Tweco FABRICATOR 252i Operating Manual
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Tweco FABRICATOR 252i Operating Manual

3-in-1 multi process welding systems
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300
FABRICATOR
252i
®
3-IN-1 Multi Process
Welding Systems
Operating
Manual
English
Canadien Français
Americas Español
Português
Revision: AF
Issue Date: June 12, 2013
Manual No.: 0-5155
3163339
Tweco.com

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  • Page 1 FABRICATOR 252i ® 3-IN-1 Multi Process Welding Systems Operating Manual English Canadien Français Americas Español Português Revision: AF Issue Date: June 12, 2013 Manual No.: 0-5155 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 While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5155 for: Tweco Fabricator 252i Inverter Power Supply Part No. W1004400 Tweco Fabricator 252i Inverter System Part No. W1004401...

  • Page 4: Table Of Contents

    Power Source Controls, Indicators and Features ..........3-4 3.07 Advanced Features Details ................3-10 3.08 Attaching the Tweco Fusion 250A MIG Gun ..........3-15 3.09 Installing a 12.5 lb spool (8" diameter) ............3-16 3.10 Installing a Standard Spool (12" diameter) ........... 3-17 3.11...
  • Page 5 6.02 Tweco Fusion 250A MIG Gun ................6-4 APPENDIX 1: OPTIONS AND ACCESSORIES ............A-1 APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM ..........A-2 TWECO - LIMITED WARRANTY TERMS ..........INSIDE REAR COVER GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......... REAR COVER...
  • Page 6 This Page Intentionally Blank...

  • Page 7: Section 1: Safety Instructions And Warnings

    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.

  • Page 8: Safety Instructions

    FABRICATOR 252i SAFETY INSTRUCTIONS 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 SAFETY INSTRUCTIONS FABRICATOR 252i 6. Be aware that welding on a ceiling, floor, bulkhead, 1. Keep your head out of the fumes. Do not breathe or partition can cause fire on the hidden side. the fumes. 7. Do not weld on closed containers such as tanks or 2.
  • Page 10 FABRICATOR 252i SAFETY INSTRUCTIONS 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

    SAFETY INSTRUCTIONS FABRICATOR 252i 1.02 General Safety Information for Victor CS Regulator LEAD WARNING Fire Prevention WARNING: This product contains chemicals, Welding and cutting operations use fire or combustion including lead, known to the State of as a basic tool. The process is very useful when properly California to cause birth defects and other controlled.
  • Page 12 FABRICATOR 252i SAFETY INSTRUCTIONS Ventilation 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

    SAFETY INSTRUCTIONS FABRICATOR 252i 1.03 Principal Safety Standards 4. NEVER use compressed gas cylinders without a pressure reducing regulator attached to the Safety in Welding and Cutting, ANSI Standard Z49.1, cylinder valve. from American Welding Society, 550 N.W. LeJeune Rd., 5.

  • Page 14: Symbol Chart

    FABRICATOR 252i SAFETY INSTRUCTIONS 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...

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

    SAFETY INSTRUCTIONS FABRICATOR 252i 1.05 Precautions De Securite En Soudage A L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 16 FABRICATOR 252i SAFETY INSTRUCTIONS 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre). AVERTISSEMENT 12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées. LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU;...
  • Page 17 SAFETY INSTRUCTIONS FABRICATOR 252i 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. AVERTISSEMENT 3. Entourez l’aire de soudage de rideaux ou de cloisons LE SOUDAGE PEUT CAUSER UN INCENDIE pour protéger les autres des coups d’arc ou de OU UNE EXPLOSION l’éblouissement;...
  • Page 18 FABRICATOR 252i SAFETY INSTRUCTIONS 8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements AVERTISSEMENT connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous. LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.
  • Page 19 SAFETY INSTRUCTIONS FABRICATOR 252i 1. Assurez-vous que les portes, les panneaux, les 1. N’ôtez pas le bouchon de radiateur tant que le moteur capots et les protecteurs soient bien fermés. n’est pas refroidi. 2. Avant d’installer ou de connecter un système, arrêtez 2.

