Tweco FABRICATOR 141i Operating Manual
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Tweco FABRICATOR 141i Operating Manual

3-in-1 multi process welding systems
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FABRICATOR
141i
®
3-IN-1 Multi Process
Welding Systems
Operating
Manual
English
Canadien Français
Americas Español
Art # A-11510_AC
Revision: AJ
Issue Date: February 6, 2015
Manual No.: 0-5145
3163339
Tweco.com

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  • Page 1 FABRICATOR 141i ® 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Art # A-11510_AC Revision: AJ Issue Date: February 6, 2015 Manual No.: 0-5145 3163339 Tweco.com...
  • Page 2 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.
  • Page 3 Tweco Fabricator 141i Portable System Package Part Number W1003141 Tweco Fabricator 141i Power Source Part Number W1003140 Tweco Fabricator 141i Portable System Package with Cart Part Number W1003142 Published by: Victor Technologies, Inc. 16052 Swingley Ridge Road, Suite 300 St. Louis, MO 63017 www.victortechnologies.com...

  • Page 4: Table Of Contents

    2.04 Description ..................... 2-1 2.05 Transportation Methods .................. 2-1 2.06 User Responsibility ..................2-2 2.07 Fabricator 141i Portable System Package (Part No. W1003141) ....2-2 2.08 Duty Cycle ....................... 2-3 2.09 Specifications ....................2-4 2.10 Options and Accessories ................2-5 SECTION 3: INSTALLATION, OPERATION AND SETUP ..........
  • Page 5 Tweco Fusion 140A MIG Gun Parts ..............6-1 6.02 Power Source ....................6-2 6.03 Hardware List ....................6-4 APPENDIX ....................A-1 APPENDIX: FABRICATOR 141I CIRCUIT DIAGRAM ............ A-2 TWECO - LIMITED WARRANTY TERMS ..........INSIDE REAR COVER INTERNATIONAL CONTACT INFORMATION ..........REAR COVER...
  • Page 6 This Page Intentionally Blank...

  • Page 7: Section 1: Safety Instructions And Warnings

    Fabricator 141i 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.
  • Page 8 Fabricator 141i 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, ARC RAYS can burn eyes and skin; NOISE flame-resistant material (wool and leather) and foot can damage hearing.
  • Page 9 Fabricator 141i 1. Keep your head out of the fumes. Do not breathe 6. Be aware that welding on a ceiling, floor, bulkhead, the fumes. or partition can cause fire on the hidden side. 2. If inside, ventilate the area and/or use exhaust at the 7.
  • Page 10 Fabricator 141i 7. Keep protective cap in place over valve except when 3. Have only qualified people remove guards or cylinder is in use or connected for use. covers for maintenance and troubleshooting as necessary. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA 4.

  • Page 11: General Safety Information For Victor Cs Regulator

    Fabricator 141i 1.02 General Safety Information for Victor CS Regulator WARNING A. Fire Prevention WARNING: This product contains chemicals, including Welding and cutting operations use fire or combustion lead, known to the State of California to cause birth as a basic tool. The process is very useful when properly defects and other reproductive harm.
  • Page 12 Fabricator 141i C. Ventilation E. Compressed Gas Cylinders The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases WARNING used for welding or cutting operations. Ade quately ventilate welding, heating, and 1. Place the cylinder (Figure 1-1) where you will cutting work areas to prevent accumula- use it.

  • Page 13: Principal Safety Standards

    Fabricator 141i 1.03 Principal Safety Standards 5. Inspect the cylinder valve for oil, grease, and damaged parts. Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. WARNING Safety and Health Standards, OSHA 29 CFR 1910, DO NOT use the cylinder if you find oil, from Superintendent of Documents, U.S.

  • Page 14: Symbol Chart

    Fabricator 141i 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage...

