Thermal Arc fabricator 210 Service Manual
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Thermal Arc fabricator 210 Service Manual

Mig welding machine
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210

Service Manual

fabricator
MiG WeldinG Machine
Art # A-07360
Revision: AI
Operating Features:
®
Issue Date: January 10, 2011
208
V
Manual No.: 0-4879B
60
Hz

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Summary of Contents for Thermal Arc fabricator 210

  • Page 1: Service Manual

    ® fabricator MiG WeldinG Machine Art # A-07360 Service Manual Revision: AI Issue Date: January 10, 2011 Manual No.: 0-4879B Operating Features:...
  • 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 0-4879B 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 Precautions De Securite En Soudage A L’arc ..........1-5 1.04 Dangers relatifs au soudage à l’arc ..............1-5 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 6 TABLE OF CONTENTS SECTION 8: CIRCUIT OPERATION ................8-1 8.01 Circuit Operation Of The Control PCB 7978050 ..........8-1 8.02 Circuit Operation Of The MIG Timer PCB 7977965 ......... 8-2 8.03 Circuit Operation Of The Digital Volt/Amp PCB 704883 ........8-2 8.04 Circuit Operation Of The Spool Gun PCB 7978034 .........

  • 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 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WARNING 5. Use approved ear plugs or ear muffs if noise level is high. WELDING can cause fire or explosion. WARNING Sparks and spatter fly off from the welding arc.
  • 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 WARNING Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. STEAM AND PRESSURIZED HOT COOLANT can burn S a f e t y a n d H e a l t h S t a n d a r d s , O S H A 2 9 C F R 1 9 1 0 , f r o m face, eyes, and skin.

  • Page 11: Precautions De Securite En Soudage A L'arc

    FABRICATOR 210 1.03 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.
  • Page 12 FABRICATOR 210 AVERTISSEMENT AVERTISSEMENT LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES LES VAPEURS ET LES FUMEES SONT DANGERE- YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’ USES POUR LA SANTE. OUIE. Le soudage dégage des vapeurs et des fumées dan- L’arc de soudage produit une chaleur et des rayons...
  • Page 13 FABRICATOR 210 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au 1. Portez un écran facial ou des lunettes protectrices approu- cadmium que si les zones à souder ont été grattées à fond, que vées. Des écrans latéraux sont recommandés.

  • Page 14: Principales Normes De Securite

    FABRICATOR 210 2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur. AVERTISSEMENT 3. N’utilisez que des outils anti-étincelles pour travailler sur un ac- cumulateur. LE CARBURANT PEUR CAUSER UN INCENDIE OU 4. N’utilisez pas une source de courant de soudage pour charger UNE EXPLOSION.

  • Page 15: Introduction

    Include the Service 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 Manual No. 0-4879B...

  • Page 16: Symbol Chart

    FABRICATOR 210 2.03 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 17: General Information

    FABRICATOR 210 2.04 General Information 2.06 Protective Filter Lenses The Fabricator 210 is a semiautomatic Gas Metal Arc Protective filter lenses are provided to reduce the Welder (GMAW-commonly MIG) with an integrated wire intensity of radiation entering the eye thus filtering out feed unit.

  • Page 18: Duty Cycle

    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.
  • Page 19 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 20: Included Items

    FABRICATOR 210 2.10 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 21: Installation

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

  • Page 22: 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 23: 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 24: 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 cyl- inder and connect the gas hose from the rear of NOTE the Power Supply to the Flow Meter outlet.
  • Page 25 FABRICATOR 210 Shielding Regulator and “Cracking” Flow Meter Shielding Shielding Shielding Art # A-07374 Stowage Hook Gas Hose Figure 3-2 Gas Cylinder Installation Manual No. 0-4879B INSTALLATION...
  • Page 26 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 27: Attaching The Gun And Cable Assembly To The Power Source

    Fabricator 210 3.08 Attaching the Gun and Cable 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 available Tweco Weldskill consumable parts.
  • Page 28 Fabricator 210 Front Panel Access Hole Art # 0-7148_AB Trigger Receptacle Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger Loosen Thumbscrew Art # A-07149 Tighten Thumbscrew Figure 3-6: Mount Gun Cable to Adapter Socket INSTALLATION...

