT/DFLT NO NO – YES

LIFT TIG Mode Advanced Features Menu Map

Left Display Right Display

Advanced Menu -

LIFT TIG Mode

TIG / CNTL

PRE- / FLOW

POST / FLOW DOWN / SLPE

FACT / DFLT

Press Advanced Button to Exit to Welding Mode

(Factory

Default

Values)

Limits Comments

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.

Advanced Menu - LIFT

TIG Options or Range

LOCL REMT

0.0 - 5.0 S

0.0 - 30.0 S

0.0 - 9999.9

NO YES

Press Advanced Button

to Exit to Welding Mode

Process

MIG

TIG

STICK

Advanced Features

Left Display: Where (2) items shown, e.g. RUN- / IN, the display will alternate (ﬂash) between the (2) items

Function Left Display

LIFT TIG Opera-

LIFT TIG/

tor 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 Knob Selection Right Knob Selection

Figure 3-6: LIFT TIG Advanced Menu

"Right

Display

(Factory

Limits Comments

Default

Values)"

LOCL = Local control of the Amps with the machines controls REMT = Remote control of the Amps with an

CNTL

REMT LOCL - REMT

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

Art # A-10506_AB

Manual 0-5193 3-13 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

"Right

Display

Function Left Display

(Factory

Default

Values)"

Limits Comments

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).

Down Slope DOWN/SLPE 0.0 S 0.0 – 30 S

Arc Hour Accumulated Run-

HR 0.0 0.0 – 9999.9

time

Restore Factory Defaults

FACT/DFLT NO NO – YES

STICK Mode Advanced Features

Left Display Right Display

Advanced Menu - STICK

Mode

STCK / CNTL

HOT- / START

HS / TIME

HS / AMPS

FACT / DFLT

Press Advanced Button to Exit to Welding Mode

Advanced Menu - STICK

Options or Range

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 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.

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

Art # A-10507_AB

Figure 3-7: STICK Advanced Menu

INSTALLATION/SETUP 3-14 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

Right Display

Function Left Display

STICK Operator Controls

STCK/CNTL LOCL LOCL - REMT

Hot Start HOT/STRT ON OFF – ON

Hot Start Time

Hot Start Amps

TIME/HS 0.5 S 0.0 - 2.0 S

AMPS/HS 140% 75 – 200%

Arc Hour Accumulated

HR 0.0 0.0 – 9999.9

Runtime

Restore Factory Defaults

FACT/DFLT NO NO – YES

(Factory De-

fault Values)

Limits Comments

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.

3.08 Attaching the MIG Gun (Euro)

1. Align the pins on the MIG Torch Cable with the pin holes of the MIG Torch receptacle on the front of the system above the positive(+) dinse type receptacle. Press the MIG Torch in and secure by turning the locking ring to the right (clockwise).Refer to Figure 3-8.

Attach MIG Torch. Turn locking ring to the right

2. If equipped, align the keyways of the MIG Torch Switch connector pigtail with the 8 pin receptacle to the right of the MIG Torch 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 Torch 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.

Art # A-10338

Figure 3-8: Mount MIG Gun Cable to Adapter Socket

Manual 0-5193 3-15 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

3.09 Installing a 5 kg (12.5 lb) spool 200mm (8") diameter

In order to ﬁt a 5 kg (12.5 lb.)/ 200mm (8") diameter spool, 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

5kg/12.5lb 200mm / 8” Wire Spool

Flat Washer Large Hole

Flat Washer Small Hole

Fibre Washer Retaining Clip Use inner holes on Spool Hub

Keyed Washer

Spring

Spool Hub

Figure 3-9: 5 kg (12.5 lb) spool 200mm (8") Diameter Spool Installation

Art # A-10926

INSTALLATION/SETUP 3-16 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

3.10 Installing a Standard Spool 300mm (12") diameter

As delivered from the factory, the unit is set for a 15kg / 33 lb. (300mm / 12") spool.

Installation of wire spool. Refer to Figure 3-10.

1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

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

Retaining Clip

Use outer holes 15kg / 33lb 300mm / 12” Wire Spool

Flat Washer Large Hole

Keyed Washer

Spring

Spool Hub

Fibre Washer

Figure 3-10: Standard 15 kg/33 lb 300mm (12") Diameter Spool Installation

Art # A-10927

Manual 0-5193 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 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.

Art # A-10030

Figure 3-11: Opening Pressure Arm and Inserting Wire

Art # A-10031

Figure 3-12: Closing Pressure Arm and Adjusting Tension

INSTALLATION/SETUP 3-18 Manual 0-5193

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 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.

Art # A-10415

Figure 3-13: Top View of Feed Plate with Pressure Arm Open

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 0-5193 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 0.9 / 1.2 mm (.035" / .045") .

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.

1.2mm (.045”) Stamping

.045

1.2

.045

1.2

1.2mm (.045”) Groove

Art: A-11202

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 MIG Gun switch. Electrode contact to work piece will cause an arc with MIG Gun switch depressed.

