Thermal Arc FABRICATOR 210 Operating Manual
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Thermal Arc FABRICATOR 210 Operating Manual

Mig welding machine
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See also: Service Manual , Owner's Manual
210
Operating Manual
FABRICATOR
MIG WELDING MACHINE
Art # A-07360
Revision No: AC.02
Operating Features:
250
250
®
Issue Date: April 27, 2006
208
208
230
230
V V
V V
Manual No.: 0-4855
60 60
H
Z

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Summary of Contents for Thermal Arc FABRICATOR 210

  • Page 1 ® FABRICATOR MIG WELDING MACHINE Art # A-07360 Operating Manual Revision No: AC.02 Issue Date: April 27, 2006 Manual No.: 0-4855 Operating Features: 60 60...
  • Page 2 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.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Fabricator 210 MIG Welding Machine Instruction Manual Number 0-4855 for: Package System Part Number 100047B-001...

  • Page 4: Table Of Contents

    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 1.03 Precautions De Securite En Soudage à L’arc ..........1-6 1.04 Dangers Relatifs au Soudage à L’arc .............. 1-6 1.05 Principales Normes De Securite ..............
  • Page 5 TABLE OF CONTENTS (continued) TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Power Supply Controls, Indicators and Features ..........4-1 4.02 Weld Mode Selector ..................4-4 4.03 TWECO Weldskill 250 AMP Weld Gun ............4-6 4.04 Installing A New Wire Conduit ................ 4-7 4.05 MIG Gun Maintenance ..................

  • Page 7: Safety Instructions And Warnings

    FABRICATOR 210 SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 8 FABRICATOR 210 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WELDING can cause fire or explosion.
  • Page 9 FABRICATOR 210 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

  • Page 10: Principal Safety Standards

    FABRICATOR 210 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S.

  • Page 11: Symbol Chart

    FABRICATOR 210 1.03 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage...

  • Page 12: Precautions De Securite En Soudage À L'arc

    FABRICATOR 210 1.03 Precautions De Securite En Soudage à L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS.
  • Page 13 FABRICATOR 210 AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons dangereuses à...
  • Page 14 FABRICATOR 210 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 15: Principales Normes De Securite

    FABRICATOR 210 Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

  • Page 16: Graphique De Symbole

    FABRICATOR 210 1.07 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage Torch de Tension dangereuse Fréquence Convertisseur...

  • Page 17: Introduction

    Include the manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature link: http://www.thermalarc.com April 27, 2006...

  • Page 18: General Information

    FABRICATOR 210 2.03 General Information 2.05 Protective Filter Lenses The Fabricator 210 is a semiautomatic Gas Metal Arc Protective filter lenses are provided to reduce the intensity Welder (GMAW-commonly MIG) with an integrated wire of radiation entering the eye thus filtering out harmful feed unit.

  • Page 19: Duty Cycle

    FABRICATOR 210 2.07 Duty Cycle The rated duty cycle of a welding Power Supply is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain the ten minute duty cycle period the following example is used.
  • Page 20 FABRICATOR 210 Fabricator 210 Package System Part Number 100047B-001 Power Source Part Number 707222 Power Source Weight 200lb (91kg) Power Source Dimensions HxWxD 32” x 21” x 36-3/4” (including wheels and cylinder carrier) (813 x 533 x 933mm) Nominal Input Voltage 208V ±10%...

  • Page 21: Included Items

    FABRICATOR 210 2.09 Included Items Fabricator 210 Package System Contents Fabricator 210 Power Source with Integrated Wirefeeder Factory Fitted Wheeling Kit Factory Fitted Single Cylinder Rack Factory Fitted Primary Power Cable 10 AWG, 10ft (3m) with Plug NEMA 6-50P Work Lead 10ft (3m) with clamp...
  • Page 22 FABRICATOR 210 April 27, 2006...

  • Page 23: Installation

    In areas, free from moisture and dust. 3.01 Environment In areas, free from oil, steam and corrosive gases. The Fabricator 210 is NOT designed for use in In areas, not subjected to abnormal vibration or shock. environments with increased hazard of electric shock.

