Tweco 281 User Manual

281

®

FABRICATOR

MIG WELDING MACHINE

Operating Manual

Version No: AI Issue Date: April 10, 2006 Manual No.: 0-4877
Operating Features:

Art # A-07447

208V230

V

60

Hz

WE APPRECIATE YOUR BUSINESS!

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

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

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

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

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

!

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 281 MIG Welding Machine
Instruction Manual Number 0-4877 for:
Package System Part Number W1001600
Power Source Part Number 707300

Published by:
Thermadyne Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermalarc.com

©Copyright 2006, 2007, 2008 by
Thermadyne Industries Inc.

All rights reserved.

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

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

Original Publication Date: April 10, 2006
Revision AI Release Date: July 8, 2008

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i

TABLE OF CONTENTS

SECTION 1:

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

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

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

1.03 Symbol Chart ................................................................................................. 1-5

1.04 Precautions de Securite En Soudage à L’arc................................................... 1-6

1.05 Dangers Relatifs au Soudage à L’arc .............................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole ................................................................................. 1-10

SECTION 2:

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

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

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

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 General Information ....................................................................................... 2-2

2.05 Safety ............................................................................................................. 2-2

2.06 Protective Filter Lenses .................................................................................. 2-2

2.07 User Responsibility ........................................................................................ 2-3

2.09 Specifications ................................................................................................. 2-3

2.08 Duty Cycle ...................................................................................................... 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 Mount the A2281 Wire Feeder ........................................................................ 3-5

3.07 Installation of Shielding Gas (GMAW) Process .............................................. 3-6

3.08 Attaching the Gun and Cable Assembly to the Remote Feeder ....................... 3-8

3.09 Selection and Installation of Feedrolls .......................................................... 3-10

3.10 Input And Output Wire Guide Installation ..................................................... 3-10

3.11 Installing Wire Spool on the Remote ............................................................ 3-11

3.12 Inserting Wire into the Feedhead .................................................................. 3-12

3.13 Wirefeeder Drive Roller Pressure Adjustment .............................................. 3-13

3.14 Wire Reel Hub Brake .................................................................................... 3-13

3.15 Spool Gun Attachment ................................................................................. 3-14

3.16 Polarity Changeover ..................................................................................... 3-15

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:

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

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

4.02 Internal Controls of A2281 Remote ................................................................ 4-7

4.03 MIG Gun Identification ................................................................................... 4-9

4.04 TWECO Weldskill 280 AMP Weld Gun .......................................................... 4-10

4.05 Installing A New Wire Conduit ...................................................................... 4-11

4.06 MIG Gun Maintenance .................................................................................. 4-12

4.07 Basic Welding Technique.............................................................................. 4-12

4.08 Stitch Welding Operation .............................................................................. 4-15

4.09 Spot Welding Operation ............................................................................... 4-15

4.10 Gas Selection for Gas Metal Arc Welding ..................................................... 4-16

4.11 Welding Setting Selection Guide .................................................................. 4-18

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: FEEDROLL KITS ........................................................................... A-2

APPENDIX 3: POWER SUPPLY CIRCUIT DIAGRAM ................................................... A-4

LIMITED WARRANTY ......................................................................................... 2

WARRANTY SCHEDULE ...................................................................................... 3

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

FABRICATOR 281

!

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled:
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

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

SAFETY IN WELDING AND CUTTING. This publication and other

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

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

9. Do not wrap cables around your body.

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

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

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

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

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

1. Do not touch live electrical parts.

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

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

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

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

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

April 10, 2008 1-1

15. Keep all panels and covers securely in place.

WARNING

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

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

2. Wear approved safety glasses. Side shields recommended.

FABRICATOR 281

g

g

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.

Eye pro tectio n filter shade selector for welding or cutting (goggles or helmet), from AWS/ANSI Z49.1:1999

Welding or Cutting

Operation

Torch So ldering All 2 Gas Tung sten Ar c Weldin
Torch Brazing All 3 or 4 Light Under 50 Amp
Oxygen Cutting

Light Under 1 in., 25 mm 3 or 4 Heavy
Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen Weldin
Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc Welding

Gas Welding

Light Under 1/8 in., 3 mm 4 or 5 Light 12
Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Heavy 14
Heavy Over 1/2 in., 12 mm 6 or 8

Shielded Metal-Arc Weldin g (Stick) Electr odes

Light Under 5/32 in., 4 mm 10 Light 20 to 100 Amp 10
Medium
Heavy

Gas Metal Arc Weld ing

Light Under 60 Amp 7 Light Under 300 Amp 9
Light
Medium
Heavy

Electrod e Size M etal

Thickness or Welding

Under 5/32 to ¼ in., 4 to 6.4m
Over ¼ in., 6.4 mm

60 to 160 Amp 11 Medium 300 to 400 Amp 12
160 to 250 Amp 12 Heavy 400 to 800 Amp 14
250 to 500 Amp 14

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.

Filter

Shade

12
14

Welding or Cuttin g

Operation

Medium

Carbon Arc Gouging

Plasma Arc Welding

Light Under 20 Amp 6 to 8

Medium 100 to 400 Amp 12
Heavy 400 to 800 Amp 14

Plasma Arc Cutting

Electrod e Size Metal

Thickness or Welding

50 to 150 Amp 12

150 to 500 Amp 14

All 12
All 14

Filter

Shade

10

1-2 April 10, 2008

WARNING

!

FABRICATOR 281

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.

April 10, 2008 1-3

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

FABRICATOR 281

1.02 Principal Safety Standards

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.

The coolant in the radiator can be very hot and under
pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to
cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

LEAD WARNING

This product contains chemicals, including lead, or oth­erwise produces chemicals known to the State of Cali­fornia to cause cancer, birth defects and other repro­ductive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)

NOTE

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “...there is now a very large volume of scientific findings based

on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”

To reduce magnetic fields in the workplace, use the following
procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from
body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.

