fabricator - Westermans International

fabricator - Westermans International
400II & 450II
FABRICATOR
MIG Power Supplies
Operation Manual
Version No: AW.05
Operating Features
Issue Date: Sept 23rd, 2009
WE APPRECIATE YOUR BUSINESS!
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 Thermadyne
Customer Service on (44) 01257 224824.
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.
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. 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 marketleading, 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.
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 best judgement, the Manufacturer assumes no
liability for its use.
Fabricator 400II MIG Welding Machine, Part Number 10-9405.
Fabricator 450II MIG Welding Machine, Part Number 10-9406.
Published by:
Thermadyne Industries Ltd
Chorley North Industrial Park
Chorley
Lancashire
PR6 7BX
England
www.thermadyne.com
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 1st, 2008
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
TABLE OF CONTENTS
SECTION 1:
1.01
1.02
1.03
1.04
SAFETY PRECAUTIONS
Safety Instructions and Warning
Declaration of Conformity
Statement of Warranty
Symbol Legend
1
1
4
5
6
SECTION 2:
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
INTRODUCTION AND DESCRIPTION
How to use this Manual
Equipment Identification
Receipt of Equipment
Description
Safety
Transporting Methods
Protected Filter Lenses
User Responsibility
Duty Cycle
7
7
7
7
8
8
8
8
9
9
SECTION 3:
3.01
3.02
3.03
3.04
3.05
3.06
INSTALLATION RECOMMENDATIONS
Environment
Location
Electrical Input Connections
Electrical Input Requirements
Input Power
Specifications
10
10
10
10
11
12
13
SECTION 4:
4.01
4.02
4.03
OPERATOR CONTROLS
Fabricator Layout
Power Source features
Control Panel features
14
14
16
16
SECTION 5:
5.01
5.02
5.03
5.04
5.05
UNDERSTANDING AND SETTING UP FOR WELDING
Control Panel description
Range of Parameters
Wire Feed description
Feed Roll information
Spool holder description
17
17
18
19
19
19
SECTION 6:
6.01
6.02
6.03
6.04
6.05
6.06
6.07
6.08
GETTING STARTED
Torch Connection
How to connect the work lead
Where to connect the work clamp
How to connect to the mains
How to fit the wire spool
Inserting the wire
How to connect the gas cylinder
How to configure the machine for aluminium welding
20
20
20
20
21
21
21
23
23
SECTION 7:
7.01
7.02
7.03
7.04
7.05
7.06
OPERATION
Setting welding current and voltage
Welding modes
Secondary parameters
Two stroke
Four stroke
Spot and stitch welding
24
24
24
24
25
25
26
SECTION 8:
8.01
8.02
8.03
8.04
8.05
8.06
8.07
BASIC WELDING TECHNIQUE
Setting of the Power Source
Position of MIG Torch
Distance of the MIG Torch Nozzle to the Work Piece
Travel Speed
Electrode Wire Size Selection
Stitch Welding Operation
Spot Welding Operation
27
27
27
27
27
27
28
28
SECTION 9:
ROUTINE MAINTENANCE & INSPECTION
29
SECTION 10:
10.01
10.02
10.03
10.04
BASIC TROUBLESHOOTING
Porosity
Inconsistent wire feed
Welding Problems
Power Source Problems
30
30
31
32
33
SECTION 11:
11.01
11.01
11.02
11.02
11.03
11.04
11.05
SPARE PARTS
Parts description Fabricator 400II
Spare part numbers Fabricator 400II
Parts description Fabricator 450II
Spare part numbers Fabricator 450II
Wire Feed Unit parts Description + Spare Part Numbers
Water Cooler Parts Description + Spare Parts List
Wire Feed motor-gearbox spare parts list
36
36
37
38
39
40
41
42
SECTION 12:
12.01
12.02
12.03
MACHINE SCHEMATICS
Power Source Schematic for the FABRICATOR 400 II
Power Source Schematic for the FABRICATOR 450 II
Wire Feed Unit Schematic
43
43
44
45
SECTION 13:
Optional accessories
46
Figures Description
Figure No
Description
Figure 1
Colour Picture of Fabricator 400II & 450II
Front page
Figure 2
Symbol Legend
6
Figure 3
Electrical Input Connections
11
Figure 4
Fabricator Layout
14
Figure 5
7 Pin Receptacle Connections
15
Figure 6
Control Panel Features
16
Figure 7
Control Panel Description1
17
Figure 8
Wire Feed Description
19
Figure 9
Feed Roll Information
19
Figure 10
Spool Holder Description
19
Figure 11
Torch Connection
20
Figure 12
Connection of Work Lead
20
Figure 13
Connection on Work Clamp
21
Figure 14
Spool Holder Description
21
Figure 15
Wire Feed Description
22
Figure 16
Pressure Roll Tension
22
Figure 17
Aluminium Liner Information
23
Figure 18
Two Stroke Description
25
Figure 19
Four Stroke Description
25
Figure 20
Spot & Stitch Description
26
Figure 21
Spot & Stitch Description
26
Figure 22
Position of MIG Torch
27
Figure 23
Wire Size Penetration Comparison
28
Figure 24
Parts Description Fabricator 400II
36
Figure 25
Parts Description Fabricator 450II
38
Figure 26
Wire Feed Unit Parts Description + Spare Part No
40
Figure 27
Water Cooler Parts description + Spare Parts List
41
Figure 28
Wire Feed Motor / Drive Spare Parts List
42
Figure 29
Power Source Schematic for Fabricator 400II
43
Figure 30
Power Source Schematic for Fabricator 450II
44
Figure 31
Wire Feed Unit Schematic
45
SECTION 1: Safety Instructions and Warnings
WARNING
ARC WELDING can be hazardous.
Protect yourself and others from possible serious injury or death. Keep children away. Pace maker 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. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain
practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are out lined 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.
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 terminal
circuits are also live when power is on. In
semiautomatic 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 10 cal codes.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.
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.
2.
3.
4.
5.
Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
Do not use worn, damaged, under sized or poorly spliced cables.
Do not wrap cables around your body.
Ground the workpiece to a good electrical (earth) ground.
Do not touch electrode while in contact with the work (ground)
circuit.
Use only well-maintained equipment. Repair or replace damaged
parts at once.
In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
Wear a safety harness to prevent falling if working above floor
level.
Keep all panels and covers securely in place.
Wear a welding helmet fitted with a proper shade of filter (see
ANSI 249.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Use approved earplugs or earmuffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
Welding or Cutting
operation
Electrode size Metal Thickness or
Welding Current
Torch soldering
All
Torch brazing
All
Oxygen cutting
Light
Under 1 in., 25 mm
Medium
1 – 6 in., 25 – 150 mm
Heavy
Over 6 in., 150 mm
Gas welding
Light
Under 1/8 in., 3 mm
Medium
1/8 – 1/2 in., 3 – 12 mm
Heavy
Over 1/2 in., 12 mm
Shielded metal-arc welding (stick) electrodes
Under 5/32 in., 4 mm
Under 5/32 to ¼ in., 4 to 6.4mm
Over ¼ in., 6.4 mm
Filter
shade
no.
