Thermal Arc 251 FABRICATOR Service Manual

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251

FABRICATOR

MIG WELDING MACHINE

Service Manual

Revision No: AG Issue Date: June 15, 2006 Manual No.: 0-4786B Operating Features:

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230 V

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 251 MIG Welding Machine Service Manual Number 0-4786B for: Package System Part Number 100048D-002 Power Source Part Number 707237

Published by: Thermadyne Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: June 15, 2006 Revision AG Date: May 23, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 Principal Safety Standards ............................................................................. 1-4

1.03 Precautions De Securite En Soudage A L’arc.................................................. 1-5

1.04 Dangers relatifs au soudage à l’arc ................................................................. 1-5

1.05 Principales Normes De Securite ..................................................................... 1-8

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 General Information ....................................................................................... 2-3

2.06 Safety ............................................................................................................. 2-3

2.07 Protective Filter Lenses .................................................................................. 2-3

2.08 User Responsibility ........................................................................................ 2-3

2.09 Duty Cycle ...................................................................................................... 2-4

2.10 Specifications for Fabricator 251 .................................................................... 2-4

2.11 Included Items for Fabricator 251 .................................................................. 2-6

2.12 Optional Accessories ...................................................................................... 2-6

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location ......................................................................................................... 3-1

3.03 Ventilation ...................................................................................................... 3-1

3.04 Primary Power Requirements ........................................................................ 3-2

3.05 Alternative Primary Input ............................................................................... 3-2

3.06 Quick Setup .................................................................................................... 3-4

3.07 Installation of Shielding Gas (GMAW) Process .............................................. 3-4

3.08 Attaching the Gun and Cable Assembly to the Power Source ......................... 3-7

3.09 Input And Output Wire Guide Installation ....................................................... 3-9

3.10 Selection and Installation of Feedrolls ............................................................ 3-9

3.11 Installing Wire Spool .................................................................................... 3-10

3.12 Inserting Wire into the Feedhead .................................................................. 3-11

3.13 Wirefeeder Feed Roll Pressure Adjustment .................................................. 3-12

3.14 Wire Spool Hub Brake .................................................................................. 3-12

3.15 Spool Gun Attachment ................................................................................. 3-13

3.16 Polarity Changeover ..................................................................................... 3-14

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 Power Supply Controls, Indicators and Features ............................................ 4-1

4.02 Weld Mode Selector ....................................................................................... 4-6

4.03 TWECO Weldskill 300 AMP Weld Gun ............................................................ 4-8

4.04 Installing A New Wire Conduit ........................................................................ 4-8

4.05 MIG Gun Maintenance .................................................................................. 4-10

4.06 Basic Welding Technique.............................................................................. 4-10

4.07 Stitch Welding Operation .............................................................................. 4-12

4.08 Spot Welding Operation ............................................................................... 4-13

4.09 Gas Selection for Gas Metal Arc Welding ..................................................... 4-14

4.10 Welding Setting Selection Guide .................................................................. 4-16

SECTION 5:

MAINTENANCE & TROUBLESHOOTING .......................................................... 5-1

5.01 Routine Maintenance & Inspection................................................................. 5-1

SECTION 6:

TROUBLESHOOTING ................................................................................ 6-1

6.01 Basic Troubleshooting .................................................................................... 6-1

6.02 Solving Problems Beyond the Welding Terminals .......................................... 6-2

6.03 Welding Problems .......................................................................................... 6-4

6.04 Power Supply Problems ................................................................................. 6-6

SECTION 7:

ADVANCED TROUBLESHOOTING .................................................................. 7-1

7.01 Preliminary Checks......................................................................................... 7-1

7.02 Initial Setup Conditions .................................................................................. 7-2

7.03 Primary Power Test ........................................................................................ 7-2

7.04 Logic and Control Tests.................................................................................. 7-3

7.05 Spool Gun Control (J1) Test ........................................................................... 7-4

7.06 Output Voltage Test ........................................................................................ 7-5

7.07 Wire Feed & Weld Test .................................................................................. 7-6

7.08 Primary Power Problems ............................................................................... 7-6

7.09 Logic and Control Problems ........................................................................... 7-7

7.10 Spool Gun Control (J1) Problem .................................................................... 7-8

7.11 Output Voltage Problem ................................................................................. 7-8

7.12 Wire Feed and Weld Problems ....................................................................... 7-9

7.13 Terminal Block Voltage Test............................................................................ 7-9

7.14 SW3 Coarse and SW4 Fine Rotary Switch Test ............................................ 7-10

7.15 MIG Timer PCB (PCB2) Test......................................................................... 7-12

7.16 Rectifier Assembly Test ............................................................................... 7-13

7.17 Main Transformer Test ................................................................................. 7-14

TABLE OF CONTENTS

SECTION 8:

CIRCUIT OPERATION................................................................................ 8-1

8.01 Circuit Operation Of The Control PCB 7977964 .............................................. 8-1

8.02 Circuit Operation Of The MIG Timer PCB 7977965 ......................................... 8-2

8.03 Circuit Operation Of The Digital Volt/Amp PCB 704883 .................................. 8-2

8.04 Circuit Operation Of The Spool Gun PCB 7978034 ......................................... 8-3

SECTION 9:

PARTS LIST .......................................................................................... 9-1

9.01 Equipment Identification................................................................................. 9-1

9.02 How To Use This Parts List ............................................................................ 9-1

9.03 External Replacement Parts............................................................................ 9-2

9.04 Internal Replacement Parts (1) ...................................................................... 9-4

9.05 Major Electrical and Mechanical Replacement Parts ...................................... 9-6

9.06 Internal Replacement Parts (2) ...................................................................... 9-7

9.07 Internal Replacement Parts-Spool Assembly ................................................. 9-8

9.08 Internal Replacement Parts-Wire Feeder ........................................................ 9-9

9.09 Wire Feeder Replacement Parts.................................................................... 9-10

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES ...................................... A-1

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM ................................................... A-2

APPENDIX 3: MAIN PCB CIRCUIT DIAGRAM ........................................................... A-4

APPENDIX 4: SPOT TIMER CIRCUIT DIAGRAM ....................................................... A-6

APPENDIX 5: SPOOL GUN PCB .......................................................................... A-8

APPENDIX 6: FEEDROLL KITS .......................................................................... A-10

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

FABRICATOR 251

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

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor level.

15. Keep all panels and covers securely in place.

WARNING

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.

June 15, 2006

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.

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3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from 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.

Eye protection filter shade selector for welding or cutting

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen C utting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

1-2

(goggles or helmet), from AWS A6.2-73.

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

June 15, 2006

WARNING

FABRICATOR 251

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

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.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

June 15, 2006

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

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1.02 Principal Safety Standards

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

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.

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FABRICATOR 251

1.03 Precautions De Securite En Soudage A L’arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des 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.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

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.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

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.

June 15, 2006

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FABRICATOR 251

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et 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.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la 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)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

épais plus de 6 po. (150 mm) 5 ou 6

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

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

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

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)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

1-6

June 15, 2006

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

FABRICATOR 251

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

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.

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.

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.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

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.

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.

June 15, 2006

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1-7

FABRICATOR 251

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.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

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.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

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.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

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.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

1-8

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.

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.

June 15, 2006

FABRICATOR 251

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.

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.

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.

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 Thermadyne at the address and phone number in your area listed in the inside back cover of this manual. Include the Service 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

June 15, 2006

2-1

FABRICATOR 251

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

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.

Burnback Time

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

June 15, 2006

FABRICATOR 251

2.05 General Information

The Fabricator 251 is a semiautomatic Gas Metal Arc Welder (GMAW-commonly MIG) with an integrated wire feed unit. The Power Supply is designed to meet the broad operating needs of the metal fabrication industry where production efficiency is vital. The Fabricator 251 is designed and manufactured to meet the requirements of CSA and IEC 60974-1 standards.

The Fabricator 251 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 251 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.

2.07 Protective Filter Lenses

Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infrared, ultraviolet radiation and a percentage of the visible light. Such filter lenses are incorporated within face shields. To prevent damage to the filter lenses from molten or hard particles an additional hard clear glass or special plastic external cover lens should be used. This cover lens should always be kept in place and replaced before the damage impairs your vision while welding.

Filter lens

Approximate range of

welding current

Up to 150 Shade 10

150-250 Shade 11 250-300 Shade 12 300-350 Shade 13

Over 350 Shade 14

required for

MIG

2.06 Safety

The following basic safety rules should always be followed:

• Ensure the machine is correctly installed, if necessary, by a qualified electrician.

• Ensure the Power Supply is grounded correctly (electrically) in accordance with local regulations.

• Excessive heat in the welding cables may cause fire. Never weld with poor electrical connections, damaged welding cables or exceed the welding cable current rating as this will produce excessive heat and may cause a fire.

• Always wear the correct protective clothing for protection from sparks, molten particles and arc rays.

• When welding in confined spaces, always ensure adequate ventilation and constant observation of the operator.

• Keep combustible materials away from the welding area. Have a suitable fire extinguisher 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.

Table 2-1: Filter Lens Size Versus Welding Current

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.

2.08 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Thermal Arc. Advice in this regard can be obtained by contacting Thermal Arc.

This equipment or any of its parts should not be altered from standard specification without prior written approval of Thermal Arc. The purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc.

June 15, 2006

2-3

FABRICATOR 251

2.09 Duty Cycle

The rated duty cycle of a welding Power Supply is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain the ten minute duty cycle period the following example is used. Suppose a welding Power Supply is designed to operate at 60% duty cycle, 250 amperes at 26.5 volts. This means that it has been designed and built to provide the rated amperage (250A) at the rated load voltage (26.5V), for 6.0 minutes out of every 10 minute period (60% of 10 minutes is 6.0 minutes). During the other 4.0 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.

2.10 Specifications for Fabricator 251

MIG Gun Specifications

Gun Catalog Number 43340 Gun Type TWECO Weldskill 300 Amp Gun Cable Length 15 ft (4.5m)

Table 2-2: MIG Gun Specifications

Wire Drive Specifications Fabricator 251

Control Circuit Supply Wire Drive Motor Supply

Wire Speed Range

30VA @ 32VAC

180VA @ 14 to 46VAC

80 to 800 ipm

(2 to 20 m/min)

Wire Diameter

.023

(0.6mm)

.030

(0.8mm)

.035

(0.9mm)

Mild Steel: YYYY

Stainless Steel: Y Y Y Y

Aluminum: Y Y Y Y

Flux Cored: Y Y Y Y

Wire Spool Size Capacity

Table 2-3: Wire Drive Specifications

44 lb, 33 lb, 10 lb, 8" and 12" wire spool sizes.

