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Tweco 251 User Manual

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208 V
230 V
H
Z
251
®
FABRICATOR
MIG WELDING MACHINE
Operating Manual
Version No: AI Issue Date: November 16, 2009 Manual No.: 0-4847 Operating Features:
208 V
Art # A-07199_AB
230 V
60
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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 Pr hazards that may exist when working with this product.
ecautions. They will help you to avoid potential
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 developing 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 251 MIG Welding Machine Instruction Manual Number 0-4847 for: Package System Part Number 100048D-002 Power Source Part Number 707520
Published by: Thermadyne Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711
www.thermalarc.com
©Copyright 2006,2007, 2008, 2009 by Thermadyne Industries Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Original Publication Date: April 28, 2006 Revision AI Date: November 16, 2009
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 A L’arc.................................................. 1-6
1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6
1.06 Principales Nor mes De Securite ..................................................................... 1-9
1.07 Graphique de Symbole ................................................................................. 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 General Information ....................................................................................... 2-2
2.05 Safety ............................................................................................................. 2-2
2.06 Pr otective Filter Lenses .................................................................................. 2-2
2.07 User Responsibility ........................................................................................ 2-2
2.08 Duty Cycle ...................................................................................................... 2-3
2.09 Specifications ................................................................................................. 2-3
2.10 Included Items ............................................................................................... 2-5
2.11 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 Mains Supply Voltage Requirements .............................................................. 3-2
3.05 Alternative Mains Supply Voltages ................................................................. 3-2
3.06 Quick Setup .................................................................................................... 3-4
3.07 Installation of Shielding Gas (GMAW) Process .............................................. 3-4
3.08 Attaching the Gun and Cable
Assembly to the Power Source....................................................................... 3-7
3.09 Input And Output Wire Guide Installation ....................................................... 3-9
3.10 Selection and Installation of Feedrolls ............................................................ 3-9
3.11 Installing Wire Spool .................................................................................... 3-10
3.12 Inserting Wire into the Feedhead .................................................................. 3-11
3.13 Wirefeeder 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 ....................................................................................... 4-6
4.03 MIG Gun Identification ................................................................................... 4-8
4.04 TWECO Weldskill 400 AMP Weld Gun ............................................................ 4-9
4.05 Installing A New Wire Conduit ...................................................................... 4-10
4.06 MIG Gun Maintenance .................................................................................. 4-11
4.07 Basic Welding Technique.............................................................................. 4-11
4.08 Stitch Welding Operation .............................................................................. 4-13
4.09 Spot Welding Operation ............................................................................... 4-13
4.10 Gas Selection for Gas Metal Arc Welding ..................................................... 4-14
4.11 Welding Setting Selection Guide .................................................................. 4-16
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 251
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SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same
r touch other people with the holder or electrode.
time o
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground) circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts at once.
13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
WARNING
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.
Manual No. 0-4847 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 251
3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
WARNING
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied 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 4Non-ferrous base metal All 11
Oxygen C utting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All12
Heavy Over 6 in., 150 mm 5 or 6Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
SAFETY INSTRUCTIONS 1-2 Manual No. 0-4847
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WARNING
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FABRICATOR 251
2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open flames.
3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving parts.
6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
Manual No. 0-4847 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 251
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1.02 Principal Safety Standards

WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.
The coolant in the radiator can be very hot and under pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
WARNING
This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Ef­fects of Power Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the ope
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body as practical.
rator.
ABOUT PACEMAKERS:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
SAFETY INSTRUCTIONS 1-4 Manual No. 0-4847
Page 11

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.
FABRICATOR 251
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
Single Phase
Three Phase
Three Phase Static Frequency Converter­Transformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW)
Wire Feed Function
Wire Feed Towards Workpiece With
t1
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld Mode
Spot Weld Mode
Spot Time
t
Preflow Time
Postflow Time
t2
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth (Ground)
Line
Line Connection
Auxiliary Power
Gas Tungsten Arc Welding (GTAW)
Air Carbon Arc Cutting (CAC-A)
Constant Current
Constant Voltage Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
2 Step Trigger Operation
Press to initiate wirefeed and welding, release to stop.
4 Step Trigger Operation
Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.
Burnback Time
t
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
Manual No. 0-4847 1-5 SAFETY INSTRUCTIONS
Receptacle Rating­Auxiliary Power
Voltage Input
V
Art # A-04130
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FABRICATOR 251
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1.04 Precautions De Securite En Soudage A L’arc
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” p Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.05 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 raccor même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
résente les pratiques sécuritaires à suivre.
dés à deux sources de courant en
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.
SAFETY INSTRUCTIONS 1-6 Manual No. 0-4847
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FABRICATOR 251
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’ arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
rsque le niveau de bruit est élevé.
lo
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant rela­tives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respi­ration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Opération de coupage
ou soudage
Brassage tendre au chalumeau
Brassage fort au chalumeau
Oxycoupage métaux ferreux toutes conditions 12
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
Soudage á l'arc avec électrode enrobees (SMAW)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de 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
filtr e oculair e
Opération de coupage
ou soudage
Soudage á l'arc sous gaz avec fil plein (GMAW)
Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)
Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)
Gougeage Air-Arc avec électrode de carbone
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
toutes conditions 12
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtr e oculair e
Manual No. 0-4847 1-7 SAFETY INSTRUCTIONS
Page 14
FABRICATOR 251
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à ad­duction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.
AVERTISSEMENT
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêche inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con­tact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.
r le courant de suivre un long parcours
1. Por tez un écran facial ou des lunettes protectr ices approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
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. 0-4847
Page 15
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.
FABRICATOR 251
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. 0-4847 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 251

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
X
%
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur Transformateur-Redresseur
Distant
Facteur de Marche
Pourcentage
Panneau/Local
Soudage Arc Electrique Avec Electrode Enrobé (SMAW)
Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)
Soudage á L’arc Avec Electrode Non Fusible (GTAW)
Decoupe Arc Carbone (CAC-A)
Courant Constant
Tension Constante Ou Potentiel Constant
Déroulement du Fil
Alimentation du Fil Vers la Pièce de Fabrication Hors Tension
Torch de
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
Duréc du Pulse
t
t1
Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.
Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.
Durée de Pré-Dèbit
Durée de Post-Dèbit
t2
Soudage
Détente à 2-Temps
Détente à 4-Temps
Courant Continue (DC)
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
115V 15A
SAFETY INSTRUCTIONS 1-10 Manual No. 0-4847
Classement de Prise­Source Auxiliaire
Haute Température
Force d'Arc
Amorçage de L’arc au Contact (GTAW)
Inductance Variable
Tension
V
t
IPM
MPM
Probléme de Terre
Pouces Par Minute
Mètres Par Minute
Art # A-07639
Page 17
FABRICATOR 251
!
SECTION 2:
INTRODUCTION

2.01 How To Use This Manual

This Owner’s 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.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.
Include all equipment identification numbers as described above along with a full description of the parts in error.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
A NOTE offers helpful information concerning certain operating procedures.
Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link:
http://www.thermalarc.com
Manual No. 0-4847 2-1 INTRODUCTION
Page 18
FABRICATOR 251

2.04 General Information

The Fabricator 251 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 251 is designed and manufactured to meet the requirements of CSA and IEC 60974-1 standards.
The Fabricator 251 gives excellent performance on mild steel, stainless steel, aluminum, silicon bronze and some hard facing wires with Argon based shielding gases. The Power Supply also gives excellent results on mild steel using Carbon Dioxide shielding gas.
The Fabricator 251 is supplied as a complete package ready to weld (apart from gas cylinder and electrode wire). The following instructions detail how to correctly set up the welder and give guidelines on gaining the best production efficiency fr these instructions thoroughly before using your Fabricator welder.
om the Power Supply. Please read

2.06 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

2.05 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 a ways use and wear a welding mask fitted with the correct filter lens.
• Do not stand on damp ground when welding.
For more complete safety advice please read section 1.
rc with naked eyes. Al-
Table 2-1: Filter Lens Size Versus Welding Current
It is recommended to use a welding helmet, conforming to the local relevant Standards when electric arc welding. Use a welding helmet in serviceable condition with the correct filter lens. Refer to Table 2-1 above and AWS table in Section 1.