2
2 or 3
3 or 4
4 or 5
5 or 6
4 or 5
5 or 6
6 or 8
10
12
14
1
Welding or Cutting operation
Gas metal arc welding
Non Ferrous base metal
Ferrous base metal
Gas tungsten arc welding (TIG)
Atomic Hydrogen welding
Carbon Arc welding
Plasma arc Welding
Carbon Arc Gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode size Metal
Filter
Thickness or Welding shade no.
Current
All
All
All
All
All
All
11
12
12
12
12
12
12
14
Under 300 Amp
300 to 400 Amp
Over 400 Amp
9
12
14
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.
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 (MSDS) 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 vapours 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 re moved 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.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work
piece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, over
heating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material
Remove all flammables within 35ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Flying sparks and hot metal can
cause Injury
3. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4. Watch for fire, and keep a fire extinguisher nearby.
5. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
6. Do not weld on closed containers such as tanks or drums.
7. 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.
8. Do not use welder to thaw frozen pipes.
9. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
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 carefuIIy.
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.
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.
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.
2
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable
3. Allow engine to cool before fuelling. If possible, check and add fuel
to cold engine before beginning job.
1. Stop engine before checking or adding fuel.
4. Do not overfill tank - allow room for fuel to expand away from any
2. Do not add fuel while smoking or if unit is near
building air intakes.
any sparks or open flames.
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.
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure
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. Re-install panels or guards and close doors when servicing is
finished and before starting engine.
1.
2.
3.
4.
Always wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery cables.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
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 Magnetic Fields
To reduce magnetic fields in the work place, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Do not coil or drape cables around the body.
3. Arrange cables to one side and away from the operator.
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.
3
1.02 DECLARATION OF CONFORMITY
Manufacturer and Merchandiser of Quality Consumables and Equipment:
Address:
Thermal Arc
Thermadyne Europe
Europa Building
Chorley North Industrial Park
Chorley
Lancashire
England
PR6 7BX
Description of equipment: Welding Equipment (GMAW) Thermal Arc Fabricator 400II and
FABRICATOR 450II and associated accessories.
* Serial numbers are unique with each individual piece of equipment and details description,
parts used to manufacture a unit and date of manufacture.
* The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (Directive 73/23/EU, as recently changed in Directive 93/68/EU and to the National
legislation for the enforcement of the Directive.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical
requirements among them are:
* EN60974-1 applicable to welding equipment and associated accessories.
* EN50199 applicable to arc welding equipment - generic emissions and regulations.
* Extensive product design verification is conducted at the manufacturing facility as part of the
routine design and manufacturing process, to ensure the product is safe and performs as
specified. Rigorous testing is incorporated into the manufacturing process to ensure the
manufactured product meets or exceeds all design specifications.
Thermal Arc has been manufacturing and merchandising an extensive equipment range with
superior performance, ultra safe operation and world class quality for more than 30 years and
will continue to achieve excellence.
Thermadyne has been manufacturing products for more than 30 years, and will continue to
achieve excellence in our area of manufacture.
4
1.03 STATEMENT OF WARRANTY
In accordance with the warranty periods stated below, Thermadyne guarantees the proposed
product to be free from defects in material or workmanship when operated in accordance with the
written instructions as defined in this operating manual.
Thermadyne welding products are manufactured for use by commercial and industrial users and
trained personnel with experience in the use and maintenance of electrical welding and cutting
equipment.
Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due
to defects in material or workmanship within the warranty period. The warranty period begins on
the date of sale to the end user.
Thermal Arc Fabricator 400II & 450II
Component
Warranty Period
Power Source
Wire Feed Unit
Optional Cooler
2 Years
2 Years
2 Years
If warranty is being sought, Please contact your Thermadyne product supplier for the warranty
repair procedure.
Thermadyne warranty will not apply to:
•
•
•
•
•
Equipment that has been modified by any other party other than Thermadyne’s own service
personnel or with prior written consent obtained from Thermadyne Service Department.
Equipment that has been used beyond the specifications established in the operating
manual.
Installation not in accordance with the installation/operating manual.
Any product that has been subjected to abuse, misuse, negligence or accident.
Failure to clean and maintain (including lack of lubrication, maintenance and protection),
the machine as set forth in the operating, installation or service manual.
Within this operating manual are details regarding the maintenance necessary to ensure trouble
free operation.
This manual also offers basic troubleshooting, operational and technical details including
application usage.
You may also wish to visit our web site www.thermadyne.com select your product class and then
select literature. Here you will find documentation including:
•
•
•
Operator manuals
Service manuals
Product guides
Alternatively please contact your Thermadyne distributor and speak with a technical
representative.
NOTE
Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne
distributor or an Authorised Service Agent approved by the Company
5
September 2009
1.04 SYMBOL LEGEND
Figure 2.
6
SECTION 2: INTRODUCTION AND DESCRIPTION
2.01 How to use this Manual
This Operator owner’s manual applies to Part Numbers: 10-9405 and 10-9406
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 possible personal injury
CAUTION
A CAUTION refers to possible equipment damage
NOTE
A NOTE offers helpful information concerning certain operating procedures
Additional copies of this manual may be purchased by contacting Thermal Arc at the
address and phone number given below:
Thermadyne Customer Service
Thermadyne Industries Ltd
Europa Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7BX.
Phone: (44) 01257 261755
Fax: (44) 01257 224842
Include the Owner’s Manual number and equipment identification numbers.
Electronic copies of this manual can also be emailed to you at no charge in
Acrobat PDF format by contacting Thermadyne Customer Service on (44) 01257 261755.
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial
number appear on a nameplate fixed to the rear panel. In some cases,Equipment
which does not have a control panel such as gun and cable assemblies is identified
only by the specification or part number printed on the shipping container.
Record the number for future reference.
2.03 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
distributor you purchased the equipment from.
Include all equipment identification numbers as described above along with a full
description of the parts in error.
Move the equipment to the installation site before unpacking the unit. Use care to
avoid damaging the equipment when using bars, hammers, etc, to unpack the unit.
7
2.04 Description
™
The Thermal Arc Fabricator 400II and Fabricator 450II are 400Volt 3 phase MIG machines
with great performance with either 400Amp maximum output @ 30% duty cycle, 20 voltage
steps or 520Amp maximum output @ 30% duty cycle, 30 voltage steps, separate
WFU's, digital meters and cylinder racks. The wire feed unit system has an option of up to
10m interconnection cables. The Wirefeeder has touch panel control pad incorporating
spot/stitch timers. The Wirefeeder also benefits from fitted wheels and conveniently
fits on a swivel mount on top of the power source or can be lifted off the pivot and
carried up on top of equipment or machinery up to 10m away. The Fabricator 400II and
Fabricator 450II are extremely versatile all round performers and offer excellent
performance on mild steel, stainless steel, aluminium, silicon bronze and some hard
facing wires with Argon based shielding gases. The Fabricator also gives excellent
results on mild steel using Carbon Dioxide shielding gas.
The following instructions detail how to correctly set up the welder and give guidelines
on gaining the best production efficiency from the Fabricator. Please read these
instructions thoroughly before using your Fabricator welder.
2.05 Safety
The following basic safety rules should always be followed:
• Ensure the machine is correctly installed, if necessary, by a qualified
electrician.
• Ensure the Power Supply is grounded correctly (electrically) in accordance with
local regulations.
• Excessive heat in the welding cables may cause fire. Never weld with poor
electrical connections, damaged welding cables or exceed the welding cable
current rating as this will produce excessive heat and may cause a fire.
