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Related Manuals for Thermal Arc Fabricator 250C III
Summary of Contents for Thermal Arc Fabricator 250C III
- Page 1 FABRICATOR MIG Power Supplies 250C III 320C III 320S III C/W VFE 4C III 400S III C/W VFE 4C III 500S III C/W VFE 4C HS III Operation Manual AW-02 Issue Date: July 13th, 2012 Version No: Operating Features...
- Page 2 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.
- Page 3 Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Fabricator 250C III MIG Welding Machine, Part Number - FAB250C Fabricator 320C III MIG Welding Machine, Part Number - FAB320C Fabricator 320S III MIG Welding Machine, Part Number - FAB320S...
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION 1: SAFETY PRECAUTIONS 1.01 Safety Instructions and Warning 1.02 Declaration of Conformity 1.03 Statement of Warranty 1.04 Symbol Legend SECTION 2: INTRODUCTION AND DESCRIPTION 2.01 How to use this Manual 2.02 Equipment Identification 2.03 Receipt of Equipment 2.04 Description 2.05 Safety 2.06 Transporting Methods... - Page 5 SECTION 7: OPERATION 7.01 Setting welding current and voltage 7.02 Welding modes 7.03 Secondary parameters 7.04 Two stroke 7.05 Four stroke 7.06 Spot and stitch welding SECTION 8: BASIC WELDING TECHNIQUE 8.01 Setting of the Power Source 8.02 Position of MIG Torch 8.03 Distance of the MIG Torch Nozzle to the Work Piece 8.04 Travel Speed 8.05 Electrode Wire Size Selection...
- Page 6 Figures Description Figure No Description Figure 1 Colour Picture of Fabricator Family Front page Figure 2 Symbol Legend Figure 3 Electrical Input Connections Figure 4 Fabricator Layout 250III / 320 Compact Figure 5 Fabricator Layout 320III / 400III Seperate Figure 6 Fabricator Layout 500III Seperate Figure 7 Basic Control Panel - Overview...
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Page 7: Safety Precautions
SECTION 1: Safety Instructions and Warnings WARNING ARC WELDING can be hazardous. Protect yourself and others from possible serious injury or death. Keep children away. Pace maker 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 FUMES AND GASES can be hazardous to your health. 5. Work in a confined space only if it is well ventilated, or while Welding produces fumes and gases. Breathing wearing an air-supplied respirator. Shielding gases used for these fumes and gases can be hazardous to your welding can displace air causing injury or death.
- Page 9 ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 3. Allow engine to cool before fuelling. If possible, check and add fuel to cold engine before beginning job. 1. Stop engine before checking or adding fuel. 4. Do not overfill tank - allow room for fuel to expand away from any 2.
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Page 11: Declaration Of Conformity
England PR6 7BX Description of equipment: Welding Equipment (GMAW) Thermal Arc Fabricator 250C III, 320CIII, 320S III, 400S III & 500S III and associated accessories. The equipment described in this manual conforms to all applicable aspects and regulations of the “Low Voltage Legislation“ (Low Voltage Directive (LVD) 2006/95/EC ) and to the National legislation for the enforcement of this Directive. -
Page 12: Statement Of Warranty
The warranty period begins on the date of sale to the end user. Thermal Arc Fabricator 250C III, 320C III, 320S III, 400S III & 500S III Component Warranty Period... -
Page 13: Symbol Legend
1.04 SYMBOL LEGEND Figure 2. -
Page 14: Section 2: Introduction And Description
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 given below: Thermadyne Customer Service... -
Page 15: Description
10m away. The Thermal Arc Fabricator range are extremely versatile all round performers that offer excellent performance on mild steel, stainless steel, aluminium, silicon bronze and some hard facing wires with Argon based shielding gases. -
Page 16: User Responsibility
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. -
Page 17: Section 3: Installation Recommendations
SECTION 3: INSTALLATION RECOMMENDATIONS 3.01 Environment The Fabricator 250C III, 320C/S III, 400S III & Fabricator 500S III are NOT designed for use in environments with increased hazard of electric shock. Examples of environments with increased hazard of electric shock are:- •... -
Page 18: Electrical Input Requirements
3.04 Electrical Input Requirements Operate the welding power source only from a three-phase 50/60 Hz, AC power supply. The input voltage must match the electrical input voltage shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required. -
Page 19: Input Power
Primary Current Max Current & Lead Size (Factory Circuit Size Duty Cycle Fitted) (Vin/Amps) Fabricator 250C III 4 core 2.5mm sq 400 / 14A 250 @ 30% Fabricator 320C III 4 core 2.5mm sq 400 / 17.5A 340 @ 25% Fabricator 320S III 4 core 2.5mm sq... -
Page 20: Specifications
Dimensions H x W x D (fully assembled) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. - Page 21 Dimensions H x W x D (fully assembled) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice.
