Welding current flows from the power source via heavy duty bayonet type terminals. If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. This distance may vary depending on the type of joint that is being welded. Page 44 Fabricator i 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 10mm stick-out 2. Page 45 Fabricator i 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 49 B Low primary voltage B Contact supply authority. If in doubt consult the electrode data sheet or your nearest Accredited Thermal Arc Distributor. It has a deep, penetrating arc and is often the first choice for repair or maintenance work. Page 53 Fabricator i 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. Page 54 Fabricator i Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down.
Page 55 Fabricator i Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a well-formed bead. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3. Vertical Down The E Stick electrode makes welding in this position particularly easy. Page 58 Fabricator i Distortion Distortion in some degree is present in all forms of welding.
In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur. Page 59 Fabricator i Overcoming Distortion Effects There are several methods of minimizing distortion effects. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.
B Increase welding current. Page 64 Wider current Grey ium, magnesium and range, Narrower more their alloys concentrated arc. Page 66 Fabricator i 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates.
B Work piece surface has B Clean surface. Replace faulty com- ponents. This includes an in- sulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc's original specifications. Page 69 2. The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
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 72 Fabricator i This page is left blank intentionally. Declaration Of Conformity How to Use This Manual Equipment Identification Receipt of Equipment Transportation Methods User Responsibility Duty Cycle Options and Accessories Electricity Supply Voltage Electromagnetic Compatibility Victor Regulator Leak Testing the System When You Finish Using the Regulator Storage of the Regulator Power Source Controls, Indicators and Features Attaching the Tweco Fusion A Gun Torch Adapter Thumb Screw Replacement Installing 4" mm Diameter Spool Installing 8" mm Diameter Spool Inserting Wire into the Wire Feed Mechanism Feed Roller Pressure Adjustment Changing the Feed Roll Wire Reel Brake Gas Regulator Operation Effects of Stick Welding Various Materials Power Source Problems Routine Service and Calibration Requirements Cleaning the Welding Power Source Cleaning the Feed Rolls Volt-Ampere Curves Power Source Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Safe practices are outlined in the American National Standard Z This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is ON. The input power circuit and machine internal circuits are also live when power is ON. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers. Disconnect input power or stop engine before installing or servicing this equipment.
Lock input power disconnect switch open, or remove line fuses so power cannot be turned ON accidentally. Turn OFF all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.
Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode. Do not use worn, damaged, undersized, or poorly spliced cables. Do not wrap cables around your body.
Ground the workpiece to a good electrical earth ground. Do not touch electrode while in contact with the work ground circuit. Use only well-maintained equipment. Repair or replace damaged parts at once. 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. Wear a safety harness to prevent falling if working above floor level. Keep all panels and covers securely in place. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin.
Noise from some processes can damage hearing. Wear approved safety glasses. Side shields recommended. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material wool and leather and foot protection. Use approved ear plugs or ear muffs if noise level is high. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
AWS F2. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. Keep your head out of the fumes. Do not breathe the fumes.
If ventilation is poor, use an approved air-supplied respirator. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator.
The coatings and any metals containing these elements can give off toxic fumes if welded. Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks or drums. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag. Wear approved face shield or safety goggles. Wear proper body protection to protect skin. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits. Do not remove radiator cap when engine is hot. Allow engine to cool. Wear gloves and put a rag over cap area when removing cap. The above procedures are among those also normally recommended for pacemaker 3.
Housekeeping E. NEVER use compressed gas cylinders without 1. LeJeune Rd. Three Phase Static Frequency Converter Government Printing Of- fice, Washington, D. Page 24 This Page Intentionally Blank Warnings will be enclosed in a phase multi process welding system that is capable of box such as this. Page 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 Safety And Installation 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool. W Power Source Dimensions H Page Environment Based on Article , 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 corresponding changes, updates, improvements or replacement of such items. Refer to Table These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. Curves of other settings fall between curves shown. Page 37 8. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Zero ohm minimum connection to 5k ohm remote control potentiometer. 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 41 Intelligent Fan Control The Fabricator i is designed with an intelligent fan control. It automatically switches the cooling fan off when it is not required. This has two main advantages; 1 to minimize power consumption, and 2 to minimize the amount of contaminants such as dust that are drawn into the Power Source.
Place unit on its back. 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.
Set these aside for reassembly. Leave screws sitting in the pockets of the panel. Gently push the bottom of the front panel upward until the thumb screw is fully exposed. Remove damaged thumb screw and replace with new one. Art A 6. In order to fit a 4" mm diameter spool assemble parts in the sequence shown below in Figure In order to re-fit a 8" mm spool assemble parts in the sequence shown below in Figure Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm Figure 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 swarf.
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 Gas Regulator Operation C. Connect the work lead to the negative welding terminal -.
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