• Always wear the correct protective clothing for protection from sparks, molten
particles and arc rays.
• When welding in confined spaces, always ensure adequate ventilation and
constant observation of the operator.
• Keep combustible materials away from the welding area. Have a suitable fire
extinguisher close by.
• Never watch the welding arc with naked eyes. Always use and wear a welding
mask fitted with the correct filter lens.
• Do not stand on damp ground when welding. For more complete safety advice
please read section 1.
2.06 Transporting Methods
This unit is equipped with handles mounted on front panel of power source.
If using a fork lift vehicle, place and secure unit on a suitable pallet before transporting.
If using an overhead crane, ensure correct slings are used before lifting.
2.07 Protective Filter Lenses
Protective filter lenses are provided to reduce the intensity of radiation entering the
eye thus filtering out harmful infrared, ultraviolet radiation and a percentage of the
visible light. Such filter lenses are incorporated within face shields. To prevent damage
to the filter lenses from molten or hard particles an additional hard clear glass or
special plastic external cover lens should be used. This cover lens should always be
kept in place and replaced before the damage impairs your vision while welding.
8
Approximate range of welding current
Up to 150
150-250
250-300
300-350
Over 350
Filter lens required for MIG
Shade 10
Shade 11
Shade 12
Shade 13
Shade 14
2.08 User Responsibility
This equipment will perform as per the information contained 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
appropriately qualified persons approved by Thermal Arc. Advice in this regard can be
obtained by contacting Thermal Arc.
This equipment or any of its parts should not be altered from standard specification
without prior written approval of Thermal Arc. The purchaser of this equipment shall
have the sole responsibility for any malfunction which results from improper use or
unauthorized modification from standard specification, faulty maintenance, damage or
improper repair by anyone other than appropriately qualified persons approve by
Thermal Arc.
2.09 Duty Cycle
The rated duty cycle of a welding Power Supply is the operating time it may be used at
its rated output current without exceeding the temperature limits of the insulation of the
component parts. To explain the ten minute duty cycle period the following example is
used. Suppose a welding Power Supply is designed to operate at 50% duty cycle, 250
amperes at 28 volts. This means that it has been designed and built to provide the
rated amperage (250A) at the rated load voltage (28V), for 5.0 minutes out of every 10
minute period (50% of 10 minutes is 5.0 minutes). During the other 5.0 minutes of the
10 minute period the Power Supply must idle and be allowed to cool. The thermal cut
out will operate if the duty cycle is exceeded.
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 personal injury and equipment damage.
9
SECTION 3: INSTALLATION RECOMMENDATIONS
3.01 Environment
The Fabricator 400II and Fabricator 450II are NOT designed for use in environments with
increased hazard of electric shock.
Examples of environments with increased hazard of electric shock are:• 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.
• 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.
• Wet or damp hot locations where humidity or perspiration considerably
reduces the skin resistance of the human body and the insulation properties of
accessories.
3.02 Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature between 0 degrees C and 40 degrees C.
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal corrosive gases, vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 300mm or more from the walls or similar that could
restrict natural air flow for cooling.
• The minimum ground clearance for these products is 130mm.
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.03 Electrical Input Connections
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.
Lockout/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.
10
3.04 Electrical Input Requirements
Operate the welding power source from a single or three-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.
Note
This unit is equipped with a three-conductor with earth power cable that is connected
at the welding power source end for three-phase electrical input power.
Do not connect an input (BROWN, BLUE or RED) conductor to the ground terminal.
Do not connect the ground (YELLOW/GREEN) conductor to an input line terminal.
Refer to Figure 3:
1
Connect end of ground (YELLOW/GREEN) conductor to a suitable ground.
Use a grounding method that complies with all applicable electrical codes.
2
Connect pramery power cable ends; line 1, line 2 and line 3 input conductors
to the de-energized line disconnect switch.
3
Use the below table as a guide to select line fuses for the disconnect
switch.
Input Voltage
Fuse Size
3Phase 400 VAC
32 Amps
Electrical Input Connections
Note
Fuse size are based on not more than 200 percent of the rated input amperage of the
welding power source (please refer beck to the local Electrical Codes).
Figure 3.
Electrical Input Connections
11
3.05 Input Power
Note
Note the available input power. Damage to the machine could occur if 460VAC or higher
is applied.
The following 400V Primary Current recommendations are required to obtain the
maximum welding current and duty cycle from this welding equipment:
Model
Primary Supply
Lead Size (Factory
Fitted)
Primary
Current Circuit Size
(Vin/Amps)
Fabricator 400II
Fabricator 450II
2.5 core 4mm sq
4 core 4mm sq
400V / 24A
400V / 43A
Max Current &
Duty Cycle
400 @ 30%
520 @ 20%
WARNING
Exceeding the duty cycle ratings will cause the thermal overload protection circuit to
become energized and shut down the output until the unit has cooled to normal
operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can cause damage to the welding power
source and will void the manufactures warranty.
NOTE
Due to variations that can occur in manufactured products, claimed performance,
voltages, ratings, all capacities, measurements, dimensions and weights quoted are
approximate only. Achievable capacities and ratings in use and operation will depend
upon correct installation, use, applications, maintenance and service.
12
3.06 Specifications
FABRICATOR 400II
FABRICATOR 450II
Mains Input Voltage
3ph 400V 50Hz
3ph 400V 50Hz
Mains protection rating
32A slow blow
32A slow blow
Maximum power consumption
16.7 kVA
28.5 kVA
Power factor cos φ
0.9
0.9
Current range I2
40A - 400A
60A - 520A
Open circuit voltage U20
19.9 - 46.6V
19.5 - 56.0V
Welding current l2
400A
InputS1 / current I1
16,7kVA/24,2A
Welding current l2
320A
InputS1 / current I1
12,4kVA/18,0A
Welding current l2
260A
InputS1 / current I1
9,5kVA/13,6A
Selection range (switched steps)
2 x 10
3 x 10
Supply voltage
24Vac
24Vac
Speed
1-19 m/min
1-19 m/min
Number of feed rolls
4
4
Spool + Spool weight
max 300 mm + 18 kg
max 300mm + 18 kg
Dimensions H x W x D
550 x 250 x 620 mm
550 x 250 x 620 mm
Protection
IP 21
IP 21
Insulation class
H
H
Standards
CE / EN 60 974-1 / EN 51099
CE / EN 60 974-1 / EN 51099
Weight
110kg
165kg
Dimensions H x W x D (fully assembled)
1360 x 370 x 760 mm
1400 x 470 x 770 mm
PRIMARY
SECONDARY
Duty
Cycle
30%
520A
Duty
Cycle
60%
400A
Duty
Cycle
100%
320A
25.5kVA/43.4A
16.8kVA/24.7A
12.0kVA/17.8A
Duty
Cycle
20%
Duty
Cycle
60%
Duty
Cycle
100%
WIRE FEEDER
SAFETY
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.
13
SECTION 4: OPERATOR CONTROLS
4.01 Fabricator Layout
Figure 4.
Power Source - Front
Power Source - Back
Wire Feed Unit - Back
Wire Feed Unit - Front
1. ON/OFF Switch This switch connects the Primary supply voltage to the power
supply when in the ‘ON’ position. This enables the Power Supply.