INSTALLATION/SETUP 3-20 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

3.15 Input And Output Wire Guide Installation

NOTE

0.9 / 1.2 mm(.035" / .045" ) 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 lockscrew 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 lockscrew.

NOTE

Before tightening the input and output guide lockscrews, install the drive roll to help in the alignment of the wire guides.

Output Wire Guide - With the MIG Gun removed, loosen the MIG Adapter Lock Nut. This will aid with alignment. With MIG gun removed, loosen the MIG Gun Adapter Lock nut. Then loosen Output guide Lock screw .Install the output wire guide( the longer one) by inserting the conical end part way into the Euro 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 lockscrew.

Input Guide Lockscrew

Output Guide Lockscrew

Input Wire Guide

Figure 3-15: Wire Guide Installation

MIG Torch Adapter Lock Bolt

Art # A-10346_AB

Output Wire Guide

Manual 0-5193 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 19 mm ( 3/4") after release of the MIG Gun trigger switch. The wire should be slack without becoming dislodged from the reel.

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

Gas regulators are 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 the manufacturer's instructions.

INSTALLATION/SETUP 3-22 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

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 pressurise 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.

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. A suitable 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.

Manual 0-5193 3-23 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

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 igni-

tion. 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 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-12227

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.

Operation

With the regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurise 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.

INSTALLATION/SETUP 3-24 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

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: 13 - 16 LPM (28 - 35 CFH)

- Outdoor welding: 16 - 22 LPM (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 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 0-5193 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 250 AMP air-cooled MIG Gun. The MIG Gun is designed with an ergonomic handle and fewer parts to cause performance problems. The MIG Gun uses standard readily available Tweco 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 positive + 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)

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.

Art # A-12228

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 MIG Gun nozzle and contact tip.

4. Fit the MIG wire spool and 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

INSTALLATION/SETUP 3-26 Manual 0-5193

10. Depress MIG Gun trigger to feed the MIG wire out through the MIG Gun gas diffuser then ﬁt the contact tip on the MIG wire and securely fasten it to the MIG Gun then ﬁt 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 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 250 AMP air-cooled MIG Gun. The MIG Gun is designed with an ergonomic handle and fewer parts to cause performance problems. The MIG Gun uses standard readily available Tweco 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 Terminal

(Dinse

type 50)

Art # A-12229

Figure 3-21: MIG Gun Polarity Negative

Manual 0-5193 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 through the MIG Gun gas diffuser then ﬁt the contact tip on the MIG wire and securely fasten it to the MIG Gun then ﬁt 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 0-5193

INSTALLATION/SETUP FABRICATOR 252i

Art # A-00503_AB

Electrode

2 to 2-1/2 Times

Electrode Diameter

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.

Figure 3-22: Electrode sharpening

Manual 0-5193 3-29 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

7. Install the tungsten with approximately 3.2mm to 6.4mm (1/8" to 1/4") 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.

Art # A-12226

Ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely ﬁxed in an upright position.

Figure 3-23: Setup for LIFT TIG (GTAW) Welding

12. You are now ready to begin LIFT TIG Welding.

Negative Output Terminal (Dinse® type 50)

INSTALLATION/SETUP 3-30 Manual 0-5193

INSTALLATION/SETUP FABRICATOR 252i

3.21 Set-up for STICK Metal Arc Welding (MMA)

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-12230

Negative Output Terminal (Dinse® type 50)

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.

NOTE

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.

Manual 0-5193 3-31 INSTALLATION/SETUP

FABRICATOR 252i INSTALLATION/SETUP

This Page Intentionally Blank

INSTALLATION/SETUP 3-32 Manual 0-5193

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

Figure 4-1

FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous ﬂux ﬁlled electrode wire and the work. Shielding is obtained through decomposition of the ﬂux within the tubular wire. Additional shielding may or may not be obtained from an externally supplied gas or gas mixture. The process is normally applied semi automatically; however the process may be applied automatically or by machine. It is commonly used to weld large diameter electrodes in the ﬂat and horizontal position and small electrode diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay work.

Nozzle

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.

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 energised until the MIG Gun trigger switch is depressed. The wire may therefore be placed on the seam or joint prior to lowering the helmet.

Manual 0-5193 4-1 BASIC WELDING

FABRICATOR 252i BASIC WELDING

10° to 20° Longitudinal

Direction of Travel

5° to 15°

Longitudinal

Angle

90°

Transverse

Angle

Butt & Horizontal Welds

Figure 4-4

5° to 15°

Longitudinal Angle

Direction of

Travel

Horizontal Fillet Weld

Figure 4-5

Direction of

Travel

Art # A-08993

30° to 60°

Transverse Angle

Art # A-08994

Travel Speed

The speed at which the molten pool travels inﬂuences the width of the weld and penetration of the welding run.

MIG Welding (GMAW) Variables

Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in short-arc welding of 0.6 - 6.4 mm (.023 - 1/4") mild sheet or plate. The applied techniques and end results in the GMAW process are controlled by these variables.