2.07 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Thermal Arc. Advice in this regard can be obtained by contacting Thermal Arc.
This equipment or any of its parts should not be altered from standard specification without prior wr of Thermal Arc. The purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc.
itten approval
INTRODUCTION 2-2 Manual No. 0-4847
Page 19
FABRICATOR 251

2.08 Duty Cycle

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

2.09 Specifications

MIG Gun Specifications
Gun Catalog Number 43340P Gun Type TWECO Weldskill 300 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 @ 24VAC
180VA @ 14 to 46VDC
80 to 800 ipm
(2 to 20 m/min)
.030"
(0.8mm)
.035"
(0.9mm)
.045"
(1.2mm)
Manual No. 0-4847 2-3 INTRODUCTION
Page 20
FABRICATOR 251
Package System Part Number Power Source Part Number Power Source Weight Power Source Dimensions HxWxD
(including wheels and cylinder carrier) Nominal Input Voltage 208V 230V
Number of Phases Frequency Flexible Supply Cable Size
Supply Plug Rated Input Current @ 100% Duty Cycle * 36A * 32.6A
Rated kVA @ 100% Duty Cycle 7.5 kVA 7.5 kVA Maximum Input Current @ 250A Output 68A 62A Generator Requirements 20 kVA 20 kVA Supply VA @ Maximum Output 15 kVA 15 kVA Recommended Primary Circuit Size 50A 50A Recommended Minimum Primary Fuse Size 50A 50A Open Circuit Voltage Range 15.6 – 45.9V DC 15.6 – 45.9V DC Welding Arc Voltage Range 14.5 – 31.7V DC 14.5 – 31.7V DC Output Current Range 20 – 300A DC 20 – 300A DC Rated Output Duty Cycle 250A/26.5V @ 60% 250A/26.5V @ 60% Maximum Duty Cycle 300A/31.7V @ 40% 300A/31.7V @ 40% 100% Duty Cycle Output Rating 195A DC at 24V 195A DC at 24V Duty Cycle Period Number of Output Voltage Values
Wire Feed Speed Range Wire Spool Size Diameter Burn-Back Timer Range Burn-Back Time Factor Spot Timer Range Dwell Timer Range Stitch Weld Time Weld (Stitch) Time Dwell (non-weld) Time Thermal Protection
Operating Temperature Range
Electrode Wire Type and Diameter
Mild / Stainless Steel
Aluminum
Flux Cored
y Set to
Fabricator 251
100048D-002
707520
227lb (103kg)
32” x 27-3/16” x 36-3/4”
(813 x 691 x 933mm)
1Ø
60 Hz
10ft (3m) 10AWG
NEMA 6-50P
10 minutes
24
.023” (0.6mm) – .045” (1.2mm) .030” (0.8mm) – 1/16” (1.6mm) .030” (0.8mm) – 1/16” (1.6mm)
80 – 800 ipm (2 – 20 m/min )
8” / 12” (200mm / 300mm)
0 – 0.6 seconds
0.16 seconds
0.5 – 9 seconds 1 – 12 seconds
0.5 – 9 seconds 1 – 12 seconds
Self-resetting thermostat fitted to rectifier and
transformer
32° to 104°F (0° to 40°C)
* The Rated Input Current should be used for the determination of cable size & supply requirements.
Table 2-4: Machine Specifications
INTRODUCTION 2-4 Manual No. 0-4847
Page 21

2.10 Included Items

Y
Y
Y
Y
Factory Fitted Wheeling Kit Factory Fitted Dual Cylinder Rack Factory Fitted Primary Power Cable 8AWG, 10ft (3m) with Plug NEMA 6-50P Work Lead 10ft (3m) Cable Stowage Hooks Y Regulator/Flow Meter – Argon Mix Gases Y Tweco Weldskill MIG Gun 280 Amp, 15ft (4.5m) Fitted Feed Roll for .035” - .045” (0.9 – 1.2mm) solid wireY

2.11 Optional Accessories

FABRICATOR 251
Fabricator 251 Package System Contents
Y
Table 2-5: Power Supply Contents
Refer to the Appendix section of this manual for the list of available options and accessories.
Manual No. 0-4847 2-5 INTRODUCTION
Page 22
FABRICATOR 251
INTRODUCTION 2-6 Manual No. 0-4847
Page 23
FABRICATOR 251
SECTION 3:
INSTALLATION

3.01 Environment

The Fabricator 251 is NOT designed for use in environments with increased hazard of electric shock.
Examples of environments with increased hazard of electric shock are:
In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;
In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or
In wet or damp hot locations wher e humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

3.02 Location

Be sure to locate the Power Supply according to the following guidelines:
In areas, free from moisture and dust. In areas, free from oil, steam and corrosive gases. In areas, not subjected to abnormal vibration or shock. In areas, not exposed to direct sunlight or rain. Place at a distance of 1 ft (300 mm) or more from walls
or similar that could restrict natural air flow for cooling. The minimum ground clearance for these products is 5.5"
(140mm).

3.03 Ventilation

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.
Manual No. 0-4847 3-1 INSTALLATION
Page 24
FABRICATOR 251
!
!

3.04 Mains Supply Voltage 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 251 be electrically connected by a qualified electrical trades­person.
The Fabricator 251 Power Supply is factory connected for the following input power supply voltage:
Input Power
Supply Lead Size
8 AWG 40 Amps 10ft (3m) 230V 250A @ 60%
Table 3-1: Factory Fitted Input Power Supply Leads Fitted to the Fabricator 251
Lead Current
Rating
Lead
Length
Machine
Voltage Setting Duty Cycle

3.05 Alternative Mains Supply Voltages

WARNING
The Fabricator 251 input power supply lead should be replaced with leads as specified in Table 3-2 when the Fabricators input power supply voltage is changed.
The Power Supply is suitable for use on the following input power supply voltages:
Input Power Supply
Voltage Setting
208V 8AWG (8.0mm2) 50 Amps 50 Amps 250A @ 60% 230V 8AWG (8.0mm2) 50 Amps 50 Amps 250A @ 60%
Mains Supply
Lead Size
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. 0-4847
Page 25
FABRICATOR 251
Changing the Voltage Selection
1. Disconnect the power supply from the input power source.
2. Refer to Figure 3-1. The power supply comes wired for 230V. Locate the two blue input power wires where they are secured to the input voltage selection block. Loosen the set screw for both voltage locations.
3. Remove the blue wires from the current location and insert them into the new voltage location. Secure by tighten­ing the set screw onto the uninsulated portion of the wires. Secure the other voltage set screw as well.
208V connection
230V connection
Art # A-07332
Figure 3-1: Voltage Selections for Fabricator 251 (Wired for 230V)
Manual No. 0-4847 3-3 INSTALLATION
Page 26
FABRICATOR 251
!

