Thermal Arc FABRICATOR 181i, Operating Manual

Page 1: ...Art A 10820 SMAW 3163339 181i Operating Manual Revision AB Issue Date April 24 2012 Manual No 0 5191 Operating Features Fabricator 3 in 1 Multi Process Welding Systems ...

Page 2: ...r and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE ...

Page 3: ... Industries Inc 16052 Swingley Ridge Road Suite 300St Louis MO 63017 USA www thermadyne com Copyright 2012 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this...

Page 4: ...n Methods 2 1 2 06 User Responsibility 2 2 2 07 Fabricator 181i Portable System Package Part No W1003181 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 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Electricity Supply Voltage 3 1 3 05 Electromagnetic Compatibility 3 3 3 06 Victor Regulator 3 4 3 07 L...

Page 5: ...ng Troubleshooting 4 7 4 03 Stick SMAW Basic Welding Technique 4 10 4 04 Effects of Stick Welding Various Materials 4 10 4 05 Stick SMAW Welding Troubleshooting 4 21 4 06 TIG GTAW Basic Welding Technique 4 23 4 07 TIG GTAW Welding Problems 4 25 SECTION 5 Power Source PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Power Source Problems 5 1 5 02 Routine Service and Calibration Requirements 5 2 5...

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Page 7: ...wrap cables around your body 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safe...

Page 8: ... R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Arc Welding SMAW 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 Less than 60 60 160 160 250 250 550 7 8 10 11 10 12 14 Gas Metal Arc Welding GMAW and Flux...

Page 9: ...ng 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 ...

Page 10: ...n cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothi...

Page 11: ...tical 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 perf...

Page 12: ...use pressure regulation equipment Deviation from the following safety and operation instructions can result in fire explosion damage to equipment or injury to the operator E Compressed Gas Cylinders The Department of Transportation DOT approves the design and manufacture of cylinders that contain gases used for welding or cutting operations 1 Place the cylinder Figure 1 1 where you will use it Kee...

Page 13: ...tting 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 We...

Page 14: ...egative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Time Postflow Time Spot Time Spot Weld Mode Continuous Weld Mode Press to initiate wirefeed and welding release to stop Purging Of Gas Inche...

Page 15: ... ET D ESSAI 1 06 Dangers relatifs au soudage à l arc AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une décharge électrique peut tuer ou brûler gravement L électrode et le circuit de soudage sont sous tension dès la mise en circuit Le circuit d alimentation et les circuits internes de l équipement sont aussi sous tension dès la mise en marche En soudage automatique ou semi automatique avec fil c...

Page 16: ...otéger le visage et les yeux lorsque vous soudez ou que vous observez l exécution d une soudure AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Arc Welding SMAW Less than 3 32 2 4 3 32 5 32 2 4 4 0 5 32 1 4 4 0 6 4...

Page 17: ... pantalon revers des bottines de sécurité et un casque 2 Portez des lunettes de sécurité approuvées Des écrans latéraux sont recommandés 3 Entourez l aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d arc ou de l éblouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des vêtements en matériaux ignifuges et du rables laine et cuir et des chaussures d...

Page 18: ...et les pièces connexes doivent être maintenus en bon état 6 Ne placez pas le visage face à l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation 8 Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes ainsi que la publication P 1 de la CGA id...

Page 19: ...bles d accumulateur 3 N utilisez que des outils anti étincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momen tanément un véhicule 5 Utilisez la polarité correcte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROID ISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de...

Page 20: ...des dommages et garder une bonne visibilité sur le travail Portez en permanence des gants de protection et des vête ments ignifuges pour la protection de la peau et des vêtements contre les étincelles et le laitier Gardez col manches et poches boutonnés Il ne faut pas remonter vos manches ou les pantalons à revers Quand vous travaillez dans un environnement non dédié au soudage ou découpage portez...

Page 21: ...ement la vanne de bouteille ne vous tenez pas directement devant Opérez toujours cette opération dans une zone bien ventilée Si une bouteille d acétylène crache un brouillard laissez reposer pendant 15 minutes Essayez de nouveau la vanne Si le problème persiste con tactez votre fournis seur de gaz 1 08 Principales Normes De Securite Safety in Welding and Cutting norme ANSI Z49 1 American Welding S...