  • Page 20: Informations Générales De Sécurité

    FABRICATOR 252i SAFETY INSTRUCTIONS 3. N’enroulez pas de câble autour du corps. Entretien des Locaux 4. Maintenez le bloc d’alimentation du poste de soudage et les câbles aussi loin que possible AVERTISSEMENT du corps. Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres substances...
  • Page 21 SAFETY INSTRUCTIONS FABRICATOR 252i 2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez AVERTISSEMENT ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez Mettez en pratique les procédures de un diable approprié...

  • Page 22: Principales Normes De Securite

    FABRICATOR 252i SAFETY INSTRUCTIONS 1.08 Principales Normes De Securite Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128. Safety and Health Standards, OSHA 29 CFR 1910, Supe- rintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 23: Graphique De Symbole

    SAFETY INSTRUCTIONS FABRICATOR 252i 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...

  • Page 24: Declaration Of Conformity

    Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excel- lence in our area of manufacture. Manufacturers responsible representative: Tom Wermert Senior Brand Manager Tweco Victor Technologies International, Inc. 16052 Swingley Ridge Road Chesterfield, Missouri 63017 USA...

  • Page 25: Section 2: Introduction

    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 iden- tification numbers.

  • Page 26: Description

    FABRICATOR 252i INTRODUCTION 2.06 Transportation Methods 2.04 Description The Tweco Fabricator 252i is a self contained single phase multi process welding power source that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and Lift WARNING TIG (GTAW) welding processes. The Fabricator 252i is ELECTRIC SHOCK can kill.

  • Page 27: Packaged Items

    • .035" (0.9 mm) • .045" (1.2 mm) - Victor® Argon Regulator / Gauge & 10 ft. (3M) Hose -Tweco WeldSkill 200 Amp electrode holder with 13 ft. (4 M) lead -Tweco WeldSkill 200 Amp ground clamp with 10 ft. (3 M) lead -Drive Rolls: • .035" / .045" (0.9 to 1.2 mm) V Grooved Lower & Flat Upper (Fitted) • .045" (1.2 mm) Flux Cored Roll...

  • Page 28: Duty Cycle

    6 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. With Factory Fitted Supply Cord and Plug TIG (GTAW) MIG (GMAW) Safe Operating Region STICK (SMAW) Welding Current Max (amps) Art # A-10666 Figure 2-3: Fabricator 252i Duty Cycle with Upgraded Supply Lead and Plug INTRODUCTION Manual 0-5155...

  • Page 29: Specifications

    250A @ 40%,20V 200A @ 60%, 18V 150A @ 100%, 16V Table 2-1: Fabricator 252i Specification 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.
  • Page 30 FABRICATOR 252i INTRODUCTION This Page Intentionally Blank INTRODUCTION Manual 0-5155...

  • Page 31: Section 3: Installation Operation And Setup

    WARNING 3.02 Location The Fabricator 252i must be electrically con- Be sure to locate the welder according to the following nected by a qualified electrical trades-person. guidelines:...

  • Page 32: Electromagnetic Compatibility

    208-230/50A 40% @ 250A 40% @ 250A 40% @ 230A Table 3-1: Input Power Source Leads for Fabricator 252i WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts.
  • Page 33 INSTALLATION/SETUP FABRICATOR 252i 2. Maintenance of Welding Equipment B. Assessment of Area The welding equipment should be routinely maintained Before installing welding equipment, the user shall make according to the manufacturer’s recommendations. All an assessment of potential electromagnetic problems in access and service doors and covers should be closed the surrounding area.