3.06 Quick Setup

CAUTION
To obtain adequate air flow and cooling for the Power Supply components, the four wheels must be fitted. Alternatively, the Power Supply may be raised 5.5" (140 mm)from the floor using supports that do not restrict airflow.
NOTE
The steps in this subsection are intended for individuals experienced in the set up of this type welder. More detailed setup instructions are in the 3.07 and following subsections.
1. Connect the work lead to the negative (-) socket (positive + for Self Shielded Flux Cored Wire)
2. Connect the (negative - for Self Shielded Flux Cored Wire)
See section 3.15 "Polarity Changeover" for more detail and exceptions!
3. Position a gas cylinder on the rear tray and se- cure to the Power Supply cylinder bracket with the chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.
If the gas cylinder is not secured to the cylin­der tray, the power supply must be kept from moving to avoid over-extending the gas hose which can result in personal injury, damage to the power supply, flow meter and gas cyl­inder.
GUN
lead to the positive (+) socket
NOTE
WARNING
7. Fit the electrode wire spool to the wire reel hub located behind the electrode wire compartment door.
8. Fit the TWECO Weldskill MIG gun and trigger wires through/to the front of the unit.
9. Remove the contact tip from the gun.
10.With the gun lead reasonably straight, feed the wire through the wire drive rolls and gun.
11.Fit the appropriate contact tip and replace insula­tor and nozzle.

3.07 Installation of Shielding Gas (GMAW) Process

NOTE
Shielding Gas is not required if the unit is used with self shielded FCAW (flux cored arc weld­ing) wires
1. Cylinder positioning: Block the wheels of the unit so
it cannot roll. Carefully stand the cylinder on the tray and with one foot, press against the bottom of the cylinder to assure it is against the back of the unit. Chain the cylinder in place. (Refer to Figure 3-2 for Wheel Kit cylinder installation)
2. Cracking: Remove the large metal cap on top of the
cylinder by rotating counter clockwise. Next remove the dust seal. Position yourself so the valve is pointed away from you and quickly open and close the valve for a burst of gas. This is called “Cracking” and is done to blow out any foreign matter that may be lodged in the fitting. (Figure 3-2.)
3. Fit Regulator/Flow Meter to cylinders: Screw the
regulator into the appropriate cylinder. (Figure 3-2) The nuts on the regulator and hose connections are right hand (RH) threaded and need to be turned in a clockwise direction in orde wrench.
r to tighten. Tighten with a
CAUTION
4. Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts provided.
5. Fit the gas Regulator/Flow Meter to the gas cylin­der and connect the gas hose from the rear of the Power Supply to the Flow Meter outlet.
6. The machine is fitted with a .035/.045” vee groove feed roll suited for hard wire. Change this feed roll if required to fit your chosen wire size.
INSTALLATION 3-4 Manual No. 0-4847
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 3-12).
Page 27
FABRICATOR 251
1
3
“Cracking”
Regulator and Flow Meter
Cap
2
Shielding Gas
4
Shielding Gas
5
Gas Hose
1 1/8”
Stowage Hook
Shielding Gas
Shielding Gas
Art # A-07278
Figure 3-2 Gas Cylinder Installation
Manual No. 0-4847 3-5 INSTALLATION
Page 28
FABRICATOR 251
Adjusting Regulator
Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-3) The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause
turbulence and weld porosity. Argon or argon based gas flow rates:
- Workshop welding: 20-30 CFH
- Outdoors welding: 30-40 CFH Helium based or CO2 gas flow rates:
- Workshop welding: 30-40 CFH
- Outdoors welding: 40-50 CFH
NOTE
All valves downstream of the r egulator must be opened to obtain a true flow rate reading on the outlet gauge. (Welding power source must be trigger ed) Close the valves after the pressure has been set.
Art # A-07280
Figure 3-3: Adjusting Flow Rate
Refer to section 4.09 for suggested gas / filler metal combinations.
NOTE
The regulator/flow meters used with ar gon based and carbon dioxide shielding gases are different. The r egulator /flow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/flow meter will need to be fitted.
INSTALLATION 3-6 Manual No. 0-4847
Page 29
FABRICATOR 251

3.08 Attaching the Gun and Cable Assembly to the Power Source

The Fabricator 251 is supplied with a Tweco Weldskill 300 AMP air-cooled gun. The Weldskill gun is designed with an ergonomic handle and fewer parts to cause performance problems. The Weldskill gun uses standard readily available Tweco Weldskill consumable parts.
1. Open the door panel to the machine by inserting your left and right index fingers into the two release mecha­nisms marked with hand arrows in Figure 3-4. Slide them toward each other and pull the cover outward and up to open.
Set up Chart
Art # A-07142_AB
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. 0-4847 3-7 INSTALLATION
Page 30
FABRICATOR 251
Front Panel Access Hole
Art # 0-7148
Trigger Receptacle
Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger
Loosen Thumbscrew
Art # A-07149
Tighten Thumbscrew
Figure 3-6: Mount Gun Cable to Adapter Socket
INSTALLATION 3-8 Manual No. 0-4847
Page 31
FABRICATOR 251

3.09 Input And Output Wire Guide Installation

Refer to Figure 3-7. Install the input wire guide (the longer one) by loosening
the input guide lockscrew and inserting the guide into the hole in the feedhead assembly. The recessed end of the guide should be toward the wire spool. Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew.
Install the output wire guide in the same manner, with the conical end toward the feed rolls. The tip of the coni­cal end should be as close to the feed rolls as practical. Tighten the output guide lockscrew.
NOTE
Before tightening the input and output guide lockscrews, install the drive roll to help in the alignment of the wire guides.
Input Guide Lockscrew
Output Guide Lockscrew
To ensure proper wire feed, the groove closest to the motor must match the electrode wire size being used.
.045” (1.2mm) Stamping
.045
1.2
.045” (1.2mm) Groove
Art: A-07150
The size that is visible when fitting the feedroll is the groove size in use.
Figure 3-8: Feedroll Example
NOTE
All grooved feed rolls have their wire size or range stamped on the side of the roll. On rolls
with different size grooves, the outer (visible when installed) stamped wire size indicates the groove in use.
Art # A-07445
Input Wire Guide
Figure 3-7: Wire Guide Installation
Output Wire Guide

3.10 Selection and Installation of Feedrolls

A Feedroll consists of two different sized grooves. As delivered from the factory the drive roll is installed for .035” / .045” .
The stamped marking on the feedroll refers to the groove furthest from the stamped marking. When mounted, that will be the groove closest to the motor and the one to thread.
Refer to feed roll kit #375980 in the Appendix for the proper selection and ordering of feed roll kits. Kit includes drive rolls, an input wire guide and an output wire guide for a specific wire type and size.
Feed rolls are removed by twisting the feed roll retainer cap and aligning the retaining knob splines/tabs with the drive gear splines. Feedrolls are installed by putting the feedroll onto the drive gear splines and twisting the feedroll retainer cap so that the splines/tabs rest against the face of the feedroll where they will click into place.
NOTE
Installation of all styles of feed rolls for the Fabricator 251 are identical.
WARNING
The welding wire is electrically Hot if it is fed by depressing gun switch. Electrode contact to work piece will cause an arc with gun switch depressed.
Manual No. 0-4847 3-9 INSTALLATION
Page 32
FABRICATOR 251

3.11 Installing Wire Spool

As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool.
Installation of wire spool
1. Remove Wire Spool Hub Nut by turning counter clock wise (to the left).
2. Remove the spring from the hub.
3. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise. Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool.
4. If using a 10 lb. wire spool place the spring on the exposed hub. Do not use the spring for larger wire spools that cover the entire hub.
5. Replace the Wire Spool Hub Nut by turning clock wise (to the right).
NOTE
The Hub tension has been pre-adjusted at the factory. However if adjustment is required, refer to section
3.12 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
Art # A-07192
smaller 10 lb wire spools only
Figure 3-9: Spool Installation
INSTALLATION 3-10 Manual No. 0-4847
Page 33
FABRICATOR 251