Preselected Variables

Preselected variables depend upon the type of material being welded, the thickness of the material, the welding position, the deposition rate and the mechanical properties. These variables are:

• Type of electrode wire

• Size of electrode wire

• Type of gas (not applicable for FCAW self shielding

wires)

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

Primary Adjustable Variables

10°

Longitudinal Angle

30° to 60°

Transverse

Angle

30° to 60° Transverse

Angle

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)

These control the process after preselected variables

Direction of Travel

• Travel speed

Secondary Adjustable Variables

Vertical Fillet Welds

Figure 4-6

Art # A-08995

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

1. Sick-out (distance between the end of the con-

30° to 60°

Transverse Angle

5° to 15° Longitudinal Angle

tact tube (tip) and the end of the electrode wire). Maintain at about 10mm (3/8") stick-out

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

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 10 - 20 mm (3/8" - 3/4"). This dis-

Gas Nozzle

Tip to

Work Distance

Average Arc Length

Electrode Stick-Out

Figure 4-8

Contact Tip (Tube)

Electrode Wire

Actual Stick-out

Art # A-08997_AD

tance may vary depending on the type of joint that is being welded.

BASIC WELDING 4-2 Manual 0-5193

BASIC WELDING FABRICATOR 252i

Transverse

Direction of Gun Travel

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 realise the effects of each angle in relation to the direction of travel.

Angle

Longitudinal Angle

Axis of Weld

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.

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.

If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound. Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information.

Electrode Wire Size Selection

The choice of Electrode wire size and shielding gas used depends on the following:

• Thickness of the metal to be welded

• Type of joint

• Capacity of the wire feed unit and Power Source

• The amount of penetration required

• The deposition rate required

• The bead prole desired

• The position of welding

• Cost of the wire

For practicing MIG welding, secure some pieces of 1.6 mm or 5.0 mm (1/16" or 3/16") mild steel plate 150 mm x 150 mm (6" x 6"). Use 0.9 mm (.035") ﬂux cored gasless wire or a solid wire with shielding gas.

Manual 0-5193 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 0-5193

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 connec-

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.

5 Welding dirty, oily, painted,

oxidised or greasy plate.

6 Distance between the MIG Gun

nozzle and the work piece.

7 Maintain the MIG Gun in good

working order.

Table 4-1: MIG (GMAW / FCAW) Welding Troubleshooting

Ensure that the shielding gas cylinder is not empty and the ﬂow meter is correctly adjusted to 31.75 CFH.

tion 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.

Clean contaminates off the work piece.

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

A Ensure that the gas holes are not blocked and gas is exiting

out of the 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.

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.

FAULT CAUSE

1 Feed roller driven by motor in the

cabinet slipped.

2 Wire spool unwound and tangled. Wire spool brake is too loose.

3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding.

4 Wire rubbed against the misaligned

guides and reduced wire feed ability.

Manual 0-5193 4-5 BASIC WELDING

Wire spool brake is too tight.

B Replace feed roller if worn.

Misalignment of inlet/outlet guides

FABRICATOR 252i BASIC WELDING

5 Liner blocked with swarf 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 accumu-

lates thus reducing wire feed ability.

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

trode wire. If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the wire jamming in the contact tip

B When using soft wire such as aluminium it may

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

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

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

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

thus reducing wire feed ability

Table 4-2: Wire Feeding Problems

Basic MIG (GMAW/FCAW) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Undercut A Welding arc voltage too

high.

B Incorrect MIG Gun angle B Adjust angle.

C Excessive heat input C Increase the MIG Gun travel speed and/or decrease

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

B Joint preparation too nar-

row 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.

A Decrease voltage or increase the wire feed speed.

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

speed and increasing voltage.

B Increase joint angle or gap.

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 low. Concave, voltage too high.

B Wire is wandering. B Replace contact tip.

C Incorrect shielding gas C Check shielding gas.

D Insufﬁcient or excessive

heat input

BASIC WELDING 4-6 Manual 0-5193

A Adjust voltage and current by adjusting the voltage

control and the wirespeed control.

D Adjust the wirespeed control or the voltage control.

BASIC WELDING FABRICATOR 252i

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

B Weld penetration narrow

and deep

C Excessive weld stresses C Increase weld metal strength or revise design

D Excessive voltage D Decrease voltage.

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

7 Cold weld puddle A Loose welding cable con-

nection.

B Low primary voltage B Contact supply authority.

C Fault in power source C Have an Accredited Tweco Service Provider test then

8 Arc does not have

a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly.

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

Table 4-3: MIG (GMAW /FCAW) Welding Problems

B Reduce current and voltage and increase MIG Gun

travel speed or select a lower penetration shielding gas.

or cool slowly.

A Check all welding cable connections.

replace the faulty component.

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.

4.03 STICK (MMA) Basic Welding Technique

Size of Electrode

The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufﬁcient current (amperage) to run the smaller size electrodes.

For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their original containers.

Electrode Polarity

Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Tweco Distributor.

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.

Manual 0-5193 4-7 BASIC WELDING

FABRICATOR 252i BASIC WELDING

Art # A-07688

Art # A-07689

Art # A-07690

B. Austenitic manganese steels

The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat.