2. Coarse Voltage Control Switch The Coarse Voltage Control sets the voltage
level to the welding terminals as it is rotated in the clockwise direction. (2 position
switch on the Fabricator 400II and 3 position on the Fabricator 450II)
3. Fine Voltage Control Switch The Fine Voltage Control switch increases the
voltage (in smaller increments than the Coarse switch) as it is rotated in the
clockwise direction. (10 position switch on both the Fabricator 400II and 450II)
4. Negative Welding Terminals The negative welding current flows from the Power
Source via the heavy duty DINSE terminals to the Metal plate via an earth lead. It
is essential, that the male plug is inserted and turned securely to achieve a
sound electrical connection.
14
5. Positive Welding Output Terminal The positive welding current flows from the
Power Source via heavy duty DINSE terminal to the WFU via an interconnecting
lead. It is essential, that the male plug is inserted and turned securely to achieve
a sound electrical connection.
WARNING
Loose welding terminal connections can cause overheating and result in the male plug
being fused in the bayonet terminal.
6. Wirefeeder Control Socket outlet This 7 pin receptacle is used to connect a
Wirefeeder to the welding power Source circuitry: To make connections, align
keyway, insert plug, and rotate threaded collar fully clockwise. The socket
information is included in the event the supplied cable is not suitable and it is
necessary to rewire a plug.
Figure 5.
Pin 1 - 24Vac supply to WFU
Pin 2 - 0Vac
Pin 3 - Contactor return
Pin 4 - Thermal overload Signal
Pin 5 - Cooling error signal
Pin 6 - Welding voltage +
Pin 7 - Ground connection
7.
Primary Power Cable The input cable connects the Primary supply voltage to the
equipment, see Section 3.04 for electrical input requirements.
8.
Gas inlet The Gas Inlet connections is a 3/8 BSP male gas fitting supplied via the
gas hose on the interconnecting lead.
9.
Wirefeeder Control Socket inlet
10. Positive Welding Input Terminal The positive welding current flows from the
Power Source via heavy duty DINSE terminal into the WFU via the
interconnecting lead. It is essential, however, that the male plug is inserted and
turned securely to achieve a sound electrical connection.
11. Interconnecting cable securing clamp
12. Wirefeeder support Allows the operator to rotate the wire feed unit to suit his
application requirements.
13. Wirefeeder Wheel Carriage Allows wire feed unit to be moved freely on the floor.
14. Control Panel see section 5.01 for further information
15. Euro Torch Adaptor Euro torch connection that accepts Euro style MIG torches.
16. Water cooling outlets Quick fit connections for water outlet / return for a water
cooled mig torch (optional).
15
4.02 Power Source Features
Features
New Digital Control panel
Touch Panel Switches
Control Knob
Digital Volt and Ammeter
ON/OFF Switch
Description
All welding parameters are adjustable
Touch switches eliminates mechanical damage
For the selected parameter, rotating the knob clockwise
or anticlockwise increases or decreases the parameter.
- Displays selected weld parameter values
- Displays welding current when welding
- Displays welding voltage when welding
- Displays wire feed speed prior to welding
Primary voltage supply ON/OFF switch located on front
panel.
4.03 Control Panel Features
Figure 6.
Item
1
2
3
4
5
6
7
8
Description
Water cooling warning indicator
Thermal overload warning indicator
Digital meters
Control knob
Wire inch button
Gas purge button
Mode selector
Secondary parameter settings button
16
SECTION 5: UNDERSTANDING & SETTING UP FOR MIG WELDING
5.01 Control panel description
Figure 7.
1
Button
• Wire inch
• Default reset (together with button 2)
2
Button
• Gas test
• Default reset (together with button 1)
3
Button
• Switches between 2T and 4T
• Press and hold for 3 seconds, this will initiate spot or interval mode
• Enters secondary parameters (together with button 5)
4
LED
5
Button
• Enters secondary parameters (together with button 3)
6
2 Stroke
Display
• Amperage (real or required)
• Wire speed
• Secondary parameters:
17
-
ISP – initial speed (soft start) [%]
PrG – Pre gas time [s]
PoG – Post gas time [s]
brn – Burn back time [s]
SPo – Time of tack welding [s]
Int - Time of interval [s]
7
LED
Cooling circuit error
9
LED
Thermal overheating. Leave the machine on to cool down by
means of the fans.
10
Display
• Voltage (actual)
• Values of the secondary parameters
• Switches and choke settings
11
LED
4 Stroke
12
LED
Flashes – spot welding mode
Lights – Interval welding mode
13
Encoder
• Sets wire speed,
• Sets secondary parameters
5.02 Range of Parameters
POS.
PARAMETER
MIN
MAX
UNIT
P1
P2
Wire speed
Time of spot
1
0,5
19
20
m/min
s
P3
Time of delay
0,5
20
s
P4
Initial wire speed
10
100
%
P5
Burn-back time
0
0,75
s
P6
Pre-gas
0
20
s
P7
Post-gas
0
20
s
18
5.03 Wire Feed Description
Figure 8.
Pos.
Description
1
Pressure roll
2
Fixing lever
3
Motor
4
Inlet liner
5
EURO connector
6
Fixing cup
7
Roll
8
Gear wheel
5.04 Feed Roll Information
Figure 9.
PS 4(W)
4-rolls
a
Grove type
Steel
Aluminium
Flux cored
b
Wire diameter
a = 22 mm
b = 30 mm
Item No
0,6-0,8
1,0-1,2
1,2-1,6
0,8-1,0
1,2-1,6
1,6-2,0
1,0-1,2
1,6-2,0
U45806
U45810
U45812
U45820
U45822
U45826
U45830
U45832
Rollers are sold indivdualy
5.05 Spool Holder Description
Figure 10.
Pos.
1
2
3
19
Description
Fixing nut
Brake bolt
Inlet (optional)
SECTION 6: GETTING STARTED
6.01 Torch Connection
Fit the MIG Torch (2) to the Euro adaptor (1) by pushing the torch connector into the
brass torch adaptor and screwing the plastic torch nut clockwise to secure the torch to
the torch adaptor. Remove the contact tip from the torch handset.
If a water cooled system is in use then connect the coolant connections (5) of the
torch with the sockets (3) and (4). Connect the red fitting together and the blue fittings
together.
Figure 11.
6.02 How to connect the work lead
Connect the work lead (7) to one of the two Negative connections (6) and fasten it by
turning the connector to the right. Connect the Work clamp (2 - figure 13) to the work
piece or at the welding table.
Figure 12.
6.03 Where to connect the work clamp
Fasten the Work clamp near the welding location, this avoids stray current flow
through mains earthing system.
20
Figure 13.
Connect the Work clamp tightly to the welding bench or to the work piece.
WARNING
Do not place the Work clamp on the welding machine or gas cylinder as welding
current may conducted via the mains earth and could cause the primary power cable
to burn out.
6.04 How to connect to the mains
Insert the mains plug into a suitable 3x400 V mains socket. The supply fuses or circuit
breaker should correspond to the technical data in section 3.
Switch the machine on by the main switch (Fig. 4, pos. 1)
The machine will then enter the manual program and on the left display will be the
wire speed in m/min.
6.05 How to fit the wire spool
Open the wire feed compartment lid on the machine or wire-feed case and un-screw
the nut (11) from the wire support coil hub (9).
Place wire spool on the hub (9) and ensure that the drive dog-pin (8) engages the
mating hole in the wire spool.
