Tweco 210-MIG User Manual

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Page 1

210

FABRICATOR

MIG WELDING MACHINE

Art # A-07360

Operating Manual

Revision: AI Issue Date: July 28, 2010 Manual No.: 0-4855 Operating Features:

250

208 V

230 V

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WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7621, or visit us on the web at www.thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

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WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Fabricator 210 MIG Welding Machine Instruction Manual Number 0-4855 for: Package System Part Number 100047B-001 Power Source Part Number 707519

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

www.thermalarc.com

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

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

Publication Date: April 27, 2006 Revision AH Date: July 28, 2010

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

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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 à 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 General Information ....................................................................................... 2-2

2.04 Safety ............................................................................................................. 2-2

2.05 Protective Filter Lenses .................................................................................. 2-2

2.06 User Responsibility ........................................................................................ 2-2

2.07 Duty Cycle ...................................................................................................... 2-3

2.08 Specifications ................................................................................................. 2-3

2.09 Included Items ............................................................................................... 2-5

2.10 Optional Accessories ...................................................................................... 2-5

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 Drive 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

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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 MIG Gun Identiﬁcation ................................................................................... 4-6

4.04 TWECO Weldskill 250A MIG Gun ................................................................... 4-7

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

4.06 MIG Gun Maintenance .................................................................................... 4-9

4.07 Basic Welding Technique................................................................................ 4-9

4.08 Stitch Welding Operation .............................................................................. 4-11

4.09 Spot Welding Operation ............................................................................... 4-12

4.10 Gas Selection for Gas Metal Arc Welding ..................................................... 4-13

4.11 Welding Setting Selection Guide .................................................................. 4-14

SECTION 5:

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

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

5.02 Basic Troubleshooting .................................................................................... 5-3

5.03 Solving Problems Beyond the Welding Terminals .......................................... 5-3

5.04 Welding Problems .......................................................................................... 5-5

5.05 Power Supply Problems ................................................................................. 5-7

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

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

APPENDIX 3: FEEDROLL KITS ........................................................................... A-4

STATEMENT OF WARRANTY

WARRANTY SCHEDULE

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

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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 time or touch other people with the holder or electrode.

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

9. Do not wrap cables around your body.

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

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

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

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

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

15. Keep all panels and covers securely in place.

WARNING

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

Manual No. 0-4855 1-1 SAFETY INSTRUCTIONS

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

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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

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 breathe the fumes.

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

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

4. Read the Material Safety Data Sheets (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

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

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

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

SAFETY INSTRUCTIONS 1-2 Manual No. 0-4855

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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.

Manual No. 0-4855 1-3 SAFETY INSTRUCTIONS

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.

WARNING

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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 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.

SAFETY INSTRUCTIONS 1-4 Manual No. 0-4855

Page 11

1.03 Symbol Chart

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

FABRICATOR 210

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

Manual No. 0-4855 1-5 SAFETY INSTRUCTIONS

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

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FABRICATOR 210

1.04 Precautions De Securite En Soudage à L’arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

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

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.05 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.

SAFETY INSTRUCTIONS 1-6 Manual No. 0-4855

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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 lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

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

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

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

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

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

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

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

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

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

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

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

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

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

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

épais plus de 6 po. (150 mm) 5 ou 6

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

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

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

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

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

Manual No. 0-4855 1-7 SAFETY INSTRUCTIONS

Page 14

FABRICATOR 210

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

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

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

SAFETY INSTRUCTIONS 1-8 Manual No. 0-4855

Page 15

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

FABRICATOR 210

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.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

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.

Manual No. 0-4855 1-9 SAFETY INSTRUCTIONS

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.

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.

Page 16

FABRICATOR 210

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

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

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

Soudage

Détente à 2-Temps

Détente à 4-Temps

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

115V 15A

SAFETY INSTRUCTIONS 1-10 Manual No. 0-4855

Classement de PriseSource Auxiliaire

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Probléme de Terre

Pouces Par Minute

Mètres Par Minute

Art # A-07639

Page 17

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 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

Manual No. 0-4855 2-1 INTRODUCTION

Page 18

FABRICATOR 210

2.03 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 from the Power Supply. Please read these instructions thoroughly before using your Fabricator welder.

2.05 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

2.04 Safety

The following basic safety rules should always be followed:

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

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

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

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

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

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

• Never watch the welding arc with naked eyes. Always use and wear a welding mask fitted with the correct filter lens.

• Do not stand on damp ground when welding.

For more complete safety advice please read section 1.

Table 2-1: Filter Lens Size Versus Welding Current

It is recommended to use a welding helmet, conforming to the local relevant Standards when electric arc welding. Use a welding helmet in serviceable condition with the correct filter lens. Refer to Table 2-1 above and AWS table in Section 1.

2.06 User Responsibility

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

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

INTRODUCTION 2-2 Manual No. 0-4855

Page 19

FABRICATOR 210

2.07 Duty Cycle

The rated duty cycle of a welding Power Supply is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain the ten minute duty cycle period the following example is used. Suppose a welding Power Supply is designed to operate at 25% 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 2.5 minutes out of every 10 minute period (25% of 10 minutes is 2.5 minutes). During the other 7.5 minutes of the 10 minute period the Power Supply must idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.

2.08 Specifications

MIG Gun Specifications

Gun Catalog Number 20584P 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

Wire Diameter

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

.023"

(0.6mm)

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

30VA @ 32VAC

180VA @ 14 to 46VDC

80 to 800 ipm

(2 to 20 m/min)

.030"

(0.8mm)

.035"

(0.9mm)

.045"

(1.2mm)

Manual No. 0-4855 2-3 INTRODUCTION

Page 20

FABRICATOR 210

pply

A50A

AOp

y Cy

(

pm (

)

(

)

(3m)

(

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

Nominal Input Voltage 208V ±10% 230V ±10% Number of Phases

uenc

Fre Flexible Supply Cable Size Su Rated Input Current @ 100% Duty Cycle *18.8A *17.0 Rated kVA @ 100% Duty Cycle 4.0kVA 4.0kV Maximum Input Current @ 250A Output 50.7 Generator Requirements 15 kVA 15 kV Supply VA @ Maximum Output 10.6 kVA 10.6 kVA Recommended Primar Recommended Minimum Primary Fuse 45

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

* The Rated Input Current should be used for the determination of cable size & supply requirements.