1-4 April 10, 2008

1.03 Symbol Chart

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

FABRICATOR 281

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

April 10, 2008 1-5

Receptacle Rating­Auxiliary Power

Voltage Input

V

Art # A-04130

FABRICATOR 281

!

1.04 Precautions De Securite En Soudage A L’arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

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

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

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

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

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

1.05 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

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

1. Ne touchez pas à des pièces sous tension.

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

6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

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

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

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

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

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

15. Fermez solidement tous les panneaux et les capots.

3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen

de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.

1-6 April 10, 2008

FABRICATOR 281

AVERTISSEMENT

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

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

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

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

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

4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.

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

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

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

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

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

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

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

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

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

Opération de coupage

ou soudage

Brassage tendre
au chalumeau

Brassage fort
au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

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

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

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

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

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

Soudage á l'arc avec
électrode enrobees
(SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

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

épais plus de 6 po. (150 mm) 5 ou 6

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

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

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

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

Nuance de

filtre oculaire

Opération de coupage

ou soudage

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

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

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

Gougeage Air-Arc avec
électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

toutes conditions 12

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

April 10, 2008 1-7

FABRICATOR 281

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.

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

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION

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

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

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

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

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

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

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

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

LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER

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

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

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

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

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

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

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

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

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

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

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

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

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

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

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

2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.

AVERTISSEMENT

PEUVENT CAUSER DES BLESSURES.

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

1-8 April 10, 2008

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION. Le carburant est hautement inflammable.

FABRICATOR 281

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.

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

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

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

Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.

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

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.

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.

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

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le
plomb, ou engendre des produits chimiques, reconnus
par l’état de Californie comme pouvant être à l’origine
de cancer, de malformations fœtales ou d’autres
problèmes de reproduction. Il faut se laver les mains
après toute manipulation. (Code de Californie de la
sécurité et santé, paragraphe 25249.5 et suivants)

1.06 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.

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.

April 10, 2008 1-9

FABRICATOR 281

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

1-10 April 10, 2008

Classement de Prise­Source Auxiliaire

Haute Température

Force d'Arc

Amorçage de L’arc au
Contact (GTAW)

Inductance Variable

Tension

V

t

IPM

MPM

Probléme de Terre

Pouces Par Minute

Mètres Par Minute

Art # A-07639

FABRICATOR 281

!

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

April 10, 2006

2-1

FABRICATOR 281

2.04 General Information

The Fabricator 281 is a 208-230 Volt MIG machine with a
best in class performance of 300 Amp maximum output
@ 40% duty cycle, 24 voltage steps, digital meter and
dual cylinder racks. The completely separate wirefeeder
system has 26ft (8m) interconnection cables, spool gun
operation on demand and spot/stitch timers. The
wirefeeder, with fitted wheels, conveniently fits on a pivot
mount on top of the power source or can be lifted off the
pivot and carried up on top of equipment or machinery
up to 26 feet away. Additionally, the spool gun connects
to the wirefeeder allowing even further distance. The
Fabricator 281 is an extremely versatile all round
performer in its class.

The Fabricator 281 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 281 is supplied as a complete package
ready to weld (apart from gas cylinder and electrode wire).
The following instructions detail how to correctly set up
the welder and give guidelines on gaining the best
production efficiency from the Power Supply. Please read
these instructions thoroughly before using your Fabricator
welder.

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

• Do not stand on damp ground when welding.

For more complete safety advice please read section 1.

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.

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.

2-2

April 10, 2006

FABRICATOR 281

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 written approval
of Thermal Arc. The purchaser of this equipment shall
have the sole responsibility for any malfunction which
results from improper use or unauthorized modification
from standard specification, faulty maintenance, damage
or improper repair by anyone other than appropriately
qualified persons approved by Thermal Arc.

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 50% duty
cycle, 250 amperes at 28 volts. This means that it has
been designed and built to provide the rated amperage
(250A) at the rated load voltage (28V), for 5.0 minutes
out of every 10 minute period (50% of 10 minutes is 5.0
minutes). During the other 5.0 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

Control Circuit Supply
Wire Motor Supply

Wire Speed Range

Wire Diameter

Mild Steel: YYYY

Stainless Steel: Y Y Y Y

Aluminum: Y Y Y Y

Flux Cored: Y Y Y Y

Wire Spool Size Capacity

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

30VA @ 24VAC

216VA @ 36VAC

80 to 800 ipm

(2 to 20 m/min)

.023

"

(0.6mm)

.030

"

(0.8mm)

.035

"

(0.9mm)

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

.045

"

(1.2mm)

1/16

"

(1.6mm)

April 10, 2006

Table 2-3: Wire Drive Specifications

2-3

FABRICATOR 281

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

(including wheels and cylinder rack and wire
feeder)

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/29.0V @ 40% 300A/29.0V @ 40%
100% Duty Cycle Output Rating 195A DC at 24V 195A DC at 24V
Duty Cycle Period
Number of Output Voltage Values

Electrode Wire Type and Diameter

Mild / Stainless Steel

Aluminum

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

Operating Temperature Range

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

80 – 800 ipm (2 – 20 m/min )

8” / 12” (200mm / 300mm)

Self-resetting thermostat fitted to rectifier and

W1001600

707300

249 lb (113kg)

58” x 27.2” x 36.8”

(1473 x 691 x 935mm)

1Ø

60 Hz

10ft (3m) 8AWG

NEMA 6-50P

10 minutes

24

0 – 0.6 seconds

0.16 seconds

0.5 – 9 seconds
1 – 12 seconds

0.5 – 9 seconds
1 – 12 seconds

transformer

32° to 104°F (0° to 40°C)

2-4

* The Rated Input Current shoul d be us ed for the determ inat i on of cabl e s i ze & supply
requirements.