3.12 Inserting Wire into the Feedhead

WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions.
1. Loosen the Spring Pressure Adjusting Knob if needed and swing it down (First part of Figure. 3-10)
2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-10)
3. Make sure the end of the wire is free of any burrs and is straight. Pass the end of wire through the Inlet Wire Guide and over the Feedroll. Make certain the proper groove is being used. (Second part of Figure. 3-10)
4. Pass the wire through the outlet guide and into the Gun liner of the Gun Cable. (Second part of Figure. 3-10)
5. Close the Pressure Roller Arm. (Figure. 3-11)
6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-11)
7. Use the Spring Pressure Adjusting Knob to cr
eate 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. 0-4847 3-11 INSTALLATION
Page 34
FABRICATOR 251
Wheel Brake Hex Head Bolt
Spool Hub Nut
Figure 3-12: Wire Installed

3.13 Wirefeeder Drive Roller Pressure Adjustment

Pressure Adjustment Device
Art # A-07162
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. 0-4847
Page 35
FABRICATOR 251

3.15 Spool Gun Attachment

A spool gun can readily be used with the Fabricator 251 power supply.
1. Attach appropriate input gas to the Spool Gun input gas connection on the rear of the unit. (Refer to Figure. 3-
13)
2. Attach the Spool Gun control cable and gas hose to the 10 pin socket and the Spool Gun Gas Outlet on the front of the unit. (Refer to Figure. 3-13)
Spool Gun 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 and the trigger is depressed, the system automatically dis­ables the internal wire feed and gas controls and selects the SPOOL GUN feeder and gas control.
Manual No. 0-4847 3-13 INSTALLATION
Page 36
FABRICATOR 251

3.16 Polarity Changeover

WARNING
ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions.
The output terminals are located on the front panel of the welding power source.
CABLE TO GUN, CABLE TO WORK
PROCESS POLARITY
1. GMAW* – Steel, Stainless Steel, Aluminum & gas shielded Flux Cored electrode wires
2. FCAW* – Gasless Flux Cored electrode wire
* Exception - Contact your filler metal supplier for the recommended polarity.
Work Lead
Art # A-07163
CABLE TO GUN CABLE TO WORK
1. D.C. Electrode Positive (DCEP) – Reverse Polarity
2. D.C. Electrode Negative (DCEN) – Straight Polarity
1. Connected to (+) Pos. output terminal
2. Connected to (-) Neg. output terminal
Table 3-3: Process Cable Connections
Connected for D.C. Electrode Positive (DCEP) Welding
CABLE CONNECTIONS
1. Connected to (-) Neg. output terminal
2. Connected to (+) Pos. output terminal
Figure 3-14: Polarity Connections for DCEP
INSTALLATION 3-14 Manual No. 0-4847
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 251
d. Place the Work Lead cable on the opposite terminal. e. Replace both terminal knobs and tightly secure them to ensure good electrical connections.
CAUTION
Ensure terminal knobs are tightly secured and that there is no connection between positive and negative terminals.
f. Reconnect the input power to the power supply.
Manual No. 0-4847 3-15 INSTALLATION
Page 38
FABRICATOR 251
NOTES:
INSTALLATION 3-16 Manual No. 0-4847
Page 39
FABRICATOR 251
SECTION 4:
OPERATION
WARNING
DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding voltage potential.

4.01 Power Supply Controls, Indicators and Features

Digital Display
Voltage / Amp Selection Button
Front Panel Access Hole Tor ch
Gun Switch Amphenol Receptacle
Negative Welding Terminal
Thermal Overload Indicator
A/V
Weldskill
17V - 21V
13V - 16V
22V - 31V
Wire Feed Speed Control
Power On/Off Switch Coarse Voltage Selector Switch
Fine Voltage Selector Switch
Spool Gun Gas Outlet
Spool Gun Interface
Amphenol Receptacle
Gun Polarity Lead
Positive Welding Terminal
Art # A-07034_AB
Figure 4-1: Fabricator Controls
Manual No. 0-4847 4-1 OPERATION
Page 40
FABRICATOR 251
On / Standby Power Switch
The indicator light is provided to indicate when the Fabricator 251 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.
Digital Display
The Digital Display allows for accurate monitoring (5% tolerance) of welding current and voltage to facilitate precise welding condition adjustments.
Value displayed for 157 Amp
Figure 4-2: Digital Display
The Digital Meter will display both welding current or arc voltage. To toggle between the current and voltage readings depress the push button switch mounted below the meter display.
The Digital Meter will hold the last reading at completion of welding for 10 seconds to allow for easy operator set up.
Value displayed for 21.9 Volts
Art # A-07279
OPERATION 4-2 Manual No. 0-4847
Page 41
Digital AMP Reading to IPM Conversion
900
800
700
600
500
400
FABRICATOR 251
STEEL
Wire Speed (IPM)
300
200
100
0
25 50 75 100 125 150 175 200 225 250 275 300 325
(.023 - STEEL)
(.030 - STEEL)
(.035 - STEEL)
Current (Amps)
(.045 - STEEL)
Art # A-07451
Figure 4-3: Steel - AMP to IPM Conversion
STAINLESS STEEL
900
800
700
600
500
400
Wire Speed (IPM)
300
200
100
0
25 50 75 100 125 150 175 200 225 250 275 300 325
(.023 - SS)
(.030 - SS)
(.035 - SS)
(.045 - SS)
Current (Amps)
Art # A-07452
Figure 4-4: Stainless Steel - AMP to IPM Conversion
Manual No. 0-4847 4-3 OPERATION
Page 42
FABRICATOR 251
900
800
700
600
ALUMINUM
500
400
Wire Speed (IPM)
300
200
100
0
25 50 75 100 125 150 175 200 225 250 275 300 325
(.030 - AL)
(.035 - AL)
(.047 - AL)
Current (Amps)
Art # A-07453
Figure 4-5: Aluminum - AMP to IPM Conversion
Thermal Overload
The critical components for thermal protection are the rectifier stack and the transformer, which are fitted with thermal overload cut out devices. If the overload is activated then the machine should be left to cool for approxi­mately 15 minutes before resuming welding. If the Power Source is operated within its duty cycle, the thermal overload will not activate. Refer to section 2.09 for an explanation of duty cycle and section 2.10 for the power supply specifications.
Wirespeed Control
The Wirespeed Control knob controls the welding current via the electrode wire feed rate, i.e. the speed of the wire feed motor.
Coarse Voltage Control Switch
The Coarse Voltage Control sets the voltage level to the welding terminals as it is rotated in either direction. Clock wise to incr
ease.
Fine Voltage Control Switch
The Fine Voltage Control switch increases the voltage (in smaller increments than the Coarse switch) as it is rotated in either direction. Clock wise to increase.
CAUTION
The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process.
OPERATION 4-4 Manual No. 0-4847
Page 43
FABRICATOR 251
Positive and Negative Welding Current Terminals
Refer back to Figure 4-1. Both terminals located at the bottom of the unit are shown without the terminal knob. Both knobs must be firmly secured before at­tempting to weld.
Gun Polarity Lead
This lead selects the welding voltage polarity of the electrode wire. Attach it to the positive welding termi­nal (+) when using steel, stainless steel or aluminium electrode wire . Attach the Gun Polarity Lead to the negative welding terminal ( - ) when using gasless flux cored electrode wire. If in doubt, consult the manufacturer of the electrode wire for the correct polarity. Also refer to section 3-15.
Positive and Negative Welding Terminal Knobs
Welding current flows from the Power Supply via heavy duty terminals. It is essential, that these termi­nal knobs are tight to achieve the necessary electrical connection.
Spool Gun Interface Amphenol Connector
The Spool Gun Interface 10 pin connector is used to connect a spool gun to the Fabricator 251 (refer to Figure 4-4 and Table 4-1).
F
E
D
G
J
I
C
H
A
Art # A-07181
Figure 4-4: Spool Gun 10 pin Receptacle
B
CAUTION
Loose welding terminal connections can cause overheating and result in failure of the termi­nals.
Gun Switch Receptacle
The Torch Trigger 4-pin receptacle is used to connect the two wires from the torch gun to the Fabricator
251. Only pins 1 and 2 are used for this.
To make connections, align keyway, insert plug, and ro­tate threaded collar fully clockwise.
1
2
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 recep- tacle.
Socket Pin Function
A Not Used B Spool Gun Motor (-) C Spool Gun Motor (+) D Spool Gun Switch
Spool Gun Speed C.W.
E
Potentiometer Spool Gun Speed Wiper
F
Potentiometer
G Spool Gun Switch
Spool Gun Speed C.C.W.
H
Potentiometer I Not Used J Not Used
Table 4-1: 10-pin Receptacle Pin Functions
NOTE
When the SPOOL GUN is properly attached
Art # A-07171
and the trigger is depressed, the system au­tomatically disables the internal wire feed and
Figure 4-3: Gun Switch Receptacle
gas control and selects the SPOOL GUN feeder and gas control.
Manual No. 0-4847 4-5 OPERATION
Page 44
FABRICATOR 251
WELD MODE
2T
SPOT
STITCH
4T