Plu

en Circuit Voltage Range 17.3 – 42.2V DC 17.3 – 42.2V DC

Arc Voltage Range 15.2 – 25.0V DC 15.2 – 25.0V DC

ut Current Range 20 – 250A DC 20 – 250A DC

cle Period

ool Size Diameter

ot Timer Range

non-weld) Time

erating Temperature Range

Fabricator 210

100047B-001

707519

Circuit Size 50

ut Duty Cycle 210A/23.0V @ 30% 210A/23.0V @ 30%

cle 250A/25.0V @ 25% 250A/25.0V @ 25%

cle Output Rating 115A DC at 20V 115A DC at 20V

ut Voltage Values

Electrode Wire T

Mild / Stainless Steel

Aluminum

Flux Cored

eed Range

Set to

Stitch) Time

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

Self-resetting thermostat fitted to rectifier

190lb

32” x 21” x 36-3/4”

10ft

NEMA 6-50P

0 – 0.6 seconds

0.16 seconds

0.5 – 9 seconds 1 – 12 seconds

assembly and transformer

32° to 104°F

86kg)

1Ø

60 Hz

10AWG

45.9

10 minutes

2 – 20 m/min

0° to 40°C

Table 2-4: Machine Specifications

INTRODUCTION 2-4 Manual No. 0-4855

Page 21

2.09 Included Items

Fabricator 210 Package System Contents

Fabricator 210 Power Source with Integrated Wirefeeder Y Factory Fitted Wheeling Kit Factory Fitted Single Cylinder Rack Y Factory Fitted Primary Power Cable 10 AWG, 10ft (3m) with Plug NEMA 6-50P Y Work Lead 10ft (3m) with clamp Y Cable Stowage Hook Y Regulator / Flowmeter - Argon Mix Gases TWECO Weldskill MIG gun 250A, 15' (4.5m) Y Drive Roll for .035"/.045" (0.9mm/1.2mm) Hard Wire Y

Table 2-5: Power Supply Contents

2.10 Optional Accessories

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

FABRICATOR 210

Manual No. 0-4855 2-5 INTRODUCTION

Page 22

FABRICATOR 210

INTRODUCTION 2-6 Manual No. 0-4855

Page 23

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 where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

3.02 Location

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

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

Manual No. 0-4855 3-1 INSTALLATION

Page 24

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 @ 25%

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 45 Amp 250A @ 25% 230V 1ø 10AWG (5mm2) 3M 50 Amps 45 Amp 250A @ 25%

Primary Input

Power Lead Size Lead Length

Input Power

Outlet Size Fuse Size Duty Cycle

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

National Electrical Code Standards permit the rating of the fuse or thermal circuit breaker protecting the circuit conductors to be double the standard rating for any circuit used exclusively for an electric arc welder. Check local requirements for your situation in this regard.

INSTALLATION 3-2 Manual No. 0-4855

Page 25

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.

Figure 3-1: Voltage Selections for Fabricator 210 (shown wired for 230V)

3.06 Quick Setup

208V connection

230V connection

CAUTION

208

230

Art # A-07393

NOTE

See section 3.15 "Polarity Changeover" for 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)

2. Connect the

(negative - for Self Shielded Flux Cored Wire)

Manual No. 0-4855 3-3 INSTALLATION

GUN

lead to the positive (+) socket

3. Position a gas cylinder on the rear tray and secure to the Power Supply cylinder bracket with the chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.

WARNING

If the gas cylinder is not secured to the cylinder tray, the power supply must be kept from moving to avoid over-extending the gas hose which can result in personal injury, damage to the power supply, flowmeter and gas cylinder.

Page 26

FABRICATOR 210

4. Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts provided.

5. Fit the gas Regulator/Flow Meter to the gas cylinder and connect the gas hose from the rear of the Power Supply to the Flow Meter outlet.

6. The machine is fitted with a .035/.045” vee groove feed roll suited for hard wire. Change this feed roll if required to fit your chosen wire size.

7. Fit the electrode wire spool to the wire reel hub located behind the electrode wire compartment door.

8. Fit the TWECO Weldskill MIG gun and trigger wires through/to the front of the unit.

9. Remove the contact tip from the gun.

10.With the gun lead reasonably straight, feed the wire through the wire drive rolls and gun.

11.Fit the appropriate contact tip and replace insulator and nozzle.

3.07 Installation of Shielding Gas (GMAW) Process

NOTE

Shielding Gas is not required if the unit is used with self shielded FCAW (flux cored arc welding) wires

1. Cylinder positioning: Block the wheels of the unit so

it cannot roll. Carefully stand the cylinder on the tray and with one foot press against the bottom of the cylinder to assure it is against the back of the unit. Chain the cylinder in place. (Refer to Figure 3-2 for Wheel Kit cylinder installation)

2. Cracking: Remove the large metal cap on top of the

cylinder by rotating counter clockwise. Next remove the dust seal. Position yourself so the valve is pointed away from you and quickly open and close the valve for a burst of gas. This is called “Cracking” and is done to blow out any foreign matter that may be lodged in the fitting. (Figure 3-2.)

3. Fit Regulator/Flow Meter to cylinders: Screw the

regulator into the appropriate cylinder. (Figure 3-2) The nuts on the regulator and hose connections are right hand (RH) threaded and need to be turned in a clockwise direction in order to tighten. Tighten with a wrench.

CAUTION

Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

4. Attach supplied gas line between the regulator output

and the desired input at the rear of the power supply depending on Spool Gun or MIG Gun use. (Refer to Figure 3-2 and 3-13).

INSTALLATION 3-4 Manual No. 0-4855

Page 27

FABRICATOR 210

“Cracking”

Cap

Shielding Gas

Regulator and Flow Meter

Shielding Gas

Gas Hose

Stowage Hook

1 1/8”

Shielding Gas

Art # A-07374

Figure 3-2 Gas Cylinder Installation

Manual No. 0-4855 3-5 INSTALLATION

Page 28

FABRICATOR 210

Adjusting Regulator

Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-3) The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause

turbulence and weld porosity. Argon or argon based gas flow rates:

- Workshop welding: 20-30 CFH

- Outdoors welding: 30-40 CFH Helium based or CO2 gas flow rates:

- Workshop welding: 30-40 CFH

- Outdoors welding: 40-50 CFH

NOTE

All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.

Art # A-07280

Figure 3-3: Adjusting Flow Rate

Refer to section 4.09 for suggested gas / filler metal combinations.

NOTE

The regulator/flow meter used with argon based and carbon dioxide shielding gases is different. The regulator/flow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/flow meter will need to be fitted.

INSTALLATION 3-6 Manual No. 0-4855

Page 29

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-08661

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.

Manual No. 0-4855 3-7 INSTALLATION

Page 30

FABRICATOR 210

Art # A-08662

Front Panel Access Hole

Trigger Receptacle

Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger

Loosen Thumbscrew

Art # A-08672

Tighten Thumbscrew

Figure 3-6: Mount Gun Cable to Adapter Socket

INSTALLATION 3-8 Manual No. 0-4855

Page 31

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

Figure 3-7: Wire Guide Installation

Output Wire Guide

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.

Manual No. 0-4855 3-9 INSTALLATION

Page 32

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

A-07192_AB

Figure 3-9: Wire Spool Installation

INSTALLATION 3-10 Manual No. 0-4855

Page 33

FABRICATOR 210

3.12 Inserting Wire into the Feedhead

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions.

1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure. 3-10)

2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-10)

3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire Guide and over the Feedroll. Make certain the proper groove is being used. (Second part of Figure. 3-10)

4. Pass the wire through the outlet guide and into the Gun liner of the Gun Cable. (Second part of Figure. 3-10)

5. Close the Pressure Roller Arm. (Figure. 3-11)

6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-11)

7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to tighten and Counter Clockwise to loosen). (Figure. 3-11)

8. Figure 3-12 shows the result with wire installed. Continue to the next section for proper setting of tension.

2 - Swing Pressure arm

1 - Loosen Adjuster and swing down

Art # A-07143

open

3 - Feed wire through here

4 - Feed wire through here

Figure 3-10: Opening Pressure Arm and Inserting Wire

7 - Adjust the tension

5 - Swing the Pressure Arm closed

Art # A-07144

6 - Swing the Adjuster back into place.