  • Page 24: Input Power Requirements

    3.05 Alternative Mains Supply Voltages WARNING The Fabricator 210 input power supply lead should be replaced with leads as specified in Table 3-2 when the Fabricators input power supply voltage is changed. The Power Supply is suitable for use on the following input power supply voltages:...

  • Page 25: Quick Setup

    Secure by tightening the set screw onto the uninsulated portion of the wires. Secure the first set screw as well. 208V connection 230V connection Art # A-07393 Figure 3-1: Voltage Selections for Fabricator 210 (Wired for 230V) 3.06 Quick Setup NOTE See section 3.15 "Polarity Changeover" for...

  • Page 26: Installation Of Shielding Gas (Gmaw) Process

    FABRICATOR 210 3.07 Installation of Shielding Gas 4. Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts provided. (GMAW) Process 5. Fit the gas Regulator/Flow Meter to the gas cylin- NOTE der and connect the gas hose from the rear of the Power Supply to the Flow Meter outlet.
  • Page 27 FABRICATOR 210 Shielding Regulator and “Cracking” Flow Meter Shielding Shielding Shielding Art # A-07374 Stowage Hook Gas Hose Figure 3-2 Gas Cylinder Installation April 27, 2006...
  • Page 28 FABRICATOR 210 Adjusting Regulator Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-3) The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause turbulence and weld porosity.

  • Page 29: Attaching The Gun And Cable Assembly To The Power Source

    Assembly to the Power Source The Fabricator 210 is supplied with a Tweco Weldskill 250 AMP gas-cooled gun. The Weldskill gun is designed with an ergonomic handle and fewer parts to cause performance problems. The Weldskill gun uses standard readily avail- able Tweco Weldskill consumable parts.
  • Page 30 FABRICATOR 210 Front Panel Access Hole Art # 0-7148 Trigger Receptacle Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger Loosen Thumbscrew Art # A-07149 Tighten Thumbscrew Figure 3-6: Mount Gun Cable to Adapter Socket April 27, 2006...

  • Page 31: Input And Output Wire Guide Installation

    Input Wire Guide Output Wire Guide Installation of all styles of feed rolls for the Figure 3-7: Wire Guide Installation Fabricator 210 are identical. 3.10 Selection and Installation of WARNING Feedrolls A drive roll consists of two different sized grooves. As...

  • Page 32: Installing Wire Spool

    FABRICATOR 210 3.11 Installing Wire Spool As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool. Installation of wire spool 1. Remove Wire Spool Hub Nut by turning counter clock wise (to the left).

  • Page 33: Inserting Wire Into The Feedhead

    FABRICATOR 210 3.12 Inserting Wire into the Feedhead WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions.

  • Page 34: Wirefeeder Drive Roller Pressure Adjustment

    FABRICATOR 210 Wheel Brake Hex Head Bolt Pressure Adjustment Device Art # A-07162 Spool Hub Nut Figure 3-12: Wire Installed 3.13 Wirefeeder Drive Roller Pressure Adjustment The roller on the swing arm applies pressure to the grooved roller via an adjustable tension devise. The Tension Adjuster should be set to a minimum pressure that will provide satisfactory wire feed without slippage.

  • Page 35: Spool Gun Attachment

    FABRICATOR 210 3.15 Spool Gun Attachment A spool gun can readily be used with the Fabricator 210 power supply. 1. Attach appropriate input gas to the Spool Gun input gas connection on the rear of the unit. (Refer to Figure. 3- 2.

  • Page 36: Polarity Changeover

    FABRICATOR 210 3.16 Polarity Changeover WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions. The output terminals are located on the front panel of the welding power source.
  • Page 37 FABRICATOR 210 Work Lead Connected for D.C. Electrode Negative (DCEN) Welding Art # A-07164 Figure 3-15: Polarity Connections for DCEN Changing polarity process. a. Locate the two terminal knobs at the front of the machine. Refer to Figures 3-14 and 3-15.
  • Page 38 FABRICATOR 210 NOTES: 3-16 April 27, 2006...