C. Cast Iron

Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

D. Copper and alloys

The most important factor is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

Figure 4-14: Horizontal Position, Butt Weld

Figure 4-15: Horizontal-Vertical (HV) Position

Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.

Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in ﬂat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-12 through 4-19.

Art # A-07687

Figure 4-12: Flat Position, Down Hand Butt Weld

Art A-07691

Figure 4-16: Vertical Position, Butt Weld

Art # A-07692

Figure 4-17: Vertical Position, Fillet Weld

Art# A-07693

Figure 4-18: Overhead Position, Butt Weld

Figure 4-13: Flat Position, Gravity Fillet Weld

Art # A-07694

Figure 4-19: Overhead Position, Fillet Weld

BASIC WELDING 4-8 Manual 0-5193

BASIC WELDING FABRICATOR 252i

Open Square Butt

Single Vee Butt Joint

Not less than

Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-20.

Joint

Gap varies from

1.6mm (1/16”) to 4.8mm (3/16”) depending on plate thickness

Single Vee Butt Joint

Lap Joint

Fillet Joint

Corner Weld

Not less than

45°

(Fillet both sides of the

1.6mm (1/16”)

Double Vee Butt Joint

1.6mm (1/16”)

Tee Joints

joint)

Edge Joint

70°

Not less than

70°

1.6mm (1/16” ) max

1.6mm (1/16”) max

Plug Weld Plug Weld

Art # A-07695_AE

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 6.4mm (1/4") thick and a 3.2mm (1/8") 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 0-5193 4-9 BASIC WELDING

FABRICATOR 252i BASIC WELDING

20°

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 1.6 - 3.2 mm (1/16 - 1/8") gap between the burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.

Another difﬁculty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Art # A-07696_AB

1.6 mm (1/16”)

Arc Length

The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will ﬁnd that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, irregular blobs. The weld bead is ﬂattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidiﬁed in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or "touch-weld" electrodes such as E7014 do not stick in this way, and make welding much easier.

Rate of Travel

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 1.6 - 2.4 mm (1/16 - 3/32") 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 6.4mm (1/4") 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 3.2mm (1/8") E7014 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

Figure 4-21: Striking an Arc

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BASIC WELDING FABRICATOR 252i

20°-30°

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.

Electrode

Tack Weld

Art # A-07697_AB

Figure 4-22: Butt Weld

B. Fillet Welds

These are welds of approximately triangular crosssection made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-15.

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

Art # A-07698

Figure 4-23: Weld Build up Sequence

Heavy plate will require several runs to complete the joint. After completing the ﬁrst run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4-23. 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.

45° from vertical

60° - 70° from line of weld

Art # A-07699_AB

Figure 4-24: Electrode Position for HV Fillet Weld

Art # A-07700_AB

5 2

Figure 4-25: Multi-runs in HV Fillet Weld

Manual 0-5193 4-11 BASIC WELDING

FABRICATOR 252i BASIC WELDING

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 3.2mm (1/8") 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

Figure 4-28: Examples of Vertical Fillet Welds

2. Vertical Down

The E7014 electrode makes welding in this

position particularly easy. Use a 3.2mm (1/8") 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 neces-

sary, overhead welding is not much more difﬁcult that downhand welding. Set up a specimen for overhead welding by ﬁrst tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead ﬁllet welds. Use a 3.2mm (1/8") 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-07703

Art # A-07704

Figure 4-27: Multi Run Vertical Fillet Weld

Figure 4-29: Overhead Fillet Weld

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BASIC WELDING FABRICATOR 252i

Upsetting

Weld

Distortion

Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.

The Cause of Distortion

Distortion is caused by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to ﬂow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in 2.0mm (5/64") 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.

Hot

Weld

Hot

Expansion with compression

Cool

Art # A-07705_AB

Figure 4-30: Parent Metal Expansion

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.

Manual 0-5193 4-13 BASIC WELDING

FABRICATOR 252i BASIC WELDING

E. Preheating

Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-32 shows a simple application. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.

Art # A-07707

Figure 4-32: Principle of Presetting

Art # A-07708

Weld

PreheatPreheat

Figure 4-34: Examples of Distortion

Art # A-07710_AB

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

Art # A-07709

Dotted lines show effect if no preheat is used

Figure 4-33: Reduction of Distortion by Preheating

Art # A-07711_AB

Figure 4-36: Step back Sequence

Figure 4-35: Welding Sequence

Art # A-07428_AB

Figure 4-37: Chain Intermittent Welding

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BASIC WELDING FABRICATOR 252i

Art # A-07713_AB

Figure 4-38: Staggered Intermittent 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

Manual 0-5193 4-15 BASIC WELDING

FABRICATOR 252i BASIC WELDING

4.04 STICK (MMA) Welding Troubleshooting

FAULT CAUSE REMEDY

1 Welding current

varying

2 A gap is left by

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

3 Non-metallic par-

ticles are trapped in the weld metal.

ARC FORCE is set at a value that causes the welding current to vary excessively with the arc length.

Reduce the ARC FORCE until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece when you “dig” the electrode into the workpiece.

A Welding current too low A Increase welding current.

B Electrode too large for

B Use smaller diameter electrode.

joint.