  • Page 29: Input And Output Wire Guide Installation

    3.10 Selection and Installation of NOTE Feedrolls Installation of all styles of feed rolls for the Fabricator 210 are identical. A drive roll consists of two different sized grooves. As delivered from the factory the drive roll is installed for .035” / .045” .

  • Page 30: Installing Wire Spool

    FABRICATOR 210 WARNING The welding wire is electrically Hot if it is fed by depressing gun switch. Electrode contact to work piece will cause an arc with gun switch depressed. 3.11 Installing Wire Spool As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool.

  • Page 31: 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 be- fore proceeding. Do not reattach the input power until told to do so in these instructions.

  • Page 32: 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 33: 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. 3-13) 2. Attach the Spool Gun control cable and gas hose to the 10 pin socket and the Spool Gun Gas Outlet on the front of the unit.

  • Page 34: Polarity Changeover

    FABRICATOR 210 3.16 Polarity Changeover WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply be- fore 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 35 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 36 FABRICATOR 210 NOTES: INSTALLATION -1 Manual No. 0-4879B...

  • Page 37: Operation

    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 38 FABRICATOR 210 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 39 Spool Gun Motor (-) connect the two wires from the torch gun to the Spool Gun Motor (+) Fabricator 210. Only pins 1 and 2 are used for this. Spool Gun Switch To make connections, align keyway, insert plug, and Spool Gun Speed C.W.

  • Page 40: Weld Mode Selector

    FABRICATOR 210 4.02 Weld Mode Selector The Weld Mode Selector switch selects the method of welding mode. WELD MODE DWELL WELD (STITCH) (SPOT / STITCH) SPOT STITCH Art # A-07183_AB Figure 4-5: Internal Welding Controls SPOT: 2T (Continuous Welding): This mode of welding is used to weld two plates This mode of welding is used to weld two or more together at a desired location by melting the top &...
  • Page 41 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, (Spot/Stitch) shaft controls the welding or ‘ON’ time the Dwell (Stitch) knob controls the length of the non- and the "DWELL (Stitch)"...

  • Page 42: 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 43: Installing A New Wire Conduit

    FABRICATOR 210 3. When the wire conduit stop meets the end of 4.04 Installing A New Wire Conduit the connector plug and the new raw end extends through the end of the conductor tube on the weld- Removal ing gun, the Allen screw in the connector plug must 1.

  • Page 44: 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 45 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 46: 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 47: Spot Welding Operation

    FABRICATOR 210 4.08 Spot Welding Operation Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. 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. Set the controls as follows for spot welding: Coarse &...

  • Page 48: Gas Selection For Gas Metal Arc Welding

    FABRICATOR 210 4.09 Gas Selection for Gas Metal Arc Welding Base Plate Transfer Suggested Welding Metal Type Filler Metal Comments Thickness Mode Shielding Gas Positions Carbon Greater than 22 ER70S-X Short 100% CO All Position High welding speeds. Good penetration Steel gauge (.030”)
  • Page 49 FABRICATOR 210 THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK Manual No. 0-4879B 4-1 OPERATION...

  • Page 50: 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% 25cfh .035” (0.9mm) .045” (1.2mm) .023” (0.6mm) Solid .030” (0.8mm) 75% Ar 25% (or hard) Steel...
  • Page 51 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...
  • Page 52 FABRICATOR 210 NOTES OPERATION 4-1 Manual No. 0-4879B...

  • Page 53: Maintenance

    SECTION 5: MAINTENANCE 5.01 Routine Maintenance & Inspection The only routine maintenance required for the Fabricator 210 is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. WARNING Disconnect the Fabricator from the Primary Input power supply voltage before disassembling.
  • Page 54 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 55: 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 56: Solving Problems Beyond The Welding Terminals

    MIG torch adaptor may be fractured or 3. Internal gas hose in disconnected from the MIG torch adaptor. the power supply Return to an Accredited Thermal Arc Service Agent for repair. 4. Welding in a windy a. Shield the weld area from the wind or...
  • Page 57 FABRICATOR 210 2. Inconsistent wire feed FAULT CAUSE REMEDY 1. Wire spool brake is a. Feed roll driven by motor in the cabinet will slip. too tight. 2. Wire spool brake is a. Wire spool can unwind and tangle too loose.

  • Page 58: Welding Problems

    FABRICATOR 210 6.03 Welding Problems FAULT CAUSE REMEDY 1. Welding arc voltage a. Reduce voltage by reducing the voltage too high. selection switch position or increase the wire feed speed. A. Undercut 2. Incorrect torch a. Adjust angle angle 3. Excessive heat a.
  • Page 59 6. Weld speed too fast a. Reduce weld speed. 1. Faulty rectifier unit a. Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component. B. Cold weld puddle 2. Loose welding cable a.
  • Page 60 FABRICATOR 210 TROUBLESHOOTING Manual No. 0-4879B...

  • Page 61: Advanced Troubleshooting

    FABRICATOR 210 SECTION 7: ADVANCED TROUBLESHOOTING If the problem cannot be solved by the basic (external) trouble shooting guide, the Power Source covers and/or the Wire Feeder covers will have to be removed. The advanced level of troubleshooting allows the technician with a few common tools to remove the covers and analyze failures.

  • Page 62: Initial Setup Conditions

    FABRICATOR 210 7.02 Initial Setup Conditions 7.03 Primary Power Test Set the power supply controls and connect cables as A. Close primary disconnect device and observe the follows: following: 1. ON/OFF Switch to OFF Position 1. Green Indictor Lamp inside ON/OFF Switch illuminates 2.

  • Page 63: Logic And Control Tests

    FABRICATOR 210 7.04 Logic and Control Tests H. Set BURNBACK CONTROL potentiometer to minimum. Set MODE SELECTOR SWITCH to SPOT position A. Depress Gun Switch and observe the following: 1. Depress Gun Switch 1. Gas flows a. Gas Flows 2. Contactor energizes b.

  • Page 64: Spool Gun Control (J1) Test

    FABRICATOR 210 7.05 Spool Gun Control (J1) Test H. Set WELD (SPOT/STITCH) TIMER CONTROL to Maximum position "4" . Set DWELL (STITCH) TIMER CONTROL to Maximum Position "4" A. Set MIG GUN / SPOOL GUN SELECTOR SWITCH to SPOOL GUN position.

  • Page 65: Output Voltage Test

    FABRICATOR 210 7.06 Output Voltage Test A. Set COARSE VOLTAGE SELECTOR SWITCH to position "1" B. Set FINE VOLTAGE SELECTOR SWITCH to position "1" C. Connect voltmeter probes to + & - WELDING TERMINALS D. Depress Gun Switch and observe voltage E.

  • Page 66: Wire Feed & Weld Test

    FABRICATOR 210 7.07 Wire Feed & Weld Test 7.08 Primary Power Problems A. Close the PRESSURE ADJUST DEVICE. Connect the A. Green Indicator in ON/OFF Switch is not GUN POLARITY LEAD to the POSITIVE WELDING illuminated and fan does turn when ON/OFF TERMINAL (+) switch is in the ON position.

  • Page 67: Logic And Control Problems

    FABRICATOR 210 7.09 Logic and Control Problems 8. Faulty MAIN PCB 1 a. Measure between JB-4 to JB-11 at PCB 1 for A. Nothing happens when gun switch is depressed; approx 30 VAC when gun switch is closed. No gas flow, contactor does not energize, feed If voltage is not present, replace PCB.

  • Page 68: Spool Gun Control (J1) Problem

    FABRICATOR 210 7.10 Spool Gun Control (J1) Problem 3. Defective MIG GUN / SPOOL GUN SELECTOR SWITCH SW2 A. Gas does not flow when jumper is connected a. Check continuity of SW2. between J11 Pins D & G 4. Defective WIRE FEED MOTOR M2 1. Defective gas solenoid SOL2 a.

  • Page 69: Terminal Block Voltage Test

    FABRICATOR 210 7.13 Terminal Block Voltage Test Line 1 208 V 208V Main Transformer 230 V 230V Fan Primary 230V Note: Voltage Tolerance = +/-5V Art # A-07541 Figure 7-1: Input Terminal Block Diagram Manual No. 0-4879B ADVANCED TROUBLESHOOTING...

  • Page 70: Sw3 Coarse And Sw4 Fine Rotary Switch Test

    FABRICATOR 210 7.14 SW3 Coarse and SW4 Fine Rotary Switch Test TOP OF SWITCH TERMINAL # TERMINAL # WIRE # Art # A-09323 BOTTOM OF SWITCH WIRE # TERMINAL # TERMINAL # WIRE # Figure7-2: 4-Position Rotary Switch, Coarse TOP OF SWITCH...
  • Page 71 FABRICATOR 210 VOLTAGE CONTROL SWITCH TEST One at a time remove SW-3 and SW-4 from front panel, disconnect wires, reconnect to panel and check continuity of switch per figure 7-5. Art # A-08571 Set Screw Knob Retainer Locking Collar Rotary Switch...

  • Page 72: Mig Timer Pcb (Pcb2) Test

    FABRICATOR 210 7.15 MIG Timer PCB (PCB2) Test Using the MAIN PCB terminal JB-5 as common measure the voltage at JD-1. This should measure 20VDC when the Gun Switch is closed. Then measure the voltage at JD-2. WELD MODE SELECTOR WITCH...

  • Page 73: Rectifier Assembly Test

    FABRICATOR 210 7.16 Rectifier Assembly Test 1. Disconnect one of the Main Transformer connections from the rectifier assembly. 2. Disconnect and isolate wires from the Negative output of the Rectifier Assembly See Figure 7-3. 3. Disconnect JB connector from MAIN PCB 1.

  • Page 74: Main Transformer Test

    FABRICATOR 210 7.17 Main Transformer Test Disconnect the secondary of the Main Transformer T2 from the rectifier bridge and measure output voltage between the two transformer output connections as follows: COARSE VOLTAGE SELECTION FINE VOLTAGE SELECTOR VOLTAGE AC (approx.) SWITCH SETTING SWITCH SETTING 13.3...

  • Page 75: Circuit Operation

    FABRICATOR 210 SECTION 8: CIRCUIT OPERATION 8.01 Circuit Operation Of The Control PCB 7978050 Power Supply 24VAC is taken from the auxiliary wiring of the fan. This voltage is then connected to the PCB 7978050 where it is half wave rectified and filtered. This voltage is then fed to a zener regulator to provide the +15VDC supply for the...
  • Page 76 FABRICATOR 210 8.02 Circuit Operation Of The MIG Timer CONNECTOR JB PCB 7977965 Terminal JB-1 wiper of wire speed control potentiometer, varies between <2V to approximately 4.7VDC This board is connected by way of a 6-way cable and (pot wiper) does not have any terminals available to measure.

  • Page 77: Circuit Operation Of The Spool Gun Pcb 7978034

    FABRICATOR 210 8.04 Circuit Operation Of The Spool Gun Terminal X2/3 wirespeed relay "normally closed" - connects to PCB 7978034 main wirespeed pot wiper measure 0 to 5VDC (depends on wire speed set- CONNECTOR X1 ting) wrt 7978050 JA/5 in normal setting...
  • Page 78 FABRICATOR 210 CIRCUIT OPERATION Manual No. 0-4879B...

  • Page 79: Parts List

    FABRICATOR 210 SECTION 9: PARTS LIST 9.01 Equipment Identification A l l i d e n t i f i c a t i o n n u m b e r s a s d e s c r i b e d i n t h e Introduction chapter must be furnished when ordering parts or making inquiries.

  • Page 80: External Replacement Parts

    FABRICATOR 210 9.03 External Replacement Parts ITEM PART NUMBER DESCRIPTION REF DESIGNATION QTY 707267PKD Panel,Cover,Fab210/251 705956PKD Handle Bar, Fab210/251/281 705936PKD Handle Mount, Fabricator 830845-001 Switch, 4 Pole, Fab210 SW1 7977884PKD Switch,DPST,Grn,16A,250V SW2 870696PKD Knob,Control,1/4" IDx1.6" 871007PKD Adaptor,Gas Connection,5/8"-18 7977978 Knob,Output Terminal,Fabs 707321PKD Panel,Front,Fab210 705937PKD Molding,Front,Fab210/251/281 871011PKD Bushing Torch 707259CLAPKD Panel,Side LH,Fab210/251 See Note 1 Screw,Hex HD,M5x13mm,Self Tap 7977683PKD...
  • Page 81 FABRICATOR 210 6, 24 25, 26 Art # A-07557 Manual No. 0-4879B PARTS LIST...

  • Page 82: Major Electrical And Mechanical Replacement Parts

    FABRICATOR 210 9.04 Major Electrical and Mechanical Replacement Parts ITEM PART NUMBER DESCRIPTION REF. DES. 8 70996WBLKPKD Bracket, Cable Hanger,Fab210 See Note 1 Screw, Hex HD, M8x12mm,Self Tap 7978035PKD Wheel, 5/8" IDx10" OD 871046PKD Clip, Retaining, 5/8" ID 871046PKD 7 07256WBLKPKD Panel, Base, Fab210/251/281 7977566 Castor, Swivel, 5" Wheel 8 70921WBLKPKD Bracket,Front Wheels 7977974 Terminal, Output, Fabricators 7977889PKD Rectifier, 250A, Fab210 BR1 707315PKD Transformer,Fab210 T2 7977832PKD Switch,Thermostat, 207°C...

  • Page 83: Internal Replacement Parts (1)

    FABRICATOR 210 9.05 Internal Replacement Parts (1) ITEM PART NUMBER DESCRIPTION REF DESIGNATION QTY 7 07216WBLKPKD Panel,Baffle,Fab210/251/281 7978050 PCB, Control, Fabricators PCB1 203627-001 Circuit Breaker, 5A CB2 7978041PKD Circuit Breaker, 2A CB1 401840-004 Cable, Power Cable, Fab190/210 707206PKD Gas Hose,5/8"BSP,Fabricators 7978001PKD Contactor,32A,3 Pole,24VAC W1 7976580 Terminal Block,6 Way,110A 707204PKD Solenoid Assy,Fabricators SOL1 707204PKD Solenoid Assy,Fabricators SOL2 7977666PKD...

  • Page 84: Internal Replacement Parts (2)

    FABRICATOR 210 9.06 Internal Replacement Parts (2) ITEM PART NUMBER DESCRIPTION REF DESIGNATION QTY 871048PKD Hub Spool Assy, Fab210/251 870734 Knob,Control,1/4" IDx.57" 871051PKD Label,Int. Controls,Fab210/251 7977965PKD PCB,Timer,Fab210/251/A2281 PCB2 871010PKD Feed Plate Assy,2 Roll,210/251 707265WBLK Panel,Internal,Fab210/251 203627-001 Circuit Breaker, 5A CB2 7978041PKD Circuit Breaker, 2A CB1 Art # A-07515 PARTS LIST Manual No. 0-4879B...

  • Page 85: Internal Replacement Parts-Spool Assembly

    FABRICATOR 210 9.07 Internal Replacement Parts-Spool Assembly ITEM PART NUMBER DESCRIPTION See Note Screw,Hex HD,3/8"-16x3/4",STZP 170459-001 Plunger, Spring, Nut Hub 405377 Nut, Wire Spool Hub 374552-001 Spacer,Spool Hub 374551 Washer,3/4",Flat,Keyed,Hub 400562-027 Spring,Spool Hub 707251PKD Shaft,Wire Spool Hub 405448 Washer,1-1/64",Flat,Nylon,Hub 405376 Hub, Wire Spool See Note Washer,1/2" IDx1.45" OD,Flat 7 07197WBLKPKD Bracket,Wire Spool,Fab210/251 See Note Nut, Hex, 1/2"-13 Note These parts are available at most hardware stores. Art # A-07517 Manual No.

  • Page 86: Internal Replacement Parts-Wire Feed

    FABRICATOR 210 9.08 Internal Replacement Parts-Wire Feed ITEM PART NUMBER DESCRIPTION Feed rolls and guides may be found in the Feed Roll kit located in the Appendix section of this manual. 870387PKD Gear, Idle Roll, 2R Plate 871010PKD Feed Plate Assy,2 Roll,210/251 870082 Knob,Control,1/4" IDx3/4" 10-6187 Knob, Torch Locking 871173PKD Adapter, Tweco #4,2R Plate See Note Screw, Skt Set, M4-0.7x 4mm 8 71012WBLKPKD Bracket, Feed Plate,Fab210/251 870891PKD Motor,Wire Drive,3.2A 20VDC See Note Screw,PHCR,M6-1x20mm, STZP See Note Screw,PHCR, M4-0.4x10mm, STZP See Note Screw,Hex HD,M8-1.25x16mm,STZP 871174PKD Guide,Outlet,.023-.035,210/251 90935 Guide, Outlet, 1.2 & 1.6MM, 210/251 Note These parts are available at most hardware stores.

  • Page 87: Wire Feeder Replacement Parts

    FABRICATOR 210 9.09 Wire Feeder Replacement Parts Item Qty Ref. Des. Description Part Number Rod, Tension Subassembly, WF 870933PKD Pressure Arm, 2R M/C, WF 870679PKD Gear, Idler Assembly, WF 871001PKD Screw, M4x10 Pan Head, WF See note Screw, M6x1, 30 MM long, WF See note Retainer, Drive Gear,2R Plate 870733PKD Gear, Drive Roll, 2R Plate 870560PKD Screw, M8 X 16 Hex Head, WF See note Screw, M6x1, 35MM Long, WF See note Clamp, MIG gun,2R Plate 171362 Feedplate, 2 Roll , WF 870558PKD Insulator, Motor, 2R Plate 870695-001PKD Pin,#6x50mm,2R & 4R Plate 870509 Note These parts are available at most hardware stores.
  • Page 88 FABRICATOR 210 PARTS LIST 9-10 Manual No. 0-4879B...

  • Page 89: Appendix 1: Optional Accessories And Consumables

    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 90: Appendix 2: Options And Accessories (Con't

    210 APPENDIX 2: OPTIONS AND ACCESSORIES (CON'T) For Tweco/Victor Inquiries and Orders: Call 1-800-318-6819 Consumable Parts Management Group SPOT WELDING NOZZLES TYPE NO. 3 NO.5 500 AMP MINI & NO. 1 NO. 2 250 NO.4 400 150 AMP Flat Arc Spot...

  • Page 91: Appendix 3: Feed Roll Kits

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

  • Page 92: Appendix 4: Power Supply Circuit Diagram

    210 APPENDIX 4: 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 93 210 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 (12) (11) NEGATIVE F3-S4 OUTPUT 12&12A BRN FINE (10) TERMINAL 47 GRY...
  • Page 94 FABRICATOR 210 This Page Intentionally Blank APPENDIX A-1 Manual No. 0-4879B...

  • Page 96: Statement Of Warranty

    STATEMENT OF WARRANTY (as of March 15, 2009) LIMITED WARRANTY: THERMADYNE warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below, THERMADYNE shall, upon written notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and recognized standard industry practice, and not been subject to misuse, repair, neglect, alteration, or accident, cor-...

  • Page 97: Warranty Schedule

    1 year / 1 year Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors See the Engine Engines and Associated Components are NOT Warranted by Thermal Arc®, Manufacturers’ Warranty Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE for Details MANUFACTURERS’...
  • Page 98 U.S. Customer Care: 800-426-1888 / 800-535-0557 Canada Customer Care: 905-827-4515 / 800-588-1714 • International Customer Care: 940-381-1212 / 940-483-8178 www.thermalarc.com • A Global Cutting & Welding Market Leader ™ W O R L D H E A D Q U A R T E R S 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 •...

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