Page 22: ...urant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639_AB 115V 15A t t1 t2 X IPM MPM t Fusible Déroulement du Fil Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Durée de Pré Dèbit Durée de Post Dèbit Duréc du Pulse Soudure Par Point Appuyez pour dèruarer l alimentation du fils et la soudure le relâcher po...

Page 23: ... 1 and IEC 60974 1 applicable to welding equipment and associated accessories 2002 95 EC RoHS directive Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous test...

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Page 25: ... 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 dam age claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described ab...

Page 26: ... approval of Thermal Arc 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 Thermal Arc 2 07 Fabricator 181i Portable System Package Part No W1003181 1 1 2 3 4 5 6 7 8 9 ...

Page 27: ... Source is designed to operate at a 20 duty cycle 180 amperes at 23 volts This means that it has been designed and built to provide the rated amperage 180 A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool A 10352 Duty Cycle percentage Safe Oper...

Page 28: ...y 50 60Hz Welding Current Range MIG Mode 10 180A Wirefeed Speed Range 100 650 IPM MIG Welding Voltage Range 14 5 23V DC Nominal OCV 62V DC Effective Input Current I1eff for MIG GMAW FCAW for LIFT TIG GTAW for STICK SMAW 15 9 Amps 14 3 Amps 17 2 Amps Maximum Input Current I1max for MIG GMAW FCAW for LIFT TIG GTAW for STICK SMAW 35 6 Amps 28 6 Amps 35 7 Amps Single Phase Generator Requirement 9 KVA ...

Page 29: ...eco WeldSkill 180A MIG Gun 12ft 3 6m Length WS180TA 12 3035 Tweco Spool Gun 160A 12ft 3 6M Length suits 4 100mm spools for aluminum welding SG160TA 12 3035 TIG Torch 17V 12 5 ft 8 pin and accessory kit with 1 16 3 32 1 8 thoriated tungstens 1 16 3 32 1 8 collets 1 16 3 32 1 8 collet bodies No 5 6 7 Alumina nozzle short back cap long back cap W4013802 Fabricator 141i 181i Carry Bag W4015300 Basic 4...

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Page 31: ...ed to abnormal vibration or shock E In areas not exposed to direct sunlight or rain F Place at a distance of 12 300mm or more from walls or similar that could restrict natural air flow for cooling G The enclosure design of this Power Source meets the requirements of IP23S as outlined in EN 60529 This provides adequate protection against solid objects greater than 1 2 12mm and direct protection fro...

Page 32: ...isconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power source whenever necessary to inspect or service the unit Do not connect an input WHITE or BLACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal Correctly installed if necessary by a qualified electrician Correctly earthed electr...

Page 33: ...ser 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 disturbanc...

Page 34: ...s should be kept as short as possible and should be positioned close together running at or close to the floor level 4 Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and ...

Page 35: ...eam equipment is compatible with the maximum delivery pressure of the regulator 5 Be sure that the regulator has the correct pressure rating and gas service for the cylinder used 6 Carefully inspect the regulator for damaged threads dirt dust grease oil orotherflammable substances Remove dust and dirt with a clean cloth Be sure the inlet swivel filter is clean and in place Attach the regulator Fig...

Page 36: ...drops there is a leak in the down stream equipment hose hose fitting outlet fitting or low pressure gauge Check for leaks using an approved leak detector solution c If the high pressure gauge drops and the low pressure gauge increases at the same time there is a leak in the regulator seat d If the regulator requires service or repair take it to a qualified repair technician 5 Once leak testing has...

Page 37: ...atures MIG LIFT TIG STICK 4T 2T SOFT A V WIRESPEED HARD DOWNSLOPE S 10 10 2 2 4 4 7 7 9 9 1 1 3 3 6 6 8 8 ARC FORCE INDUCTANCE 2 4 6 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Art A 10353_AB Figure 3 4 Front Panel Art A 10354 16 17 15 Figure 3 5 Rear Panel 18 19 20 21 Art A 10355 Figure 3 6 Wire Feed Compartment Control ...

Page 38: ... mode NOTE The preview functionality provided on this power source is intended to act as a guide only Some differences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc ie dip versus spray transfer Where exact settings are requir...

Page 39: ...e 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 term...

Page 40: ...ltifunction Control Voltage Down Slope Arc Force The multifunction control knob is used to adjust Voltage MIG Mode Down slope LIFT TIG Mode and Arc Force STICK Mode depending on the welding mode selected NOTE The preview functionality provided on this power source is intended to act as a guide only Some differences may be observed between preview values and actual welding values due to factors inc...

