140
180
®
FABRICATOR
PORTABLE MIG WELDING MACHINE
Service Manual
Art # A-07923
Revision No: AA Issue Date: January 25, 2008 Manual No.: 0-4992
Operating Features:
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 judgment,
the Manufacturer assumes no liability for its use.
Fabricator 140 and 180 MIG Welding Machine
Service Manual Number 0-4992 for :
Fabricator 140 Catalog Number W1002500
Fabricator 180 Catalog Number W1002600
Published by:
Thermadyne Industries
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2008 by
Thermadyne Industries
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: January 25, 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 Symbol Chart ................................................................................................. 1-5
1.04 Precautions De Securite En Soudage A L’arc.................................................. 1-6
1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6
1.06 Principales Normes De Securite ..................................................................... 1-9
1.07 Graphique de Symbole ................................................................................. 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 General ........................................................................................................... 2-2
2.05 Machine Specifications ................................................................................... 2-3
2.06 Volt - Amp Curves .......................................................................................... 2-4
2.07 Duty Cycle ...................................................................................................... 2-5
2.08 Fabricator 180A MIG Gun ............................................................................... 2-6
2.09 Installing a New Wire Liner ............................................................................ 2-7
2.10 MIG Gun Maintenance .................................................................................... 2-7
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Location ......................................................................................................... 3-1
3.02 Safety ............................................................................................................. 3-1
3.03 Grounding ...................................................................................................... 3-1
3.04 Electrical Input Requirements ........................................................................ 3-1
3.05 Requirements for Maximum Output ............................................................... 3-2
3.06 Installation of Shielding Gas (GMAW) Process .............................................. 3-2
3.07 Attaching the Gun and Cable Assembly to the Power Source ......................... 3-5
3.08 Polarity Changeover ....................................................................................... 3-6
3.09 Installing Wire Spool ...................................................................................... 3-7
3.10 Feedrolls ......................................................................................................... 3-8
3.11 Install Wir
e into the Feedhead ........................................................................ 3-9
3.12 Install Wire into the Welding Gun ................................................................. 3-11
TABLE OF CONTENTS (continued)TABLE OF CONTENTS
SECTION 4:
OPERATION........................................................................................... 4-1
4.01 General Safety Precautions ............................................................................ 4-1
4.02 Fabricator Controls ......................................................................................... 4-2
4.03 Gas Metal Arc Welding (GMAW) .................................................................... 4-4
4.04 Flux Cored Arc Welding (FCAW) ..................................................................... 4-4
4.05 Shutdown Procedures .................................................................................... 4-4
4.06 Basic Welding Technique................................................................................ 4-5
4.07 Welding Gun Positions ................................................................................... 4-6
4.08 MIG Welding (GMAW) Variables .................................................................... 4-7
4.09 Establishing the Arc and Making Weld Beads ................................................. 4-8
4.10 Pre-Weld Procedure ....................................................................................... 4-8
4.11 Welding Procedure ......................................................................................... 4-8
4.12 Reference Tables ............................................................................................ 4-9
4.13 Fabricator 140 Welding Setting Selection Guide ........................................... 4-10
4.14 Fabricator 180 Welding Setting Selection Guide ........................................... 4-12
4.15 Gas Selection for Gas Metal Arc Welding ..................................................... 4-14
SECTION 5:
BASIC TROUBLESHOOTING ........................................................................ 5-1
5.01 Cleaning of the Unit ........................................................................................ 5-1
5.02 Cleaning of the Feed Rolls .............................................................................. 5-1
5.03 Basic Troubleshooting .................................................................................... 5-1
5.04 Solving Problems Beyond the Welding Terminals .......................................... 5-1
5.05 Welding Problems .......................................................................................... 5-3
5.06 Power Source Problems .................................................................................5-5
SECTION 6:
ADVANCED TROUBLESHOOTING .................................................................. 6-1
6.01 Pre Power-Up Checks..................................................................................... 6-1
6.02 Initial Setup Conditions .................................................................................. 6-1
6.03 Primary Power Test ........................................................................................ 6-1
6.04 Logic & Control Test....................................................................................... 6-1
6.05 Spool Gun Control Test .................................................................................. 6-2
6.06 Output Voltage Test ........................................................................................ 6-2
6.07 Wire Feed & Weld Test ................................................................................... 6-2
6.08 Primary Power Problems ............................................................................... 6-3
6.09 Logic & Control Problems .............................................................................. 6-4
6.10 Wire Feed and Weld Problems ....................................................................... 6-5
6.11 Rectifier Assembly Test Procedure................................................................. 6-5
6.12 T1 Transformer Test Procedure ...................................................................... 6-6
6.13 C1 & C2 Test Procedure ................................................................................. 6-6
TABLE OF CONTENTS
SECTION 7:
PARTS LIST .......................................................................................... 7-1
7.01 Equipment Identification................................................................................. 7-1
7.02 How To Use This Parts List ............................................................................ 7-1
7.03 Front Panel ..................................................................................................... 7-2
7.04 Rear Panel ...................................................................................................... 7-3
7.05 Power Supply ................................................................................................. 7-4
7.06 Wire Feeder Parts ........................................................................................... 7-6
7.07 Feed Plate Parts .............................................................................................. 7-8
7.08 Accessories .................................................................................................. 7-10
APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1
APPENDIX 2: FABRICATOR 180 SYSTEM SCHEMATIC ............................................... A-2
APPENDIX 3: FABRICATOR 140 SYSTEM SCHEMATIC ............................................... A-4
APPENDIX 4: FEED ROLL KITS ........................................................................... A-6
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
SAFETY INSTRUCTIONS FABRICATOR 140, 180
!