Press then release the inch switch
(located on the control panel) to adjust the
brake (10), the wire spool should not continue to run on when the feed motor stops.
Figure 14.
6.06 Inserting the wire
Un-screw the contact tip in the MIG torch
Open the wire feed compartment lid on the machine or wire-feed case.
Cut off the curved or damaged end of welding wire and feed it through the inlet guide
(Fig. 15, pos. 14). The diameter of the wire should correspond to the diameter of the
feedrolls. The wire size is on the face of the feedrolls.
21
Open the pressure lever (12) and thread the wire through the inlet guide (14) past the
rollers and then through the outlet guide (15).
Put the pressure roll down ensuring that the teeth of the gears fit together and fix by
setting the lever (12) into vertical position.
Adjust the pressure so that it provides constant movement. Do not over tighten
pressure arm setting as damage to motor gearbox may occur.
Figure 15.
Switch ON machine at main ON/OFF switch, stretch torch cable out straight and press
the inch button switch
on the wire feed front panel. Adjust the pressure at the
pressure adjustment screws (12) so the wire-feed rolls drive the wire consistently
without slipping. The wire should not be deformed.
Figure 16.
Adjust the pressure adjustment (12) next to the inlet guide (14) to a lower pressure
less then the pressure adjustment (12) next to the outlet guide (15), this will ensure
that the wire will be locate correctly in the wire-feed unit.
Press the inch switch
till the wire appears approximately 20 mm out of the torch
neck. Screw in the contact tip corresponding to the wire diameter and cut off the wire
stick out.
22
6.07 How to connect the gas cylinder
If the Power Source Wheel Kit is fitted, position a gas cylinder on the rear tray and lock
secruely to the Power Source cylinder bracket with the chains provided. If this
arrangement is not used then ensure that the gas cylinder is secured to a building pillar,
wall bracket or otherwise securely fixed in an upright position.
Open the gas valve once to blow out possible dirt particles.
Connect the gas regulator to the gas cylinder valve.
Connect the gas hose to the gas regulator.
Open the gas cylinder valve and adjust the gas flow on the gas regulator while
pressing the gas purge button
on the wire feeder control panel, The flow rate will
be shown at the flowmeter. This should be approximately wire diameter x 10 l/min.
6.08 How to configure the machine for aluminium welding
Change the feedrolls to U groove for aluminium wire.
Change the torch liner to a nylon or teflon liner.
Remove the capillary tube (23) at the central connection.
Cut the teflon liner close to the end of the feedroll and pull the brass tube over the
teflon liner with the corresponding length to stabilise it.
Fasten the torch and thread in the wire electrode.
NOTE
The parts required for the torch depends on the type torch and wire diameter. Please
refer to the torch spare list.
Figure 17.
Pos
2
19
20
21
22
23
16
Description
Central connection
Nipple for 4.0 mm and 4.7 external diameter
O-ring 3,5 x 1.5 mm to prevent gas outlet
liner nut
Nylon or Teflon liner
Support tube for nylon or teflon liner with 4 mm OD, it substitute the outlet
guide in the central connection (16). A 4.7 mm diameter liner does not
require the support tube is required.
Feedroll
23
SECTION 7: OPERATION
7.01 Setting welding current and voltage
When the wire had been installed and gas had been set it is possible to start welding.
The appliance must be plugged into the mains, the main switch (Fig. 4, Page 14) in the
"I" position, and the green LED will illuminate.
To select the voltage use step switches (Fig. 4, Page 14).
To select the current (that is linked to the wire speed) use potentiometer encoder (Fig.
7, Page 14).
7.02 Welding modes
The Fabricator torch operator controls work in four modes:
• Continuous two stroke (2T)
• Continuous four stroke (4T)
• Spot welding
• Interval welding
7.03 Secondary parameters
If necessary, it is possible to change the secondary parameters:
Initial wire speed (soft start)
Pre gas time
Post gas time
Burn back time
Time of spots (tack or interval welding)
Time of intervals (interval welding)
ISP
PrG
PoG
brn
SPo
Int
Press buttons 3 and 5 at the same time for at least (3s)
On left display will appear ISP. On the right display will appear value of the chosen
parameter.
By means of the Encoder you can change the parameter.
to select the next parameter. When you press the button 3, the
Use the button 3
value of the previous parameter had been stored.
24
7.04 Two stroke
Press the button 3
(2T/4T) and select the LED 4
. Welding procedure starts
by pressing the button in the torch handle. It is necessary to keep the torch button
pressed all the time during welding. The welding stops by releasing the torch button.
Figure 18.
1 - 1st stroke – pressing the torch button
2 - 2nd stroke – releasing the torch button
7.05 Four stroke
Press the button 3
(2T/4T ) and select the LED 4
The four stroke mode is
being used mostly for long welds, when there is no need to hold the torch button
pressed. The welding procedure start by pressing the torch button; after releasing the
torch button the welding continues. The welding stops after the second pressing and
releasing the torch button then.
Figure 19.
1 - 1st stroke – pressing the torch button
3 - 3rd stroke – pressing the torch button
2 - 2nd stroke – releasing the torch button
4 - 4th stroke – releasing the torch button
25
7.06 Spot and stitch welding
Keep pressing the button 3 for at least (3s)
(2T/4T)
If led LED 12
continuously lights the spot mode has been selected. If led 12
flashes the interval mode has been selected.
You can have spot or interval welding both in stroke and in 4 stroke mode (by means
of short pressing the button 3
- LEDs 4
and 11
indicate the mode.
To get out of this mode, keep pressing the button '3' for more than 3 seconds.
The spot welding mode is being used for welding short welds of the same length. The
pressing the torch button activates the time circuit that starts and end the welding
procedure. This mode is available in 2T or 4T mode.
Figure 20.
1
- 1st stroke – pressing the torch button
2
- 2nd stroke – releasing
The interval welding mode is being used for welding repeated short welds of the same
length of welding time and the pause time. By pressing the torch button activate the
time circuit that starts and end the welding procedure. This mode is available in 2T or
4T mode.
Figure 21.
1
- 1st stroke – pressing the torch button
2
26
- 2nd stroke – releasing the torch button
SECTION 8: BASIC WELDING TECHNIQUE
8.01 Setting of the Fabricator
The Fabricators Power Source has two control settings that have to balance. These are
the Wirespeed control and the Voltage Control switches. 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 welding current level,
but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little
change in welding current.
When changing to a different electrode wire diameter, different control settings are
required. A thinner electrode wire needs more Wirespeed to achieve the same current
level.
A satisfactory weld cannot be obtained if the wirespeed and voltage switch settings
are not adjusted to suit the electrode wire diameter and 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 electrode wire, causing spatter. The
correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit
and heard by a smooth regular arc sound.
8.02 Position of MIG Torch
MIG torch angle to the weld has an effect on the width of the weld run. Refer to figure
17.
Figure 22.
8.03 Distance of the MIG Torch Nozzle to the Work Piece
The electrode stick out from the MIG Torch nozzle should be between 2.0mm (5/64”)
and 5.0mm. (13/64”) This distance may vary depending on the type of joint that is being
welded.
8.04 Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the
welding run.
8.05 Electrode Wire Size Selection
The choice of electrode wire size in conjunction with shielding gas used depends on:
a) Thickness of the metal to be welded,
b) Type of joint,
27
c) Capacity of the wire feed unit and power Source,
d) The amount of penetration required,
e) The deposition rate required,
f) The bead profile desired,
g) The position of welding and
h) Cost of the electrode wire.