Page 41: ...ly 10 Arc Control Inductance The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc Lower arc control settings make the arc softer with less weld spatter Higher arc control settings give a stronger driving arc which can increase weld penetration Soft means maximum inductance while Hard means minimum inductance 11 Trigger Mode Control MIG and LIFT TIG Mode ...

Page 42: ... values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc ie dip versus spray transfer Where exact settings are required in the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate 14 Thermal Overload Indicator This weldi...

Page 43: ...te switch ie in both local and remote modes Should a remote device be connected and the remote local switch set to remote the maximum setting of the Power Source will be determined by the respective front panel control irrespective of the remote control device setting As an example if the output current on the Power Source front panel is set to 50 and the remote control device is set to 100 the ma...

Page 44: ...G Gun Adaptor and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position Art A 10356 MIG GunAdaptor MIG Gun Connector MIG Gun Connector Locking Screw 8 pin socket 8 pin plug Figure 3 8 Attaching MIG Gun ...

Page 45: ...is nut with nylon insert tightens the brake The brake is correctly adjusted when the spool stops within 4 100mm to 8 200mm measured at the outer edge of the spool after MIG Gun trigger is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and possibly an increas...

Page 46: ... trigger is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and possibly an increased incidence of electrode wire Burnback into contact tip Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 8 200mm diameter spool NOTE This ...

Page 47: ...guide and into the MIG Gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 3 11 Remove the contact tip from the MIG Gun With the MIG Gun lead reasonably straight feed the wire through the MIG Gun by depressing the trigger switch Fit the appropriate contact tip WARNING Before connecting the work clamp to the work make sure the Electricity Su...

Page 48: ...e screw clockwise WARNING Before changing the feed roller ensure that the Electricity Supply to the Power Source is switched off CAUTION The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 3 16 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an counterclockwise direction Once the feed roll is removed then to replac...

Page 49: ...ckwise to tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 3 8 10mm 3 4 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and possibly an increased incidence of el...

Page 50: ...ods 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 ...

Page 51: ...g 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 Art A 10362 Shielding Gas Hose Fitted with 5 8 18 UNF connection Primary Cord Work Lead Nega...

Page 52: ... Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection D Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information E Switch the LOCAL REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sour...

Page 53: ... 5191 3 23 INSTALLATION OPERATION AND SETUP A 09587_AD MIG Gun Polarity Lead Negative Welding Terminal Positive Welding Terminal MIG Gun 8 pin Plug Work Lead Figure 3 17 Setup for MIG FCAW Welding with Flux Cored Gasless Wire ...

Page 54: ...switch inside the wire feed compartment to SPOOL GUN Connect the shielding gas for the to the Shielding Gas Inlet on the rear panel of the Power Source 1 Make sure the welding power source is turned OFF before connecting the welding gun 2 Open side panel and loosen thumb screw 3 Insert the back end of the Spool gun into the gun receiving bushing 4 Tighten thumb screw and replace side panel 5 Conne...

Page 55: ...ermal Arc 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 E Fit the gas regulator flow gauge to the shielding gas cylinder refer to Section 3 14 then connect the shielding gas hose from the TIG torch to the regulator flow gauge outlet Note that the TIG torch shielding gas hose is connected directly to the regulato...

Page 56: ...rch trigger switch to TIG weld OR a Thermal Arc 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 TIG Torch Connect to shielding gas regulator flow gauge Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping Negative welding terminal Positive welding term...

Page 57: ...duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Electricity Supply is switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of ...

Page 58: ...Fabricator 181i INSTALLATION OPERATION AND SETUP 3 28 Manual 0 5191 ...

Page 59: ...wever 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 Art A 8991_AB Shielding Gas Molten Weld Metal Solidified Weld Metal Nozzle Electrode Arc Base Metal GMAW Process Figure 4 1 FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuses together the p...

Page 60: ...roper filter lenses and use the proper safety equipment CAUTION Do not pull the welding MIG Gun back when the arc is established This will create excessive wire extension stick out and make a very poor weld The electrode wire is not energized until the MIG Gun trigger switch is depressed The wire may therefore be placed on the seam or joint prior to lowering the helmet Butt Horizontal Welds Direct...