Table 2-4: Machine Specifications

April 10, 2006

FABRICATOR 281

2.10 Included Items

Fabricator 281 Package System Contents

A2281 Wire Feeder with 26 ft (8m) Interconnection leads
Factory Fitted Wheeling Kit
Factory Fitted Dual Cylinder Rack
Factory Fitted Primary Power Cable 8AWG, 10ft (3m) with Plug
NEMA 6-50P
Work Lead 26 ft (8m)
Cable Storage Hooks
Gas Regulator/Flowmeter – Argon Mix Gases
Tweco Weldskill MIG Gun 280 Amp, 15ft (4.5m)
Fitted Feed Roll for .035” - .045” (0.9 – 1.2mm) solid wire

Table 2-5: Power Supply Contents

2.11 Optional Accessories

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

April 10, 2006

2-5

FABRICATOR 281

2-6

April 10, 2006

SECTION 3:

INSTALLATION

FABRICATOR 281

3.01 Environment

The Fabricator 281 is NOT designed for use in
environments with increased hazard of electric shock.

Examples of environments with increased hazard of
electric shock are:

In locations in which freedom of movement is restricted,
so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical
contact with conductive parts;

In locations which are fully or partially limited by
conductive elements, and in which there is a high risk of
unavoidable or accidental contact by the operator, or

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

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.

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 (300mm) or more from walls

or similar that could restrict natural air flow for cooling.
The minimum ground clearance for these products is 5.5

inches (140mm).

3.03 Ventilation

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

April 10, 2006

3-1

FABRICATOR 281

!

!

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 281 be electrically connected by a qualified electrical trades­person.

The Fabricator 281 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 281

Lead Current

Rating

Lead

Length

Machine

Voltage Setting Duty Cycle

3.05 Alternative Mains Supply Voltages

WARNING

The Fabricator 281 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) 40 Amps 50Amp 250A @ 60%
230V 8AWG (8.0mm2) 40 Amps 50Amp 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.

April 10, 2006

3-2

FABRICATOR 281

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 281 (Wired for 230V)

April 10, 2006

3-3

FABRICATOR 281

!

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” (140mm) 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. Mount the A2281 wire feeder unit on top of the
Fabricator 281 power supply.

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

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

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

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

9. Remove the contact tip from the gun.

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

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

GUN

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

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

lead to the positive (+) socket

NOTE

WARNING

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

5. Fit the gas Regulator/Flowmeter to the gas
cylinder and connect the gas hose from the rear
of the Wirefeeder to the Flowmeter outlet.

3-4

April 10, 2006

FABRICATOR 281

3.07 Mount the A2281 Wire Feeder

1. Mount the A2281 wire feeder unit on top of the
Fabricator 281 power supply by engaging its
swivel receptacle into the turret on top of the
Fabricator 281. Refer to Figure 3-2.

NOTE

To minimize the lifting weight of the A2281
wire feeder unit, do not install the wire spool
on it until it has been mounted.

2. Attach the supplied 26 ft (8m) Interconnection
Cable Assembly to the the A2281 wire feeder's
rear panel by firmly threading each of the three
cables' connectors to their mating sockets. Use
the power supply end of the cable as a reference
guide as shown in Figure 3-3.

26ft (8m) Interconnection Cable Assembly

Turret

Art # A-07454

Figure 3-2: Mount the Wire Feeder on to the Turret

Art # A-07455

To Positive Welding
Terminal

To Gas Regulator

To 7-pin Amphenol Socket on Front Panel

April 10, 2006

Figure 3-3: Attach the Interconnection Cable Assembly

3-5

FABRICATOR 281

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 3-5
#1 for Wheel Kit cylinder installation)

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

cylinder by rotating counter clockwise (Figure 3-5 #2).
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 3-5 # 3.)

3. Fit Regulator/Flowmeter to cylinders:

Screw the regulator into the appropriate cylinder.
(Figure 3-5 #4) The nuts on the regulator and hose
connections are right hand (RH) threaded and need
to be turned in a clockwise direction in order to tighten.
Tighten with a wrench.

Adjust control knob of regulator to the required flow rate,
indicated on gauge dial. (Refer to Figure 3-4 and data
charts Approx. 20 CFH)

The gas flow rate should be adequate to cover the weld
zone to stop weld porosity. Excessive gas flow rates may
cause turbulence and weld porosity.

Argon or argon based gas flow rates:

- Workshop welding: 20-30 CFH

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

- Workshop welding: 30-40 CFH

- Outdoors welding: 40-50 CFH

NOTE

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

CAUTION

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

4. Attach supplied gas line: 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 3-5 #5 and
3-14).

Adjusting Regulator

Art # A-07280

Figure 3-4: Adjusting flow rate

Refer to section 5.03 for suggested gas / filler metal
combinations.

NOTE

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

3-6

April 10, 2006

FABRICATOR 281

1

3

“Cracking”

Regulator and
Flowmeter

Cap

2

Shielding
Gas

4

Shielding
Gas

Gas Hose

5

1 1/8”

Shielding
Gas

To A2281 Wire
Feeeder Gas Inlet

Stowage Hook

Shielding
Gas

Art # A-07603

April 10, 2006

Figure 3-5 Gas Cylinder Installation

3-7

FABRICATOR 281

3.08 Attaching the Gun and Cable Assembly to the Remote Feeder

The Fabricator 281 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 A2281 remote wire
feeder by depressing the release mechanism and
pulling the cover outward and up.

4. Align the keyways of the Gun Switch connector
and the receptacle below the gun cable and plug
them together. Secure by turning the locking ring
to the right (clockwise ). Refer to Figure 3-7.

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.

Art # A-07458

Art # A-07457

Figure 3-6: 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 3-6 and 3-7.

3. Loosen the thumbscrew and insert the gun cable
end as far as it will go. Tighten thumbscrew. Refer
to Figure 3-8.

Front Panel
Access Hole

Trigger Receptacle

Lubricate O-ring

Figure 3-7: Route Gun Cable Through Front Panel

Access Hole and Connect Trigger

3-8

April 10, 2006

Thumbscrew

FABRICATOR 281

Art # A-07459

April 10, 2006

Figure 3-8: Mount Gun Cable to Adapter Socket

3-9

FABRICATOR 281

3.09 Selection and Installation of Feedrolls

WARNING

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.

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.

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.