C Insufﬁcient gap. C Allow wider gap.

A Non-metallic particles may

be trapped in undercut

A If a bad undercut is present clean slag out and

cover with a run from a smaller gauge electrode.

from previous run.

B Joint preparation too

restricted.

C Irregular deposits allow

B Allow for adequate penetration and room for

cleaning out the slag.

C If very bad, chip or grind out irregularities.

slag to be trapped.

D Lack of penetration with

slag trapped beneath weld bead.

D Use smaller electrode with sufﬁcient current to

give adequate penetration. Use suitable tools to remove all slag from comers.

E Rust or mill scale is pre-

E Clean joint before welding.

venting full fusion.

F Wrong electrode for posi-

tion in which welding is done.

Art # A-04273

F Use electrodes designed for position in which

welding is done, otherwise proper control of slag is difﬁcult.

Incorrect sequence Insufﬁcient

gap

Figure 4-39: Example of insufﬁcient gap or incorrect sequence

Table 4-5a: STICK (MMA) metal welding trouble shooting

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BASIC WELDING FABRICATOR 252i

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 (MMA) mode.

MIG (GMAW) welding.

A Small electrodes used on

A Use larger electrodes and preheat the plate.

heavy cold plate.

B Welding current is too low. B Increase welding current.

C Wrong electrode angle. C Adjust angle so the welding arc is directed more

into the base metal.

D Travel speed of electrode

D Reduce travel speed of electrode.

is too high.

E Scale or dirt on joint

E Clean surface before welding.

surface.

Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high

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

Lack of inter-run fusion

Art # A-04274_AB

Lack of Root Fusion

Figure 4-40: Example of Lack of Fusion

Table 4-5b: STICK (MMA) metal welding trouble shooting

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FABRICATOR 252i BASIC WELDING

4.05 TIG (GTAW) Basic Welding Technique

Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based. A ﬁller metal may also be added manually in some circumstances depending on the welding application.

Art # A-09658_AC

Gas Cup

Either Ceramic,

Work Piece

Can Be Any Commercial

Metal

Welds Made With or Without

Addition of Filler Metal

High-lmpact or

Water Cooled

Metal

Tungsten Electrode

Non-Consumable

Inert Gas Shields Electrode and Weld Puddle

Figure 4-41: TIG (GTAW) Welding Application Shot

Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

1.0mm (0.040”) 30-60

1.6mm (1/16") 60-115

2.4mm (3/32”) 100-165

3.2mm (1/8” ) 135-200

4.0mm (5/32”) 190-280

5mm (3/16” ) 250-340

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

Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range (Amps)

1.6mm (1/16”) 20-90

2.4mm (3/32”) 65-115

3.2mm (1/8” ) 100-165

5mm (3/16” ) 200-350

Table 4-7: Filler Wire Selection Guide

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BASIC WELDING FABRICATOR 252i

Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Zirconated 1%

Ceriated 2%

The Fabricator 252i Inverter is not suited for AC TIG welding.

TIG Welding Filler Rods

Welding Application Features Colour Code

DC welding of mild steel, stainless steel and copper

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

AC & DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Table 4-8

NOTE

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.

Red

White

Grey

Base Metal

Thickness

1.0mm

0.040”

1.2mm

0.045”

1.6mm 1/16”

3.2mm

1/8”

4.8mm 3/16”

6.4mm

1/4”

TIG Welding is generally regarded as a specialised 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

1.0mm

0.040”

1.0mm

0.040”

1.6mm 1/16”

2.4mm 3/32”

3.2mm

1/8”

Table 4-9

Filler Rod

Diameter (if

required)

1.6mm 1/16”

2.4mm 3/32”

3.2mm

1/8”

4.0mm 5/32”

Argon Gas Flow Rate

LPM (CFH)

5-7

(10-15)

5-7

(10-15)

(15)

(20)

Joint Type

Butt/Corner

Lap/Fillet

Butt/Corner

Lap/Fillet

Butt/Corner

Lap/Fillet

Butt/Corner

Lap/Fillet

Butt/Corner

Lap/Fillet

Butt/Corner

Lap/Fillet

Manual 0-5193 4-19 BASIC WELDING

FABRICATOR 252i BASIC WELDING

4.06 TIG (GTAW) Welding Problems

FAULT CAUSE REMEDY

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 oxidises

when an arc is struck.

Welding current is too low Increase weld current and/or faulty joint

preparation.

Welding current is too high Decrease weld current.

Travel speed too fast Reduce travel speed.

Travel speed too slow Increase travel speed.

Wrong placement of ﬁller rod Re-position ﬁller rod.

A TIG Torch lead connected to

positive welding terminal.

A Connect TIG Torch lead to negative

welding terminal.

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 impuri-

ties.

F Gas regulator turned OFF. F Turn ON.

G TIG Torch valve is turned OFF. G Turn ON.

H The electrode is too small for

the welding current.

I Power source is set for MIG

welding.

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.

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.

H Increase electrode diameter or reduce

the welding current.

I Set Power Source to LIFT TIG mode.

A Clean the electrode by grinding off the

contaminates.