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:
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 semi-automatic 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.
SAFETY IN WELDING AND CUTTING. This publication and other
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.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and 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.
January 25, 2008 1-1 Manual 0-4991
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
FABRICATOR 140, 180 SAFETY INSTRUCTIONS
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.
WARNING
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
Manual 0-4992 1-2 January 25, 2008
(goggles or helmet), from AWS A6.2-73.
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
SAFETY INSTRUCTIONS FABRICATOR 140, 180
!
2. If used in a closed area, vent engine exhaust outside and away
WARNING
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.
January 25, 2008 1-3 Manual 0-4991
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.
FABRICATOR 140, 180 SAFETY INSTRUCTIONS
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.
LEAD WARNING
This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California
Health & Safety Code § 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
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.
Manual 0-4992 1-4 January 25, 2008
SAFETY INSTRUCTIONS FABRICATOR 140, 180
1.03 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
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
January 25, 2008 1-5 Manual 0-4991
Receptacle RatingAuxiliary Power
Voltage Input
V
Art # A-04130
FABRICATOR 140, 180 SAFETY INSTRUCTIONS
!
1.04 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.
1.05 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.
Manual 0-4992 1-6 January 25, 2008
SAFETY INSTRUCTIONS FABRICATOR 140, 180
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
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtre oculaire
January 25, 2008 1-7 Manual 0-4991
FABRICATOR 140, 180 SAFETY INSTRUCTIONS
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
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.
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.
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.
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.
Manual 0-4992 1-8 January 25, 2008
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
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.
SAFETY INSTRUCTIONS FABRICATOR 140, 180
4. N’utilisez pas une source de courant de soudage pour charger un
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.
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.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le
plomb, ou engendre des produits chimiques, reconnus
par l’état de Californie comme pouvant être à l’origine
de cancer, de malformations fœtales ou d’autres
problèmes de reproduction. Il faut se laver les mains
après toute manipulation. (Code de Californie de la
sécurité et santé, paragraphe 25249.5 et suivants)
1.06 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.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
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.
January 25, 2008 1-9 Manual 0-4991
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.
FABRICATOR 140, 180 SAFETY INSTRUCTIONS
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
X
%
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Distant
Facteur de Marche
Pourcentage
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Torch de
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
Duréc du Pulse
t
t1
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Durée de Pré-Dèbit
Durée de Post-Dèbit
t2
Soudage
Détente à 2-Temps
Détente à 4-Temps
Courant Continue (DC)
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
115V 15A
Manual 0-4992 1-10 January 25, 2008
Classement de PriseSource Auxiliaire
Haute Température
Force d'Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
V
t
IPM
MPM
Probléme de Terre
Pouces Par Minute
Mètres Par Minute
Art # A-07639
INTRODUCTION FABRICATOR 140, 180
!
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This Service Manual applies to just specification or catalog
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.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
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 Library link:
http://www.thermalarc.com
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
January 25, 2008 2-1 Manual 0-4992
FABRICATOR 140, 180 INTRODUCTION
2.04 General
The Thermal Arc Fabricator 140 / 180 Machines are both
single-phase input welding machine and come equipped
with the following:
1. Built-in Wire Feeder and Wire Spool Hub
2. Quick Connect Welding Gun and Cable (10 Foot
Length)
3. Work Cable and Clamp
4. Regulator/Flow Meter
5. Input Cord
6. Spare Parts Kit (4 contact tips)
7. Operational Manual
8. 0.5 lb Spool of Wire
The welding system is designed for use with the following
processes:
1. GMAW – Gas metal arc welding (MIG). Requires
the use of a shielding gas and regulator.
