Fabricator 210 Operator Manual

Fabricator 210 Operator Manual
210
®
FABRICATOR
MIG WELDING MACHINE
Art # A-07360
Operating Manual
Revision No: AC.02
Operating Features:
Issue Date: April 27, 2006
250
208
V
Manual No.: 0-4855
230
V
60 HZ
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
1-800-752-7621, or visit us on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid
potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.
We distinguish ourselves from our competition through 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 210 MIG Welding Machine
Instruction Manual Number 0-4855 for:
Package System Part Number 100047B-001
Power Source Part Number 707222
Published by:
Thermadyne Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
©Copyright 2006 by
Thermadyne Industries Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: April 27, 2006
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01
1.02
1.03
1.03
1.04
1.05
1.07
Arc Welding Hazards ...................................................................................... 1-1
Principal Safety Standards ............................................................................. 1-4
Symbol Chart ................................................................................................. 1-5
Precautions De Securite En Soudage à L’arc .................................................. 1-6
Dangers Relatifs au Soudage à L’arc .............................................................. 1-6
Principales Normes De Securite ..................................................................... 1-9
Graphique de Symbole ................................................................................. 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10
How To Use This Manual ................................................................................ 2-1
Equipment Identification................................................................................. 2-1
General Information ....................................................................................... 2-2
Safety ............................................................................................................. 2-2
Protective Filter Lenses .................................................................................. 2-2
User Responsibility ........................................................................................ 2-2
Duty Cycle ...................................................................................................... 2-3
Specifications ................................................................................................. 2-3
Included Items ............................................................................................... 2-5
Optional Accessories ...................................................................................... 2-5
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
3.12
3.13
3.14
3.15
3.16
Environment ................................................................................................... 3-1
Location ......................................................................................................... 3-1
Ventilation ...................................................................................................... 3-1
Input Power Requirements ............................................................................. 3-2
Alternative Mains Supply Voltages ................................................................. 3-2
Quick Setup .................................................................................................... 3-3
Installation of Shielding Gas (GMAW) Process .............................................. 3-4
Attaching the Gun and Cable Assembly to the Power Source ......................... 3-7
Input And Output Wire Guide Installation ....................................................... 3-9
Selection and Installation of Feedrolls ............................................................ 3-9
Installing Wire Spool .................................................................................... 3-10
Inserting Wire into the Feedhead .................................................................. 3-11
Wirefeeder Drive Roller Pressure Adjustment .............................................. 3-12
Wire Reel Hub Brake .................................................................................... 3-12
Spool Gun Attachment ................................................................................. 3-13
Polarity Changeover ..................................................................................... 3-14
TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Power Supply Controls, Indicators and Features ............................................ 4-1
4.02 Weld Mode Selector ....................................................................................... 4-4
4.03 TWECO Weldskill 250 AMP Weld Gun ............................................................ 4-6
4.04 Installing A New Wire Conduit ........................................................................ 4-7
4.05 MIG Gun Maintenance .................................................................................... 4-8
4.06 Basic Welding Technique ................................................................................ 4-8
4.07 Stitch Welding Operation .............................................................................. 4-10
4.08 Spot Welding Operation ............................................................................... 4-11
4.09 Gas Selection for Gas Metal Arc Welding ..................................................... 4-12
4.10 Welding Setting Selection Guide .................................................................. 4-14
SECTION 5:
MAINTENANCE & TROUBLESHOOTING .......................................................... 5-1
5.01 Routine Maintenance & Inspection................................................................. 5-1
5.02 Basic Troubleshooting .................................................................................... 5-3
5.03 Solving Problems Beyond the Welding Terminals .......................................... 5-3
5.04 Welding Problems .......................................................................................... 5-5
5.05 Power Supply Problems ................................................................................. 5-7
APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES ...................................... A-1
APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM ................................................... A-2
APPENDIX 3: FEEDROLL KITS ........................................................................... A-4
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
FABRICATOR 210
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01
Arc Welding Hazards
7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
WARNING
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill.
11. Do not touch electrode while in contact with the work (ground)
circuit.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power
is on. In 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.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
1. Do not touch live electrical parts.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
April 27, 2006
1-1
FABRICATOR 210
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
WARNING
FUMES AND GASES can be hazardous to your health.
1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
2. Do not weld where flying sparks can strike flammable material.
1. Keep your head out of the fumes. Do not breath the fumes.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator.
5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Electrode Size
Filter
2
3 or 4
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
4 or 5
5 or 6
6 or 8
10
12
14
Welding or cutting
Electrode Size
Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
Filter
11
12
12
12
12
12
12
14
9
12
14
April 27, 2006
FABRICATOR 210
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged.
4. Do not overfill tank — allow room for fuel to expand.
Shielding gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
WARNING
MOVING PARTS can cause injury.
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.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
3. Keep cylinders away from any welding or other electrical circuits.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
6. Turn face away from valve outlet when opening cylinder valve.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
WARNING
Engines can be dangerous.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
WARNING
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.
4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas.
5. Observe correct polarity (+ and –) on batteries.
April 27, 2006
1-3
FABRICATOR 210
1.02
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
!
WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume of scientific
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields and interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results
are complex. Current scientific understanding does not yet allow us
to interpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1-4
April 27, 2006
FABRICATOR 210
1.03
Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
April 27, 2006
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
Voltage Input
Art # A-04130
1-5
FABRICATOR 210
1.03
Precautions De Securite En Soudage à L’arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04
Dangers Relatifs au Soudage à L’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension
dès la mise en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à la terre
est dangereux.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3
Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
1-6
April 27, 2006
FABRICATOR 210
AVERTISSEMENT
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de
soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
Soudage aux gaz
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
Opération de coupage
ou soudage
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
mince
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais
Soudage á l'arc avec
électrode enrobees
(SMAW)
4 ou 5
Gougeage Air-Arc avec
électrode de carbone
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
épais
14
moins de 5/32 po. (4 mm)
10
5/32 á 1/4 po. (4 á 6.4 mm)
12
mince
moins de 300 amperès
9
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 á 400 amperès
12
plus de 400 amperès
14
Coupage á l'arc Plasma (PAC)
épais
April 27, 2006
1-7
FABRICATOR 210
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
soudage.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
2. Portez des vêtements appropriés pour protéger la peau.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1-8
April 27, 2006
FABRICATOR 210
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. Arrêtez
le moteur avant de vérifier le niveau e
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
AVERTISSEMENT
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1.05
Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
April 27, 2006
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-9
FABRICATOR 210
1.07
Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Mono Phasé
Déroulement du Fil
Hors Tension
Trois Phasé
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Tri-Phase Statique
Tension dangereuse
Fréquence Convertisseur
Transformateur-Redresseur
Torch de Soudage
Augmentez/Diminuer
Distant
Purge Du Gaz
Facteur de Marche
Mode Continu de
Soudure
Pourcentage
Soudure Par Point
Disjoncteur
Source AC Auxiliaire
X
%
Fusible
Panneau/Local
Intensité de Courant
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Tension
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Hertz (cycles/sec)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Fréquence
Decoupe Arc Carbone
(CAC-A)
t
Duréc du Pulse
Durée de Pré-Dèbit
t1
t2
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Détente à 4-Temps
Courant Constant
Négatif
Positif
Tension Constante
Ou Potentiel Constant
Courant Continue (DC)
Haute Température
Terre de Protection
Amorçage de L’arc au
Contact (GTAW)
Connexion de la Ligne
115V 15A
1-10
Classement de PriseSource Auxiliaire
t
Probléme de Terre
IPM
Pouces Par Minute
MPM
Mètres Par Minute
Force d'Arc
Ligne
Source Auxiliaire
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Inductance Variable
V
Tension
Art # A-07639
April 27, 2006
FABRICATOR 210
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Service Manual applies to only the specification or
part numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the rear panel. In some cases, the
nameplate may be attached to the control panel.
Equipment which does not have a name plate such as
gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
i for future reference.
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
in your area listed in the inside back cover of this manual.
Include the manual number and equipment identification
numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature link:
http://www.thermalarc.com
April 27, 2006
2-1
FABRICATOR 210
2.03 General Information
2.05 Protective Filter Lenses
The Fabricator 210 is a semiautomatic Gas Metal Arc
Welder (GMAW-commonly MIG) with an integrated wire
feed unit. This Power Supply is designed to meet the broad
operating needs of the metal fabrication industry where
production efficiency is vital. The Fabricator 210 is
designed and manufactured to meet the requirements of
CSA and IEC 60974-1 standards.
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.
The Fabricator 210 gives excellent performance on mild
steel, stainless steel, aluminum, silicon bronze and some
hard facing wires with Argon based shielding gases. The
Power Supply also gives excellent results on mild steel
using Carbon Dioxide shielding gas.
The Fabricator 210 is supplied as a complete package
ready to weld (apart from gas cylinder and electrode wire).
The following instructions detail how to correctly set up
the welder and give guidelines on gaining the best
production efficiency from the Power Supply. Please read
these instructions thoroughly before using your Fabricator
welder.
2.04 Safety
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
Table 2-1: Filter Lens Size Versus Welding Current
• Ensure the machine is correctly installed, if necessary, by a qualified electrician.