Weld metal deposition rate is proportional to current density. Current density is defined
as the current per cross sectional area of the electrode wire and is normally expressed
as amps per mm2. An example is tabled below.
Electrode Wire
Current Density
Deposition Rate
Current (Amps)
Size
(Amps/mm2)
(kg/hour)
0.9mm (.035”)
200
314
3.2
1.2mm (.045”)
200
177
2.8
The table above - 0.9mm (.035”) / 1.2mm (.045”) wire deposition rate
This demonstrates that where the upper limit of current is limited by machine capacity
and duty cycle, higher deposition rates and therefore greater productivity will be
achieved by using smaller electrode wire. The Fabricatoria a particularly efficient MIG
welder with 0.9mm steel wire in spray tranfer mode.
Higher current density (or smaller diameter wire) also gives deeper penetration as
shown Figure 23.
0.9 mm (.035")
1.2mm (.045")
Figure 23.
Penetration comparison using the same current (200A) for both electrodes Figure 23 Wire penetration comparison
8.06 Stitch Welding Operation
Stitch welding is normally used to bridge excessive gaps between panels or when
welding very thin material to prevent heat build up and distortion.
Please refer to section 7.06 for Stitch function control.
8.07 Spot Welding Operation
Fit a spot welding nozzle to the MIG Torch for consistent spot welding operations.
The Fabricator will operate effectively using 0.8mm welding wire when
spot welding. Penetration depth is limited when using 0.6mm welding wire for
spot welding.
Please refer to section 7.06 for Spot welding control.
28
SECTION 9: ROUTINE MAINTENANCE & INSPECTION
The only routine maintenance required for the Fabricator range of machines is a
thorough cleaning and inspection, with the frequency depending on the usage and the
operating environment.
WARNING
Disconnect the FABRICATOR from the Mains supply voltage before disassembling.
Special maintenance is not necessary for the control unit parts in the Power Source
and Wirefeeder. If these parts are damaged for any reason, replacement is
recommended.
CAUTION
Do not blow air into the Power Source / Wirefeeder during cleaning. Blowing air into
the Power Source / Wirefeeder can cause metal particles to interfere with sensitive
electronic components and cause damage to the Power Source / Wirefeeder.
To clean the Power Source / Wirefeeder, disconnect it from the mains supply voltage
then open the enclosure and use a vacuum cleaner to remove any accumulated dirt
and dust. The Power Source / Wirefeeder should also be wiped clean. If necessary,
solvents that are recommended for cleaning electrical apparatus may be used.
WARNING
Do not attempt to diagnose or repair unless you have had training in electronic
measurement and troubleshooting techniques.
Troubleshooting and repairing of Fabricator 400II and 450II welding equipment should
only be carried out only by suitably qualified or competent person.
A ‘competent person’ must be a person who has acquired through training, qualification
or experience, or a combination of them, the knowledge and skills enabling that person
to safely carry out a risk assessment and repairs to the electrical equipment in question.
The person carrying out the servicing needs and repairs must know what to look at, what
to look for and what to do.
29
SECTION 10: BASIC TROUBLESHOOTING
Basic level of troubleshooting is that which can be performed without special
equipment or knowledge, and without removing the covers from the Power Source /
Wirefeeder.
If major components are faulty, then the Power Source / Wirefeeder should be
returned to your local THERMAL ARC Distributor for repair.
Solving Problems beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at
the wire spool then work through to the MIG torch. There are two main areas where
problems occur with MIG Equipment:10.01 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:
1
Gas cylinder contents and flow
Ensure that the gas cylinder is not empty
meter.
and the flow meter is correctly adjusted to
15 litres per minute.
2
Gas leaks
Check for gas leaks between the
regulator/cylinder connection and in the
gas hose to the Power Source.
3
Internal gas hose in the Power
Ensure the hose from the solenoid valve
to Source. The Mig torch adaptor has not
fractured and that it is connected to the
Mig torch adaptor.
4
Welding in a windy environment.
5
Welding dirty, oily, painted,
oxidised or greasy plate.
6
Distance between the MIG torch
nozzle and the work piece
Maintain the MIG torch in good
working order
7
Shield the weld area from the wind or
increase the gas flow.
Clean contaminates off the plate
Keep the distance between the MIG torch
nozzle and the work piece to a minimum.
Ensure that the gas holes are not
blocked. and gas is exiting out of the
torch nozzle.
Do not restrict gas flow by allowing
spatter to build up inside the Mig torch
nozzle.
Check that the MIG torch O-rings are not
damaged
WARNING
DISENGAGE THE DRIVE ROLL WHEN TESTING FOR GAS FLOW BY EAR.
30
10.02 Inconsistent wire feed
Wire feeding problems can be reduced by checking the following points:
1
Wire spool brake is too tight
Feed roller driven by motor in the cabinet
will slip.
2
Wire spool brake is too loose
Wire spool can unwind and tangle.
3
Worn or incorrect feed roller size
Use 'U' groove drive feed roller matched
to the aluminium wire size you are
welding.
Use 'V' groove drive feed roller matched
to the steel wire size you are welding.
Use ‘knurled V’ groove drive feed roller
matched to the flux cored wire size you
are welding.
4
Mis-alignment of inlet/outlet guides Wire will rub against the mis-aligned
guides and reduces wire feedability.
5
Liner blocked with swarf
Swarf is produced by the wire passing
through the feed roller, if excessive
pressure is applied to the pressure roller
adjuster.
Swarf can also be produced by the wire
passing through an incorrect feed roller
groove shape or size.
Swarf is fed into the liner where it
accumulates thus reducing wire
feedability
6
Incorrect or worn contact tip
The contact tip transfers the weld current
to the electrode wire. If the hole in the
contact tip is to large then arcing may
occur inside the contact tip resulting in
the electrode wire jamming in the contact
tip
When using soft electrode wire such as
aluminium it may become jammed in the
contact tip due to expansion of the wire
when heated. A contact tip designed for
soft electrode wires should be used.
7
Poor work lead contact to work
If the work lead has a poor electrical
piece
contact to the work piece then the
connection point will heat up and result in
a reduction of power at the arc.
8
Bent or Mis-Shaped liner
This will cause friction between the wire
and the liner thus reducing wire
feedability
31
10.03 Welding Problems
FAULT
Undercut.
CAUSE
A. Welding arc voltage
too high.
B. Incorrect torch angle
C. Excessive heat input
REMEDY
A. Reduce voltage by reducing
the voltage selection switches
position or increase the wire
feed speed.
B. Adjust angle
C. Increase the torch travel
speed and/or reduce welding
current by reducing the voltage
selection switches position or
reducing the wire feed speed.
2
Lack of
penetration.
A. Welding current too
low
B. Joint preparation too
narrow or gap too tight
C. Shielding gas
incorrect
A. Increase welding current by
increasing wire feed speed
and increasing voltage
selection switch position.
B. Increase joint angle or gap
C. Change to a gas which
gives higher penetration
3
Lack of fusion.
Voltage too low
4
Excessive spatter.
A. Voltage too high
B. Voltage too low
Increase voltage by increasing
voltage selection switches
position.