4.02 Weld Mode Selector

The Weld Mode Selector switch selects the method of welding mode.
Art # A-07183_AB
Figure 4-5: 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.
3
4
2
MIN
DWELL
(STITCH)
6
5
WELD MODE
SPOT STITCH
7
8
9
10
11
12
t
2T
t
4T
WELD
(SPOT / STITCH)
3
2
1
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. (Refer to Figure 4-6 for control).
4
5
6
7
8
9
t
WELD MODE
STITCH
SPOT
2T
Art # A-07427_AB
4T
Art # A-07466
Figure 4-6: For Reference only
SPOT:
Figure 4-7: Spot Weld
NOTE
A spot nozzle should be used on the MIG gun to obtain consistent spot welds.
OPERATION 4-6 Manual No. 0-4847
Page 45
FABRICATOR 251
WELD MODE
2T
SPOT
STITCH
4T
BURNBACKBURNBACK
Art # A-07431_AB
t
STITCH:
This mode of welding is used to weld two or more components together with a stitch weld. The WELD (Spot/Stitch) shaft controls the welding or ‘ON’ time and the "DWELL (Stitch)" shaft controls the interval or ‘OFF’ time for stitch welding. (Refer to Figure 4-6 for control).
Art # A-07428
Figure 4-8: Stitch Welding
4T (Latch):
This mode of welding is mainly used for long weld runs, as the operator need only press the trigger to activate the weld, then press the trigger again to stop. This replaces the need for the operator to depress and hold the trigger for the complete length of the weld run.
WELD MODE
STITCH
SPOT
2T
4T
Dwell Stitch
DWELL (STITCH) CONTROL KNOB
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.
DWELL
(STITCH)
6
7
5
4
3
2
MIN
Art # A-07430_AB
8
9
10
11
12
t
Figure 4-11: Dwell (Stitch) Control
Burnback Control
Burnback time is the difference between the wirefeed motor stopping and the welding current ceasing. The Burnback time allows the electrode wire to burn out of the molten metal weld pool. The Burnback time is factory set for optimum performance. Burnback time is adjusted by the knob of the potentiometer. Clock- wise adjustment increases Burnback time.
Art # A-07427_AB
Figure 4-9: For Reference only
WELD (Spot/Stitch)
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.
WELD
(SPOT / STITCH)
4
5
3
2
1
MIN
Art # A-07429_AB
Figure 4-10: Weld (Spot/Stitch) Control
6
7
8
9
t
Figure 4-12: Burnback Control
Manual No. 0-4847 4-7 OPERATION
Page 46
FABRICATOR 251

4.03 MIG Gun Identification

The FABRICATOR 251 comes with one of two versions of the TWECO Weldskill 280A 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
Red O-Rings
Different Strain Reliefs
Different Labels
Different Gun Switch Plugs
Black O-Rings
Art # A-08069
Figure 4-12: MIG Gun Identification
OPERATION 4-8 Manual No. 0-4847
Page 47
FABRICATOR 251

4.04 TWECO Weldskill 400 AMP Weld Gun

The TWECO Weldskill 400 AMP Fabgun fitted to the FABRICATOR 251 offers robust construction, unparalleled reliabil- ity and easy replacement of consumable parts. The TWECO Weldskill gun has an operating capacity in excess of the capacity of the FABRICATOR and can be expected to give trouble free service.
6
5
4
7
3
2
1
Art # A-07344
Figure 4-13: TWECO WeldSkill 400 AMP Fabgun
TWECO Weldskill 400A Fa bgun — Original Parts Installed
Item Description "T" S eries Part No. "P" Series Part No.
1 NOZZLE 1/2" WS24-62 WS24-62 2 NOZZLE INSULATOR WS34A WS34A 3 CONTACT TIP .035" WS14-35 WS14-35 4 GAS DIFFUSER WS54A WS54A 5 CONDUCTOR TUBE WM63J-50 W M63J-50 6 HANDLE ASSEMBLY WM1-80 TA1-80 7 TRIGGER SWITCH ASSEMBLY WM91 WM91
Table 4-2 MIG Gun Original Parts Consumables
TWECO Weldskill MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO Weldskill. Not only will this give greater reliability (and hence greater productivity) but it will reduce stockholding of consumable parts. See your Thermal Arc distributor for details.
Gun Consumable Parts
See Appendix at the back of this manual.
Manual No. 0-4847 4-9 OPERATION
Page 48
FABRICATOR 251

4.05 Installing A New Wire Conduit

1. Be sure the MIG gun cable is arranged in a straight line, free from twists, when installing or removing a wire conduit. Remove the old conduit by first removing the MIG gun nozzle, contact tip, insulator and gas diffuser. Then loosen Allen screws in the conductor tube and connector plug and pull the old wire conduit out of the cable assembly from the connector plug end.
2. To install a new conduit, first inspect the o-ring gas seal on the conduit for cuts or damage. Start from the connector plug end of the assembly and begin pushing the conduit through the connector plug, cable assem­bly and into the gun. If the conduit should lodge along the way, gently whip or work the cable assembly to aid forward movement.
When the conduit stop meets the end of the connector plug and the new raw end extends through the end of the conductor tube on the welding gun, tighten the Allen screw in the connector plug onto the conduit to prevent its backward movement.
CONDUCTOR TUBE
CONDUIT LINER
ALLEN SCREW
REMOVE CONSUMABLES
CONDUIT LINER
1 1/16" (27mm)
Art # A-08236
O-RINGS
ALLEN SCREW
CONNECTOR PLUG
Figure 4-14: Conduit Trim Length
NOTE
When the conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug, the “raw end” of the conduit will protrude out of the open end of the gun conductor tube. Trim the conduit as shown in Figure 4-14. The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed.
3. Replace Gas Diffuser, Contact Tip, Insulator and Nozzle.
4. Tighten the Allen screw in the conductor tube.
CAUTION
Do not over tighten the conductor tube screw as this action will result in the distortion of the conduit and will lead to wire feedability problems.
OPERATION 4-10 Manual No. 0-4847
Page 49
FABRICATOR 251

