ESAB FUSION™ Air-Cooled Mig Gun 140 AMP, 180 AMP, 220 AMP Manuel utilisateur

TWECO

®

FUSION

™

Safety and

Operating

Instructions

AIR-COOLED MIG GUN 140 AMP, 180 AMP, 220 AMP

Tweco.com

English

Canadien Français

Americas Español

Revision: C Issue Date: June 12, 2013 Manual No.: 89200014

IMPORTANT: Included inside - special

instructions for liner replacement.

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to

have you as our customer and will strive to provide you with the best

service and support in the industry. This product is backed by our extensive

warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you

with this high performance product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust,

when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies

Inc. We distinguish ourselves from our competition through market-

leading innovation and truly dependable products that will stand the test of

time.

We strive to enhance your productivity, efﬁciency and welding performance

enabling you to excel in your craft. We design products with the welder in

mind delivering- advanced features, durability, ease of use and ergonomic

comfort.

Above all, we are committed to a safer working environment within the

welding industry. Your satisfaction with this product and its safe operation

is our ultimate concern. Please take the time to read the entire manual,

especially the Safety Precautions.

If you have any questions or concerns regarding your new Tweco product,

please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada),

or visit us on the web at www.Tweco.com

i

!

WARNINGS

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s

judgment, the Manufacturer assumes no liability for its use.

FUSION MIG Gun

Safety and Operating Instructions

Instruction Guide Number: 89200014

Published by:

Victor Technologies International, Inc.

2800 Airport Rd.

Denton, TX. 76207

(940) 566-2000

www.tweco.com

U.S. Customer Care: (800) 426-1888

Canada Customer Care: 905-827-4515

International Customer Care: (940) 381-1212

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: December 3, 2012

Revision Date: June 12, 2013

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

ii

Table of Contents

SECTION 1: SAFETY PRECAUTIONS .........................................................................1

1.01 Safety Precautions ........................................................................... 1

SECTION 2: INTRODUCTION ......................................................................................4

2.01 How to Use this Manual ................................................................... 4

2.02 Receipt of Equipment ....................................................................... 4

SECTION 3: TWECO

®

FUSION MIG GUN INSTALLATION ............................................5

3.01 Direct Plug MIG Gun Installation ...................................................... 5

3.02 Compatible Welding Machines .........................................................6

3.03 Duty Cycle ........................................................................................ 6

3.04 Tweco

®

Fusion MIG Gun Selection Guide ......................................... 7

3.05 Tweco

®

Fusion MIG Gun Part Number Identiﬁcation ........................ 7

3.06 Tweco

®

MIG-Kwik Connection and Adapter Kit Installation .............. 8

SECTION 4: WIRE CONDUIT, TIP, NOZZLE REPLACEMENT.........................................9

4.01 Conduit Identiﬁcation Tweco

®

Style ................................................. 9

4.02 Conduit Removal .............................................................................. 9

4.03 Conduit Installation - Velocity Contact Tip Style ............................... 9

4.04 Replacing Velocity Contact Tip ...................................................... 10

4.05 Velocity Contact Tip Identiﬁcation .................................................. 11

4.06 Velocity Nozzle Identiﬁcation..........................................................11

4.07 Conductor Tube Identiﬁcation ........................................................12

4.08 Replace Conductor Tube ................................................................ 12

SECTION 5: MAINTENANCE AND TROUBLESHOOTING............................................13

SECTION 6: REPLACEMENT PARTS .........................................................................14

6.01 Tweco

®

Fusion MIG Gun Parts ...................................................... 14

6.02 Tweco

®

Fusion MIG Gun Consumables .......................................... 16

SECTION 7: STATEMENT OF WARRANTY ................................................................18

7.01 Warranty Schedule .........................................................................18

GLOBAL CONTACT INFORMATION....................................Rear Cover

SAFETY AND OPERATING INSTRUCTIONS

189200014

SECTION 1:

SAFETY PRECAUTIONS

1.01 SAFETY PRECAUTIONS

!

WARNING

SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not

properly installed, used, and maintained. Misuse of this equipment and other

unsafe practices can be hazardous. The operator, supervisor, and helper must read

and understand the following safety warnings and instructions before installing

or using any welding or cutting equipment, and be aware of the dangers of the

welding or cutting process. Training and proper supervision are important for a

safe work place. Keep these instructions for future use. Additional recommended

safety and operating information is referenced in each section.