It is recommended to use a welding helmet, conforming
to the local relevant Standards when electric arc welding.
Use a welding helmet in serviceable condition with the
correct filter lens. Refer to Table 2-1 above and AWS table
in Section 1.
• Ensure the Power Supply is grounded correctly
(electrically) in accordance with local regulations.
2.06 User Responsibility
The following basic safety rules should always be followed:
• 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 handy.
• 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.
2-2
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 approved by Thermal Arc.
April 27, 2006
FABRICATOR 210
2.07 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 30% duty cycle, 250
amperes at 26.2 volts. This means that it has been designed and built to provide the rated amperage (250A) at the
rated load voltage (26.2V), for 3.0 minutes out of every 10 minute period (30% of 10 minutes is 3.0 minutes). During
the other 7.0 minutes of the 10 minute period the Power Supply must idle and be allowed to cool. The thermal cutout
will operate if the duty cycle is exceeded.
2.08 Specifications
MIG Gun Specifications
Gun Catalog Number
20584
Gun Type
TWECO Weldskill 250 AMP
Gun Cable Length
15 ft (4.5m)
Table 2-2: MIG Gun Specifications
Control Circuit Supply
Wire Drive Motor Supply
Wire Speed Range
Wire Diameter
Mild Steel:
Stainless Steel:
Aluminum:
Flux Cored:
Wire Spool Size Capacity
Wire Drive Specifications
30VA @ 32VAC
180VA @ 14 to 46VDC
80 to 800 ipm
(2 to 20 m/min)
.023"
.030"
.035"
.045"
(0.6mm)
(0.8mm)
(0.9mm)
(1.2mm)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
44 lb, 33 lb, 10 lb, 8" and 12" wire spool sizes.
Table 2-3: Wire Drive Specifications
April 27, 2006
2-3
FABRICATOR 210
Fabricator 210
100047B-001
Package System Part Number
707222
Power Source Part Number
Power Source Weight
200lb (91kg)
32” x 21” x 36-3/4”
Power Source Dimensions HxWxD
(including wheels and cylinder carrier)
(813 x 533 x 933mm)
Nominal Input Voltage
208V ±10%
230V ±10%
1Ø
Number of Phases
60 Hz
Frequency
Flexible Supply Cable Size
10ft (3m) 10AWG
Supply Plug
NEMA 6-50P
Rated Input Current @ 100% Duty Cycle
*22.6A
*20.4A
4.7kVA
4.7kVA
Rated kVA @ 100% Duty Cycle
53.8A
49A
Maximum Input Current @ 250A Output
15 kVA
15 kVA
Generator Requirements
Supply VA @ Maximum Output
11.2 kVA
11.2 kVA
50A
50A
Recommended Primary Circuit Size
45A
45A
Recommended Minimum Primary Fuse
17.3 – 42.2V DC
17.3 – 42.2V DC
Open Circuit Voltage Range
15.2 – 26.2V DC
15.2 – 26.2V DC
Welding Arc Voltage Range
Output Current Range
20 – 250A DC
20 – 250A DC
210A/23.3V @ 40% 210A/23.3V @ 40%
Rated Output Duty Cycle
250A/26.2V @ 30% 250A/26.2V @ 30%
Maximum Duty Cycle
137A DC at 21V
137A DC at 21V
100% Duty Cycle Output Rating
Duty Cycle Period
10 minutes
Number of Output Voltage Values
16
Electrode Wire Type and Diameter
Mild / Stainless Steel
.023” (0.6mm) – .045” (1.2mm)
Aluminum
.030” (0.8mm) – .045” (1.2mm)
Flux Cored
.030” (0.8mm) – .045” (1.2mm)
Wire Feed Speed Range
80 – 800 ipm (2 – 20 m/min )
8” / 12” (200mm / 300mm)
Wire Spool Size Diameter
0 – 0.6 seconds
Burn-Back Timer Range
Burn-Back Time Factory Set to
0.16 seconds
Spot Timer Range
0.5 – 9 seconds
Dwell Timer Range
1 – 12 seconds
Stitch Weld Time Weld (Stitch) Time
0.5 – 9 seconds
Dwell (non-weld) Time
1 – 12 seconds
Thermal Protection
Self-resetting thermostat fitted to rectifier
assembly and transformer
Operating Temperature Range
32° to 104°F (0° to 40°C)
* The Rated Input Current should be used for the determination of cable size & supply
requirements.
Table 2-4: Machine Specifications
2-4
April 27, 2006
FABRICATOR 210
2.09 Included Items
Fabricator 210 Package System Contents
Fabricator 210 Power Source with Integrated Wirefeeder
Factory Fitted Wheeling Kit
Factory Fitted Single Cylinder Rack
Factory Fitted Primary Power Cable 10 AWG, 10ft (3m) with Plug
NEMA 6-50P
Work Lead 10ft (3m) with clamp
Cable Stowage Hook
Regulator / Flowmeter - Argon Mix Gases
TWECO Weldskill MIG gun 250A, 15' (4.5m)
Drive Roll for .035"/.045" (0.9mm/1.2mm) Hard Wire
Accessories Box
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Table 2-5: Power Supply Contents
2.10 Optional Accessories
Refer to the Appendix section for the list of available options and accessories.
April 27, 2006
2-5
FABRICATOR 210
2-6
April 27, 2006
FABRICATOR 210
SECTION 3:
INSTALLATION
3.01 Environment
3.02 Location
Be sure to locate the Power Supply according to the
following guidelines:
In areas, free from moisture and dust.
In areas, free from oil, steam and corrosive gases.
The Fabricator 210 is NOT designed for use in
environments with increased hazard of electric shock.
Examples of environments with increased hazard of
electric shock are:
In locations in which freedom of movement is restricted,
so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical
contact with conductive parts;
In locations which are fully or partially limited by
conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator, or
In areas, not subjected to abnormal vibration or shock.
In areas, not exposed to direct sunlight or rain.
Place at a distance of 1 ft (300 mm) or more from walls
or similar that could restrict natural air flow for cooling.
The minimum ground clearance for these products is 5.5"
(140 mm).
3.03 Ventilation
Since the inhalation of welding fumes can be harmful,
ensure that the welding area is effectively ventilated.
In wet or damp hot locations where humidity or
perspiration considerably reduces the skin resistance of
the human body and the insulation properties of
accessories.
Environments with increased hazard of electric shock do
not include places where electrically conductive parts in
the near vicinity of the operator, which can cause increased
hazard, have been insulated.
April 27, 2006
3-1
FABRICATOR 210
3.04 Input Power Requirements
The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. Too low of a supply voltage may
cause poor welding performance or wirefeeder malfunction. Too high of a supply voltage will cause components to
overheat and possibly fail.
Install a power outlet for each Power Supply and fit fuses as per the machine specifications.
!
WARNING
Thermal Arc advises that your Fabricator 210 be electrically connected by a qualified electrical tradesperson.
The Fabricator 210 Power Supply is factory connected for the following input power supply voltage:
Input Power
Lead Current Lead
Machine
Supply Lead Size
Rating
Length Voltage Setting Duty Cycle
10 AWG
30 Amps 10ft (3m)
230V 1ø
250A @ 30%
Table 3-1: Factory Fitted Input Power Supply Leads Fitted to the Fabricator 210
3.05 Alternative Mains Supply Voltages
!
WARNING
The Fabricator 210 input power supply lead should be replaced with leads as specified in Table 3-2 when
the Fabricators input power supply voltage is changed.
The Power Supply is suitable for use on the following input power supply voltages:
Input Power Supply Primary Input
Input Power
Voltage Setting
Power Lead Size Lead Length Outlet Size Fuse Size Duty Cycle
208V 1ø
10AWG (5mm2)
3M
50 Amps
45 Amp 250A @ 30%
230V 1ø
10AWG (5mm2)
3M
50 Amps
45 Amp 250A @ 30%
Table 3-2: Mains Supply Lead Sizes for Alternative Mains Supply Voltages
National Electrical Code Standards permit the rating of the fuse or thermal circuit breaker protecting the circuit conductors
to be double the standard rating for any circuit used exclusively for an electric arc welder. Check local requirements for
your situation in this regard.
3-2
April 27, 2006
FABRICATOR 210
Changing the Voltage Selection
1. Disconnect the power supply from the main power source.
2. Refer to Figure 3-1. The power supply comes wired for 230V. Locate the black input power wire secured to the
input voltage selection block. Loosen the set screw for both voltage locations.
3. Remove the black wire from the current location and Insert the uninsulated wires into the new voltage location.
Secure by tightening the set screw onto the uninsulated portion of the wires. Secure the first set screw as well.
A
208V connection
208
230
230V connection
Art # A-07393
Figure 3-1: Voltage Selections for Fabricator 210 (Wired for 230V)
3.06 Quick Setup
NOTE
CAUTION
To obtain adequate air flow and cooling for
the Power Supply components, the four
wheels must be fitted. Alternatively, the Power
Supply may be raised 5.5" (140 mm) from the
floor using supports that do not restrict
airflow.
NOTE
The steps in this subsection are intended for
individuals experienced in the set up of this
type welder. More detailed setup instructions
are in the following subsections.