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Page 22: Section 4: Operator Controls
SECTION 4: OPERATOR CONTROLS 4.01 Fabricator Layout – 250C III & 320C III Compact Unit Figure 4. Power Source Front Power Source Back Power Source WFU Side... - Page 23 ‘ON’ position. This enables the Power Supply. A3. Voltage Control Switch The Voltage Control switch increases the voltage as it is rotated in the clockwise direction. (10 position switch on the Fabricator 250C III and a 12 position switch on the 320C III) A4.
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Page 24: Fabricator Layout 320S & 400S
4.02 Fabricator Layout – 320S III & 400S III C/W VFE 4C III Wire Feed Unit Figure 5. Power Source Front Power Source Back Power Source Connection Side Power Source WFU Side... - Page 25 A1. ON/OFF Switch This switch connects the Primary supply voltage to the power supply when in the ‘ON’ position. This enables the Power Supply. A2. Course Voltage Control Switch This Voltage Control switch increases the voltage as it is rotated in the clockwise direction. (2 position switch on the Fabricator 400S III Only) A3.
- Page 26 A15. Wirefeeder Control Socket outlet This Female 7 pin receptacle is used to connect a Wirefeeder to the welding power Source circuitry: 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 rewire a plug.
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Page 28: Fabricator Layout 500S
4.03 Fabricator Layout – 500S III C/W VFE 4C III Wire Feed Unit (Inc Cooler Option) Figure 6. Power Source Front Power Source Back Power Source Connection Side Power Source WFU Side... - Page 29 A1. ON/OFF Switch This switch connects the Primary supply voltage to the power supply when in the ‘ON’ position. This enables the Power Supply. A2. Course Voltage Control Switch A 3 position Voltage Control switch, which increases the voltage as it is rotated in the clockwise direction. (please ensure this switch is not turned when the machine is under load) A3.
- Page 30 A16. Wirefeeder Control Socket inlet This male 7 pin receptacle is used to connect a Wirefeeder from the welding power source circuitly. A17. Gas inlet The Gas Inlet connections, a quick fit connector supplied via the gas hose from the interconnecting lead. A18.
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Page 31: Understanding And Setting Up For Welding
SECTION 5: UNDERSTANDING & SETTING UP FOR WELDING 5.01 POWER SOURCE FEATURES Description FEATURES Digital Control panel All welding parameters are adjustable Touch Panel Switches Touch switches eliminates mechanical damage Control Knob Encoder For the selected parameter, rotating the knob clockwise or anticlockwise increases or decreases the parameter. -
Page 32: Basic Control Panel - Overview
5.02 BASIC CONTROL PANEL - OVERVIEW Figure 7. Basic control panel – 250C III Compact Only Machine On/Off Switch Voltage Control Switch (250II = 10 Position switch) Voltage Control Switch (320III = 12 Position switch) Wire Speed Dial Spot Time Dial... -
Page 33: Digital Control Panel - Overview
5.03 DIGITAL CONTROL PANEL – OVERVIEW Figure 8. Digital control panel – Compact Model shown above Please Note: On the 320S III, 400S III & 500S III Separate the Digital Control PCB is fitted on the separate Wire Feed Unit. Control PCB, C/W Digital Display and Encoder Machine ON / OFF Switch Voltage Control Switch –... -
Page 34: Digital Control Panel Description
5.04 DIGITAL CONTROL PANEL DESCRIPTION Figure 9. Fig. 1 – Digital Control Panel Pos. Symbol Description Button Wire inch Default RESET (together with button X2) Button Gas test Default RESET (together with button X1) Button Switches between 2T or 4T, ... - Page 35 Left Display - X8 shows: Amperage (real or required) Wire speed Secondary parameters: ISP – initial speed (soft start) [%] PrG – Pre gas time [s] PoG – Post gas time [s] – Burn back time [s] SPo –...