Page 61: ...ost of the welding done by all processes is on carbon steel The items below describe the welding variables in short arc welding of 24 ga 0 6mm to 6 4mm mild sheet or plate The applied techniques and end results in the MIG 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 posi...

Page 62: ... to the position of the welding 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 welding 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 push...

Page 63: ...evel 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 elec...

Page 64: ...Fabricator 181i BASIC WELDING GUIDE 4 6 Manual 0 5191 Thermal Arc MIG Lift TIG Stick Wire Selection Chart Art A 10366_AB Table 4 1 MIG Lift TIG Stick Welding Set up Chart ...

Page 65: ... the MIG Gun and out thru the MIG Gun nozzle 2 Shielding gas cylinder contents and flow gauge Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to workshop welding 28 35 CFH or outdoors welding 35 46 CFH 3 Gas leaks Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Source 4 Internal gas hose in the Power Source...

Page 66: ... accumu lates thus reducing wire feedability 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 aluminum it may be come jammed in the contact tip due to expansion of the wire when he...

Page 67: ...eed B Weld penetration narrow and deep B Reduce current and voltage and increase MIG Gun travel speed or select a lower penetration shielding gas C Excessive weld stresses C Increase weld metal strength or revise design D Excessive voltage D Decrease voltage E Cooling rate too fast E Slow the cooling rate by preheating part to be welded or cool slowly 7 Cold weld puddle A Loose welding cable conne...

Page 68: ...ead 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 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 wel...

Page 69: ...ication 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 15 through 4 22 Art A 07687 Figure 4 11 Flat Position Down Hand Butt Weld Art A 07688 Figure 4 12 Flat Position Gravity Fillet Weld ...

Page 70: ...ator 181i BASIC WELDING GUIDE 4 12 Manual 0 5191 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 ...

Page 71: ... less than 70 Double Vee Butt Joint 1 16 1 6mm Lap Joint Tee Joints Fillet both sides of the joint Edge Joint Fillet Joint Corner Weld Plug Weld Plug Weld Not less than 70 Single Vee Butt Joint Not less than 45 1 16 1 6mm max Art A 10367 Figure 4 19 Typical Joint Designs for Arc Welding Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commen...

Page 72: ...de 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 10368 1 16 1 6mm Figure 4 20 Striking an Arc Arc Length The securing of an arc length necessary to produce a neat weld soon bec...

Page 73: ...trapped by the second run Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 22 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a ...

Page 74: ... be about 10º from the horizontal to enable a good bead to be deposited Refer Figure 4 25 Use a short arc and do not attempt to weave on the first run When the first run has been completed de slag the weld deposit and begin the second run at the bottom This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges At the completion of each side motion pau...

Page 75: ...hat 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 ...

Page 76: ...tal 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 acros...

Page 77: ... 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 ...

Page 78: ...on Art A 07710_AB 1 Block Sequence The spaces between the welds are filled in when the welds are cool 2 3 Figure 4 34 Welding Sequence Art A 07711_AB 4 3 2 1 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 ...

Page 79: ... irregularities 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 prevent ing full fusion E Clean joint before welding F Wrong electrode for position in which welding is done F Use electrodes designed for position in which welding is done ot...

Page 80: ...e weld area from the wind F Electrode damaged ie flux coating incomplete F Discard damaged electrodes and only use elec trodes with a complete flux coating 7 Crack occurring in weld metal soon after solidification commences A Rigidity of joint A Redesign to relieve weld joint of severe stresses or use crack resistance electrodes B Insufficient throat thickness B Travel slightly slower to allow gre...

Page 81: ...n the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High Impact or Water Cooled Metal Inert Gas Shields Electrode and Weld Puddle Tungsten Electrode Non Consumable Art A 10369 Figure 4 38 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 1 6...

Page 82: ...ungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate CFH Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0mm 1 16 1 6mm 10 15 Butt Corner Lap Fillet 0 045 1 2mm 45 55 50 60 30 45 35 50 0 040 1 0mm 1 16 1 6mm 10 15 Butt Corner Lap Fillet 1 16 1 6mm 60 70 70 90 40 60 50 70 1 16 1 6mm 1 16 1 6mm 15 Butt Corner Lap Fillet 1 8 3 2mm 80 100 90 115 65 85 90 110 1 16 1 6mm...