1. Connect the work lead to the negative (-) socket
(positive + for Self Shielded Flux Cored Wire)
2. Connect the GUN lead to the positive (+) socket
(negative - for Self Shielded Flux Cored Wire)
April 27, 2006
See section 3.15 "Polarity Changeover" for
more detail and exceptions!
3. Position a gas cylinder on the rear tray and secure to the Power Supply cylinder bracket with
the chain 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.
!
WARNING
If the gas cylinder is not secured to the cylinder tray, the power supply must be kept from
moving to avoid over-extending the gas hose
which can result in personal injury, damage
to the power supply, flowmeter and gas cylinder.
3-3
FABRICATOR 210
4. Fix the cable stowage hook to the Power Supply
cylinder bracket with the bolts provided.
5. Fit the gas Regulator/Flow Meter to the gas cylinder and connect the gas hose from the rear of the
Power Supply to the Flow Meter outlet.
6. The machine is fitted with a .035/.045” vee groove
feed roll suited for hard wire. Change this feed
roll if required to fit your chosen wire size.
7. Fit the electrode wire spool to the wire reel hub
located behind the electrode wire compartment
door.
8. Fit the TWECO Weldskill MIG gun and trigger
wires through/to the front of the unit.
9. Remove the contact tip from the gun.
10. With the gun lead reasonably straight, feed the
wire through the wire drive rolls and gun.
11. Fit the appropriate contact tip and replace insulator and nozzle.
3.07 Installation of Shielding Gas
(GMAW) Process
NOTE
Shielding Gas is not required if the unit is used
with self shielded FCAW (flux cored arc welding) wires
1. Cylinder positioning: Block the wheels of the unit so
it cannot roll. Carefully stand the cylinder on the tray
and with one foot press against the bottom of the cylinder to assure it is against the back of the unit. Chain
the cylinder in place. (Refer to Figure 3-2 for Wheel
Kit cylinder installation)
2. Cracking: Remove the large metal cap on top of the
cylinder by rotating counter clockwise. Next remove
the dust seal. Position yourself so the valve is pointed
away from you and quickly open and close the valve
for a burst of gas. This is called “Cracking” and is
done to blow out any foreign matter that may be
lodged in the fitting. (Figure 3-2.)
3. Fit Regulator/Flow Meter to cylinders: Screw the
regulator into the appropriate cylinder. (Figure 3-2)
The nuts on the regulator and hose connections are
right hand (RH) threaded and need to be turned in a
clockwise direction in order to tighten. Tighten with a
wrench.
CAUTION
Match regulator to cylinder. NEVER CONNECT
a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
4. Attach supplied gas line between the regulator output
and the desired input at the rear of the power supply
depending on Spool Gun or MIG Gun use. (Refer to
Figure 3-2 and 3-13).
3-4
April 27, 2006
FABRICATOR 210
1
Cap
2
Shielding
Gas
4
Regulator and
Flow Meter
“Cracking”
/8”
3
11
Shielding
Gas
Shielding
Gas
Shielding
Gas
Art # A-07374
Stowage Hook
5
Gas Hose
Figure 3-2 Gas Cylinder Installation
April 27, 2006
3-5
FABRICATOR 210
Adjusting Regulator
Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-3)
The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause
turbulence and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 20-30 CFH
- Outdoors welding: 30-40 CFH
Helium based or CO2 gas flow rates:
- Workshop welding: 30-40 CFH
- Outdoors welding: 40-50 CFH
NOTE
All valves downstream of the regulator must be opened to obtain a true flow rate reading
on the outlet gauge. (Welding power source must be triggered) Close the valves after the
pressure has been set.
Art # A-07280
Figure 3-3: Adjusting Flow Rate
Refer to section 4.09 for suggested gas / filler metal combinations.
NOTE
The regulator/flow meter used with argon based and carbon dioxide shielding gases is
different. The regulator/flow meter supplied is for argon based shielding gases. If carbon
dioxide is to be used a suitable carbon dioxide regulator/flow meter will need to be fitted.
3-6
April 27, 2006
FABRICATOR 210
3.08 Attaching the Gun and Cable
Assembly to the Power Source
The Fabricator 210 is supplied with a Tweco Weldskill 250 AMP gas-cooled gun. The Weldskill gun is designed with
an ergonomic handle and fewer parts to cause performance problems. The Weldskill gun uses standard readily available Tweco Weldskill consumable parts.
1. Open the door panel to the machine by inserting your left and right index fingers into the two release mechanisms marked with hand arrows in Figure 3-4. Slide them toward each other and pull the cover outward and
up to open.
Set up Char t
Art # A-07392
Figure 3-4: Door Panel Opening
NOTE
Lubricate the O-ring on the quick-connect fitting of the gun cable with grease (Dow company #4 compound or equivalent, or Thermal Arc #903910)
2. Route the gun cable through the access hole in the front panel. Refer to Figures 3-5 and -3-6.
3. Loosen the thumbscrew and insert the gun cable end as far as it will go. Tighten thumbscrew. Refer to Figure
3-6.
4. Align the keyways of the Gun Switch connector with the receptacle below the gun cable and plug them together. Secure by turning the locking ring to the right (clockwise ). Refer to Figure 3-6.
NOTE
When disconnecting gun switch leads from the machine, loosen the locking ring and grab the connectors
and pull. Do not pull on the wires.
5. To remove the gun, reverse these directions.
April 27, 2006
3-7
FABRICATOR 210
Front Panel
Access Hole
Art # 0-7148
Trigger Receptacle
Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger
Loosen Thumbscrew
Art # A-07149
Tighten Thumbscrew
Figure 3-6: Mount Gun Cable to Adapter Socket
3-8
April 27, 2006
FABRICATOR 210
3.09 Input And Output Wire Guide
Installation
To ensure proper wire feed, the groove closest to the
motor must match the electrode wire size being used.
Refer to Figure 3-7.
.045” (1.2mm) Stamping
Install the input wire guide (the longer one) by loosening
the input guide lockscrew and inserting the guide into
the hole in the feedhead assembly. The recessed end of
the guide should be toward the wire spool. Adjust the
guide so that it is clear of the drive rolls and tighten the
input guide lockscrew.
Install the output wire guide in the same manner, with
the conical end toward the feed rolls. The tip of the conical end should be as close to the drive rolls as practical.
Tighten the output guide lockscrew.
.045
1.2
.045” (1.2mm) Groove
Art: A-07150
NOTE
Before tightening the input and output guide
lockscrews, install the drive roll to help in the
alignment of the wire guides.
Input Guide Lockscrew
Output Guide Lockscrew
The size that is visible when
fitting the feedroll is the groove
size in use.
Figure 3-8: Drive Roll Example
NOTE
All grooved feed rolls have their wire size or
range stamped on the side of the roll. On rolls
with different size grooves, the outer (visible
when installed) stamped wire size indicates
the groove in use.
Refer to feed roll kit #375980 in the Appendix for the
proper selection and ordering of feed roll kits. Kit includes
drive rolls, an input wire guide and an output wire guide
for a specific wire type and size.
Art # A-07445
Feed rolls are removed by twisting the feed roll retainer
cap and aligning the retaining knob splines/tabs with the
drive gear splines. Feedrolls are installed by putting the
feedroll onto the drive gear splines and twisting the
feedroll retainer cap so that the splines/tabs rest against
the face of the feedroll where they will click into place.
Input Wire Guide
Output Wire Guide
Figure 3-7: Wire Guide Installation
3.10 Selection and Installation of
Feedrolls
A drive roll consists of two different sized grooves. As
delivered from the factory the drive roll is installed for
.035” / .045” .
The stamped marking on the feedroll refers to the groove
furthest from the stamped marking. When mounted, that
will be the groove closest to the motor and the one to
thread.
April 27, 2006
NOTE
Installation of all styles of feed rolls for the
Fabricator 210 are identical.
WARNING
The welding wire is electrically Hot if it is fed
by depressing gun switch. Electrode contact
to work piece will cause an arc with gun switch
depressed.
3-9
FABRICATOR 210
3.11 Installing Wire Spool
As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool.
Installation of wire spool
1. Remove Wire Spool Hub Nut by turning counter clock wise (to the left).
2. Remove the spring from the hub.
3. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool
rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the
wire spool.
4. If using a 10 lb. wire spool place the spring on the exposed hub. Do not use the spring for larger wire spools
that cover the entire hub.
5. Replace the Wire Spool Hub Nut by turning clock wise (to the right).
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section
3.12 and Figure 3-12.
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Wire Spool Hub Nut
*Spring
Drive Pin
* The Spring is for use with
smaller 10 lb wire spools only
Art # A-07192
Figure 3-9: Spool Installation
3-10
April 27, 2006
FABRICATOR 210
3.12 Inserting Wire into the Feedhead
WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before
proceeding. Do not reattach the input power until told to do so in these instructions.