A. Lower voltage by reducing
the voltage selection switches
or increase wirespeed control.
B. Raise voltage by increasing
the voltage selection switches
or reduce wirespeed control.
5
Irregular weld
shape.
A. Incorrect voltage and
current settings.
Convex, voltage too low.
Concave, voltage too
high.
B. Wire is wandering
C. Incorrect shielding
gas
D. Insufficient or
excessive heat input
1
32
A. Adjust voltage and current
by adjusting the voltage
selection switches and the
wirespeed control.
B. Replace contact tip
C. Check shielding gas.
D. Adjust the wirespeed
control or the voltage selection
switches.
10.03
Welding Problems (continued)
6
FAULT
Weld cracking.
CAUSE
A. Weld beads too small
B. Weld penetration
narrow and deep
C. Excessive weld
stresses
D. Excessive voltage
E. Cooling rate too fast
7
Cold weld puddle.
A. Faulty rectifier unit
B. Loose welding cable
connection.
C. Low Primary Voltage
8
Arc does not have
a crisp sound that
short arc exhibits
when the wirefeed
speed and voltage
are adjusted
correctly.
The MIG torch has been
connected to the wrong
voltage polarity on the
front panel.
10.04
1
2
3
REMEDY
A. Decrease travel speed
B. Reduce current and voltage
and increase Mig torch travel
speed or select a lower
penetration shielding gas.
C. Increase weld metal
strength or revise design
D. Decrease voltage by
reducing the voltage selection
switches.
E. Slow the cooling rate by
preheating part to be welded
or cool slowly.
A. Have an Accredited
THERMAL ARC Service Agent
to test then replace the faulty
component.
B. Check all welding cable
connections.
C. Contact supply authority
Connect the MIG torch to the
positive (+) welding terminal
for solid wires and gas
shielded flux cored wires.
Refer to the electrode wire
manufacturer for the correct
polarity.
Power Source Problems
FAULT
Indicator light is
ON but welding
arc can not be
established.
Mains supply
voltage is ON.
Indicator light is
not lit and welding
arc can not be
established.
Mains indicator
light is not lit but
welding arc can be
established.
CAUSE
Voltage switch in
standby position.
A. Primary fuse is
blown.
B. Broken connection in
primary circuit.
Indicator light is open
circuit.
33
REMEDY
Switch the voltage selection
switches to a welding
setting.
A Replace primary fuse. Have
B an Accredited THERMAL
ARC Service Agent check
primary circuit.
Have an Accredited
THERMAL ARC Service
Agent replace Indicator
light.
10.04 Power Source Problems (continued)
FAULT
CAUSE
4 Mains supply voltage is Torch trigger switch
ON and Indicator light is leads are disconnected.
lit but when the torch
trigger switch is
depressed nothing
happens.
REMEDY
Reconnect.
5 Mains supply voltage is
ON, no wire feed but gas
flows from the MIG Torch
when the torch trigger
switch is depressed.
A. Electrode wire stuck
in conduit liner or
contact tip (burn-back
jam).
B. Faulty control PCB
A. Check for clogged / kinked
MIG Torch conduit or worn
contract tip. Replace faulty
component(s).
B. Have an Accredited
THERMAL ARC Service Agent
investigate the fault.
6 Wire feeds when the
torch trigger switch is
depressed but arc can
not be established.
Poor or no work lead
connection.
Clean work clamp area and
ensure good electrical contact.
7 Wire continues to feed
when the torch trigger
switch is released.
The Mode Selection has
been set to 4T (latch
operation).
Set the Mode Selector Switch
has been set to 2T (normal
operation).
8 Jerky wire feed
A. Worn or dirty contact
tip
B. Worn feed roll.
C. Excessive back
tension from wire reel
hub.
D. Worn, kinked or dirty
conduit liner
A. Gas hose is cut.
B. Gas passage
contains impurities.
C. Gas regulator turned
off.
A. Replace contact tip
B. Replace feed roll
C. Reduce brake tension on
spool hub
D. Clean or replace conduit
liner
Gas valve has jammed
open due to impurities in
the gas or the gas line.
Have an Accredited
THERMAL ARC Service Agent
repair or replace gas valve.
9 No gas flow
10 Gas flow continues
after the torch trigger
switch has been
released.
34
A Replace or repair.
B Disconnect gas hose from
the rear of FABRICATOR or
wirefeeder then raise gas
pressure and blow out the
impurities.
C Turn on.
Page left blank intentionally
35
SECTION 11: SPARE PARTS
11.01 Parts Description Fabricator 400II
Figure 24.
36
11.01 Spare part numbers Fabricator 400II
FAB 400II
G1
G2
G3
G4
G5
G6
G7
G8
G9
G10
G11
G12
G13
G14
G15
G16
G17
G18
G19
G20
G21
G22
G23
G24
G25
G26
G27
G28
G29
G30
G31A/B
G32
G33
G34
G35
G36
G37
G38
G39
G40
G41
G42
G43
FAB3598
FAB3599
FAB3467B
FABVS040372
FAB3253-1
FABVM0048
FABVM0024
FAB2446
FAB3461
FAB2295-1
FAB3252
FABAO-20610
FABVS040258
FAB277136
FAB2015
FAB1343
FAB1835-1
FAB4165
FABT40.P
FAB3270-4Z
FAB1538-1
FAB4172
FAB1005
FAB2285-1
FAB2285
FAB3293
FAB2626
FAB2036
FABVM0198
FABV0044B
FABV0249B = G31A
FABV0001
FABV0042
FABV0040B
FABV0047B
FABV0043B
FABV0041
FABV0011
FABV0005
FABV0018
FABV0015
FABV0013
FABV0012
Handle - Holder L
Handle - Holder R
Wire Feed Holder
Clamp for Interconnecting Lead
Front Wheel (Castor)
Mains Cable 32A 4 x 2.5
Earthing cable 3 m 400A 35-50
Rear wheel 200x50x20
Fan Cover
Filter FC 61113
Filter FZ 730 43
Quick Connector 35-70 Panel Socket
Chain 70 cm
Contactor (24V/50Hz)
Knob arrow (fine/ course switch)
Knob (on/off switch)
Thermostat 115 C
Choke
Main Transformer + Switch + TERMINAL
Transformer Aux with filter
Rectifier
Fan
Switch ON/OFF
Clamp Nut (Mains Cable)
Clamp Body (Mains Cable)
Input Terminal board 1916
Switch VS16 12510010A1 (10pos) Fine
Switch VS16 2253A8 (3pos) Course
Bundle (Wire Loom)
Side Panel
FABV0250B = G31B
Split side panels
Base Panel
Central Support Panel
Front Panel
Front Panel Cover
Top Panel (Power Source)
Rear (Back) Panel
Holder gas bottle
Carriage unit
Strut
Tube of handle
Support of choke
Tube of carriage unit
1
1
1
1
2
1
1
2
2
1
3
3
2
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
Please note: If your machine does not have G31A/B split side panels fitted but a single piece side panel
then the part number for the single side panel is FABV0045B
37
11.02 Parts description Fabricator 450 II
Figure 25.