Figure 3-11: Closing Pressure Arm and Adjusting Tension

Manual No. 0-4855 3-11 INSTALLATION

Page 34

FABRICATOR 210

Wheel Brake Hex Head Bolt

Wire Spool Hub Retaining Pin

Figure 3-12: Wire Installed

3.13 Wirefeeder Drive Roller Pressure Adjustment

Pressure Adjustment Device

Art # A-08651

The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise. The Tension Adjuster should be set to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire out of the MIG gun reveals no deformation or wear, the conduit liner should be checked for kinks or clogging from metal flakes. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the Tension Adjusting knob clockwise. The use of excessive pressure may cause rapid wear of the feed roller, motor shaft and motor bearings.

NOTE

Genuine TWECO contact tips and liners should be used. Many non-genuine liners use inferior materials which can

cause wire feed problems.

3.14 Wire Reel Hub Brake

The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the hex head bolt inside the open end of the wire reel hub. Clockwise rotation will tighten the brake. (Refer to Figure 3-12 above).

CAUTION

Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, over heating of electrical componentry and possibly an increased incidence of wire Burnback into the contact tip.

NOTE

Correct adjustment will result in the wire reel circumference continuing no further than 0.75" (20mm) after release of the Gun trigger switch. The wire should be slack without becoming dislodged from the reel.

INSTALLATION 3-12 Manual No. 0-4855

Page 35

FABRICATOR 210

3.15 Spool Gun Attachment

A spool gun can readily be used with the Fabricator 210 power supply.

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

13)

2. Attach the Spool Gun control cable and gas hose to the 10 pin socket and the Spool Gun Gas Outlet on the front of the unit. (Refer to Figure. 3-13)

Spool Gun Gas Input Connection

Spool Gun 10 Pin Socket

Main Gun Gas Input Connection

Rear Panel

Art # A-07345_AC

Spool Gun Gas Outlet Connection

Front Panel

Figure 3-13 Spool Gun Connections

NOTE

When the SPOOL GUN is properly attached, Spool Gun/MIG Gun switch is set to Spool Gun and the trigger is depressed, the internal wire feed and gas control are disabled and the SPOOL GUN feeder and gas control operate.

Manual No. 0-4855 3-13 INSTALLATION

Page 36

FABRICATOR 210

3.16 Polarity Changeover

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions.

The output terminals are located on the front panel of the welding power source.

CABLE TO GUN, CABLE TO WORK

PROCESS POLARITY

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

2. FCAW* – Gasless Flux Cored electrode wire

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

Work Lead

Art # A-07163

CABLE TO GUN CABLE TO WORK

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

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

1. Connected to (+) Pos. output terminal

2. Connected to (-) Neg. output terminal

Table 3-3: Process Cable Connections

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

CABLE CONNECTIONS

1. Connected to (-) Neg. output terminal

2. Connected to (+) Pos. output terminal

Figure 3-14: Polarity Connections for DCEP

INSTALLATION 3-14 Manual No. 0-4855

Page 37

Work Lead

Connected for D.C. Electrode Negative

Art # A-07164

(DCEN) Welding

Figure 3-15: Polarity Connections for DCEN

Changing polarity process.

a. Locate the two terminal knobs at the front of the machine. Refer to Figures 3-14 and 3-15. b. Remove both terminal knobs by rotating counterclockwise. c. Set up the desired lead polarity as per Table 3-3 and as shown in Figures 3-14 or 3-15.

FABRICATOR 210

d. Place the Work Lead cable on the opposite terminal. e. Replace both terminal knobs and tightly secure them to ensure good electrical connections.

CAUTION

Ensure terminal knobs are tightly secured and that there is no connection between positive and negative terminals.

f. Reconnect the input power to the power supply.

Manual No. 0-4855 3-15 INSTALLATION

Page 38

FABRICATOR 210

NOTES:

INSTALLATION 3-16 Manual No. 0-4855

Page 39

FABRICATOR 210

SECTION 4:

OPERATION

WARNING

DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding voltage potential.

4.01 Power Supply Controls, Indicators and Features

Front Panel Access Hole Torch

Gun Switch

Receptacle

Negative Welding Terminal

15V - 17V

22V - 26V

17V - 19V

19V - 21V

Weldskill

Thermal Overload Indicator

Wire Feed Speed Control

Power ON/OFF Switch

CoarseVo

FineVo

ltage Switch Selector

Spool Gun Gas Outlet

Spool Gun Interface

Amphenol Receptacle

Gun Polarity Lead

Positive Welding Terminal

Art # A-08650

Figure 4-1: Fabricator Controls

Manual No. 0-4855 4-1 OPERATION

Page 40

FABRICATOR 210

ON / OFF Power Switch

The indicator light is provided to indicate when the Fabricator 210 is connected to the Input Power Supply Voltage. With the switch in the Standby position, the auxiliary power and the fan are turned off and the switch is illuminated.

WARNING

When the light is lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential.

Thermal Overload

The critical component for thermal protection are the rectifier stack and the transformer, which are fitted with thermal overload cut out devices. If the overload is activated then the machine should be left to cool for approximately 15 minutes before resuming welding. If the Power Source is operated within its duty cycle, the thermal overload will not activate. Refer to section 2.09 for an explanation of duty cycle and section 2.10 for the power supply specifications.

Wirespeed Control

The Wirespeed Control knob controls the welding current via the electrode wire feed rate, i.e. the speed of the wire feed motor. The wire speed is variable from 80 to 800IPM (2-20 m/min).

Coarse Voltage Switch Selector

The Coarse Voltage Switch Selector sets the voltage level to the welding terminals as it switches from 1 to 4.

Fine Voltage Switch Selector

The Fine Voltage Switch Selector increases the voltage (in smaller increments than the Coarse switch) as it switches from 1 to 4.

CAUTION

The Coarse & Fine Voltage Switch Selectors MUST NOT BE SWITCHED during the welding process.

OPERATION 4-2 Manual No. 0-4855

Page 41

FABRICATOR 210

Positive and Negative Welding Current Terminals

Refer back to Figure 4-1. Both terminals located at the bottom of the unit are shown without the terminal knob. Both knobs must be firmly secured before attempting to weld.

Gun Polarity Lead

This lead selects the welding voltage polarity of the electrode wire. Attach it to the positive welding terminal (+) when using steel, stainless steel or aluminium electrode wire. Attach the Gun Polarity Lead to the negative welding terminal ( - ) when using gasless flux cored electrode wire. If in doubt, consult the manufacturer of the electrode wire for the correct polarity. Also refer to section 3-16.

Positive and Negative Welding Terminal Knobs

Welding current flows from the Power Supply via heavy duty terminals. It is essential, that these terminal knobs are tight to achieve the necessary electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in failure of the terminals.

Gun Switch Receptacle

The Torch Trigger 4-pin receptacle is used to connect the two wires from the torch gun to the Fabricator

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

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

Spool Gun Interface Amphenol Connector

The Spool Gun Interface 10 pin connector is used to connect a spool gun to the Fabricator 210 (refer to Figure 4-3 and Table 4-1).