1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure. 3-10)
2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-10)
3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire
Guide and over the Feedroll. Make certain the proper groove is being used. (Second part of Figure. 3-10)
4. Pass the wire through the outlet guide and into the Gun liner of the Gun Cable. (Second part of Figure. 3-10)
5. Close the Pressure Roller Arm. (Figure. 3-11)
6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-11)
7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to tighten and Counter
Clockwise to loosen). (Figure. 3-11)
8. Figure 3-12 shows the result with wire installed. Continue to the next section for proper setting of tension.
1 - Loosen
Adjuster and
swing down
2 - Swing
Pressure arm
open
4 - Feed wire
through here
3 - Feed wire
through here
Art # A-07143
Figure 3-10: Opening Pressure Arm and Inserting Wire
7 - Adjust
the tension
5 - Swing
the Pressure
Arm closed
6 - Swing the
Adjuster back into
place.
Art # A-07144
Figure 3-11: Closing Pressure Arm and Adjusting Tension
April 27, 2006
3-11
FABRICATOR 210
Wheel Brake Hex Head Bolt
Pressure Adjustment
Device
Art # A-07162
Spool Hub Nut
Figure 3-12: Wire Installed
3.13 Wirefeeder Drive Roller Pressure Adjustment
The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise. The Tension
Adjuster should be set to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping
occurs, and inspection of the wire out of the MIG gun reveals no deformation or wear, the conduit liner should be
checked for kinks or clogging from metal flakes. If this is not the cause of slipping, the feedroll pressure can be
increased by rotating the Tension Adjusting knob clockwise. The use of excessive pressure may cause rapid wear of
the feed roller, motor shaft and motor bearings.
NOTE
Genuine TWECO contact tips and liners should be used. Many non-genuine liners use inferior materials
which can cause wire feed problems.
3.14 Wire Reel Hub Brake
The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is
considered necessary, adjustment can be made by turning the hex head bolt inside the open end of the wire reel hub.
Clockwise rotation will tighten the brake. (Refer to Figure 3-12 above).
CAUTION
Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, over heating of electrical componentry and possibly an increased incidence of wire Burnback into the contact tip.
NOTE
Correct adjustment will result in the wire reel circumference continuing no further than 0.75" (20mm) after
release of the Gun trigger switch. The wire should be slack without becoming dislodged from the reel.
3-12
April 27, 2006
FABRICATOR 210
3.15 Spool Gun Attachment
A spool gun can readily be used with the Fabricator 210 power supply.
1. Attach appropriate input gas to the Spool Gun input gas connection on the rear of the unit. (Refer to Figure. 313)
2. Attach the Spool Gun control cable and gas hose to the 10 pin socket and the Spool Gun Gas Outlet on the
front of the unit. (Refer to Figure. 3-13)
Main Gun
Gas Input
Connection
Spool Gun
Gas Input
Connection
Rear Panel
Spool Gun
Gas Outlet
Connection
Spool Gun
10 Pin
Socket
Art # A-07371
Front Panel
Figure 3-13 Spool Gun Connections
NOTE
When the SPOOL GUN is properly attached, Spool Gun/MIG Gun switch is set to Spool Gun and the trigger
is depressed, the internal wire feed and gas control are disabled and the SPOOL GUN feeder and gas
control operate.
April 27, 2006
3-13
FABRICATOR 210
3.16 Polarity Changeover
WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before
proceeding. Do not reattach the input power until told to do so in these instructions.
The output terminals are located on the front panel of the welding power source.
CABLE TO GUN, CABLE TO WORK
CABLE CONNECTIONS
CABLE TO GUN
CABLE TO WORK
1. GMAW* – Steel, Stainless Steel,
1. Connected to (+) 1. Connected to (-)
1. D.C. Electrode Positive
Aluminum & gas shielded Flux
Pos. output
Neg. output
(DCEP) – Reverse Polarity
Cored electrode wires
terminal
terminal
2. Connected to (-) 2. Connected to (+)
2. FCAW* – Gasless Flux Cored
2. D.C. Electrode Negative
Neg. output
Pos. output
electrode wire
(DCEN) – Straight Polarity
terminal
terminal
* Exception - Contact your filler metal supplier for the recommended polarity.
PROCESS
POLARITY
Table 3-3: Process Cable Connections
Work Lead
Art # A-07163
Connected for D.C.
Electrode Positive
(DCEP) Welding
Figure 3-14: Polarity Connections for DCEP
3-14
April 27, 2006
FABRICATOR 210
Work Lead
Connected for D.C.
Electrode Negative
(DCEN) Welding
Art # A-07164
Figure 3-15: Polarity Connections for DCEN
Changing polarity process.
a. Locate the two terminal knobs at the front of the machine. Refer to Figures 3-14 and 3-15.
b. Remove both terminal knobs by rotating counterclockwise.
c. Set up the desired lead polarity as per Table 3-3 and as shown in Figures 3-14 or 3-15.
d. Place the Work Lead cable on the opposite terminal.
e. Replace both terminal knobs and tightly secure them to ensure good electrical connections.
CAUTION
Ensure terminal knobs are tightly secured and that there is no connection between positive and negative
terminals.
f. Reconnect the input power to the power supply.
April 27, 2006
3-15
FABRICATOR 210
NOTES:
3-16
April 27, 2006
FABRICATOR 210
SECTION 4:
OPERATION
WARNING
DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at
welding voltage potential.
4.01 Power Supply Controls, Indicators and Features
Thermal Overload Indicator
Spool / MIG Gun Selector Switch
Wire Feed Speed Control
Power ON/OFF Switch
Coarse Voltage Switch Selector
17V - 21V
Front Panel
Access Hole
Torch
13V - 16V
22V - 31V
Fine Voltage Switch Selector
Spool Gun Gas Outlet
Gun Switch
Receptacle
Spool Gun Interface
Amphenol Receptacle
Gun Polarity Lead
Negative Welding
Terminal
Positive Welding
Terminal
Art # A-07372
Figure 4-1: Fabricator Controls
April 27, 2006
4-1
FABRICATOR 210
ON / OFF Power Switch
The indicator light is provided to indicate when the Fabricator 210 is connected to the Input Power Supply Voltage.
With the switch in the Standby position, the auxiliary power and the fan are turned off and the switch is illuminated.
WARNING
When the light is lit, the machine is connected to the Mains supply voltage and the internal electrical
components are at Mains voltage potential.
Thermal Overload
The critical component for thermal protection are the rectifier stack and the transformer, which are fitted with
thermal overload cut out devices. If the overload is activated then the machine should be left to cool for approximately
15 minutes before resuming welding. If the Power Source is operated within its duty cycle, the thermal overload
will not activate. Refer to section 2.09 for an explanation of duty cycle and section 2.10 for the power supply
specifications.
Wirespeed Control
The Wirespeed Control knob controls the welding current via the electrode wire feed rate, i.e. the speed of the wire
feed motor. The wire speed is variable from 80 to 800IPM (2-20 m/min).
Coarse Voltage Switch Selector
The Coarse Voltage Switch Selector sets the voltage level to the welding terminals as it switches from 1 to 4.
Fine Voltage Switch Selector
The Fine Voltage Switch Selector increases the voltage (in smaller increments than the Coarse switch) as it switches
from 1 to 4.
CAUTION
The Coarse & Fine Voltage Switch Selectors MUST NOT BE SWITCHED during the welding process.
4-2
April 27, 2006
FABRICATOR 210
Positive and Negative Welding Current Terminals
Refer back to Figure 4-1. Both terminals located at
the bottom of the unit are shown without the terminal
knob. Both knobs must be firmly secured before
attempting to weld.
Spool Gun Interface Amphenol Connector
The Spool Gun Interface 10 pin connector is used to
connect a spool gun to the Fabricator 210 (refer to
Figure 4-4 and Table 4-1).
Gun Polarity Lead
This lead selects the welding voltage polarity of the
electrode wire. Attach it to the positive welding terminal
(+) when using steel, stainless steel or aluminium
electrode wire. Attach the Gun Polarity Lead to the
negative welding terminal ( - ) when using gasless
flux cored electrode wire. If in doubt, consult the
manufacturer of the electrode wire for the correct
polarity. Also refer to section 3-16.
E
F
D
J
G
H
C
I
A
B
Positive and Negative Welding Terminal Knobs
Welding current flows from the Power Supply via
heavy duty terminals. It is essential, that these terminal
knobs are tight to achieve the necessary electrical
connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in failure of the
terminals.
Gun Switch Receptacle
The Torch Trigger 4-pin receptacle is used to connect
the two wires from the torch gun to the Fabricator
210. Only pins 1 and 2 are used for this.
To make connections, align keyway, insert plug, and rotate
threaded collar fully clockwise.
Art # A-07181
Figure 4-4: Spool Gun 10 pin receptacle
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 wire a plug or
cable to interface with the SPOOL GUN 10-pin
receptacle.
Socket Pin
A
B
C
D
E
F
G
H
I
J
1
2
Function
Not Used
Spool Gun Motor (-)
Spool Gun Motor (+)
Spool Gun Switch
Spool Gun Speed C.W.
Potentiometer Maximum
Spool Gun Speed Wiper
Potentiometer
Spool Gun Switch
Spool Gun Speed C.C.W.
Potentiometer Minimum
Not Used
Not Used
Table 4-1: 10-pin Receptacle Pin Functions
NOTE
Art # A-07171
Figure 4-3: Gun Switch Receptacle
April 27, 2006
When the SPOOL GUN is properly attached
and the trigger is depressed, the system
automatically disables the internal wire feed
and gas control and selects the SPOOL GUN
feeder and gas control.