2. FCAW – Flux-cored arc welding – Does not require
the use of a shielding gas.
As delivered from the factory, the Fabricator 140 is set
up for .024" (0.6mm) diameter solid wire and the
Fabricator 180 is set up for .030” (0.8mm) diameter solid
wire.
The feed roll can be
set up the Fabricator 140 for .030” (0.8mm) diameter
solid wire and the Fabricator 180 for .024" (0.6mm)
diameter solid wire.
Optional feedrolls, contact tips and gun liners are available
to convert the gun and feed system to use the following
wires.
1. .023” - .035" (0.6mm – 0.9mm) Solid Wire (Mild
Steel and Stainless Steel)
2. .030" - .035” (0.8mm – 0.9mm) Self-Shielding Wire
3. .030" (0.8mm) Aluminum Wire
Refer to section 3.10 Feedrolls and Appendix 4 for more
information.
reversed in either machine which will
Also refer to OPTIONAL EQUIPMENT LIST and 180A MIG
Gun sections included in this manual.
Manual 0-4992 2-2 January 25, 2008
INTRODUCTION FABRICATOR 140, 180
g
g)
g)
pply
pply
p
y Cy
p
(
p
)
p
p
(
)
(
)
(
)
(
)
2.05 Machine Specifications
Description Fabricator 140 Fabricator 180
Package System Part Number W1002500 W1002600
Power Source Wei
Power Source Dimensions HxWxD
Number of Phases
Frequency
Flexible Su
Su
Nominal In
Rated Input Current ^ 15A ^ 21A
Rated kVA @ 100% Dut
Rated In
Maximum In
Generator Requirements # 6kVA # 8.5kVA
Supply VA @ max. output # 5.1kVA # 7kVA
O
Out
Duty Cycle Period
Number of Output Voltage Values 4 6
Minimum Mains Circuit to suit factory fitted Plug
& Lead
Maximum Mains Circuit to suit factory fitted Plug
& Lead (Weld Current @ Duty Cycle)
Wire Size Range
Lead Plug Type 5-15P 6-50P
ut Current 15A (65A@40%) 21A
en Circuit Voltage Range 20.5 – 34V 19.5 – 38V
ut Current Range 30 – 140A 30 – 180A
Weld Current @ Duty Cycle
ht 64 lb (29 k
15.8 x 10.0 x 21.3”
400 x 255 x 540mm
60Hz
Cable Size 7 ft (2.3 m) 14AWG 8 ft (2.5 m) 12AWG
ut Voltage 120V AC 230V AC
cle 1kVA 1.9kVA
ut Current 24A (90A@20%
10 Minutes
(+) 15A (65A@40%) (+) 21A (130A@25%)
(+) 24A (90A@20%) (+) 31A (180A@15%)
Steel
Stainless Steel .023” - .030”
0.6 - 0.8mm
Flux Core .030” - .035”
(0.8 - 0.9mm)
Aluminum .030” - .035” (0.8 - 0.9mm)
.023” - .030” - .035"
0.6 - 0.8 - 0.9mm
80 lb (36 k
1
130A@25%)
31A (180A@15%)
.023” - .030” - .035"
0.6 - 0.8 - 0.9mm
.030” - .035” - .045"
(0.8 - 0.9 - 1.2mm)
^ The Rated Input Current should be used for the determination of cable size & supply requirements.
+ Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for
your situation in this regard.
# Generator Requirements at the Maximum Output Duty Cycle.
January 25, 2008 2-3 Manual 0-4992
Table 2-1: Specifications
FABRICATOR 140, 180 INTRODUCTION
[
]
2.06 Volt - Amp Curves
36
[V out]
Fabricator 140
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
I out
0
0 102030405060708090100110120130140150
Figure 2-1: Volt/Amp curves of the Fabricator 140
40
[V out]
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
FABRICATOR 180
[I out]
Art # A-07888
Figure 2-2: Volt/Amp curves of the Fabricator 180
Manual 0-4992 2-4 January 25, 2008
INTRODUCTION FABRICATOR 140, 180
2.07 Duty Cycle
Duty Cycle is the amount of arc-on time (actual welding time) during any 10 minute period that a machine can operate
at it’s rated output without damaging internal components. For example, the Fabricator 180 is designed for 25% duty
cycle at 130 amps. This means that it has been designed and built to provide the rated amperage, 130 amps, for 2.5
minutes out of every 10 minute period. During the other 7.5 minutes of the 10 minute period, the Fabricator 180 must
idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.