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Page 36: Wire Feeder Motor & Feedroll Assembly
5.05 WIRE FEEDER MOTOR & FEEDROLL ASSEMBLY Figure 10. Wire feed Assembles 4 rolls & 2 rolls Pos. Description Fixing shaft Pressure arm Liner- Feeder EURO connector Roll, Plastic cup... -
Page 37: Wire Feed Rollers
5.06 WIRE FEED ROLLERS (250C, 320C, 320S, 400S & 500S) Figure 11. 2 Roll (30mm) 4 Roll (30mm) 4 Roll (40mm) 250C 320C, 320S & 400S 500S a = 22mm a = 22mm a = 32mm B = 30mm B = 30mm B = 40mm Grove Type Wire Diameter... -
Page 38: Section 6: Getting Started
SECTION 6: GETTING STARTED 6.01 Torch Connection Fit the MIG Torch (2) to the Euro adaptor (1) by pushing the torch connector into the brass torch adaptor and screwing the plastic torch nut clockwise to secure the torch to the torch adaptor. Remove the contact tip from the torch handset. If a water cooled sys tem is in us e then c onnect the coolant c onnections (5) of the torch with the sockets (3) and (4). -
Page 39: How To Connect To The Mains
Figure 15. Connect the Work clamp tightly to the welding bench or to the work piece. WARNING Do not place the Work clamp on the welding machine or gas cylinder as welding current may conducted via the mains earth and could cause the primary power cable to burn out. - Page 40 Open the pressure lever (12) and thread the wire through the inlet guide (14) past the rollers and then through the outlet guide (15). Put the pressure roll down ensuring that the teeth of the gears fit together and fix by setting the lever (12) into vertical position.
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Page 41: How To Connect The Gas Cylinder
6.07 How to connect the gas cylinder If the Power Source Wheel Kit is fitted, position a gas cylinder on the rear tray and lock secruely to the Power Source cylinder bracket with the chains 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. -
Page 42: Section 7: Operation
SECTION 7: OPERATION 7.01 Setting welding current and voltage When the wire had been installed and gas had been set it is possible to start welding. The appliance must be plugged into the mains, the main switch (Fig. 4, Page 16) in the "I"... -
Page 43: Two Stroke
7.04 Two stroke Press the button 3 (2T/4T) and select the LED 4 . Welding procedure starts by pressing the button in the torch handle. It is necessary to keep the torch button pressed all the time during welding. The welding stops by releasing the torch button. Figure 20. -
Page 44: Spot And Stitch Welding
7.06 Spot and stitch welding Keep pressing the button 3 for at least (3s) (2T/4T) If led LED 12 continuously lights the spot mode has been selected. If led 12 flashes the interval mode has been selected. You can have spot or interval welding both in stroke and in 4 stroke mode (by means of short pressing the button 3 - LEDs 4 and 11... -
Page 45: Section 8: Basic Welding Technique
SECTION 8: BASIC WELDING TECHNIQUE 8.01 Setting of the Fabricator The Fabricators Power Source has two control settings that have to balance. These are the Wirespeed control and the Voltage Control switches. The welding current is determined by the Wirespeed control, the current will increase with increased Wirespeed, resulting in a shorter arc. -
Page 46: Stitch Welding Operation
c) Capacity of the wire feed unit and Power Source, d) The amount of penetration required, e) The deposition rate required, f) The bead profile desired, g) The position of welding and h) Cost of the electrode wire. Weld metal deposition rate is proportional to current density. Current density is defined as the current per cross sectional area of the electrode wire and is normally expressed as amps per mm2. -
Page 47: Routine Maintenance & Inspection
SECTION 9: ROUTINE MAINTENANCE & INSPECTION The only routine maintenance required for the Fabricator range of machines is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. WARNING Disconnect the FABRICATOR from the Mains supply voltage before disassembling. Special maintenance is not necessary for the control unit parts in the Power Source and Wirefeeder. -
Page 48: Section 10: Basic Troubleshooting
Wirefeeder. If major components are faulty, then the Power Source / Wirefeeder should be returned to your local THERMAL ARC Distributor for repair. Solving Problems beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. -
Page 49: Inconsistent Wire Feed
10.02 Inconsistent wire feed Wire feeding problems can be reduced by checking the following points: Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip. Wire spool brake is too loose Wire spool can unwind and tangle. Worn or incorrect feed roller size Use 'U' groove drive feed roller matched to the aluminium wire size you are... -
Page 50: Welding Problems
10.03 Welding Problems FAULT CAUSE REMEDY Undercut. A. Welding arc voltage A. Reduce voltage by reducing too high. the voltage selection switches B. Incorrect torch angle position or increase the wire C. Excessive heat input feed speed. B. Adjust angle C. -
Page 51: Power Source Problems
Cold weld puddle. A. Faulty rectifier unit A. Have an Accredited B. Loose welding cable THERMAL ARC Service Agent connection. to test then replace the faulty C. Low Primary Voltage component. B. Check all welding cable connections. - Page 52 B. Faulty control PCB B. Have an Accredited THERMAL ARC Service Agent investigate the fault. 6 Wire feeds when the Poor or no work lead Clean work clamp area and torch trigger switch is connection.