4-3
FABRICATOR 210
4.02 Weld Mode Selector
The Weld Mode Selector switch selects the method of welding mode.
DWELL
(STITCH)
2
WELD
(SPOT / STITCH)
WELD MODE
SPOT
STITCH
2
4T
2T
3
1
4
MIN
3
1
4
MIN
t
t
BURNBACK
Art # A-07183
Figure 4-5: Internal Welding Controls
SPOT:
2T (Continuous Welding):
This mode of welding is used to weld two or more
components together with a continuous weld. When
the MIG gun trigger switch is depressed welding
commences. When the MIG gun trigger switch is
released welding ceases.
This mode of welding is used to weld two plates
together at a desired location by melting the top &
bottom plates together to form a nugget between
them. The spot time period is set by the Weld (Spot/
Stitch) control knob located in the electrode wire
compartment.
WELD MODE
SPOT
STITCH
4T
Art # A-07427
2T
Art # A-07466
Figure 4-6: For Reference Only
Figure 4-7: Spot Weld
NOTE
A spot nozzle should be used on the MIG gun
to obtain consistent spot welds.
4-4
April 27, 2006
FABRICATOR 210
STITCH:
Dwell Stitch
This mode of welding is used to weld two or more
components together with a stitch weld. The WELD
(Spot/Stitch) shaft controls the welding or ‘ON’ time
and the "DWELL (Stitch)" shaft controls the interval
or ‘OFF’ time for stitch welding.
DWELL (STITCH) TIMER CONTROL
When the Weld Mode control is in the Stitch position, the
Dwell (Stitch) knob controls the length of the non-weld
portion of stitch welding (off time when wire stops feeding).
DWELL
(STITCH)
2
3
Art # A-07428
Figure 4-8: Stitch Welding
4T (Latch):
This mode of welding is mainly used for long weld
runs, as the operator need only press the trigger to
activate the weld, then press the trigger again to stop.
This replaces the need for the operator to depress
and hold the trigger for the complete length of the
weld run.
WELD MODE
SPOT
Art # A-07430
1
4
MIN
t
Figure 4-11: Dwell (Stitch) Control
Burnback Control
Burnback time is the difference between the wirefeed
motor stopping and the welding current ceasing. The
Burnback time allows the electrode wire to burn out
of the molten metal weld pool. The Burnback time is
factory set for optimum performance. Burnback time
is adjusted by the knob of the potentiometer.
Clockwise adjustment increases Burnback time.
STITCH
4T
2T
Art # A-07431
Art # A-07427
BURNBACK
Figure 4-9: For Reference Only
Figure 4-12: Burnback Control
WELD (Spot/Stitch) Timer Control
WELD MODE - SPOT
When the Weld Mode control is in the Spot position,
the Weld (Spot/Stitch) knob controls the duration of
a single spot weld.
WELD MODE - STITCH
When the Weld Mode control is in the Stitch position,
the Weld (Spot/Stitch) knob controls the length of
the stitch weld on time.
WELD
(SPOT / STITCH)
2
3
Art # A-07429
1
4
MIN
t
Figure 4-10: Weld (Spot/Stitch) Control
April 27, 2006
4-5
FABRICATOR 210
4.03 TWECO Weldskill 250 AMP Weld Gun
The TWECO Weldskill 250 AMP gun fitted to the FABRICATOR 210 offers robust construction, unparalleled reliability
and easy replacement of consumable parts. The TWECO Weldskill gun has an operating capacity in excess of the
capacity of the FABRICATOR and can be expected to give trouble free service.
6
5
7
4
3
2
1
Art # A-07344
Figure 4-11: TWECO WeldSkill 250 AMP
Item
1
2
3
4
5
6
7
Original Parts Installed
Description
Part No.
NOZZLE 1/2"
22-50
NOZZLE INSULATOR
32
CONTACT TIP .035"
14-35
GAS DIFFUSER
52
CONDUCTOR TUBE
WM62J-50
HANDLE ASSY
TA1-80
TRIGGER
WM91
Qty
1
1
1
1
1
1
1
Table 4-2 MIG Gun Original Parts Consumables
TWECO Weldskill MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole
shop can be converted to TWECO Weldskill. Not only will this give greater reliability (and hence greater productivity)
but it will reduce stockholding of consumable parts. See your Thermal Arc distributor for details.
Gun Consumable Parts
See Appendix at the back of this manual.
4-6
April 27, 2006
FABRICATOR 210
Allen screw in the connector plug must be securely
tightened onto the conduit to prevent its backward
movement.
4.04 Installing A New Wire Conduit
Removal
1. Be sure the MIG gun cable is arranged in a straight
line, free from twists, when installing or removing a
wire conduit.
2. Unscrew and remove the MIG gun nozzle and contact tip.
3. Loosen the Allen screw in the gas diffuser and unscrew it from the conductor tube.
4. Loosen the Allen screw in the connector plug and pull
the old wire conduit out of the cable assembly from
the connector plug end.
Installation
1. Inspect the two O-ring gas seals on the connector
plug for cuts or damage.
2 Start from the connector plug end of the assembly
and begin pushing the conduit through the connector
plug, cable assembly and into the gun. If the conduit
should lodge along the way, gently whip or work the
cable assembly to aid forward movement.
3. When the wire conduit stop meets the end of the connector plug and the new raw end extends through the
end of the conductor tube on the welding gun, the
NOTE
When the conduit is fully inserted into the cable
assembly and the conduit stop is firmly against
the Connector Plug, the “raw end” of the
conduit will protrude out of the open end of
the gun conductor tube. Trim the conduit as
shown in Figure 4-13. The trimmed end which
seats in the Gas Diffuser must be filed and
reamed smooth on the inside and outside radii
so wire feed will not be obstructed.
4. Replace the Gas Diffuser and tighten its Allen screw
against the conduit.
5. Replace the Contact Tip and Nozzle.
CAUTION
Do not over tighten the Allen screws as this
will distort the conduit and lead to wire
feedability problems.
CONDUCTOR TUBE
CONDUIT LINER
ALLEN SCREW
REMOVE
CONSUMABLES
1 1/16"
(27mm)
Art # A-07330
O-RINGS
ALLEN SCREW
CONDUIT LINER
CONNECTOR PLUG
Figure 4-13: Conduit Installation and Trim Length
April 27, 2006
4-7
FABRICATOR 210
4.05 MIG Gun Maintenance
Remove dust and metallic particles from the gun conduit by forcing clean, dry compressed air into the conduit once
a week. This will minimize wire feeding problems.
4.06 Basic Welding Technique
Setting of the Power Supply
The setting of the Fabricator 210 requires some practice by the operator, the welding Power Supply having two control
settings that have to balance. These are the Wire Speed control and the Voltage Control switches. The welding current
is determined by the Wire Speed control, the current will increase with increased Wire Speed, 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 Wire Speed to achieve the same current level.
A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the
electrode wire diameter and dimensions of the work piece.
If the Wire Speed 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 Wire Speed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.
MIG Gun Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the welding run.
Position of MIG gun
The angle of MIG gun to the weld has an effect on the width of the weld run. Refer to Figure 4-14.
Forehand
Vertical
Art # A-05148
Figure 4-14: MIG Gun Angle
4-8
April 27, 2006
FABRICATOR 210
Distance from the MIG Gun Nozzle to the Work Piece
The electrode stick out from the MIG gun nozzle should be between 5/64" (2.0mm) to 13/64" (5.0mm). This distance
may vary depending on the type of joint that is being welded.
Flux Cored Wire
Solid Wire
1/4”
(6.4mm)
.023”
(.6mm)
5/16”
(7.9mm)
.030”
(.8mm)
3/8”
(9.5mm)
.035”
(.9mm)
9/16”
(14.3mm)
11/16”
(17.5mm)
.035”
(.9mm)
Gas
Nozzle
Contact
Tip
Art # A-07186
Distance: ±1/16”
.045”
(1.1mm)
Wire Diameter
Figure 4-15: Optimum Contact Tip to Work Distances
Electrode Wire Size Selection
The choice of electrode wire size in conjunction with shielding gas used depends on:
- Thickness of the metal to be welded,
- Type of joint,
- Capacity of the wire feed unit and power supply,
- The amount of penetration required,
- The deposition rate required,
- The bead profile desired,
- The position of welding and
- 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 in Table 4-3 below.
Electrode Wire Size Current (Amps) Current Density(Amps/mm2)
.035”( 0.9mm)
200
314
.045”(1.2mm)
200
177
Deposition Rate(lbs/hour)
7.0
6.2
Table 4-3: .035"(0.9mm) , .045"(1.2mm) Wire Deposition Rate
April 27, 2006
4-9
FABRICATOR 210
Advantages of MIG welding forehand:
- Allows superior visibility of the weld zone
- Flatter weld bead
- Shallower penetration
Forehand
Vertical
Backhand
Art # A-07185
Figure 4-16: MIG Gun Angle
4.07 Stitch Welding Operation
Welding consumable costs can be reduced by replacing a continuous weld bead with the Stitch weld bead. It will
also reduce heat distortion in thin plate.
