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Summary of Contents for FABRICATOR 252i

Page 1: ...FABRICATOR 252i 3 IN 1 Multi Process Welding Systems Operating Manual 300 Tweco com 3163339 English Canadien Fran ais Americas Espa ol Portugu s Revision AF Issue Date June 12 2013 Manual No 0 5155...

Page 2: ...stinguish ourselves from our competition through market leading innovation and truly dependable products that will stand the test of time We strive to enhance your productivity efficiency and welding...

Page 3: ...Victor Technologies International Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www victortechnologies com Copyright 2011 2012 2013 by Victor Technologies International Inc...

Page 4: ...SECTION 3 INSTALLATION OPERATION AND SETUP 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Mains Supply Voltage Requirements 3 1 3 05 Electromagnetic Compatibility 3 2 3 06 Power...

Page 5: ...ER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Power Source Problems 5 1 5 02 Routine Service and Calibration Requirements 5 3 5 03 Cleaning the Welding Power Source 5 6 5 04 Cleaning th...

Page 6: ...This Page Intentionally Blank...

Page 7: ...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...

Page 8: ...mission 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 Ar...

Page 9: ...ing 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...

Page 10: ...an 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...

Page 11: ...cable around the body 4 Keep welding Power Source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers C...

Page 12: ...ressure 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 De...

Page 13: ...utting 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...

Page 14: ...AW Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line C...

Page 15: ...ENT L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler gravement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et le...

Page 16: ...ing Society AWS Miami Florida Guide de teinte des lentilles Proc d Taille de l lectrode en mm po Courant d arc amp res Gamme d intensit minimum Num ro de teinte recommand e Confort Soudage l arc avec...

Page 17: ...paisse un pantalon revers des bottines de s curit et un casque 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons p...

Page 18: ...du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation 8 Lisez et respectez les consignes relatives aux...

Page 19: ...torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d ter compl tement le bouchon PLOMB AVERTISSEMENT AVERTISSEMENT Ce produit contient des produits chimiques notamment du plomb r...

Page 20: ...contenant des vapeurs combustibles des liquides inflammables ou des poussi res explosives B Entretien des Locaux AVERTISSEMENT Ne laissez jamais l oxyg ne en contact avec la graisse l huile ou d autr...

Page 21: ...etlamanutentiondesbouteilles AVIS Ce document CGA p t peut tre obtenu en crivant Compressed Gas Association 4221 Walney Roed 5th Floor Chantilly VA 20151 2923 USA 2 Placez le bouchon de protection de...

Page 22: ...W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders docu ment P 1 C...

Page 23: ...tensit de Courant Tension Hertz cycles sec Fr quence N gatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 1...

Page 24: ...1 UL 60974 1 IEC 60974 5 applicable to welding equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 whe...

Page 25: ...tallation site before un crating the unit Use care to avoid damaging the equip ment when using bars hammers etc to un crate the unit 2 01 How to Use This Manual This Operating Manual usually applies t...

Page 26: ...ided This equipment must be checked periodically Defective equipment including welding leads should not be used Parts that are broken missing plainly worn distorted or contaminated should be replaced...

Page 27: ...ps 1 each 030 0 8 mm 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 l...

Page 28: ...0 duty cycle 250 amperes at 26 5 volts This means that it has been designed and built to provide the rated amperage 250A for 4 minutes i e arc welding time out of every 10 minute period 40 of 10 minut...

Page 29: ...MIG Mode 20 300 Amps Welding Current Range LIFT TIG Mode 5 300 Amps Welding Current Range STICK Mode 20 230 Amps Effective Input Current I1eff 22 4 Amps Maximum Input Current I1max 34 7 Amps Single P...

Page 30: ...FABRICATOR 252i INTRODUCTION INTRODUCTION 2 6 Manual 0 5155 This Page Intentionally Blank...

Page 31: ...to locate the welder according to the following guidelines A In areas free from moisture and dust B Ambient temperature between 32 F to 104 F C In areas free from oil steam and corrosive gases D In a...

Page 32: ...lified Electrical Tradesperson 3 05 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situa...

Page 33: ...d the Welding Power Source enclosure 2 Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service door...

