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T.L. FAHRINGER FW-200 HPA Owner's Manual

Flash-butt welder
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FW-200 HPA
FLASH-BUTT WELDER
OWNER'S MANUAL
T. L. Fahringer Co.
P.O. Box 1412
Brandon, FL 33509-1412
Toll Free: 800-237-3829
Local: 813-681-2373
Web: www.fahringer.com

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Summary of Contents for T.L. FAHRINGER FW-200 HPA

  • Page 1 FW-200 HPA FLASH-BUTT WELDER OWNER’S MANUAL T. L. Fahringer Co. P.O. Box 1412 Brandon, FL 33509-1412 Toll Free: 800-237-3829 Local: 813-681-2373 Web: www.fahringer.com...
  • Page 2 IMPORTANT: PLEASE READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE OPERATING THIS MACHINE. PERFORMING IMPROPER PROCEDURES MAY VOID THE WARRANTY ON THIS MACHINE AND COULD CAUSE SERIOUS INJURY TO THE OPERATOR.

  • Page 3: Table Of Contents

    Section 3: Maintenance Care and Maintenance of Welding Jaws ……………………………... 3-1 Reconditioning Welding Jaws ………………………………………... 3-1 Periodic Maintenance ………………………………………………… 3-1 Removing Clamps, Lower Jaws & Guide Rails ……………………… 3-3 Installing Clamps, Lower Jaws & Guide Rails ………………………. 3-4 FW-200 HPA, Rev. 4...

  • Page 4: Section 1: Installation

    Section 1 INSTALLATION...

  • Page 5: Items Required For Installation

    SILICONE FREE Welding anti-spatter spray (Recommend: WELD AID PRODUCTS Nozzle-Kleen #2) Cloth rags Fine Grit surfacing stone, 2” wide x 6” long (Recommend: NORTON #IB6 Sharpening Stone) Dial or digital calipers, 4” - 6” Compressed air hose with nozzle FW-200 HPA, Rev. 4...

  • Page 6: Installation Procedures

    18) Plug the water pump into the auto-switching outlet on the back of the welder, or other power source, and ensure the water cooling system is operating. 19) Before running the welder make sure to replace all covers. NEVER WELD WITHOUT ALL COVERS IN PLACE. FW-200 HPA, Rev. 4...

  • Page 7: Section 2: Operating Instructions

    Section 2 OPERATING INSTRUCTIONS...
  • Page 8 FW-200 HPA, Rev. 4...

  • Page 9: Explanations Of Controls

    5 = 5.4 volts 6 = 6.0 volts S2 - LINE VOLTAGE SWITCH Compensates for high or low power voltage. Select the setting that is closest to, but not below, the incoming voltage level powering the machine. FW-200 HPA, Rev. 4...
  • Page 10 Toggle clamps Up and DOWN. JAW GAP ADJUSTMENT SCREW Adjusts the distance between the jaws. CW - Adjusts the jaw gap larger CCW - Adjusts the jaw gap smaller JAW GAP DISTANCE INDICATOR Indicates the current distance between the jaws. FW-200 HPA, Rev. 4...
  • Page 11 Guides to align the blade horizontally. Guides to align either the back edge or tooth edge of the blade are available. Positions 1-4 on the tooth edge guides are for smaller to larger tooth sizes, respectively. FW-200 HPA, Rev. 4...

  • Page 12: General Setup

    This procedure only needs to be performed if the cam does not stop at its correct positions. THIS PROCEDURE SHOULD ONLY BE PERFORMED WITH THE ASSISTANCE OF AN AUTHORIZED T. L. FAHRINGER CO. SERVICE TECHNICIAN! FW-200 HPA, Rev. 4...