Coarse & Fine Voltage Selector Switches and Wire Speed Control
Set these controls to obtain the desired welding conditions for the wire and material being welded.
Mode Selector Switch
Set the WELD MODE switch to STITCH.
Weld (Spot/Stitch) Timer Control
Adjust the WELD (Spot/Stitch) Timer Control knob for the desired weld or ‘ON’ time while stitch welding.
Dwell Time
Adjust the DWELL (Stitch) Timer Control knob for the desired interval or ‘OFF’ time while stitch welding.
4-10
April 27, 2006
FABRICATOR 210
4.08 Spot Welding Operation
Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to Figure 4-17
and the Spot Welding Nozzle table below. The Fabricator 210 will operate effectively using .030” (0.8mm) electrode
wire when spot welding. Penetration depth is limited when using .024”(0.6mm) electrode wire for spot welding.
Set the controls as follows for spot welding:
Coarse & Fine Voltage Selector Switches and Wirespeed Control
Select higher Voltage Selector switch positions and set the Wirespeed Control between 354 to 590 ipm (9 to 15 m/
min) for maximum penetration.
Mode Selector Switch
Set the WELD MODE switch to
SPOT.
Spot Time
Adjust the WELD (Spot/Stitch) control knob for the desired weld or ‘ON’ time for spot welding.
Dwell Time
The DWELL (Stitch) control knob has no affect in this mode of operation.
22-62-AOS
Art # A-07678
Figure 4-17: Spot Welding Nozzle
SPOT WELDING NOZZLES
TYPE
NO. 2 250 AMP
Flat Arc Spot
22-62-FAS 12201520 (5/8" Bore)
Inside Corner Arc Spot
22-62-IAS
1220-1521
(5/8” Bore)
22-62-IAS
1220-1522
(5/8” Bore)
N/A
Outside Corner Arc Spot
Automotive Stud Nozzle
April 27, 2006
4-11
FABRICATOR 210
4.09 Gas Selection for Gas Metal Arc Welding
Suggested
Shielding
Gas
Metal Type
Base Plate
Thickness
Filler
Metal
Transfer
Mode
Carbon
Steel
Greater than 22
gauge (.030”)
ER70S-X
Short
Circuit
100% CO2
All
Position
Welding
High welding speeds. Good
penetration and pool control.
Greater than 22
gauge (.030”)
ER70S-X
Short
Circuit
75% Argon
25% CO2
Suitable for high-current and highspeed welding.
Greater than 22
gauge (.030”)
ER70S-X
Short
Circuit
92% Argon
8% CO2
All
Position
Welding
All
Position
Welding
Greater than 10
gauge (1/8”)
ER70S-X
Spray
Transfer
92% Argon
8% CO2 or
80% Argon
20% O2
75% Argon
25% CO2
Flat & HV Good arc stability, weld soundness,
Fillet
and increasing width of fusion.
Short
Circuit
92% Argon
8% CO2
All
Position
Welding
Spray
transfer
92% Argon
8% CO2 or
80% Argon
20% O2
98% Argon
2% CO2
Flat & HV Reduces undercutting. Higher
Fillet
deposition rates and improved bead
wetting. Deep penetration and good
mechanical properties.
Good control of melt-through and
All
Position distortion. Used also for spray arc
Welding welding. Pool fluidity sometimes
sluggish depending on the base alloy.
All
Low CO2 percentages in Helium mix
Position minimizes carbon pickup, which can
Welding cause intergranular corrosion with
some alloys. Helium improves wetting
action and contour. CO2 percentages
above 5% should be used with
caution on some alloys.
Flat & HV Good arc stability. Produces a fluid
Fillet
but controllable weld pool, good
coalescence, and bead contour.
Minimizes undercutting on heavier
thickness.
Short
Low Alloy Greater than 22 See * below
Circuit
and High gauge (.030”)
Globular
Alloy Steel
Greater than 22 See * below
gauge (.030”)
Greater than
3/32”
See * below
Greater than 14 See * below
gauge (.075”)
Stainless Greater than 22
gauge (.030”)
Steel
Greater than
3/32”
Short
Circuit
ER308-X
ER309-X
ER316-X
Short
Circuit
90% Helium
7.5% Argon
2.5% CO2 or
81% Argon
18% Helium
1 % CO2
ER308-X
ER309-X
ER316-X
Spray
Transfer
ER4043
ER5356
Spray
Transfer
90% Helium
7.5% Argon
2.5% CO2 or
81% Argon
18% Helium
1 % CO2
Argon
Welding
Positions
All
Position
Welding
Comments
Higher deposition rates without meltthrough. Minimum distortion and
spatter. Good pool control for out-ofposition welding.
High welding speeds. Good
penetration and pool control.
Applicable for out-of-position welds.
Suitable for high-current and highspeed welding.
Good coalescence and bead contour.
Good mechanical properties.
All
Excellent cleaning action. Provides
Position more stable arc than helium-rich
Welding mixtures.
* Contact your Filler Metal Supplier for recommended filler metal for the base metal to be welded.
Aluminum Greater than 18
gauge (.045”)
Table 4-4: Gas Selection Chart
4-12
April 27, 2006
FABRICATOR 210
THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK
April 27, 2006
4-13
FABRICATOR 210
4.10 Welding Setting Selection Guide
Material Type
Wire Type
Shielding Gas
and Flow Rate
Wire Size
(Diameter)
.023” (0.6mm)
100% CO2
25cfh
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
.023” (0.6mm)
Steel
Solid
(or hard)
ER70S-6
75% Ar 25%
CO2 ,25cfh
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
.023” (0.6mm)
92% Ar
8% CO2
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
Flux Core
Steel
E71T-1
E71T-GS
E71T-11
100% CO2
75% Ar
25% CO2
25cfh
Art # A-07440
Stainless
Steel
None
.045” (1.2mm)
.030” (0.8mm)
4043 ER
5183 ER
5356 ER
100% Ar
25cfh
Stainless
7.5% Ar
90% He
2.5% CO2
35cfh
ER308LSi
ER309LSi
ER316LSi
.030” (0.8mm)
.035” (0.9mm)
Aluminum
Aluminum
.045” (1.2mm)
.035” (0.9mm)
.045” (1.2mm)
.030” (0.8mm)
.035” (0.9mm)
Table 4-5: Welding Selection Guide
4-14
April 27, 2006
FABRICATOR 210
1
1
2
Coarse
Voltage
Fine
Voltage
3
3
4
22 ga. (0.8mm) 18 ga. (1.2mm) 16 ga. (1.6mm) 1/8” (3.2mm)
1/4
1/4
1
1
2/2
2/2
2/1
2/2
1/3
1/3
1.5
1
2/1
1/4
1/4
2.25
1.5
1
1
2.25
1.25
1
2/3
2/3
2/3
2/3
2/2
2/2
2/2
2/2
1/3
1/3
1.25
.75
2/1
1/4
1/4
2.25
1.25
1
2/2
2/2
2/2
2/2
3/1
1/1
1
1/3
1/3
2.75
2.25
2
1
3.75
1.75
1.75
1
3.75
2
1.5
1.5
2.25
1.5
1.5
2/4
3/2
3/3
3/2
2/4
3/1
2/4
3/1
4/1
4/2
4/2
3/1
3/2
2/1
1/4
2/4
1/2
1/1
4
3
1/4
1/4
4
4
3/1
3/3
3/3
2/2
1
2/3
2/2
April 27, 2006
1.5
.75
2/4
2/3
2.25
1.25
3/1
3/1
4
4
2.75
2
5.25
4
2.5
2
8.25
5.25
4.25
3
2.75
2
1.75
1.75
4.5
5
4
3.5
2.25
3/16” (5.0mm)
1/4” (6.4mm)
3/1
3/2
3/3
3/4
3/4
3/1
3/2
3/1
3/2
4/1
4/2
4/2
3/3
4/1
2/2
2/4
2/4
3/3
3/4
4/1
3/2
3/2
4.25
5
3.5
2.25
5.5
4.25
4
2.25
3/4
3/4
3/4
3/3
3/3
3/2
3/3
3/8” (9.5mm)
1/2” (12.7mm)
6
6.5
4.25
3
4/2
4/1
4/1
7.5
5.25
3.5
4/3
4/4
4/2
8.5
7.25
4
8.25
5.25
4
2.75
3/4
3/4
3/4
7.25
5.5
3.25
4/3
4/3
4/1
8.5
7.75
3.75
8.25
5.25
4.25
3.5
4
3.5
2.5
2
5
5.5
4.75
3.5
2.75
4/2
4/3
4/2
4/1
2/4
3/1
3/2
3/4
4/1
4/2
3/4
3/4
5.75
5.5
3.5
5
4
5
2.5
4/3
4/3
4/3
4/3
3/2
3/3
3/3
7
4/4
8.5
6
4
5.75
4/4
4/4
4.5
10
5.75
5.25
3
4/3
4/3
10
3.5
6
6.25
5.5
5.5
3.5
4/2
4/3
3/4
4/1
8.75
5.75
4/3
5.75
6.25
4.75
4/4
6.25
4-15
Art # A-07440
4
THICKNESS**
Coarse Voltage
Fine Voltage
Step
Wire
Speed
2
FABRICATOR 210
NOTES
4-16
April 27, 2006
FABRICATOR 210
SECTION 5:
MAINTENANCE &
TROUBLESHOOTING
5.01 Routine Maintenance & Inspection
The only routine maintenance required for the Fabricator
210 is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.