The Fabricator 140 is designed for 20% duty cycle at 90 Amps.
The Fabricator 180 is designed for 25% duty cycle at 130 Amps
If the unit overheats and the thermostat opens, wait 15 minutes for unit to cool.
Fabricator 140 at Rated Duty Cycle
1
0
23
45678
Min ute s
910
Art # A-07889
Fabricator 180 at Rated Duty Cycle
01
23
45678
Min ute s
Figure 2-3: Duty Cycle of Fabricator 140 and Fabricator 180
91
0
January 25, 2008 2-5 Manual 0-4992
FABRICATOR 140, 180 INTRODUCTION
2.08 Fabricator 180A MIG Gun
The Fabricator 180A MIG Gun (Figure 2-4) fitted to the FABRICATOR 140 and 180 offers robust construction, unparalleled
reliability and easy replacement of consumable parts. The Fabricator 180A MIG Gun has an operating capacity in
excess of the capacity of the FABRICATOR and can be expected to give trouble free service.
2
4
3
1
Item Description Part No. Size
1 Nozzle 21-50
11-23 .023” (0.6mm)
2 Contact Tip
5
3 Gas Diffuser 35-50
6
Conductor Tube
4
Assembly 180 Gun
5 Handle Torch Black W7004069
Switch Trigger
6
180Gun
Cable Assembly,
7
180Gun
8 Wire Liner 35-40-15
11-30 .030” (0.8mm)
11-35 .040” (1.0mm)
W7004068
W7004070
W7004071
7
Art # A-07956
12
9 Gas Inlet Nipple N/A
Guide, Outlet,
10
F140/180
11 Connector Plug N/A
12 Gun Switch Lead N/A
Connector 6-pin
180SG/180Gun
8
9
11
Figure 2-4: Exploded View of Fabricator 180A MIG Gun
10
W7004023
W7004067
Manual 0-4992 2-6 January 25, 2008
INTRODUCTION FABRICATOR 140, 180
2.09 Installing a New Wire Liner
1. Be sure that the Fabricator 180A MIG Gun cable is arranged in a straight line and free from twists when installing
or removing a wire liner (8). Remove the old liner by first removing the gun’s nozzle (1), contact tip (2) and gas
diffuser (3). Then remove the outlet guide (10) from the connector plug and pull the old wire liner out of the cable
assembly from the connector plug end.
2. To install a new wire liner, first inspect the o-ring gas seal on the liner for cuts or damage. Start from the connector
plug end of the assembly and begin pushing the liner through the connector plug, cable assembly (7), and into the
gun handle (5). If the liner should lodge along the way, gently whip or work the cable assembly (7) to aid forward
movement.
3. When the wire liner meets the end of the connector plug and the new raw end extends through the end of the
conductor tube assembly (4), the outlet guide (10) in the connecto
to prevent its backward movement.
NOTE
When the liner assembly is fully inserted into the cable assembly and the liner stop is firmly against the
connector plug, the “raw end” of the liner will protrude out of the open end of the gun conductor tube. Trim
the wire liner so that it protrudes past the end of the conductor tube assembly (4) by approximately the
1
length of the gas diffuser (3); 1
/16" ± 1/16" (27mm ± 1.5mm). See Figure 2-5. The trimmed end which seats
in the gas diffuser (3) must be filed and reamed smooth on the inside and outside radii so wire feed will not
be obstructed.
r plug must be securely tightened onto the liner
4. Replace gas diffuser (3), contact tip (2) and nozzle (1).
Gas Diffuser
Wire Liner
Art # A-08333
Figure 2-5: Trim Wire Liner to Length Of Gas Diffuser
x x
2.10 MIG Gun Maintenance
Remove dust and metallic particles from the gun conduit by forcing clean, dry compresses air into the conduit once a
week. This will minimize wire feeding problems.
January 25, 2008 2-7 Manual 0-4992
FABRICATOR 140, 180 INTRODUCTION
Manual 0-4992 2-8 January 25, 2008
INSTALLATION FABRICATOR 140, 180
SECTION 3:
INSTALLATION
3.01 Location
For best operating characteristics and longest unit life,
take care in selecting the installation site. Avoid locations
exposed to high humidity, dust, high ambient temperature,
or corrosive fumes. Moisture can condense on electrical
components, causing corrosion or shorting of circuits.
Dirt on components will retain this moisture and also
increases wear on moving parts.