B Clean surface.

C Gas contaminated with air. C Check gas lines for cuts and loose ﬁt-

ting or change gas cylinder.

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BASIC WELDING FABRICATOR 252i

8 Poor weld ﬁnish Inadequate shielding gas. Increase gas ﬂow or check gas line for

gas ﬂow problems.

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. C Select the right rate for the welding job.

D Incorrect shielding gas is being

used.

E Poor work clamp connection to

work piece.

10 Arc ﬂutters during TIG

welding.

Tungsten electrode is too large for the welding current.

Table 4-10: TIG (GTAW) Welding 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.

Refer to Table 4-10.

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 0-5193 4-21 BASIC WELDING

FABRICATOR 252i BASIC WELDING

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BASIC WELDING 4-22 Manual 0-5193

PROBLEMS/SERVICE FABRICATOR 252i

SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE

SERVICE REQUIREMENTS

5.01 Power Source Problems

Error Code CAUSE REMEDY

ERR 01Over Temperature

Fault

ERR 02Input Power Fault Signal from Power board

ERR 03VBIAS Voltage Low

Fault

ERR

ERR 08Input Sensor Fault Unexpected reading of

ERR

ERR 10Inverter Output Fault Substandard output

ERR

ERR 24Code Memory Fault Welder detected a fault in

Ground Fault Excessive current detected

Fan Fault Cooling Fan Failure detected

Trigger Fault Fault occurred detecting

Wirefeed Fault Welder detects prolonged

Weld Fault Welder detected a 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)

on Ground wire of power connection

voltage or current sensor during power-up self test

on Inverter board

voltage condition detected by controller before weld started

trigger state/condition

open circuit during MIG weld

during the weld process

program ﬂash memory

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.

Manual 0-5193 5-1 PROBLEMS AND ROUTINE SERVICE

FABRICATOR 252i PROBLEMS/SERVICE

ERR 25Nonvolatile Memory

Fault

ERR 26Unknown PCB Fault Welder control board cannot

ERR 30Service Mode Switch

Fault

ERR 31Controller Fault Welder control board has

ERR 33Calibration Fault An output (current, voltage,

ERR 34User Calibration

Abort

ERR 35Parameter Fault Welder control board has

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.

Welder detected a fault in parameter NVROM.

identify an attached inverter board and/or determine its own identity

SERVICE DIP switch is enabled

detected a hardware fault on itself

or motor) fault was detected while attempting a calibration process

User-initiated abort/ interruption of an active calibration process occurred (usually, release of trigger too early)

detected a parameter out of range

Table 5-1: Power Source Problems

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.

Welding is disabled while SERVICE Mode DIP switch is enabled. Disable SERVICE Mode switch to resume welding.

Consult an Accredited Tweco Service Provider if 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)

PROBLEMS AND ROUTINE SERVICE 5-2 Manual 0-5193

PROBLEMS/SERVICE FABRICATOR 252i

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.

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

Minimum Insulation

Resistance (MΩ)

2.5

Manual 0-5193 5-3 PROBLEMS AND ROUTINE SERVICE

FABRICATOR 252i PROBLEMS/SERVICE

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 -

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.

PROBLEMS AND ROUTINE SERVICE 5-4 Manual 0-5193

PROBLEMS/SERVICE FABRICATOR 252i

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.

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 utilised.

Manual 0-5193 5-5 PROBLEMS AND ROUTINE SERVICE

FABRICATOR 252i PROBLEMS/SERVICE

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

PROBLEMS AND ROUTINE SERVICE 5-6 Manual 0-5193

PROBLEMS/SERVICE FABRICATOR 252i

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.

Manual 0-5193 5-7 PROBLEMS AND ROUTINE SERVICE

FABRICATOR 252i PROBLEMS/SERVICE

This Page Intentionally Blank

PROBLEMS AND ROUTINE SERVICE 5-8 Manual 0-5193

REPLACEMENT PARTS FABRICATOR 252i

SECTION 6: KEY SPARE PARTS

6.01 Fabricator 252i Power Supply Replacement Panels

Art # A-10784_AB

Figure 6-1: Structural Replacement Parts

FABRICATOR 252i POWER SOURCE SPARE PARTS (LEFT SIDE)

ITEM PART NUMBER DESCRIPTION

1 W7005323 Latch,Slide

2 W7005366 Door, 252I

3 W7005386 Panel,Rear,252I

4 W7005367 Panel, Side, 252I

5 W7005303 Bkt,Spool Support,252I

6 W7005300 Panel,Center,252I

7 W7005360 Panel, Front 252I

8 831596 Door, Chart Label

Table 6-1

Manual 0-5193 6-1 REPLACEMENT PARTS

FABRICATOR 252i REPLACEMENT PARTS

Figure 6-2: Wire Feed Replacement Parts

FABRICATOR 252i POWER SOURCE SPARE PARTS (LEFT SIDE)

ITEM PART NUMBER DESCRIPTION

1 W7005311 Spool Hub Assembly

2 W7005353 Wire Drive Assembly, 252I. (Does Not Include Motor)

3 375838-002 Guide, Inlet 0.6 - 1.6mm (.023 - 1/16")