  • Page 15: Precautions De Securite En Soudage A L'arc

    Fabricator 141i 1.05 Precautions De Securite En Soudage A L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDI- AQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 16 Fabricator 141i 8. N’utilisez pas de câbles électriques usés, endom- 14. Portez un harnais de sécurité si vous travaillez en magés, mal épissés ou de section trop petite. hauteur. 9. N’enroulez pas de câbles électriques autour de votre 15. Fermez solidement tous les panneaux et les capots.
  • Page 17 Fabricator 141i indiquée ci-après) pour vous protéger le visage et si nécessaire portez un respirateur à adduction d’air. les yeux lorsque vous soudez ou que vous observez Car ces revêtements et tout métal qui contient ces l’exécution d’une soudure. éléments peuvent dégager des fumées toxiques au moment du soudage.
  • Page 18 Fabricator 141i 11. Portez des vêtements protecteurs non huileux, tels 7. Laissez en place le chapeau de bouteille sauf si en des gants en cuir, une chemise épaisse, un pantalon utilisation ou lorsque raccordé pour utilisation. revers, des bottines de sécurité et un casque.
  • Page 19 Fabricator 141i 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT AVERTISSEMENT CAUSER DES BLESSURES. LA VAPEUR ET LE LIQUIDE DE REFROI- Des pièces en mouvement, tels des ventila- DISSEMENT BRULANT SOUS PRESSION teurs, des rotors et des courroies peuvent PEUVENT BRULER LA PEAU ET LES YEUX.

  • Page 20: Informations Générales De Sécurité

    Fabricator 141i des faits scientifiques visant à atténuer ou éviter des risques potentiels ». AVERTISSEMENT Pour atténuer les champs magnétiques sur les lieux de travail, respectez les procédures qui suivent : N’effectuez d’opérations de soudage JAMAIS sur un récipient qui a contenu des liquides ou 1.
  • Page 21 Fabricator 141i manches et poches boutonnés. Il ne faut pas remonter AVIS vos manches ou les pantalons à revers. Ce document CGA p. t peut être obtenu en écrivant à “Compressed Gas Association”, Quand vous travaillez dans un environnement non 4221 Walney Roed, 5th Floor.

  • Page 22: Principales Normes De Securite

    Fabricator 141i 1.08 Principales Normes De Securite Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128. Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 23: Graphique De Symbole

    Fabricator 141i 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage Torch de Tension dangereuse Fréquence Convertisseur...
  • Page 24 Fabricator 141i This Page Intentionally Blank SAFETY INSTRUCTIONS AND WARNINGS 1-18 Manual 0-5145...

  • Page 25: Section 2: Introduction

    WARNING 2.04 Description Gives information regarding possible per- The Tweco Fabricator 141i is a self contained single sonal injury. Warnings will be enclosed in a phase multi process welding system that is capable of box such as this.

  • Page 26: User Responsibility

    This equipment or any of its parts should not be altered from standard specification without prior written approval of Tweco. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Tweco.

  • Page 27: Duty Cycle

    2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. Fabricator 141i Safe Operating TIG (GTAW) Region STICK (SMAW) / MIG (GMAW/ FCAW) Art # A-11276_AB Welding Current (amps) Figure 2-1: Fabricator 141i Duty Cycle Manual 0-51 INTRODUCTION...

  • Page 28: Specifications

    Fabricator 141i 2.09 Specifications DESCRIPTION FABRICATOR 141i MULTI PROCESS 3 IN 1 WELDER Power Source Part No. W1003140 Power Source Dimensions H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm) Power Source Weight 32.2lb(14.6kg) Cooling Fan Cooled Welder Type...

  • Page 29: Options And Accessories

    Source (Based on Article 630, National Electrical Code) Tweco continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speci fications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the correspond- ing changes, updates, improvements or replacement of such items.
  • Page 30 This Page Intentionally Blank...

  • Page 31: Section 3: Installation, Operation And Setup

    Fabricator 141i SECTION 3: INSTALLATION, OPERATION AND SETUP G. The enclosure design of this Power Source meets the 3.01 Environment requirements of IP23S as outlined in EN 60529. This This Power Source is designed for use in environments provides adequate protection against solid objects with increased hazard of electric shock.
  • Page 32 Fabricator 141i WARNING The Fabricator 141i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 140 VAC or higher is applied to the Primary Power Cable. WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts.

  • Page 33: Electromagnetic Compatibility

    Fabricator 141i NOTE Welding arc outs may be experienced if an extension cord is used when STICK welding when operating the Power Source on 95 VAC due to the lack of DC voltage at the STICK electrode. Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors.

  • Page 34: Victor Flowmeter/ Regulator

    Fabricator 141i 7. The time of day that welding or other activities be considered. However. Metallic components are to be carried out. bonded to the work piece will increase the risk that the operator could receive a shock 8. The compatibility of other equipment in the...
  • Page 35 Fabricator 141i 4. Be sure that the flowmeter/ regulator has the correct pressure rating and gas service for the WARNING cylinder used. Use the flowmeter/ regulator for the gas and 5. Carefully inspect the flowmeter/ regulator for pressure for which it is designed. NEVER...