3.10 Input And Output Wire Guide Installation

Refer to Figure 3-10.
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.

Figure 3-9: 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.

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 281 are identical.

Input Guide Lockscrew

Output Guide Lockscrew

Art # A-07445

Input Wire Guide

Output Wire Guide

Figure 3-10: Wire Guide Installation

3-10

April 10, 2006

3.11 Installing Wire Spool on the Remote

As delivered from the factory, the unit is set for a 33/44
lb. or 12" (300mm) spool.

FABRICATOR 281

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.

Wire Spool Hub Nut
Alignment Pin

Hub Tension Bolt

Additional Wire Spool
Support Shaft Hole

*Spring

1

2

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.

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

Art # A-07460

3

Figure 3-11: Spool Installation

April 10, 2006

3-11

FABRICATOR 281

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. 3-11)

2. Move the Pressure (top) Roller Arm by swinging it to the right. (Second part of Figure. 3-11)

3. Make sure the end of the wire is free of any burrs and is straight. Pase 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. 3-11)

4. Pass the wire through the outlet guide and into the Gun liner of the Gun Cable. (Second part of Figure. 3-11)

5. Close the Pressure Roller Arm. (Figure. 3-12)

6. Swing the Spring Pressure Adjusting Knob back into place. (Figure. 3-12)

7. Use the Spring Pressure Adjusting Knob to create a “snug” condition. (Clockwise to tighten and Counter
Clockwise to loosen). (Figure. 3-12)

8. Figure 3-13 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 3-11: Opening Pressure Arm and Inserting Wire

7 - Adjust
the tension

3-12

5 - Swing
the Pressure
Arm closed

Art # A-07144

6 - Swing the
Adjuster back into
place.

Figure 3-12: Closing Pressure Arm and Adjusting Tension

April 10, 2006

Spool Hub Nut

FABRICATOR 281

Spool Hub Brake Hex Head Bolt

Wire Drive
Pressure Adjusting Device

Figure 3-13: Wire Installed

3.13 Wirefeeder Drive Roller Pressure Adjustment

The roller on the swing arm applies pressure to the
grooved roller via 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.

Art # A-07461

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 3-13 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
3/4-inch (20mm) after release of the Gun
trigger switch. The wire should be slack
without becoming dislodged from the reel.

April 10, 2006

3-13

FABRICATOR 281

3.15 Spool Gun Attachment

A spool gun can readily be used with the Fabricator 281 power supply.

1. Attach appropriate input gas to the Spool Gun input gas connection on the rear of the unit (Refer to
Figure. 3-14).

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. 3-14)

Spool Gun
Interface
Amphenol
Receptacle

Main Gun
Gas Input
Connection

Spool Gun
Gas Input
Connection

Spool Gun
Welding Cable
Connection

2281

A

Weldskill

Spool Gun
Gas Outlet
Connection

Front Panel

Art # A-07477

Rear Panel

Figure 3-14 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.

3-14

April 10, 2006

FABRICATOR 281

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 WIREFEEDER 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.

Cable to work

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

CABLE CONNECTIONS

1. Connected to (-)
Neg. output
terminal

2. Connected to (+)
Pos. output
terminal

Cable from wirefeeder
connected to

+

terminal

April 10, 2006

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

Art # A-07479

Figure 3-15: Polarity Connections for DCEP

3-15

FABRICATOR 281

Cable from wirefeeder
connected to

Changing polarity process.

a. Locate the two terminal knobs at the front of the machine. Refer to Figures 3-15 and 3-16.
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 3-15 or 3-16.

-

terminal

Connected for D.C.
Electrode Negative
(DCEN) Welding

Art # A-07480

Figure 3-16: Polarity Connections for DCEN

Cable to work

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.

3-16

April 10, 2006

FABRICATOR 281

SECTION 4:

OPERATION

WARNING

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

4.01 Power Supply Controls, Indicators and Features

Front Panel
Torch Access
Hole

2281

A

Weldskill

Wire Speed Control

Gun Switch
Amphenol
Receptacle

Digital Display

Voltage / Amp
Selection Butt

Coarse Voltage
Selector Switch

Negative Welding
Terminal

on

Power OnStandby Switch

Spool Gun Interface
Amphenol Receptacle

Thermal Overload Indicator

A/V

Weldskill

17V- 21V

13V- 16V

22V- 31V

Power On/Off Switch

Fine Voltage

Wirefeeder Interface
Amphenol Receptacle

Positive Welding
Terminal

Selector Switch

April 10, 2006

Art # A-07462

Figure 4-1: Fabricator 281 Controls

4-1

FABRICATOR 281

On / Standby Power Switch

The indicator light is provided to indicate when the Fabricator 281 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

Value displayed for 21.9 Volts

Art # A-07279

Figure 4-2: Digital Display

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

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

4-2

April 10, 2006

Digital AMP Reading to IPM Conversion

900

800

700

600

500

400

FABRICATOR 281

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

April 10, 2006

(.023 - SS)

(.030 - SS)

(.035 - SS)

(.045 - SS)

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

Current (Amps)

Art # A-07452

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

4-3

FABRICATOR 281

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

Wirespeed Control

The Wirespeed Control knob controls the welding current via the electrode wire feed rate, i.e. the speed of the wire
feed motor.

Coarse Voltage Control Switch

The Coarse Voltage Control sets the voltage level to the welding terminals as it is rotated in the clockwise direction.

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.

CAUTION

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

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.

4-4

April 10, 2006

Positive and Negative Welding Terminal Knobs

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

CAUTION

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

Gun Switch Receptacle

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

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

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

FABRICATOR 281

F

G

H

Art # A-07181

Figure 4-4: Spool Gun 10 pin receptacle

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

E

D

J

I

A

C

B

1

2

Art # A-07171

Figure 4-3: Gun Switch Receptacle

Spool Gun Interface Amphenol Connector

The Spool Gun Interface 10 pin connector is used to
connect a spool gun to the A2281 Wirefeeder (refer
to Figure 4-4 and Table 4-1).