!

WARNING

WARNING: This product contains chemicals, including lead, known to the State

of California to cause birth defects and other reproductive harm. Wash hands

after handling.

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and maintain equipment in accordance with the National Electrical Code

(NFPA 70) and local codes. Do not service or repair equipment with power

ON. Do not operate equipment with protective insulators or covers removed.

Service or repair to equipment must be done by qualiﬁed and/or trained

personnel only.

Do not contact electrically live parts. Always wear dry welding gloves that are in good condition.

Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,

chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground

connections must be checked periodically to determine if they are mechanically strong, and

electrically adequate for the required current. When engaged in AC welding/cutting under wet

conditions or where perspiration is a factor, the use of automatic controls for reducing the no

load voltage is recommended to reduce shock hazards. Accidental contact must be prevented

when using open circuit voltage exceeding 80 volts AC, or 100 volts DC by adequate insulation

or other means. When welding is to be suspended for any length of time, such as during lunch

or overnight, all electrode holders and electrodes should be removed from the electrode holder

and the power supply should be turned OFF to prevent accidental contact. Keep MIG Guns,

electrode holders, TIG torches, Plasma torches, and electrodes away from moisture and water.

See safety and operating references 1, 2, and 8.

2

SAFETY AND OPERATING INSTRUCTIONS

89200014

SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH

Ventilation must be adequate to remove smoke, fumes, and gases during operation

to protect operators and others in the area. Vapors of chlorinated solvents can form

the toxic gas “Phosgene” when exposed to ultraviolet radiation from an electric

arc. All solvents, degreasers, and potential sources of these vapors must be removed

from the operating area. Use air-supplied respirators if ventilation is not adequate

to remove all fumes and gases. Oxygen supports, and vigorously accelerates ﬁre and should

never be used for ventilation.

See safety and operating references 1, 2, 3, and 4.

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN

Welding and cutting processes produce extreme localized heat and strong

ultraviolet rays. Never attempt to weld/cut without a federally compliant welding

helmet with the proper lens. A number 12 to 14 shade ﬁlter lens provides the

best protection against arc radiation. When in a conﬁned area, prevent the

reﬂected arc rays from entering around the helmet. Approved shielding curtains

and appropriate goggles should be used to provide protection to others in the surrounding area.

Skin should be protected from arc rays, heat, and molten metal. Always wear protective gloves

and clothing. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings,

etc. should be worn for out-of-position welding and cutting, or for heavy operations using large

electrodes. Hightop work shoes provide adequate protection from foot burns. For added protection,

use leather spats. Flammable hair preparations should not be used when welding/cutting. Wear

ear plugs to protect ears from sparks. Where work permits, the operator should be enclosed in

an individual booth painted with a low reflective material such as zinc oxide.

See safety and operating references 1, 2, and 3.

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS

Combustibles reached by the arc, ﬂame, ﬂying sparks, hot slag, and heated

materials can cause ﬁre and explosions. Remove combustibles from the work

area and/or provide a ﬁre watch. Avoid oily or greasy clothing as a spark may

ignite them. Have a ﬁre extinguisher nearby, and know how to use it. If welding/

cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must

be taken to prevent ignition of nearby combustibles on the other side. Do not weld/cut containers

that have held combustibles. All hollow spaces, cavities, and containers should be vented prior

to welding/cutting to permit the escape of air or gases. Purging with inert gas is recommended.

Never use oxygen in a welding torch. Use only inert gases or inert gas mixes as required by the

process. Use of combustible compressed gases can cause explosions resulting in personal injury

or death. Arcing against any compressed gas cylinder can cause cylinder damage or explosion.

See safety and operating references 1, 2, 5, 7, and 8.

NOISE CAN DAMAGE HEARING

Noise from the air carbon-arc process can damage your hearing. Wear protective

hearing devices to ensure protection when noise levels exceed OHSA standards.

Adequate hearing protection devices must be worn by operators and surrounding

personnel to ensure personal protection against noise. See safety and operating

references 1, 2, and 6.

SAFETY AND OPERATING INSTRUCTIONS

389200014

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139,

251, 252, 253, 254 and 1000. U.S. Government Printing Ofﬁce, Washington, DC 20402.

2. ANSI Z49.1 “Safety in Welding and Cutting”.

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.

4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National

Standards Institute, 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.

6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”. The

American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.

8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park,

Quincy, MA 02269.