.045

(1.2mm)

1/16

(1.6mm)

2-4

June 15, 2006

FABRICATOR 251

Fabricator 251

Package System Part Number Power Source Part Number Power Source Weight Power Source Dimensions HxWxD

(including wheels and cylinder carrier) Nominal Input Voltage 208V 230V

Number of Phases Frequency Flexible Supply Cable Size

Supply Plug Rated Input Current @ 100% Duty Cycle * 36A * 32.6A

Rated kVA @ 100% Duty Cycle 7.5 kVA 7.5 kVA Maximum Input Current @ 250A Output 68A 62A Generator Requirements 20 kVA 20 kVA Supply VA @ Maximum Output 15 kVA 15 kVA Recommended Primary Circuit Size 50A 50A Recommended Minimum Primary Fuse Size ** 70A ** 70A Open Circuit Voltage Range 15.6 – 45.9V DC 15.6 – 45.9V DC Welding Arc Voltage Range 14.5 – 31.7V DC 14.5 – 31.7V DC Output Current Range 20 – 300A DC 20 – 300A DC Rated Output Duty Cycle @ 104ºF 250A/26.5V @ 60% 250A/26.5V @ 60% Maximum Duty Cycle @ 104ºF 300A/31.7V @ 40% 300A/31.7V @ 40% 100% Duty Cycle Output Rating @ 104ºF 195A DC at 24V 195A DC at 24V Duty Cycle Period Number of Output Voltage Values

Electrode Wire Type and Diameter

Mild / Stainless Steel

Aluminum

Flux Cored Wire Feed Speed Range Wire Spool Size Diameter Burn-Back Timer Range Burn-Back Time Factory Set to Spot Timer Range Dwell Timer Range Stitch Weld Time Weld (Stitch) Time Dwell (non-weld) Time Thermal Protection

Operating Temperature Range

.023” (0.6mm) – .045” (1.2mm) .030” (0.8mm) – 1/16” (1.6mm) .030” (0.8mm) – 1/16” (1.6mm)

Self-resetting thermostat fitted to rectifier and

100048D-002

707237

227lb (103kg)

32” x 27-3/16” x 36-3/4”

(813 x 691 x 933mm)

1Ø

60 Hz

10ft (3m) 10AWG

NEMA 6-50P

10 minutes

80 – 800 ipm (2 – 20 m/min )

8” / 12” (200mm / 300mm)

0 – 0.6 seconds

0.16 seconds

0.5 – 9 seconds 1 – 12 seconds

transformer

32° to 104°F (0° to 40°C)

* The Rated Input Current shoul d be us ed for the determ ination of cable s ize & s upply requirements.

** Mot or s t art fus es or t herm al circui t break ers are rec omm ended for this applic at ion. Check local requirements for your s i t uation in this regard.

June 15, 2006

Table 2-4: Machine Specifications

2-5

FABRICATOR 251

2.11 Included Items for Fabricator 251

Fabricator 251 Package System Contents

Factory Fitted Wheeling Kit Factory Fitted Dual Cylinder Rack Factory Fitted Primary Power Cable 8AWG, 10ft (3m) with Plug NEMA 6-50P Work Lead 10ft (3m) Cable Stowage Hooks Y Regulator/Flow Meter – Argon Mix Gases Y Tweco Weldskill MIG Gun 300 Amp, 15ft (4.5m) Fitted Feed Roll for .035” - .045” (0.9 – 1.2mm) solid wire Y Accessories Box Y

Table 2-8: Power Supply Contents

2.12 Optional Accessories

Refer to the Appendix section of this manual for the list of available options and accessories.

2-6

June 15, 2006

FABRICATOR 251

SECTION 3:

INSTALLATION

3.01 Environment

The Fabricator 251 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 wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

3.02 Location

Be sure to locate the Power Supply according to the following guidelines:

In areas, free from moisture and dust. In areas, free from oil, steam and corrosive gases. In areas, not subjected to abnormal vibration or shock. In areas, not exposed to direct sunlight or rain. Place at a distance of 1 foot (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" (140mm).

3.03 Ventilation

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

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.

June 15, 2006

3-1

FABRICATOR 251

3.04 Primary Power Requirements

The primary supply voltage should be within ± 10% of the rated primary 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 251 be electrically connected by a qualified electrical tradesperson.

The Fabricator 251 Power Supply is factory connected for the following input power supply voltage:

Input Power

Supply Lead Size

8 AWG 40 Amps 10ft (3m) 230V 250A @ 60%

Table 3-1: Factory Fitted Input Power Supply Leads Fitted to the Fabricator 251

Lead Current

Rating

Lead

Length

Machine

Voltage Setting Duty Cycle

3.05 Alternative Primary Input

WARNING

The Fabricator 251 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

Voltage Setting

208V 8AWG (8.0mm2) 50 Amps *70Amp 250A @ 60% 230V 8AWG (8.0mm2) 50 Amps *70Amp 250A @ 60%

Primary Input

Supply Lead Size

Input Power

Outlet Size Fuse Size Duty Cycle

Table 3-2: Primary Input Supply Lead Sizes for Alternative Mains Supply Voltages

*Motor start fuses or thermal circuit breakers are recommended for this application. 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

June 15, 2006

FABRICATOR 251

Changing the Voltage Selection

1. Disconnect the power supply from the input power source.

2. Refer to Figure 3-1. The power supply comes wired for 230V. Locate the two blue input power wires where they are secured to the input voltage selection block. Loosen the set screw for both voltage locations.

3. Remove the blue wires from the current location and Insert them into the new voltage location. Secure by tightening the set screw onto the uninsulated portion of the wires. Secure the other voltage set screw as well.

208V connection

230V connection

Art # A-07332

Figure 3-1: Voltage Selections for Fabricator 251 (Wired for 230V)

June 15, 2006

3-3

FABRICATOR 251

3.06 Quick Setup

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 3.07 and following subsections.

1. Connect the work lead to the negative (-) socket (positive + for Self Shielded Flux Cored Wire)

GUN

2. Connect the (negative - for Self Shielded Flux Cored Wire)

See Section 3.16 "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.

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, flow meter and gas cylinder.

lead to the positive (+) socket

NOTE

WARNING

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

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.

3-4

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).

June 15, 2006

FABRICATOR 251

“Cracking”

Regulator and Flow Meter

Cap

Shielding Gas

Gas Hose

1 1/8”

Stowage Hook

Shielding Gas

Art # A-07278

June 15, 2006

Figure 3-2 Gas Cylinder Installation

3-5

FABRICATOR 251

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 meters used with argon based and carbon dioxide shielding gases are 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

June 15, 2006

FABRICATOR 251

3.08 Attaching the Gun and Cable Assembly to the Power Source

The Fabricator 251 is supplied with a Tweco Weldskill 300 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 Chart

Art # A-07142

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.

June 15, 2006

3-7

FABRICATOR 251

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

June 15, 2006

FABRICATOR 251

3.09 Input And Output Wire Guide Installation

Refer to Figure 3-7. 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 feed 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 feed rolls as practical. Tighten the output guide lockscrew.

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

To ensure proper wire feed, the groove closest to the motor must match the electrode wire size being used.

.045” (1.2mm) Stamping

.045

1.2

.045” (1.2mm) Groove

Art: A-07150

The size that is visible when ﬁtting the feedroll is the groove size in use.

Figure 3-8: Feedroll 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.

Art # A-07445

Input Wire Guide

Output Wire Guide

Figure 3-7: Wire Guide Installation

3.10 Selection and Installation of Feedrolls

A Feedroll 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.

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.

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.

NOTE

Installation of all styles of feed rolls for the Fabricator 251 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.

June 15, 2006

3-9

FABRICATOR 251

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

3.14 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

* The Spring is for use with smaller 10 lb wire spools only

3-10

Drive Pin

Art # A-07192

Figure 3-9: Spool Installation

June 15, 2006

FABRICATOR 251

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.

2 - Swing Pressure arm

1 - Loosen Adjuster and swing down

Art # A-07143

open

3 - Feed wire theough here

4 - Feed wire through here

Figure 3-10: Opening Pressure Arm and Inserting Wire

7 - Adjust the tension

Figure 3-11: Closing Pressure Arm and Adjusting Tension

June 15, 2006

5 - Swing the Pressure Arm closed

6 - Swing the Adjuster back into place.

Art # A-07144

3-11

FABRICATOR 251

Wheel Brake Hex Head Bolt

Spool Hub Nut

Figure 3-12: Wire Installed

3.13 Wirefeeder Feed Roll Pressure Adjustment

Pressure Adjustment Device

Art # A-07162

The idler roll on the swing arm applies pressure to the grooved drive roll via an adjustable tension devise. The Pressure Adjustment Device 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 Pressure Adjustment Device 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 Spool Hub Brake

The wire spool 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 spool 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 components and possibly an increased incidence of wire Burnback into the contact tip.

Correct adjustment will result in the wire spool 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

NOTE

June 15, 2006

FABRICATOR 251

3.15 Spool Gun Attachment

A spool gun can readily be used with the Fabricator 251 power supply.

1. Attach appropriate input gas to the Spool Gun input gas connection on the rear of the unit. (Refer to Figure. 3-

13)

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)

Spool Gun 10 Pin

Socket

Spool Gun

Gas Input Connection

Main Gun Gas Input Connection

Rear Panel

Spool Gun Gas Outlet Connection

Art # A-07345

When the SPOOL GUN is properly attached and the trigger is depressed, the system automatically disables the internal wire feed and gas controls and selects the SPOOL GUN feeder and gas control.

June 15, 2006

Front Panel

Figure 3-13 Spool Gun Connections

NOTE

3-13

FABRICATOR 251

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

PROCESS POLARITY

1. GMAW* – Steel, Stainless Steel, Aluminum & gas shielded Flux Cored electrode wires

2. FCAW* – Gasless Flux Cored electrode wire

* Exception - Contact your filler metal supplier for the recommended polarity.

Work Lead

Art # A-07163

CABLE TO GUN CABLE TO WORK

1. D.C. Electrode Positive (DCEP) – Reverse Polarity

2. D.C. Electrode Negative (DCEN) – Straight Polarity

1. Connected to (+) Pos. output terminal

2. Connected to (-) Neg. output terminal

Table 3-3: Process Cable Connections

Connected for D.C. Electrode Positive (DCEP) Welding

CABLE CONNECTIONS

1. Connected to (-) Neg. output terminal

2. Connected to (+) Pos. output terminal

Figure 3-14: Polarity Connections for DCEP

3-14

June 15, 2006

Work Lead

Connected for D.C. Electrode Negative

Art # A-07164

(DCEN) Welding

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.

FABRICATOR 251

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.

June 15, 2006

3-15

FABRICATOR 251

NOTES:

3-16

June 15, 2006

FABRICATOR 251

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

Digital Display

Voltage / Amp Selection Button

Front Panel Access Hole Torch

Gun Switch Amphenol Receptacle

Negative Welding Terminal

Thermal Overload Indicator

A/V

Weldskill

17V - 21V

13V - 16V

22V - 31V

Wire Feed Speed Control

Power On/Off Switch Coarse Voltage Selector Switch

Fine Voltage Selector Switch

Spool Gun Gas Outlet

Spool Gun Interface

Amphenol Receptacle

Gun Polarity Lead

Positive Welding Terminal

Art # A-07034

June 15, 2006

Figure 4-1: Fabricator Controls

4-1

FABRICATOR 251

On / Standby Power Switch

The indicator light is provided to indicate when the Fabricator 251 is connected to the Primary Input Power Supply Voltage.

With the On/Off Switch in the Off 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 Primary supply voltage and the internal electrical components are at Mains voltage potential.

Digital Display

The Digital Display allows for accurate monitoring (5% tolerance) of welding current and voltage to facilitate precise welding condition adjustments.

Value displayed for 157 Amp

Value displayed for 21.9 Volts

Art # A-07279

Figure 4-2: Digital Display

The Digital Meter will display both welding current or arc voltage. To toggle between the current and voltage readings depress the push button switch mounted below the meter display.

4-2

June 15, 2006

FABRICATOR 251

The Digital Meter will hold the last reading at completion of welding for 10 seconds to allow for easy operator set up.

Digital AMP Reading to IPM Conversion

STEEL

900

800

700

600

500

400

Wire Speed (IPM)

300

200

100

25 50 75 100 125 150 175 200 225 250 275 300 325

(.023 - STEEL)

(.030 - STEEL)

(.035 - STEEL)

Current (Amps)

(.045 - STEEL)

Art # A-07451

Figure 4-3: Steel - AMP to IPM Conversion

STAINLESS STEEL

900

800

700

600

500

400

Wire Speed (IPM)

300

200

100

25 50 75 100 125 150 175 200 225 250 275 300 325

(.023 - SS)

June 15, 2006

(.030 - SS)

(.035 - SS)

(.045 - SS)

Current (Amps)

Figure 4-4: Stainless Steel - AMP to IPM Conversion

Art # A-07452

4-3

FABRICATOR 251

900

800

700

600

ALUMINUM

500

400

Wire Speed (IPM)

300

200

100

25 50 75 100 125 150 175 200 225 250 275 300 325

(.030 - AL)

(.035 - AL)

(.047 - AL)

Current (Amps)

Art # A-07453

Figure 4-5: Aluminum - AMP to IPM Conversion

Thermal Overload

The critical components 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 varies the wirespeed 80 - 800 ipm (2 - 20 m/min), i.e. the speed of the wire feed motor.