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 251 requires some practice by the operator, the welding Power Supply having two control settings that have to balance. These are the Wire Speed control and the Voltage Control switches. The welding current is determined by the Wire Speed control, the current will increase with increased Wire Speed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the welding current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding current.
When changing to a different electrode wire diameter, different control settings are requi needs more Wire Speed to achieve the same current level.
A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the work piece.
If the Wire Speed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the electrode wire, causing spatter. The correct setting of voltage and Wire Speed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.
MIG Gun Travel Speed
Speed at which a weld travels influences the width of the weld and penetration of the welding run.
Position of MIG gun
The angle of MIG gun to the weld has an effect on the width of the weld run. Refer to Figure 4-15.
Forehand
Art # A-05148
Vertical
red. A thinner electrode wire
Figure 4-15: MIG Gun Angle
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.
Manual No. 0-4847 4-11 OPERATION
Page 50
FABRICATOR 251
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,
- The deposition rate required,
11/16”
Tip
Contact
.045”
(1.1mm)
Gas
Nozzle
Distance: ±1/16”
Wire Diameter
- The bead profile desired,
- The position of welding and
- Cost of the electrode wire.
Weld metal deposition rate is proportional to current density. Current density is defined as the current per cross sectional area of the electrode wire and is normally expressed as amps per mm
2
. An example is in Table 4-3 below.
Electrode Wire Size Current (Amps) Current Density(Amps/mm2) Deposition Rate(lbs/hour)
.035”( 0.9mm) 200 314 7.0 .045”(1.2mm) 200 177 6.2
Table 4-3: .035"(0.9mm) , .045"(1.2mm) Wire Deposition Rate
Advantages of MIG welding forehand:
- Allows superior visibility of the weld zone
- Flatter weld bead
- Shallower penetration
Forehand
Vertical
Backhand
Art # A-07185
Figure 4-17: MIG Gun Angle
OPERATION 4-12 Manual No. 0-4847
Page 51
FABRICATOR 251

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) Time
Adjust the WELD (Spot/Stitch)control knob for the desired weld or ‘ON’ time while stitch welding.
Dwell Time
Adjust the DWELL (Stitch) control knob for the desired interval or ‘OFF’ time while stitch welding.

4.09 Spot Welding Operation

Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to the Spot Welding Nozzle table. The Fabricator 251 will operate effectively using .030” (0.8mm) electrode wire when spot welding. Penetration depth is limited when using .024”(0.6mm) electrode wire for spot welding. Set the controls as follows for spot welding:
Coarse & Fine Voltage Selector Switches and
Wirespeed Control
Select higher Voltage Selector switch positions and set the Wirespeed Control between 354 to 590 ipm (9 to 15 m/min) for maximum penetration.
Mode Selector Switch
Set the WELD MODE switch to SPOT.
Spot Time
Adjust the WELD (Spot/Stitch) control knob for the desired weld or ‘ON’ time for spot welding.
Dwell Time
SPOT WELDING NOZZLES
TYPE NO.4 400 AMP
Flat Arc Spot
Inside Corner Arc Spot 24A-75-IAS
Outside Corner Arc Spot 24A-75-IAS
Automotive Stud Nozzle N/A
24A-62-FAS 1240-1520 (5/8" Bore) 24A-75-FAS 1240-1530 (3/4" Bore) 24A-100-FAS 1240-1550 (1" Bore)
1240-1531 (3/4” Bore)
1240-1532 (3/4” Bore)
DWELL (Stitch)
The
control knob has no affect in
this mode of operation.
Manual No. 0-4847 4-13 OPERATION
Page 52
FABRICATOR 251

4.10 Gas Selection for Gas Metal Arc Welding

Metal Type
Carbon
Steel
Low Alloy
and High
Alloy Steel
Stainless
Steel
Aluminum Greater than 18
* 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”
gauge (.045”)
Filler
Metal
ER70S-X Short
ER70S-X Short
ER70S-X Short
ER70S-X Spray
See * below Short
See * below Short
See * below Spray
See * below Short
ER308-X ER309-X ER316-X
ER308-X ER309-X ER316-X
ER4043 ER5356
Transfer
Mode
Circuit
Circuit
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
minimum
80% Argon
20% O2
75% Argon
25% CO2
92% Argon
8% CO2
92% Argon
8% CO2 or
minimum
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
2
Argon All
Welding
Positions
All Position Welding
All Position Welding
All Position Welding
Flat & HV
Fillet
All Position Welding
All Position Welding
Flat & HV
Fillet
All Position Welding
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 melt- through. Minimum distortion and spatter. Good pool control for out-of- position 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.
Comments
percentages in Helium mix
2
percentages
2
Table 4-4: Gas Selection Chart
OPERATION 4-14 Manual No. 0-4847
Page 53
FABRICATOR 251
This Page Is Intentionally Blank
Manual No. 0-4847 4-15 OPERATION
Page 54
FABRICATOR 251

4.11 Welding Setting Selection Guide

Material Type
Steel
Wire Type
Solid
(or hard)
ER70S-6
Shielding Gas and Flow Rate
100% CO
2
25cfh
75% Ar 25%
CO
2
,25cfh
92% Ar
8% CO
2
Wire Size (Diameter)
.035” (0.9mm)
.045” (1.2mm)
.023” (0.6mm)
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
.023” (0.6mm)
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
Aluminum
Stainless
Art # A-07439
Steel
Steel
100%
25cfh
Flux Core
E71T-1
E71T-GS
E71T-11
None
Aluminum
4043 ER 5183 ER 5356 ER
Stainless
ER308LSi ER309LSi ER316LSi
Table 4-5: Welding Selection Guide
100% Ar
25cfh
7.5% Ar 90% He
2.5% CO 35cfh
CO
2
2
.045” (1.2mm)
1/16” (1.6mm)
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
1/16” (1.6mm)
.030” (0.8mm)
.035” (0.9mm)
.045” (1.2mm)
.030” (0.8mm)
.035” (0.9mm)
OPERATION 4-16 Manual No. 0-4847
Page 55
FABRICATOR 251
M
L
22 ga. (0.8mm) 18 ga. (1.2mm) 16 ga. (1.6mm) 1/8” (3.2mm) 1/4” (6.4mm) 3/8” (9.5mm) 1/2” (12.7mm) 5/8” (15.9mm)
Coarse
Voltage
H
Fine
Voltage
M/2
1.5
L/6
L/6
1.5
1.5
M/1
2.25
M/1
2
M/1
1.5
L/8
2.25
L/8
1.25
M/1
2.75
M/2
1.75
M/1
1.25
Coarse Voltage
Fine Voltage
Step
M/3
1.5
M/5
1.75
M/1
3
M/3
3
M/4
2.5
L/8
1.5
M/2
4.5
M/3
2.5
M/4
2.5
L/8
1.5
Wire
Speed
M/4
M/7
M/4
M/7
M/5
M/5
M/5
M/6
M/5
M/6
2
2
4.5
4
3.25
2
6
4.5
3
2.25
H/1
H/2
M/8
M/7
M/8
H/2
H/3
H/4
H/4
5
3.5
5.25
5.75
3
7.75
5.75
5.5
3
H/3
H/3
H/1
H/1
H/2
H/4
H/5
H/5
THICKNESS
**
H/4
6
8.5
H/5
3.5
4.25
H/3
7
8.25
H/3
6.75
8
H/4
4.25
5
H/5
6.5
7.25
H/7
7
7.5
H/6
3.25
3.5
H/5
7.25
H/7
4.5
H/4
5.75
H/5
4.5
L/5
L/8
L/7
M/2 M/3
1.5
M/3
1.5
4.5
3.25
2.5
2
M/6
H/1
L/6
L/8
M/1
M/2
L/8
M/4
M/4
2
1.5
1.75
2
1
4.25
4
3
2.5
M/7
H/2
M/2
L/8
M/4
M/7
M/5
M/5
M/6
M/7
M/6
2.25
2
2.75
2
2
1
5
4.5
3
5
3.5
H/1
H/4
M/5
M/4
M/7
H/2
H/1
H/2
H/2
H/1
H/1
4
2.75
6
3.5
3.25
1.5
7
6.75
3.5
6.5
4.5
H/4
M/8
M/6
M/8
H/3
H/3
H/4
H/6
H/1
5.5
7.5
4.5
3.75
2.5
7.75
5
6
6
H/4
M/8
M/8
H/5
H/7
H/5
5.5
5.5
3.75
5.75
6.5
6
H/5
M/8
H/4
H/6
H/6
7
5.5
4.5
6.25
6.5
Art # A-07439
Manual No. 0-4847 4-17 OPERATION
Page 56
FABRICATOR 251
NOTES
OPERATION 4-18 Manual No. 0-4847
Page 57
FABRICATOR 251
SECTION 5:
MAINTENANCE & TROUBLESHOOTING