Page 34: ...1 Fabricator Control Panel 11 12 13 14 15 Art A 10504 10 Figure 3 2 Fabricator Front Connections WARNING DO NOT TOUCH the electrode wire while it is being fed through the system The electrode wire wi...

Page 35: ...he button will illuminate to identify which mode is selected 2T or 4T In the 4T mode once the weld has been started you can release the trigger and continue welding until the trigger is activated agai...

Page 36: ...ile a weld is in progress if this occurs the left display will briefly switch to show the adjusted value as the knob is turned and will automatically revert back to showing the weld current measuremen...

Page 37: ...isplay is also used for providing error messages to the user and showing other information which will be explained in Section 5 9 Right Digital Display MIG Mode This digital meter is used to display t...

Page 38: ...ote Control Socket Socket Pin Function 1 Not connected 2 Trigger Switch Input 3 Trigger Switch Input 4 Not connected 5 5k ohm maximum connection to 5k ohm remote control potentiometer 6 Zero ohm minim...

Page 39: ...ch Input E Wire Speed Pot Voltage Pot CW 10K ohm F Wiper Arm Speed Pot G Trigger Switch Input Solenoid H Wire Speed Pot Voltage Pot ACW I Solenoid J Peripheral Program Resistor Table 3 4 13 Positive W...

Page 40: ...cess Once the weld ing process is changed the setting will revert to the factory default General Operation TIG Process MIG STICK Select the weld process Control No 3 you wish to view Advanced Features...

Page 41: ...FCAW Mode Advanced Features Menu Map RUN IN POST FLOW BURN BACK WIRE SHRP Advanced Menu MIG Mode Wire Feed Speed ARC TYPE MIG CNTL PRE FLOW SPOT STCH DWEL TIME ON OFF STCH TIME AUTO CV Advanced Menu M...

Page 42: ...ot SPOT OFF OFF ON Spot is used to weld two thin plates together at a desired location by melting the top bottom plates together to form a nugget between them The weld time is set by the Spot Time Spo...

Page 43: ...lection Right Knob Selection Left Display Right Display HR TIG CNTL DOWN SLPE Advanced Menu LIFT TIG Options or Range Press Advanced Button to Exit to Welding Mode 0 0 5 0 S LOCL REMT NO YES 0 0 9999...

Page 44: ...d is in hours and read only It will rollover to 0 once 10 000 hours have been reached Restore Factory Defaults FACT DFLT NO NO YES When YES is selected all the user adjustable val ues in this table ex...

Page 45: ...selected all the user adjustable val ues in this table except Arc Hour Accumulated Runtime are reset to the Factory Default Values 3 08 Attaching the Tweco Fusion 250A MIG Gun 1 Unscrew the Locking Sc...

Page 46: ...Hub Retaining Clip Grasp the loop and pull 2 Place Wire Spool onto the hub loading it so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise Make sure to align...

Page 47: ...gn the spool alignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool NOTE The Hub tension has been pre adju...

Page 48: ...over the Feedroll Make certain the proper groove is being used Second part of Figure 3 11 4 Pass the MIG wire over the drive roll groove through the outlet guide and out past the MIG Gun Adaptor Then...

Page 49: ...uine 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 adjustab...

Page 50: ...oved feed rolls have their wire size or range stamped on the side of the roll On rolls with different size grooves the outer visible when installed stamped wire size indicates the groove in use Refer...

Page 51: ...ll the drive roll to help in the alignment of the wire guides Output Wire Guide With the Fusion 250A MIG Gun removed loosen the MIG Adapter Lock Nut This will aid with alignment Then loosen Output Gui...

Page 52: ...ment will result in the wire reel circumference continuing no further than 3 4 19 mm after release of the MIG Gun trigger switch The wire should be slack without becoming dislodged from the reel 3 17...

Page 53: ...provided Equipment must be checked periodically and repaired replaced or reset as necessary for continued safe and reliable performance Defective equipment should not be used Parts that are broken mi...

Page 54: ...n MIG Gun in the top fitting Art A 10549 Ensure that the gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed in an upright position Figure 3 18 Attach gas line to pro...