  • Page 36: Leak Testing The System

    Fabricator 141i a) If the high-pressure gauge reading drops, there is a leak in the cylinder valve, inlet WARNING fitting, or high-pressure gauge. Stand to the side of the cylinder opposite b) If the low-pressure gauge drops, there is a...

  • Page 37: Power Source Controls, Indicators And Features

    Fabricator 141i 3.10 Power Source Controls, Indicators and Features POWER FAULT LIFT TIG STICK STICK SOFT HARD SOFT HARD DOWNSLOPE (S) DOWNSLOPE (S) ARC FORCE (%) WIRESPEED INDUCTANCE WIRESPEED ARC FORCE (%) INDUCTANCE Art # A-11509_AC Art # A-10354 Figure 3-4: Front Panel...
  • Page 38 4. MIG Gun Adapter (Tweco Style) The MIG Gun adapter is standard Tweco connection with an 8 pin gun trigger for the Fusion MIG Gun. Connect the MIG Gun by pushing the MIG Gun connector into the brass MIG Gun Adapter firmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment to secure the Fusion MIG Gun in position.
  • Page 39 Fabricator 141i 5. Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the Power Source to the appropriate welding accessory such as the MIG Gun (via the MIG Gun polarity lead), electrode holder lead or work lead.
  • Page 40 Fabricator 141i Negative Trigger Switch Spool Gun Motor Positive Remote Volts in MIG (GMAW/FCAW) Remote Wirespeed in MIG (GMAW/FCAW) mode Remote Amps in LIFT TIG (GTAW) mode Art # A-10421_AC Figure 3-7: Remote Control Socket Socket Pin Function Spool gun motor (0V)
  • Page 41 Fabricator 141i 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.
  • Page 42 Fabricator 141i 13. Digital Voltage Meter (Right Digital Display) The digital voltage meter is used to display the both the preview voltage (MIG mode only) and actual output voltage (all modes) of the Power Source. At times of non-welding, the voltage meter will display a preview value in MIG mode. This value can be adjusted by varying the multifunction control knob (Control No.
  • Page 43 Fabricator 141i 17. Intelligent Fan Control When Power Supply is first turned on it will default in MIG Mode. The Fan will operate for approximately 10 seconds, then shut down. When triggered in MIG mode, fan will not turn on until Power Supply reaches temperatures in which cooling is required.

  • Page 44: Attaching The Fusion 140A Mig Gun

    Fabricator 141i 3.11 Attaching the Fusion 140A MIG Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter.

  • Page 45: Inserting Wire Into The Wire Feed Mechanism

    Fabricator 141i 3.12 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in a counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm.

  • Page 46: Installing 4" (100Mm) Diameter Spool

    Fabricator 141i 3.13 Installing 4" (100mm) Diameter Spool As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 3-11.

  • Page 47: Installing 8" (200Mm) Diameter Spool

    Fabricator 141i 3.14 Installing 8" (200mm) Diameter Spool As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool. In order to re-fit a 8" (200mm) spool assemble parts in the sequence shown below in Figure 3-12.

  • Page 48: Feed Roller Pressure Adjustment

    Fabricator 141i 3.15 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and debris.

  • Page 49: Wire Reel Brake

    Fabricator 141i 3.17 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake.

  • Page 50: Flowmeter/ Regulator Operation

    Fabricator 141i 3.18 Flowmeter/ Regulator Operation With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal parts.

  • Page 51: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    Fabricator 141i 3.19 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire A. Select MIG mode with the process selection control. (Refer to Section 3.10 for further information) B. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
  • Page 52 Fabricator 141i Art # A-10362 Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. Positive Welding Shielding Gas Hose Fitted Terminal (+) with 5/8"-18 UNF connection MIG Gun Negative Welding...

  • Page 53: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    Fabricator 141i 3.20 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 3.10.12 for further information). B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
  • Page 54 Fabricator 141i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead. A-09587_AD Work Lead Figure 3-17: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire INSTALLATION, OPERATION AND SETUP 3-24 Manual 0-5145...

  • Page 55: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    Fabricator 141i 3.21 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire Set the Process Selection Control to MIG for Spool Gun welding. For setup and operation of the spool gun, please refer to the spool gun operations manual.

  • Page 56: Setup For Lift Tig (Gtaw) Welding

    NOTE A Tweco 17V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Tweco Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.
  • Page 57 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Tweco Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing...