Coarse Voltage Control Switch

The Coarse Voltage Control sets the voltage level to the welding terminals as it is rotated from L to H. Clock wise to increase.

Fine Voltage Control Switch

The Fine Voltage Control switch increases the voltage (in smaller increments than the Coarse switch) as it is rotated from position 1 to 8. Clock wise to increase.

The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process.

4-4

CAUTION

June 15, 2006

FABRICATOR 251

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.

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.

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.

Spool Gun Interface Amphenol Connector

The Spool Gun Interface 10 pin connector is used to connect a spool gun to the Fabricator 251 (refer to Figure 4-4 and Table 4-1).

Art # A-07181

Figure 4-4: Spool Gun 10 pin Receptacle

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

251. Only pins 1 and 2 are used for this.

To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

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 Function

A Not Used B Spool Gun Motor (-) C Spool Gun Motor (+) D Spool Gun Switch

Spool Gun Speed C.W.

Potentiometer Spool Gun Speed Wiper

Potentiometer

G Spool Gun Switch

Spool Gun Speed C.C.W.

Potentiometer I Not Used J Not Used

Table 4-1: 10-pin Receptacle Pin Functions

Art # A-07171

Figure 4-3: Gun Switch Receptacle

June 15, 2006

NOTE

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.

4-5

FABRICATOR 251

BURNBACK

WELD MODE

MIN

WELD

(SPOT / STITCH)

(STITCH)

SPOT

STITCH

t t

MIN

DWELL

WELD MODE

SPOT

STITCH

4.02 Weld Mode Selector

The Weld Mode Selector switch selects the method of welding mode.

Art # A-07183

DWELL

(STITCH)

MIN

BURNBACK

Figure 4-5: Internal Welding Controls

WELD MODE

STITCH

SPOT

WELD

(SPOT / STITCH)

MIN

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.

Figure 4-6: For Reference only

Art # A-07427

WELD MODE

STITCH

SPOT

SPOT:

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. (Refer to Figure 4-6 for control).

Art # A-07466

Figure 4-7: Spot Weld

NOTE

A spot nozzle should be used on the MIG gun to obtain consistent spot welds.

4-6

June 15, 2006

FABRICATOR 251

WELD MODE

SPOT

STITCH

MIN

WELD

(SPOT / STITCH)

(STITCH)

MIN

DWELL

BURNBACK

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. (Refer to Figure 4-6 for control).

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

STITCH

SPOT

DWELL STITCH TIMER CONTROL

DWELL (STITCH) CONTROL KNOB

When the Weld Mode control is in the Stitch position, the Dwell (Stitch) timer controls the length of the non-weld portion of stitch welding off time when wire stops feeding.

DWELL

(STITCH)

MIN

Art # A-07430

Figure 4-11: Dwell (Stitch) Timer 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.

BURNBACK

Art # A-07427

Figure 4-9: For Reference only

WELD (Spot/Stitch) ,MODE SELECTOR

WELD MODE - SPOT

When the Weld Mode control is in the Spot position, the Weld (Spot/Stitch) timer 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) timer controls the length

of the stitch weld on time when wire feeds.

(SPOT / STITCH)

MIN

Figure 4-10: Weld (Spot/Stitch) Timer Control

Art # A-07429

Art # A-07431

Figure 4-12: Burnback Control

WELD

June 15, 2006

4-7

FABRICATOR 251

4.03 TWECO Weldskill 300 AMP Weld Gun

The TWECO Weldskill 300 AMP gun fitted to the FABRICATOR 251 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.

Art # A-07210

Figure 4-13: TWECO WeldSkill 300 AMP

Original Parts Installed

Item Des cription Part No . Qty

1 NOZZ LE 24A-62 1 2 NOZZLE INSULATOR 34 1 3 C ONTACT TIP 14 -35 1 4 GAS DIFFUSER 54A 1 5 CONDUCTOR TUBE WM63J-50 1 6 HANDLE ASSY TA1-80 1 7 TRIGGER SW ITCH WM91 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.

4.04 Installing A New Wire Conduit

1. Be sure the MIG gun cable is arranged in a straight line, free from twists, when installing or removing a wire conduit. Remove the old conduit by first removing the MIG gun nozzle, contact tip, insulator and gas diffuser. Then loosen Allen screws in the conductor tube and connector plug and pull the old wire conduit out of the cable assembly from the connector plug end.

4-8

June 15, 2006

FABRICATOR 251

2. To install a new conduit, first inspect the o-ring gas seal on the conduit for cuts or damage. 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.

When the 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, tighten the Allen screw in the connector plug onto the conduit to prevent its backward movement.

CONDUCTOR TUBE

CONDUIT LINER

ALLEN SCREW

REMOVE CONSUMABLES

1 1/16" (27mm)

O-RINGS

Art # A-07330

CONDUIT LINER

ALLEN SCREW

CONNECTOR PLUG

Figure 4-14: Conduit Trim Length

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 4-14. 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.

3. Replace Gas Diffuser, Contact Tip, Insulator and Nozzle.

4. Tighten the Allen screw in the conductor tube.

Do not over tighten the conductor tube screw as this action will result in the distortion of the conduit and will lead to wire feed problems.

June 15, 2006

CAUTION

4-9

FABRICATOR 251

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 251 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 4-15.

Forehand

Art # A-05148

Vertical

Figure 4-15: MIG Gun Angle

4-10

June 15, 2006

FABRICATOR 251

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.

Art # A-07186

1/4” (6.4mm)

.023”

(.6mm)

Solid Wire

5/16” (7.9mm)

.030”

(.8mm)

3/8” (9.5mm)

.035”

(.9mm)

Flux Cored Wire

9/16”

(14.3mm)

.035”

(.9mm)

11/16”

(17.5mm)

Figure 4-16: 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,

Tip

Contact

.045”

(1.1mm)

Gas

Nozzle

Distance: ±1/16”

Wire Diameter

- 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 mm

. An example is in Table 4-3 below.

Electrode Wire Size Current (Amps) Current Density(Amps/mm2) Deposition Rate(lbs/hour)

.035”( 0.9mm) 200 314 7.0 .045”(1.2mm) 200 177 6.2

Table 4-3: .035" (0.9mm) , .045"(1.2mm) Wire Deposition Rate

June 15, 2006

4-11

FABRICATOR 251

Advantages of MIG welding forehand:

- Allows superior visibility of the weld zone

- Flatter weld bead

- Shallower penetration

Forehand

Vertical

Backhand

Art # A-07185

Figure 4-17: 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) Time

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.

4-12

June 15, 2006

FABRICATOR 251

4.08 Spot Welding Operation

Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to the spot welding nozzle table below. The Fabricator 251 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 selector switch to SPOT.

Spot Time

Adjust the WELD (Spot/Stitch) timer control knob for the desired weld or ‘ON’ time for spot welding.

Dwell Time

The

DWELL (Stitch)

timer control knob has no affect in this mode of operation.

SPOT WELDING NOZZLES

TYPE NO.4 400 AMP

Flat Arc Spot

Inside Corner Arc Spot 24A-75-IAS

Outside Corner Arc Spot 24A-75-IAS

Automotive Stud Nozzle N/A

24A-62-FAS 1240-1520 (5/8" Bore) 24A-75-FAS 1240-1530 (3/4" Bore) 24A-100-FAS 1240-1550 (1" Bore)

1240-1531 (3/4” Bore)

1240-1532 (3/4” Bore)

June 15, 2006

4-13

FABRICATOR 251

4.09 Gas Selection for Gas Metal Arc Welding

Suggested

Shielding

Gas

100% CO

Welding

Positions

All

Position

High welding speeds. Good penetration and pool control.

Metal Type

Carb on

Steel

Base Plate

Thickness

Greater than 22

gauge (.030”)

Filler Metal

Transfer

Mode

ER70S-X Short

Circuit

Welding

Greater than 22

gauge (.030”)

ER70S-X Short

Circuit

75% Argon

25% CO2

All

Position

Suitable for high-current and highspeed welding.

Welding

Greater than 22

gauge (.030”)

ER70S-X Short

Circuit

92% Argon

8% CO2

All Position Welding

Higher deposition rates without meltthrough. Minimum distortion and spatter. Good pool control for out-ofposition welding.

Greater than 10

gauge (1/8”)

ER70S-X Spray

Transfer

92% Argon

8% CO2 or

Flat & HV

Fillet

Good arc stability, weld soundness, and increasing width of fusion.

minimum

80% Argon

20% O2

Low Alloy

and High

Alloy Steel

Greater than 22

gauge (.030”)

See * below Short

Circuit

Globular

75% Argon

25% CO2

All Position Welding

High welding speeds. Good penetration and pool control. Applicable for out-of-position welds. Suitable for high-current and highspeed welding.

Greater than 22

gauge (.030”)

See * below Short

Circuit

92% Argon

8% CO2

All Position

Good coalescence and bead contour. Good mechanical properties.

Welding

Greater than

3/32”

See * below Spray

transfer

92% Argon

8% CO2 or

minimum

80% Argon

Flat & HV

Fillet

Reduces undercutting. Higher deposition rates and improved bead wetting. Deep penetration and good mechanical properties.

20% O2

Greater than 14

gauge (.075”)

See * below Short

Circuit

98% Argon

2% CO2

All Position Welding

Good control of melt-through and distortion. Used also for spray arc welding. Pool fluidity sometimes sluggish depending on the base alloy.

Stainless

Steel

Greater than 22

gauge (.030”)

ER308-X ER309-X ER316-X

Short

Circuit

90% Helium

7.5% Argon

2.5% CO2 or 81% Argon

18% Helium

1 % CO2

All Position Welding

Low CO

percentages in Helium mix

minimizes carbon pickup, which can cause intergranular corrosion with some alloys. Helium improves wetting action and contour. CO above 5% should be used with caution on some alloys.

Greater than

3/32”

ER308-X ER309-X ER316-X

Spray

Transfer

90% Helium

7.5% Argon

2.5% CO2 or 81% Argon

18% Helium

Flat & HV

Fillet

Good arc stability. Produces a fluid but controllable weld pool, good coalescence, and bead contour. Minimizes undercutting on heavier thickness.

1 % CO2

Aluminum

Greater than 18

gauge (.045”)

ER4043 ER5356

Spray

Transfer

Argon All

Position Welding

Excellent cleaning action. Provides more stable arc than helium-rich mixtures.

* Contact your Filler Metal Supplier for recommended filler metal for the base metal to be welded.