Adequate air circulation is needed at all times in order to
assure proper operation. Provide a minimum of 12”
(300mm) of free air space at both the front and rear of
the unit. Make sure that the ventilation openings are not
obstructed.
CAUTION
The Fabricator is not suitable for use in rain.
The Fabricator 180’s power cord is equipped with a NEMA
6-50P plug and will only connect to a NEMA 6-50P
receptacle.
CAUTION
Consult the nameplate for proper input voltage
and input amperage. The method of
installation, conductor size, and over-current
protection shall conform to the requirements
of the local electrical code. All installation
wiring and machine connection shall be done
by a competent electrician.
The National Electrical Code (Article 630B) provides
standards for amperage handling capability of supply
conductors based on the duty cycle of the welding power
source. The Fabricator 140 has a 20% duty cycle (2
minutes of every 10 minutes can be used for welding)
and the Fabricator 180 has a 25% duty cycle. The power
cords supplied with these units comply with these
standards. Ensure that the building supply and receptacle
comply with NEC standards and any additional state and
local codes.
3.02 Safety
Refer to additional installation instructions under the
SAFETY INSTRUCTIONS AND WARNINGS (Section 1) in
this manual.
3.03 Grounding
The internal frame of this welding machine should be
grounded for personal safety. Where grounding is
mandatory under state or local codes, it is the
responsibility of the user to comply with all applicable
rules and regulations. Where no state or local codes exist,
it is recommended that the National Electrical Code be
followed.
3.04 Electrical Input Requirements
Plug the input cord into a properly grounded and protected
(by fuse or circuit breaker) mains receptacle capable of
handling a minimum of 20 Amperes. The Fabricator 140
requires a 120VAC supply voltage and the Fabricator 180
requires a 230VAC supply voltage.
The Fabricator 140’s power cord is equipped with a NEMA
5-15P plug and will only connect to a NEMA 5-15P
receptacle.
NOTE
The supply wiring for the welding power
source must be capable of handling a
minimum of 20 amperes. The welding power
source must be the only load connected to
the supply circuit. Poor unit performance or
fr equently opening line fuses or circuit
breakers can result fr om an inadequate or
improper supply.
CAUTION
Do not connect the Fabricator 140 to an input
power supply with a rated voltage that is
greater than 132 +10% VAC.
the power cord ground prong.
CAUTION
Do not connect the Fabricator 180 to an input
power supply with a rated voltage that is
greater than 255 + 10% VAC.
the power cord ground prong.
Do not remove
Do not remove
January 25, 2008 3-1 Manual 0-4992
FABRICATOR 140, 180 INSTALLATION
3.05 Requirements for Maximum Output
In order to obtain the maximum output capability of the
Fabricator 140, a branch circuit capable of 20 amperes at
115 to 125 Volts 60 Hz is required. In order to obtain the
maximum output capability of the Fabricator 180, a branch
circuit capable of 30 amperes at 230 to 250 Volts 60 Hz is
required. This generally applies when welding steel that
is equal to or greater than 12 gauge (0.105” 2.5mm) in
thickness.
The rated output with this installation is 90 amperes, 18
Volt, 20% duty cycle (2 minutes out of every 10 minutes
used for welding) for the Fabricator 140, and 130 amperes,
20 Volt, 25% duty cycle (2.5 minutes out of every 10
minutes used for welding) for the Fabricator 180.
3.06 Installation of Shielding Gas
(GMAW) Process
Refer to Figure 3-1.
NOTE
Shielding Gas is not required if the unit is using
self-shielded FCAW (flux cored arc welding)
wires.
1. Cylinder Positioning: Chain the cylinder to a wall or
other support to prevent the cylinder from falling over.
If an optional portable mounting arrangement is used,
follow the instructions that are provided with it.
2. Remove Cylinder Cap: Remove the large metal cap
on top of the cylinder by rotating counter clockwise.
Next remove the dust seal.
3. Cracking: 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.
CAUTION
KEEP FACE WELL AWAY FROM THE
CYLINDER VALVE DURING “CRACKING”
.
Never “crack” a fuel gas cylinder valve near
other welding works, sparks or open flames.
Ensure that the surrounding area is well
ventilated.
4. Fit Regulator/Flowmeter to Cylinders:
Screw the regulator into the appropriate cylinder. The
nuts on the regulator and hose connections are right
hand (RH) threaded and need to be turned in a
clockwise direction in order to tighten. Tighten with a
wrench.
CAUTION
Match regulator to cylinder. NEVER CONNECT
a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
Manual 0-4992 3-2 January 25, 2008
5. Attach Supplied Gas Line: 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.
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