  • Page 58: Setup For Stick (Smaw) Welding

    Fabricator 141i 3.23 Setup for STICK (SMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

  • Page 59: Torch Adapter Thumb Screw Replacement

    Fabricator 141i 3.24 Torch Adapter Thumb Screw Replacement WARNING All power to unit should be removed. 1. Place unit on its back. Art # A-11482_AB 2. Remove 2 screws in bottom of the front panel. A securing block will become detached and fall free from the front panel as you turn each screw out.
  • Page 60 Fabricator 141i 3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang downwardly. Tension Knob Pressure Arm Art # A-11484 4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed.

  • Page 61: Section 4: Basic Welding Guide

    Fabricator 141i SECTION 4: BASIC WELDING GUIDE 4.01 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the MIG mode of welding, where a welding MIG Gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
  • Page 62 Fabricator 141i Position of MIG Gun The angle of MIG Gun to the weld has an effect on the width of the weld. Push Vertical Drag/Pull Art # A-07185_AB Figure 4-3 The welding Gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the MIG Gun so that the welding seam is viewed at all times.
  • Page 63 Fabricator 141i 10° to 20° Longitudinal Angle 10° Longitudinal Angle 30° to 60° 30° to 60° Transverse Transverse Angle Angle Direction of Travel Vertical Fillet Welds Art # A-08995 Figure 4-6 Direction of Travel 30° to 60° Transverse Angle 5° to 15°...
  • Page 64 Fabricator 141i Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are: 1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 3/8"...
  • Page 65 Fabricator 141i 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.
  • Page 66 Fabricator 141i Tweco MIG, Lift TIG, Stick Wire Selection Chart Art # A-11577_AC Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart BASIC WELDING GUIDE Manual 0-5145...

  • Page 67: Mig (Gmaw/Fcaw) Welding Troubleshooting

    Fabricator 141i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG Gun. There are two main areas where problems occur with MIG, Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
  • Page 68 Fabricator 141i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the Wire spool brake is too tight or drive roll tension not cabinet slipped tight enough.
  • Page 69 Fabricator 141i Basic MIG Welding Troubleshooting FAULT CAUSE REMEDY 1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed. B Incorrect MIG Gun angle B Adjust angle. C Excessive heat input C Increase the MIG Gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed.

  • Page 70: Stick (Smaw) Basic Welding Technique

    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. BASIC WELDING GUIDE...

  • Page 71: Effects Of Stick Welding Various Materials

    Fabricator 141i 4.04 Effects of Stick Welding Various Materials High Tensile and Alloy Steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and 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.
  • Page 72 Fabricator 141i Art # A-07688 Figure 4-12: Flat Position, Gravity Fillet Weld Art # A-07689 Figure 4-13: Horizontal Position, Butt Weld Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position Art A-07691 Figure 4-15: Vertical Position, Butt Weld BASIC WELDING GUIDE...
  • Page 73 Fabricator 141i Art # A-07692 Figure 4-16: Vertical Position, Fillet Weld Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld Manual 0-5145 4-13 BASIC WELDING GUIDE...
  • Page 74 Fabricator 141i 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.
  • Page 75 Fabricator 141i 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.
  • Page 76 Fabricator 141i Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1/16"(1.6mm) to 3/32"(2.4mm) gap between them and tack weld at both ends.
  • Page 77 Fabricator 141i A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 1/8"(3.2mm) E7014 Stick electrode at 100 amps, position angle iron with one leg horizontal and the other vertical.
  • Page 78 Fabricator 141i C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 1/8"(3.2mm) E7014 Stick electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet.
  • Page 79 Fabricator 141i 2. Vertical Down The E7014 Stick electrode makes welding in this position particularly easy. Use a 1/8"(3.2mm) electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag.
  • Page 80 Fabricator 141i 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"...
  • Page 81 Fabricator 141i 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.

  • Page 82: Stick (Smaw) Welding Troubleshooting

    Fabricator 141i Art # A-07711_AB Figure 4-35: Step back Sequence Art # A-07428_AB Figure 4-36: Chain Intermittent Welding Art # A-07713_AB Figure 4-37: Staggered Intermittent Welding 4.05 Stick (SMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob is...
  • Page 83 Fabricator 141i FAULT CAUSE REMEDY 3 Non-metallic par- A Non-metallic particles may A If a bad undercut is present clean slag bout and ticles are trapped be trapped in undercut from cover with a run from a smaller gauge electrode.
  • Page 84 Fabricator 141i FAULT CAUSE REMEDY 5 Portions of the A Small electrodes used on A Use larger electrodes and preheat the plate. weld run do not heavy cold plate. fuse to the surface B Welding current is too low. B Increase welding current.