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Page 54: Section 11: Spare Parts
SECTION 11: SPARE PARTS 11.01 Parts Description Fabricator 250C & 320C Figure 26. -
Page 55: Spare Part Numbers Fabricator 250C & 320C
11.01 Spare Part Numbers Fabricator 250C & 320C Pos Item No Title Quantity Thermal Arc 250C III & 320C III 1 FABV20214‐5A Facia panel 1 2 FABV0316 Corner Right 1 3 FABV0317 Corner Left 1 4 FABV10014‐2 Corner support right galvanized 1 5 FABV10015‐2 Corner support left galvanized 1 6 FABV20219‐2 PCB cover galvanized 1 7 ... - Page 56 Thermal Arc 250C III & 320C III (Continued) 37 FAB2164 Knob + Red Cap 1 38 FAB2446 Rear wheel 2 39 FAB3253‐1 Front Wheel 2 40 FAb2681 Door Lock 2 41 FAB4121 Door Hinge 2 42 FAB1812 Gas heater connector 1 43 FAB2917 Shunt 400A 60mV 2 44 FAB4316 Wire Feed Motor C/W Gearbox 2 roll 250C 1 44 FAB4322‐1 Wire Feed Motor C/W Gearbox 4 roll 320C 1 ...
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Page 57: Parts Description Fabricator 320S & 400S
11.02 Parts Description Fabricator 320S & 400S Figure 27. -
Page 58: Spare Part Numbers Fabricator 320S & 400S
11.02 Spare Part Numbers Fabricator 320S & 400S Pos Item No Title Quantity Thermal Arc 320S III & 400S III 1 FABV20214‐5A Facia panel matt 1 2 FABV0316 Corner Right 1 3 FABV0317 Corner Left 1 4 FABV10014‐2 Corner support right galvanized 1 5 FABV10015‐2 Corner support left galvanized 1 6 FABV20219‐2 PCB cover galvanized 1 7 ... - Page 59 Thermal Arc 320S III & 400S III (Continued) 48 FABT40WSK.TERP Transformer 400S + Switch + TERMINAL 49 FAB1538‐1 Rectifier 320S & 400S 1 50 FABV20009‐1 Holder of choke galvanized 2 51 FABV20215‐3 Support of facia panel galvanized 1 52 FABV20010‐3 Holder of rectifier 320S & 400S galvanized 1 53 FABVS040372 Clamp for the cable Bundle 1 55 FAB3467B Wire Feed holder 1 56 FABAO‐20610 Quick Connector 35‐70 Panel Socket 1 57 FABVM0344 Bundle clamp 1 ...
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Page 60: Vfe 4C Wfu Description + Spare Part Numbers
11.03 VFE 4C III Wire Feed Unit Parts Description + Spare Part Numbers Figure 28. Pos Item No Title Quantity VF E4C III Wire feed unit FABV10001‐5 Bottom galvanized WFU 1 1 FABV10019‐2 PCB cover galvanized WFU 1 2 FABV10004‐6 Barrier of connectors galvanized 1 3 FABV10002‐3 Cover upper PS matt 1 4 FABV10006‐4 Cover left Gloss ... - Page 61 VF E4C III Wire feed unit (Continued) FAB2927 Front Wheel 2 15 FAB2928 Rear Wheel 2 16 FAB4220 Handle 1 17 18 FAB4322‐1 Feed Motor / Gearbox (VF E4C III Fab 320S/400S) 1 FAB302P010000 Gas hose 0.75 19 FABV9040157.Y Cables PS4W mont. cas. 0.34m 70mm DIGITAL 1 20 FAB2557 Solenoid Valve 24V 50Hz AC 1 21 FAB7.686.300 Door Lock 2 22 FAB4121 Door Hinge 2 23 FABVM0112.YQ ...