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

April 10, 2006

Wirefeeder Control Socket

The Wirefeeder 7 pin receptacle is used to connect a
Wirefeeder to the welding Power Source.

4-5

FABRICATOR 281

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 Wirefeeder 7pin receptacle.

7

21

435

76

Art # A-07478

Figure 7 - Wirefeeder 7 pin receptacle

Socket Pin Function

1

2 24VAC circuit active
3 Power Source thermostat
4 Power Source thermostat
5 24VAC circuit common
6 Power Source Negative Welding Terminal
7 Power Source Positive Welding Terminal

Output to energise the power supply contactor, 24VAC
(contact closure is provided between socket pins 1 and 2 to energise the contactor)

Table 4-2: Wirefeeder Control Socket Pins

4-6

April 10, 2006

4.02 Internal Controls of A2281 Remote

FABRICATOR 281

(STITCH)DWELLBURNBACK WELD (SPOT / STITCH)

6

7

8

5

4

3

2

MIN

t

9
10

11

12

t

WELD MODE

SPOT STITCH

2T

t

4T

WELD MODE

(STITCH)DWELLBURNBACK WELD(SPOT / STITCH)

SPOT

STITCH

2T

4T

6

7

8

5

4

9
10

3

2

11

MIN

12

t

4

5

3

2

1

MIN

4

5

3

6

7

2

1

8

MIN

9

t

6

7

8

9

t

Art # A-07463

Figure 4-5: Internal Welding Controls

WELD Mode Selector

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

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.

April 10, 2006

4-7

FABRICATOR 281

WELD MODE

2T

SPOT

STITCH

4T

MIN

4

1

3

2

WELD

(SPOT / STITCH)

t

4

(STITCH)

1

3

2

t

MIN

DWELL

BURNBACK

SPOT:

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

WELD MODE

STITCH

SPOT

2T

Art # A-07427

4T

Figure 4-6: Spot Weld

NOTE

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

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.

WELD (Spot/Stitch)

WELD

(SPOT / STITCH)

MIN

Art # A-07429

Figure 4-8: Weld (Spot/Stitch) Control

WELD MODE - SPOT

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

WELD MODE - STITCH

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

the stitch weld.

Dwell Stitch

DWELL

(STITCH)

MIN

Art # A-07430

Art # A-07428

Figure 4-7: Stitch Welding

4T (Latch):

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

Figure 4-9: Dwell (Stitch) Control

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.

Burnback Control

BURNBACK

Art # A-07431

Figure 4-10: Burnback Control

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

4-8

April 10, 2006

FABRICATOR 281

4.03 MIG Gun Identification

The FABRICATOR 281 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

Different Strain Reliefs

Different Labels

April 10, 2006

Red O-Rings

Different Gun Switch Plugs

Figure 4-12: MIG Gun Identification

Black O-Rings

Art # A-08069

4-9

FABRICATOR 281

4.04 TWECO Weldskill 400 AMP Weld Gun

The TWECO Weldskill 400 A Fabgun fitted to the FABRICATOR 281 offers robust construction, unparalleled reliability
and easy replacement of consumable parts. The TWECO Weldskill gun has an operating capacity in excess of the
capacity of the FABRICATOR and can be expected to give trouble free service.

6

5

4

7

3

2

1

Art # A-07344

Figure 4-13: TWECO WeldSkill 400 AMP Fabgun

TWECO W e ldskill 400A MIG Gun — Original Parts Installed

Item Des criptio n "T" Seri es P art No. "P " S eri es P a rt No .

1 NOZZLE 1/2" W S24A -62 WS 24A-62
2 N OZZLE INSULATO R WS34 A WS34 A
3 CONTA CT TIP .035" W S 14-35 W S 14-35
4 GAS DIFFUSER WS54A W S54A
5 CONDUCTOR TUBE W M 63 J-50 W M 6 3J-50
6 HANDLE ASSEMBLY WM1-80
7 TRIGGER SWITCH ASSEMBLY W M91 WM91

FAB1-80

Table 4-2 MIG Gun Original Parts Consumables

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

Gun Consumable Parts

See Appendix at the back of this manual.

4-10

April 10, 2006

FABRICATOR 281

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.

April 10, 2006

4-11

FABRICATOR 281

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

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

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

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

MIG Gun Travel Speed

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

Position of MIG gun

The angle of MIG gun to the weld has an effect on the width of the weld run. Refer to Figure 4-13.

Forehand

Art # A-05148

Figure 4-13: MIG Gun Angle

Vertical

4-12

April 10, 2006

FABRICATOR 281

Distance from the MIG Gun Nozzle to the Work Piece

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

Art # A-07186

1/4” (6.4mm)

.023”

(.6mm)

Solid Wire

5/16” (7.9mm)

.030”

(.8mm)

3/8” (9.5mm)

.035”

(.9mm)

Flux Cored Wire

9/16”

(14.3mm)

.035”

(.9mm)

11/16”

(17.5mm)

Figure 4-14: 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,

Tip

Contact

.045”

(1.1mm)

Gas

Nozzle

Distance: ±1/16”

Wire Diameter

- The deposition rate required,

- The bead profile desired,

- The position of welding and

- Cost of the electrode wire.

Weld metal deposition rate is proportional to current density. Current density is defined as the current per cross

2

sectional area of the electrode wire and is normally expressed as amps per mm

. An example is in Table 4-3 below.

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

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

Table 4-3: .035"(0.9mm) , .045"(1.2mm) wire deposition rate

April 10, 2006

4-13

FABRICATOR 281

Advantages of MIG welding forehand:

• Allows superior visibility of the weld zone

• Flatter weld bead

• Shallower penetration

Forehand

Vertical

Figure 4-15: MIG Gun Angle

Backhand

Art # A-07185

4-14

April 10, 2006

FABRICATOR 281

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 knobfor 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 below. The Fabricator 281
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

The

DWELL (Stitch)

control knob has no affect in

this mode of operation.