  • Page 85: Tig (Gtaw) Basic Welding Technique

    Fabricator 141i FAULT CAUSE REMEDY 8 The Stick elec- The Stick electrode being Use E6013 or E7018 Stick electrodes for steel or trode is difficult to used is not suitable for use 300 series stainless steel Stick electrodes for 300 run with multiple with this machine.
  • Page 86 Wider current Grey num, magnesium and range, Narrower more their alloys concentrated arc. Table 4-8 NOTE The Fabricator 141i is not suited for AC TIG welding. Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type...

  • Page 87: Tig (Gtaw) Welding Problems

    Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www. victortechnologies.com or contact Tweco. 4.07 TIG (GTAW) Welding Problems...
  • Page 88 Fabricator 141i FAULT CAUSE REMEDY 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the con- by contact with work taminates. piece or filler rod mate- rial. B Work piece surface has B Clean surface.

  • Page 89: Power Source Problems And Routine Service Requirements

    Fabricator 141i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Primary Power Supply is A Power Source is not in the correct A Set the Power Source to the correct ON, power indicator is illu- mode of operation.
  • Page 90 E Replace gas cylinder. 8 Gas flow continues after Gas valve has jammed open due to Have an accredited Tweco service the torch trigger switch has debris in the gas or the gas line. provider repair or replace gas valve.

  • Page 91: Routine Service

    The inspection and testing of the Power Source and associated accessories shall be carried out in accordance with Section 5 of EN 60974-1: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an insulation resistance test and an earthing test to ensure the integrity of the Power Source is compliant with Tweco's original specifications.

  • Page 92: Cleaning The Welding Power Source

    Curves of other settings fall between curves shown. Fabricator 141i TIG (GTAW) MIG (GMAW/ FCAW) STICK (SMAW) 90 100 110 120 130 140 150 Welding Current (Amps) Art # A-11807 Figure 5-1: Fabricator 141i Volt-Ampere Curves TROUBLE SHOOTING AND SERVICE Manual 0-5145...

  • Page 93: Section 6: Key Spare Parts

    5B Tweco Control Wire 35K-350-1 2000-2352 5C Tweco Control Wire WS-354-TA-LC 2060-2141 & Plug Table 6-1: Tweco Fusion 140A MIG Gun Parts ** Patent Pending Figure 6-1 * Refer to Tweco Catalog No. 64-2103 for additional options. Manual 0-5145 KEY SPARE PARTS...

  • Page 94: Power Source

    Fabricator 141i 6.02 Power Source Figure 6-2 KEY SPARE PARTS Manual 0-5145...
  • Page 95 Fabricator 141i FABRICATOR 141i POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006216 PCB,Power,141i W7006227 PCB,Control,141i W7003033 Solenoid,Valve,24VDC W7006226 PCB, Remote Interface Integrated with Display, 141i W7006209 Wiredrive Assy,w/ Motor,141i W7004906 Feedroll retaining thumb screw 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed W7004947 Fan,24VDC,4.75"x4.75"x1",141i...

  • Page 96: Hardware List

    Screw Hexagon HD 9/32 × 16 ×19 Wirefeeder Plate Screw Skt Set M4 × 0.7 Tweco No. 4 Torch Adaptor Screw Hexagon M6 × 1.0-10 ST ZP Tweco No. 4 Torch Adaptor Nut Hexagon M10 × 1. 5 ST ZP Tweco No.
  • Page 97 Fabricator 141i SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL SCREW ITEM 4, 2 OFF USED...
  • Page 98 Fabricator 141i This Page Intentionally Blank KEY SPARE PARTS Manual 0-5145...

  • Page 99: Appendix

    Fabricator 141i APPENDIX This Page Intentionally Blank. Manual 0-5145 APPENDIX...

  • Page 100: Appendix: Fabricator 141I Circuit Diagram

    Fabricator 141i APPENDIX: FABRICATOR 141i CIRCUIT DIAGRAM CONNECTOR LAY WVIN QF/DY NTCS FUNS 1 2 3 APPENDIX Manual 0-5145...
  • Page 101 Fabricator 141i YOUT DIAGRAM DRIVE SOURCE Art # A-11792 _AC Manual 0-5145 APPENDIX...

  • Page 102: Tweco - Limited Warranty Terms

    “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, oper- ated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized...
  • Page 103 * 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Victor Regulator for Fabricator 141i (No labor) 1 Years Parts and Labor Unless specified 95S, Water recirculators All Plasma Welding consols (i.e WC-1 Controller, WT Timer,...
  • Page 104 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...

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