9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards

Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

®

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

4

SAFETY AND OPERATING INSTRUCTIONS

89200014

SECTION 2:

INTRODUCTION

2.01 HOW TO USE THIS MANUAL

To ensure safe operation, read the entire manual, including the chapters 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:

NOTE

NOTE conveys installation, operation, or maintenance information which is

important but not hazard-related.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may

result in injury.

!

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in death or serious injury.

2.02 RECEIPT OF EQUIPMENT

When you receive the equipment, check it against the invoice to make sure it is complete and

inspect the equipment for possible damage due to shipping. If there is any damage, notify the

carrier immediately to ﬁle a claim. Furnish complete information concerning damage claims

or shipping errors to the location in your area, listed on the back cover of this manual. Include

a full description of the parts in error.

If you want additional or replacement copies of this manual, please contact Tweco

®

at the

address and phone number in your area listed on the back cover of this manual. Include the

Manual number (from page i). You may download a copy from our website www.tweco.com.

SAFETY AND OPERATING INSTRUCTIONS

589200014

SECTION 3:

TWECO

®

FUSION MIG GUN INSTALLATION

NOTE

Be certain that the end user (welder, operator, or helper) reads and understands

these instructions. Be certain that the welder also reads Section 1 “Safety

Precautions.”

!

WARNING

Electric shock can cause injury or death.

POWER

SOURCE

WIRE FEEDER

GROUND

WORK PIECE

GUN

Figure 1: Standard MIG Gun Installation

NOTE

When installing or replacing Contact Tip be sure to tighten fully.

3.01 DIRECT PLUG MIG GUN INSTALLATION

Direct plug MIG Guns install by directly inserting the rear connector plug into the feeder wire

guide outlet (see Figure 2) and tightening the plug retaining screw. Follow the instructions

provided with the wire feeder in use for wire installation and MIG Gun setup . All models of

MIG Guns, except the Euro-Kwik guns, require a control wire assembly to attach the MIG Gun

trigger leads to the feeder. The control wire assemblies extending out the rear end of the MIG

Gun plugs into the control wire receptacle on the feeder. Euro-Kwik connections are installed by

inserting the gun connection into the feeder receptacle, aligning the conduit plug ﬁrst, then the

gas plug. Push until all ﬁttings are seated, then tighten the nut hand tight as shown in Figure 3.

Figure 2

Figure 3

6

SAFETY AND OPERATING INSTRUCTIONS

89200014

3.02 COMPATIBLE WELDING MACHINES

(8 pin connector)

F140L F180L F220L

LINCOLN

®

SP140T

SP180T

Powermig 140C

Powermig 180C

Easy-Core 125

Pro-Core 125

Weld-Pak 125HD

Easy-MIG 140

Pro-MIG 140

Weld-Pak 140HD

MIG-Pak 140

Easy-MIG 180

Pro-MIG 180

Weld-Pak 180HD

MIG-Pak 180

F140X F180X F220X

ESAB

®

MigMaster 173

MigMaster 160

F140M F180M F220M

MILLER

®

ELECTRIC

Millermatic 130

Millermatic 130XP

Millermatic 135

Millermatic 140

Millermatic 150

Millermatic 155

Millermatic 175

Millermatic 180

Millermatic 185

Millermatic 200

Millermatic 210

Millermatic 211

Millermatic 212

F140TA F180TA F220TA

THERMAL ARC

®

3 IN 1

Fabricator 141i

Fabricator 181i

Fabricator 211i

TWECO

®

F140 F180 F220

THERMAL ARC

®

/ FIREPOWER

®

Fabricator 140*

Fabricator 180*

* Use w/ 350-174-TA180

Fabricator 190

†

Fabricator 210

†

Use w/ WM354MF

LINCOLN

®

SP100

SP100T

SP125 PLUS

SP130

SP170T

SP175 PLUS

TWECO

®

MILLER

®

LINCOLN

®

EURO-KWIK

(4 pin connector)

MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN

is a registered trademark of LINCOLN Electric Co.; The aforementioned registered trademarks are no way afﬁliated

with Tweco Products, Inc. or Victor Technologies, Inc. Tweco is a registered trademark of Victor Technologies, Inc.