4 See Appendix 1 Roll, Pressure No Groove

5 See Appendix 1 Roll, Feed Dual V

Art # 10332_AD

6 W6000801 Guide, Outlet 0.9 - 1.2mm (.030 - .045")

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

Table 6-2

REPLACEMENT PARTS 6-2 Manual 0-5193

REPLACEMENT PARTS FABRICATOR 252i

Art # A-10333_AC

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, 250i Main Power 2 W7005347 PCB, EMI, 250A 3 W7005307 Socket 8 pin with harness 4 W7005388 PCB, Control Assy, 250i 5 W7005304 Dinse, Socket Panel, 50mm

6 W7005357

Socket 10 pin w/harness (Note: 10 pin Control Plug Part# is W7005358)

7 W7005315 Solenoid,24V,0-0.8MPa 8 W7005351 Inductor

9 W7005302 Transformer, Main, 250i 10 W7005331 PCB, Mov/Bridge, 250A 11 W7005317 Fan, 92x25 LS 24V 12 W7005316 Fan, 92x38 HS 24V

13 W7005355 Inlet, Gas, QC, Male 14 W7005335 Knob, 6mm, D Shaft, Snap Fit 15 W7005352 Ribbon Cable 16 W7005362 Panel Mounted Gas Fitting 17 W7005305 Wiring Harness, with plugs 18 W7005324 Current Transformer

Table 6-3

Manual 0-5193 6-3 REPLACEMENT PARTS

FABRICATOR 252i REPLACEMENT PARTS

This Page Intentionally Blank

REPLACEMENT PARTS 6-4 Manual 0-5193

APPENDIX FABRICATOR 252i

Mild Steel /

Stainless Steel

Mild Steel /

Stainless Steel

Mild Steel /

Stainless Steel

Mild Steel /

Stainless Steel

Mild Steel /

Stainless Steel

1.0mm (.040")

Flux Cored

375832

407002-003

1.2mm (.045")

Flux Cored

170924-010

1.6mm (1/16")

Flux Cored

170924-001

0.9mm (.035")

Aluminium

408023-001

APPENDIX 1: OPTIONS AND ACCESSORIES

Description Part Number

Tweco TWE2 MIG Torch, 3 M (9.8ft) 161.550.307

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 W7004930 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

Accessory Kit P062900010

Table A-1: Options and Accessories

W4013600

Top

Drive

Roll

Bottom

Drive

Roll

Mild Steel Stainless Steel

0.6 to 1.2mm .023” to .045”

Flux Cored

0.8 to 1.0mm .030” to .040”

Flux Cored

1.2 to 1.6mm .045” to 1/16”

Aluminium

0.9 to 1.2mm .035” to 3/64”

Art # A-11203

Figure A-1: Drive Roll Chart

Wire Size Wire Type Top Drive Roll Bottom Drive Roll Inlet Guide Outlet Guide

0.6mm (.023")

0.8mm (.030")

0.9mm (.035")

1.0mm (.040")

1.2mm (.045")

0.8mm (.030") Flux Cored 375832 407002-002

0.9mm (.035") Flux Cored 375832 407002-002

1.0mm (.040") Aluminium 408023-009 408023-009

1.2mm (.045") Aluminium 408023-002 408023-002

407002-001 407002-002

407002-001 407002-003

375838-003 W6000800

375838-001 W6000801

375838-001 W6000801 375838-001 W6000801 375838-001 W6000801 375838-001 W6000801 375838-002 W6000802

375647 W6000804 375647 W6000804 375647 W6000804

Table A-2: Wire, Drive Roll and Guide Recommended Combinations

Manual 0-5193 A-1 APPENDIX

FABRICATOR 252i APPENDIX

APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM

GND

FRONT PANEL

VIDENT

SOL+

WFSPOT2

VBIAS

TRIG2 MOTOR+ MOTOR-

VPOT2

VPOT1

WFSPOT1

VBIAS

TRIG1

I E G F H D C B A

8 7 6 5

N/C

4 3 2

N/C

1 2 3 4 5

POT_RETURN

TRIG_SOL_RTN

POT_RETURN

TRIG_RETURN

LINE

BREAKER

LOAD

CONTROL BOARD

NOTE 1

FERRITE

AUX TRIG

FRONT PANEL

EMI BOARD

WELD OUTPUT +

WELD OUTPUT -

FRONT PANEL

NOTES:

1. EMI ASSEMBLY, COMMON MODE CHOKE AND FERRITE (IF USED)

Art # A-10334

CURRENT SENSOR

1 2 3 4

INDUCTOR

Rev

Revision

Date

APPENDIX A-2 Manual 0-5193

APPENDIX FABRICATOR 252i

123456789

CHASSIS GND

BRIDGE + BRIDGE -

BRIDGE / MOV BOARD

P1 P2 P3

NI CANI CA

123

123456789

NOTE 1

COMMON MODE CHOKE

MOTOR

12341324121

101112

GAS SOL

TIG SOL

BREAKER

FAN

P6P5

DC+

Rev

00 PROTOTYPE

Revision

P12

2 1

1 2 3 4 5 6

GAC 07/12/2011

P10

HI-POT

TEMP SW

P11

P13

SECSEC CT

TRANSFORMER

PRI PRI

P14

HI-POT

Date

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

GND PRI

Art # A-10334_AB

Victor Technologies, Inc.