SPOT WELDING NOZZLES

TYPE NO.4 400 AMP

Flat Arc Spot

Inside Corner Arc Spot 24A-75-IAS

Outside Corner Arc Spot 24A-75-IAS

Automotive Stud Nozzle N/A

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

1240-1531
(3/4” Bore)

1240-1532
(3/4” Bore)

April 10, 2006

4-15

FABRICATOR 281

4.10 Gas Selection for Gas Metal Arc Welding

Suggested

Shielding

Gas

100% CO

2

Welding

Positions

All

Position

High welding speeds. Good
penetration and pool control.

Metal Type

Carb on

Steel

Base Plate

Thickness

Greater than 22

gauge (.030”)

Filler
Metal

Transfer

Mode

ER70S-X Short

Circuit

Welding

Greater than 22

gauge (.030”)

ER70S-X Short

Circuit

75% Argon

25% CO2

All

Position

Suitable for high-current and high­speed welding.

Welding

Greater than 22

gauge (.030”)

ER70S-X Short

Circuit

92% Argon

8% CO2

All
Position
Welding

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

Greater than 10

gauge (1/8”)

ER70S-X Spray

Transfer

92% Argon

8% CO2 or

Flat & HV

Fillet

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

minimum

98% Argon

2% O2

Low Alloy

and High

Alloy Steel

Greater than 22

gauge (.030”)

See * below Short

Circuit

Globular

75% Argon

25% CO2

All
Position
Welding

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

Greater than 22

gauge (.030”)

See * below Short

Circuit

92% Argon

8% CO2

All
Position

Good coalescence and bead contour.
Good mechanical properties.

Welding

Greater than

3/32”

See * below Spray

transfer

92% Argon

8% CO2 or

minimum

98% Argon

Flat & HV

Fillet

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

2% O2

Greater than 14

gauge (.075”)

See * below Short

Circuit

98% Argon

2% CO2

All
Position
Welding

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

Stainless

Steel

Greater than 22

gauge (.030”)

ER308-X
ER309-X
ER316-X

Short

Circuit

90% Helium

7.5% Argon

2.5% CO2

All
Position
Welding

Low CO

percentages in Helium mix

2

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

Greater than

3/32”

ER308-X
ER309-X
ER316-X

Spray

Transfer

81% Argon

18% Helium

1 % CO2 or
98% Argon

2% CO2 or

Flat & HV

Fillet

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

2% O2

Aluminum

Greater than 18

gauge (.045”)

ER4043
ER5356

Spray

Transfer

Argon All

Position
Welding

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

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

Comments

percentages

2

4-16

April 10, 2006

FABRICATOR 281

This Page Is Intentionally Blank

April 10, 2006

4-17

FABRICATOR 281

4.11 Welding Setting Selection Guide

Material Type W ire Type

Art # A-07449

Solid

Steel

(or hard)

ER70S-6

Shielding Gas

and Flow Rate

100% CO

25cfh

75% Ar 25%

2

CO

,25cfh

92% Ar

8% CO

2

Wire Size

(Diameter)

2

.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)

Steel

Aluminum

Stainless

Steel

Flux Core

E71T-1

E71T-GS

E71T-11

Aluminum

4043 ER
5183 ER
5356 ER

Stainless

ER308LSi
ER309LSi
ER316LSi

100% CO

25cfh

None

100% Ar

25cfh

7.5% Ar
90% He

2.5% CO
35cfh

.045” (1.2mm)

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)

4-18

April 10, 2006

FABRICATOR 281

M

L

Coarse Voltage

22 ga. (0.8mm)

H

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)

M/2

L/8

M/1

2.25

L/8

M/2

1.25

M/1

L/8

M/1

2.25

L/8

M/2

1.25

M/1

Fin e V oltage

1.5

2.75

1.75

1.25

2.75

1.75

1.25

Coarse Voltage

Fine Voltage

Step

M/3

1.5

L/8

1.25

M/2

4.5

M/3

2.5

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/5

M/5
M/6

M/5
M/6

M/5
M/6

M/5
M/6

2

1.5

6

4.5

3

2.25
6

4.5
3

2.25

H/1
H/1

M/8
M/8
H/1

H/2
H/3

H/4
H/4

4

2.5

6
5

3.25

7.75

5.75

5.5
3

H/3
H/3

H/2
H/3
H/2

H/4
H/5
H/5

THICKNESS

5.5

3.5

6.25

6.25

3.75

6.5
7

3.25

H/4

7.5

H/4

3.7

H/3

8.25

H/3

6.25

H/4

4.5

H/5

7.25

H/7

7.5

H/6

3.5

H/5
H/7

H/4
H/5

7.25

4.5

5.75

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

7

M/8

5.5

H/4

4.5

H/6

6.25

H/6

6.5

April 10, 2006

4-19

FABRICATOR 281

NOTES

4-20

April 10, 2006

SECTION 5:

MAINTENANCE & TROUBLESHOOTING

5.01 Routine Maintenance & Inspection

FABRICATOR 281

The only routine maintenance required for the Fabricator
281 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.

April 10, 2006

5-1

FABRICATOR 281

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

Clean exterior of both units

Gas and
air lines

6 Months

Visually check and use a vacuum to carefully clean the interior

5-2

Art # A-07464

April 10, 2006

FABRICATOR 281

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:

1. Porosity

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

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

FAULT CAUSE REMEDY

a. Ensure that the gas cylinder is not
empty and the flow meter is correctly
adjusted to 25CFM (15 litres per minute)
a. Check for gas leaks between the
reulator/flowmeter connection and in the
gas hose to the power supply
a. The hose from the solenoid valve to
the MIG torch adaptor may be fractured
or disconnected from the MIG torch
adaptor. Return to an Accredited Thermal
Arc Service Agent for repair.
a. Shield the weld area from the wind or
increase the gas flow

a. Clean contaminates off the plate

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

Porosity

1. Gas cylinder
contents and flow meter

2. Gas leaks

3. Internal gas hose in
the power supply

4. Welding in a windy
environment

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

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

7. Maintain the MIG
torch in good working
order.

April 10, 2006

Table 5-1: Porosity Problems

5-3

FABRICATOR 281

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

a. This will cause friction between the wire and the liner thus
reducing wire feedability