3.03 DUTY CYCLE

MIG GUN Duty Cycle

140 AMP 20% Duty Cycle , Mixed Gases

180 AMP 40% Duty Cycle , Mixed Gases

220 AMP 40% Duty Cycle , Mixed Gases

SAFETY AND OPERATING INSTRUCTIONS

789200014

3.04 TWECO

®

FUSION MIG GUN SELECTION GUIDE

140 AMP MIG Gun* 180 AMP MIG Gun* 220 AMP MIG Gun*

Rear Connector

(Replacement)

Rear

Connection

Part Number

Stock Number

Part Number

Stock Number

Part Number

Stock Number

Part Number

Stock Number

Tweco

®

F140T-10-3035

1017-1320

F180T-12-3035

1017-1331

F220T-15-3035

1023-1260

350-174H

2035-2110

Miller

®

F140M-10-3035

1017-1319

F180M-12-3035

1017-1330

F220M-15-3035

1023-1259

350-174MH

2035-2111

Lincoln

®

F140L-10-3035

1017-1318

F180L-12-3035

1017-1329

F220L-15-3035

1023-1258

350-174LH

2035-2112

Euro-Kwik

F140X-10-3035

1017-1323

F180X-10-3035

1017-1335

F180X-12-3035

1017-1336

F180X-12-3035

1017-1334

F220X-10-3035

1023-1264

F220X-12-3035

1023-1265

F220X-15-3035

1023-1263

174EX-1

2040-2276

141i

ThermalArc

F140TA-10-3035

1017-1321

-- --

350-174H

2035-2110

181i

ThermalArc

--

F180TA-12-3035

1017-1332

--

211i

ThermalArc

-- --

F220TA-12-3035

1023-1261

*Rear connector supplied as standard

3.05 TWECO

®

FUSION MIG GUN PART NUMBER IDENTIFICATION

NOTE

Tweco Fusion MIG Guns, as a general rule, have a specific nomenclature

incorporated within each part number to help determine the wire size of each

MIG Gun.

Example Part Number:

140, 180, or 220 AMP

F220TA153545

T=Tweco

TA=Tweco (Bundle)

L=Lincoln

M=Miller

X, XE=Euro-Kwik

Tweco Fusion

15 foot (5 M) cable

.035"-.045" Wire Capacity

(0,9 mm - 1,2 mm)

So a part number "F220TA153545" would identify the MIG Gun as a: Tweco Fusion 220A MIG

Gun bundle pack with a 8-pin rear connector, 15 foot (4,6 M) long cable and having a 0.35"

to 0.45" (0,9 mm to 1,2 mm) diameter wire capacity. (See "3.02 Compatible Welding

Machines").

So a part number"F180T123545" would identify the MIG Gun as a: Tweco Fusion 180A MIG

Gun with a 4-pin Tweco rear connector, 12 foot (3,7 M) long cable and having a 0.35" to 0.45"

(0,9 mm to 1,2 mm) diameter wire capacity.

MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN is

a registered trademark of LINCOLN Electric Co.; The aforementioned registered trademarks are no way afﬁliated with

Tweco Products, Inc. or Victor Technologies, Inc. Tweco is a registered trademark of Victor Technologies, Inc.

8

SAFETY AND OPERATING INSTRUCTIONS

89200014

3.06 TWECO

®

MIG-KWIK CONNECTION AND ADAPTER KIT

INSTALLATION

Installation of a Tweco MIG Gun with a Tweco connector plug, may require an adapter kit.

Choose the correct adapter kit for your wire feeder from the Adapter Kit Listing. (Refer to the

Tweco Adapter Kit Listing, Form No. TLAK-97 for more detail.) To install, follow the instructions

furnished with the adapter kit. Figure 4 shows the general adapter kit installation.

Receptacle

(TLAK-1 or 6TLAK-1)

Receptacle

(TAK-1 or 6TAK-1)

ADAPTER PLUG

WIRE FEEDER

GAS HOSE

POWER CABLE

CONTROL WIRE

MIG GUN

Figure 4

1. Screw adapter plug into the receptacle and tighten.

2. Insert the adapter plug and receptacle into the wire feeder wire guideout. Tighten the

wire guide attachment screw.

3. If needed, attach a proper sized welding cable from the welding power source to the

receptacle power connection.

4. Attach a gas hose to the receptacle and to the feeder gas solenoid.

NOTE

When using an adapter kit, the gas must be attached to the receptacle to provide

gas to the MIG Gun. If the feeder gas supply is attached to the feeder wire guideout

block, it must be rerouted to the receptacle.

