Thermal Arc 211i Operating Manual

Art # A-11239 211i Operating Manual Revision: AA Issue Date: May 4, 2012 Manual No.: 0-5157 Operating Features: Fabricator ® 3 in 1 Multi-process welding system 3163339

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world- wide service network. To locate your nearest distributor or service agency call 1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at www.Thermalarc.com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product. We have made every effort to provide you with accurate instructions, drawings, and photographs of the product(s) while writing this manual. However errors do occur 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 If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.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 IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist. We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise. Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5157 for: Thermal Arc Fabricator 211i Portable System Package Part Number W1004201 Thermal Arc Fabricator 211i Portable System with Cart Part Number W1004202 Thermal Arc Fabricator 211i Power Source Part Number W1004200 Published by: Thermadyne Industries, Inc. 16052 Swingley Ridge Road, Suite 300 St, 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 Manual, whether such error results from negligence, accident, or any other cause. Publication Date: May 4, 2012 Revision Date: Record the following information for Warranty purposes: Where Purchased: _____________________________________ Purchase Date: _____________________________________ Equipment Serial #: _____________________________________

SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1 1.01 Arc Welding Hazards........................................................................................ 1-1 1.02 General Safety Information For Victor CS Regulator.......................................... 1-5 1.03 Principal Safety Standards............................................................................... 1-7 1.04 Symbol Chart................................................................................................... 1-8 1.05 Precautions De Securite En Soudage A L’arc................................................... 1-9 1.06 Dangers relatifs au soudage à l’arc.................................................................. 1-9 1.07 Informations Générales de Sécurité............................................................... 1-13 1.08 Principales Normes De Securite.................................................................... 1-15 1.09 Graphique de Symbole................................................................................... 1-16 1.10 Declaration Of Conformity............................................................................. 1-17 SECTION 2: INTRODUCTION .............................................................................. 2-1 2.01 How To Use This Manual................................................................................. 2-1 2.02 Equipment Identification.................................................................................. 2-1 2.03 Receipt Of Equipment...................................................................................... 2-1 2.04 Description...................................................................................................... 2-1 2.05 Transportation Methods................................................................................... 2-2 2.06 User Responsibility.......................................................................................... 2-2 2.07 Fabricator 211i Portable System Package (Part No. W1004201)..................... 2-2 2.08 Duty Cycle........................................................................................................ 2-3 2.09 Specifications.................................................................................................. 2-4 2.10 Optional Accessories....................................................................................... 2-6 2.11 Volt-Ampere Curves......................................................................................... 2-7 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 ............................................................................................ 3-1 3.05 Electromagnetic Compatibility......................................................................... 3-4 3.06 Victor Regulator............................................................................................... 3-5 3.07 Leak Testing The System................................................................................. 3-8 3.08 When You Finish Using The Regulator............................................................. 3-8 3.09 Storage Of The Regulator................................................................................ 3-8 3.10 Fabricator 211i Power Source Controls, Indicators And Features.................... 3-9 3.11 Attaching The TWECO WeldSkill 220A MIG Gun............................................ 3-16 3.12 Installing 33/44 lb Spool (12" diameter) ....................................................... 3-17 3.13 Installing 12.5 lb Spool ( 8" diameter)........................................................... 3-18 3.14 Installing 1 lb Spool (4" diameter)................................................................. 3-19 3.15 Inserting Wire Into The Wire Feed Mechanism.............................................. 3-20

3.16 Feed Roller Pressure Adjustment................................................................... 3-21 3.17 Changing the Feed Roll.................................................................................. 3-21 3.18 Wire Reel Brake............................................................................................. 3-22 3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire..................... 3-22 3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire.................... 3-23 3.21 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire.3-25 3.22 Setup For LIFT TIG (GTAW) Welding.............................................................. 3-26 3.23 Setup For STICK (SMAW) Welding ............................................................... 3-28 SECTION 4: BASIC WELDING GUIDE.............................................................................. 4-1 4.01 MIG (GMAW/FCAW) Basic Welding Technique................................................ 4-1 4.02 MIG (GMAW/FCAW) Welding Troubleshooting................................................ 4-5 4.03 STICK (SMAW) Basic Welding Technique........................................................ 4-8 4.04 Effects of Arc Welding Various Materials......................................................... 4-8 4.04 STICK (SMAW) Welding Troubleshooting...................................................... 4-16 4.05 TIG (GTAW) Basic Welding Technique........................................................... 4-18 4.06 TIG (GTAW) Welding Problems...................................................................... 4-20 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 5.03 Cleaning the Welding Power Source................................................................ 5-5 5.04 Cleaning the Feed Rolls.................................................................................... 5-6 SECTION 6: KEY SPARE PARTS........................................................................... 6-1 6.01 Tweco WeldSkill 220A MIG Gun ..................................................................... 6-1 6.02 Power Source Spare Parts............................................................................... 6-2 APPENDIX 1: FABRICATOR 211i CIRCUIT DIAGRAM .................................................. A-1

1.01 Arc Welding Hazards WARNING ELECTRIC SHOCK can kill. 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. 1. Do not touch live electrical parts. 2. Wear dry, hole-free insulating gloves and body protection. 3. Insulate yourself from work and ground using dry insulating mats or covers. 4. 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. 5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. 6. Turn OFF all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service. 7. 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. 8. Do not use worn, damaged, undersized, or poorly spliced cables. 9. Do not 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 safety harness to prevent falling if working above floor level. 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. 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 Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1-2 Manual 0-5157 15. Keep all panels and covers securely in place. WARNING ARC RAYS can burn eyes and skin; NOISE can damage hearing. 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. 1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching. 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. 5. Use approved ear plugs or ear muffs if noise level is high. WARNING FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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) 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 Cored Arc Welding (FCAW) Less than 60 60-160 160-250 250-550 7 10 10 10 - 11 12 14 Gas Tungsten arc Welding (GTAW) Less than 50 50-150 150-500 8 8 10 10 12 14 Air Carbon Arc Cutting (CAC-A) (Light) (Heavy) Less than 500 500-1000 10 11 12 14 Plasma Arc Welding (PAW) Less than 20 20-100 100-400 400-800 6 8 10 11 6 to 8 10 12 14 Plasma Arc Cutting (PAC) Less than 20 20-40 40-60 60-80 80-300 300-400 400-800 4 5 6 8 8 9 10 4 5 6 8 9 12 14 * As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.

1. Keep your head out of the fumes. Do not breathe the fumes. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 3. If ventilation is poor, use an approved air-supplied respirator. 4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners. 5. 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. 6. 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. 7. 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 air- supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. WARNING WELDING can cause fire or explosion. 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. 1. Protect yourself and others from flying sparks and hot metal. 2. Do not weld where flying sparks can strike flammable material. 3. Remove all flammables within 35 ft (10.7 m) of the welding 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 or drums. 8. Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long, possibly unknown paths and causing electric shock and fire hazards. 9. Do not use welder to thaw frozen pipes. 10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag. 1. Wear approved face shield or safety goggles. Side shields recommended. 2. Wear proper body protection to protect skin. WARNING CYLINDERS can explode if damaged. 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. 1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs. 2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping. 3. Keep cylinders away from any welding or other electrical circuits. 4. Never allow a welding electrode to touch any cylinder. 5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

1-4 Manual 0-5157 6. Turn face away from valve outlet when opening cylinder valve. 7. Keep protective cap in place over valve except when cylinder is in use or connected for use. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. ! WARNING Engines can be dangerous. WARNING ENGINE EXHAUST GASES can kill. Engines produce harmful exhaust gases. 1. Use equipment outside in open, well-ventilated areas. 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING ENGINE FUEL can cause fire or explosion. Engine fuel is highly flammable. 1. Stop engine before checking or adding fuel. 2. Do not add fuel while smoking or if unit is near any sparks or open flames. 3. Allow engine to cool before fuelling. If possible, check and add fuel to cold engine before beginning job. 4. Do not overfill tank — allow room for fuel to expand. 5. Do not spill fuel. If fuel is spilled, clean up before starting engine. WARNING MOVING PARTS can cause injury. Moving parts, such as fans, rotors, and belts can 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 clothing, and tools away from moving parts. 6. Reinstall panels or guards and close doors when servicing is finished and before starting engine. WARNING SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin. Batteries contain acid and generate explosive gases. 1. Always wear a face shield when working on a battery. 2. Stop engine before disconnecting or connecting battery cables. 3. Do not allow tools to cause sparks when working on a battery. 4. Do not use welder to charge batteries or jump start vehicles. 5. Observe correct polarity (+ and –) on batteries. WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin. The coolant in the radiator can be very hot and under pressure. 1. Do not remove radiator cap when engine is hot. Allow engine to cool. 2. Wear gloves and put a rag over cap area when removing cap. 3. Allow pressure to escape before completely removing cap.

NOTE Considerations About Welding And The Effects of Low Frequency Electric and Mag- netic Fields The following is a quotation from the General Conclu- sions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA- BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cel- lular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with, and produce changes in, biologi- cal systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.” To reduce magnetic fields in the workplace, use the following procedures. 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape 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. 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 performed cor­rectly in the proper environment. 1. The work area must have a fireproof floor. 2. Work benches or tables used during welding or cutting operations must have fireproof tops. 3. Use heat resistant shields or other approved mate- rial to protect nearby walls or unprotected flooring from sparks and hot metal. 4. Keep an approved fire extinguisher of the proper size and type in the work area. Inspect it regu- larly to ensure that it is in proper working order. Know how to use the fire extin­guisher. 5. Move combustible materials away from the work site. If you ­can not move them, protect them with fireproof covers. ­ ! WARNING NEVER perform welding, heating, or cut- ting operations on a container that has held toxic, combustible or flammable liq­uids, or vapors. NEVER perform welding, heating, or cutting operations in an area containing combustible vapors, flam­mable liquids, or explosive dust. B Housekeeping ! WARNING NEVER allow oxygen to contact grease, oil, or other flam­mable substances. Although oxy- gen by itself will not burn, these substances become highly explosive. They can ignite and burn violently in the presence of oxygen. Keep ALL apparatus clean and free of grease, oil and other flammable substances.

1-6 Manual 0-5157 C Ventilation ! WARNING Ade­quately ventilate welding, heating, and cutting work areas to prevent accumula- tion of explosive or toxic concen­trations of gases. Certain combinations of metals, coatings, and gases generate toxic fumes. Use respiratory protection equipment in these circumstances. When welding/brazing, read and understand the Material Safety Data Sheet for the welding/brazing alloy. D Personal Protection Gas flames produce infrared radiation which may have a harm­ful effect on the skin and especially on the eyes. Select goggles or a mask with tempered lenses, shaded 4 or darker, to protect your eyes from injury and provide good visibility of the work. Always wear protective gloves and flame-resistant clothing to protect skin and clothing from sparks and slag. Keep collars, sleeves, and pockets buttoned. DO NOT roll up sleeves or cuff pants. When working in a non-welding or cutting environment, always wear suitable eye protection or face shield. ! WARNING Practice the following safety and operation precautions EVERY TIME you 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. Keep the cylinder in a vertical position. Secure it to a cart, wall, work bench, post, etc. Figure 1-1: Gas Cylinders ! WARNING Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or mis­use of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, flames or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Com- pressed Gases in Containers” publication. NOTE CGA P-1 publication is available by writing the Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly,VA 20151- 2923 2. Place the valve protection cap on the cylinder whenever mov­ing it, placing it in storage, or not using it. Never drag or roll cylinders in any way. Use a suitable hand truck to move cylin­ders. 3. Store empty cylinders away from full cylinders. Mark them “EMPTY” and close the cylinder valve. 4. NEVER use compressed gas cylinders without a pressure reducing regulator attached to the cylinder valve. ­ 5. Inspect the cylinder valve for oil, grease, and damaged parts.

! WARNING DO NOT use the cylinder if you find oil, grease or damaged parts. Inform your gas supplier of this condition immediately. 6. Momentarily open and close (called “cracking”) the cylinder valve to dislodge any dust or dirt that may be present in the valve. CAUTION Open the cylinder valve slightly. If you open the valve too much, the cylinder could tip over. When cracking the cylinder valve, DO NOT stand directly in front of the cylinder valve. Always perform cracking in a well ventilated area. If an acetylene cylinder sprays a mist when cracked, let it stand for 15 minutes. Then, try to crack the cylinder valve again. If this problem persists, contact your gas supplier. 1.03 Principal Safety Standards Safety in Welding and Cutting, 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 Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-8 Manual 0-5157 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Gas Tungsten Arc Welding (GTAW) Air Carbon Arc Cutting (CAC-A) Constant Current Constant Voltage Or Constant Potential High Temperature Fault Indication Arc Force Touch Start (GTAW) Variable Inductance Voltage Input Single Phase Three Phase Three Phase Static Frequency Converter- Transformer-Rectifier Dangerous Voltage Off On Panel/Local Shielded Metal Arc Welding (SMAW) Gas Metal Arc Welding (GMAW) 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 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 Inches Per Minute Meters Per Minute Welding Gun Burnback Time Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow. 4 Step Trigger Operation 2 Step Trigger Operation S See Note See Note S Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides. Cannot be disposed with household garbage.