WARNING

5-4

Figure 5-2: Trouble Shooting for Inconsistent Wire Feed

April 10, 2006

5.04 Welding Problems

FAULT CAUSE REMEDY

A. Undercut. 1. Welding arc voltage

2. Incorrect torch

3. Excessive heat

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

B. Lack of penetration. 1. Welding current too

2. Joint preparation too

3. Shielding gas

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

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

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

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

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

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

E. Irregular weld

shape.

too high.

angle

input

low

narrow or gap too
tight

incorrect

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

FABRICATOR 281

a. Reduce voltage by reducing the voltage

selection switch position or increase the
wire feed speed.

a. Adjust angle

a. Increase the torch travel speed and/or

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

a. Increase welding current by increasing

wire feed speed and increasing voltage
selection switch position.

a. Increase joint angle or gap

a. Change to a gas which gives higher

penetration

selection switch position.

selection switch or increase wirespeed
control.

selection switch or reduce wirespeed
control.

a. Adjust voltage and current by adjusting

the voltage selection switch and the
wirespeed control.

April 10, 2006

2. Wire is wandering a. Replace contact tip

3. Incorrect shielding
gas

4. Insufficient or
excessive heat input

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

a. Check shielding gas.

a. Adjust the wire speed control or the

voltage selection switch.

Table 5-3a: Welding Problems and Solutions

5-5

FABRICATOR 281

FAULT CAUSE REMEDY

A. Weld cracking 1. Weld beads are too

2. Weld penetration

3. Excessive weld

4. Excessive voltage a. Decrease voltage by reducing the

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

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

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

a. Decrease travel speed

small

a. Reduce current and voltage and increase

narrow and deep

stresses

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

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

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

2. Loose welding cable
connection.

3. Low Primary Voltage a. Contact supply authority

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

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

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

a. Increase weld metal strength or revise

design

voltage selection switch.

to be welded or cool slowly.

Agent to test then replace the faulty
component.

a. Check all welding cable connections.

a. Connect the MIG torch to the positive

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

5-6

Table 5-3b: Welding Problems and Solutions continued

April 10, 2006

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 281

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.

2. Wirefeeder interconnection
is not connected to the
power supply

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. Connect the wirefeeder

interconnection cables to the
power supply.

a. Check for clogged / kinked MIG

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

a. Have an Accredited Thermal Arc

Service Agent investigate the
fault.

a. Clean work clamp area and

ensure good electrical contact.

a. Set the Weld Mode Switch to 2T

(normal operation).

a. Reduce brake tension on spool

hub

a. Clean or replace conduit liner

pressure.

repair.

a. Disconnect gas hose from the

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

J. Gas flow continues after the gun

April 10, 2006

trigger switch has been
released.

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

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

a. Have an Accredited Thermal Arc

Service Agent repair or replace
gas valve.

Table 5-4: Power Supply Problems

5-7

FABRICATOR 281

NOTES

5-8

April 10, 2006

FABRICATOR 281

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES

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

GUNS

Tweco® WeldSkill 15ft 43340P Gun assembly with 15ft cable (supplied with package), 300

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

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

ACCESSORIES

Single Cylinder W4010001 Rack Easy fit, cylinder rack mounts 1 cylinder

Victor Regulator/Flowmeter
Mixed Gases
Victor Regulator/Flowmeter
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 Flowmeter Regulator, Argon-

Argon/CO2 mix gases

0781-2725 Medalist™ 1400 Series, HRF Flowmeter Regulator, CO2 gas

April 10, 2006

A-1

FABRICATOR 281

APPENDIX 2: FEEDROLL KITS

DRIV E ROL L KI T S ( #3759 80- S eries) 2 ROLL

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

Double Smooth

Top

Bottom

Wire Type
Wire Size

.024" / 0.6mm 375980-031 - - - - ­.030", .035" / 0.8, 0.9mm 375980-001 375980-003 375980-010 - - ­.030", .035", .045" / 0.8, 0.9, 1.2mm 375980-028* 375980-029 - - - ­.035" / 0.9mm 375980-040* - - - - 375980-032
.035", .045" 3/64" / 0.9, 1.2, 1.2mm - - 375980-030 - - ­.045" / 1.2mm 375980-002* 375980-004 - 375980-092 375980-022 ­3/64 / 1.2mm - - 375980-011 - - 375980-033
.052" / 1.3mm 375980-090* - 375980-012 - - ­.052", 1/16" / 1.3, 1.6mm - -

Notes: 1) One Kit (# 375980-028) is supplied standard w ith each w ire feeder.

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

3) Narrow 30° "V"

Flat Flat Knurled

Double

Smooth "V"

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

Double

Smooth "V"

"V"

Double Smooth

"V"

Double

Knurled "V" Double Cog Double "U"

Double

Knurled "V" Double Cog Double "U"

375980-017 375980-023

-

A-2

April 10, 2006

FABRICATOR 281

THIS PAGE HAS BEEN LEFT BLANK INTENTIONALLY

April 10, 2006

A-3

FABRICATOR 281

APPENDIX 3: POWER SUPPLY CIRCUIT DIAGRAM

• Note the model and specification number shown on the equipment nameplate

4 BLK

33 BLU

Y2

SPOOL

Solenoid

4A BLK

SW3

FINE

60 RED

40B BLK

37A RED

40A BLK

(2) (1)

(4) (3)

(8) (7)

10B RED

7B BLK

L1
White

L2
Black

Green\Yellow

Input Terminal Block

TS2

26 BLK

NEG

48 ORN

POS

7977947

FABRICATOR 281

Input Terminal Block

1

2

Earth

SW1

5

Fan motor

BLU

TS1

32V Aux

2A

CB1

47 GRY

31 BLK

27 RED

UMBILICAL CABLE

M1

25 BLU

30 BRN

2B PNK

24 WHT

1234567

J1

TB17977948

5432167

1B RED

2A

CB1

3 ORN

6

31 ORN

30 BRN

BLU

30C BRN

31A BLK

SW4 - 32 VAC

1 RED

1A RED

2&2A PNK

31A ORN

1D RED

1C RED

31B ORN

38 WHT

36 GRY

L1

K1\3

[5]