Art # A-07181

Figure 4-3: Spool Gun 10 pin receptacle

To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the SPOOL GUN 10-pin receptacle.

Socket Pin Function

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

Spool Gun Speed C.W.

F G Spool Gun Switch

I Not Used

J Not Used

Table 4-1: 10-pin Receptacle Pin Functions

Potentiometer Maximum Spool Gun Speed Wiper Potentiometer

Spool Gun Speed C.C.W. Potentiometer Minimum

NOTE

When the SPOOL GUN is properly attached and the trigger is depressed, the system

Art # A-07171

Figure 4-2: Gun Switch Receptacle

Manual No. 0-4855 4-3 OPERATION

automatically disables the internal wire feed and gas control and selects the SPOOL GUN feeder and gas control.

Page 42

FABRICATOR 210

WELD MODE

SPOT

STITCH

4.02 Weld Mode Selector

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

Art # A-07183_AB

Figure 4-4: Internal Welding Controls

2T (Continuous Welding):

This mode of welding is used to weld two or more components together with a continuous weld. When the MIG gun trigger switch is depressed welding commences. When the MIG gun trigger switch is released welding ceases.

MIN

DWELL

(STITCH)

WELD MODE

SPOT STITCH

WELD

(SPOT / STITCH)

MIN

This mode of welding is used to weld two plates together at a desired location by melting the top & bottom plates together to form a nugget between them. The spot time period is set by the Weld (Spot/ Stitch) control knob located in the electrode wire compartment.

WELD MODE

STITCH

SPOT

Art # A-07427_AB

Art # A-07466

Figure 4-5: For Reference Only

Figure 4-6: Spot Weld

SPOT:

NOTE

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

STITCH:

OPERATION 4-4 Manual No. 0-4855

Page 43

FABRICATOR 210

WELD MODE

SPOT

STITCH

BURNBACKBURNBACK

Art # A-07431_AB

This mode of welding is used to weld two or more components together with a stitch weld. The WELD (Spot/Stitch) shaft controls the welding or ‘ON’ time and the "DWELL (Stitch)" shaft controls the interval or ‘OFF’ time for stitch welding.

Art # A-07428

Figure 4-7: Stitch Welding

4T (Latch):

This mode of welding is mainly used for long weld runs, as the operator need only press the trigger to activate the weld, then press the trigger again to stop. This replaces the need for the operator to depress and hold the trigger for the complete length of the weld run.

WELD MODE

STITCH

SPOT

Dwell Stitch

DWELL (STITCH) TIMER CONTROL

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

DWELL

(STITCH)

MIN

Art # A-07430_AB

Figure 4-10: Dwell (Stitch) Control

Burnback Control

Burnback time is the difference between the wirefeed motor stopping and the welding current ceasing. The Burnback time allows the electrode wire to burn out of the molten metal weld pool. The Burnback time is factory set for optimum performance. Burnback time is adjusted by the knob of the potentiometer. Clockwise adjustment increases Burnback time.

Art # A-07427_AB

Figure 4-8: For Reference Only

WELD (Spot/Stitch) Timer Control

WELD MODE - SPOT

When the Weld Mode control is in the Spot position, the Weld (Spot/Stitch) knob controls the duration of a single spot weld.

WELD MODE - STITCH

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

the stitch weld on time.

Art # A-07429_AB

Figure 4-9: Weld (Spot/Stitch) Control

WELD

(SPOT / STITCH)

MIN

Figure 4-11: Burnback Control

Manual No. 0-4855 4-5 OPERATION

Page 44

FABRICATOR 210

4.03 MIG Gun Identification

The FABRICATOR 210 comes with one of two versions of the TWECO Weldskill 210A MIG gun. The two guns can be easily distinguished from one another by their several obvious physical differences as depicted below.

Be sure to identify which version you have before ordering the replacement parts listed on the

following page.

“P” Series “T” Series

Different Hooks

Different Triggers

Different Strain Reliefs

Different Labels

Red O-Rings

Different Gun Switch Plugs

Figure 4-12: MIG Gun Identification

OPERATION 4-6 Manual No. 0-4855

Black O-Rings

Art # A-08069

Page 45

FABRICATOR 210

4.04 TWECO Weldskill 250A MIG Gun

The TWECO Weldskill 250A Fabgun MIG gun fitted to the FABRICATOR 210 offers robust construction, unparalleled reliability and easy replacement of consumable parts. The TWECO Weldskill 250A MIG gun has an operating capacity in excess of the capacity of the FABRICATOR and can be expected to give trouble free service.

Art # A-07986

Figure 4-13: TWECO WeldSkill 250A Fabgun MIG Gun

TWECO Weldskill 250A MIG Gun — Original Parts Installed

Item Description "T" S eries Part No. "P" S eries Part No.

1 NOZZLE 1/2" WS22-50 WS22-50 2 NOZZLE INSULATOR WS32 WS32 3 CONTACT TIP .035" W S14-35 WS14-35 4 GAS DIFFUSER WS52 WS52 5 CONDUCTOR TUBE WM62J-50 WM62J-50 6 HANDLE ASSEMBLY WM1-80 TA1-80 7 TRIGGER SWITCH ASSEMBLY WM91 WM91

Table 4-2: TWECO WeldSkill 250A fABGUN MIG Gun Replacement Parts

TWECO Weldskill MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO Weldskill. Not only will this give greater reliability (and hence greater productivity) but it will reduce stockholding of consumable parts. See your Thermal Arc distributor for details.

Additional MIG Gun Parts

See Appendix at the back of this manual.

Manual No. 0-4855 4-7 OPERATION

Page 46

FABRICATOR 210

4.05 Installing A New Wire Conduit

Removal

1. Be sure the MIG Gun cable is arranged in a straight line, free from twists, when installing or removing a wire conduit.

2. Unscrew and remove the MIG Gun Nozzle by hand and the Contact Tip using a pair of slip-joint pliers. Note that the Insulator is inside the Nozzle and can not be removed.

3. Loosen the allen screw in the Gas Diffuser and unscrew it from the Conductor Tube using a 1/2-in. (13mm) open end wrench across the flats.

4. Loosen the allen screw in the Connector Plug using a 5/64-in. allen wrench and pull the old Wire Conduit out of the cable assembly from the Connector Plug end.

Installation

1. Inspect the two O-ring gas seals on the Connector Plug for cuts or damage.

3. When the Wire Conduit Liner stop meets the end of the Connector Plug and the new raw end extends through the end of the Conductor Tube on the welding gun, the allen screw in the connector plug must be securely tightened onto the Wire Conduit to prevent its backward movement.

NOTE

When the Wire Conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug, the “raw end” of the Wire Conduit will protrude out of the open end of the gun Conductor Tube. Trim the Wire Conduit as shown in Figure 4-14. The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed.

3. Replace the Gas Diffuser and tighten its allen screw against the Wire Conduit.

4. Replace the Contact Tip and Nozzle.

2 Start from the Connector Plug end of the assembly

and begin pushing the Wire Conduit through the Connector Plug, cable assembly and into the gun. If the Wire Conduit should lodge along the way, gently whip or work the cable assembly to aid forward movement.