Comments

percentages

4-14

Table 4-4: Gas Selection Chart

June 15, 2006

FABRICATOR 251

THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK

June 15, 2006

4-15

FABRICATOR 251

4.10 Welding Setting Selection Guide

Material Type Wire Type

Solid

Steel

(or hard)

ER70S-6

Shielding Gas

and Flow Rate

100% CO

25cfh

75% Ar 25%

,25cfh

92% Ar

8% CO

Wire Size

(Diameter)

.035” (0.9mm) .045” (1.2mm)

.023” (0.6mm) .030” (0.8mm)

.035” (0.9mm) .045” (1.2mm)

.023” (0.6mm) .030” (0.8mm)

.035” (0.9mm) .045” (1.2mm)

Aluminum

Stainless

Art # A-07439

Steel

100%CO

25cfh

Flux Core

E71T-1

E71T-GS

E71T-11

None

Aluminum

4043 ER 5183 ER 5356 ER

Stainless

ER308LSi ER309LSi ER316LSi

Table 4-5: Welding Selection Guide

100% Ar

25cfh

7.5% Ar 90% He

2.5% CO 35cfh

.045” (1.2mm) 1/16” (1.6mm)

.030” (0.8mm) .035” (0.9mm)

.045” (1.2mm) 1/16” (1.6mm)

.030” (0.8mm) .035” (0.9mm)

.045” (1.2mm)

.030” (0.8mm) .035” (0.9mm)

4-16

June 15, 2006

FABRICATOR 251

22 ga. (0.8mm) 18 ga. (1.2mm) 16 ga. (1.6mm) 1/8” (3.2mm) 1/4” (6.4mm) 3/8” (9.5mm) 1/2” (12.7mm) 5/8” (15.9mm)

Coarse

Voltage

Fine

Voltage

M/2

1.5

L/6 L/6

1.5

M/1

2.25

M/1

1.5

L/8

2.25

L/8

1.25

M/1

2.75

M/2

1.75

M/1

1.25

Coarse Voltage

Fine Voltage

Step

M/3

1.5

M/5

1.75

M/1

M/3

M/4

2.5

L/8

1.5

M/2

4.5

M/3

2.5

M/4

2.5

L/8

1.5

Wire

Speed

M/4 M/7

M/5 M/5

M/5 M/6

2 2

4.5 4

3.25 2

4.5 3

2.25

H/1 H/2

M/8 M/7 M/8

H/2 H/3

H/4 H/4

3.5

5.25

5.75 3

7.75

5.75

5.5 3

THICKNESS

H/3

3.5

H/1

6.75

H/2

4.25

H/4

6.5

H/5

3.25

H/4 H/5

H/3 H/3 H/4

H/5 H/7 H/6

8.5

4.25

8.25 8 5

7.25

7.5

3.5

H/5

7.25

H/7

4.5

H/4

5.75

H/5

4.5

L/5

L/8 L/7

M/2 M/3

1.5

M/3

1.5

4.5

3.25

2.5 2

M/6 H/1

L/6 L/8

M/1

M/2 L/8

M/4 M/4

1.5

1.75 2

4.25 4

2.5

M/7 H/2

M/2 L/8

M/4 M/7

M/5 M/5 M/6

M/7 M/6

2.25 2

2.75 2

2 1

4.5 3

3.5

H/1 H/4

M/5 M/4

M/7 H/2

H/1 H/2 H/2

H/1 H/1

2.75 6

3.5

3.25

1.5 7

6.75

3.5

6.5

4.5

H/4

M/8 M/6

M/8 H/3

H/3 H/4

H/6 H/1

5.5

7.5

4.5

3.75

2.5

7.75 5

6 6

H/4

M/8 M/8

H/5 H/7

H/5

5.5

3.75

5.75

6.5 6

H/5

M/8 H/4

H/6

5.5

4.5

6.25

6.5

Art # A-07439

June 15, 2006

4-17

FABRICATOR 251

NOTES

4-18

June 15, 2006

FABRICATOR 251

SECTION 5:

MAINTENANCE & TROUBLESHOOTING

5.01 Routine Maintenance & Inspection

The only routine maintenance required for the Fabricator 251 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.

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.

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.

June 15, 2006

5-1

FABRICATOR 251

Warning! Disconnect input power before maintaining.

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Maintain more often if used under severe conditions

Each Use

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Gas lines

6 Months

Visually check and use a vacuum to carefully

clean the interior

Clean exterior of power supply

Art # A-07269

5-2

June 15, 2006

FABRICATOR 251

SECTION 6:

TROUBLESHOOTING

WARNING

Disconnect the Fabricator from the Input power supply voltage before disassembling.

WARNING

Do not attempt to diagnose or repair unless you have had training in electronic measurement and troubleshooting techniques.

6.01 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.

June 15, 2006

6-1

FABRICATOR 251

6.02 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

a. Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 25CFM (15 litres per minute) a. Check for gas leaks between the reulator/flowmeter 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.

Porosity

1. Gas cylinder contents and flow meter

2. Gas leaks

3. Internal gas hose in the power supply

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.

Disengage the drive roll when testing for gas flow by ear.

6-2

Table 6-1: Porosity Problems

WARNING

June 15, 2006

2. Inconsistent wire feed

FAULT CAUSE REMEDY

Inconsistent

Wire Feeding

1. Wire spool brake is too ti

2. Wire spool brake is too loose.

3. Worn or incorrect feed roller size.

4. Misalignment of inlet/outlet guides.

5. Liner blocked with slag.

6. Incorrect or worn contact tip.

7. Poor work lead contact to work piece.

8. Bent liner.

ht.

FABRICATOR 251

a. Feed roll driven by motor in the cabinet will slip.

a. Wire spool can unwind and tangle

a. Use ‘U’ groove drive feed roll matched to the aluminum wire size you are welding. b. Use ‘V’ groove drive feed roll matched to the steel wire size you are welding. C. Use ‘knurled V’ groove drive feed roll matched to the flux cored wire size you are welding.

a. Wire will rub against the misaligned guides and reduces wire feedability.

a. Slag is produced by the wire passing through the feed roller, if excessive pressure is applied to the pressure roller adjuster. Slag can also be produced by the wire passing through an incorrect feed roller groove shape or size. Slag 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

June 15, 2006

Figure 6-2: Trouble Shooting for Inconsistent Wire Feed

6-3

FABRICATOR 251

6.03 Welding Problems

FAULT CAUSE REMEDY

1. Welding arc voltage

A. Undercut 2. Incorrect torch

3. Excessive heat

4. Weld speed too fast a. Reduce weld speed.

too high.

angle

input

a. Reduce voltage by reducing the voltage

selection switch position or increase the wire feed speed.

a. Adjust angle

a. Increase the torch travel speed and/or

reduce welding current by reducing the voltage selection switch position or reducing the wirefeed speed.

1. Welding current too low

B. Lack of penetration 2. Joint preparation too

narrow or gap too tight

3. Shielding gas incorrect

4. Weld speed too fast a. Reduce weld speed.

C. Lack of fusion

2. Weld speed too fast a. Reduce weld speed.

1. Voltage too high a. Lower voltage by reducing the voltage

D. Excessive spatter 2. Voltage too low a. Raise voltage by increasing the voltage

3. Weld speed too fast a. Reduce weld speed.

1. Incorrect voltage and

1. Voltage too low a. Increase voltage by increasing voltage

current settings. Convex, voltage too low. Concave, voltage too high.

a. Increase welding current by increasing

wire feed speed and increasing voltage selection switch position.

a. Increase joint angle or gap

a. Change to a gas which gives higher

penetration

selection switch position.

selection switch or increase wirespeed control.

selection switch or reduce wirespeed control.

a. Adjust voltage and current by adjusting

the voltage selection switch and the wirespeed control.

E. Irregular weld

shape

3. Incorrect shielding

4. Insufficient or

5. Weld speed too fast a. Reduce weld speed.

2. Wire is wandering a. Replace contact tip

gas

excessive heat input

Table 6-3a: Welding Problems and Solutions

6-4

a. Check shielding gas.

a. Adjust the wire speed control or the

voltage selection switch.

June 15, 2006

FABRICATOR 251

FAULT CAUSE REMEDY

1. Weld beads are too small

2. Weld penetration narrow and deep

A. Weld cracking 3. Excessive weld

stresses

4. Excessive voltage a. Decrease voltage by reducing the

5. Cooling rate too fast a. Slow the cooling rate by preheating part

6. Weld speed too fast a. Reduce weld speed.

1. Faulty rectifier unit a. Have an Accredited THERMAL ARC

2. Loose welding cable connection.

3. Low Primary Voltage a. Contact supply authority

4. Weld speed too fast a. Reduce weld speed. C. Arc does not have a

crisp sound that short arc exhibits when the wirefeed

1. The MIG torch has been connected to the wrong polarity on the front panel.

speed and voltage are adjusted correctly.

2. Weld speed too fast a. Reduce weld speed.

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

voltage selection switch.

to be welded or cool slowly.

Service Agent to test then replace the faulty component.

a. Check all welding cable connections. B. Cold weld puddle

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.

June 15, 2006

Table 6-3b: Welding Problems and Solutions continued

6-5

FABRICATOR 251

6.04 Power Supply Problems

FAULT CAUSE REMEDY

A. Indicator light is ON but welding

arc can not be established.

is ON. Indicator light is not lit and welding arc can not be established.

C. Green ON/OFF indicator light is

not lit but welding arc can be established.

D. Primary power supply voltage is

ON and Indicator light is lit but when the gun trigger switch is depressed nothing happens.

E. Primary power supply voltage is

ON, no wire feed but gas flows from the MIG Gun when the gun trigger switch is depressed.

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. Power On/Off switch in “Off” position.

1. Primary fuse is blown. a. Replace primary fuse. B. Primary power supply voltage

2. Broken connection in primary circuit.

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

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 a. Replace

2. Worn feed roll a. Replace

3. Excessive back tension from wire reel hub roll.

4. Worn, kinked or dirty conduit liner

5. Low Swing Arm pressure a. Increase the Swing Arm

1. Gas hose is cut or pinched a. Check hose and replace or

2. Gas passage contains impurities

3. Gas regulator turned off a. Turn on.

a. Switch the power On/Standby

switch to the “On” position .

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. Reduce brake tension on spool

hub

a. Clean or replace conduit liner

pressure.

repair.

a. Disconnect gas hose from the

rear of Fabricator then raise gas pressure and blow out the impurities.

J. Gas flow continues after the gun

trigger switch has been released.

6-6

4. Gas cylinder is empty a. Check cylinder volume and replace or refill as needed.

1. Gas valve has jammed open due to impurities in the gas or the gas line.

a. Have an Accredited Thermal Arc

Service Agent repair or replace gas valve.

Table 6-4: Power Supply Problems

June 15, 2006

FABRICATOR 251

SECTION 7:

ADVANCED TROUBLESHOOTING

If the problem cannot be solved by the basic (external) trouble shooting guide, the Power Source covers and/or the Wire Feeder covers will have to be removed. The advanced level of troubleshooting allows the technician with a few common tools to remove the covers and analyze failures.

CAUTION:

Never open the Power Source covers unless the Mains supply voltage to the Power Source is disconnected from the Mains power point and the ON/OFF Power Switch Indicator is off

WARNING

Disconnect the Fabricator from the Input power supply voltage before disassembling.

WARNING

Do not attempt to diagnose or repair unless you have had training in electronic measurement and troubleshooting techniques.

7.01 Preliminary Checks

Vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

1. Check general machine completeness.

2. Check tightness of mounting and STRUCTURAL HARDWARE and all terminations and ELECTRICAL FITTINGS.

3. NO DEFORMATION present to detract from machine’s appearance or performance.

4. SWITCH AND KNOBS on front panel are secure and align with their respective markings and correct fuse(s) fitted.

5. AUXILIARY WIRING clear of Rectifier Heatsink, Inductor, Shunt or Main Transformer.

6. SUPPLY CABLE gland is correctly fastened.

7. Primary or secondary wiring does not impede AIR FLOW from the transformer windings, diode heatsink, inductor or rest on sharp edges of any sheet metal.

8. CLEARANCE of more than 10mm between adjacent bare conductors and/or any sheet metal.

9. For COMPACT version set WIRE SPOOL TENSION on hub between 1.0Nm and 1.5Nm to slowly rotate empty spool. DRIVE ROLLER TENSION to mid-position.

10. VISUAL INSPECTION - PASS

June 15, 2006

7-1

FABRICATOR 251

7.02 Initial Setup Conditions

Set the power supply controls and connect cables as follows:

1. ON/OFF Switch to OFF Position

2. MIG GUN / SPOOL GUN SELECTOR SWITCH to MIG GUN position

3. WIREFEED SPEED CONTROL to "4"

4. COARSE VOLTAGE SELECTOR SWITCH to position "1"

5. FINE VOLTAGE SELECTOR SWITCH to position "1"

6. WELD (SPOT/STITCH) TIMER CONTROL to minimum

7. WELD MODE SWITCH to position "2T"

8. DWELL STITCH TIMER CONTROL to minimum

9. BURNBACK CONTROL to minimum

10.Disconnect & Isolate the GUN POLARITY LEAD from OUTPUT WELDING TERMINALS

11.Connect Work cable to (-) NEGATIVE OUTPUT WELDING TERMINAL

7.03 Primary Power Test

A. Close primary disconnect device and observe the

following:

1. Green Indictor Lamp inside ON/OFF Switch illuminates

B. Set ON/OFF Switch to ON position and observe the

following:

1. Fan turns on

2. Digital Display turns on. The meter has two display modes: Voltage or

Amperage. If last displayed character on the left is "A", depress the VOLTAGE / AMPERAGE SELECTION Switch once. The left character will change to "V".