  • Page 34: Power Source Controls, Indicators And Features

    FABRICATOR 252i INSTALLATION/SETUP 3.06 Power Source Controls, Indicators and Features Art # A-10503_AB Figure 3-1: Fabricator Control Panel 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.
  • Page 35 INSTALLATION/SETUP FABRICATOR 252i 2. Fault Indicator 5. Advanced Features Button Advanced Features The yellow fault indicator will be illuminated when any of the faults are detected. ALL Faults will illuminate the Press and release the Advanced Features button to enter indicator or exit from the advanced programming mode.
  • Page 36 FABRICATOR 252i INSTALLATION/SETUP 6. Left Knob: Amperage Control (Wirespeed) 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...
  • Page 37 The display is also used for providing error messages to the user and showing other information, which will be The MIG Gun Adapter is the connection point for the Tweco explained in Section 5. Fusion 250A MIG Gun. Refer to section 3.08 for the correct procedure for attaching the Tweco Fusion 250A MIG Gun.
  • Page 38 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. Trigger Switch...
  • Page 39 INSTALLATION/SETUP FABRICATOR 252i 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.

  • Page 40: Advanced Features Details

    FABRICATOR 252i INSTALLATION/SETUP 14. Negative Welding Output Terminal Select the weld process (Control No 3) you wish to view Advanced Features for. The negative welding terminal is used to connect the welding output of the power source to the appropri-...
  • Page 41 INSTALLATION/SETUP FABRICATOR 252i Process STICK If the welder is in Advanced Features mode and the Weld Process Selection button (Control No 3) is pressed, the welder will exit Advanced Features mode, saving any change made, and change to the next weld process function in the sequence: MIG, LIFT TIG, STICK.
  • Page 42 FABRICATOR 252i INSTALLATION/SETUP Right Display Function Left Display (Factory De- Limits Comments fault Values) LOCL = Local control of the Wirespeed MIG Operator and Voltage with the machines controls. MIG/CNTL LOCL LOCL - REMT Controls REMT = Remote control of the Wirespeed and Voltage with an accessory device.
  • Page 43 INSTALLATION/SETUP FABRICATOR 252i Right Display Function Left Display (Factory De- Limits Comments fault Values) Provides Arc On Hours that the power source has Arc Hour Accu- welded. The number displayed is in hours and mulated Run- 0.0 – 9999.9 read only. It will rollover to 0 once 10,000 hours time have been reached.
  • Page 44 FABRICATOR 252i INSTALLATION/SETUP Right Display Function Left Display (Factory De- Limits Comments fault Values) 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).

  • Page 45: Attaching The Tweco Fusion 250A Mig Gun

    2. Push the Tweco Fusion 250A MIG Gun into MIG Gun Adaptor firmly using a twisting action. 3. Lock the Tweco Fusion 250A MIG Gun into the MIG Gun Adaptor by turning the Locking Screw clockwise in the MIG Gun Adapter within the Wire Feed Compartment to secure the Tweco Fusion 250A MIG Gun in posi- tion.

  • Page 46: Installing A 12.5 Lb Spool (8" Diameter)

    FABRICATOR 252i INSTALLATION/SETUP 4. If equipped, align the keyways of the MIG Gun Switch connector pigtail with the 8 pin receptacle to the right of the MIG Gun cable and plug them together. Secure by turning the locking ring to the right (clockwise ). Refer to Figure 3-8.

  • Page 47: Installing A Standard Spool (12" Diameter)

    INSTALLATION/SETUP FABRICATOR 252i 3.10 Installing a Standard Spool (12" diameter) As delivered from the factory, the unit is set for a 33 lb. or 12" spool. Installation of wire spool. Refer to Figure 3-10. 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

  • Page 48: Inserting Wire Into The Feed Mechanism

    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.

  • Page 49: Feed Roller Pressure Adjustment

    Tension Adjusting knob clockwise. The use of excessive pressure may cause rapid wear of the feed roller, motor shaft and motor bearings. NOTE Genuine TWECO Velocity contact tips and liners should be used. Many non-genuine liners use inferior materials which can cause wire feed problems. 3.13 Feed Roller Alignment The bottom Feed Roll is adjustable in and out to provide for best alignment of wire as it feeds into the outlet guide.

  • Page 50: Changing The Feed Roll

    NOTE Installation of all styles of feed rolls for the Fabricator 252i are identical. WARNING The welding wire is electrically Hot if it is fed by depressing Fusion 250A MIG Gun switch. Electrode contact to work piece will cause an arc with MIG Gun switch depressed.