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). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT. Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dom- mages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires. En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes. La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité. SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN 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, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux. 1. Ne touchez pas à des pièces sous tension. 2. Portez des gants et des vêtements isolants, secs et non troués. 3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen de tapis isolants ou autres. 4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle. 5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables. 6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé. 7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte- électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode. 8. N’utilisez pas de câbles électriques usés, endom- magés, mal épissés ou de section trop petite. 9. N’enroulez pas de câbles électriques autour de votre corps.

1-10 Manual 0-5157 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder. 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre). 12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées. 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu. 14. Portez un harnais de sécurité si vous travaillez en hauteur. 15. Fermez solidement tous les panneaux et les capots. AVERTISSEMENT LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe. 1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure. AWS F2.2 : 2001 (R2010), Modifié avec l’accord de l’American Welding Society (AWS), Miami, Florida Guide de teinte des lentilles Procédé Taille de l’électrode en mm (po) Courant d’arc (ampères) Gamme d’intensité minimum Numéro de teinte recommandée* (Confort) Soudage à l’arc avec électrode enrobée (procédé SMAW) Moins de 2,4 (3/32) 3/32-5/32 (2,4-4,0) 5/32-1/4 (4,0-6,4) Plus de 1/4 (6,4) Moins de 60 60-160 160-250 250-550 7 8 10 11 - 10 12 14 Soudage à l’arc sous gaz avec fil plein (procédé GMAW) et soudage avec fil fourré (procédé FCAW) Moins de 60 60-160 160-250 250-550 7 10 10 10 - 11 12 14 Soudage à l’électrode réfractaire (procédé GTAW) Moins de 50 50-150 150-500 8 8 10 10 12 14 Coupage à l’arc avec électrode de carbone et jet d’air (procédé AAC) (Clair) (Sombre) Moins de 500 500- 1000 10 11 12 14 Soudage à l’arc au plasma (procédé PAW) Moins de 20 20-100 100-400 400-800 6 8 10 11 6 à 8 10 12 14 Coupage plasma (procédé PAC) Moins de 20 20-40 40-60 60-80 80-300 300-400 400-800 4 5 6 8 8 9 10 4 5 6 8 9 12 14 * En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors du soudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante lumière jaune; il est préférable d’utiliser un filtre qui absorbe cette lumière jaune ou le sodium du spectre de la lumière visible. Tableau 1-1

AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L’arc produit des étincellies et des projec- tions. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact ac- cidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie. 1. Protégez-vous, ainsi que les autres, contre les étin- celles et du métal chaud. 2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables. 3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soi- gneusement avec des bâches approuvées. 4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures. 5. Méfiez-vous des incendies et gardez un extincteur à portée de la main. 6. N’oubliez pas qu’une soudure réalisée sur un pla- fond, un plancher, une cloison ou une paroi peut enflammer l’autre côté. 7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril. 8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie. 9. Ne dégelez pas les tuyaux avec un source de courant. 10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage. 11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un 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 de sécurité. 5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé. AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE. Le soudage dégage des vapeurs et des fumées dangereuses à respirer. 1. Eloignez la tête des fumées pour éviter de les re- spirer. 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc. 3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé. 4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants. 5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respira- tion. 6. Ne soudez pas à proximité d’opérations de dégrais- sage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants. 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

1-12 Manual 0-5157 AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLES- SURES. Le piquage et le meulage produisent des particules métalliques volantes. En refroid- issant, la soudure peut projeter du éclats de laitier. 1. Portez un écran facial ou des lunettes protec- trices approuvées. Des écrans latéraux sont recommandés. 2. Portez des vêtements appropriés pour protéger la peau. AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEU- VENT EXPLOSER Les bouteilles contiennent des gaz pro- tecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin. 1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage. 2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées. 3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage. 4. Empêchez tout contact entre une bouteille et une électrode de soudage. 5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipe- ments 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, identifiée dans la liste de documents ci-dessous. AVERTISSEMENT LES MOTEURS PEUVENT ETRE DAN- GEREUX LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS. Les moteurs produisent des gaz d’échappement nocifs. 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. 2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâti- ment. AVERTISSEMENT LE CARBURANT PEUR CAUSER UN IN- CENDIE OU UNE EXPLOSION. Le carburant est hautement inflammable. 1. Arrêtez le moteur avant de vérifier le niveau e car- burant ou de faire le plein. 2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue. 3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage. 4. Ne faites pas le plein de carburant à ras bord: pré- voyez de l’espace pour son expansion. 5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES. Des pièces en mouvement, tels des ventila- teurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples. 1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés. 2. Avant d’installer ou de connecter un système, arrêtez le moteur. 3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire. 4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative. 5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils. 6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur. AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOS- ER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR PEUT BRULER LA PEAU ET LES YEUX. Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives. 1. Portez toujours un écran facial en travaillant sur un accumu-lateur. 2. Arrêtez le moteur avant de connecter ou de décon- necter des câbles 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 refroidissement d’un radiateur peut être brûlant et sous pression. 1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi. 2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter. 3. Laissez la pression s’échapper avant d’ôter com- plètement le bouchon. 1.07 Informations Générales de Sécurité A Prévention D’incendie Les opérations de soudage utilisent le feu ou la combustion comme outil de base. Ce processus est très utile quand il est cor­rectement contrôlé. 1. La zone doit comporter un sol ignifugé. 2. Les établis ou tables utilisés pendant les opéra- tions de soudage doivent avoir un revêtement ignifuge. 3. Utilisez des écrans résistants à la chaleur ou en matériau approuvé pour protéger les cloisons proches ou le sol vul­nérable des étincelles et du métal chaud. 4. Gardez un extincteur approuvé du bon type et de la bonne taille dans la zone de travail. Inspectez-le régulièrement pour vous assurer qu’il est en état de fonctionner. Apprenez à vous en servir. 5. Enlevez tous les matériaux combustibles de la zone de travail. Si vous ne pouvez pas les enlever, protégez-les avec une cou­vre ignifuge.

1-14 Manual 0-5157 ! AVERTISSEMENT N’effectuez JAMAIS d’opérations de soudage sur un récipient qui a contenu des liquides ou vapeurs toxiques, combustibles ou in- flammables. N’effectuez JAMAIS d’opérations de soudage dans une zone contenant des vapeurs combustibles, des liquides inflam- mables ou des poussières explosives. B Entretien des Locaux ! AVERTISSEMENT Ne laissez jamais l’oxygène en contact avec la graisse, l’huile ou d’autres substances in- flammables. Bien que l’oxygène elle­même ne brûle pas, ces substances peuvent devenir extrême­ment explosives. Elles peuvent pren- dre feu et brûler violem­ment en présence d’oxygène. Gardez TOUS les appareils propres et exempts de graisse, huile ou autres substances inflammables. C Aération ! AVERTISSEMENT Ventilez les zones de soudage, chauffage et découpage de façon adéquate pour éviter l’accumulation de gaz explosifs ou toxiques. Certaines combinaisons de métaux, revête- ments et gaz génèrent des fumées toxiques: Utilisez un équipement de protection res- piratoire dans ces circonstances. Si vous soudez ou brasez, lisez et assimilez la fiche technique de sécurité de matériau relative à l’alliage de soudage/brasage. D Protection Personnelle Les flammes de gaz produisent une radiation infrarouge qui peut avoir un effet néfaste sur la peau, et particu- lièrement sur les yeux. Choisissez des lunettes ou un masque avec des verres trempés assombris au niveau 4 ou plus sombre, pour protéger vos yeux des dommages et garder une bonne visibilité sur le travail. Portez en permanence des gants de protection et des vête­ments 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 toujours une protection des yeux appropriées ou un masque facial. ! AVERTISSEMENT Mettez en pratique les procédures de sé- curité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pression. Si vous déviez de ces procédures, cela peut entraîner incendie, explosion, dégâts matériels et/ou blessures corporelles pour l’opérateur. E Bouteilles de Gaz Comprimé Le Département des Transports américain (DOT) ap- prouve la conception et la fabrication des bouteilles qui contiennent les gaz utilisés pour les opérations de soudage ou de découpage. 1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la en position verticale. Fixez-la sur un chariot une cloison, un établi, etc. Le schéma 1-1: Cylindres de gaz

! AVERTISSEMENT Les bouteilles sont sous haute pression. Manip- ulez-les avec précautions. Des accidents sérieux peuvent résulter d’une mauvaise manutention ou d’un mauvais emploi des bouteilles de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez pas, ne l’exposez pas à une chaleur excessive, aux flammes ou étincelles. NE la cognez PAS contre d’autres bouteilles. Contactez votre fournisseur de gaz ou reportez­vous à la publication CGA P-1 “Manipulation sécurisée des gaz compri- més en conteneur” pour plus d’informations sur l’utilisation et la manutention des bouteilles. AVIS Ce document CGA p. t peut être obtenu en écrivant à “Compressed Gas Association”, 4221 Walney Roed, 5th Floor. Chantilly, VA 20151.2923, USA. 2. Placez le bouchon de protection de vanne sur la bouteille à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne faites jamais glisser ou rouler d’aucune manière les bouteilles. Utilisez un diable approprié pour les déplacer. 3. Entreposez les bouteilles vides à l’écart des bouteilles pleines. Marquez-les “VIDE” et refer- mez leur vanne. 4. N’utilisez JAMAIS des bouteilles de gaz comprimé sans un régulateur de pression en série sur la vanne de bouteille. 5. Inspectez la vanne de bouteille pour y détecter de l’huile ou de la graisse, ou dès pièces endommagées. ! AVERTISSEMENT N’UTILISEZ PAS la bouteille si vous trouvez de l’huile, de la graisse ou des pièces endom- magées. Informez immédiate­ment votre fournisseur de’ gaz de cet état. 6. Ouvrez et fermez momentanément la vanne de la bouteille, délogeant ainsi d’éventu lIes pous- sières ou saletés. qui pour­raient être présentes dans la vanne. Mise en Garde Ouvrez la vanne de bouteille légèrement. Si vous l’ouvrez trop en grand, la bouteille pourrait se renverser. Quand vous ouvrez/ fermez rapidement 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, con­tactez votre fournis- seur de gaz. 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, Su- perintendent 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 Haz- ardous Substances, norme AWS F4.1, American Weld- ing Society, 550 N.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, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Stan- dards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme 51B NFPA, Na- tional Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-16 Manual 0-5157 Soudage á L’arc Avec Electrode Non Fusible (GTAW) Decoupe Arc Carbone (CAC-A) Courant Constant Tension Constante Ou Potentiel Constant Haute Température Force d’Arc Amorçage de L’arc au Contact (GTAW) Inductance Variable Tension Mono Phasé Trois Phasé Tri-Phase Statique Fréquence Convertisseur Transformateur-Redresseur Tension dangereuse Hors Tension Sous Tension Panneau/Local Soudage Arc Electrique Avec Electrode Enrobé (SMAW) Soudage á L’arc Avec Fil Electrodes Fusible (GMAW) Augmentez/Diminuer Disjoncteur Source AC Auxiliaire Distant Facteur de Marche Pourcentage Intensité de Courant Tension Hertz (cycles/sec) Fréquence Négatif Positif Courant Continue (DC) Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise- Source Auxiliaire Art # A-07639F_AC 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 démarrer l’alimentation du fils et la soudure, le relâcher pour arrêter. Purge Du Gaz Mode Continu de Soudure Pouces Par Minute Mètres Par Minute Torche de Soudage Probléme de Terre Maintenez appuyez pour pré-dèbit, relailez pour initier l’arc. Appuyez pour arrêter l’arc, et mainteuir pour pré-dèbit. Détente à 4-Temps Détente à 2-Temps V S S Voir Note Voir Note Avis : Pour les environnements avec des risques de choc électrique, le fournisseur d’énergie portant la marque conforme à EN50192 lorsqu’utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à l’hauteur de buse correctement installé. Ne pas déposer avec les déchets ménagers. Indication d’erreur 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle.