5. Insert the MIG gun rear connection plug into the receptacle and tighten the attachment

screw.

6. Attach the control wire plug assembly to the wire feeder MIG gun control circuit. Then

plug the ﬂat double female plug into the MIG Gun.

The gun should now be installed and ready to feed wire as recommended by the feeder

manufacturer.

SAFETY AND OPERATING INSTRUCTIONS

989200014

SECTION 4:

WIRE CONDUIT, TIP, NOZZLE REPLACEMENT

4.01 CONDUIT IDENTIFICATION TWECO

®

STYLE

The procedure for removal and installation of a wire conduit is similar for all Tweco MIG Guns. Conduits

may be identiﬁed by the type of conduit stop and the part number marking on each conduit stop.

Example Part Number:

4.02 CONDUIT REMOVAL

1. Lay the MIG Gun out on a table or on the ﬂoor in a straight line. Make sure the gun is

fully extended and all twists in the cable are removed.

2. Remove the nozzle and contact tip from the gun assembly. Then loosen the conduit

set screw in the rear connector plug.

NOTE

On Miller

®

Direct Plug MIG Guns, remove the nipple on the end of the connector

plug. On Euro-Kwik connections, remove the conduit retaining cap.

3. Grip the conduit stop and remove the conduit with a twisting motion. On Miller

®

Direct

Plug MIG Guns, twisting the rear of the gun approximately two revolution counter-

clockwise will raise the conduit stop out of the connector plug recess.

4.03 CONDUIT INSTALLATION - VELOCITY CONTACT TIP STYLE

!

WARNING

Failure to follow Conduit Installation Instructions will cause wire feed issues.

1. Uncoil the conduit and lay it in a straight line. Insert the conduit into the rear connector plug.

Push the conduit into the gun with short strokes.

NOTE

If the conduit hangs up gently whip the cable while applying pressure to the

conduit. New liners must be cut to the correct length.

2. When the conduit is completely in the gun, tighten the rear conduit set screw. On Miller

®

guns, reinstall the nipple. On Euro-Kwik guns, reinstall the conduit retaining cap.

IMPORTANT!

3. The new conduit liner will need to be cut to

length. This can be done by trimming the conduit

to the appropriate length.

1/8” (3,2 mm)

Velocity

Conductor Tube

42-3035-15

42 Series

.035" (0.8mm) Wire Capacity

Liner Length Ft

10

SAFETY AND OPERATING INSTRUCTIONS

89200014

4. File the cut conduit end to remove burrs.

5. Replace the contact tip.

6. Replace the nozzle. Hand tighten

(Nozzle secures tip).

NOTE

For proper operation the nozzle MUST be tight.

The MIG Gun is now ready to be reinstalled on the

feeder.

4.04 REPLACING VELOCITY CONTACT TIP

CAUTION

While nozzle and contact tip are removed, maintain an adequate distance of the

wire from metal objects to avoid burnbacks to conduit or conductor tube.

1. Remove worn nozzle and tip. (Clean nozzle if reusing.)

2. Slide new contact tip into the conductor tube end.

3. Replace the nozzle. Hand tighten (Nozzle secures tip).

NOTE

For proper operation the nozzle MUST be tight.

4. Trim wire to desired stick out.

The MIG Gun is now ready for operation.

SAFETY AND OPERATING INSTRUCTIONS

1189200014

4.05 VELOCITY CONTACT TIP IDENTIFICATION

Velocity Contact Tips may be identiﬁed by the tip type and the part number marking on each tip.

Example Part Number:

VTSARZT30

Velocity

Tip

Blank=CU,

RZ=CHROM ZIR,

RS=SILVER ZIR

T=Tapered,

Blank=None

S=Small,

M=Medium,

L=Large

A=Alum,

Blank=Other

Wire Size: 23=0.023” 116=1/16”

30=0.030” 564=5/64”

35=0.035” 332=3/32”

40=0.040” 764=7/64”

45=0.045” 18=1/8”

So a part number "VTSARZT30" would be: Velocity Tip Type, Small Size, Aluminum, RZ Alloy,

Tapered for wire size 0.030 diameter.

A part number "VTMA40" would be: Velocity Tip Type, Medium Size, CU, wire size 0.040 diameter.

4.06 VELOCITY NOZZLE IDENTIFICATION

Nozzles for the Velocity contact tip MIG Guns may be identiﬁed by their type and part number marking

on each nozzle.