  • Page 51: Input And Output Wire Guide Installation

    Then loosen Output Guide Lock Screw. Install the Output Wire Guide (the longer one) by inserting the conical end part way into the Tweco Adapter from the front of the machine. Now install the MIG Gun pressing the output guide further in until the tip of the guide is as close to the feed rolls as practical. Secure the MIG Gun. Tighten the MIG Adapter Lock Nut, then tighten the Output Guide Lock Screw.

  • Page 52: Wire Reel Brake

    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.
  • Page 53 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 pressurize a regulator that has loose or damaged parts or is in a questionable condition. NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been relieved.
  • Page 54 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 ignition.
  • Page 55 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.

  • Page 56: Set-Up Mig (Gmaw) Welding With Gas Shielded Mig Wire

    3.18 Set-up MIG (GMAW) Welding with Gas Shielded MIG Wire The Fabricator 252i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Gun. The Tweco Fusion 250A MIG Gun is designed with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Gun uses standard readily available Tweco Velocity consumable parts.

  • Page 57: Set-Up For Mig (Fcaw) Welding With Gasless Mig Wire

    3.19 Set-up for MIG (FCAW) Welding with Gasless MIG Wire The Fabricator 252i is supplied with a Tweco Fusion 250 AMP air-cooled MIG Gun. The Tweco Fusion 250A MIG Gun is designed with an ergonomic handle and fewer parts to cause performance problems. The Fusion MIG Gun uses standard readily available Tweco Velocity consumable parts.

  • Page 58: Set-Up For Lift Tig (Gtaw) Welding

    FABRICATOR 252i INSTALLATION/SETUP 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.
  • Page 59 INSTALLATION/SETUP FABRICATOR 252i 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.

  • Page 60: Set-Up For Stick Metal Arc Welding (Smaw)

    FABRICATOR 252i INSTALLATION/SETUP 3.21 Set-up for STICK Metal Arc Welding (SMAW) WARNING Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment. NOTE The following set up is known as DC Electrode Positive or reverse polarity. Please consult with the STICK electrode manufacturer for specific polarity recommendations.

  • Page 61: Section 4: Basic Welding Guide

    BASIC WELDING FABRICATOR 252i SECTION 4: Shielding Gas Nozzle (Optional) (Optional) BASIC WELDING GUIDE Molten Metal Flux Cored Molten Electrode Slag Slag 4.01 MIG (GMAW/FCAW) Basic Welding Solidified Technique Base Metal Weld Metal Two different welding processes are covered in this sec-...
  • Page 62 FABRICATOR 252i BASIC WELDING 10° to 20° Longitudinal 5° to 15° Angle 10° Longitudinal Angle Longitudinal Angle 30° to 60° 30° to 60° Transverse Transverse Angle Angle Direction of 90° Travel Transverse Angle Direction of Travel Vertical Fillet Welds Art # A-08995...
  • Page 63 BASIC WELDING FABRICATOR 252i 3. Nozzle Angle. This refers to the position of the MIG Setting of the Power Source Gun in relation to the joint. The transverse angle Power source and Wirefeeder setting requires some prac- is usually one half the included angle between tice by the operator, as the welding plant has two control plates forming the joint.
  • Page 64 FABRICATOR 252i BASIC WELDING Tweco MIG, Lift TIG, Stick Wire Selection Chart Figure 4-11 BASIC WELDING Manual 0-5155...

  • Page 65: Mig (Gmaw/Fcaw) Welding Troubleshooting

    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.
  • Page 66 FABRICATOR 252i BASIC WELDING 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. cabinet slipped. 2 Wire spool unwound and tangled. Wire spool brake is too loose.