38
11.02 Spare part numbers Fabricator 450II
FAB 450II
Position Item No Description G1
G2
G3*
G4
G5
G6
G7
G8
G9
G10
G11
G12
G13
G14
G15
G16
G17
G18
G19
G20
G21
G22
G23
G24
G25
G26
G27
G28
G29
G30
G31
G32
G33
G34
G35
G36
G37
G38
G39
G40
G41
G42
FABVM0025
FABVM0104
FAB4142-1Z
FAB2671-1
FABVM0236-1
FABT51WSK.TERP
FAB3293
FAB277264
FAB4172
FAB3461
FABVS040258
FABVS040372
FAB3646
FAB3467B
FAB1141
FAB2015
FAB1005
FAB2295-1
FAB2549
FABAO-20610
FAB3598
FAB3599
FAB4122
FAB3254-1
FAB3252
FAB1831
FAB2631
FABV0074
FABV0075
FABV0076
FABV0077B
FABV0078B
FABV0079B
FABV0080
FABV0081B
FABV0083
FABV0084
FABV0085
FABV0086
FABV0087
FABV0089
FABV0092B
Earthing cable 3 m 500 A 50-70
Mains Cable 4 x 4mm2
Transformer Aux with filter
Rectifier
Bundle (Wire Loom)
Transformer + Switch + TERMINAL
Input Terminal board 1916
Contactor (24V/50Hz)
Fan
Fan Cover
Chain 70 cm
Clamp for Interconnecting Lead
Choke
Wire Feed Holder
Knob (fine/course switch)
Knob (on/off switch)
Switch ON/OFF
Filter FC 61113
Outlet GP16
Quick Connector 35-70 Panel Socket
Handle - Holder L
Handle - Holder R
Rear wheel 250x50x20
Front Wheel (Castor)
Filter FZ 730 43
Switch VS32 1353S8 (3pos) Course
Switch VS32 12510010 (10pos) Fine
Holder gas bottle lower
Holder gas bottle upper
Base Panel
Side Panel
Side Panel
Front Panel
Rear (Back) Panel
Top Panel (Power Source)
Support WS
Carriage unit WS
Support crane eye front
Support crane eye back
Handle Bar
Holder rectifier
Front panel cover
39
Quantity
1
1
1
1
1
1
1
1
3
3
2
1
1
1
2
1
1
1
1
4
1
1
2
2
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11.03
Wire Feed Unit Parts Description + Spare Part Numbers
Figure 26.
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
F33
F34
F35
F36
FAB2917
FAB2532
FAB3598
FAB3599
FAB3467A
FAB4212
FABVS040373
FAB2164
FABBG-90625
FAB3440
FABR0141
FAB4121
FAB3979.d
FAB4171
FABK910
FAB711P001206
FAB2557
FAB2681
FABVM0112.YQ
FABVM0082
FAB302P010000
FAB4220
FAB177.0003
FABV0053B
FABV0052
FABV0055
FABV0060B
FABV0058
FABV0056
FABV0065B
FABV0054
FABV0222B
FABV0223B
FABV0057
FABVS040329
FABR2000
Shunt 400A 60mV
Spool Holder Black
Handle – Holder L
Handle - Holder R
Feeder holder
Facia panel new HS4615
Isolation of shunt
Knob 28N6+Red cover, washer
Euro Connector (Brass)
Euro Cover (Black)
Nut G1/4 + insulation for valve 2557
Hinge O430-30 M5
PC Board
Feed Motor / Gearbox
Adapter up to 18 kg
Connector TKB 50-70
Solenoid Valve 24V 50Hz
Lock (side panel)
Shunt Loom
Cables
Gas Hose 4,9x1,5
Wire Feed Unit Handle
Quick Connector. (Water Outlets)
Front Panel
Back Panel
Base panel
Fixed Side Panel WFU
Case regulator PS
Bottom wheel kit
Front panel (for PCB)
Support PS
Side Panel WFU (opening)
Top Panel
Handle Bar
M12x100 with clamber G1/8
Washer Al M10/14x1mm FABORY45191
40
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
2
2
11.04
Water Cooler Parts Description + Spare Parts List.
Figure 27.
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
F23
F35
F36
F37
F38
FAB2457
FAB4131
FAB4132
FAB3490
FABV9040171-1
FABVS040323
FAB2252
FAB3624
FAB2578
FAB2577
FAB2546
FABVM0239
FABV0069
FABV0070
FABV0071
FABV0072
FABV0073
FAB177.0003
FABVS040329
FABR2000
FABR558
FABR557
Pump MTP-600 with plastic cover
Heat Exchanger
Tank with the Cap
Fitting GES 8/R 1/4
Pressure Switch Adaptor
Adaptor W M12x100
Pressure switch 5611 1/8 G
Fan A2175 HBL-TC GN
Outlet 11 Gland
Outlet 11 Body
Clamp 8-12 Gemi
Hose Set ATA WS HD
Side WS cooling unit
Case WS cooling unit
Cover upper WS cooling unit
Support of heat exchanger WS cooling unit
Ground WS cooling unit
Quick Connector. G1/8 AG
Adaptor W M12x100 with clamber G1/8
Washer Al M10/14x1mm FABORY45191
Sticker blue circle for C-H
Sticker red circle for C-H
41
1
1
1
2
1
2
1
1
1
1
10
1
1
1
1
1
1
2
2
2
2
2
11.05
Wire Feed Motor/Gearbox Parts Description + Spare Part Numbers
Figure 28.
Item Number Part Number
FAB4171
Description
Wire Drive Complete with Motor
1
FAB4238
Motor / Gearbox
2
FABHFA-002
Pressure Arm Complete
3
FABHF404-00-05
Wire feeder body (Casting)
4
FABHFA-001
Fixing Arm Complete
5
FABHF401-00-07
Pivot
6
FABHF404-01-04Z
Gear Wheel
7
FABGB
Gusset for roll - parallel key (woodruff key)
8
See fig 9. Page 19
Roller
9
FABHF401-01-11
Fixing Cap
10
FABHF404-00-12
FABHF404-01-05
Cover
11
Gear Wheel (Drive)
42
SECTION 12:
MACHINE SCHEMATICS
12.01 Power Source Schematic for the FABRICATOR 400 II
Figure 29.
43
12.02 Power Source Schematic for the FABRICATOR 450 II
Figure 30.
44
12.03 Wire Feed Unit Schematic
Figure 31.
45
SECTION 13:
OPTIONAL ACCESSORIES
Part No.
Description
A.028
VM0263
VM0266
VM0267
Water Cooler c/w fittings
1m Interconnecting cable assy (air cooled)
5m Interconnecting cable assy (air cooled)
10m Interconnecting cable assy (air cooled)
VM0264
VM0265
VM0268
1m Interconnecting cable assy (water cooled)
5m Interconnecting cable assy (water cooled)
10m Interconnecting cable assy (water cooled)
U45806
U45810
U45812
U45820
U45822
U45826
U45830
U45832
0.6/0.8mm
1.0/1.2mm
1.2/1.6mm
10/1.2mm
1.2/1.6mm
1.6/2.0mm
1.0/1.2mm
1.2/1.6mm
Hard Wire V Groove Feed Roll
Hard Wire VGroove Feed Roll
Hard Wire VGroove Feed Roll
Soft Wire UGroove Feed Roll
Soft Wire U Groove Feed Roll
Soft Wire U Groove Feed Roll
Cored Wire V Groove Feed Roll
Cored Wire VGroove Feed Roll
46
Page left blank intentionally
47
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX:
(636) 728-3010
Email: [email protected]
www.thermalarc.com
48
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