5.01 Routine Maintenance & Inspection

The only routine maintenance required for the Fabricator 251 is a thorough cleaning and inspection, with the fre­quency depending on the usage and the operating environment.
WARNING
Disconnect the Fabricator from the Input power supply voltage before disassembling.
Special maintenance is not necessary for the control unit parts in the Power Supply. If these parts are damaged for any reason, replacement is recommended.
CAUTION
Do not blow air into the Power Supply during cleaning. Blowing air into the Power Supply can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Supply.
To clean the Power Supply, disconnect it from the mains supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The Power Supply should also be wiped clean. If necessary, sol­vents that are recommended for cleaning electrical apparatus may be used.
Troubleshooting and repairing the Fabricator should be carried out only by those who are familiar with electrical equipment.
WARNING
Do not attempt to diagnose or repair unless you have had training in electronic measurement and trouble­shooting techniques.
Manual No. 0-4847 5-1 SERVICE
Page 58
FABRICATOR 251
Warning! Disconnect input power before maintaining.
Visual check of regulator and pressure
Visually inspect the torch body and consumables
Maintain more often if used under severe conditions
Each Use
Visual check of torch Consumable parts
Weekly
Visually inspect the cables and leads. Replace as needed
Replace all broken parts
3 Months
Gas lines
6 Months
Visually check and use a vacuum to carefully
clean the interior
Clean exterior of power supply
Art # A-07269
SERVICE 5-2 Manual No. 0-4847
Page 59
FABRICATOR 251

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 reulator/flowmeter connection and in the gas hose to the power supply a. The hose from the solenoid valve to the MIG torch adaptor may be fractured or disconnected from the MIG torch adaptor. Return to an Accredited Thermal Arc Service Agent for repair. a. Shield the weld area from the wind or increase the gas flow
a. Clean contaminates off the plate
a. Keep the distance between the MIG torch nozzle and the work piece to a minimum. a. Ensure that the gas holes are not blocked and gas is exiting out of the torch nozzle. Refer to WARNING below b. Do not restrict gas flow by allowing spatter to build up inside the MIG torch nozzle. C. Check that the MIG gun O-rings are not damaged.
Porosity
1. Gas cylinder contents and flow meter
2. Gas leaks
3. Internal gas hose in the power supply
4. Welding in a windy environment
5. Welding dirty, oily, painted, oxidized or
easy plate.
gr
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. 0-4847 5-3 SERVICE
Page 60
FABRICATOR 251
g
Disengage the drive roll when testing for gas flow by ear.
2. Inconsistent wire feed
FAULT CAUSE REMEDY
Inconsistent
Wire Feeding
1. Wire spool brake is too ti
2. Wire spool brake is too loose.
3. Worn or incorrect feed roller size.
4. Misalignment of inlet/outlet guides.
5. Liner blocked with swarf.
6. Incorrect or worn contact tip.
7. Poor work lead contact to work piece.
8. Bent liner.
ht.
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.
a. Wire will rub against the misaligned guides and reduces wire feedability.
a. Swarf is produced by the wir 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
WARNING
e passing through the feed roller,
Figure 5-2: Trouble Shooting for Inconsistent Wire Feed
SERVICE 5-4 Manual No. 0-4847
Page 61

5.04 Welding Problems

FAULT CAUSE REMEDY
1. Welding arc voltage
A. Undercut 2. Incorrect torch
3. Excessive heat
4. Weld speed too fast a. Reduce weld speed.
too high.
angle
input
FABRICATOR 251
a. Reduce voltage by reducing the voltage
selection switch position or increase the wire feed speed.
a. Adjust angle
a. Increase the torch travel speed and/or
reduce welding current by reducing the voltage selection switch position or reducing the wirefeed speed.
1. Welding current too low
B. Lack of penetration 2. Joint preparation too
narrow or gap too tight
3. Shielding gas incorrect
4. Weld speed too fast a. Reduce weld speed.
C. Lack of fusion
2. Weld speed too fast a. Reduce weld speed.
1. Voltage too high a. Lower voltage by reducing the voltage
D. Excessive spatter 2. Voltage too low a. Raise voltage by increasing the voltage
3. Weld speed too fast a. Reduce weld speed.
1. Incorrect voltage and
1. Voltage too low a. Increase voltage by increasing voltage
current settings. Convex, voltage too low. Concave, voltage too high.
a. Increase welding current by increasing
wire feed speed and increasing voltage selection switch position.
a. Increase joint angle or gap
a. Change to a gas which gives higher
penetration
selection switch position.
selection switch or increase wirespeed control.
selection switch or reduce wirespeed control.
a. Adjust voltage and current by adjusting
the voltage selection switch and the wirespeed control.
E. Irregular weld
shape
3. Incorrect shielding
4. Insufficient or
5. Weld speed too fast a. Reduce weld speed.
2. Wire is wandering a. Replace contact tip
a. Check shielding gas.
gas
a. Adjust the wire speed control or the
excessive heat input
voltage selection switch.
Table 5-3a: Welding Problems and Solutions
Manual No. 0-4847 5-5 SERVICE
Page 62
FABRICATOR 251
FAULT CAUSE REMEDY
1. Weld beads are too
2. Weld penetration
A. Weld cracking 3. Excessive weld
4. Excessive voltage a. Decrease voltage by reducing the
1. Faulty rectifier unit a. Have an Accredited THERMAL ARC
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.
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.
Service Agent to test then replace the faulty component.
a. Check all welding cable connections. B. Cold weld puddle
a. Connect the MIG torch to the positive
(+) welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.
Table 5-3b: Welding Problems and Solutions continued
SERVICE 5-6 Manual No. 0-4847
Page 63

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 251
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. 0-4847 5-7 SERVICE
Page 64
FABRICATOR 251
NOTES
SERVICE 5-8 Manual No. 0-4847
Page 65
FABRICATOR 251