  • Page 67: Stick (Smaw) Basic Welding Technique

    A Loose welding cable connection. A Check all welding cable connections. B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited Tweco Service Provider test then replace the faulty component. 8 Arc does not have The MIG Gun has been con-...
  • Page 68 FABRICATOR 252i BASIC WELDING 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 Art # A-07687 weld area, and, if suitable precautions are not taken,...
  • Page 69 BASIC WELDING FABRICATOR 252i Art # A-07694 Art# A-07693 Figure 4-18: Overhead Position, Butt Weld Figure 4-19: Overhead Position, Fillet Weld Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure...
  • Page 70 FABRICATOR 252i BASIC WELDING off the plate and set it firmly on the work bench so that Arc Length welding can be carried out in the downhand position. Make The securing of an arc length necessary to produce a neat sure that the work clamp is making good electrical contact weld soon becomes almost automatic.
  • Page 71 BASIC WELDING FABRICATOR 252i slag from running ahead of the weld. Refer to Figure 20°-30° 4-24. Do not attempt to build up much larger than Electrode Tack Weld 1/4" (6.4 mm) width with a 1/8" (3.2 mm) electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg.
  • Page 72 FABRICATOR 252i BASIC WELDING hold in a vice so that the specimen is positioned Art # A-07701 in the overhead position as shown in the sketch. The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-29). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run.
  • Page 73 BASIC WELDING FABRICATOR 252i B. Expansion and Contraction of Parent Metal in B. Distribution of Stresses the Fusion Zone: Distortion may be reduced by selecting a welding While welding is proceeding, a relatively small sequence which will distribute the stresses suitably volume of the adjacent plate material is heated to a so that they tend to cancel each other out.
  • Page 74 Cast Iron ENi-Cl Suitable for joining all cast irons except white cast iron. Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc. Table 4-4: Tweco Electrode Selection Chart BASIC WELDING 4-14 Manual 0-5155...

  • Page 75: Stick (Smaw) Welding Troubleshooting

    BASIC WELDING FABRICATOR 252i 4.04 STICK (SMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE is set at a val- Reduce the ARC FORCE until welding current is varying ue that causes the welding reasonably constant while prohibiting the elec-...
  • Page 76 FABRICATOR 252i BASIC WELDING FAULT CAUSE REMEDY 4 A groove has been A Welding current is too A Reduce welding current. formed in the base high. metal adjacent to B Welding arc is too long. B Reduce the length of the welding arc.

  • Page 77: Tig (Gtaw) Basic Welding Technique

    BASIC WELDING FABRICATOR 252i 4.05 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non-consumable) electrode and the work piece.
  • Page 78 Grey num, magnesium and range, Narrower more their alloys concentrated arc. Table 4-8 NOTE The Fabricator 252i Inverter is not suited for AC TIG welding. TIG Welding Filler Rods Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas...

  • Page 79: Tig (Gtaw) Welding Problems

    BASIC WELDING FABRICATOR 252i 4.06 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive beard build up Welding current is too Increase weld current and/or faulty joint or poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 80 9 Arc start is not smooth. A Tungsten electrode is A Select the right size electrode. Refer too large for the weld- to Table 4-6 Tweco Electrode Selection ing current. Chart. B The wrong electrode B Select the right electrode type. Refer...

  • Page 81: Section 5: Power Source Problems And Routine Service Requirements

    Power board indicates Over B. Ensure that air vents are not blocked/ temperature fault condition of obstructed power components C. Consult an Accredited Tweco Service Provider. Input Power Fault Signal from Power board A. Check input power connections and cables...
  • Page 82 A. Welding may still be possible, but no weld Fault parameter NVROM. setting changes can be saved. B. Consult an Accredited Tweco Service Provider. Unknown PCB Fault Welder control board cannot Consult an Accredited Tweco Service Provider. identify an attached inverter...

  • Page 83: Routine Service And Calibration Requirements

    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.
  • Page 84 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 sup- plying Tweco welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
  • Page 85 FABRICATOR 252i 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...

  • Page 86: Cleaning The Welding Power Source

    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 torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch...

  • Page 87: Cleaning The Feed Rolls

    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.
  • Page 88 FABRICATOR 252i PROBLEMS/SERVICE This Page Intentionally Blank PROBLEMS AND ROUTINE SERVICE Manual 0-5155...