K1\2

[3]

K1\1

L2 T3

[1] [2]

CONTACTOR
24V 50/60Hz

W1

31B BLK

Y1

NORM

Solenoid

37 RED

40 BLK

TEMP

LED1

39 RED

T1

[6]

4C BLK

[4]

4B BLK

24 WHT

32A WHT

38A WHT

X1/5
X1/6
X1/4
X3/6

X3/5

BURNBACK
100K

34 BLU

SW2

COARSE

8 BRN

9 BLK

10 RED

10C RED

11 GRY

12 BRN

16 WHT

17 BLK

13 VIO

7C BLK

Input Terminal block

3

208

4

MIG GUN

K2

SPOOL

R2

35 WHT

(10)

(12)

(6)

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

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

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

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

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

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

8&8A BRN

(9)

9&9A BLK

(11)

10&10A RED

(5)

11&11A GRY

12&12A BRN

16&16A WHT

17&17A BLK

13&13A VIO

14&14A BLU

15&15A ORN

PCB 3

7978034

X3/2

58 BRN

MIG Gun Switch

S2

T2

F2

S3

T3

T4

T5

F3

2 & 2A PNK

TRANS 251US COIL

X3/1

59 GRY

0V

208V

230V

X2/4

54 BLK

F1

T1

S1

X2/5

T1

56 RED

A-4

Art # A-07465

32 WHT
48 ORN

47 GRY

JB/11
JB/9

JB/7

JA/7

JA/6

JA/5

JB/5

JB/10

JB/4

JE/1

JE/2

JA/2

JA/1

April 10, 2006

FABRICATOR 281

S4

F4

SWITCH 2 COARSE

SWITCH

POSITION

1

XX
2
3X

BR1

Bridge Rectifier

543

1
26

X

Varistor

8

X

+

9711

POSITION

10 12

X

C1 - C4

C5

4 x 22,000uF

47 GRY

SWITCH 3 FINE

SWITCH

1
2

X

3X
4X

X

5
6

X

7X
8X

68 ORN

5A

CB2

48 ORN

543

1
26

X
X
X
X

8

L1

Inductor

21 ORN

22 VIO

23 GRY

SHUNT

9711

10 12

XX
X

X
X

PLUGSOCKET

30A BRN

31B BLK

PLUGSOCKET

13
14 18

X

X

X

X

X

X

X

X1/6
X1/5
X1/4

X1/3

X1/1

17

15
16

20

X
X

X
X

+

POSITIVE
OUTPUT
TERMINAL

PCB 4

704883

DIG METER

-

NEGATIVE
OUTPUT
TERMINAL

2119 23

22 24

X
X

XX
X

MIG GUN SWITCH

MIG

K3

SPOOL

SPOOL

MIG GUN

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

43A BLK

-

43 BLK

Wire Feeder Motor

JB/8

55 BLK

M2

POWER SOURCE

WIREFEEDER

57 VIO

45 VIO

46 RED

+

44 BRN

JB/6

WIRESPEED

49 BLU49A BLU

JB/3

R1

50 VIO

JB/1

1K

51 ORN

53 WHT

52A BRN

52 BRN

JB/2

J1

A
B
C
D
E
F
G
H
I
J

18-1SF

MIG Timer PCB
7977965 (PCB2)

Main PCB 7977964 (PCB1)

April 10, 2006

JC

Art # A-07465

A-5

LIMITED WARRANTY

y

r

t

f

f

r

y

y

April 2006

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of a uthorized distributors ("Purchaser") th at its products will be free
of defects in workmanship or material. Should any failure to conform to this warrant
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommenda tions and recognized stan dard industry practic e, and not subject to misu se,
repair, neglect, alteration, or damage, correct such defects by suitable repair o
replacement, at Thermal Arc's sole option, of any components or parts of the produc
determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o
merchantability, fitness for any particular purpose, or other warranty o
quality, whether express, implied, or statutory.

Limitation of liability: Therm al Arc shall not under an y circumstances be lia ble for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of thermal arc 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 Thermal Arc, whethe
arising out of contract, tort, includ ing negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.

No employee, agent, or representative of thermal arc is authorized to change this
warranty in any way or grant any ot her warranty, and ther mal arc shall not be bound b
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.

This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in thermal arc's sole judgment, impaired the
safety or perf ormance of any thermal arc product. Pur chaser’s rig hts under this warrant
are void if the product is sold to purchaser by unaut horized persons.

The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Ther mal Arc delivered the product to the authorized distributor.

Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Th ermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated April 1
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.

st

2006

WARRANTY SCHEDULE

April 2006

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Ex p lorer

Original Main Power Stators and Inductors . ......... ........................................................................ 3 years

Original Main Power R e ctifiers, Control P.C. Boards............................................................. ...... 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine Manufactures Warranty for

Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

GTAW (TIG) & MULTI-PROCESS IN VERTER WELDING EQUIP MENT WARRANTY PERIOD LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

Welding Conso l e , Weld Controller, Wel d Ti mer... .............................. ............................. ............. 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Dragster 85

Original Main Power Magnetics.....................................................................................................1 year 1 year

Original Main Power Rectifiers, Control P.C. Boards....................................................................1 year 1 year

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

160S, 300S, 400S

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards ...................................................................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators .......................................................................................................................1 year 1 year

Plasma Welding Torches.............................................................................................................180 days 180 days

Gas Regulators (Supplied with power sources) .......................................................................... 180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts........ .................. ......... .......... ................ ................ ... ................ .............90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years
3 years

1 year

1 year

1 year

1 year

1 year

1 year

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

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: [phone]
Fax: [phone]

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

World Headquarters

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

Telephone: [phone]
Fascimile: [phone]
Email: [e-mail]

www.thermalarc.com