Page 55: ...wise until the required flow rate is indicated on the gauge Close downstream valve 3 Adjust regulator pressure adjusting screw to the required flow rate indicated on gauge dial Refer to Figure 3 19 Th...

Page 56: ...larity Lead to the positive welding terminal If in doubt consult the MIG electrode wire manufacturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential h...

Page 57: ...acturers recommendation 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...

Page 58: ...Section 3 17 then connect the shielding gas hose from the rear of the power source to the regulator flow gauge outlet 7 Turn the Main ON OFF switch ON located on the rear panel 8 Select MIG mode with...

Page 59: ...pencil in order to achieve optimum welding results See illustration It is critical to grind the tungsten electrode in the direction the grinding wheel is turning Grind at a 30 degree angle and never...

Page 60: ...Switch the ON OFF Switch located on the rear panel to OFF 2 Attach the STICK and Work Leads as shown in Figure 3 24 Negative Output Terminal Dinse type 50 Art A 10553 Figure 3 24 Setup for STICK Weld...

Page 61: ...rc welding process which fuses together the parts to be welded by heating them with an arc between a continu ous flux filled electrode wire and the work Shielding is obtained through decomposition of...

Page 62: ...r plate The applied techniques and end results in the GMAW process are controlled by these variables Preselected Variables Preselected variables depend upon the type of material being welded the thick...

Page 63: ...ator as the welding plant has two control settings that have to balance These are the Wirespeed control refer to section 3 06 4 and the welding Voltage Control refer to section 3 06 10 The welding cur...

Page 64: ...FABRICATOR 252i BASIC WELDING BASIC WELDING 4 4 Manual 0 5155 Tweco MIG Lift TIG Stick Wire Selection Chart A 12128 Figure 4 11...

Page 65: ...empty and the flow meter is correctly adjusted to 31 75 CFH 2 Gas leaks Check for gas leaks between the regulator cylinder connec tion and in the gas hose to the Power Source 3 Internal gas hose in t...

Page 66: ...y occur inside the contact tip resulting in the wire jamming in the contact tip B When using soft wire such as aluminum it may become jammed in the contact tip due to expansion of the wire when heated...

Page 67: ...have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG Gun has been con nected to the wrong voltage polarity on the front panel Connect the MIG...

Page 68: ...empts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron D Copper and alloys The most important factor i...

Page 69: ...6mm to 3 16 4 8mm depending on plate thickness Joint Open Square Butt 1 16 1 6mm max 1 16 1 6mm Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 16 1 6mm Lap Joint Tee Joints Fillet bot...

Page 70: ...arc length necessary to produce a neat weld soon becomes almost automatic You will find that a long arc produces more heat A very long arc produces a crackling or spluttering noise and the weld metal...

Page 71: ...ing the electrode to a position perpen dicular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent sl...

Page 72: ...deposit the first run by simply drawing the electrode along at a steady rate You will notice that the weld deposit is rather convex due to the effect of gravity before the metal freezes Art A 07704 F...

Page 73: ...A Peening This is done by hammering the weld while it is still hot The weld metal is flattened slightly and because of this the tensile stresses are reduced a little The effect of peening is relative...

Page 74: ...eet metal or for welding on plated dirty painted or greasy steel It has a deep penetrating arc and is often the first choice for repair or maintenance work Mild Steel E6013 This all position electrode...

Page 75: ...Non metallic particles may be trapped in undercut from previous run A If a bad undercut is present clean slag out and cover with a run from a smaller gauge electrode B Joint preparation too restricte...

Page 76: ...edge of weave to allow weld metal buildup G Power source is set for MIG GMAW welding G Set power source to STICK SMAW mode 5 Portions of the weld run do not fuse to the surface of the metal or edge of...

Page 77: ...g on the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Elect...

Page 78: ...ss DC Current for Mild Steel DC Current for Stainless Steel Tungsten 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 0...

Page 79: ...avel speed 5 Uneven 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 connect ed to positive welding...

Page 80: ...electrode is too large for the weld ing current A Select the right size electrode Refer to Table 4 6 Tweco Electrode Selection Chart B The wrong electrode is being used for the welding job B Select th...