CONDUCTOR TUBE

CONDUIT LINER

ALLEN SCREW

DIFFUSER

NOZZLE

CONTACT TIP

5/64-IN. ALLEN SCREW

1 1/16" (27mm)

O-RINGS

CAUTION

Do not over-tighten the allen screw as this will distort the Wire Conduit and lead to wire feedability problems.

Art # A-07330

CONDUIT LINER

CONNECTOR PLUG

Figure 4-14: Conduit Installation and Trim Length

OPERATION 4-8 Manual No. 0-4855

Page 47

FABRICATOR 210

4.06 MIG Gun Maintenance

Remove dust and metallic particles from the gun conduit by forcing clean, dry compressed air into the conduit once a week. This will minimize wire feeding problems.

4.07 Basic Welding Technique

Setting of the Power Supply

The setting of the Fabricator 210 requires some practice by the operator, the welding Power Supply having two control settings that have to balance. These are the Wire Speed control and the Voltage Control switches. The welding current is determined by the Wire Speed control, the current will increase with increased Wire Speed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the welding current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding current.

When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more Wire Speed to achieve the same current level.

A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the work piece.

If the Wire Speed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the electrode wire, causing spatter. The correct setting of voltage and Wire Speed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.

MIG Gun Travel Speed

Speed at which a weld travels influences the width of the weld and penetration of the welding run.

Position of MIG gun

The angle of MIG gun to the weld has an effect on the width of the weld run. Refer to Figure 4-14.

Forehand

Art # A-05148

Figure 4-15: MIG Gun Angle

Vertical

Manual No. 0-4855 4-9 OPERATION

Page 48

FABRICATOR 210

Distance from the MIG Gun Nozzle to the Work Piece

The electrode stick out from the MIG gun nozzle should be between 5/64" (2.0mm) to 13/64" (5.0mm). This distance may vary depending on the type of joint that is being welded.

Art # A-07186

1/4” (6.4mm)

.023”

(.6mm)

Solid Wire

5/16” (7.9mm)

.030”

(.8mm)

3/8” (9.5mm)

.035”

(.9mm)

Flux Cored Wire

9/16”

(14.3mm)

.035”

(.9mm)

(17.5mm)

Figure 4-16: Optimum Contact Tip to Work Distances

Electrode Wire Size Selection

The choice of electrode wire size in conjunction with shielding gas used depends on:

- Thickness of the metal to be welded,

- Type of joint,

- Capacity of the wire feed unit and power supply,

- The amount of penetration required,

11/16”

Tip

Contact

.045”

(1.1mm)

Gas

Nozzle

Distance: ±1/16”

Wire Diameter

- The deposition rate required,

- The bead profile desired,

- The position of welding and

- Cost of the electrode wire.

Weld metal deposition rate is proportional to current density. Current density is defined as the current per cross sectional area of the electrode wire and is normally expressed as amps per mm

. An example is in Table 4-3 below.

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

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

Table 4-3: Wire Deposition Rate

OPERATION 4-10 Manual No. 0-4855

Page 49

Advantages of MIG welding forehand:

- Allows superior visibility of the weld zone

- Flatter weld bead

- Shallower penetration

FABRICATOR 210

Forehand

Vertical

Figure 4-17: MIG Gun Angle

Backhand

Art # A-07185

4.08 Stitch Welding Operation

Welding consumable costs can be reduced by replacing a continuous weld bead with the Stitch weld bead. It will also reduce heat distortion in thin plate.

Coarse & Fine Voltage Selector Switches and Wire Speed Control

Set these controls to obtain the desired welding conditions for the wire and material being welded.

Mode Selector Switch

Set the WELD MODE switch to STITCH.

Weld (Spot/Stitch) Timer Control

Adjust the WELD (Spot/Stitch) Timer Control knob for the desired weld or ‘ON’ time while stitch welding.

Dwell Time

Adjust the DWELL (Stitch) Timer Control knob for the desired interval or ‘OFF’ time while stitch welding.

Manual No. 0-4855 4-11 OPERATION

Page 50

FABRICATOR 210

4.09 Spot Welding Operation

Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to Figure 4-18 and the Spot Welding Nozzle table below. The Fabricator 210 will operate effectively using .030” (0.8mm) electrode wire when spot welding. Penetration depth is limited when using .024”(0.6mm) electrode wire for spot welding. Set the controls as follows for spot welding:

Coarse & Fine Voltage Selector Switches and Wirespeed Control

Select higher Voltage Selector switch positions and set the Wirespeed Control between 354 to 590 ipm (9 to 15 m/ min) for maximum penetration.

Mode Selector Switch

Set the WELD MODE switch to

SPOT.

Spot Time

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

Dwell Time

DWELL (Stitch)

The

control knob has no affect in this mode of operation.

22-62-AOS

Art # A-07678

Figure 4-18: Spot Welding Nozzle

SPOT WELDING NOZZLES

TYPE NO. 2 250 AMP

Flat Arc Spot

22-62-FAS 12201520 (5/8" Bore)

Inside Corner Arc Spot 22-62-IAS

1220-1521 (5/8” Bore)

Outside Corner Arc Spot 22-62-IAS

1220-1522 (5/8” Bore)

Automotive Stud Nozzle N/A

OPERATION 4-12 Manual No. 0-4855

Page 51

4.10 Gas Selection for Gas Metal Arc Welding

FABRICATOR 210

Metal Type

Carb on

Steel

Low Alloy

and High

Alloy Steel

Stainless

Steel

Aluminum

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

Base Plate

Thickness

Greater than 22

gauge (.030”)

Greater than 22

gauge (.030”)

Greater than 22

gauge (.030”)

Greater than 10

gauge (1/8”)

Greater than 22

gauge (.030”)

Greater than 22

gauge (.030”)

Greater than

3/32”

Greater than 14

gauge (.075”)

Greater than 22

gauge (.030”)

Greater than

3/32”

Greater than 18

gauge (.045”)

Filler

Metal

ER70S-X Short

ER70S-X Spray

See * below Short

See * below Spray

See * below Short

ER308-X ER309-X ER316-X

ER4043 ER5356

Transfer

Mode

Circuit

Transfer

Circuit

Globular

Circuit

transfer

Circuit

Short

Circuit

Spray

Transfer

Spray

Transfer

Suggested

Shielding

Gas

100% CO

75% Argon

25% CO2

92% Argon

8% CO2

92% Argon

8% CO2 or

80% Argon

20% O2

75% Argon

25% CO2

92% Argon

8% CO2

92% Argon

8% CO2 or

80% Argon

20% O2

98% Argon

2% CO2

90% Helium

7.5% Argon

2.5% CO2 or

81% Argon

18% Helium

1 % CO2

90% Helium

7.5% Argon

2.5% CO2 or

81% Argon

18% Helium

1 % CO2

Argon All

Welding

Positions

All Position Welding

Flat & HV

Fillet

All Position Welding

Flat & HV

Fillet

All Position Welding

Flat & HV

Fillet

Position Welding

High welding speeds. Good penetration and pool control.

Suitable for high-current and highspeed welding.