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES

For Tweco/Victor Inquiries and Orders:
Call 1-800-318-6819 Consumable Parts Management Group
GUNS
Tweco® WeldSkill 15ft 43340P Gun assembly with 15ft cable (supplied with package),
400 Amp @ 30% Duty Tweco® No. 4 12ft 412-3545 Gun assembly with 12ft cable, 400 Amp @ 60% Tweco® No. 4 15ft 415-3545 Gun assembly with 15ft cable, 400 Amp @ 60% Tweco® Spraymaster 12ft MS212-3545 Gun assembly with 12ft cable, 250 Amp @ 80% Tweco® Spraymaster 15ft MS215-3545 Gun assembly with 15ft cable, 250 Amp @ 80% Spool Gun 25ft W4011000 Gun assembly with 25ft cable, 200 Amp @ 60%
Spool Gun 25ft 90906 Gun assembly with 25ft cable, 300 Amp @ 60%
ACCESSORIES
Victor Regulator/Flow Meter Mixed Gases Victor Regulator/Flow Meter CO2
TIPS
14-23 .023” (0.6mm) 14-30 .030” (0.8mm) 14-40 .035” (0.9mm) 14-35 .040” (1.0mm) 14-45 .045” (1.2mm) 14-116 1/16” (1.6mm)
NOZZLES
24A-38 3/8” (9.5mm) 24A-50 1/2” (12.7mm) 24A-62 5/8” (16mm) 24A-75 3/4” (19mm)
CONDUITS
42-23-15 .023”, 15ft (7.6m) 42-3035-15 .030”-.035”, 15ft (4.5m) 44-3545-15 .035”-.045”, 15ft (4.5m) 44N-3545-15 .035”-3/64”, 15ft (4.5m) 44-116-15 1/16” 15ft (4.5m)
0781-2723 Medalist™ 1400 Series, HRF Flow Meter Regulator,
Argon-Argon/CO2 mix gases
0781-2725 Medalist™ 1400 Series, HRF Flow Meter Regulator, CO2
gas
Manual No. 0-4847 A-1 APPENDIX
Page 66
FABRICATOR 251

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM

• Note the model and part number shown on the equipment nameplate
4A BLUE
FABRICATOR 251
W1
L1 White
L2 Black
Input Termi nal Block
Ear th
Green\Yell ow
1
1B RED
2
2B PNK
2A
CB1
3 ORN
1A RED
2&2A PNK
1 RED
1D RED
1C RED
L1
K1\3
[5]
K1\2
[3]
K1\1
L3
[1] [2]
CONT ACTOR 24V 50/ 60Hz
[6]
[4]
T1
4C BLUE
4B BLUE
T3
4 BLUE
(2) (1)
(4) (3)
(8) (7)
10B RED
SW2
COARS E
8 BRN
9 BLK
10 RED
10C RED
11 GRY
12 BRN
16 WHT
(10)
(12)
(6)
(24) (23)(12)(11)
(18) (17)(6) (5)
(22) (21)(10)(9)
(20) (19)(8) (7)
8&8A BRN
(9)
9&9A BLK
(11)
10&10A RED
(5)
11&11A GRY
12&12A BRN
16&16A WHT
17&17A BLK
S W1
Input Termi nal Block
BLU
5 6
BLU
Fan motor
M1
24V Aux
30C BRN 31D O RN
S OL2
31B ORN
31A ORN
31E ORN
Y2
SPOOL
Sol enoid
Y1
NORM
Sol enoid
32B WHT
32A WHT
33 BLU
S OL1
31C ORN
31 ORN
30B BRN
60 RED
30 BRN
SW3
FINE
30A BRN
7B
BLUE
BLUE
X1/5 X1/6 X1/4
X3/6
X3/5
32 WHT
17 BLK
13 VIO
7C
Voltage Terminal bl ock
3
4
X3/2
Torch
58 BRN
Trigger
R2
BURNBACK 100K
34 BL U
35 WHT
(16) (15)(4) (3)
(14) (13)(2) (1)
PCB 3
7978034
X3/1
59 GRY
TS1
37 ORN
TS2
13&13A VIO
2 & 2A PNK
14&14A BLU 208VAC
15&15A ORN 230VAC
X2/4
38 WHT
TEMP
LED1
38A WHT
54 BL K
36 GRY
39 RE D
X2/5
56 RE D
JA/7
JA/6
JE/1
JB/5
JB/4
JB/11
JB/10
JE/2
JA/5
JA/2
Main PCB 7978050 (PCB1)
Ar t # A-07223
APPENDIX A-2 Manual No. 0-4847
JA/1
Page 67
FABRICATOR 251
T1
S2
T2
F2
S3
T3
T4
T5
F3
F1
0V
T1
208V
S1
230V
TRANS 251 US COIL
S4
F4
X3/4 X3/3 X2/3 X2/1 X2/2 X1/1 X1/2 X1/3
SWITCH 2 COARS E
POSITIO N
1
XX 2 3X
543
1
26
X
8
X
BR1
Br idge Recti fier
Var is to r
VR1
43A BLK
55 BLK
57 VIO
45 VI O
9711
10 12
X
C1-C4
+
4 x 22, 000 uF
47 GRY
SWITCH 3 FI NE
SWI TCH
POSITIO N
1
X 2 3X
X 4X 5
X 6 7X
X 8X
543
1
26
X
X
X
X
8
9711
10 12
X X
X X
L1
0.1u F 630V
C5
WIRE SPEED 1K
Indu ct or
21 ORN
22 VIO
23 GRY
48 ORN
5A
CB2
SHUNT
53 WHT
RI
50 VIO
PLUGSOCKET
30C BRN
31D ORN
PLUGSOCKET
15
13
14 181716
XX
X
X
X
X
X
X
X
X
X
X1/6
PCB 4
X1/5 X1/4
20
X X
+
2119 23
22 24
X X
POSITIVE OUTPUT TERMINAL
X
704883
X1/3
DIG METER
X1/1
-
NEGATIVE OUTPUT TERMINAL
J1
A B C D E F G H I J
18-1S F
MIG Timer PCB 7977965 (PCB2)
JC
JUMPER
JD-1 JD-2
NOTE:
M2
46 RE D +
-
Wi re Feeder Mo to r
43 BL K
JB/8
47 GRY
48 ORN
49 BL U 49 A BLU
44 BRN
JB/7
JB/9
JB/6
JB/3
51 ORN
52 BRN 52A BRN
JB/1
JB/2
Remove this jumper and use these pins when connecting a replacement 7978050 Control PCB
Manual No. 0-4847 A-3 APPENDIX
Ar t # A-07223_AB
Page 68
FABRICATOR 251

APPENDIX 3: FEEDROLL KITS

DRIV E ROL L KI TS ( #3759 80- S eries) 2 ROL L
Style 1 Style 2 Style 3 Style 4 Style 5 Style 6
Double Smooth
Top
Bottom
Wire Type Wire Size
.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 - - 3759 8 0-030 - - ­.045" / 1.2mm 375980-002* 375980-004 - 375980-092 375980-022 ­3/64 / 1.2mm - - 375980-011 - - 375980-033 .052" / 1.3mm 375980-090* - 375980-012 - - ­.052", 1/16" / 1.3, 1.6mm - -
Notes: 1) One Kit (# 375980-028) is supplied standard with each w ire feeder.
2) Drive Roll Kits include: Drive Ro lls; Input & Output Guides
3) Narrow 30° "V"
Flat Flat Knurled
Double
Smooth "V"
Hard Hard Soft/Hard/Tubular H a rd/Tubular Tubular Soft (Aluminum)
Double
Smooth "V"
"V"
Double Smooth
"V"
Double
Knurled "V"
Double
Knurled "V"
375980-017 375980-023
Double Cog Double "U"
Double Cog Double "U"
-
APPENDIX A-4 Manual No. 0-4847
Page 69

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, indir ect or consequential damages, such as, but not limited to, damage or loss of pu 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.
rchased or replacement goods, business interruption or
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 Pu THERMADYNE warrantiesWarranty SCHEDULE
rchaser’s risk and expense. This warranty supersedes all previous
Page 70

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 Inductors5 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-Conductors1 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 Rectifie All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors1 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-Conductors3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors1 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-Conducto 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-Conductors1 year / 1 year
rs, Control P.C. Boards, Power Switch Semi-Conductors3 years / 3 years
rs 3 years / 3 years
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 year All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors1 year / 1 year
GENERAL ARC EQUIPMENT Parts / Labor
FirePower® MIG Welders 5-2-1 years / NA Water Recirculators1 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
s
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
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