1.10 Declaration Of Conformity Manufacturer: Thermadyne Corporation Address: 16052 Swingley Ridge Road, Suite 300 St Louis, Mo63017 USA The equipment described in this manual has been designed to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements. Among them are: • CSA E60974-1, UL60974-1 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 testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Tom Wermert Elaine Slatter Senior Brand Manager Thermal Arc Country Manager/Director Thermadyne Industries, Inc Thermadyne Canada 16052 Swingley Ridge Road 2070 Wyecroft Raod Chesterfield, Missouri 63017 USA Oakville, Ontario L6L5V6 Canada 3163339

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2.03 Receipt Of Equipment When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equip- ment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage 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 above along with a full description of the parts in error. 2.04 Description The Thermal Arc Fabricator 211i is a self contained single phase multi process welding system that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding processes. The Power Source is equipped with an integrated wire feed unit, digital volt- age and amperage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional. The Power Source is also fully compliant to Standard CSA E60974-1-00 and UL 60974.1. The Thermal Arc Fabricator 211i provides excellent weld- ing performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to cor- rectly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source. Please read these instructions thoroughly before using the unit. 2.01 How To Use This Manual To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows: ! WARNING A WARNING gives information regarding pos- sible personal injury. CAUTION A CAUTION refers to possible equipment damage. NOTE A NOTE offers helpful information concerning certain operating procedures. You will also notice icons from the safety section appear- ing throughout the manual. These are to advise you of specific types of hazards or cautions related to the por- tion of information that follows. Some may have multiple hazards that apply and would look something like this: 2.02 Equipment Identification The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equip- ment which does not have a control panel such as gun and cable assemblies is identified only by the specifica- tion or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

! WARNING ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source. ! WARNING FALLING EQUIPMENT can cause serious per- sonal injury and equipment damage. Lift Power Source with handles built into the top of the front and rear molded panels. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure Power Source on a proper skid before transporting. 2.06 User Responsibility This equipment will perform as per the information con- tained herein when installed, operated, maintained and repaired in accordance with the instructions provided. 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 immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by ap- propriately qualified persons approved by Thermal Arc. Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor. This equipment or any of its parts should not be altered from standard specification without prior written 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 re- pair by anyone other than appropriately qualified persons approved by Thermal Arc. 2.07 Fabricator 211i Portable System Package (Part No. W1004201) • Fabricator 211i Power Source • 12 ft. (3.6 m) Tweco WeldSkill 220 Amp MIG Gun • Victor Argon Regulator / Flowmeter • Drive Rolls: .023"/.030" (0.6/0.8mm) "V" groove, .023"/.035" (0.6/0.9mm)"V" groove (fitted with .035" groove lined up) , .030"/.035" (0.8/0.9mm) "V" knurled for Flux Cored Wire, • Contact Tips (1 each) .023"(0.6mm),.030"(0.8mm), .035"(0.9mm) (fitted) • Electrode Holder with 13 ft. (4m) lead • Work Clamp with 10ft. (3.1m) lead • Shielding Gas hose assembly • 15A/20A Adapter Plug from 208/230V AC 50 Amps to 115V Amps Circuits • Thermal Arc Cap • Electrodes • Operating Manual • DVD Figure 2-1: Fabricator 211i System Packaged W1004201

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 210 amperes at 24.5 volts. This means that it has been designed and built to provide the rated am- perage (210A) 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 allowed to cool. The thermal cut out will operate if the duty cycle is exceeded. 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 FABRICATOR 211i Welding Current (AMPS) SAFE OPERATING REGION (MIG, TIG & STICK) 0 0 10 20 30 40 60 70 50 80 100 90 Duty Cycle (PERCENTAGE) MIG STICK / TIG Art # A-11265 Figure 2-2: Fabricator 211i Duty Cycle on 208/230V AC Welding Current (AMPS) Duty Cycle (PERCENTAGE) Art # A-11274 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 FABRICATOR 211i SAFE OPERATING REGION (MIG, TIG & STICK) TIG STICK MIG Figure 2-3: Fabricator 211i Duty Cycle on 115V AC

Power Source Part No. W1004200 Power Source Dimensions H17.12" x W10.47" x D 24.29" (435mm x 266mm x D617mm) Power Source Mass 57.3lb (26kg) Cooling Fan Cooled Welder Type Multi Process Welding System Applicable Standard CSA E60974-1-00 / UL60974-1 / IEC 60974-1 Number of Phases Single Phase Nominal Supply Voltage 208/230 VAC ± 10% 115VAC± 10% Nominal Supply Frequency 50/60Hz 50/60HZ Welding Current Range MIG Mode STICK Mode TIG Mode 10-210 Amps 10-200 Amps 10-200 Amps 10-140 Amps 10-110 Amps 10-150 Amps Wirefeed Speed Range 100 - 600 IPM 100 - 400 IPM MIG Welding Voltage Range 14.5 - 24.5V DC 14.5 - 19V DC Nominal OCV 70V DC Effective Input Current (I1eff) for MIG (GMAW/FCAW) for STICK (SMAW) for LIFT TIG (GTAW) 14.4A/11.2A 16.8A/15.8A 11.7A/11.5A 15.5A 17.8A 17.4A Maximum Input Current (I1max) for MIG (GMAW/FCAW) for STICK (SMAW) for LIFT TIG (GTAW) 32.2A/25.0A 33.6A/31.6A 23.3A/22.9A 24.5A 30.1A 29.4A Single Phase Generator Requirement 7.5 kVA *3.7 kVA MIG (GMAW/FCAW) Welding Output, 104°F, 10 min. 210A @ 20%,24.5V 122A @ 60%, 20.1V 95A @ 100%, 18.8V 110A @ 45%,19.5V 99A @ 60%, 19.0V 77A @ 100%, 17.9V STICK (SMAW) Welding Output,1040°F, 10 min. 200A @ 25%,28.0V 130A @ 60%, 25.2V 101A @ 100%, 24.0V 110A @ 35%,24.4V 90A @ 60%, 23.6V 70A @ 100%, 22.8V TIG (GTAW) Welding Output, 104°F, 10 min. 200A @ 25%,18.0V 130A @ 60%, 15.2V 101A @ 100%, 14.0V 150A @ 35%,16.0V 115A @ 60%, 14.6V 90A @ 100%, 13.6V Open Circuit Voltage 70 V Protection Class IP23S Table 2-1: Fabricator 211i Specifications Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements. Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local require- ments for your situation in this regard. Note 3: Generator Requirements at the Maximum Output Duty Cycle. * Some 115 VAC, 15 amp/20 amps electrical outlets fitted with GFCI (Ground Fault Circuit Interrupt) protection amy nuisance trip with this equipment due to worn or out of tolerance components in the GFCI. In such cases have the 115 VAC, 15 amp/20 amp FGCI electrical outlet replaced by a qualified electrical trades person.

capable of carrying 30 amperes and protected by fuses or circuit breaker is recommended for this applica- tion. Fuse size is based on not more than 200 percent of the rated input amperage of the welding Power Source (Based on Article 630, National Electrical Code) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications 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. The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications due to in part, but not exclusively, to any one or more of the fol- lowing; variations or changes in manufactured components, installation and conditions and local power grid supply conditions.

26V TIG Torch & Accessories (required for TIG welding) Part No. W4014603 Tweco Spool Gun (required for aluminum MIG welding.. ) Part No. 1027-1390 Professional 4 Wheel Cart, Dual Cylinder.................... Part No. W4015002 Professional 4 Wheel Cart, Single Cylinder................. Part No. W4015001 Small Cart, Single Cylinder.......................................... Part No. W4014700 Roll Cage....................................................................... Part No. W4015104 Foot Control.................................................................. Part No. 600285 Tweco Helmet (USA Only)............................ Part No. 4100-1004 Drive Roll .023" - .030" (0.6/0.8mm ) V groove, (fitted) Part No. 7977036 Drive Roll .023" - .035" (0.6/0.9 mm) V groove .. Part No. W4014800 Drive Roll .035"/.045" (0.9/1.2 mm) V groove ... Part No. 7977660 Drive Roll .030" - .035" (0.8/0.9 mm) U groove... Part No. 7977731 Drive Roll .040" - 3/64" (1.0/1.2 mm) U groove .. Part No. 7977264 Drive Roll .030" - .035" (0.8/0.9 mm) V knurled . Part No. 7977732 Drive Roll .045"(1.2 mm) V knurled .............. Part No. 704277 Stick Lead, 200A, 13ft, 50mm Dinse............. Part No. WS200E13 Ground Lead, 200A, 10Ft, 50mm Dinse........... Part No. WS200G10 Victor Argon Regulator/ Flowgauge ..................... Part No. 130781-4169 Accessory Kit for TIG Torch.................................... Part No. P062900010 12.5 ft cable length; 12.5 ft gas hose length; 8 pin control plug; 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 160A, 12ft (3.6M) Length, suits 4" (100mm) spools For remote amperage control when TIG welding WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only) 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

Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. Art # A-11297 Figure 2-4: Fabricator 211i Volt-Ampere Curves

FABRICATOR 211i INTRODUCTION INTRODUCTION 2-8 Manual 0-5157

with increased hazard of electric shock. Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock. Please refer to relevant local standards for further information prior to using in such areas. A. Examples of environments with increased hazard of electric shock are: 1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts. 2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator. 3. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories. B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated. 3.02 Location Be sure to locate the welder according to the following guidelines: A. In areas, free from moisture and dust. B. Ambient temperature between 14° F (0° C) to 104° F (40° C). C. In areas, free from oil, steam and corrosive gases. D. In areas, not subjected to abnormal vibration or shock. E. In areas, not exposed to direct sunlight or rain. F. Place at a distance of 12" (305mm) or more from walls or similar that could restrict natural air flow for cooling. SECTION 3: INSTALLATION, OPERATION AND SETUP 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 from vertical drops. Under no circumstances should the Power Source be operated or connected in a micro environment that will exceed the stated conditions. For further information please refer to EN 60529. H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use. WARNING This equipment should be electrically con- nected by a qualified electrician. 3.03 Ventilation ! WARNING Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated. 3.04 Electricity Supply The Electricity Supply voltage should be within 208/230V AC ± 10% or 115 V AC ± 10%. Too low a supply voltage may cause poor welding performance in STICK mode such as the arc snuffing out during welding. Too high a supply voltage will cause components to overheat and possibly fail. The Welding power Source must be: • Correctly installed, if necessary, by a qualified electrician. • Correctly earthed (electrically) in accordance with local regulations. • Connected to the correct size power point and fuse as per the Specifications on page 2-4.

PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts. SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting OFF and red-tagging circuit breaker or other disconnecting device. Power Cords Included With Power Supply Attached to the power supply is an input power cord with a 208/230Volt 50 Amp NEMA 6-50 P for plug. Supplied adapter allow for connection of the power supply input cable plug to 115 V input power. Art# A-11275 Figure 3-1: 115 VAC Adapter Electrical Input Requirements Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit. The Welding Power Source must be: Do not connect in 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 (electrically) in accordance with local regulations. • Connected to the correct size power point, fuse and primary supply lead based on Table 3-1. Refer to Figure 3-1 and Table 3-1.

not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source. 50 / 60 Hz Single Phase Supply Supply Voltage 208/230V AC 115V AC Input Current at Maximum Output 32 Amps 30 Amps Maximum Recommended Fuse* or Circuit Breaker Rating * Time Delay Fuse, UL class RK5. Refer to UL248 50 Amps 50 Amps 30 Amps 30 Amps Maximum Recommended Fuse^ or Circuit Breaker Rating ^Normal Operating , UL class K5. Refer to UL248 Minimum Recommended Cord Size 12 AWG 12 AWG Maximum Recommended Extension Cord Length 50 ft 25 ft Minimum Recommended Grounding Conductor Size 12 AWG 12AWG Table 3-1: Electrical Service Guide CAUTION The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when welding with this product due to the amperage rating of the time-delay fuses or circuit breaker. Art# A-11240 Primary Power Cable 115 115 V, V, 20A, 1Ø 15A, 1Ø 208/230V, 50A, 1Ø The Adapter enable connection to all these power outlets 115 VAC Adapter Figure 3-2: Electrical Input Connections

! WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation. A. Installation and Use - Users Responsibility The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user 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 electromag- netic screen enclosing the Welding Power Source and the work, complete with associated input filters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer Troublesome. NOTE The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. B. Assessment of Area Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account. 1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment. 2. Radio and television transmitters and receivers. 3. Computer and other control equipment. 4. Safety critical equipment, e.g. guarding of industrial equipment. 5. The health of people around, e.g. the use of pace-makers and hearing aids. 6. Equipment used for calibration and measurement. 7. The time of day that welding or other activities are to be carried out. 8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures. The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. C. Methods of Reducing Electromagnetic Emissions 1. Electricity Supply Welding equipment should be connected to the Electricity Supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the Electricity Supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions. 3. Welding Cables The welding cables should be kept as short as possible and should be positioned close together but never coiled and 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 the electrode at the same time. The operator should be insulated from all such bonded metallic components. 5. Earthing/grounding of the Work Piece Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations. 6. Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications. 3.06 Victor Regulator Pressure regulator (Figure 3-3) attached to the cylinder valve reduce high cylinder pressures to suitable low working pressures for welding, cutting, and other applications. LOW PRESSURE GAUGE (DELIVERY) HIGH PRESSURE GAUGE (SUPPLY) INLET CONNECTION OUTLET CONNECTION PRESSURE ADJUSTING SCREW Art # A-09414 Figure 3-3: Victor CS Regulator ! WARNING Use the regulator for the gas and pressure for which it is designed. NEVER alter a regulator for use with any other gas.

system. 1. Note the maximum inlet pressure stamped on the regulator. DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator. 2. The regulator body will be stamped “IN” or “HP” at the inlet port. Attach the inlet port to the system supply pressure connection. 3. Wrap pipe threads with Teflon tape 1 1/2 to 2 turns to effect a seal. If other sealants are used, they must be compatible with the gas that will be used in the system. 4. If gauges are to be attached to the regulator and the regu­lator is stamped and listed by a third party (i.e. “UL” or “ETL”). The following requirements must be met: a) Inlet gauges over 1000 PSIG (6.87 mPa) shall conform with the requirements of UL 404, “Indicating Pres- sure Gauges for Compressed Gas Service.” b) Low pressure gauges must be UL recognized for the class of regulator they are being used on according to UL252A. ! WARNING Do not use a regulator that delivers pressure exceeding the pressure rating of the downstream equipment unless pro­visions are made to prevent over-pressurization (i.e. system relief valve). Make sure the pressure rating of the down­stream 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, or other flammable substances. Remove dust and dirt with a clean cloth. Be sure the inlet swivel filter is clean and in place. Attach the regulator (Figure 3-4) to the cylinder valve. Tighten securely with a wrench. ! WARNING DO NOT attach or use the regulator if oil, grease, flamma­ble substances or damage is present! Have a qualified repair technician clean the regulator or repair any damage. Art # A-09845 Figure 3-4: Regulator to Cylinder Valve

sure on the adjusting spring and the screw turns freely. 8. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the regulator from high pres­sures. Relief valves are not intended to protect down­stream equipment from high pressures. ! WARNING DO NOT tamper with the relief valve or remove it from the regulator. ! WARNING Stand to the side of the cylinder opposite the regulator when opening the cylinder valve. Keep the cylinder valve between you and the regulator. For your safety, NEVER STAND IN FRONT OF OR BEHIND A REGULA- TOR WHEN OPENING THE CYLINDER VALVE! 9. Slowly and carefully open the cylinder valve (Figure 3-5) until the maximum pressure shows on the high pres- sure gauge. Art # A-09828 Figure 3-5: Open Cylinder Valve 10. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless regula- tors, the indicator will register the cylinder contents open. 11. On acetylene cylinders, open the valve 3/4 of a turn and no more than 1-1/2. ! WARNING Acetylene delivery pressure must not exceed 15 PSIG (103 kPa) or 30 PSIG (207 kPa). Acetylene can dis- sociate (decompose with explosive violence) above these pressure limits. CAUTION Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn off the cylinder quickly, if necessary. 12. Attach the desired downstream equipment.

Leak test the system before putting into operation. 1. Be sure that there is a valve in the downstream equipment to turn off the gas flow. 2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure. 3. Close the cylinder valve. 4. Turn the adjusting screw/knob counterclockwise one turn. a) If the high-pressure gauge reading drops, there is a leak in the cylinder valve, inlet fitting, or high-pressure gauge. b) If the low-pressure gauge drops, there is a leak in the down­stream 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 been performed and there are no leaks in the system, slowly open the cylinder valve and proceed. ! WARNING If a leak has been detected anywhere in the system, dis­continue use and have the system repaired. DO NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pressure. 3.08 When You Finish Using The Regulator 1. Close the cylinder valve. 2. Open the valve on the downstream equipment. This drains all pressure from the system. 3. Close the valve on the downstream equipment. 4. Turn the adjusting screw counterclockwise to release the ten­sion on the adjusting spring. 5. Check the gauges after a few minutes for verification that the cylinder valve is closed completely. 3.09 Storage Of The Regulator When the regulator is not in use and has been removed from the cylinder, it should be stored in an area where it will be pro­tected from dust, oil, and grease. The inlet and outlet should be capped to protect against internal contamination and prevent insects from nesting.

Art # A-11241 MIG LIFT TIG STICK 4T 2T WIRESPEED DOWNSLOPE (S) ARC FORCE (%) INDUCTANCE SOFT HARD 2 4 6 8 POWER FAULT A 0 1 2 4 7 9 1 3 6 8 V 0 1 2 4 7 9 1 3 6 8 IG L 3 4 5 6 7 8 9 11 10 12 13 2 1 14 16 15 21 210 24.5 3A Figure 3-6: Front and Control Panel Figure 3-7: Rear Panel Connections Art # A-10938 17 Figure 3-8: Wire Feed Compartment Control

The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/ OFF switch located on the rear panel is in the ON position. 2. Thermal Overload Indicator (Fault Indicator) This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled. Once the power source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not switch the unit off should a thermal overload condition be present. 3. Digital Wirespeed/Amperage Meter (Left Digital Display) MIG Mode This digital meter is used to display the pre-set (preview) Wirefeed Speed in IPM (Inches per minute) in MIG mode and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Amperage Control Knob (4). STICK and LIFT TIG Modes The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set (preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Amperage Control Knob (4). When welding, this digital meter will display actual welding amperage in all modes. At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approxi- mately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode. NOTE The preview functionality provided on this power source is intended to act as a guide only. Some differ- ences 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 required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate. 3A Wirespeed Indicator The Wirespeed Indicator illuminates when MIG mode is selected to identify that the Digital Wirespeed/Amperage Meter is previewing Wirespeed in IPM (inches per minute). The Wirespeed Indicator extinguishes when the user is MIG (GMAW/FCAW) welding or depressing the MIG gun trigger and the Digital Wirespeed/Amperage Meter displays actual welding amperage of the power source.

In MIG mode, the Wirespeed/Amperage control knob adjusts the speed of the wire feed motor (which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc). The optimum wire speed depends upon the material type and the welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required settings for a basic range of MIG (GMAW/FCAW) welding applications. In STICK and LIFT TIG modes, the Wirespeed/Amperage control knob adjusts the amount of amperage (weld cur- rent) delivered to the welding arc by the Power Source. It directly adjusts the Power Source to deliver the desired level of weld current. NOTE The preview functionality provided on this power source is intended to act as a guide only. Some differ- ences 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 required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate. 5. MIG Gun Adapter (Tweco Style) The MIG Gun adapter is the connection point for the Tweco Gun. Connect the MIG Gun by pushing the MIG Gun connector into the brass MIG Gun Adapter firmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment to secure the Tweco MIG Gun in position. Failure to properly lock the Tweco MIG Gun into the MIG Gun Adapter will result in the Tweco MIG Gun being pushed out of the MIG Gun Adapter by the MIG welding wire or lack of shielding gas (porosity in the weld) at the weld zone. To remove the MIG gun simply reverse these directions. 6. Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG gun (via the MIG polarity lead), electrode holder lead or work lead. Positive welding current flows from the power source via this heavy duty bayonet type terminal. 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 terminal. 7. MIG Polarity Lead The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using gasless wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt, consult the manu- facturer 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 terminal.

The negative welding terminal is used to connect the welding output of the power source to the appropriate weld- ing accessory such as the MIG gun (via the MIG polarity lead), TIG torch or work lead. Negative welding current flows to the power source via this heavy duty bayonet type terminal. 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 terminal. 9. 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 Remote Wirespeed in MIG (GMAW/FCAW) mode Remote Amps in LIFT TIG (GTAW) mode Remote Volts in MIG (GMAW/FCAW) 1 2 3 4 5 6 7 8 W V 3 4 5 6 7 8 1 2 Negative Spool Gun Motor Positive Art # A-10421_AC Figure 3-9: Remote Control Socket Socket Pin Function 1 Spool Gun Motor Negative 2 Trigger Switch Input 3 Trigger Switch Input 4 Spool Gun Motor (+24V DC) 5 5k ohm (maximum) connection to 5k ohm remote control potentiometer. 6 Zero ohm (minimum) connection to 5k ohm remote control potentiometer. 7 Wiper arm connection to 5k ohm remote control Wirespeed MIG mode potentiometer. Wiper arm connection to 5k ohm remote control Amps LIFT TIG mode potentiometer. 8 Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer. Table 3- 2 Note that the remote local switch (item 18) located in the wirefeed compartment should be set to remote for the amperage/voltage controls to be operative. 10. Multifunction 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.

ences 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 required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate. When MIG Mode is Selected In this mode the control knob is used to adjust the output voltage of the unit. The welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required will dependent on the type of welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications. When STICK Mode is Selected In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob anti-clockwise When LIFT TIG Mode is Selected In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufficiently. Note that when in 2T normal mode (refer item 12), the unit will enter down slope mode as soon as the trigger switch is released (ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding current to zero over 5 seconds). If no down slope time is selected then the welding output will cease immediately. If the unit is set to 4T latch mode, to enter down slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output will cease immediately. 11. 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. 12. Trigger Mode Control (MIG and LIFT TIG Mode only) The trigger mode control is used to switch the functionality of the of the torch trigger between 2T (normal) and 4T (latch mode) 2T (Normal Mode) In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding. 4T (Latch Mode) This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and realized, thus eliminating the need for the operator to hold the torch trigger. Note that when operating in LIFT TIG mode, the power source will remain activated until the selected downslope time has elapsed (refer Item 10).

The process selection control is used to select the desired welding mode. Three modes are available, MIG (GMAW/ FCAW), LIFT TIG (GTAW) and STICK (SMAW) modes. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set up details, section 3.21 for LIFT TIG (GTAW) set-up details or section 3.22 for STICK (SMAW) set-up details. Note that when the unit is powered off the mode selection control will automatically default to MIG mode. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up. 14. Digital Voltage Meter (Right Digital Display) MIG Mode This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This value can be adjusted by varying the Multifunction Control Knob (10). STICK and LIFT TIG Modes This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during non- welding or welding. This value cannot be adjusted by varying the Multifunction Control Knob (10). When welding, this digital meter will display actual welding voltage in all modes. At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approxi- mately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode. NOTE The preview functionality provided on this power source is intended to act as a guide only. Some differ- ences 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 required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate. 15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation) The Gas Inlet connection,5/8-18 UNF female thread is used to supply the appropriate MIG welding gas to the Power Source. Refer to section 3.18 or 3.19 for MIG (GMAW/FCAW) set up details ! WARNING Only Inert Shielding Gases specifically designed for welding applications should be used. 16. On / Off Switch This Single Phase circuit breaker performs a dual function. It is used to turn the unit on/off and it will also trip in the event of a fault.

electrical components are at Mains voltage potential. 17. Wiredrive Motor Circuit Breaker The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload. NOTE If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button. 18. Local / Remote Switch (located in wirefeed compartment) The remote / local switch is used only when a remote control device (such as a TIG torch with remote current control) is fitted to the unit via the remote control socket (item 9). When the local/remote switch is in the remote position, the unit will detect a remote device and work accordingly. When in the local mode, the unit will not detect the remote device and will operate from the power source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local remote 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 maximum achievable output from the unit will be 50%. Should 100% output be required, the respective front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output. 19. Burnback Control (located in wirefeed compartment) The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG gun after the comple- tion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG gun at the completing of welding), turn the burnback control knob anti clockwise. To increase the burnback time (or shorten the amount of wire protruding from the torch at the completing of welding), turn the Burnback Control knob clockwise. 20. MIG Gun & Spool Gun Switch The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun functionality and Spool Gun functionality 21. Cooling Fan The Fabricator 211i 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. Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required. Note in STICK mode the fan operates continuously.