This completes the Primary Power Test. If the above are all correct then proceed to Section 7.04. If the above does not function as noted then note the symptom and proceed to Section 7.08 Primary Power Problems.

12.Disengage PRESSURE ADJUST DEVICE so wire will not feed (See figure 3-10)

7-2

June 15, 2006

FABRICATOR 251

7.04 Logic and Control Tests

A. Depress Gun Switch and observe the following:

1. Gas flows

2. Contactor energizes

3. Feed Roll Turns

4. Display reads approx "15.0 V"

B. Release Gun Switch

1. Gas flow stops

2. Contactor de-energizes

3. Feed Roll stops

4. Display reads "00.0V"

C. Set WELD MODE SELECTOR SWITCH to position "4T".

Depress Gun Switch and observe the following:

1. Gas flows

2. Contactor energizes

3. Feed Roll Turns

4. Display reads approx "15.0 V"

D. Release GUN switch

1. Gas continues to flow 2 Contactor remains energized

3. Feed roll continues to turn

4. Display reads approx "15.0 V"

E. Depress Gun Switch

1. Gas flow stops

2. Contactor de-energizes

3. Feed Roll stops

4. Display reads approx "0.0 V"

F. Set WELD MODE SELECTOR SWITCH to position "2T".

Set BURNBACK CONTROL potentiometer to maximum position. Depress Gun Switch and observe the following:

1. Gas flows

G. Release Gun Switch

1. Feed Roll stops immediately

2. Display reads "15.0 V"

2. After 1 ½ seconds

a. Gas flow stops b. Contactor de-energizes c. Display reads "0.0 V"

H. Set BURNBACK CONTROL potentiometer to minimum.

Set MODE SELECTOR SWITCH to SPOT position

1. Depress Gun Switch a. Gas Flows b. Contactor energizes c. Feed Roll turns d. Display reads "15.0 V" e. After .5 seconds

1. Gas flow stops

2. Contactor de-energizes

3. Feed Roll stops

4. Display reads "0.0 V"

I. Set WELD (SPOT/STITCH) TIMER CONTROL to

Maximum position (4)

1. Depress Gun Switch a. Gas flows b. Contactor energizes c. Feed roll turns d. Display reads "15.0 V" e. After 12 seconds

1. Gas flow stops

2. Contactor de-energizes

3. Drive roll stops

4. Display reads "0.0 V"

2. Contactor energizes

3. Feed roll turns

4. Display reads approx "15.0 V"

June 15, 2006

7-3

FABRICATOR 251

J. Set MODE SELECTOR SWITCH to STITCH position.

Set WELD (SPOT/STITCH) TIMER CONTROL to minimum.

1. Depress Gun Switch a. Gas Flows b. Contactor energizes c. Feed Roll begins a cycle of turning for .5

seconds then stop turning for .5 seconds

d. Display reads "15.0 V"

2. Released Gun Switch a. Gas flow stops b. Contactor de-energizes c. Feed Roll stops d. Display reads "0.0 V"

K. Set WELD (SPOT/STITCH) TIMER CONTROL to

Maximum position "4" . Set DWELL (STITCH) TIMER CONTROL to Maximum Position "4"

O. Set WIRE SPEED CONTROL to "4" P. Set COARSE VOLTAGE SELECTOR SWITCH to

position "L". Q. Set FINE VOLTAGE SELECTOR SWITCH to position "1". This completes the Logic & Control Tests. If the above

are all correct then proceed to Section 7.05. If the above does not function as noted then note the symptom and proceed to Section 7.09 Logic & Control Problems.

7.05 Spool Gun Control (J1) Test

A. Set MIG GUN / SPOOL GUN SELECTOR SWITCH to

SPOOL GUN position.

B. Connect inlet gas supply hose to spool gun gas inlet

Jumper J1 terminals D & G

1. Depress Gun Switch a. Gas flows b. Contactor energizes c. Feed roll begins a cycle of turning for 12

seconds then stop turning for 12 seconds

d. Display reads "15.0 V"

2. Release Gun Switch a. Gas flow stops b. Contactor de-energizes c. Feed Roll Stops d. Display reads "0.0 V"

L. Connect voltmeter probes to JB-6 (-) and J6-8 (+).

Depress the gun trigger and vary the WIRE SPEED CONTROL potentiometer from minimum to maximum. The voltage should vary from approx 4VDC up to approx 27 VDC.

M. Set COARSE VOLTAGE SELECTOR SWITCH to

position "H". Set FINE VOLTAGE SELECTOR SWITCH to position "8".

N. Connect voltmeter probes to JB-6 (-) and J6-8 (+).

Depress the gun trigger and vary the WIRE SPEED CONTROL potentiometer from minimum to maximum. The voltage should vary from approx 2VDC up to approx 25 VDC.

1. Gas Flows from Spool Gun gas outlet port on the front panel

2. Contactor W1 Closes

3. Feed Roll does not turn

C. Check voltages at the following points:

J11 PINS

From Pin H to JB-5 on MAIN PCB 1VDC From Pin E to JB-5 4.5VDC From Pin C to Pin B 14VDC*

(*Because there is no load from a motor this voltage will slowly drop)

This completes the Spool Gun Control (J1) Test. If the above are all correct, then proceed to Section 7.06. If the above does not function as noted then note the symptom and proceed to Section 7.10 Spool Gun (J1) Control Problems.

7-4

June 15, 2006

FABRICATOR 251

7.06 Output Voltage Test

A. Set COARSE VOLTAGE SELECTOR SWITCH to position "L" B. Set FINE VOLTAGE SELECTOR SWITCH to position "1" C. Connect voltmeter probes to + & - WELDING TERMINALS D. Depress Gun Switch and observe voltage E. Repeat voltage measurements in each of the 24 combinations of the OUTPUT VOLTAGE CONTROL SWITCHES.

The voltages should measure approx as outlined below.

EACH SUCCESSIVE READING MUST BE INCREASING IN VALUE

COARSE VOLTAGE SELECTOR

SWITCH SETTING

L 1 15.3 L 2 15.9 L 3 16.2 L 4 16.9 L 5 17.4 L 6 18.1 L 7 18.5

L 8 19.3 M 1 20.4 M 2 21.4 M 3 22.1 M 4 23.1 M 5 24.1 M 6 25.3 M 7 26.2 M 8 27.2

H 1 29.9 H 2 32.1 H 3 33.5 H 4 35.9 H 5 38.2 H 6 41.5 H 7 43.5

FINE VOLTAGE SELECTOR

SWITCH SETTING

VOLTAGE

F. Set COARSE VOLTAGE SELECTOR SWITCH to position "L" G. Set FINE VOLTAGE SELECTOR SWITCH to position "1" This completes the Output Voltage Tests. If the above are all correct then proceed to Section 7.07. If the above does

not function as noted then note the symptom and proceed to Section 7.13 Output Voltage Test.

June 15, 2006

7-5

FABRICATOR 251

7.07 Wire Feed & Weld Test

A. Close the PRESSURE ADJUST DEVICE. Connect the GUN

POLARITY LEAD to the POSITIVE WELDING TERMINAL (+).

B. Position the gun in a position ready to weld. Close the

Gun Switch

1. Gas flows

2. Contactor Energizes

3. Wire feeds out of gun

4. Welding arc establishes

This completes the Wire Feed Test. If the above does not function as noted then proceed to Section 7.12 Wire Feed Problems.

7.08 Primary Power Problems

A. Green Indicator in ON/OFF Switch is not

illuminated and fan does turn when ON/OFF switch is in the ON position.

1. Incorrect or insufficient primary voltage

a. Measure voltage at Primary Power Receptacle.

If voltage is not correct check primary fuses/ breakers.

2. Defective or improperly wired input power cable or plug.

a. Measure for 230VAC primary voltage at the

terminal block where the input power cable is connected. If incorrect, check wiring in plug and continuity of primary input cable.

3. Circuit breaker CB1 tripped

a. Reset breaker

4. Defective or improperly wired input power cable or plug.

a. Measure for primary voltage at the Input

Terminal Block between terminals 1 & 2 for 208 VAC input or between terminals 1 & 3 for 230VAC input (see Input Terminal Block Figure

7.1).

B. Green Indicator in ON/OFF Switch is illuminated

but digital display is off and fan does not turn, when ON/OFF switch is in the ON position.

1. Circuit Breaker CB1 tripped

a. Reset CB1

2. Defective ON/OFF Switch SW1

a. Measure for 230VAC at Input Terminal Block

between terminals 4 & 5. If voltage is not present, replace SW1.

3. Defective Fan Motor/Aux Transformer Assembly M1

a. Measure for 230VAC at Input Terminal Block

between terminals 4 & 5. If voltage is present, replace M1.

7-6

4) Green Indicator in ON/OFF Switch is illuminated and fan turns, but digital display is off, when ON/ OFF switch is in the ON position.

1) Defective PCB 4

a) Measure for 32VAC at PCB4 between X1-1

to X1-3. If voltage is correct, replace PCB 4.

June 15, 2006

FABRICATOR 251

7.09 Logic and Control Problems

A. Nothing happens when gun switch is depressed;

No gas flow, contactor does not energize, feed rolls do not turn. TEMPERATURE LED is on.

1. Unit overheated.

a. Allow unit to cool

2. Insufficient airflow around / through unit.

a. See installation section 3.02 for clearance

requirements

3. Open Thermal Protection Switch TS1 or TS2

a. Check continuity on the MAIN PCB JA

connector between pins 5 & 7 and if open check the switches TS1 & TS2 individually and replace the defective switch.

B. Nothing happens when gun switch is depressed;

No gas flow, contactor does not energize, feed rolls do not turn. TEMPERATURE led is off.

1. MIG GUN / SPOOL GUN SELECTOR SWITCH SW2 is in SPOOL GUN position

8. Faulty MAIN PCB 1

a. Measure between JB-4 to JB-11 at PCB 1 for

approx 30 VAC when gun switch is closed. If voltage is not present, replace PCB.

9. Faulty SPOOL GUN PCB (PCB 3)

a) Measure at PCB1 between JB-5 to JA-2 for

21VDC. If voltage is not present, replace PCB3

C. When gun switch is closed, gas flows, contactor

does not energize, feed roll does not turn.

1. Defective Contactor W1

a. Measure for 30VAC on the contactor coil

between White wire (#31C) and white wire (#32A). If voltage is present replace W1.

D. When Gun Switch is closed, no gas flows but

contactor closes and feed rolls turn.

1. Gas supply not connected or turned on

a. Verify gas supply to unit is correct and

connected to the gas inlet labeled:

a. Set SW2 to MIG GUN position

2. Defective SW2

a. Check continuity of SW2.

3. Defective gun switch

a. Check continuity of gun switch

4. Open wires between gun receptacle and MAIN PCB (PCB 1)

a. Measure between JA-1 to JA-2 at the Control

PCB for approx 40 VDC when switch is open and then drops to 0 VDC when gun switch is closed. If it does not drop check continuity of the wires.