16052 Swingley Ridge Road, Suite 300

St Louis, Missouri 63017 USA

Date Printed

Drawn

Size

Drawing Number

7/12/2011

GAC

Date Revised

7/12/2011

Date

02/14/2011

Sheet

1 1

42X500100

Manual 0-5193 A-3 APPENDIX

This Page Intentionally Blank

TWECO - LIMITED WARRANTY TERMS

LIMITED WARRANTY: Tweco®, Inc, A Victor Technologies Company, warrants to customers of its authorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Tweco products as stated below, Tweco shall, upon notiﬁcation thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Tweco’s speciﬁcations, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Tweco’s sole option, of any components or parts of the product determined by Tweco to be defective.

TWECO MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: TWECO SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Tweco with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Tweco whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Tweco is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN TWECO’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY TWECO PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

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

LIMITED WARRANTY & WARRANTY SCHEDULE

In accordance with the warranty periods stated below, Victor Technologies guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as deﬁned in this operating manual.

Victor Technologies welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment.

Victor Technologies will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the warranty period. The warranty period begins on the date of sale to the end user.

Tweco Fabricator 252i

Component Warranty Period

Power Source 2 Years

Electrode Holder / Lead & Work Lead 3 Months MIG Torch Consumables NIL

If warranty is being sought, Please contact your Victor Technologies product supplier for the warranty repair procedure.

Victor Technologies warranty will not apply to:

• Equipment that has been modied by any other party other than Victor Technologies’s own service personnel or with prior written consent obtained from Victor Technologies Service Department.

• Equipment that has been used beyond the specications established in the operating manual.

• Installation not in accordance with the installation/operating manual.

• Any product that has been subjected to abuse, misuse, negligence or accident.

• Failure to clean and maintain (including lack of lubrication, maintenance and protection), the machine as

set forth in the operating, installation or service manual.

Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation.

This manual also offers basic troubleshooting, operational and technical details including application usage.

You may also wish to visit our web site www.victortechnologies.com, select your product class, and then select literature. Here you will ﬁnd documentation including:

• Operator manuals

• Service manuals

• Product guides

Alternatively, please contact your Victor Technologies distributor and speak with a technical representative.

NOTE

Warranty repairs must be performed by either a Victor Technologies Service Centre, a Victor Technologies distributor or an Authorised Service Agent approved by the Company.

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™

T ECHNOLOGIES

™

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

TWECO FABRICATOR 252i 3-IN-1 Multi Process Welding Systems Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 General Safety Information for Victor CS Regulator

1.03 Principal Safety Standards

1.04 Declaration of Conformity

SECTION 2: INTRODUCTION

2.01 How to Use This Manual

2.03 Receipt of Equipment

2.04 Symbol Chart

2.05 Description

2.06 User Responsibility

2.07 Transportation Methods

2.08 Packaged Items

2.09 Duty Cycle

SECTION 3: INSTALLATION OPERATION AND SETUP

3.01 Environment

3.03 Ventilation

3.02 Location

3.04 Mains Supply Voltage Requirements

3.05 Electromagnetic Compatibility

3.06 Power Source Controls, Indicators and Features

3.07 Advanced Features Details

3.08 Attaching the MIG Gun (Euro)

3.09 Installing a 5 kg (12.5 lb) spool 200mm (8") diameter

3.10 Installing a Standard Spool 300mm (12") diameter

3.11 Inserting Wire into the Feed Mechanism

3.12 Feed Roller Pressure Adjustment

3.13 Feed Roller Alignment

3.14 Changing the Feed Roll

3.15 Input And Output Wire Guide Installation

3.16 Wire Reel Brake

3.17 Shielding Gas Regulator Operating Instructions

3.18 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire

3.19 Set-up for MIG (FCAW) Welding with Gasless MIG Wire

3.20 Set-up for LIFT TIG (GTAW) Welding

3.21 Set-up for STICK Metal Arc Welding (MMA)

4.01 MIG (GMAW/FCAW) Basic Welding Technique

4.02 MIG (GMAW/FCAW) Welding Troubleshooting

4.03 STICK (MMA) Basic Welding Technique

4.04 STICK (MMA) Welding Troubleshooting

4.05 TIG (GTAW) Basic Welding Technique

4.06 TIG (GTAW) Welding Problems

5.01 Power Source Problems

5.02 Routine Service and Calibration Requirements

5.03 Cleaning the Welding Power Source

5.04 Cleaning the Feed Rolls

SECTION 6: KEY SPARE PARTS

6.01 Fabricator 252i Power Supply Replacement Panels

APPENDIX 1: OPTIONS AND ACCESSORIES

APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM

TWECO - LIMITED WARRANTY TERMS

LIMITED WARRANTY & WARRANTY SCHEDULE