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

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

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

Reduces undercutting. Higher deposition rates and improved bead wetting. Deep penetration and good mechanical properties. Good control of melt-through and distortion. Used also for spray arc welding. Pool fluidity sometimes sluggish depending on the base alloy.

Low CO minimizes carbon pickup, which can cause intergranular corrosion with some alloys. Helium improves wetting action and contour. CO above 5% should be used with caution on some alloys. Good arc stability. Produces a fluid but controllable weld pool, good coalescence, and bead contour. Minimizes undercutting on heavier thickness.

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

percentages in Helium mix

Comments

percentages

Table 4-4: Gas Selection Chart

Manual No. 0-4855 4-13 OPERATION

Page 52

FABRICATOR 210

4.11 Welding Setting Selection Guide

Material Type

Steel

Wire Type

Solid

(or hard)

ER70S-6

Shielding Gas

and Flow Rate

100% CO

25cfh

75% Ar 25%

,25cfh

Wire Size

(Diameter)

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

.045” (1.2mm)

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

.045” (1.2mm)

.023” (0.6mm)

Steel

Aluminum

Stainless

Steel

Flux Core

E71T-1

E71T-GS

E71T-11

Aluminum

4043 ER 5183 ER 5356 ER

Stainless

ER308LSi ER309LSi ER316LSi

92% Ar

8% CO

100% CO

75% Ar

25% CO

25cfh

None

100% Ar

25cfh

7.5% Ar 90% He

2.5% CO

35cfh

.030” (0.8mm)

.035” (0.9mm)

.045” (1.2mm)

.030” (0.8mm)

.035” (0.9mm)

.045” (1.2mm)

.030” (0.8mm)

.035” (0.9mm)

.045” (1.2mm)

.030” (0.8mm)

.035” (0.9mm)

OPERATION 4-14 Manual No. 0-4855

Page 53

FABRICATOR 210

Coarse

Voltage

22 ga. (0.8mm)

18 ga. (1.2mm) 16 ga. (1.6mm) 1/8” (3.2mm) 3/16” (5.0mm) 1/4” (6.4mm) 3/8” (9.5mm) 1/2” (12.7mm)

1/4

1/3

1.5

1/3

2/2

2/1

2/2

2/1

1/4

Fine

Voltage

2.25

1.5

2.25

1.25

2/3

2/2

Coarse Voltage

Fine Voltage

Step

2.75

2.25

3.75

1.75

2/4

3/2

3/3

3/2

2/4

3/1

2/4

3/1

Wire

Speed

2.75

5.25

2.5

3/1

3/3

3/4

3/1

3/2

3/1

3/2

4.25

3/2

3/4

3.5

3/4

2.25

3/3

5.5

3/3

4.25

3/2

3/3

2.25

THICKNESS

6.5

4.25

8.25

5.25

2.75

4/2

7.5

4/1

5.25

4/1

3.5

3/4

7.25

3/4

5.5

3/4

3.25

4/3

8.5

4/4

7.25

4/2

4/3

8.5

4/3

7.75

4/1

3.75

1/3

2/2

1.25

.75

2/1

1/4

1/1

1/2

1/1

2/3

2/2

2.25

1.25

1.5

.75

2/2

3/1

1/3

1/4

2/4

2/3

3.75

1.5

2.25

1.5

2.25

1.25

4/1

4/2

3/1

3/2

2/1

1/4

2/4

3/1

3/3

3/1

8.25

5.25

4.25

2.75

1.75

4.5

3.5

2.25

4/1

4/2

3/3

4/1

2/2

2/4

3/3

3/4

4/1

3/2

8.25

5.25

4.25

3.5

2.5

5.5

4.75

3.5

2.75

4/2

4/3

4/2

4/1

2/4

3/1

3/2

3/4

4/1

4/2

3/4

5.75

5.5

3.5

2.5

6.25

5.5

3.5

4/3

3/2

3/3

4/2

4/3

3/4

4/1

5.75

5.25

8.75

5.75

6.25

4.75

4/4

8.5

4/4

4.5

4/4

4/3

3.5

4/3

5.75

4/4

6.25

Manual No. 0-4855 4-15 OPERATION

Page 54

FABRICATOR 210

NOTES

OPERATION 4-16 Manual No. 0-4855

Page 55

FABRICATOR 210

SECTION 5:

MAINTENANCE &

TROUBLESHOOTING

5.01 Routine Maintenance & Inspection

The only routine maintenance required for the Fabricator 210 is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

WARNING

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

Special maintenance is not necessary for the control unit parts in the Power Supply. If these parts are damaged for any reason, replacement is recommended.

To clean the Power Supply, disconnect it from the mains supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The Power Supply should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.

Troubleshooting and repairing the Fabricator should be carried out only by those who are familiar with electrical equipment.

WARNING

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

CAUTION

Do not blow air into the Power Supply during cleaning. Blowing air into the Power Supply can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Supply.

Manual No. 0-4855 5-1 SERVICE

Page 56

FABRICATOR 210

Warning! Disconnect input power before maintaining.

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Maintain more often if used under severe conditions

Each Use

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Gas lines

6 Months

Visually check and use a vacuum to carefully

clean the interior

Clean exterior of power supply

Art # A-07269

SERVICE 5-2 Manual No. 0-4855

Page 57

FABRICATOR 210

5.02 Basic Troubleshooting

The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and without removing the covers from the Power Supply.

If major components are faulty, then the Power Supply should be returned to an Accredited Thermal Arc Service Agent for repair.

5.03 Solving Problems Beyond the Welding Terminals

The general approach to fix GMAW/FCAW problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur:

Porosity

When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal.

Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points:

FAULT CAUSE REMEDY

a. Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 25CFM (15 litres per minute)

a. Check for gas leaks between the regulator/flow meter connection and in the gas hose to the power supply a. The hose from the solenoid valve to the MIG torch adaptor may be fractured or disconnected from the MIG torch adaptor. Return to an Accredited Thermal Arc Service Agent for repair. a. Shield the weld area from the wind or increase the gas flow

a. Clean contaminates off the plate

a. Keep the distance between the MIG torch nozzle and the work piece to a minimum.

a. Ensure that the gas holes are not blocked and gas is exiting out of the torch nozzle. Refer to WARNING below b. Do not restrict gas flow by allowing spatter to build up inside the MIG torch nozzle. C. Check that the MIG gun O-rings are not damaged.

Porosity

1. Gas cylinder contents and flow meter

2. Gas leaks

3. Internal gas hose in the power supply

4. Welding in a windy environment

5. Welding dirty, oily, painted, oxidized or greasy plate.

6. Distance between the MIG torch nozzle and the work piece.

7. Maintain the MIG torch in good working order.

Table 5-1: Porosity Problems

Manual No. 0-4855 5-3 SERVICE

Page 58

FABRICATOR 210

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

2. Inconsistent wire feed

FAULT CAUSE REMEDY

1. Wire spool brake is too tight.

2. Wire spool brake is too loose.

3. Worn or incorrect feed roller size.

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

a. Wire spool can unwind and tangle

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

WARNING

Inconsistent

Wire Feeding

4. Misalignment of inlet/outlet guides.

5. Liner blocked with swarf.

6. Incorrect or worn contact tip.

7. Poor work lead contact to work piece.

8. Bent liner.

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

a. Swarf is produced by the wire passing through the feed roller, if excessive pressure is applied to the pressure roller adjuster. Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size. Swarf is fed into the liner where it accumulates thus reducing wire feedability. a. The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip. When using soft electrode wire such as aluminum it may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft electrode wires should be used. a. If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc. a. This will cause friction between the wire and the liner thus reducing wire feedability.