5) Faulty Fan/Aux. transformer assembly M1

a. With Gun Switch depressed, measure for approx

30 VAC between the brown (#30) and orange (#31C). If low or not present, replace M1.

6. Faulty MAIN PCB (PCB 1)

a. Measure at PCB 1 between JB-5 to JA-1 for

40VDC. If voltage is not present, replace PCB-1

7). Faulty MIG TIMER PCB (PCB 2)

a. See Section 7.15

2. Defective Gas Solenoid SOL1

a. With gun switch closed, measure for 30VAC

on the gas solenoid between Orange wires (#31A & 31B) and Blue wire (#33). If voltage is present replace gas solenoid.

3. Defective MIG GUN / SPOOL GUN SELECTOR SWITCH SW2

a. With gun switch closed, measure for 30VAC

on the gas solenoid between Orange wires (#31A or 31B) and Blue wire (#33). If voltage is not present, check SW2.

E. When Gun Switch is closed, gas flows, contactor

closes, display shows 15 volts, but feed rolls do not turn

1. CB2 5 amp Circuit Breaker tripped

a. Reset CB2

2. Defective WIRE FEED MOTOR M2

a. With Gun Switch closed, measure for approx

2-16 vdc variation at the control PCB between JB-6 to JB-8 as the WIRE SPEED CONTROL potentiometer is varied from minimum to maximum. If voltage is correct, replace motor.

June 15, 2006

7-7

FABRICATOR 251

3. Open wire from Rectifier assembly to Control PCB.

a. With gun switch closed, measure for approx

15 VDC at Control PCB between JB7 (-) to JB9 (+). If no voltage, check wire continuity and replace open wire.

4. Faulty MAIN PCB

a. With gun switch closed, measure voltage be-

tween JB-6(-) to JB-8 (+) for approx 10 VDC. If voltage is 0 VDC, replace Control PCB.

5. Defective PCB 3

a. With Gun switch closed and WIRE FEED SPEED

set to "4" , measure voltage between JB-8 on the MAIN PCB to X1-3 on PCB 3 for approximately 12VDC . If voltage is not present, replace PCB 3.

F. When Gun Switch is closed, gas flows, contactor

closes, display shows 0 volts, and feed roll does not turn.

1. Defective Contactor W1

7.10 Spool Gun Control (J1) Problem

A. Gas does not flow when jumper is connected

between J11 Pins D & G

1. Gas supply not connected or turned on

a. Verify gas supply to unit is correct and con-

nected to the gas inlet labeled:

2. Defective gas solenoid SOL2

a. Measure for 32VAC at SOL2 between Orange

wires (# 31B) and Red wire (#60). If voltage is correct replace SOL2.

3. Defective PCB3

a. With Gun Switch closed, measure for 230VAC

at the contactor between terminals T1 to T3. If voltage is low or not present, replace W1.

2. Defective FINE or COARSE VOLTAGE CONTROL SWITCH

a. See VOLTAGE CONTROL SWITCH test

procedure, page 7-11.

3. Defective Rectifier assembly

a) Check per the diode test procedure page XXX.

4. Defective Main transformer

a) Check main transformer per test procedure

page XXX.

G. When Gun Switch is closed, gas flows, contactor

closes, feed roll turns, but display shows 0 volts.

1. Open wire between shunt and PCB4.

a. Check wire continuity and replace if open.

2. PCB 4 is defective.

a. Measure voltage between X1-3 to X1-1 for

32VAC. If voltage is correct, replace PCB4.

a. Measure voltage between X3-5 to X3-4 on

PCB3 for 0VAC. If voltage not correct, replace PCB3.

B. Voltages to J1 are not correct when jumper is

installed between pins D & G

1. Defective PCB 3

a. Measure voltage between X3-3 to X3-4 for

0VDC when jumper is installed between J1- D & G. If voltage is correct, replace PCB 3.

7.11 Output Voltage Problem

A. Output is low in one or more OUTPUT VOLTAGE

CONTROL SWITCH positions

1. Defective OUTPUT VOLTAGE SELECTION SWITCH

a. Check continuity of switch. See test procedure

page 7-11.

2. Defective MAIN TRANSFORMER

a. Check Main transformer per test procedure on

page 7-14.

7-8

June 15, 2006

FABRICATOR 251

7.12 Wire Feed and Weld Problems

A. Poor or inconsistent arc transfer or no arc transfer

1. Poor work cable connection or open work cable

a. Clean contact point, check continuity of cable and cable to clamp connection. Replace if work cable if

required.

B. Wire feed and welding problems

(Refer to sections 6.03 & 6.03 )

7.13 Terminal Block Voltage Test

Note: Voltage Tolerance = +/-5V

L 1

L 2

Main

Transformer

Fan Primary

208 V

230 V

208V

230V

Fan

Figure 7-1: Input Terminal Block Diagram

230V

Input Voltage Selection Wire

Art # A-07541_AB

June 15, 2006

7-9

FABRICATOR 251

7.14 SW3 Coarse and SW4 Fine Rotary Switch Test

10C RED

10 RED

9 BLK

3711

9A BLK

TOP OF SWITCH

WIRE No'S.

TERMINAL No'S.

159

8 BRN

10A RED

4A BLK

2610

8A BRN

10B RED

4 BLK

TERMINAL No'S.

WIRE No'S.

TERMINAL No'S.

BOTTOM OF SWITCH

4812

TERMINAL No'S.

WIRE No'S.

Figure7-2: 3-Position Rotary Switch, Coarse

17 BLK

3 7 11 15

11 GRY

17A BLK

11A GRY

19 23

WIRE No'S.

TERMINAL No'S.

7-10

15913

12 BRN

13 PUR

7B BLK

2 6 10 14

4 8 12 16

16 WHT

10B RED

13A PUR

7C BLK

18 22

20 24

16A WHT

12A BRN

10C RED

Figure 7-3: 8-Position Rotary Switch,

TOP OF SWITCH

TERMINAL No'S.

WIRE No'S.

TERMINAL No'S.

BOTTOM OF SWITCH

TERMINAL No'S.

WIRE No'S.

Fine

June 15, 2006

VOLTAGE CONTROL SWITCH TEST

One at a time remove SW-3 and SW-4 from front panel, disconnect wires, reconnect to panel and check continuity of switch per figure 7-5.

Set Screw

FABRICATOR 251

Knob

Retainer

Locking Collar

Rotary Switch (SW4 Fine)

SWITCH 2 COARSE

POSITION

26 L M HX

Figure 7-4: Rotary Switch SW3 and SW4 Removal

9711

10 12

SWITCH 3 FI NE

SWI TCH

POSITION

1 26

X 2 3X

X 4X 5

X 6 7X

X 8X

9711

10 12

X X

13 14 18

X X

2119 23

22 24

X X

June 15, 2006

Figure 7-5: SW3 & SW4 Continuity

7-11

FABRICATOR 251

7.15 MIG Timer PCB (PCB2) Test

Using the MAIN PCB terminal JB-5 as common measure the voltage at JD-1. This should measure 20VDC when the Gun Switch is closed. Then measure the voltage at JD-2.

WELD MODE SELECTOR WITCH

POSITION

2T 10VDC when Gun Switch closed. Drops

SPOT 10VDC for duration of SPOT TIME then

STITCH 10 VDC for durations of STICH TIME.

4T 14VDC at 1st Gun Switch closure

VOLTAGE AT JD-2

0VDC when Gun Switch is released.

3.3VDC. Drops to 0VDC when Gun Switch is released.

3.3VDC for durations of DWELL TIME. Drops to 0VDC when Gun Switch is released.

Drops to 0VDC at second Gun Switch closure.

If the voltages are not found to be correct, replace PCB2. To confirm the rest of the circuitry is working, disconnect JC connector from Main PCB and place a jumper between

JD-1 to JD-2. When the Gun Switch is closed: (This test disables the Timer functions and will only function as if in the 2T WELD MODE)

Gas Flows Contactor energizes Feed Roll turns Display reads output voltage

7-12

June 15, 2006

FABRICATOR 251

7.16 Rectifier Assembly Test

1. Disconnect one of the Main Transformer connections from the rectifier assembly.

2. Disconnect and isolate wires from the Negative output of the Rectifier Assembly See Figure 7-3.

3. Disconnect JB connector from MAIN PCB 1.

4. Using a meter check the diode readings between the following points: Forward biased diode junction:

Positive meter probe on rectifier plates 2 and 3 to plates 1 & 4 Negative meter probe on rectifier plates 1 & 4 to plates 2 & 3

Remove and isolate from rectiﬁer assembly

1 2

3 4

Art # A-07575

Figure 7-3: Rectifier Assembly Test

Double forward biased junction:

Positive meter probe on rectifier plates 1 & 4 to positive rectifier output terminal (Picture needed)

June 15, 2006

7-13

FABRICATOR 251

7.17 Main Transformer Test

Disconnect the secondary of the Main Transformer T2 from the rectifier bridge and measure output voltage between the two transformer output connections as follows:

COARSE VOLTAGE SELECTION FINE VOLTAGE SELECTOR VOLTAGE AC (approx.) SWITCH SETTING SWITCH SETTING

L 1 11.8 L 2 12.2 L 3 12.5 L 4 12.9 L 5 13.2 L 6 13.8 L 7 14.0 L 8 14.6 M 1 15.3 M 2 16.0 M 3 16.5 M 4 17.3 M 5 17.9 M 6 18.9 M 7 19.5 M 8 20.6 H 1 22.1 H 2 23.6 H 3 24.7 H 4 26.4 H 5 28.0 H 6 30.2 H 7 31.8 H 8 34.8

7-14

June 15, 2006

FABRICATOR 251

SECTION 8:

CIRCUIT OPERATION

8.01 Circuit Operation Of The Control PCB 7977964

Power Supply

24VAC is taken from the auxiliary wiring of the fan. This voltage is then connected to the PCB 7977964 where it is half wave rectified and filtered. This voltage is then fed to a zener regulator to provide the +15VDC supply for the electronics on the circuit board

Inputs to the Control PCB

CONNECTOR JA

Terminal JA-1

trigger input=40VDC trigger open, approx 20VDC trigger closed reference JA-5

Terminal JA-2

trigger input=0VDC trigger open, approx 20VDCV trigger closed reference JA-5

Terminal JA-3

spot timer pot=12VDCV trigger closed 0VDC trigger open reference JA-5

Terminal JA-4

spot timer pot= ramps up to 12V from 0V when trigger closed 0VDC when trigger open reference JA-5

Terminal JA-5

PCB common

CONNECTOR JE

Burnback potentiometer 100k potentiometer between pins

Terminal JE-1

burnback potentiometer 0VDC reference PCB common

Terminal JE-2

burnback potentiometer approx 13VDC when trigger on ramps down to zero after trigger is released reference JA-5

Terminal JA-6

over temperature LED anode = approx 2VDC when overtemp led is ON, 0V when off reference JA-5

Terminal JA-7

over temperature switch=0VDC temp switch closed, approx 15VDCV switch open reference JA-5

June 15, 2006

8-1

FABRICATOR 251

CONNECTOR JB

Terminal JB-1

wiper of wire speed control potentiometer, varies between <2V to approximately 4.7VDC (pot wiper) reference JA-5 or JB-5

Terminal JB-2

wire speed control potentiometer minimum (pot low) approximately 2VDC reference JA-5

Terminal JB-3

wire speed control potentiometer maximum approximately 4.7VDC reference JA-5

Terminal JB-4

32VAC supply from auxiliary winding on fan reference JA-5 or JB-5

Terminal JB-5

PCB common. Return for 32VAC supply from auxiliary winding on M1

8.02 Circuit Operation Of The MIG Timer PCB 7977965

This board is connected by way of a 6-way cable and does not have any terminals available to measure.