  • Page 39: Operation

    FABRICATOR 210 SECTION 4: OPERATION WARNING DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding voltage potential. 4.01 Power Supply Controls, Indicators and Features Thermal Overload Indicator Spool / MIG Gun Selector Switch...
  • Page 40 ON / OFF Power Switch The indicator light is provided to indicate when the Fabricator 210 is connected to the Input Power Supply Voltage. With the switch in the Standby position, the auxiliary power and the fan are turned off and the switch is illuminated.
  • Page 41 The Spool Gun Interface 10 pin connector is used to the bottom of the unit are shown without the terminal connect a spool gun to the Fabricator 210 (refer to knob. Both knobs must be firmly secured before Figure 4-4 and Table 4-1).

  • Page 42: Weld Mode Selector

    FABRICATOR 210 4.02 Weld Mode Selector The Weld Mode Selector switch selects the method of welding mode. WELD WELD DWELL DWELL WELD MODE WELD MODE (STITCH) (STITCH) (SPOT / STITCH) (SPOT / STITCH) STITCH STITCH SPOT SPOT 4T 4T 2T 2T...
  • Page 43 FABRICATOR 210 STITCH: Dwell Stitch This mode of welding is used to weld two or more DWELL (STITCH) TIMER CONTROL components together with a stitch weld. The WELD When the Weld Mode control is in the Stitch position, the (Spot/Stitch) shaft controls the welding or ‘ON’ time Dwell (Stitch) knob controls the length of the non-weld and the "DWELL (Stitch)"...

  • Page 44: Tweco Weldskill 250 Amp Weld Gun

    4.03 TWECO Weldskill 250 AMP Weld Gun The TWECO Weldskill 250 AMP gun fitted to the FABRICATOR 210 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.

  • Page 45: Installing A New Wire Conduit

    FABRICATOR 210 4.04 Installing A New Wire Conduit Allen screw in the connector plug must be securely tightened onto the conduit to prevent its backward Removal movement. 1. Be sure the MIG gun cable is arranged in a straight NOTE...

  • Page 46: Mig Gun Maintenance

    Setting of the Power Supply The setting of the Fabricator 210 requires some practice by the operator, the welding Power Supply having two control settings that have to balance. These are the Wire Speed control and the Voltage Control switches. The welding current is determined by the Wire Speed control, the current will increase with increased Wire Speed, resulting in a shorter arc.
  • Page 47 FABRICATOR 210 Distance from the MIG Gun Nozzle to the Work Piece The electrode stick out from the MIG gun nozzle should be between 5/64" (2.0mm) to 13/64" (5.0mm). This distance may vary depending on the type of joint that is being welded.

  • Page 48: Stitch Welding Operation

    FABRICATOR 210 Advantages of MIG welding forehand: - Allows superior visibility of the weld zone - Flatter weld bead - Shallower penetration Vertical Forehand Backhand Art # A-07185 Figure 4-16: MIG Gun Angle 4.07 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.

  • Page 49: Spot Welding Operation

    Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to Figure 4-17 and the Spot Welding Nozzle table below. The Fabricator 210 will operate effectively using .030” (0.8mm) electrode wire when spot welding. Penetration depth is limited when using .024”(0.6mm) electrode wire for spot welding.

  • Page 50: Gas Selection For Gas Metal Arc Welding

    FABRICATOR 210 4.09 Gas Selection for Gas Metal Arc Welding Suggested Base Plate Filler Transfer Welding Metal Type Shielding Comments Thickness Metal Mode Positions Greater than 22 ER70S-X Short High welding speeds. Good Carbon 100% CO gauge (.030”) Circuit Position penetration and pool control.
  • Page 51 FABRICATOR 210 THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK April 27, 2006 4-13...

  • Page 52: Welding Setting Selection Guide

    FABRICATOR 210 4.10 Welding Setting Selection Guide Shielding Gas Wire Size Material Type Wire Type (Diameter) and Flow Rate .023” (0.6mm) .030” (0.8mm) 100% CO 25cfh .035” (0.9mm) .045” (1.2mm) .023” (0.6mm) Solid .030” (0.8mm) 75% Ar 25% (or hard)
  • Page 53 FABRICATOR 210 THICKNESS ** Coarse Voltage Fine Voltage Step Wire Coarse Fine Speed Voltage Voltage 22 ga. (0.8mm) 18 ga. (1.2mm) 16 ga. (1.6mm) 1/8” (3.2mm) 3/16” (5.0mm) 1/4” (6.4mm) 3/8” (9.5mm) 1/2” (12.7mm) 2.25 2.75 4.25 2.25 2.75 4.25 5.25...
  • Page 54 FABRICATOR 210 NOTES 4-16 April 27, 2006...