Figure 5-2: Trouble Shooting for Inconsistent Wire Feed

SERVICE 5-4 Manual No. 0-4855

Page 59

5.04 Welding Problems

FAULT CAUSE REMEDY

A. Undercut. 1. Welding arc voltage

2. Incorrect torch

3. Excessive heat

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

B. Lack of penetration. 1. Welding current too

2. Joint preparation too

3. Shielding gas

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

C. Lack of fusion. 1. Voltage too low a. Increase voltage by increasing voltage

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

D. Excessive spatter. 1. Voltage too high a. Lower voltage by reducing the voltage

2. Voltage too low a. Raise voltage by increasing the voltage

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

E. Irregular weld

shape.

too high.

angle

input

low

narrow or gap too tight

incorrect

1. Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high.

FABRICATOR 210

a. Reduce voltage by reducing the voltage

selection switch position or increase the wire feed speed.

a. Adjust angle

a. Increase the torch travel speed and/or

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

a. Increase welding current by increasing

wire feed speed and increasing voltage selection switch position.

a. Increase joint angle or gap

a. Change to a gas which gives higher

penetration

selection switch position.

selection switch or increase wirespeed control.

selection switch or reduce wirespeed control.

a. Adjust voltage and current by adjusting

the voltage selection switch and the wirespeed control.

2. Wire is wandering a. Replace contact tip

3. Incorrect shielding gas

4. Insufficient or excessive heat input

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

a. Check shielding gas.

a. Adjust the wire speed control or the

voltage selection switch.

Table 5-3a: Welding Problems and Solutions

Manual No. 0-4855 5-5 SERVICE

Page 60

FABRICATOR 210

FAULT CAUSE REMEDY

A. Weld cracking 1. Weld beads are too

2. Weld penetration

3. Excessive weld

4. Excessive voltage a. Decrease voltage by reducing the

B. Cold weld puddle. 1. Faulty rectifier unit a. Have an Accredited Thermal Arc Service

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

crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly.

a. Decrease travel speed

small

a. Reduce current and voltage and increase

narrow and deep

stresses

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

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

7. Incorrect filler wire a. Check compatability to base metal

2. Loose welding cable connection.

3. Low Primary Voltage a. Contact supply authority

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

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

MIG torch travel speed or select a lower penetration shielding gas.

a. Increase weld metal strength or revise

design

voltage selection switch.

to be welded or cool slowly.

Agent to test then replace the faulty component.

a. Check all welding cable connections.

a. Connect the MIG torch to the positive

(+) welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

Table 5-3b: Welding Problems and Solutions continued

SERVICE 5-6 Manual No. 0-4855

Page 61

5.05 Power Supply Problems

FAULT CAUSE REMEDY

A. Indicator light is ON but welding

arc can not be established.

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

C. Mains indicator light is not lit

but welding arc can be established.

D. Mains supply voltage is ON and

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

E. Mains supply voltage is ON, no

wire feed but gas flows from the MIG Gun when the gun trigger switch is depressed.

F. Wire feeds when the gun trigger

switch is depressed but arc can not be established.

G. Wire continues to feed when the

gun trigger switch is released.

H. Jerky wire feed

I. No gas flow

FABRICATOR 210

1. Power On/Standby switch in standby position.

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

2. Broken connection in primary circuit.

1. Indicator light is open circuit.

1. Gun trigger switch leads are disconnected.

1. Electrode wire stuck in conduit liner or contact tip (burn-back jam).

2. Faulty control PCB or Tweco Gun

1. Poor or no work lead connection.

1. The Weld Mode Switch has been set to 4T (latch operation).

1. Worn or dirty contact tip a. Replace

2. Worn feed roll a. Replace

3. Excessive back tension from wire reel hub roll.

4. Worn, kinked or dirty conduit liner

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

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

2. Gas passage contains impurities

3. Gas regulator turned off a. Turn on.

a. Switch the power On/Standby

switch to the “On” position .

a. Have an Accredited Thermal Arc

Service Agent check primary circuit.

a. Have an Accredited Thermal Arc

Service Agent replace Indicator light.

a. Reconnect.

a. Check for clogged / kinked MIG

Gun conduit or worn contract tip. Replace faulty component(s).

a. Have an Accredited Thermal Arc

Service Agent investigate the fault.

a. Clean work clamp area and

ensure good electrical contact.

a. Set the Weld Mode Switch to 2T

(normal operation).

a. Reduce brake tension on spool

hub

a. Clean or replace conduit liner

pressure.

repair.

a. Disconnect gas hose from the

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

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

J. Gas flow continues after the gun

trigger switch has been released.

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

a. Have an Accredited Thermal Arc

Service Agent repair or replace gas valve.

Table 5-4: Power Supply Problems

Manual No. 0-4855 5-7 SERVICE

Page 62

FABRICATOR 210

NOTES

SERVICE 5-8 Manual No. 0-4855

Page 63

FABRICATOR 210

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES

For Tweco/Victor Inquiries and Orders:

Call 1-800-318-6819 Consumable Parts Management Group

GUNS

Tweco® WeldSkill 12ft 20584P Gun assembly with 15ft cable (supplied with package),

210 Amp @ 30% Tweco® No. 2 12ft 212-3035 Gun assembly with 12ft cable, 250 Amp @ 60% Tweco® No. 2 15ft 215-4035 Gun assembly with 15ft cable, 250 Amp @ 60% Tweco® Spraymaster 12ft MS212-3545 Gun assembly with 12ft cable, 250 Amp @ 80% Tweco® Spraymaster 15ft MS215-3545 Gun assembly with 15ft cable, 250 Amp @ 80% Spool Gun 25ft W4011000 Gun assembly with 25ft cable, 200 Amp @ 60%

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

ACCESSORIES

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

TIPS

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

NOZZLES

22-37 3/8” (9.5mm) 22-50 1/2” (12.7mm) 22-62 5/8” (16mm)

CONDUITS

42-23-15 .023”, 15ft (7.6m) 42-3035-15 .030”-.035”, 15ft (4.5m) 42-4045-15 .040”-.045”, 15ft (4.5m) 42N-3545-15 .035”-3/64”, 15ft (4.5m) for Aluminum wire

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

Argon-Argon/CO2 mix gases

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

gas

Manual No. 0-4855 A-1 APPENDIX

Page 64

FABRICATOR 210

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM

L1 White

L2 Black

Earth

Green\Yellow

Input Terminal Block

1B BRN

208V

230V

SW1

BLU

15B BLU

INDL

14&14A BLK

CB1 2A

3 VIO

BLU

1 BRN

1D BRN

15&15A BLU

1C BRN

1A BRN

[5]

[3]

[1] [2]

CONTACTOR 24V 50/60Hz

31C ORN

K1\3

K1\2

K1\1

[6]

[4]