Page 81: ...d problem in spool feedplate Verify wire is not contacting chassis ERR 08 Input Sensor Fault Unexpected reading of voltage or current sensor during power up self test A Inspect ribbon cable between po...

Page 82: ...ry calibration B Check MIG wire spool feedplate area for wire feed issues correct and retry calibration ERR 34 User Calibration Abort User initiated abort interruption of an active calibration process...

Page 83: ...it is operated B Insulation Resistance Minimum insulation resistance for in service Tweco Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5 2 belo...

Page 84: ...nsure that 1 Flexible cord is of the multi core tough rubber or plastic sheathed type of adequate rating correctly connected and in good condition 2 Welding terminals are in suitable condition and are...

Page 85: ...Minute of wire drive motors to be checked to ensure it falls within required Tweco power source wire feeder specifications Accuracy of digital meters to be checked to ensure it falls within applicable...

Page 86: ...Visually inspect the torch body and consumables Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Bring the unit to an a...

Page 87: ...brush Also wipe off or clean the grooves on the upper feed roll After cleaning tighten the feed roll retaining knobs CAUTION Do NOT use compressed air to clean the Welding Power Source Compressed air...

Page 88: ...FABRICATOR 252i PROBLEMS SERVICE PROBLEMS AND ROUTINE SERVICE 5 8 Manual 0 5155 This Page Intentionally Blank...

Page 89: ...ment Panels 1 2 3 4 5 7 6 Art A 10784 Figure 6 1 FABRICATOR 252i POWER SOURCE SPARE PARTS Panels Sheet Metal ITEM PART NUMBER DESCRIPTION 1 W7005323 Latch Slide 2 W7005366 Door 252i 3 W7005314 Panel R...

Page 90: ...E SPARE PARTS LEFT SIDE ITEM PART NUMBER DESCRIPTION 1 W7005311 Spool Hub Assembly 2 W7005353 Wire Drive Assembly 250i Does not include motor 3 375838 002 Guide Inlet 0 6 1 6mm 4 See Appendix 1 Roll P...

Page 91: ...317 Fan 92x25 LS 24V 5 W7005322 Shroud Heatsink Tunnel 6 W7005331 PCB Mov Bridge 250A 7 W7005302 Transformer Main 250i 8 W7005315 Solenoid 24V 0 0 8MPa 9 W7005351 Inductor 252i 10 W7005355 Circuit Bre...

Page 92: ...FABRICATOR 252i REPLACEMENT PARTS REPLACEMENT PARTS 6 4 Manual 0 5155 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...

Page 93: ...ctor Replacement Kit MS102 RK 8B Cablehoz Rear Mechanical Connector Replacement Kit MS172 RK 8C Cablehoz Front Mechanical Connector Replacement Kit for Euro Style 172X M 9 9A Miller Rear Connector 350...

Page 94: ...FABRICATOR 252i REPLACEMENT PARTS REPLACEMENT PARTS 6 6 Manual 0 5155 This Page Intentionally Blank...

Page 95: ...nd Accessories Top Drive Roll Bottom Drive Roll HARD 023 035 FLUX CORED 030 035 FLUX CORED 045 1 16 SOFT 035 3 64 Art A 10669 Figure A 1 Drive Roll Chart Wire Size Wire Type Top Drive Roll Bottom Driv...

Page 96: ...WELD OUTPUT 1 WELD OUTPUT 1 2 3 4 CURRENT SENSOR INDUCTOR BREAKER LINE LOAD TRIG_RETURN WFSPOT1 N C VPOT1 N C TRIG1 POT_RETURN VBIAS 1 2 3 4 5 6 7 8 J I H G F E D C B A TRIG_SOL_RTN SOL VBIAS VIDENT W...

Page 97: ...etary to Victor Technologies Title Not for release reproduction or distribution without written consent 7 12 2011 Date Printed Date Revised 7 12 2011 00 PROTOTYPE GAC 07 12 2011 1 50 1 2 3 4 5 6 7 8 9...

Page 98: ...AL 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 any...

Page 99: ...ts No Labor Victor Professional Victor Technologies 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 p...

Page 100: ...800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 6...

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