Example Part Number:

Blank=Standard,

H=Heavy Duty

VNSH50FS

Velocity

Nozzle

Blank=Std Recess,

F=Flush,

P=Protrude,

R= Recess ¼” (6.35mm)

FAS=Spot Weld

FC=Flux Core

S=Small Nozzle,

M=Medium Nozzle,

L=Large Nozzle

Oriﬁce Opening Size: 37=3/8” 62=5/8”

50=1/2” 75=3/4”

Blank=Threaded,

S=Slip

So a part number "VNSH50F" would be: Velocity Nozzle Type, Small Nozzle Size, Heavy Duty,

oriﬁce opening size of 0.50 inch, Flush end, Slip ﬁt.

A part number "VNS50" would be: Velocity Nozzle Type, Small Nozzle Size, Standard Duty,

oriﬁce opening size of 0.50 inch, Standard Recess end, Threaded ﬁt.

12

SAFETY AND OPERATING INSTRUCTIONS

89200014

4.07 CONDUCTOR TUBE IDENTIFICATION

Conductor tubes for the Velocity Contact Tip on the Tweco Fusion MIG Guns may be identiﬁed

by their type and part number marking on each tube.

Example Part Number:

FVCTS22060

Fusion

Maximum

Amp Rating

Velocity

Conductor Tube

Bend Angle: 60˚S=Small Tip,

M=Medium Tip,

L=Large Tip

So a part number "FVCTS22060" would be: Tweco Fusion Gun Type, Velocity 220 Amp Conductor

Tube, Small Tip Size, 60 degree bend.

4.08 REPLACE CONDUCTOR TUBE

Remove the MIG gun from the feeder prior to beginning these steps. The conductor tube is

attached to the Tweco® Fusion MIG Gun by one set screw on the side of the conductor tube.

To remove:

1. Remove the front end consumables from the conductor tube.

2. Lay MIG gun on side, screw side up and remove both handle screws at the front of the

gun handle.

3. Lay the gun back down on its side and untwist the handle back cap.

4. Remove the top handle half being careful to keep all components in place in the lower

handle half.

5. Loosen the socket head cap screw securing the conductor tube in place inside the handle

with a 5/32" Allen wrench.

6. Remove conductor tube.

7. Slide the new tube over the liner and insert into the brass connection within the handle.

Conﬁrm the tube is correctly aligned with the MIG Gun handle and wrench tighten the

socket head cap screw.

8. Re-assemble the handle.

9. Check conductor tube alignment and re-assemble the front end consumables.

The MIG gun is now ready for operation.

1/8”

(3,2 mm)

Handle screws

Back Cap

SAFETY AND OPERATING INSTRUCTIONS

1389200014

SECTION 5:

MAINTENANCE AND TROUBLESHOOTING

Contact tips and nozzles should be cleaned frequently. Spatter buildup may cause bridging

between nozzle and tip. This could cause electrical shorting between the nozzle and work

piece as well as poor or improper gas ﬂow. Regularly inspect the conductor tube, handle,

cable, and other parts of the MIG Gun for abrasion, cuts, or undue wear. Replace or repair any

parts found deﬁcient.

Problem Possible Cause Corrective Action

Wire feed inconsistent

or not smooth

1. Loose contact tip. 1. Tighten nozzle.

2. Excessively worn contact tip. 2. Replace contact tip.

3. Spatter buildup on end of

contact tip.

3. Clean or replace contact tip.

4. Sharp bends or kinks in

conduit.

4. Straighten or replace conduit.

5. Dirty or plugged conduit. 5. Replace conduit.

6. Conduit pulled back from

contact tip.

6. Reposition conduit and cable.

7. Machine improperly adjusted. 7. Reset machine per machine

and wire manufacturers’

recommendations.

MIG Gun is running hot

1a. Loose contact tip. 1a. Tighten nozzle.

b. Liner is too long b. Trim liner correctly.

2. Loose power connections. 2. Inspect complete gun for loose

connections and repair.

3. Loose or undersize ground

cable or ground clamp.

3. Tighten or replace as required.

4. Operating gun above

recommended amperage

rating.

4. Readjust machine to correct

setting for size of gun being used.

5. Operating gun above

recommended duty cycle

rating.

5. Readjust machine to correct

setting for size of gun being used.

6. Loose set screw in conductor

tube connector.