  • Page 13: Timing Calibration

    If the anneal pattern is uneven, adjust both clamps evenly to compensate. Be sure to adjust both clamps by the same amount. If the clamps get out of sync they will need to be reset with a carbon paper check. FW-200 HPA, Rev. 4...
  • Page 14 12) The straightedge should be touching all four guides. (Proceed to step 15 if the inner guides are aligned.) 13) Perform steps 5-8. 14) Repeat step 13, if necessary, for the remaining inner guide. Unclamp and remove the straightedge from the jaws. FW-200 HPA, Rev. 4...

  • Page 15: Forge Pressure Switch Calibration

    10) Make sure the disc’s set screw is tight. If it is not, tighten it, and then recheck the calibration from step 4. 11) Replace the top cover on the machine. 12) Replace the left cover on the front of machine. 13) Exit out of SETUP mode. 14) The forge pressure switch is now calibrated. FW-200 HPA, Rev. 4...

  • Page 16: Weld Setup

    Press the WELD BUTTON to start the weld cycle. Both clamps must be DOWN. Unclamp & remove the blade when the weld cycle is finished. The weld cycle is finished when the green weld light goes out and the yellow advance light comes on. FW-200 HPA, Rev. 4...

  • Page 17: Anneal Setup

    The anneal cycle is finished when ANNEAL TIMER 2 reaches zero and the yellow advance light comes on. NOTE: The anneal cycle can be stopped early by pressing the ANNEAL BUTTON while the anneal cycle is running. 2-10 FW-200 HPA, Rev. 4...

  • Page 18: Obtaining New Anneal Settings

    Both clamps must be DOWN. 10) Unclamp and remove the blade when the cycle is finished. a) Automatic cycle is finished when both clamps release and the machine moves back to the weld start position after annealing. 2-11 FW-200 HPA, Rev. 4...
  • Page 19 FW-200 HPA SETTINGS ANNEAL SETTINGS WELD SETTINGS RAMP STAGE SOAK STAGE FORGE FOLLOW BLADE JAW GAP TIMING WELD FLASHING DELAY TIME ANNEAL ANNEAL ANNEAL ANNEAL PRESSURE PRESSURE SIZE/TYPE (in) (in) VOLTAGE SPEED (sec) HEAT 1 TIME 1 HEAT 2 TIME 2...
  • Page 20 FW-200 HPA SETTINGS ANNEAL SETTINGS WELD SETTINGS RAMP STAGE SOAK STAGE FORGE FOLLOW BLADE JAW GAP TIMING WELD FLASHING DELAY TIME ANNEAL ANNEAL ANNEAL ANNEAL PRESSURE PRESSURE SIZE/TYPE (in) (in) VOLTAGE SPEED (sec) HEAT 1 TIME 1 HEAT 2 TIME 2...

  • Page 21: Section 3: Maintenance

    Section 3 MAINTENANCE...

  • Page 22: Care And Maintenance Of Welding Jaws

    • Clean and inspect all parts for wear and damage. • Clean and inspect the flash guard for any cracks or holes and replace if necessary. • Inspect lower jaws for uneven wear, pitting and cracking. FW-200 HPA, Rev. 4...
  • Page 23 Check the timing calibration (see GENERAL SETUP). • Check the jaw gap indicator calibration (see GENERAL SETUP). • Check the water-cooling pump for proper operation. Check water lines and fittings for leaks. Fill the water tank as needed. FW-200 HPA, Rev. 4...
  • Page 24 REMOVING THE GUIDE MOUNT RAILS • Remove the two guide rail mount screws. (See Diagram) • The inner guide mount may need to be removed if it is in the way of the guide rail mount screws. FW-200 HPA, Rev. 4...
  • Page 25 6) Check the jaw gap indicator calibration and clamping pressure distribution as described in the GENERAL SETUP section. FW-200 HPA, Rev. 4...
  • Page 26 WARRANTY Your New FAHRINGER model FW-200 HPA welder is guaranteed against defects in material and workmanship for a period of one full year from the date of shipment. Rrepairs, rebuilds and upgrades are guaranteed for 6 months from the date of shipment. This warranty covers all parts and labor needed should repair become necessary due to such defects.

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