  • Page 55: Maintenance & Troubleshooting

    FABRICATOR 210 To clean the Power Supply, disconnect it from the mains SECTION 5: supply voltage then open the enclosure and use a vacuum MAINTENANCE & cleaner to remove any accumulated dirt and dust. The Power Supply should also be wiped clean. If necessary,...
  • Page 56 FABRICATOR 210 Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch Visual check of Consumable parts regulator and pressure Weekly Visually inspect the torch Visually inspect the body and consumables cables and leads.

  • Page 57: 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.
  • Page 58 FABRICATOR 210 WARNING Disengage the drive roll when testing for gas flow by ear. 2. Inconsistent wire feed FAULT CAUSE REMEDY 1. Wire spool brake is too a. Feed roller driven by motor in the cabinet will slip. tight. 2. Wire spool brake is too a.

  • Page 59: Welding Problems

    FABRICATOR 210 5.04 Welding Problems FAULT CAUSE REMEDY A. Undercut. 1. Welding arc voltage a. Reduce voltage by reducing the voltage too high. selection switch position or increase the wire feed speed. 2. Incorrect torch a. Adjust angle angle 3. Excessive heat a.
  • Page 60 FABRICATOR 210 FAULT CAUSE REMEDY A. Weld cracking 1. Weld beads are too a. Decrease travel speed small 2. Weld penetration a. Reduce current and voltage and increase narrow and deep MIG torch travel speed or select a lower penetration shielding gas.

  • Page 61: Power Supply Problems

    B. Mains supply voltage is ON. 1. Primary fuse is blown. a. Replace primary fuse. Indicator light is not lit and 2. Broken connection in a. Have an Accredited Thermal Arc welding arc can not be primary circuit. Service Agent check primary established.
  • Page 62 FABRICATOR 210 NOTES April 27, 2006...

  • Page 63: Appendix 1: Optional Accessories And Consumables

    FABRICATOR 210 APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES For Tweco/Victor Inquiries and Orders: Call 1-800-318-6819 Consumable Parts Management Group GUNS Tweco® WeldSkill 12ft 20584 Gun assembly with 15ft cable (supplied with package), 250 Amp @ 30% Tweco® No. 2 12ft...

  • Page 64: Appendix 2: Power Supply Circuit Diagram

    FABRICATOR 210 APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM 1E BRN Input Terminal Block 1F BRN White 1B BRN 208V 14&14A BLK 1 BRN K1\3 1D BRN 1H BRN K1\2 Black 230V 1C BRN 1G BRN COARSE K1\1 1A BRN Earth...
  • Page 65 FABRICATOR 210 Bridge Rectifier POSITIVE OUTPUT Inductor TERMINAL 8&8A BRN (12) (11) + C1 Varistor 9&9A BLK (10) F1-S2 COARSE (14) (13) (16) (15) 10&10A RED 11&11A GRY NEGATIVE (12) (11) F3-S4 OUTPUT 12&12A BRN FINE (10) TERMINAL 47 GRY...

  • Page 66: Appendix 3: Feedroll Kits

    FABRICATOR 210 APPENDIX 3: FEEDROLL KITS DRIVE ROLL KITS (#375980-Series) 2 ROLL Style 1 Style 2 Style 3 Style 4 Style 5 Style 6 Double Smooth Double Flat Flat Knurled Double Cog Double "U" "V" Knurled "V" Double Double Double Smooth...

  • Page 68: Limited Warranty

    No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt.

  • Page 69: Warranty Schedule

    WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS ARRANTY ERIOD ABOR Scout, Raider, Explorer Original Main Power Stators and Inductors .................. 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards ..............3 years...

  • Page 71: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan West Malaysia 800-426-1888 Telephone: 603+ 6092 2988 Fax: 800-535-0557...
  • Page 72 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...

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