Fit the MIG gun to the power source by pushing the MIG gun connector into the MIG gun adapter and screwing the plastic nut clockwise to secure the MIG gun to the MIG gun adapter. Connect the 8 pin plug by aligning he keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position. Wire Drive Tension Screw Pressure Roller Arm Outlet Guide Inlet Guide Art # A-11242 MIG Gun Connector Locking Screw 8 pin plug MIG Gun Adapter MIG Gun Connector 8 pin socket Figure 3-10: Attaching MIG Gun

As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 33/44 lb. or 12" diameter. Installation of wire spool, Refer to Figure 3-11. 1. Remove Wire Spool 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 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-adjusted at the factory. However if adjustment is required, refer to Section 3.16 CAUTION Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly and don’t let go of it. Wire Spool Hub Nut Spring 33/44 lb (12") Wire Spool Retaining Clip Use inner holes on Spool Hub Flat Washer Small Hole Fiber Washer Spool Hub Keyed Washer Flat Washer Large Hole Pin Art # A-11266 Figure 3-11: 33/44 lb (12") Spool Installation

In order to fit a 12.5 lb spool (8" diameter) assemble parts in the sequence shown in Figure 3-9. Installation of wire spool: 1. Remove Wire Spool 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 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-adjusted at the factory. However if adjustment is required, refer to section 3.16 CAUTION Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly and don’t let go of it. Wire Spool Hub Nut Spring 12.5 lb (8") Wire Spool Retaining Clip Use inner holes on Spool Hub Flat Washer Small Hole Fiber Washer Spool Hub Keyed Washer Flat Washer Large Hole Pin Art # A-11267 Figure 3-12: 12.5lb (8") Spool Installation

In order to fit a 1 lb spool (4" diameter) assemble parts in the sequence shown in Figure 3-13. Installation of wire spool: 1. Remove Wire Spool 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 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-adjusted at the factory. However if adjustment is required, refer to section 3.16 CAUTION Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly and don’t let go of it. Fiber Washer Art # A-11298 Wire Spool Hub Nut Spring 1lb (4") Diameter Wire Spool Flat Washer Small Hole Keyed Washer Flat Washer Large Hole Figure 3-13: 1lb (4") Spool Installation

Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti-clockwise direction. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 3-14). With the MIG welding wire feeding from the bottom of the spool (Figure 3-15) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the MIG gun. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly (Figure 3-14). 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 Supply is switched off. The electrode wire will be at welding voltage potential while it is being feed through the system. Keep MIG gun away from eyes and face. Wire Drive Tension Screw Pressure Roller Arm Outlet Guide Inlet Guide Art # A-10426 Figure 3-14: Wire Drive Assembly Components MIG Welding Wire Art # A-10427_AB Figure 3-15: MIG Welding Wire - Installation

The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping oc- curs, 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 not the cause of slipping, the feed roll pressure can be increased by rotating the pressure 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. 3.17 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions. A dual groove feed roller is supplied as standard. It can accommodate 0.6/0.8mm diameter hard wires. Select the roller required with the chosen wire size marking facing outward. GROOVE “B” GROOVE “A” GROOVE “A” SIZE GROOVE “B” SIZE A-09583 Figure 3-16: Dual Groove Feed Roller Feed Roll Retaining Screw Art # A-10428 Figure 3-17: Changing the Feed Roll

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 Thumb Screw inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 10-20mm 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 com- ponentry and possibly an increased incidence of electrode wire Burnback into contact tip. Spool Hub Tension Thumb Screw Art # A-10429 Figure 3-18: Wire Reel Brake 3.19 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire A. Select MIG mode with the process selection control. (refer to Section 3.10.13 for further information) B. Connect the MIG polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufac- turer. 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. C. Fit the MIG gun to the power source. (Refer to section 3.11 Attaching the TWECO WeldSkill 220A MIG gun). D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire 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. E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.06) then connect the shielding gas hose from the rear of the power source to the regulator/flowmeter outlet. F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information. G. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources Wirespeed and Voltage controls. H. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to MIG GUN.

Secure the welding grade shielding gas cylinder in an upright position by chaining 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. Shielding Gas Hose Fitted with Quick Connect Positive Welding Terminal (+) MIG Polarity Lead Work Lead Negative Welding Terminal (-) Art # A-11244 MIG Gun 8 pin plug Figure 3-19: Setup for MIG Welding with Gas Shielded MIG Wire 3.20 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 3.10.13 for further information). B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufac- turer. 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. C. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire 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. D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

wire feed compartment to LOCAL to use the Power Sources Wirespeed and Voltage controls. F. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to MIG GUN. WARNING Before connecting the work clamp to the work make sure the Electricity Supply is switched off. 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. Work Lead Positive Welding Terminal (+) Negative Welding Terminal (-) MIG Polarity Lead Art # A-11245 MIG Gun 8 pin plug Figure 3-20: Setup for MIG Welding with Gasless MIG Wire

Select MIG mode with the Process Selection Control. For setup and operation of the spool gun, please refer to the spool gun operations manual. Switch the MIG GUN/SPOOL GUN 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. Connect gas supply fi tting and tighten with a wrench. 6. Align Control Plug to panel fi tting and tighten securely. ! WARNING Before connecting the work clamp to the work make sure the main power supply is switched off. Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping. Art # A-10363

terminal. Remove any packing material prior to use. Do not block the air vents at the front or rear of the Welding Power Source. Negative Welding Terminal (-) Work Lead Spool Gun Positive Welding Terminal (+) Shielding Gas Hose Fitted with Quick Connect MIG polarity lead Spool Gun Switch Remote Control Socket Art # A-10576 Figure 3-21: Setup for Spool Gun Welding with Gas Shielded MIG Wire 3.22 Setup For LIFT TIG (GTAW) Welding A. Select LIFT TIG mode with the process selection control (refer to Section 3.10.13 for further information). B. Connect the TIG Torch to the negative welding terminal (-). 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. C. Connect the work lead to the positive welding terminal (+). 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. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below. The TIG torch will require a trigger switch to operate in LIFT TIG Mode. NOTE A Thermal Arc 26V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a 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.

connect the shielding gas hose from the TIG torch to the regulator/flowmeter outlet. Note that the TIG torch shield- ing gas hose is connected directly to the regulator/flowmeter. The power source is not fitted with a shielding gas solenoid to control the gas flow in LIFT TIG mode therefore the TIG torch will require a gas valve. ! WARNING Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure the Electricity Supply is switched off. Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. CAUTION Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source. Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal. F. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage using a Foot Control. Positive Welding Terminal (+) Negative Welding Terminal (-) Work Lead TIG Torch TIG Remote Control Art # A-11246 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. Note: A Thermal Arc 26V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a 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. Figure 3-22: Setup for TIG Welding

A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufac- turer. 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. B. Connect the work lead to the negative welding terminal (-). 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. C. Select STICK mode with the process selection control (refer to Section 3.10.13 for further information). 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 the Welding Power Source. C. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage control using a Hand Pendant Control. Positive Welding Terminal (+) Negative Welding Terminal (-) Work Lead Electrode Holder Art # A-11247 Figure 3-23: Setup for Manual Arc Welding.

4.01 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this sec- tion GMAW and FCAW, with the intention of providing the very basic concepts in using the MIG mode of welding, where a MIG Gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture. GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO2 welding, Micro Wire Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable electrode and the work. Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mix- ture. The process is normally applied semi automatically; however 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 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 the flux within the tubular wire. Additional shielding may or may not be ob- tained from an externally supplied gas or gas mixture. The process is normally applied semi automatically; however the process may be applied automatically or by machine. It is commonly used to weld large diameter electrodes in the flat and horizontal position and small electrode diameters in all positions. The process is used to a lesser degree for welding stainless steel and for overlay work. Art # A-08992_AB Molten Slag Nozzle (Optional) FCAW Process Flux Cored Electrode Arc Shielding Gas (Optional) Slag Molten Metal Base Metal Solidified Weld Metal Figure 4-2 Position of MIG Gun The angle of MIG Gun to the weld has an effect on the width of the weld. Push Vertical Drag/Pull Art # A-07185_AB Figure 4-3 The MIG Gun should be held at an angle to the weld joint. (See Secondary Adjustment Variables below) Hold the MIG Gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment. CAUTION Do NOT pull the MIG Gun back when the arc is established. This will create excessive wire ex- tension (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 Direction of Travel 5° to 15° Longitudinal Angle 90° Transverse Angle Art # A-08993 Figure 4-4

Direction of Travel 5° to 15° Longitudinal Angle 30° to 60° Transverse Angle Art # A-08994 Figure 4-5 Vertical Fillet Welds Art # A-08995 30° to 60° Transverse Angle 30° to 60° Transverse Angle Direction of Travel 10° Longitudinal Angle 10° to 20° Longitudinal Angle Figure 4-6 Overhead Weld Art # A-08996 30° to 60° Transverse Angle Direction of Travel 5° to 15° Longitudinal Angle Figure 4-7 Distance from the MIG Gun Nozzle to the Work Piece The electrode wire stick out from the MIG Gun nozzle should be between 3/8" - 3/4" (10 - 20 mm). This dis- tance may vary depending on the type of joint that is being welded. Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run. MIG Welding (GMAW) Variables Most of the welding done by all processes is on carbon steel. The items below describe the welding variables in short-arc welding of .023 - 1/4" (0.6 mm - 6.4 mm) mild sheet or 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 thickness of the material, the welding position, the deposition rate and the mechanical proper- ties. These variables are: • Type of electrode wire • Size of electrode wire • Type of gas (not applicable for FCAW self shielding wires) • Gas flow rate (not applicable for FCAW self shielding wires) Primary Adjustable Variables These control the process after preselected variables have been found. They control the penetration, bead width, bead height, arc stability, deposition rate and weld soundness. They are: • Arc Voltage • Welding current (wire feed speed) • Travel speed 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. Sick-out (distance between the end of the con- tact tube (tip) and the end of the electrode wire). Maintain at about 3/8" (10 mm) stick-out 2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed decreases weld current. Art # A-08997_AD Gas Nozzle Electrode Wire Average Arc Length Electrode Stick-Out Tip to Work Distance Actual Stick-out Contact Tip (Tube) Figure 4-8 3. Nozzle Angle. This refers to the position of the 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 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)

handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel. Transverse and Longitudinal Nozzle Axes Art # A-08998_AB Longitudinal Angle Axis of Weld Transverse Angle Figure 4-9 Art # A-08999_AC Nozzle Angle, Right Handed Operator Direction of Gun Travel Leading or “Pushing” Angle (Forward Pointing) Trailing or “Pulling” Angle (Backward Pointing) 90° Figure 4-10 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. The easiest welding procedure for the beginner to experi- ment with MIG welding is the flat position. The equipment is capable of flat, vertical and overhead positions. For practicing MIG welding, secure some pieces of 1/16" or 3/16" (1.6 mm or 5.0 mm) mild steel plate 6" x 6" (150 mm x 150 mm). Use .035" (0.9 mm) flux cored gasless wire or a solid wire with shielding gas. Setting of the Power Source Power source setting requires some practice by the op- erator, 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 current is determined by the Wirespeed control, the current will increase with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the current level, 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, dif- ferent 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 electrode wire diameter and the dimensions of the work piece. If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The cor- rect setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound. Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information. Electrode Wire Size Selection The choice of Electrode wire size and shielding gas used depends on the following: • Thickness of the metal to be welded • Type of joint • Capacity of the wire feed unit and Power Source • The amount of penetration required • The deposition rate required • The bead profile desired • The position of welding • Cost of the wire