6. Tighten set screw.

Porous weld

1. Poor or improper gas flow. 1. Check gas flow out of gun nozzle.

Check for leaks or restrictions in

gas hoses and connections.

2. Dirty or contaminated wire. 2. Change wire.

3. Base metal contaminated. 3. Replace base metal.

Conduit gets hung-up

inside of the gun

1. Burr on the end of the cut

conduit.

2. Conduit liner has kinks.

1. Remove the burr with a file.

2. Replace conduit.

14

SAFETY AND OPERATING INSTRUCTIONS

89200014

SECTION 6:

REPLACEMENT PARTS

6.01 TWECO

®

FUSION MIG GUN PARTS

3

5a (VNS-FC

TIP HOLDER)

5b (VNS-FC-I

TIP HOLDER INSULATOR)

1

2

4

SAFETY AND OPERATING INSTRUCTIONS

1589200014

Item No. Description Part No. Stock No.

1 Nozzle**

VNS-50 1220-1201

VNS-50F 1220-1200

VNS-62 1220-1203

VNS-62F 1220-1202

VNS-37 1220-1206

VNS-37F 1220-1204

VNS-75FAS 1220-1205

2 Contact Tip**

VTS-23 1110-1308

VTS-30 1110-1309

VTS-35 1110-1310

VTS-40 1110-1311

VTS-45 1110-1312

VTSA-364 1110-1313

VTS-52 1110-1314

VTS-116 1110-1315

VTSA-116 1110-1317

VTS-564 1110-1316

3 Velocity 60° Conductor Tube FVCTS-220-60 1620-1108

4 Conduit Assembly* WS42-3035-15 1420-1140

5a FC Tip Holder VNS-FC 1220-1207

5b FC Tip Holder Insulator VNS-FC-I 1220-1208

*Refer to Tweco Catalog No. 64-2103 for additional options.

** Patent Pending

Additional options

Description Part No. Stock No.

Rear Connector Plugs - Tweco

®

350-174H 2035-2110

Rear Connector Plugs - Miller

®

350-174MH 2035-2111

Rear Connector Plugs - Lincoln

®

350-174LH 2035-2112

MILLER is a registered trademark of Miller Electric Mfg. Co.; ESAB is a registered trademark of ESAB AB; LINCOLN

is a registered trademark of LINCOLN Electric Co.; The aforementioned registered trademarks are no way afﬁliated

with Tweco Products, Inc. or Victor Technologies, Inc. Tweco is a registered trademark of Victor Technologies, Inc.

16

SAFETY AND OPERATING INSTRUCTIONS

89200014

6.02 TWECO

®

FUSION MIG GUN CONSUMABLES

VNS-50F

FUSION

™

180

5/8” (15,9 mm)

VNS-37

3/8” (9,5 mm)5/8” (15,9 mm)

VNS-75FAS

VNS-50

1/2” (12,7 mm) 1/2” (12,7 mm)

VNS-37F

3/8” (9,5 mm)

VNS-62F

VNS-62

3/4” (19,1 mm)

VNS-FC

Velocity

Nozzle

Velocity

Contact Tip

VTS-23

VTS-45

VTSA-116

VTS-564

VTS-52

VTS-116

VTS-364

VTS-35

VTS-40

VTS-30

140A MIG GUN

180A MIG GUN

220A MIG GUN

OPTIONAL

STANDARD

Conductor Tube Indicator Line

(Score line here indicates this

conductor tube is replaceable.)

Blank=Std Recess,

F=Flush,

P=Protrude,

R= Recess ¼” (6.35mm)

FAS=Spot Weld

FC=Flux Core

VELOCITY NOZZLE IDENTIFICATION

VTSARZT30

Velocity

Tip

Blank=CU,

RZ=CHROM ZIR,

RS=SILVER ZIR

T=Tapered,

Blank=None

S=Small,

M=Medium,

L=Large

A=Alum,

Blank=Other

Wire Size: 23=0.023” 116=1/16”

30=0.030” 564=5/64”

35=0.035” 332=3/32”

40=0.040” 764=7/64”

45=0.045” 18=1/8”

Blank=Standard,

H=Heavy Duty

VNSH50FS

Velocity

Nozzle

S=Small Nozzle,

M=Medium Nozzle,

L=Large Nozzle

Oriﬁce Opening Size: 37=3/8” 62=5/8”

50=1/2” 75=3/4”

Blank=Threaded,

S=Slip

VELOCITY CONTACT TIP IDENTIFICATION

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