  • Page 89: Section 6: Key Spare Parts

    REPLACEMENT PARTS FABRICATOR 252i SECTION 6: KEY SPARE PARTS 6.01 Fabricator 252 Power Supply Replacement Panels Art # A-10784 Figure 6-1 FABRICATOR 252i POWER SOURCE SPARE PARTS (Panels/Sheet Metal) ITEM PART NUMBER DESCRIPTION W7005323 Latch, Slide W7005366 Door, 252i W7005314...

  • Page 90: Replacement Parts

    FABRICATOR 252i REPLACEMENT PARTS Art # 10332 Figure 6-2 FABRICATOR 252i POWER SOURCE SPARE PARTS (LEFT SIDE) ITEM PART NUMBER DESCRIPTION W7005311 Spool Hub Assembly W7005353 Wire Drive Assembly, 250i. (Does not include motor) 375838-002 Guide, Inlet 0.6-1.6mm See Appendix 1...
  • Page 91 REPLACEMENT PARTS FABRICATOR 252i Art # A-10668 Figure 6-3: Right side and Front Replacement Parts FABRICATOR 252i POWER SOURCE SPARE PARTS (RIGHT SIDE AND FRONT) ITEM PART NUMBER DESCRIPTION W7005330 PCB, 252i Main Power W7005318 Circuit Breaker, 50A (On Off Switch)

  • Page 92: Tweco Fusion 250A Mig Gun

    FABRICATOR 252i REPLACEMENT PARTS 6.02 Tweco Fusion 250A MIG Gun Torch Part No: FV215TA-3545 Art# A-11673_AB Figure 6-4: Tweco Fusion 250 A MIG Gun REPLACEMENT PARTS Manual 0-5155...
  • Page 93 MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN is a registered trademark of LINCOLN Electric Co.; The aforementioned registered trademarks are no way affiliated with Tweco Products, Inc. or Victor Technologies. Tweco is a registered trademark of Victor Technologies.
  • Page 94 FABRICATOR 252i REPLACEMENT PARTS This Page Intentionally Blank REPLACEMENT PARTS Manual 0-5155...

  • Page 95: Appendix 1: Options And Accessories

    APPENDIX FABRICATOR 252i APPENDIX 1: OPTIONS AND ACCESSORIES Description Part Number Tweco Fusion 250A MIG Gun, 15ft 1023-1097 26 TIG torch 12.5ft (3.8m); accessory kit with 1/16”, 3/32”, 1/8” thoriated tungstens with collets, collet bodies No.5,6,7 Alumina W4013600 Nozzle - Gas Hose 9” (230mm) long with 5/8” 18 UNF male fitting, Torch switch &...

  • Page 96: Appendix 2: Fabricator 252I Circuit Diagram

    FABRICATOR 252i APPENDIX APPENDIX 2: FABRICATOR 252i CIRCUIT DIAGRAM NOTE 1 LINE BREAKER FERRITE EMI BOARD LOAD FRONT PANEL VIDENT SOL+ POT_RETURN TRIG_SOL_RTN WFSPOT2 VBIAS TRIG2 MOTOR+ MOTOR- VPOT2 AUX TRIG VPOT1 WFSPOT1 POT_RETURN VBIAS TRIG_RETURN TRIG1 FRONT PANEL CONTROL BOARD...
  • Page 97 APPENDIX FABRICATOR 252i CHASSIS GND NOTE 1 BRIDGE + BRIDGE - COMMON MODE CHOKE BRIDGE / MOV BOARD GND PRI HI-POT TEMP SW HI-POT TRANSFORMER Art # A-10334_AB Revision Date Victor Technologies, Inc. PROTOTYPE 07/12/2011 16052 Swingley Ridge Road, Suite 300...

  • Page 98: Tweco - Limited Warranty Terms

    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,...

  • Page 99: Warranty Schedule

    WARRANTY SCHEDULE 5 Years Parts* / 3 Years Labor ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster Portafeed, Ultrafeed, Ultima 150, WC 100B * 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards. * 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Victor Regulator for Fabricator 181i (No labor)
  • Page 100 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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