8.03 Circuit Operation Of The Digital Volt/Amp PCB 704883

Terminal X13/1

24VAC supply for board measure 24VAC wrt X13/3

Terminal X13/2

no connection

Terminal X13/3

24VAC supply for the board measure 24VAC wrt X13/1

Terminal X13/4

PCB common, weld volts negative shunt negative PCB 0V

Terminal JB-6

Motor positive terminal 0VDC - 24VDC with speed pot reference JB-8

Terminal JB-7

negative welding output voltage reference JB-9

Terminal JB-8

Motor negative terminal 0VDC to -24VDC with speed pot reference JB-6

Terminal JB-9

positive welding voltage

Terminal JB-10

return for 32VAC supply from auxiliary winding on M1 reference JB-5

Terminal JB-11

relay contact to control SOL1 & W1 closes to complete circuit to JB-10 reference JB-4

Terminal X13/5

shunt positive measure a few hundred mV wrt X13/4 when welding output is loaded

Terminal X13/6

weld volts positive measure welding output voltage wrt X13/4

CONNECTOR JB

Torch circuit jumper installed

8-2

June 15, 2006

FABRICATOR 251

8.04 Circuit Operation Of The Spool Gun PCB 7978034

CONNECTOR X1

Terminal X1/1

motor relay "normally open" - connects to spool gun motor measure 0 to 24VDC (depends on wire speed setting) wrt 7977964 JB/8 in spool gun setting

Terminal X1/2

motor relay "common" - connects to motor output from 7977964 PCB connects to 7977964 JB/6

Terminal X1/3

motor relay "normally closed" - connects to main wire feed motor measure 0 to 24VDC (depends on wire speed setting) wrt 7977964 JB/8 in normal setting

Terminal X1/4

solenoid relay "normally open" - connects to spool gun solenoid

Terminal X1/5

solenoid relay "common" - connects to 24VAC supply

Terminal X1/6

solenoid relay "normally closed" - connects to main solenoid

CONNECTOR X2

Terminal X2/1

wirespeed relay "normally open" - connects to spool gun wirespeed pot wiper measure 0 to 5VDC (depends on wire speed setting) wrt 7977964 JA/5 in spool gun setting

Terminal X2/2

wirespeed relay "common" - connects to wirespeed potentiometer input of 7977964 PCB measure 0 to 5VDC (depends on wire speed setting) wrt 7977964 JA/5

Terminal X2/4

trigger relay - connects to trigger input of 7977964 PCB

Terminal X2/5

trigger relay - connects to trigger input of 7977964 PCB

Terminal X2/6

no connection

CONNECTOR X3

Terminal X3/1

normal trigger input measure approx 2.5VDC wrt D11 anode when trigger open & approx 6VDC when trigger closed wrt D11 anode

Terminal X3/2

normal trigger input measure approx 14VDC wrt D11 anode when trigger open & approx 6VDC when trigger closed wrt D11 anode

Terminal X3/3

spool gun trigger input measure approx 2.5VDC wrt D11 anode when trigger open & approx 6VDC when trigger closed wrt D11 anode

Terminal X3/4

spool gun trigger input measure approx 14VDC wrt D11 anode when trigger open & approx 6VDC when trigger closed wrt D11 anode

Terminal X3/5

24VAC supply for board measure approx 24VAC wrt X3/6

Terminal X3/6

24VAC supply for board measure approx 24VAC wrt X3/5

Terminal X2/3

wirespeed relay "normally closed" - connects to main wirespeed pot wiper measure 0 to 5VDC (depends on wire speed setting) wrt 7977964 JA/5 in normal setting

June 15, 2006

8-3

FABRICATOR 251

8-4

June 15, 2006

SECTION 9:

PARTS LIST

9.01 Equipment Identification

All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Part or Assembly numbers.

9.02 How To Use This Parts List

The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to other parts. The part descriptions may be indented to show part relationships.

FABRICATOR 251

To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.

PART NUMBER:

Fabricator 251 100048D-002

June 15, 2006

9-1

FABRICATOR 251

9.03 External Replacement Parts

ITEMITEM

ITEM

ITEMITEM

1 707267PKD Panel, Cover, Fab210/251 1 2 705956PKD Handle Bar, Fab210/251/281 1 3 705936PKD Handle Mount, Fabricator 2 4 870696PKD Knob,Control, 1/4" IDx1.6" 1 5 7977884PKD Switch, DPST, Grn, 16A, 250V SW1 1 6 871007PKD Adaptor, Gas Connection, 5/8"-18 1 7 7977978 Knob, Output Terminal, Fabs 2 8 707262PKD Panel, Front, Fab251 1 9 705937PKD Molding, Front, Fab210/251/281 1 10 871011PKD Bushing Torch 1 11 707259CLAPKD Panel, Side LH, Fab210/251 1 12 SEE NOTE 1 Screw, Hex HD, M5x13mm, Self Tap 41 13 7977683PKD Latch, Slide, Door Latch 2 14 704883PKD PCB, Digital Meter, Fab251/281 PCB4 1 15 707258PKD Door, Fab210/251 1 16 871024PKD Box, Parts, Fab210/251/281 1

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

REF DESIGNAREF DESIGNA

REF DESIGNA

REF DESIGNAREF DESIGNA

TIONTION

TION

TIONTION

QTYQTY

QTY

QTYQTY

17 707305PKD Harness, Control Wiring, Fab251 1 18 707304PKD Harness, Power Wiring, 251/281 1 19 707264PKD Panel, Rear, Fab251 1 20 831275PKD Label, Weld Guide, Fab251 1 21 706916PKD Work Cable & Clamp, Fab210/251 1 22 705620PKD Chain, 700mm Long, Fabricators 2 23 See Note 2 Potentiometer, 1K R1 1 24 870734 Knob, Control, 1/4" IDx.57" 4 25 See Note 2 Potentiometer, 100K R2 1

Note

1. These parts are available at most hardware stores.

2. These parts are available at most electronic parts stores.

9-2

June 15, 2006

FABRICATOR 251

4, 23

Art # A-07513

24, 25

June 15, 2006

9-3

FABRICATOR 251

9.04 Internal Replacement Parts (1)

ITEMITEM

ITEM

ITEMITEM

1 707216WBLKPKD Panel, Baffle, Fab210/251/281 1 2 7977964 PCB, Control, Fabricators PCB1 1 3 203627-001 Circuit Breaker, 5A CB2 1 4 7978041PKD Circuit Breaker, 2A CB1 1 5 401840-003 Cable, Power Cable, Fab251/281 1 6 707206PKD Gas Hose, 5/8"BSP,Fabricators 1 7 7978001PKD Contactor, 32A, 3 Pole,24VAC W1 1 8 7976580 Terminal Block, 6 Way, 110A 1 9 707204PKD Solenoid Assy, Fabricators SOL1 1 10 707204PKD Solenoid Assy, Fabricators SOL2 1 11 7977951 Switch, 32A,3 Pos, Fab251/281 SW2 1 12 7977950 Switch, 32A,8 Pos,Fab251/281 SW3 1 13 7978034PKD PCB, Spool Gun, Fab251/281 PCB3 1 14 7978038PKD Fan Assy, 208-230VAC, 8", 24Vac M1 1 15 7977965PKD PCB, Timer, Fab210/251/A2281 PCB2 1

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

REF DESIGNAREF DESIGNA

REF DESIGNA

REF DESIGNAREF DESIGNA

TIONTION

TION

TIONTION

QTYQTY

QTY

QTYQTY

9-4

June 15, 2006

FABRICATOR 251

Art # A-07516

June 15, 2006

9-5

FABRICATOR 251

9.05 Major Electrical and Mechanical Replacement Parts

ITEMITEM

ITEM

ITEMITEM

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

REF DESIGNAREF DESIGNA

REF DESIGNA

REF DESIGNAREF DESIGNA

TIONTION

TION

TIONTION

QTYQTY

QTY

QTYQTY

1 707230WBLK Bracket, Cable Hanger, 251/281 1 2 See Note 1 Screw, Hex HD,M8x12mm, Self Tap 2 3 7978035PKD Wheel, 5/8" IDx10" OD 2 4 871046PKD Clip, Retaining, 5/8" ID 2 5 707256WBLKPKD Panel, Base, Fab210/251/281 1 6 7977566 Castor, Swivel, 5" Wheel 2 7 870921WBLKPKD Bracket, Front Wheels 1 8 7977974 Terminal, Output, Fabricators 2 9 7977962 Rectifier, 300A, Fab251/281 BR1 1 10 707308PKD Transformer, Fab251/281 T1 1 11 7977832PKD Switch, Thermostat, 207°C TH1 1 12 See Note 2 Switch, Thermostat, 100°C TH2 1 13 706968 Reactor, Fab251/281 L1 1 14 10-6131 Capacitor 22000uF, 63V C1-C4 4

Note

1. These parts are available at most hardware stores.

2. These parts are available at most electronic parts stores.

1012

9-6

Art # A-07558

June 15, 2006

9.06 Internal Replacement Parts (2)

FABRICATOR 251

ITEMITEM

ITEM

ITEMITEM

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

REF DESIGNAREF DESIGNA

REF DESIGNA

REF DESIGNAREF DESIGNA

TIONTION

TION

TIONTION

QTYQTY

QTY

QTYQTY

1 871048PKD Hub Spool Assy, Fab210/251 1 2 870734 Knob,Control, 1/4" IDx.57" 4 3 871051PKD Label, Int. Controls, Fab210/251 1 4 7977965PKD PCB, Timer, Fab210/251/A2281 PCB2 1 5 871010PKD Feed Plate Assy, 2 Roll, 210/251 1 6 707265WBLK Panel, Internal, Fab210/251 1 7 203627-001 Circuit Breaker, 5A CB2 1 8 7978041PKD Circuit Breaker, 2A CB1 1

Art # A-07515

June 15, 2006

9-7

FABRICATOR 251

9.07 Internal Replacement Parts-Spool Assembly

ITEMITEM

ITEM

ITEMITEM

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

QTYQTY

QTY

QTYQTY

1 See Note Screw, Hex HD, 3/8"-16x3/4",STZP 1 2 170459-001 Plunger, Spring, Nut Hub 2 3 405377 Nut, Wire Spool Hub 1 4 374552-001 Spacer, Spool Hub 1 5 374551 Washer, 3/4", Flat,Keyed, Hub 1 6 400562-027 Spring, Spool Hub 1 7 707251PKD Shaft, Wire Spool Hub 1 8 405448 Washer, 1-1/64", Flat, Nylon, Hub 1 9 405376 Hub, Wire Spool 1 10 See Note Washer, 1/2" IDx1.45" OD, Flat 2 11 707197WBLKPKD Bracket, Wire Spool, Fab210/251 1 12 See Note Nut, Hex, 1/2"-13 1

Note

These parts are available at most hardware stores.

Art # A-07517

9-8

June 15, 2006

9.08 Internal Replacement Parts-Wire Feeder

FABRICATOR 251

ITEMITEM

ITEM

ITEMITEM

ARAR

T NUMBERT NUMBER

T NUMBER

ARAR

T NUMBERT NUMBER

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

QTYQTY

QTY

QTYQTY

Feed rolls and guides may be found in the Feed Roll kit located in the Appendix section of this manual.

1 870387PKD Gear, Idle Roll, 2R Plate 1 2 871010PKD Feed Plate Assy, 2 Roll, 210/251 1 3 870082 Knob, Control, 1/4" ID x 3/4" 1 4 10-6187 Knob, Torch Locking 1 5 871173PKD Adapter, Tweco #4, 2R Plate 1 6 See Note Screw, Skt Set, M4-0.7x 4mm 1 7 871012WBLKPKD Bracket, Feed Plate, Fab210/251 1 8 870891PKD Motor, Wire Drive, 3.2A 20VDC 1 9 See Note Screw, PHCR, M6-1x20mm, STZP 3 10 See Note Screw, PHCR, M4-0.4x10mm, STZP 2 11 See Note Screw, Hex HD, M8-1.25x16mm, STZP 1 12 871174PKD Guide, Outlet, .023-.035, 210/251 1 13 90935 Guide, Outlet, 1.2 & 1.6MM, 210/251 1

Note

These parts are available at most hardware stores.