SELECT PROCESS STICK Set-Up Guide 1 Note: STICK set-up guide parameters may vary depending upon welding position, joint design. STICK ELECTRODE SELECTION ELECTRODE DIAMETER Amperage Display 60-85 70 90-125 100 125-170 150 Arc Force Knob - 50% - 50% - 50% Polarity Selection Amperage Display 55-90 75 90-135 115 135-180 160 Arc Force Knob - 50% - 50% - 50% Polarity Selection Amperage Display 65-100 85 95-150 125 145-220 175 Arc Force Knob - 50% - 50% - 50% Polarity Selection Amperage Display 55-100 80 95-140 120 140-195 165 Arc Force Knob - 50% - 50% - 50% Polarity Selection Amperage Display 85-120 100 130-170 150 185-200 200 Arc Force Knob - 50% - 50% - 50% Polarity Selection Amperage Display 40-70 60 75-110 90 110-150 130 Arc Force Knob - 50% - 50% - 50% Polarity Selection 2 2 2 2 2 2 3 3 3 3 3 3 DC Reverse Polarity (Positive) DC Reverse Polarity (Positive) DC Reverse Polarity (Positive) DC Reverse Polarity (Positive) DC Reverse Polarity (Positive) DC Reverse Polarity (Positive) E6011 E6013 E7018 E308L-16 E316L-16 E7014 E7024 b a 3/32" (2.4 mm) 1/8" (3.2 mm) 5/32" (4.0 mm) Range Optimum Range Optimum Range Optimum Note: LIFT TIG set-up guide parameters may vary depending upon welding position, joint design. MATERIAL SELECTION 1 LIFT TIG a SELECT PROCESS e TUNGSTEN DIAMETER c FILLER ROD (If Required) d SHIELD GAS AMPERAGE RANGE (MS) Min-115 (SS) Min-70 (MS) 115-170 (SS) 65-150 (MS) 160-200 (SS) 135-180 b Mild & Stainless Steel Argon Argon Argon Amperage Display Amperage Display Amperage Display 1/16" (1.6 mm) 3/32" (2.4 mm) 1/8" (3.2 mm) 1/8" (3.2 mm) 3/32" (2.4 mm) 1/16" (1.6 mm) LIFT TIG Set-Up Guide 2 2 2 Part Number Feed Roll Type W4014800 .023" / .035" (0.6 / 0.9 mm) V Groove (Hard) 7977036 .023" / .030" (0.6 / 0.8 mm) V Groove (Hard) 7977660 .035" / .045" (0.9 / 1.2 mm) V Groove (Hard) 7977731 .030" / .035" (0.8 / 0.9 mm) U Groove (Soft) 7977264 .040" / 3/64" (1.0 / 1.2 mm) U Groove (Soft) 7977732 .030" / .035" (0.8 / 0.9 mm) V Groove Knurled (Flux-Cored) 704277 .045" (1.2 mm) V Groove Knurled (Flux-Cored) This set-up information is intended to act as a guide only. Please refer to operating manual for further information. 831593_AA Drive Rolls a b c MATERIAL SELECTION SELECT PROCESS WELDING WIRE TYPE SHIELD GAS TO BE USED MATERIAL THICKNESS 22 ga. (0.8 mm) 18 ga. (1.2 mm) 16 ga. (1.6 mm) 1/8" (3.2 mm) 3/16" (4.7 mm) 1/4" (6.4 mm) MIG Set-Up Guide MIG 1 230VAC 24 ga. (0.6 mm) 22 ga. (0.8 mm) 18 ga. (1.2 mm) 16 ga. (1.6 mm) 1/8" (3.2 mm) 3/16" (4.7 mm) 1/4" (6.4 mm) 3/8" (9.5 mm) Wirespeed Display 142 174 219 268 - - Voltage Display 13.7 15 16 18 - - Inductance Display 10 10 8 10 - - ER70S-6 .030" (0.8 mm) Mild Steel 75% Ar, 25% CO2 139 152 168 220 274 326 484 600 13.5 14 15.2 16 19.5 22 23 25 10 8 8 8 8 6 6 4 Wirespeed Display 142 165 178 226 293 - Voltage Display 12.9 14 14.8 17.9 19 - Inductance Display 10 10 10 10 10 - ER70S-6 .035" (0.9 mm) Mild Steel 75% Ar, 25% CO2 - 139 165 178 226 281 326 432 - 13 14 14.8 17.9 20.4 21.2 23 - 10 10 10 10 8 8 8 Mild Steel Wirespeed Display 219 277 281 - - - Voltage Display 11.4 15.5 17 - - - Inductance Display 8 8 6 - - - ER70S-6 .023" (0.6 mm) 100% C02 - 249 278 290 500 600 - - - 13 16.4 17 23 25 - - - 10 8 8 6 2 - - Mild Steel Wirespeed Display 139 168 197 300 - - Voltage Display 12.9 15.5 17 19 - - Inductance Display 10 10 10 10 - - ER70S-6 .030" (0.8 mm) 100% C02 - 139 168 197 300 393 464 600 - 12.9 15.5 16.5 19 21.5 23 24 - 10 10 10 10 10 10 10 Mild Steel Wirespeed Display 123 152 174 226 - - Voltage Display 13 16.5 17.5 19 - - Inductance Display 8 10 10 10 - - ER70S-6 .035" (0.9 mm) 100% C02 - 123 152 174 213 278 290 - - 13 16.5 17.5 20.5 22.8 23.5 - - 8 10 10 8 8 6 - Mild Steel Wirespeed Display - 149 191 255 274 - Voltage Display - 13.5 15 17.5 19 - Inductance Display - 10 10 10 10 - E71T-11 .030" (0.8 mm) Self Shielding - - 149 191 255 274 300 400 - - 13.7 15.2 18 20 21.5 24 - - 10 10 10 10 10 10 Mild Steel Self Shielding Wirespeed Display - 113 139 200 255 300 Voltage Display - 13.2 13.5 15 16.8 18 Inductance Display - 8 10 10 10 10 E71T-11 .035" (0.9 mm) - - 113 139 200 255 300 377 - - 13.2 13.5 15 16.8 18 18 - - 8 10 10 10 10 10 Tri-Mix 90% He, 7.5% Ar, 2.5% CO2 Stainless Steel Wirespeed Display 101 162 181 - - - Voltage Display 10 17 17.6 - - - Inductance Display 10 6 6 - - - ER308L / ER316L .030" (0.8 mm) - 101 162 181 281 300 390 432 - 10 17 17.5 19.8 21.6 22.6 25 - 10 6 6 6 2 2 2 Stainless Steel Wirespeed Display - 149 174 - - - Voltage Display - 16.2 18 - - - Inductance Display - 2 2 - - - ER308L / ER316L .035" (0.9 mm) - - 149 175 220 300 316 348 - - 16 18 21 21.5 23 24 - - 2 2 2 2 2 2 Wirespeed Display - 322 345 400 - - Voltage Display - 13.7 15.4 16.5 - - Inductance Display - 2 2 2 - - ER4043 .035" (0.9 mm) 100% Argon Aluminum Use Spool Gun - - 322 345 400 554 600 - - - 13.7 15.4 16.5 17.6 19 - - - 2 2 2 2 2 - Wirespeed Display - 203 255 297 - - Voltage Display - 13.2 13.9 15.8 - - Inductance Display - 2 2 2 - ER4043 3/64" (1.2 mm) 100% Argon Aluminum Use Spool Gun - - 204 255 297 316 339 352 - - 13.2 13.9 15.8 17.1 18.5 20 - - 2 2 2 2 2 2 Mild Steel Self Shielding Wirespeed Display - - - - - - Voltage Display - - - - - - Inductance Display - - - - - - - - - 107 129 108 200 242 - - - 13.2 14.5 17 19 20 - - - 10 10 10 10 10 E71T-11 .045" (1.2 mm) d Note: MIG set-up guide parameters are given as a reference. Optimal settings may vary depending upon welding position, joint design, and wire/gas compositions. Wirespeed Display 194 255 287 400 - - Voltage Display 13.8 15 16.7 19 - - Inductance Display 10 8 6 10 - - ER70S-6 .023" (0.6 mm) 75% Ar, 25% CO2 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 2 3 4 - 194 255 287 457 522 600 - - 13.8 15 16.7 19.8 21.5 23 - - 10 8 6 6 6 4 - Mild Steel Tri-Mix 90% He, 7.5% Ar, 2.5% CO2 115 VAC / 30A Electrical Outlet* 115 VAC / 20A Electrical Outlet 115 VAC / 15A Electrical Outlet *Refer to operating manual Item Part Number Torch Parts Description 1 1210-1112 Nozzle, 1/2" (12.7 mm) 2 1110-1100 Contact Tip, .023" (0.6 mm) 1110-1101 Contact Tip, .030" (0.8 mm) 1110-1102 Contact Tip, .035" (0.9 mm) 1110-1103 Contact Tip, .040" (1.0 mm) 1110-1104 Contact Tip, .045" (1.2 mm) 1110-1213 Contact Tip, 3/64" AL (1.2 mm) Item Part Number Torch Parts Description 3 1510-1101 Gas Difuser 1420-1103 Liner, .023" (0.6 mm) Hard Wire 1420-1113 Liner, .030"-.035" (0.8 mm-0.9 mm) Hard Wire 1420-1123 Liner, .040”-.045" (1.0 mm-1.2 mm) Hard Wire 1420-1003 Liner, .030"-3/64" (0.8 mm-1.2 mm) AL Wire 1023-1257 Tweco WeldSkill 220A MIG Gun, 12 ft, .030"-.035” Wire Setup 1 2 3 Tweco® MIG Gun Consumables (MS=Mild Steel SS= Stainless Steel) MIG LIFT TIG STICK 4T 2T WIRESPEED DOWNSLOPE (S) ARC FORCE (%) E D 2 4 6 8 POWER FAULT A 0 1 2 4 7 9 3 6 8 V 0 1 2 4 7 9 1 3 6 Set Wirespeed (MIG) Set Amperage (LIFT TIG) Set Amperage (STICK) Set Voltage (MIG) Set Down Slope (LIFT TIG) Set Arc Force Control (STICK) Set Inductance Set Polarity (Refer to Operating Manual for further information. Note: If in doubt consult the electrode data sheet or your nearest accredited Thermal Arc Distributor.) DC Reverse Polarity (Positive) DC Straight Polarity (Negative) MIG STICK TIG Easy Steps For Welding E 2 + - + - + - + - MIG M 1 Select Process: MIG, LIFT TIG or STICK 3 4 - abricator I Art # A-11299 Table 4-1

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. Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points. FAULT/CONDITION CAUSE 1 Shielding gas cylinder contents and flow meter. Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to 31.75 CFH. 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 connec- tion and in the gas hose to the Power Source. 4 Internal gas hose in the Power Source. Ensure the hose from the solenoid valve to the MIG Gun adapter has not fractured and that it is connected to the MIG Gun adapter. 5 Welding in a windy environment. Shield the weld area from the wind or increase the gas flow. 6 Welding dirty, oily, painted, oxidized or greasy plate. Clean contaminates off the work piece. 7 Distance between the MIG Gun nozzle and the work piece. Keep the distance between the MIG Gun nozzle and the work piece to a minimum. 8 Maintain the MIG Gun in good working order. A Ensure that the gas holes are not blocked and gas is exiting out of the MIG Gun nozzle. B Do NOT restrict gas flow by allowing spatter to build up inside the MIG Gun nozzle. C Check that the MIG Gun O-rings are not damaged. Table 4-2: Solving Problems beyond the Welding Terminals - Porosity

! WARNING Disengage the feed roll when testing for gas flow by ear. Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the cabinet slipped. Wire spool brake is too tight. 2 Wire spool unwound and tangled. Wire spool brake is too loose. 3 Worn or incorrect feed roller size A Use a feed roller matched to the size you are welding. B Replace feed roller if worn. 4 Wire rubbed against the misaligned guides and reduced wire feed ability. Misalignment of inlet/outlet guides 5 Liner blocked with swarf A Increased amounts of swarf are produced by the wire passing through the feed roller when excessive pres- sure is applied to the pressure roller adjuster. B Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size. C Swarf is fed into the conduit liner where it accumu- lates thus reducing wire feed ability. 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 heated. A contact tip designed for soft wires should be used. 7 Poor work lead contact to work piece If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc. 8 Bent liner This will cause friction between the wire and the liner thus reducing wire feed ability Table 4-3: Wire Feeding Problems

FAULT CAUSE REMEDY 1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed. B Incorrect MIG Gun angle B Adjust angle. C Excessive heat input C Increase the MIG Gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed. 2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed speed and increasing voltage. B Joint preparation too nar- row or gap too tight B Increase joint angle or gap. C Shielding gas incorrect C Change to a gas which gives higher penetration. 3 Lack of fusion Voltage too low Increase voltage. 4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control. B Voltage too low B Increase the voltage or decrease wirespeed. 5 Irregular weld shape A Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high. A Adjust voltage and current by adjusting the voltage control and the wirespeed control. B Wire is wandering. B Replace contact tip. C Incorrect shielding gas C Check shielding gas. D Insufficient or excessive heat input D Adjust the wirespeed control or the voltage control. 6 Weld cracking A Weld beads too small A Decrease travel speed 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 con- nection. A Check all welding cable connections. B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited Thermal Arc Service Provider test then replace the faulty component. 8 Arc does not have a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG Gun has been connected to the wrong voltage polarity on the front panel. Connect the MIG Polarity Cable to the positive (+) welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

setup chart param- eters Contact tip has arc marks in the bore causing exces- sive drag on the wire. Replace the contact tip with only a Genuine Tweco contact tip. Table 4-4: MIG (GMAW /FCAW) Welding Problems 4.03 STICK (SMAW) Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes. For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitable electrode for a given application. Storage of Electrodes Always store electrodes in a dry place and in their original containers. Electrode Polarity Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Thermal Arc Distributor. 4.04 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 weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result. Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace. Hydrogen controlled Electrodes must be used for this application. B. Austenitic 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 welding by quenching after each weld or skip welding to distribute the heat. C. Cast Iron Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts 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 is the high rate of heat conductivity of copper, making preheating of heavy sections necessary to give proper fusion of weld and base metal.