WARNING
Disconnect the Fabricator from the Input
power supply voltage before disassembling.
To clean the Power Supply, 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 Supply should also be wiped clean. If necessary,
solvents that are recommended for cleaning electrical
apparatus may be used.
Troubleshooting and repairing the Fabricator should be
carried out only by those who are familiar with electrical
equipment.
WARNING
Do not attempt to diagnose or repair unless
you have had training in electronic measurement and troubleshooting techniques.
Special maintenance is not necessary for the control unit
parts in the Power Supply. If these parts are damaged for
any reason, replacement is recommended.
CAUTION
Do not blow air into the Power Supply during
cleaning. Blowing air into the Power Supply
can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Supply.
April 27, 2006
5-1
FABRICATOR 210
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
Replace all
broken parts
Gas lines
Clean exterior
of power
supply
6 Months
Visually check and
use a vacuum to carefully
clean the interior
Art # A-07269
5-2
April 27, 2006
FABRICATOR 210
5.02 Basic Troubleshooting
The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and
without removing the covers from the Power Supply.
If major components are faulty, then the Power Supply should be returned to an Accredited Thermal Arc Service Agent
for repair.
5.03 Solving Problems Beyond the Welding Terminals
The general approach to fix GMAW/FCAW problems is to start at the wire spool then work through to the MIG torch.
There are two main areas where problems occur:
Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from
some contaminant within the molten weld pool which is in the process of escaping during solidification of the
molten metal.
Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be
reduced by checking the following points:
FAULT
CAUSE
REMEDY
1. Gas cylinder
contents and flow
meter
a. Ensure that the gas cylinder is not empty
and the flow meter is correctly adjusted to
25CFM (15 litres per minute)
2. Gas leaks
3. Internal gas hose in
the power supply
Porosity
4. Welding in a windy
environment
5. Welding dirty, oily,
painted, oxidized or
greasy plate.
6. Distance between the
MIG torch nozzle and
the work piece.
7. Maintain the MIG
torch in good
working order.
a. Check for gas leaks between the
regulator/flow meter connection and in
the gas hose to the power supply
a. The hose from the solenoid valve to the
MIG torch adaptor may be fractured or
disconnected from the MIG torch adaptor.
Return to an Accredited Thermal Arc
Service Agent for repair.
a. Shield the weld area from the wind or
increase the gas flow
a. Clean contaminates off the plate
a. Keep the distance between the MIG torch
nozzle and the work piece to a minimum.
a. Ensure that the gas holes are not blocked
and gas is exiting out of the torch nozzle.
Refer to WARNING below
b. Do not restrict gas flow by allowing
spatter to build up inside the MIG
torch nozzle.
C. Check that the MIG gun O-rings are not
damaged.
Table 5-1: Porosity Problems
April 27, 2006
5-3
FABRICATOR 210
WARNING
Disengage the drive roll when testing for gas flow by ear.
2. Inconsistent wire feed
FAULT
Inconsistent
Wire Feeding
CAUSE
1. Wire spool
brake is too
tight.
2. Wire spool
brake is too
loose.
REMEDY
a. Feed roller driven by motor in the cabinet will slip.
a. Wire spool can unwind and tangle
3. Worn or
incorrect
feed roller size.
a. Use ‘U’ groove drive feed roller matched to the
aluminum wire size you are welding.
b. Use ‘V’ groove drive feed roller matched to the steel
wire size you are welding.
C. Use ‘knurled V’ groove drive feed roller matched to
the flux cored wire size you are welding.
4. Misalignment of
inlet/outlet
guides.
a. Wire will rub against the misaligned guides and
reduces wire feedability.
5. Liner blocked
with swarf.
6. Incorrect or
worn contact
tip.
7. Poor work lead
contact to work
piece.
8. Bent liner.
a. 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.
a. The contact tip transfers the weld current to the
electrode wire. If the hole in the contact tip is too
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 aluminum
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.
a. If the work lead has a poor electrical contact to the
work piece then the connection point will heat up and
result in a reduction of power at the arc.
a. This will cause friction between the wire and the liner
thus reducing wire feedability.
Figure 5-2: Trouble Shooting for Inconsistent Wire Feed
5-4
April 27, 2006
FABRICATOR 210
5.04 Welding Problems
FAULT
A. Undercut.
CAUSE
1. Welding arc voltage
too high.
REMEDY
a. Reduce voltage by reducing the voltage
selection switch position or increase the
wire feed speed.
2. Incorrect torch
angle
3. Excessive heat
input
a. Adjust angle
4. Weld speed too fast
B. Lack of penetration.
a. Increase the torch travel speed and/or
reduce welding current by reducing the
voltage selection switch position or
reducing the wirefeed speed.
a. Reduce weld speed.
1. Welding current too
low
a. Increase welding current by increasing
wire feed speed and increasing voltage
selection switch position.
a. Increase joint angle or gap
C. Lack of fusion.
2. Joint preparation too
narrow or gap too
tight
3. Shielding gas
incorrect
4. Weld speed too fast
1. Voltage too low
D. Excessive spatter.
2. Weld speed too fast
1. Voltage too high
2. Voltage too low
E. Irregular weld
shape.
3. Weld speed too fast
1. Incorrect voltage and
current settings.
Convex, voltage too
low. Concave, voltage
too high.
a. Change to a gas which gives higher
penetration
a. Reduce weld speed.
a. Increase voltage by increasing voltage
selection switch position.
a. Reduce weld speed.
a. Lower voltage by reducing the voltage
selection switch or increase wirespeed
control.
a. Raise voltage by increasing the voltage
selection switch or reduce wirespeed
control.
a. Reduce weld speed.
a. Adjust voltage and current by adjusting
the voltage selection switch and the
wirespeed control.
2. Wire is wandering
a. Replace contact tip
3. Incorrect shielding
gas
4. Insufficient or
excessive heat input
5. Weld speed too fast
a. Check shielding gas.
a. Adjust the wire speed control or the
voltage selection switch.
a. Reduce weld speed.
Table 5-3a: Welding Problems and Solutions
April 27, 2006
5-5
FABRICATOR 210
FAULT
A. Weld cracking
CAUSE
1. Weld beads are too
small
2. Weld penetration
narrow and deep
3. Excessive weld
stresses
4. Excessive voltage
5. Cooling rate too fast
6. Weld speed too fast
7. Incorrect filler wire
B. Cold weld puddle.
C. Arc does not have a
crisp sound that
short arc exhibits
when the wirefeed
speed and voltage
are adjusted
correctly.
1. Faulty rectifier unit
2. Loose welding cable
connection.
3. Low Primary Voltage
4. Weld speed too fast
1. The MIG torch has
been connected to
the wrong polarity on
the front panel.
2. Weld speed too fast
REMEDY
a. Decrease travel speed
a. Reduce current and voltage and increase
MIG torch travel speed or select a lower
penetration shielding gas.
a. Increase weld metal strength or revise
design
a. Decrease voltage by reducing the
voltage selection switch.
a. Slow the cooling rate by preheating part
to be welded or cool slowly.
a. Reduce weld speed.
a. Check compatability to base metal
a. Have an Accredited Thermal Arc Service
Agent to test then replace the faulty
component.
a. Check all welding cable connections.
a. Contact supply authority
a. Reduce weld speed.
a. 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.
a. Reduce weld speed.
Table 5-3b: Welding Problems and Solutions continued
5-6
April 27, 2006
FABRICATOR 210
5.05 Power Supply Problems
FAULT
A. Indicator light is ON but welding
arc can not be established.
B. Mains supply voltage is ON.
Indicator light is not lit and
welding arc can not be
established.
CAUSE
1. Power On/Standby switch
in standby position.
1. Primary fuse is blown.
2. Broken connection in
primary circuit.
C. Mains indicator light is not lit
but welding arc can be
established.
D. Mains supply voltage is ON and
Indicator light is lit but when the
gun trigger switch is depressed
nothing happens.
E. Mains supply voltage is ON, no
wire feed but gas flows from the
MIG Gun when the gun trigger
switch is depressed.
1. Indicator light is open
circuit.
1. Gun trigger switch leads
are disconnected.
1. Electrode wire stuck in
conduit liner or contact tip
(burn-back jam).
2. Faulty control PCB or
Tweco Gun
F. Wire feeds when the gun trigger
switch is depressed but arc can
not be established.
G. Wire continues to feed when the
gun trigger switch is released.
H. Jerky wire feed
I. No gas flow
1. Poor or no work lead
connection.
1. The Weld Mode Switch has
been set to 4T (latch
operation).
1. Worn or dirty contact tip
2. Worn feed roll
3. Excessive back tension
from wire reel hub roll.
4. Worn, kinked or dirty
conduit liner
5. Low Swing Arm pressure
1. Gas hose is cut or pinched
2. Gas passage contains
impurities
3. Gas regulator turned off
4. Gas cylinder is empty
J. Gas flow continues after the gun
trigger switch has been
released.