June 15, 2006

12 or 13

Art # A-07518

9-9

FABRICATOR 251

9.09 Wire Feeder Replacement Parts

ItemItem

QtyQty

RefRef

Item

ItemItem

Qty

QtyQty

Ref

RefRef

. Des.. Des.

. Des.

. Des.. Des.

1 1 Rod, Tension Subassembly, WF 870933PKD 2 1 Pressure Arm, 2R M/C, WF 870679PKD 3 1 Gear, Idler Assembly, WF 871001PKD 4 2 Screw, M4x10 Pan Head, WF See note 5 3 Screw, M6x1, 30 MM long, WF See note 6 1 Retainer, Drive Gear,2R Plate 870733PKD 7 1 Gear, Drive Roll, 2R Plate 870560PKD 8 2 Screw, M8 X 16 Hex Head, WF See note 9 1 Screw, M6x1, 35MM Long, WF See note 10 1 Clamp, MIG gun,2R Plate 171362 11 1 Feedplate, 2 Roll , WF 870558PKD 12 1 Insulator, Motor, 2R Plate 870695-001PKD 13 1 Pin,#6x50mm,2R & 4R Plate 870509

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

Note

These parts are available at most hardware stores.

9-10

Art # A-07624

June 15, 2006

FABRICATOR 251

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES

For T weco/V ictor Inquiries and Orders: Call 1-800-318-6819 Consumable Parts Management Group

GUNS

Tweco® WeldSkill 15ft 43340 Gun assembly with 15ft cable (supplied with package),

300 Amp @ 30% Tweco® No. 4 12ft 412-3545 Gun assembly with 12ft cable, 400 Amp @ 60% Tweco® No. 4 15ft 415-3545 Gun assembly with 15ft cable, 400 Amp @ 60% Tweco® Spraymaster 12ft MS212-3545 Gun assembly with 12ft cable, 250 Amp @ 80% Tweco® Spraymaster 15ft MS215-3545 Gun assembly with 15ft cable, 250 Amp @ 80% Spool Gun 25ft W4011000 Gun assembly with 25ft cable, 200 Amp @ 60%

Spool Gun 25ft 90906 Gun assembly with 25ft cable, 300 Amp @ 60%

ACCESSORIES

Victor Regulator/Flow Meter Mixed Gases Victor Regulator/Flow Meter CO2

TIPS

14-23 .023” (0.6mm) 14-30 .030” (0.8mm) 14-40 .035” (0.9mm) 14-35 .040” (1.0mm) 14-45 .045” (1.2mm) 14-116 1/16” (1.6mm)

NOZZLES

24A-38 3/8” (9.5mm) 24A-50 1/2” (12.7mm) 24A-62 5/8” (16mm) 24A-75 3/4” (19mm)

CONDUITS

42-23-15 .023”, 15ft (7.6m) 42-3035-15 .030”-.035”, 15ft (4.5m) 44-3545-15 .035”-.045”, 15ft (4.5m) 44N-3545-15 .035”-3/64”, 15ft (4.5m) 44-116-15 1/16” 15ft (4.5m)

0781-2723 Medalist™ 1400 Series, HRF Flow Meter Regulator,

Argon-Argon/CO2 mix gases

0781-2725 Medalist™ 1400 Series, HRF Flow Meter Regulator, CO2

gas

June 15, 2006

A-1

FABRICATOR 251

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM

• Note the model number shown on the equipment nameplate

FABRICATOR 251

L1 White

Black

Input Termi nal Block

Ear th

Green\Yell ow

1B RED

2B PNK

CB1

3 ORN

1A RED

2&2A PNK

1 RED

1D RED

1C RED

K1\3

[5]

K1\2

[3]

K1\1

[1] [2]

CONT ACTOR 24V 50/60 Hz

[6]

[4]

4C BLUE

4B BLUE

4A BLUE

4 BLUE

(2) (1)

(4) (3)

(8) (7)

10B RED

SW2

COARSE

8 BRN

9 BLK

10 RED

10C RED

11 GRY

12 BRN

16 WH T

(10)

(12)

(6)

(24) (23)(12)(11)

(18) (17)(6) (5)

(22) (21)(10)(9)

(20) (19)(8) (7)

8&8A BRN

(9)

9&9A BLK

(11)

10&10A RED

(5)

11&11A GRY

12&12A BRN

16&16A WHT

17&17A BLK

SW1

Input Termi nal Block

BLU

5 6

BLU

Fan motor

24V Aux

30C BRN 31 D ORN

SOL2

31B ORN

31 A ORN

31E ORN

SP OOL

Solenoid

NORM

Solenoid

32B WHT

32A WHT

33 BLU

SOL1

31C ORN

31 ORN

30B BRN

60 RED

30 BR N

SW3 FINE

30A BRN

BLUE

X1/5 X1/6 X1/4

X3/6

X3/5

32 WHT

17 BLK

13 VIO

Voltage Terminal block

X3/2

Torch

58 BRN

Trigger

BURNBACK 100K

34 BLU

35 WHT

(16) (15)(4) (3)

(14) (13)(2) (1)

PCB 3

7978034

X3/1

59 GRY

TS1

37 ORN

TS2

13&13A VIO

2 & 2A PNK

14&14A BLU 208VAC

15&15A ORN 230VAC

X2/4

38 WHT

TEMP

LED1

38A WHT

54 BLK

36 GRY

39 RED

X2/5

56 RED

Art # A-07223

A-2

JA/7

JA/6

JE/1

JB/5

JB/4

JB/11

JB/10

JE/2

JA/5

JA/1

JA/2

Main PCB 7977964 (PCB1)

June 15, 2006

FABRICATOR 251

208V

230V

TRANS 251US COIL

X3/4 X3/3 X2/3 X2/1 X2/2 X1/1 X1/2 X1/3

SWITCH 2 COARSE

POSITION

XX 2 3X

543

BR1

Br idge Rectiﬁer

Var is tor

VR1

43A BLK

55 BLK

57 VIO

45 VIO

9711

10 12

C1-C4

4 x 22,000 uF

47 GRY

SWITCH 3 FINE

SWI TCH

POSITION

X 2 3X

X 4X 5

X 6 7X

X 8X

543

9711

10 12

X X

0.1u F 630V C5

WIRES PEE D 1K

Indu ct or

21 ORN

22 VIO

23 GRY

48 ORN

CB2

SHUNT

53 WHT

50 VIO

PLUGSOCKET

30C BRN

31D ORN

PLUGSOCKET

14 18

X1/6

PCB 4

X1/5 X1/4

X X

2119 23

22 24

X X

POSITIVE OUTPUT TERMINAL

704883

X1/3

DIG METER

X1/1

NEGATIVE OUTPUT TERMINAL

A B C D E F G H I J

18-1SF

MIG Timer PCB

46 RED +

Wi re Fee der Mo tor

JUMPER

43 BLK

JD-1 JD-2

NOTE:

JB/8

Remove this jumper and use these pins when connecting a replacement 7977964 Control PCB

June 15, 2006

7977965 (PCB2)

47 GRY

48 ORN

49 BLU 49 A BLU

44 BRN

JB/7

JB/9

JB/6

JB/3

51 ORN

52 BRN 52 A BRN

JB/1

JB/2

Art # A-07223

A-3

FABRICATOR 251

APPENDIX 3: MAIN PCB CIRCUIT DIAGRAM

30 VAC

Art # A-07520

A-4

June 15, 2006

FABRICATOR 251

82 BENNING SREET WEST LEBANON, NH 03784, USA

DESCRIPTION: FABRICATOR MAIN PCB

7977964

Art # A-07520

June 15, 2006

A-5

FABRICATOR 251

APPENDIX 4: SPOT TIMER CIRCUIT DIAGRAM

Art # A-07521

A-6

June 15, 2006

FABRICATOR 251

June 15, 2006

DESCRIPTION:

CODE DESIGN:

82 BENNING SREET WEST LEBANON, NH 03784, USA

FABRICATOR SPOT TIMER

7977965

Art # A-07521

A-7

FABRICATOR 251

APPENDIX 5: SPOOL GUN PCB

24VAC_1 24VAC_2

SPOOL TRIG

NORM TRIG

CON6

C11 100n

R10 270R

12 13

+14Vdc

22u 50V

100n

U3D

LM324

BC337-40

R20 22K

R16 22K

+35Vdc

D12

D13

1N4004

100n

R25 100K

R22 22K

470u 50V

D10

D11

1N4004

+14Vdc

6 5 4 3 2 1

+14Vdc +14Vdc

R13 22K

+14Vdc

R26 22K

D18

1N4004

D15

1N4004

+14Vdc

Vin

LM317T

C9 100n

1N4004

R19 22K

R18 6K8

ADJ

R9 2K7

+Vout

+14Vdc

VCC

GND

D CLK

100n

U2B

4013

U3A

LM324

4 11

C8 100n

R14

22K

R23 22K

D17

1N4004

D16

1N4004

R24 100K

R21 22K

No. ZONE REVISION EC No. DATE

2 3

C10 100n

R15 22K

U3C

LM324

BC337-40

R17 22K

U3B

5 6

LM324

DATEEC No.REVISIONZONENo.

A-8

June 15, 2006

FABRICATOR 251

+14Vdc

22u 50v

R11 22K

+35Vdc

560R 1/2W

CLK

U2A

4013

AZ945

1N4004

D4 1N4148

1N4148

560R 1/2W

1N4004

+35Vdc

AZ945

R5 22K

+35Vdc

560R 1/2W

1N4004

Q1 BC337-40

AZ945

spool

MOT SPOOL

1 2

MOT COM MOT LOC

GV SPOOL

GV COM

GV LOC

CON6

Install jumper for use with MILLER spool gun which has no speed pot on the spool gun

norm

JUMPER

POT SPOOL POT COM

POT LOC

TRIG

N/C

CON6

1N4148

R12 22K

FINISH

UNLESS OTHERW ISE SPE C IFIE D

ALL DIMENSIONS IN MILLIMETERS ANGLES +/- 1 DEGREE SURFACE FINISH -N8 DIMENSIONS +/- 0,5 mm

FITS - THREADS; NUT 6H; BOLT 6g HOLES H13

5 6 87

1N4148

C2 100n

R7 22K

R6 22K

1N4148

R8 2K7

G:\ENG\ARC\PCB'S\797803~1\7978034.SCH

SCALE DRAWN DATE PASSED

NTS AM 11/05 MW

AUXILIARY TITLE PRIME TITLE

SPOOL GUN PCB

+35Vdc

560R 1/2W

D14 1N4004

AZ945

Q2 BC337-40

REF. ASSY

PART No.

PCB ARTWORK ISSUE

ISSUE SHEET OF

7978034

June 15, 2006

A-9

FABRICATOR 251

APPENDIX 6: FEEDROLL KITS

FE E D ROL L KIT S ( #375980 - Series) 2 ROLL

Style 1 Style 2 Style 3 Style 4 S tyle 5 Style 6

Double Smooth

Top

Bottom

Wire Type Wire Size

.024" / 0.6mm 375980-031 - - - - .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 .035", .045" 3/64" / 0.9, 1.2, 1.2mm - - 375980-030 - - .045" / 1.2mm 375980-002* 375980-004 - 375980-092 375980-022 3/64 / 1.2mm - - 375980-011 - - 375980-033 .052" / 1.3mm 375980-090* - 375980-012 - - .052", 1/16" / 1.3, 1.6mm - -

Notes: 1) One Kit (# 375980-028) is supplied standard with each wire feeder.

2) Feed Roll Kits include: Drive Rolls; Input & Output Guides

3) Narrow 30° "V"

Flat Flat Knurled

Double

Smooth "V"

Hard Hard Soft/Hard/Tubular Hard/Tubular Tubular Soft (Aluminum)

Double

Smooth "V"

"V"

Double Smooth

"V"

Double

Knurled "V" Double Cog Double "U"

Double

Knurled "V" Double Cog Double "U"

375980-017 375980-023

A-10

June 15, 2006

Thermal Arc 251 FABRICATOR Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual