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®
FABRICATOR
MIG WELDING MACHINE
Service Manual
Art # A-07360
Revision: AE Issue Date: June 19, 2006 Manual No.: 0-4879B
Operating Features:
250
208
V
230
V
60
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Fabricator 210 MIG Welding Machine
Instruction Manual Number 0-4879B for:
Package System Part Number 100047B-001
Power Source Part Number 707222
Published by:
Thermadyne Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
©Copyright 2006, 2007,2008 by
Thermadyne Industries Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: June 19, 2006
Revision AE Date: May 23, 2008
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 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 ................................................................................................. 2-4
2.11 Included Items ............................................................................................... 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 Input Power Requirements ............................................................................. 3-2
3.05 Alternative Mains Supply Voltages ................................................................. 3-2
3.06 Quick Setup .................................................................................................... 3-3
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 D
rive Roller Pressure Adjustment .............................................. 3-12
3.14 Wire Reel 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 ....................................................................................... 4-4
4.03 TWECO Weldskill 250 AMP Weld Gun ............................................................ 4-6
4.04 Installing A New Wire Conduit ........................................................................ 4-7
4.05 MIG Gun Maintenance .................................................................................... 4-8
4.06 Basic Welding Technique................................................................................ 4-8
4.07 Stitch Welding Operation .............................................................................. 4-10
4.08 Spot Welding Operation ............................................................................... 4-11
4.09 Gas Selection for Gas Metal Arc Welding ..................................................... 4-12
4.10 Welding Setting Selection Guide .................................................................. 4-14
SECTION 5:
MAINTENANCE ....................................................................................... 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
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 ....................................................................... 7-8
7.13 Terminal Block 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 Major Electrical and Mechanical Replacement Parts ...................................... 9-4
9.05 Internal Replacement Parts (1) ...................................................................... 9-5
9.06 Internal Replacement Parts (2) ...................................................................... 9-6
9.07 Internal Replacement Parts-Spool Assembly ................................................. 9-7
9.08 Internal Replacement Parts-Wire Feed ........................................................... 9-8
9.09 Wire Feeder Replacement Parts...................................................................... 9-9
APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES ...................................... A-1
APPENDIX 2: OPTIONS AND ACCESSORIES (CON'T) ................................................. A-2
APPENDIX 3: FEED ROLL KITS .......................................................................... A-3
APPENDIX 4: POWER SUPPLY CIRCUIT DIAGRAM ................................................... A-4
APPENDIX 5: MAIN PCB CIRCUIT DIAGRAM ........................................................... A-6
APPENDIX 6: SPOT TIMER CIRCUIT DIAGRAM ....................................................... A-8
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
FABRICATOR 210
!
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
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
r touch other people with the holder or electrode.
time o
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 19, 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.
1-1
FABRICATOR 210
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
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 respir ator. 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 4Non-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) All12
Heavy Over 6 in., 150 mm 5 or 6Atomic 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 19, 2006
WARNING
!
FABRICATOR 210
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 19, 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.
1-3
FABRICATOR 210
!
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 ope
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
rator.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1-4
June 19, 2006
FABRICATOR 210
!
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” p
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 raccor
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.
résente les pratiques sécuritaires à suivre.
dés à deux sources de courant en
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 19, 2006
1-5
FABRICATOR 210
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
rsque le niveau de bruit est élevé.
lo
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 cour ant
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
filtr e 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 cour ant
toutes conditions 12
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtr e oculaire
1-6
June 19, 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 210
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 empêche
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.
r le courant de suivre un long parcours
1. Por tez un écran facial ou des lunettes protectr ices
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 19, 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 210
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
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 19, 2006
FABRICATOR 210
!
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Service Manual applies to only the specification or
part numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
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 Thermal Arc 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 19, 2006
2-1
FABRICATOR 210
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
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
t1
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
Preflow Time
Postflow Time
t2
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
t
Disturbance In
Ground System
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
2-2
Receptacle RatingAuxiliary Power
Voltage Input
V
Art # A-04130
June 19, 2006
FABRICATOR 210
2.05 General Information
The Fabricator 210 is a semiautomatic Gas Metal Arc
Welder (GMAW-commonly MIG) with an integrated wire
feed unit. This Power Supply is designed to meet the broad
operating needs of the metal fabrication industry where
production efficiency is vital. The Fabricator 210 is
designed and manufactured to meet the requirements of
CSA and IEC 60974-1 standards.
The Fabricator 210 gives excellent performance on mild
steel, stainless steel, aluminum, silicon bronze and some
hard facing wires with Argon based shielding gases. The
Power Supply also gives excellent results on mild steel
using Carbon Dioxide shielding gas.
The Fabricator 210 is supplied as a complete package
ready to weld (apart from gas cylinder and electrode wire).
The following instructions detail how to correctly set up
the welder and give guidelines on gaining the best
production efficiency fr
these instructions thoroughly before using your Fabricator
welder.
om the Power Supply. Please read
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 pro-
tection 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 a
ways 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.
rc with naked eyes. Al-
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 wr
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.
itten approval
June 19, 2006
2-3
FABRICATOR 210
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 30% duty cycle, 250
amperes at 26.2 volts. This means that it has been designed and built to provide the rated amperage (250A) at the
rated load voltage (26.2V), for 3.0 minutes out of every 10 minute period (30% of 10 minutes is 3.0 minutes). During
the other 7.0 minutes of the 10 minute period the Power Supply must idle and be allowed to cool. The thermal cutout
will operate if the duty cycle is exceeded.
2.10 Specifications
MIG Gun Specifications
Gun Catalog Number 20584
Gun Type TWECO Weldskill 250 AMP
Gun Cable Length 15 ft (4.5m)
Table 2-2: MIG Gun Specifications
Wire Drive Specifications
Control Circuit Supply
Wire Drive Motor Supply
Wire Speed Range
30VA @ 32VAC
180VA @ 14 to 46VDC
80 to 800 ipm
(2 to 20 m/min)
Wire Diameter
.023"
(0.6mm)
.030"
(0.8mm)
.035"
(0.9mm)
Mild Steel: Y Y Y Y
Stainless Steel: Y Y Y Y
Aluminum: Y Y Y
Flux Cored: 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)
2-4
June 19, 2006
FABRICATOR 210
g
q
y
pply
g
A
A
A49A
A
y
A50A
A
AOp
g
p
p
y Cy
y Cy
y Cy
p
p
p
g
y
p
g
(
(
p
pm (
)
)
(
)
)
)
)
(3m)
yp
(
Fabricator 210
Package System Part Number
Power Source Part Number
Power Source Wei
ht
Power Source Dimensions HxWxD
Nominal Input Voltage 208V ±10% 230V ±10%
Number of Phases
Fre
uenc
Flexible Supply Cable Size
Su
Plu
Rated Input Current @ 100% Duty Cycle *22.6A *20.4
Rated kVA @ 100% Duty Cycle 4.7kVA 4.7kV
Maximum Input Current @ 250A Output 53.8
Generator Requirements 15 kVA 15 kV
Supply VA @ Maximum Output 11.2 kVA 11.2 kVA
Recommended Primar
Circuit Size 50
Recommended Minimum Primary Fuse 45
en Circuit Voltage Range 17.3 – 42.2V DC 17.3 – 42.2V DC
Weldin
Out
Rated Out
Maximum Dut
100% Dut
Dut
Number of Out
Wire Feed S
Wire S
Burn-Back Timer Ran
Burn-Back Time Factor
S
Dwell Timer Ran
Stitch Weld Time Weld
Dwell
Thermal Protection
O
* The Rated Input Current should be used for the determination of cable size & supply
requirements.
Arc Voltage Range 15.2 – 26.2V DC 15.2 – 26.2V DC
ut Current Range 20 – 250A DC 20 – 250A DC
ut Duty Cycle 210A/23.3V @ 40% 210A/23.3V @ 40%
cle 250A/26.2V @ 30% 250A/26.2V @ 30%
cle Output Rating 137A DC at 21V 137A DC at 21V
cle Period
ut Voltage Values
Electrode Wire T
Mild / Stainless Steel
Aluminum
Flux Cored
eed Range
ool Size Diameter
e and Diameter
.023” (0.6mm) – .045” (1.2mm
.030” (0.8mm) – .045” (1.2mm
.030” (0.8mm) – .045” (1.2mm
80 – 800 i
8” / 12” (200mm / 300mm
e
Set to
ot Timer Range
e
Stitch) Time
non-weld) Time
Self-resetting thermostat fitted to rectifier
erating Temperature Range
100047B-001
707222
200lb
91kg)
32” x 21” x 36-3/4”
1Ø
60 Hz
10ft
10AWG
NEMA 6-50P
45
10 minutes
16
2 – 20 m/min
0 – 0.6 seconds
0.16 seconds
0.5 – 9 seconds
1 – 12 seconds
0.5 – 9 seconds
1 – 12 seconds
assembly and transformer
32° to 104°F
0° to 40°C
June 19, 2006
Table 2-4: Machine Specifications
2-5
FABRICATOR 210
Y
Y
Y
Y
Y
2.11 Included Items
Fabricator 210 Package System Contents
Fabricator 210 Power Source with Integrated Wirefeeder Y
Factory Fitted Wheeling Kit
Factory Fitted Single Cylinder Rack
Factory Fitted Primary Power Cable 10 AWG, 10ft (3m) with Plug
NEMA 6-50P Y
Work Lead 10ft (3m) with clamp
Cable Stowage Hook Y
Regulator / Flowmeter - Argon Mix Gases
TWECO Weldskill MIG gun 250A, 15' (4.5m)
Drive Roll for .035"/.045" (0.9mm/1.2mm) Hard Wire Y
Accessories Box Y
Table 2-5: Power Supply Contents
2.12 Optional Accessories
Refer to the Appendix section for the list of available options and accessories.
2-6
June 19, 2006
FABRICATOR 210
SECTION 3:
INSTALLATION
3.01 Environment
The Fabricator 210 is NOT designed for use in
environments with increased hazard of electric shock.
Examples of environments with increased hazard of
electric shock are:
In locations in which freedom of movement is restricted,
so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical
contact with conductive parts;
In locations which are fully or partially limited by
conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator, or
In wet or damp hot locations wher e 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 ft (300 mm) or more from walls
or similar that could restrict natural air flow for cooling.
The minimum ground clearance for these products is 5.5"
(140 mm).
3.03 Ventilation
Since the inhalation of welding fumes can be harmful,
ensure that the welding area is effectively ventilated.
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 19, 2006
3-1
FABRICATOR 210
!
!
3.04 Input Power Requirements
The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. Too low of a supply voltage may
cause poor welding performance or wirefeeder malfunction. Too high of a supply voltage will cause components to
overheat and possibly fail.
Install a power outlet for each Power Supply and fit fuses as per the machine specifications.
WARNING
Thermal Arc advises that your Fabricator 210 be electrically connected by a qualified electrical tradesperson.
The Fabricator 210 Power Supply is factory connected for the following input power supply voltage:
Input Power
Supply Lead Size
10 AWG 30 Amps 10ft (3m) 230V 1ø 250A @ 30%
Table 3-1: Factory Fitted Input Power Supply Leads Fitted to the Fabricator 210
Lead Current
Rating
Lead
Length
Machine
Voltage Setting Duty Cycle
3.05 Alternative Mains Supply Voltages
WARNING
The Fabricator 210 input power supply lead should be replaced with leads as specified in Table 3-2 when
the Fabricators input power supply voltage is changed.
The Power Supply is suitable for use on the following input power supply voltages:
Input Power Supply
Voltage Setting
208V 1ø 10AWG (5mm2) 3M 50 Amps *60Amp
230V 1ø 10AWG (5mm2) 3M 50 Amps *50Amp
Primary Input
Power Lead Size Lead Length
Input Power
Outlet Size Fuse Size
Table 3-2: Mains 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 19, 2006
FABRICATOR 210
!
Changing the Voltage Selection
1. Disconnect the power supply from the main power source.
2. Refer to Figure 3-1. The power supply comes wired for 230V. Locate the black input power wire secured to the
input voltage selection block. Loosen the set screw for both voltage locations.
3. Remove the black wire from the current location and Insert the uninsulated wires into the new voltage location.
Secure by tightening the set screw onto the uninsulated portion of the wires. Secure the first set screw as well.
A
3.06 Quick Setup
208V connection
208
230
230V connection
Art # A-07393
Figure 3-1: Voltage Selections for Fabricator 210 (Wired for 230V)
NOTE
See section 3.15 "Polarity Changeover" for
CAUTION
more detail and exceptions!
To obtain adequate air flow and cooling for
the Power Supply components, the four
wheels must be fitted. Alternatively, the Power
Supply may be raised 5.5" (140 mm) from the
floor using supports that do not restrict
airflow.
NOTE
The steps in this subsection are intended for
individuals experienced in the set up of this
type welder. More detailed setup instructions
are in the following subsections.
1. Connect the work lead to the negative (-) socket
(positive + for Self Shielded Flux Cored Wire)
GUN
2. Connect the
(negative - for Self Shielded Flux Cored Wire)
June 19, 2006
lead to the positive (+) socket
3. Position a gas cylinder on the rear tray and se-
cure to the Power Supply cylinder bracket with
the chain provided. If this arrangement is not used
then ensure that the gas cylinder is secured to a
building pillar, wall bracket or otherwise securely
fixed in an upright position.
WARNING
If the gas cylinder is not secured to the cylinder tray, the power supply must be kept from
moving to avoid over-extending the gas hose
which can result in personal injury, damage
to the power supply, flowmeter and gas cylinder.
3-3
FABRICATOR 210
4. Fix the cable stowage hook to the Power Supply
cylinder bracket with the bolts provided.
5. Fit the gas Regulator/Flow Meter to the gas cylinder and connect the gas hose from the rear of the
Power Supply to the Flow Meter outlet.
6. The machine is fitted with a .035/.045” vee groove
feed roll suited for hard wire. Change this feed
roll if required to fit your chosen wire size.
7. Fit the electrode wire spool to the wire reel hub
located behind the electrode wire compartment
door.
8. Fit the TWECO Weldskill MIG gun and trigger
wires through/to the front of the unit.
9. Remove the contact tip from the gun.
10.With the gun lead reasonably straight, feed the
wire through the wire drive rolls and gun.
11.Fit the app
tor and nozzle.
ropriate contact tip and replace insula-
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 or
wrench.
der to tighten. Tighten with a
CAUTION
Match regulator to cylinder. NEVER CONNECT
a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
4. Attach supplied gas line between the regulator output
and the desired input at the rear of the power supply
depending on Spool Gun or MIG Gun use. (Refer to
Figure 3-2 and 3-13).
3-4
June 19, 2006
FABRICATOR 210
1
3
“Cracking”
Cap
2
Shielding
Gas
4
Regulator and
Flow Meter
Shielding
Gas
5
Gas Hose
Stowage Hook
1 1/8”
Shielding
Gas
Shielding
Gas
Art # A-07374
June 19, 2006
Figure 3-2 Gas Cylinder Installation
3-5
FABRICATOR 210
Adjusting Regulator
Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-3)
The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause
turbulence and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 20-30 CFH
- Outdoors welding: 30-40 CFH
Helium based or CO2 gas flow rates:
- Workshop welding: 30-40 CFH
- Outdoors welding: 40-50 CFH
NOTE
All valves downstream of the r egulator must be opened to obtain a true flow rate reading
on the outlet gauge. (Welding power source must be trigger ed) 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 r egulator/flow meter used with argon based and carbon dioxide shielding gases is
different. The r egulator /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 19, 2006
FABRICATOR 210
3.08 Attaching the Gun and Cable Assembly to the Power Source
The Fabricator 210 is supplied with a Tweco Weldskill 250 AMP gas-cooled gun. The Weldskill gun is designed with
an ergonomic handle and fewer parts to cause performance problems. The Weldskill gun uses standard readily available Tweco Weldskill consumable parts.
1. Open the door panel to the machine by inserting your left and right index fingers into the two release mechanisms marked with hand arrows in Figure 3-4. Slide them toward each other and pull the cover outward and
up to open.
Set up Chart
Art # A-07392
Figure 3-4: Door Panel Opening
NOTE
Lubricate the O-ring on the quick-connect fitting of the gun cable with grease (Dow company #4 compound or equivalent, or Thermal Arc #903910)
2. Route the gun cable through the access hole in the front panel. Refer to Figures 3-5 and -3-6.
3. Loosen the thumbscrew and insert the gun cable end as far as it will go. Tighten thumbscrew. Refer to Figure
3-6.
4. Align the keyways of the Gun Switch connector with the receptacle below the gun cable and plug them together. Secure by turning the locking ring to the right (clockwise ). Refer to Figure 3-6.
NOTE
When disconnecting gun switch leads from the machine, loosen the locking ring and grab the connectors
and pull. Do not pull on the wires.
5. To remove the gun, reverse these directions.
June 19, 2006
3-7
FABRICATOR 210
Front Panel
Access Hole
Art # 0-7148
Trigger Receptacle
Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger
Loosen Thumbscrew
Art # A-07149
Tighten Thumbscrew
Figure 3-6: Mount Gun Cable to Adapter Socket
3-8
June 19, 2006
FABRICATOR 210
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 drive rolls and tighten the
input guide lockscrew.
Install the output wire guide in the same manner, with
the conical end toward the feed rolls. The tip of the conical end should be as close to the drive rolls as practical.
Tighten the output guide lockscrew.
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: Drive Roll Example
NOTE
All grooved feed rolls have their wire size or
range stamped on the side of the roll. On rolls
with different size grooves, the outer (visible
when installed) stamped wire size indicates
the groove in use.
Art # A-07445
Input Wire Guide
Output Wire Guide
Figure 3-7: Wire Guide Installation
3.10 Selection and Installation of
Feedrolls
A drive roll consists of two different sized grooves. As
delivered from the factory the drive roll is installed for
.035” / .045” .
The stamped marking on the feedroll refers to the groove
furthest from the stamped marking. When mounted, that
will be the groove closest to the motor and the one to
thread.
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 210 are identical.
WARNING
The welding wire is electrically Hot if it is fed
by depressing gun switch. Electrode contact
to work piece will cause an arc with gun switch
depressed.
June 19, 2006
3-9
FABRICATOR 210
3.11 Installing Wire Spool
As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool.
Installation of wire spool
1. Remove Wire Spool Hub Nut by turning counter clock wise (to the left).
2. Remove the spring from the hub.
3. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool
rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the
wire spool.
4. If using a 10 lb. wire spool place the spring on the exposed hub. Do not use the spring for larger wire spools
that cover the entire hub.
5. Replace the Wire Spool Hub Nut by turning clock wise (to the right).
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section
3.12 and Figure 3-12.
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and don’t let go of it.
Wire Spool
Wire Spool Hub Nut
*Spring
Drive Pin
* The Spring is for use with
smaller 10 lb wire spools only
3-10
Art # A-07192
Figure 3-9: Spool Installation
June 19, 2006
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