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Natu- rally enough, different types of electrodes would be used for different metals as described in the preceding section. Welding Position The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numer- ous 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 Art # A-07689 Figure 4-13: Horizontal Position, Butt Weld Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position Art A-07691 Figure 4-15: Vertical Position, Butt Weld 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

repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints. In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-19. Gap varies from 1/16” (1.6mm) 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 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-10672 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 commence is to run beads on a piece of scrap plate. Use mild steel plate about 1/4" (6.4 mm) thick and a 1/8" (3.2 mm) electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position. Make sure that the work clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax and you will find that the job becomes much easier. You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting alight to your clothes. 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. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you are risking an electric shock. Striking the Arc Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it. This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck. As soon as the arc is established, maintain a 1/16" -1/8" (1.6 mm - 3.2 mm) gap between the burning electrode 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-10673 20° 1/16” (1.6 mm) Figure 4-20: Striking an Arc Arc Length The securing of an 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 comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick twist back over the weld to detach it. Contact or "touch-weld" electrodes such as E7014 do not stick in this way, and make welding much easier. Rate of Travel After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced. If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large. Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1/16" - 3/32" (1.6 mm - 2.4 mm) gap between them and tack weld at both ends. This is to prevent contraction stresses from the cool- ing weld metal pulling the plates out of alignment. Plates thicker than 1/4" (6.4 mm) should have their mating edges beveled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 1/8" (3.2 mm) E7014 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.

rate of travel along the joint sufficient to produce a well-formed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld. Art # A-07697_AB Tack Weld 20°-30° Electrode Tack Weld Figure 4-21: Butt Weld Art # A-07698 Figure 4-22: Weld Build up Sequence Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean the weld with a wire brush. It is important to do this to prevent slag being 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 suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld. B. Fillet Welds These are welds of approximately triangular cross- section made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 4-14. A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 1/8" (3.2 mm) E7014 electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet. Strike the arc and immediately bring the electrode to a position perpen- dicular to the line of the fillet and about 45º from the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-23. Do not attempt to build up much larger than 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. Multi- runs can be made as shown in Figure 4-24. Weaving in HV fillet welds is undesirable. Art # A-07699_AB 45° from vertical 60° - 70° from line of weld Figure 4-23: Electrode Position for HV Fillet Weld Art # A-07700_AB 1 2 3 4 5 6 Figure 4-24: Multi-runs in HV Fillet Weld

1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 1/8" (3.2 mm) E7014 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet. The electrode needs to 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, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 4-26 illustrates multi-run technique and Figure 4-27 shows the effects of pausing at the edge of weave and of weaving too rapidly. Art # A-07701 Figure 4-25: Single Run Vertical Fillet Weld Art # A-07702 Figure 4-26: Multi Run Vertical Fillet Weld Art # A-07703 Figure 4-27: Examples of Vertical Fillet Welds 2. Vertical Down The E7014 electrode makes welding in this position particularly easy. Use a 1/8" (3.2 mm) electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45º. 3. Overhead Welds Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for over- head 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 4-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique is not advisable for overhead fillet welds. Use a 1/8" (3.2 mm) E6013 electrode at 100 amps, and 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 Figure 4-28: Overhead Fillet Weld

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. The study of distortion is so complex that only a brief outline can be attempted hear. The Cause of Distortion Distortion is caused by: A. Contraction of Weld Metal: Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means that a cube of molten metal would contract approxi- mately 2.2 per cent in each of its three dimensions. In a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore, cooling causes the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great, as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is relatively weak, for example, a butt joint in 5/64" (2.0 mm) sheet, the contracting weld metal 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 "across the weld" or "along the weld", it meets considerable resistance, and to fulfill the desire for continued expansion, it has to deform plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a strong pull on adjacent metal. Several things can then happen. The metal in the weld area is stretched (plastic defor- mation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "locked-up" stresses in the job. Figures 4-29 and 4- 30 illustrate how distortion is created. Art # A-07705_AB Hot Hot Weld Upsetting Expansion with compression Cool Figure 4-29: Parent Metal Expansion Art # A-07706_AB Weld Permanent Upset Contraction with tension Figure 4-30: Parent Metal Contraction Overcoming Distortion Effects There are several methods of minimizing distortion ef- fects. 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 relatively shallow, and is not advisable on the last layer. B. Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out. See Fig- ures 4-30 through 4-33 for various weld sequences. Choice of a suitable weld sequence is probably the most effective method of overcoming distortion, although an unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is often successful in eliminating 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.

ence or to find by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded, constructional stresses can be made to pull the parts into correct alignment. A simple example is shown in Figure 4-31. E. Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion. Figure 4-32 shows a simple applica- tion. By removing the heating source from b and c as soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion. Art # A-07707 Figure 4-31: Principle of Presetting Art # A-07708 B Preheat Preheat Dotted lines show effect if no preheat is used Weld C Figure 4-32: Reduction of Distortion by Preheating Art # A-07709 Figure 4-33: Examples of Distortion 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

FAULT CAUSE REMEDY 1 Welding current varying ARC FORCE is set at a val- ue that causes the welding current to vary excessively with the arc length. Reduce the ARC FORCE until welding current is reasonably constant while prohibiting the elec- trode from sticking to the work piece when you “dig” the electrode into the workpiece. 2 A gap is left by failure of the weld metal to fill the root of the weld. A Welding current too low A Increase welding current. B Electrode too large for joint. B Use smaller diameter electrode. C Insufficient gap. C Allow wider gap. 3 Non-metallic par- ticles are trapped in the weld metal. A 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 restricted. B Allow for adequate penetration and room for cleaning out the slag. C Irregular deposits allow slag to be trapped. C If very bad, chip or grind out 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 pre- venting full fusion. E Clean joint before welding. F Wrong electrode for posi- tion in which welding is done. F Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult. Art # A-04273 Incorrect sequence Insufficient gap Figure 4-38: Example of insufficient gap or incorrect sequence Table 4-5a:

formed in the base metal adjacent to the toe of a weld and has not been filled by the weld metal (undercut). A Welding current is too high. A Reduce welding current. B Welding arc is too long. B Reduce the length of the welding arc. C Angle of the electrode is incorrect. C Electrode should not be inclined less than 45° to the vertical face. D Joint preparation does not allow correct electrode angle. D Allow more room in joint for manipulation of the electrode. E Electrode too large for joint. E Use smaller gauge electrode. F Insufficient deposit time at edge of weave. F Pause for a moment at 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 the joint. A Small electrodes used on heavy cold plate. A Use larger electrodes and preheat the plate. B Welding current is too low. B Increase welding current. C Wrong electrode angle. C Adjust angle so the welding arc is directed more into the base metal. D Travel speed of electrode is too high. D Reduce travel speed of electrode. E Scale or dirt on joint surface. E Clean surface before welding. Art # A-04274_AB Lack of fusion caused by dirt, electrode angle incorrect, rate of travel too high Lack of side fusion, scale dirt, small electrode, amperage too low Lack of inter-run fusion Lack of Root Fusion Figure 4-39: Example of Lack of Fusion Table 4-5b: STICK (SMAW) metal welding trouble shooting

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. Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based. A filler metal may also be added manually in some circumstances depending 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 Electrode and Weld Puddle Tungsten Electrode Non-Consumable A-09658_AB Figure 4-40: TIG (GTAW) Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current (Amps) 0.040” (1.0mm) 30-60 1/16” (1.6mm) 60-115 3/32” (2.4mm) 100-165 1/8” (3.2mm) 135-200 5/32” (4.0mm) 190-280 3/16” (5mm) 250-340 Table 4-6: Current Ranges for Various Tungsten Electrode Sizes Guide for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range (Amps) 1/16” (1.6mm) 20-90 3/32” (2.4mm) 65-115 1/8” (3.2mm) 100-165 3/16” (5mm) 200-350 Table 4-7: Filler Wire Selection Guide

Electrode Type (Ground Finish) Welding Application Features Color Code Thoriated 2% DC welding of mild steel, stainless steel and copper Excellent arc starting, Long life, High current carrying capacity Red Zirconated 1% High quality AC weld- ing of aluminum, magnesium and their alloys. Self cleaning, Long life, Maintains balled end, High current car- rying capacity. White Ceriated 2% AC & DC welding of mild steel, stainless steel, copper, alumi- num, magnesium and their alloys Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc. Grey Table 4-8 NOTE The Fabricator 211i Inverter is not suited for AC TIG welding. TIG Welding Filler Rods Base Metal Thickness 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” 1.0mm 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 3/32” 2.4mm 15 Butt/Corner Lap/Fillet 3/16” 4.8mm 115-135 140-165 100-125 125-150 3/32” 2.4mm 1/8” 3.2mm 20 Butt/Corner Lap/Fillet 1/4” 6.4mm 160-175 170-200 135-160 160-180 1/8” 3.2mm 5/32” 4.0mm 20 Butt/Corner Lap/Fillet Table 4-9 TIG Welding is generally regarded as a specialized process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual.

FAULT CAUSE REMEDY 1 Excessive bead build up or poor penetration or poor fusion at edges of weld. Welding current is too low Increase weld current and/or faulty joint preparation. 2 Weld bead too wide and flat or undercut at edges of weld or excessive burn through. Welding current is too high Decrease weld current. 3 Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart. Travel speed too fast Reduce travel speed. 4 Weld bead too wide or excessive bead build up or excessive penetration in butt joint. Travel speed too slow Increase travel 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 terminal. A Connect TIG Torch lead to negative weld- ing terminal. B No gas flowing to weld- ing region. B Check the gas lines for kinks or breaks and gas cylinder contents. C TIG Torch is clogged with dust or dirt. C Clean TIG Torch. D Gas hose is cut. D Replace gas hose. E Gas passage contains impurities. E Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities. F Gas regulator turned OFF. F Turn on. G TIG Torch valve is turned OFF. G Turn on. H The electrode is too small for the welding current. H Increase electrode diameter or reduce the welding current. I Power source is set for MIG welding. I Set Power Source to LIFT TIG mode.

A Electrode contaminated by contact with work piece or filler rod mate- rial. A Clean the electrode by grinding off the contaminates. B Work piece surface has foreign material on it. B Clean surface. C Gas contaminated with air. C Check gas lines for cuts and loose fitting or change gas cylinder. 8 Poor weld finish Inadequate shielding gas. Increase gas flow or check gas line for gas flow problems. 9 Arc start is not smooth. A Tungsten electrode is too large for the weld- ing current. A Select the right size electrode. Refer to Thermal Arc Electrode Selection Chart. B The wrong electrode is being used for the welding job. B Select the right electrode type. Refer to Thermal Arc Electrode Selection Chart. C Gas flow rate is too high. C Select the right rate for the welding job. Refer to Table 4-9. 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. Tungsten electrode is too large for the weld- ing current. Select the right size electrode. Refer to Thermal Arc Electrode Selection Chart. 11 Tungsten blackens due to lack of shielding gas A Gas valve on the TIG Torch has not be turned on. A Turn on TIG Torch gas valve before you commence welding. B Gas cylinder valve off or TIG Torch hose not connected to regulator B Turn on gas cylinder valve or connect TIG Torch hose to regulator. Table 4-10: TIG (GTAW) Welding Problems

FABRICATOR 211i BASIC WELDING BASIC WELDING 4-22 Manual 0-5157

SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY 1 Electricity Supply is ON, power indicator is illumi- nated however unit will not commence welding when the torch trigger switch is depressed. A Power source is not in the correct mode of operation. A Set the power source to the cor- rect mode of operation with the process selection switch. B Faulty torch trigger. B Repair or replace torch trigger switch/lead. 2 Fault Indicator is illumi- nated and unit will not commence welding when the torch trigger switch is depressed. Duty cycle of power source has been exceeded. Leave the power source switched ON and allow it to cool. Note that fault indicator must be extinguished prior to com- mencement of welding. 3 Unit will not feed wire in MIG mode. A Electrode wire stuck in conduit liner or contact tip (burn-back jam). A Check for clogged / kinked MIG gun conduit liner or worn con- tact tip. Replace faulty compo- nents. B Internal fault in power source B Have an Accredited Thermal Arc Service Provider investigate the fault. 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 selec- tion 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 cannot be established in MIG mode. A MIG gun polarity lead is not connected into a welding output terminal. A Connect the MIG gun polar- ity lead to either the positive welding output terminal or the negative welding output terminal as required. B Poor or no work lead contact. B Clean work clamp area and en- sure good electrical contact. 6 Inconsistent wire feed. A Worn or dirty contact tip. A Replace if necessary. B Worn feed roll. B Replace. C Excessive brake tension on wire reel hub. C Reduce brake tension on spool hub D Worn, kinked or dirty con- duit liner D Clean or replace conduit liner

5-2 Manual 0-5157 7 No gas flow in MIG mode. A Gas hose is damaged. A Replace or repair. B Gas passage contains impurities. B Disconnect gas hose from the rear of power source and blow out impurities. C Gas regulator turned off. C Turn on regulator. D Empty gas cylinder. D Replace gas cylinder. 8 Gas flow continues after the trigger switch has been released (MIG mode). Gas valve has jammed open due to impurities in the gas or the gas line. Have an accredited Thermal Arc service provider repair or replace gas valve. 9 Power indicator will not illuminate and welding arc cannot be established. The Electricity Supply has exceeded voltage limits of the power source. Ensure that the Electricity Sup- ply is within 115V ± 10% or 208/230VAC ± 10%. 10 TIG electrode melts when arc is struck. TIG torch is connected to the (+) VE terminal. Connect the TIG torch to the (-) VE terminal. 11 Arc flutters during TIG welding. Tungsten electrode is too large for the welding cur- rent. Select the correct size of tung- sten electrode. Refer to Table 4-7. Table 5-1: Power Source Problems 5.02 Routine Service and Calibration Requirements ! WARNING 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 Thermal Arc Service Provider. Disconnect the Welding Power Source from the Electricity Supply before disassembling. Routine Inspection, Testing & Maintenance The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc's original specifications. A. Testing Schedule 1. For transportable equipment, at least once every 3 months; and 2. For fixed equipment, at least once every 12 months. The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, includ- ing the date of the most recent inspection. A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated. B. Insulation Resistance Minimum insulation resistance for in-service Thermal Arc Inverter Power Sources shall be measured at a volt- age of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.

Components to be Tested Minimum Insulation Resistance (MΩ) Input circuit (including any connected control circuits) to welding circuit (including any connected control circuits) 5 All circuits to exposed conductive parts 2.5 Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage exceeding extra low voltage 10 Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage not exceeding extra low voltage 1 Separate welding circuit to separate welding circuit 1 Table 5-2: Minimum Insulation Resistance Requirements: Thermal Arc Inverter Power Sources C. Earthing The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and - 1. The earth terminal of a fixed power source; or 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 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 equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure 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 shrouded to prevent inadvertent contact or short circuit. 3. The Welding System is clean internally, especially from metal filing, slag, and loose material. E. Accessories Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used. F. Repairs If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited Thermal Arc Service Provider.

5-4 Manual 0-5157 Power Source Calibration A. Schedule Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below - 1. For transportable equipment, at least once every 3 months; and 2. For fixed equipment, at least once every 12 months. B. Calibration Requirements Where applicable, the tests outlined in Table 5-3 below shall be conducted by an accredited Thermal 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 Accuracy of digital meters to be checked to ensure it falls within applicable Thermal Arc power source specifications Table 5-3: Calibration Parameters Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified. C. Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certi- fied laboratories) shall be utilized.

5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Electricity Supply before disassembling. To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated dirt, 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. Warning! Disconnect input power before maintaining. Each Use Visual check of regulator and pressure Visual check of torch Consumable parts Weekly 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 authorized Thermal Arc Service Provider to remove any accumulated dirt and dust from the interior. This may need to be done more frequently under exceptionally dirty conditions. Maintain more often if used under severe conditions Art # A-10502

5-6 Manual 0-5157 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. CAUTION Do NOT use compressed air to clean the Welding Power Source. Compressed air can force metal par- ticles to lodge between live electrical parts and earthed metal parts within the Welding Power Source. This may result in arcing between these parts and their eventual failure.

6.01 Tweco WeldSkill 220A MIG Gun MIG Gun Part No: WS220TA-15-3035 Art # A-11248 Figure 6-1: Tweco WeldSkill 220 MIG Gun TWECO WELDSKILL 220A MIG GUN PARTS ITEM PART NO. DESCRIPTION 1 1210-1112 Nozzle 1/2" - 12.7 mm Flush 2 1110-1102 Contact Tip .035" - 0.9mm 3 1510-1140 Gas Diffuser 4 2042-2053 Microswitch 5 2042-2054 Trigger Lever 6 2042-2055 Trigger Lever Spring 7 2035-12110 Tweco Rear Connector Plug 8 1420-1140 Conduit Assembly .030" to .035" - 0.8mm to 0.9mm Table 6-1: Tweco WeldSkill 220 MIG Gun Parts

Art # A-11250 1 2 3 6 7 9 8 10 11 12 14 13 15 16 18 19 4 5 20 22 23 24 25 26 17 30 31 29 32 33 34 36 35 Figure 6-2

2 W7005601 PCB Control, Fab 211i 3 W7005602 PCB Display, Fab 211i 4 W7005607 PCB Spool Gun, Fab 211i 5 W7005603 Wiredrive Assembly, Fab 211i 6 W7004906 Thumbscrew,Feedroll Positioner 7 W4014800 DRIVE RL2 Roll, .023/.035 “V” 8 W7005622 Fan Assembly, Fab 211i UL/CSA 9 W7003010 Rectifier Bridge,1000V,50A 10 W7003033 Gas Solenoid Valve Assy 11 W7003215 Gas Inlet Fitting 12 W7004909 Connector Socket,50 Dinse 13 W7004955 Connector Plug,50 Dinse 14 W7004942 Socket,8 Pin,w/ Harness 15 W7005623 Switch CB,Main On-Off 16 W7004911 CT, Output 17 W7005617 Spool Hub Assembly 18 W7005608 Washer,Friction,Spool Hub 19 W7005609 Spool Hub 20 W7004966 Adapter,Tweco 4,141i-211i 21 W7005619 Guide,Inlet,.023-.045 (not shown) 22 W7004967 Guide,Outlet,.023-.045 23 W7005624 Front, Panel, Fab 211i UL/CSA 24 W7005610 Panel, Base, Fab 211i 25 W7005625 Center Panel, Fab 211i 26 W7005626 Rear, Panel, Fab 211i UL/CSA 27 W7005631 Panel, Cover, Fab 211i (not shown) 28 W7005627 Panel, Door, Fab 211i (not shown) 29 W7005628 Panel,Control,Fab 211i 30 W7004972 Knob,1/4” IDx1” ODx0.9” H 31 W7005630 Knob,1/4” IDx1.25” ODx.9” H 32 W7005629 Circuit Breaker,4A 33 W7004943 Switch,250V/2A 34 870734 Knob,1/4” IDx.72” ODx.9” H 35 W7004940 PCB, Burnback Potentiometer 36 W7005632 Shroud, WF Motor, 211i Table 6-2: Fabricator 211i Parts

Art # A-11249 ACOUT DC - DC + RED BLACK +15V 1 IGBT Driver A 2 IGBT Driver B 3 GND 7 Over Current Signal 6 OT2 Funs RED Main Power PCB1 Control PCB2 4 GND 1 +15V 2 -15V 3 Current Feedback Current Sensor CONNECTOR LAYOUT DIAGRAM M W P B F I Funs DRIVE ON 1 FAN PFC CIRCUIT GUN MB BLACK POS NEG + - BLACK WVIN OT1 DRIVE IFB RED YELLOW GRAY WHITE J5 IN 1 IGBT Driver B 4 IGBT Driver A 5 1 +15V 2 IGBT Driver A 3 IGBT Driver B 7 GND 6 Over Current Signal 4 IGBT Driver B 5 IGBT Driver A 1 1 1 +24VDC 1 -24VDC 3 GND 2 1 +24VDC 2 GND 3 -24VDC DY2 SOURCE 1 + 1 1 MOTOR PWM CONTROL CIRCUIT PWM PWM 1 PWM RETURN 2 PWM (MOTOR DRIVER 5VDC PEAK) 1 1 1 1 1 ACOUT SHEETMETAL COVER 60W3Ω RX VR BR1 BR2 + + + + + + 1 1 1 GAS SOLENOID 1 1 1 1 1 Wirefeeder Power Fault MIG LIFT TIG STICK 2T Normal 4T Latch Process Trigger Wirefeed / Amps Volts Down Slope / Arc Force(%) Arc Control Amps / Wirefeed Display Volts Display 1 2 3 4 5 6 7 8 Front View 8A/250V Fuse MIG GUN SPOOL GUN 1 1 K1 L1 L2 GND OT1 OT2 CR SOURCE QF / DY WVIN PFC 2 MB 1 POT1 1 CR JC QF / DY GND +24VDC 3 POT MAX (+5VDC) 2 WIPER 1 POT MIN RED BLK YEL 1 +24VDC 1 1 - OUTPUT 3 + OUTPUT 8 Pin Remote Control Spool Gun 1 SPOOL GUN (0V) 1 TORCH SWITCH (+24V) 2 TORCH SWITCH RIN (0VDC) 3 SPOOL GUN (+2VDC) 4 TORCH SWITCH RIN (0VDC) 5 TORCH SWITCH RIN (0VDC) 6 (REMOVE VOLTAGE) POT WIPER 7 (REMOVE AMPS/WIRESPEED) POT WIPER 8 1 LOCAL REMOTE 3 -15VDC 1 1 GUN +24VDC 1 GND 1 1 +15VDC 1 +15VDC GND DISPLAY DATA &EPROM (D-IN) 1 SEIAL DISPLAY DATA (LOAD) 2 SEIAL DISPLAY DATA (CLK) 3 2T/4T PUSHBUTTON 4 SERIAL DISPLAY DATA (EPROM) 5 STICK 6 +15VDC 9 PROCESS PUSHBUTTON 8 POT3 B 11 POT2 WIPER 12 POT3 A (PANEL DEMAND) 13 POT1 WIPER 14 +15VDC 15 GND J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 1 1 RED WHITE YELLOW RED BLACK 1 +24CDC GND +24CDC 1 N/A 2 WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE WHITE RED JC 1 +5VDC 2 TO U15 PIN6 INPUT 230V/115V OUTPUT CONTROL SIGNAL 1 SPOOL GUN PCB3 W7005607 PP 15V FUSE SGM W7005600 W7005601 W7005602 Display PCB4 1 J14 DY1 QF/FJ J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26 9 2 J 8 2 J 7 2 J J30 MT J31 J32 J33 J34 J35 75ć 75ć RED RED BLACK BLACK RED BLACK CON3 FJ BURN BACK PCB 5 W7004940 RED YELLOW RED BLACK INPUT 115/208/230VAC 50/60Hz 50/60Hz 50/60Hz --

Effective 08/01/2011 This warranty supersedes all previous THERMADYNE® warranties. LIMITED WARRANTY: THERMADYNE® warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE® products as stated below, THERMADYNE® shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE®’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at THERMADYNE®’s sole option, of any components or parts of the product determined by THERMADYNE® to be defective. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LIMITATION OF LIABILITY: THERMADYNE® shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE® 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 THERMADYNE® whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMADYNE® PRODUCT. THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus 1 year from the date THERMADYNE® delivered the product to the authorized distributor.

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) 1 Years Parts and Labor Unless specified 95S, Water recirculators All Plasma Welding consols (i.e WC-1 Controller, WT Timer, WF-100 Capstain Feeder, etc) 180 days parts and Labor Unless specified Plasma Welding Torch and leads packages Gas Regulators "Supplied with power sources" (No Labor) 90 days parts / No Labor Remote Controls MIG and TIG Torches (Supplied with power sources) Replacement repair parts 30 days parts / No Labor MIG Torch for Fabricator 181i 5-2-1 years Parts / No Labor 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) days of the repair. * No employee, agent, or representative of THERMADYNE® is authorized to change this warranty in any way or grant any other warranty, and THERMADYNE® shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of THERMADYNE®’s obligations to purchaser with respect to the product. * This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in THERMADYNE®'s sole judgment, impaired the safety or performance of any THERMADYNE® product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

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