1H BRN

1G BRN

1E BRN

1F BRN

8 LT BRN

9 BLK

(3) (4)

(1) (2)

(5) (6)

10 RED 11 GRY

(7) (8)

(3) (4)

12 DK BRN

(1)

(5) (6)

13A VIO

(7)

(2)

(8)

SW3

COARSE

6 WHT

SW4

FINE

Input Termi nal Block

SWITCH 3 COARSE AND SWITCH 4 FINE

TRAN

T2 S2 T2 F2 T2 S2 T2 F2

TAP

SWITCH

POSITION

26 1 2

X 3 4

5 6

543

XXX

Fan motor

24V Aux

131215

9711

10 14 16

FABRICATOR 210

S OL2

30C BRN 31D ORN

31B ORN

31A ORN

SPOOL

Sol enoid

NORM

Sol enoid

32B WHT

32A WHT

33 BLU

S OL1

31C ORN 31 ORN

30B BRN

60 RED

30 BRN

X1/5 X1/6 X1/4

X3/6

X3/5

X3/2

Torch

58 BRN

Trigger

BURNBACK 100K

30A BRN

32 WHT

34 BLU

35 WHT

JE/1

JB/5

JB/4

JB/11

JB/10

JE/2

PCB 3

7978034

X3/1

59 GRY

TS1

37 ORN

TS2

JA/7

38 WHT

TEMP

LED1

38A WHT

36 GRY

39 RED

JA/6

JA/5

Main PCB 7978050 (PCB1)

X2/4

X2/5

54 BLK

56 RED

JA/1

JA/2

Art # A-08666

APPENDIX A-2 Manual No. 0-4855

Page 65

FABRICATOR 210

SW3

COARSE

SW4

FINE

(12)

(10)

(14)

(16)

5 PNK

(12)

(10)

(14) (13)

(16) (15)

(11)

(9)

(13)

(15)

(11)

(9)

15&15A BLU

8&8A BRN

9&9A BLK

10&10A RED

11&11A GRY

12&12A BRN

13&13A VIO

2 & 2A PNK

14&14A BLK

F1-S2

F3-S4

F5-S6

208V

230V

TRANS 251 US COIL

43A BLK

Bridge Rectifier

55 BLK

57 VIO

BR1

Varistor

POSITIVE

A B C D E F G H I J

18-1S F

OUTPUT TERMINAL

NEGATIVE OUTPUT TERMINAL

Inductor

200,000uF

47 GRY

45 VIO

10K

48 ORN

53 WHT

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

WIRE SPEED 1K

50 VIO

MIG Timer PCB 7977965 (PCB2)

52 BRN 52A BRN

JB/2

46 RED

44 BRN

47 GRY

48 ORN

49 BLU 49A BLU

51 ORN

JB/7

JB/6

JB/9

JB/1

JB/3

JUMPER

JD-1 JD-2

NOTE:

Wi re Feeder Mo tor

43 BLK

JB/8

Remove this jumper and use these pins when connecting a replacement 7978050 Control PCB

Art # A-08666_AB

Manual No. 0-4855 A-3 APPENDIX

Page 66

FABRICATOR 210

APPENDIX 3: FEEDROLL KITS

DRIVE ROLL KITS (#375980-Series) 2 ROLL

Style 1 Style 2 Style 3 Style 4 Style 5 Style 6

Double Smooth

Top

Bottom

Wire Type

Wir e Siz e

.023" / 0.6mm 375980-031 - - - - -

.030", .035" / 0.8, 0.9mm 375980-001 375980-003 375980-010 - - -

.030", .035", .045" / 0.8, 0.9, 1.2mm 375980-028* 375980- 029 - - - -

.035" / 0.9mm 375980-040* - - - - 375980-032

.035", .045" 3/64" / 0.9, 1.2, 1.2mm - - 375980-030 - - -

.045" / 1.2mm 375980-002* 375980-004 - 375980-092 375980- 022 -

3/64 / 1.2mm - - 375980-011 - - 375980-033

.052" / 1.3mm 375980-090* - 375980-012 - - .052", 1/16" / 1.3, 1.6mm - - -

Notes: 1) One Kit is supplied standard w ith each w ire feeder.

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

3) Narrow 30° "V"

Flat Flat Knurled

Dou ble

Smooth "V"

Hard Hard Soft/Hard/Tubular Hard/Tubular Tubular Sof t (Aluminum)

Double

Smooth "V"

"V"

Double Smooth

"V"

Double

Knurled "V"

Double

Knurled "V"

375980-017 375980-023

Double Cog Double "U"

APPENDIX A-4 Manual No. 0-4855

Page 67

Page 68

Statement of Warranty

(as of March 15, 2009)

LIMITED WARRANTY:

THERMADYNE warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below, THERMADYNE shall, upon written notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and recognized standard industry practice, and not been subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at THERMADYNE’s sole option, of any components or parts of the product determined by THERMADYNE to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

THERMADYNE shall not under any circumstances be liable for special, indirect or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, business interruption or loss of profit, or claims of customers of distributor (hereinafter the “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by THERMADYNE whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous THERMADYNE warrantiesWarranty SCHEDULE

Page 69

Warranty SCHEDULE

(as of March 15, 2009) The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized

distributor delivers the products to the purchaser. THERMADYNE reserves the right to request documented evidence of date of purchase.

ENGINE DRIVEN WELDERS Parts / Labor

Scout®, Raider®, Explorer™

Original Main Power Stators and Inductors 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year Engines and Associated Components are NOT Warranted by Thermal Arc®, Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE MANUFACTURERS’ WARRANTY FOR DETAILS.

GMAW/FCAW (MIG) WELDING EQUIPMENT Parts / Labor

Fabricator® 140, 180, 190, 210, 251, 281; Fabstar® 4030; PowerMaster® 350, 350P, 500, 500P, 320SP, 400SP, 500SP; Excel-Arc® 6045; Wire Feeders: Ultrafeed®, Porta-feed®

Original Main Power Transformer and Inductor 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT Parts / Labor

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year

PLASMA WELDING EQUIPMENT Parts / Labor

Ultima® 150

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years Welding Console, Weld Controller, Weld Timer 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year

SMAW (Stick) WELDING EQUIPMENT Parts / Labor

Dragster™ 85; 95S

Original Main Power Magnetics 1 year / 1 year Original Main Power Rectifiers, Control P.C. Boards 1 year / 1 year All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

See the Engine

Manufacturers’ Warranty

for Details

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

GENERAL ARC EQUIPMENT Parts / Labor

FirePower® MIG Welders 5-2-1 years / NA Water Recirculators 1 year / 1 year Plasma Welding Torches 180 days / 180 days Gas Regulators (Supplied with Power Sources) 180 days / NA MIG and TIG Torches (Supplied with Power Sources) 90 days / NA Replacement Repair Parts 90 days / NA MIG, TIG and Plasma Welding Torch Consumable Items NA / NA

Page 70

Page 71

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Bolsena, 7 20098 S. Giuliano Milan, Italy Tel: (39) 02-36546801 Fax: (39) 02-36546840

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Page 72

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017

Telephone: (636) 728-3000 FAX:

(636) 728-3010

Email: sales@thermalarc.com

www.thermalarc.com