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Page 62: Parts Description Fabricator 500S
11.04 Parts Description Fabricator 500S Figure 29. -
Page 63: Spare Part Numbers Fabricator 500S
11.04 Spare Part Numbers Fabricator 500S Pos Item No Title Quantity Thermal Arc 500S III 1 FABVA0237‐6A Facia panel matt 1 2 FABV0316 Corner Right 1 3 FABV0317 Corner Left 1 4 FABV10014‐4 Corner support right galvanized 1 5 FABV10015‐4 Corner support left galvanized 1 6 FABV10219‐4 PCB cover galvanized 1 7 FABVA0201‐6 Bottom galvanized ... - Page 64 Thermal Arc 500S III (Continued) 61 FABVM0364 Bundle Generator 1 62 FAB2073 LED Sleeve 10mm RTF‐1090 1 63 FAB4298 Packing HP208/6,35‐38mm 1 66 FAB1343 Knob arrow OM‐R/5 Red 1 67 FAB1141 Knob arrow OS‐C/6 Black 2 68 FAB4236 Filter FC 61113 + R 1 69 FAB3252 Filter FZ 730 43 3 71 FABVM0370 Cables 500S 1 76 FABVM0104 Mains Cable 4x4mm 1 ...
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Page 65: Vfe 4C Hs Wfu Description + Spare Part Numbers
11.05 VFE 4C HS III Wire Feed Unit Parts Description + Spare Part Numbers Figure 30. Pos Item No Title Quantity VF E4C III Wire feed unit FABV10001‐5 Bottom galvanized WFU 1 1 FABV10019‐2 PCB cover galvanized WFU 1 2 FABV10004‐6 Barrier of connectors galvanized 1 3 FABV10002‐3 Cover upper PS matt 1 4 FABV10006‐4 ... - Page 66 VF E4C III Wire feed unit (Continued) FABV0318 Feeder Cover Plastic 1 14 FAB2927 Front Wheel 2 15 FAB2928 Rear Wheel 2 16 FAB4220 Handle 1 17 18 FAB4322‐1 Feed Motor / Gearbox (VF E4C III Fab 320S/400S) 1 FAB302P010000 Gas hose 0.75 19 FABV9040157.Y Cables PS4W mont. cas. 0.34m 70mm DIGITAL 1 20 FAB2557 Solenoid Valve 24V 50Hz AC 1 21 FAB7.686.300 Door Lock 2 22 FAB4121 ...
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Page 67: Water Cooler Parts Description + Spare Parts List
11.06 Water Cooler Parts Description + Spare Part Numbers Figure 31. Pos Item No Title Quantity Cooler for 500S III 1 FABV10241‐6 Body Panel galvanized 1 2 FABV10503‐4 Holder of ventilator galvanized 1 3 FABV10243‐7A Cover matt 1 4 FABV10245‐6A Cover upper matt 1 5 FAB2457 Pump MTP‐600 with plastic cover 1 6 FABVM0373 ... -
Page 68: Section 12: Machine Schematics
SECTION 12: MACHINE SCHEMATICS 12.01 Power Source Schematic Fabricator 250C III & 320C III Figure 32. -
Page 69: Schematic For The Fab 320S & 400S
12.02 Power Source Schematic Fabricator 320S III & 400S III Figure 33. -
Page 70: Schematic For The Fab 500S
12.03 Power Source Schematic Fabricator 500S III Figure 34. -
Page 71: Wire Feed Unit Schematic
12.04 Wire Feed Unit Schematic (VFE 4C III & VFE 4C HS III WFU) Figure 35. -
Page 72: Section 13: Optional Accessories
SECTION 13: OPTIONAL ACCESSORIES Part No Description A.028E Water Cooler c/w fittings (500S Only) VM0391E 1.6M Interconnecting Cable Assy (air Cooled) 320S VM0393E 5M Interconnecting Cable Assy (air Cooled) 320S VM0394E 10M Interconnecting Cable Assy (air Cooled) 320S VM0263E 1.6M Interconnecting Cable Assy (air Cooled) 400S/500S VM0266E 5M Interconnecting Cable Assy (air Cooled) 400S/500S VM0267E... - Page 73 This page has been left blank intentionally...
- Page 74 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 FAX: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...
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