1. Gas valve has jammed
open due to impurities in
the gas or the gas line.
REMEDY
a. Switch the power On/Standby
switch to the “On” position .
a. Replace primary fuse.
a. Have an Accredited Thermal Arc
Service Agent check primary
circuit.
a. Have an Accredited Thermal Arc
Service Agent replace Indicator
light.
a. Reconnect.
a. Check for clogged / kinked MIG
Gun conduit or worn contract
tip. Replace faulty
component(s).
a. Have an Accredited Thermal Arc
Service Agent investigate the
fault.
a. Clean work clamp area and
ensure good electrical contact.
a. Set the Weld Mode Switch to 2T
(normal operation).
a. Replace
a. Replace
a. Reduce brake tension on spool
hub
a. Clean or replace conduit liner
a. Increase the Swing Arm
pressure.
a. Check hose and replace or
repair.
a. Disconnect gas hose from the
rear of Fabricator then raise gas
pressure and blow out the
impurities.
a. Turn on.
a. Check cylinder volume and
replace or refill as needed.
a. Have an Accredited Thermal Arc
Service Agent repair or replace
gas valve.
Table 5-4: Power Supply Problems
April 27, 2006
5-7
FABRICATOR 210
NOTES
5-8
April 27, 2006
FABRICATOR 210
APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES
For Tweco/Victor Inquiries and Orders:
Call 1-800-318-6819 Consumable Parts Management Group
GUNS
Tweco® WeldSkill 12ft
Tweco® No. 2 12ft
Tweco® No. 2 15ft
Tweco® Spraymaster 12ft
Tweco® Spraymaster 15ft
Spool Gun 25ft
Spool Gun 25ft
ACCESSORIES
Victor Regulator/Flow Meter
Mixed Gases
Victor Regulator/Flow Meter
CO2
TIPS
20584
212-3035
215-4035
MS212-3545
MS215-3545
W4011000
90906
0781-2723
0781-2725
Gun assembly with 15ft cable (supplied with package),
250 Amp @ 30%
Gun assembly with 12ft cable, 250 Amp @ 60%
Gun assembly with 15ft cable, 250 Amp @ 60%
Gun assembly with 12ft cable, 250 Amp @ 80%
Gun assembly with 15ft cable, 250 Amp @ 80%
Gun assembly with 25ft cable, 200 Amp @ 60%
Gun assembly with 25ft cable, 300 Amp @ 60%
Medalist™ 1400 Series, HRF Flow Meter Regulator,
Argon-Argon/CO2 mix gases
Medalist™ 1400 Series, HRF Flow Meter Regulator, CO2
gas
14-23
14-30
14-35
14-40
14-45
.023” (0.6mm)
.030” (0.8mm)
.035” (0.9mm)
.040” (1.0mm)
.045” (1.2mm)
22-37
22-50
22-62
3/8” (9.5mm)
1/2” (12.7mm)
5/8” (16mm)
NOZZLES
CONDUITS
42-23-15
42-3035-15
42-4045-15
42N-3545-15
April 27, 2006
.023”, 15ft (7.6m)
.030”-.035”, 15ft (4.5m)
.040”-.045”, 15ft (4.5m)
.035”-3/64”, 15ft (4.5m)
A-1
FABRICATOR 210
APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM
TB
Input Terminal Block
L1
White
1B BRN
1 BRN
K1\3
[5]
3
1G BRN
[1]
31C ORN
BLU
BLU
M1
Fan motor
SW3
(6)
(7)
(8)
(3)
(4)
SW4
(1)
(2)
FINE
(5)
(6)
(8)
(7)
58 VIO
SPOOL
GUN
Solenoid
32A WHT
Y1 SOL1
33 BLU
31A ORN
MIG
SW2
NORM
SPOOL
BURNBACK
100K
Solenoid
31 ORN
35 WHT
34 BLU
32 WHT
30A BRN
30 BRN
JE/2
JE/1
JB/11
JB/10
JB/4
JB/5
FABRICATOR 210
(2)
Y2 SOL2
31B ORN
32V Aux
13A VIO
12 DK BRN
CONTACTOR
24V 50/60Hz
5
(4)
(1)
(5)
[2]
SW1
4
(3)
COARSE
K1\1
1A BRN
3 VIO
INDL
1C BRN
1H BRN
6 WHT
CB1
2A
[6]
K1\2
[3]
[4]
10 RED 11 GRY
15B BLU
Earth
Green\Yellow
15&15A BLU
230V
8 LT BRN
9 BLK
14&14A BLK
2
1D BRN
L2
Black
1F BRN
W1
1
208V
1E BRN
JUMPER
JD-1
JD-2
SWITCH 3 COARSE AND SWITCH 4 FINE
TRAN
T2 S2 T2 F2 T2 S2 T2 F2
TAP
3
5
7
9
11 13 15
1
SWITCH
POSITION
1
2
3
4
2
4
X
6
X
X
X
X
X
8
X
X
10
12
X
14
X
X
X
X
X
16
X
X
NOTE:
Remove this jumper
and use these pins
when connecting a
replacement 7977964
Control PCB
Art # A-07209
A-2
April 27, 2006
FABRICATOR 210
BR1
+
Bridge Rectifier
Inductor
8&8A BRN
SW3
(11)
(10)
(9)
(14)
(13)
F7
+ C1
Varistor
9&9A BLK
R1
C2
F1-S2
COARSE
F2
11&11A GRY
S3
SW4
(12)
(11)
FINE
(10)
(9)
12&12A BRN
(14)
(13)
13&13A VIO
10K
5 PNK
10&10A RED
200,000uF
(16)(15)
(16)
S1
S7
48 ORN
(12)
POSITIVE
OUTPUT
TERMINAL
-
F3-S4
NEGATIVE
OUTPUT
TERMINAL
47 GRY
T2
J1
F4
(15)
A
B
C
D
E
F
G
H
I
J
2 & 2A PNK 0V F6
Torch Trigger
57 VIO
6 VIO
Wire Feeder Motor
55 BLK
WIRESPEED
1K
9 RED
M2
18-1SF
54A BLK
WHITE 4
49A BLU
CB2
5A
+
-
38 WHT
TH2
7 VIO
S5
230V
TRANS 210 US COIL
52A BRN
53 WHT
15&15A BLU
SPOOL
MIG
2 RED
54 BLK
SPOOL
MIG
MIG
SW2
52 BRN
5 ORN
49 BLU
48 ORN
47 GRY
8 BRN
43 BLK
39 RED
36 GRY
JA/1
JA/2
JB/2
JB/1
JA/3
JA/9
JA/7
JA/6
JA/8
JA/4
JA/3
JA/5
JA/6
JA/7
JC
38A WHT
LED
SPOOL
TEMP
37 ORN
TH1
F5-S6
208V
43A BLK
14&14A BLK
Main PCB 7977964 (PCB1)
MIG Timer PCB
7977965 (PCB2)
Art # A-07209
April 27, 2006
A-3
FABRICATOR 210
APPENDIX 3: FEEDROLL KITS
DRIVE ROLL KITS (#375980-Series) 2 ROLL
Top
Bottom
Wire Type
Style 1
Style 2
Flat
Double
Smooth "V"
Flat Knurled
Double
Smooth "V"
Hard
Hard
375980-031
-
Style 3
Double Smooth
"V"
Double Smooth
"V"
Style 4
Double
Knurled "V"
Double
Knurled "V"
Soft/Hard/Tubular Hard/Tubular
Style 5
Style 6
Double Cog
Double "U"
Double Cog
Double "U"
Tubular
Soft (Aluminum)
Wire Size
.023" / 0.6mm
-
-
-
-
.030", .035" / 0.8, 0.9mm
375980-001 375980-003
375980-010
-
-
.030", .035", .045" / 0.8, 0.9, 1.2mm
375980-028* 375980-029
-
-
-
-
.035" / 0.9mm
375980-040*
-
-
-
-
375980-032
-
-
375980-030
-
-
-
-
375980-092
375980-022
-
-
375980-033
-
.035", .045" 3/64" / 0.9, 1.2, 1.2mm
.045" / 1.2mm
3/64 / 1.2mm
.052" / 1.3mm
.052", 1/16" / 1.3, 1.6mm
375980-002* 375980-004
-
-
375980-011
-
375980-090*
-
-
375980-012
-
-
-
375980-017
375980-023
Notes: 1) One Kit is supplied standard w ith each w ire feeder.
2) Drive Roll Kits include: Drive Rolls; Input, Output & Center Guides
3) Narrow 30° "V"
A-4
April 27, 2006
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of
merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whether
arising out of contract, tort, including negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1st 2006
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERS
W ARRANTY P ERIOD
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
LABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer ............................................................. See the Engine Manufactures Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
PLASMA WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
1 year
SMAW (Stick) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
GENERAL ARC EQUIPMENT
W ARRANTY P ERIOD
LABOR
Water Recirculators ....................................................................................................................... 1 year
1 year
Plasma Welding Torches.............................................................................................................180 days
180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
Nil
Nil
MIG, TIG and Plasma welding torch consumable items................................................................... Nil
Nil
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: [email protected]
www.thermalarc.com
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