Page 83: ...en leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidizes when an arc is struck A TIG Torch lead connected to positive welding terminal A Connect TIG Torch lead to negative welding terminal B No gas flowing to weld ing region B Turn TIG Torch gas valve ON Check the gas lines for kinks or breaks and gas cylinder contents C TIG Torch is clogged ...

Page 84: ...de is being used for the welding job B Select the right electrode type Refer to Table 4 9 Tungsten Electrode Types C Gas flow rate is too high C Select the right rate for the welding job Refer to Table 4 10 D Incorrect shielding gas is being used D Select the right shielding gas E Poor work clamp con nection to work piece E Improve connection to work piece 10 Arc flutters during TIG welding Tungst...

Page 85: ... components B MIG GUN SPOOL GUN switch is switched to SPOOL GUN B Switch the MIG GUN SPOOL GUN switch to MIG GUN 4 Welding wire continues to feed when torch trigger is released A Trigger mode selection switch is in 4T latch mode A Change the trigger mode selection switch from 4T latch mode to 2T normal mode B Torch trigger leads shorted B Repair or replace torch trigger switch lead 5 Welding arc c...

Page 86: ...ource 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 Thermal Arc s original specifications If equipment is to be used in a hazardous location or environments with a high ri...

Page 87: ...ing sup plying Thermal Arc 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 e...

Page 88: ...rmal Arc service agent Testing Requirements Output current A to be checked to ensure it falls within applicable Thermal Arc Power Source specifications Output Voltage V to be checked to ensure it falls within applicable Thermal Arc Power Source specifications Motor Speed RPM of wire drive motors to be checked to ensure it falls within required Thermal Arc Power Source wire feeder specifications Ac...

Page 89: ... metal filings slag and loose material Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current 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 CAUTI...

Page 90: ... Manual 0 5191 5 05 Volt Ampere Curves Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown Art A 11296 Figure 5 1 Fabricator 181i Volt Ampere Curves ...

Page 91: ...Fabricator 181i Manual 0 5191 5 7 Trouble Shooting and Service ...

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Page 93: ... WS180TA 12 3035 Art A 10370 Figure 6 1 TWECO WELDSKILL 180A MIG GUN PARTS ITEM PART NO DESCRIPTION 1 1210 1112 Nozzle 2 1110 1101 Contact Tip 3 1510 1101 Gas Diffuser 4 2042 2053 Microswitch 5 2042 2054 Trigger Lever 6 2042 2055 Trigger Lever Spring 7 2035 2110 Tweco Rear Connector Plug 8 1420 1113 Conduit Assembly Table 6 2 ...

Page 94: ...Fabricator 181i KEY SPARE PARTS 6 2 Manual 0 5191 6 02 Power Source Art A 11243_AB Figure 6 2 31 ...

Page 95: ... 181i 18 W7004975 Panel Front 19 W7004976 Panel Rear 20 W7004922 Handle 181i 21 W7004977 Side and Top Panels not shown 22 W7004966 Adapter Tweco 4 181i 23 W7004925 Guide Inlet 023 045 181i 24 W7004967 Guide Inlet 023 045 181i 25 W7004978 Panel Door not shown 26 W7004928 Panel Base 181i 27 870734 Knob 1 4 IDx 72 ODx 9 H 28 W7004972 Knob 1 4 IDx1 ODx0 9 H 29 W7004957 Panel Front Control 181i 30 W700...

Page 96: ...Fabricator 181i KEY SPARE PARTS 6 4 Manual 0 5191 This page is left blank intentionally ...

Page 97: ...or 181i Manual 0 5191 1 APPENDIX FABRICATOR 181i CIRCUIT DIAGRAM J24 J10 J8 CONNECTOR LAYOUT DIAGRAM J19 J1 J3 J7 J13 J16 J5 J15 J18 DRIVE PWM WVIN IFB MB SOURCE GUN QF DY OT FUNS CR NTCS ON 4 1 2 3 Art A 11230 ...

Page 98: ...T 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 Thermal Arc 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 Thermal A...

Page 99: ...bor FirePower Welders 5 Years Parts No Labor Victor Professional Thermadyne limited warranty shall not apply to Consumable Parts for MIG TIG Plasma welding Plasma cutting and Oxy fuel torches O rings fuses filters or other parts that fail due normal wear Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE repair facility within thirty 30...

Page 100: ... 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 Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbou...