Thermal Arc 281 FABRICATOR Service Manual
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Thermal Arc 281 FABRICATOR Service Manual

Thermal Arc 281 FABRICATOR Service Manual

Mig welding machine
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281

Service Manual

FABRICATOR
MIG WELDING MACHINE
Version No: AE.01
Operating Features:
®
Art # A-07447
Issue Date: June 9, 2006
208
230
60
V
V
Manual No.: 0-4880B
Hz

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Summary of Contents for Thermal Arc 281 FABRICATOR

  • Page 1: Service Manual

    ® FABRICATOR MIG WELDING MACHINE Art # A-07447 Service Manual Version No: AE.01 Issue Date: June 9, 2006 Manual No.: 0-4880B Operating Features:...
  • Page 3 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 Service Manual Number 0-4880B for: Package System Part Number W1001600 Power Source Part Number 707300...

  • 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 Internal Controls of A2281 Remote ..............4-7 4.03 TWECO Weldskill 300 AMP Weld Gun ............4-9 4.04 Installing A New Wire Conduit ..............4-10 4.05 MIG Gun Maintenance ..................
  • Page 6 TABLE OF CONTENTS SECTION 8: CIRCUIT OPERATION ................8-1 8.01 Circuit Operation Of The Control PCB 7977964 ..........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 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.
  • Page 8 FABRICATOR 281 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. 5.
  • Page 9 FABRICATOR 281 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. ENGINE FUEL can cause fire or explosion.

  • Page 10: Principal Safety Standards

    FABRICATOR 281 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: Precautions De Securite En Soudage A L'arc

    FABRICATOR 281 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 281 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 13 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 AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.

  • Page 14: Principales Normes De Securite

    FABRICATOR 281 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. fumées d’échappement doivent être envoyées à...

  • 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 Library link: http://www.thermalarc.com June 9, 2006...

  • Page 16: Symbol Chart

    FABRICATOR 281 2.04 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 Transformer-Rectifier Purging Of Gas Increase/Decrease...

  • Page 17: General Information

    FABRICATOR 281 2.05 General Information • Never watch the welding arc with naked eyes. Al- ways use and wear a welding mask fitted with the The Fabricator 281 is a 208-230 Volt MIG machine with a correct filter lens. best in class performance of 300 Amp maximum output •...

  • Page 18: User Responsibility

    This equipment or any of its parts should not be altered exceeded. 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...
  • Page 19 FABRICATOR 281 Package System Part Number W1001600 Power Source Part Number 707300 Power Source Weight 249 lb (113kg) Dimensions HxWxD 58” x 27.2” x 36.8” (including wheels and cylinder rack and wire (1473 x 691 x 935mm) feeder) Nominal Input Voltage 208V 230V Number of Phases...

  • Page 20: Included Items

    FABRICATOR 281 2.11 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 –...

  • Page 21: Installation

    FABRICATOR 281 SECTION 3: INSTALLATION 3.01 Environment 3.02 Location The Fabricator 281 is NOT designed for use in Be sure to locate the Power Supply according to the environments with increased hazard of electric shock. following guidelines: Examples of environments with increased hazard of In areas, free from moisture and dust.

  • Page 22: Primary Input Voltage Requirements

    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 trades- person. The Fabricator 281 Power Supply is factory connected for the following input power supply voltage:...
  • Page 23 FABRICATOR 281 Changing the Voltage Selection 1. Disconnect the power supply from the Primary 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.

  • Page 24: Quick Setup

    FABRICATOR 281 6. Fit the electrode wire spool to the wire reel hub 3.06 Quick Setup located behind the electrode wire compartment door. CAUTION 7. Fit the TWECO Weldskill MIG gun and trigger wires through/to the front of the unit. To obtain adequate air flow and cooling for 8.

  • Page 25: Mount The A2281 Wire Feeder

    FABRICATOR 281 3.07 Mount the A2281 Wire Feeder 2. Attach the supplied 26 ft (8m) Interconnection Cable Assembly to the the A2281 wire feeder's 1. Mount the A2281 wire feeder unit on top of the rear panel by firmly threading each of the three Fabricator 281 power supply by engaging its cables' connectors to their mating sockets.

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

    FABRICATOR 281 Adjusting Regulator 3.08 Installation of Shielding Gas (GMAW) Process Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-4 and data NOTE charts Approx. 20 CFH) Shielding Gas is not required if the unit is used The gas flow rate should be adequate to cover the weld with self shielded FCAW (flux cored arc zone to stop weld porosity.
  • Page 27 FABRICATOR 281 Shielding Regulator and Flowmeter “Cracking” Shielding Shielding Shielding To A2281 Wire Art # A-07278 Feeeder Gas Inlet Stowage Hook Gas Hose Figure 3-5 Gas Cylinder Installation June 9, 2006...

  • Page 28: Attaching The Gun And Cable Assembly To The Remote Feeder

    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.
  • Page 29 FABRICATOR 281 Thumbscrew Art # A-07459 Figure 3-8: Mount Gun Cable to Adapter Socket June 9, 2006...

  • Page 30: Selection And Installation Of Feedrolls

    FABRICATOR 281 3.10 Selection and Installation of WARNING Feedrolls A Feedroll consists of two different sized grooves. As The welding wire is electrically Hot if it is fed delivered from the factory the feedroll is installed for .035” by depressing gun switch. Electrode contact / .045”...

  • Page 31: Installing Wire Spool On The Remote

    FABRICATOR 281 3.12 Installing Wire Spool on the Remote As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool. Installation of wire spool Wire Spool Hub Nut 1. Remove Wire Spool Hub Nut by turning counter Alignment Pin clock wise (to the left).

  • Page 32: Inserting Wire Into The Feedhead

    FABRICATOR 281 3.13 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.

  • Page 33: Wirefeeder Feedroll Pressure Adjustment

    FABRICATOR 281 Spool Hub Brake Hex Head Bolt Wire Drive Pressure Adjusting Device Spool Hub Nut Art # A-07461 Figure 3-13: Wire Installed 3.15 Wire Spool Hub Brake 3.14 Wirefeeder Feedroll Pressure Adjustment The wire spool hub incorporates a friction brake which is adjusted during manufacture for optimum braking.

  • Page 34: Spool Gun Attachment

    FABRICATOR 281 3.16 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.

  • Page 35: Polarity Changeover

    FABRICATOR 281 3.17 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 CABLE CONNECTIONS PROCESS...
  • Page 36 FABRICATOR 281 Cable from wirefeeder Cable to work connected to terminal Connected for D.C. Electrode Negative (DCEN) Welding Art # A-07480 Figure 3-16: Polarity Connections for DCEN Changing polarity process. a. Locate the two terminal knobs at the front of the machine. Refer to Figures 3-15 and 3-16. b.

  • Page 37: Operation

    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 A2281 Weldskill Wire Speed Control...
  • Page 38 FABRICATOR 281 On / Off 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 Off 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.
  • Page 39 FABRICATOR 281 Digital AMP Reading to IPM Conversion STEEL Current (Amps) Art # A-07451 Figure 4-3: Steel - AMP to IPM Conversion STAINLESS STEEL Current (Amps) Art # A-07452 Figure 4-4: Stainless Steel - AMP to IPM Conversion June 9, 2006...
  • Page 40 FABRICATOR 281 ALUMINUM 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.
  • Page 41 FABRICATOR 281 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.
  • Page 42 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.

  • Page 43: Internal Controls Of A2281 Remote

    FABRICATOR 281 4.02 Internal Controls of A2281 Remote WELD MODE BURNBACK DWELL (STITCH) WELD (SPOT / STITCH) SPOT STITCH WELD MODE BURNBACK DWELL (STITCH) WELD (SPOT / STITCH) SPOT STITCH Art # A-07463 Figure 4-5: Internal Welding Controls WELD Mode Selector Switch The Weld Mode Selector switch selects the method of welding mode.
  • Page 44 FABRICATOR 281 SPOT: WELD (Spot/Stitch) This mode of welding is used to weld two plates WELD WELD together at a desired location by melting the top & (SPOT / STITCH) (SPOT / STITCH) bottom plates together to form a nugget between them.

  • Page 45: Tweco Weldskill 300 Amp Weld Gun

    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.

  • Page 46: Installing A New Wire Conduit

    FABRICATOR 281 4.04 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.

  • Page 47: Mig Gun Maintenance

    FABRICATOR 281 4.05 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. 4.06 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.
  • Page 48 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. Flux Cored Wire Solid Wire Art # A-07186...
  • Page 49 FABRICATOR 281 Advantages of MIG welding forehand: • Allows superior visibility of the weld zone • Flatter weld bead • Shallower penetration Vertical Forehand Backhand Art # A-07185 Figure 4-15: MIG Gun Angle June 9, 2006 4-13...

  • Page 50: Stitch Welding Operation

    FABRICATOR 281 4.07 Stitch Welding Operation 4.08 Spot Welding Operation Welding consumable costs can be reduced by Fit an optional spot welding nozzle to the MIG gun replacing a continuous weld bead with the Stitch weld for consistent spot welding operations. Refer to the bead.

  • Page 51: Gas Selection For Gas Metal Arc Welding

    FABRICATOR 281 4.09 Gas Selection for Gas Metal Arc Welding Suggested Base Plate Filler Transfer Welding Metal Type Shielding Comments Thickness Metal Mode Positions Carbon Greater than 22 ER70S-X Short High welding speeds. Good 100% CO Steel gauge (.030”) Circuit Position penetration and pool control.

  • Page 52: Welding Setting Selection Guide

    FABRICATOR 281 4.10 Welding Setting Selection Guide Shielding Gas W ire Size Material Type W ire Type (Diameter) and Flow Rate Art # A-07449 .035” (0.9mm) 100% CO 25cfh .045” (1.2mm) .023” (0.6mm) .030” (0.8mm) 75% Ar 25% Solid ,25cfh .035”...
  • Page 53 FABRICATOR 281 Coarse Voltage Fine Voltage THICKNESS Step Wire Coarse Voltage Fine Voltage Speed 22 ga. (0.8mm) 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) 7.25 1.25 2.25 2.75 1.25 1.75 6.25 8.25 1.25 6.25...
  • Page 54 FABRICATOR 281 NOTES 4-18 June 9, 2006...

  • Page 55: Maintenance

    FABRICATOR 281 SECTION 5: MAINTENANCE 5.01 Routine Maintenance & Inspection To clean the Power Supply, disconnect it from the mains The only routine maintenance required for the Fabricator supply voltage then open the enclosure and use a vacuum 281 is a thorough cleaning and inspection, with the fre- cleaner to remove any accumulated dirt and dust.
  • Page 56 FABRICATOR 281 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 cables and leads. Replace as needed. body and consumables 3 Months Clean exterior of both units...

  • Page 57: Troubleshooting

    If major components are faulty, then the Power Supply a. Ensure that the gas holes are not blocked and should be returned to an Accredited Thermal Arc Service gas is exiting out of the torch nozzle. Refer to Agent for repair.
  • Page 58 FABRICATOR 281 WELDING MACHINE 4. Misalignment of inlet/outlet guides. a. Wire will rub against the misaligned guides and reduces wire feedability. 5. Liner blocked with slag. a. Swarf is produced by the wire passing through the feed roll, if excessive pressure is applied to the pressure roll adjuster.

  • Page 59: Welding Problems

    FABRICATOR 281 WELDING MACHINE 6.03 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 angle a. Adjust angle 3.
  • Page 60 6. Weld speed too fast a. Reduce weld speed. G. Cold weld puddle. 1. Faulty rectifier unit a. Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component. 2. Loose welding cable a. Check all welding cable connections.

  • Page 61: Power Supply Problems

    Gun when the gun trigger switch is (burn-back jam). Replace faulty component(s). depressed. 2. Faulty control PCB or Tweco Have an Accredited Thermal Arc Service Agent investigate the fault. F. Wire feeds when the gun trigger switch 1. Poor or no work lead...

  • Page 62: Wire Feeder Problems

    FABRICATOR 281 WELDING MACHINE 6.05 Wire Feeder Problems FAULT CAUSE REMEDY Primary Input supply Broken connection in Have an Accredited Thermal voltage is ON. Indicator primary circuit. Arc Service Agent check light is not lit and welding primary circuit. arc can not be established. Two amp wire feeder Reset the wire feeder circuit circuit breaker in the power...

  • Page 63: Advanced Troubleshooting

    FABRICATOR 281 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 64: Initial Setup Conditions

    FABRICATOR 281 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. Green Indictor Lamp inside ON/OFF Switch (SW1) FABRICATOR 281 POWER SUPPLY on the Power Supply illuminates 1.

  • Page 65: Logic And Control Tests

    FABRICATOR 281 7.04 Logic and Control Tests G. Release Gun Switch 1. Feed Roll stops immediately A. Depress Gun Switch and observe the following: 2. Display reads "15.0 V" 1. Gas flows 3. After 1 ½ seconds 2. Contactor energizes a.

  • Page 66: Spool Gun Control (J1) Test

    FABRICATOR 281 J. Set MODE SELECTOR SWITCH to STITCH position. This completes the Logic & Control Tests. If the above Set WELD (SPOT/STITCH) TIMER CONTROL to are all correct then proceed to paragraph 'C'. If the above minimum. does not function as noted then note the symptom and proceed to Section 7.09 Logic &...

  • Page 67: Output Voltage Test

    FABRICATOR 281 7.06 Output Voltage Test A. Set COARSE VOLTAGE SELECTOR SWITCH to position "L" 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 68: Wire Feed & Weld Test

    FABRICATOR 281 7.07 Wire Feed & Weld Test B. Green Indicator in ON/OFF Switch (SW1) on Power Supply is illuminated. When ON/OFF switch A. Close the PRESSURE ADJUST DEVICE. Connect the GUN (SW1) is in the ON position, the fan does not run POLARITY LEAD to the POSITIVE WELDING TERMINAL and the Digital Display is off.

  • Page 69: Logic And Control Problems

    FABRICATOR 281 7.09 Logic and Control Problems a. Measure between JB-5 to JB-11 for approx 32VAC when Gun Switch is closed. If voltage A. Nothing happens when gun switch is depressed; is present, replace PCB 1 No gas flow, contactor does not energize, feed C.

  • Page 70: Spool Gun Control (J1) Problem

    FABRICATOR 281 a. Measure between JB-7 to JB-9 for approx a. Measure voltage between X1-3 to X1-1 for 15VDC. If voltage is not correct, then check 32VAC. If voltage is correct, replace PCB4. connections to J1 on Power Supply to A2281 7.10 Spool Gun Control (J1) Problem Terminal Block.

  • Page 71: Wire Feed And Weld Problems

    FABRICATOR 281 7.12 Wire Feed and Weld Problems A. Poor or inconsistent arc transfer or no arc transfer 1. Poor work cable connection or open work cable a. Clean contact point, check continuity of cable and cable to clamp connection. Replace if work cable if required.

  • Page 72: Sw3 Coarse And Sw4 Fine Rotary Switch Test

    FABRICATOR 281 7.14 SW3 Coarse and SW4 Fine Rotary Switch Test WIRE No'S. TERMINAL No'S. TOP OF SWITCH TERMINAL No'S. WIRE No'S. WIRE No'S. TERMINAL No'S. BOTTOM OF SWITCH TERMINAL No'S. WIRE No'S. Figure7-2: 3-Position Rotary Switch, Coarse WIRE No'S. TERMINAL No'S.
  • Page 73 FABRICATOR 281 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. Set Screw Knob Retainer Locking Collar Rotary Switch (SW4 Fine) Figure 7-4: Rotary Switch SW3 and SW4 Removal SWITCH 2 COARSE SWITCH 3 FI NE...

  • Page 74: Mig Timer Pcb (Pcb2) Test

    FABRICATOR 281 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 VOLTAGE AT JD-2 POSITION 10VDC when Gun Switch closed.

  • Page 75: Rectifier Assembly Test

    FABRICATOR 281 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. 4.

  • Page 76: Main Transformer Test

    FABRICATOR 281 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 11.8 12.2...

  • Page 77: Circuit Operation

    FABRICATOR 281 SECTION 8: CIRCUIT OPERATION 8.01 Circuit Operation Of The Control PCB 7977964 Power Supply 24VAC is taken from the auxiliary wiring of the fan. This voltage is then connected to the PCB 7977964 where it is half wave rectified and filtered. This voltage is then fed to a zener regulator to provide the +15VDC supply for the electronics on the circuit board Inputs to the Control PCB CONNECTOR JA...

  • Page 78: Circuit Operation Of The Digital Volt/Amp Pcb 704883

    FABRICATOR 281 CONNECTOR JB 8.02 Circuit Operation Of The MIG Timer PCB 7977965 Terminal JB-1 wiper of wire speed control potentiometer, This board is connected by way of a 6-way cable and varies between <2V to approximately 4.7VDC does not have any terminals available to measure. (pot wiper) reference JA-5 or JB-5...

  • Page 79: Circuit Operation Of The Spool Gun Pcb 7978034

    FABRICATOR 281 8.04 Circuit Operation Of The Spool Gun Terminal X2/4 trigger relay - connects to trigger input of PCB 7978034 7977964 PCB CONNECTOR X1 Terminal X2/5 trigger relay - connects to trigger input of Terminal X1/1 7977964 PCB motor relay "normally open" - connects to spool gun motor Terminal X2/6...
  • Page 80 FABRICATOR 281 June 9, 2006...

  • Page 81: Parts List

    FABRICATOR 281 WELDING MACHINE SECTION 9: PARTS LIST 9.01 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Part or Assembly numbers.

  • Page 82: Power Supply External Replacement Parts (1)

    FABRICATOR 281 WELDING MACHINE 9.03 Power Supply External Replacement Parts (1) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF. DES . DES .
  • Page 83 FABRICATOR 281 WELDING MACHINE Art # A-07534 June 9, 2006...

  • Page 84: Power Supply External Replacement Parts (2)

    FABRICATOR 281 WELDING MACHINE 9.04 Power Supply External Replacement Parts (2) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 707282CLAPKD Panel,Top,Fab281 401840-003 Cable, Power Cable, Fab251/281 707256WBLKPKD Panel,Base,Fab210/251/281 See Note 1...

  • Page 85: Power Supply Electrical Replacement Parts

    FABRICATOR 281 WELDING MACHINE 9.05 Power Supply Electrical Replacement Parts ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNATION...

  • Page 86: Remote Parts (1)

    FABRICATOR 281 WELDING MACHINE 9.06 Remote Parts (1) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNATION TION...

  • Page 87: Remote Parts (2)

    FABRICATOR 281 WELDING MACHINE 9.07 Remote Parts (2) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 7977978 Knob,Output Terminal,Fabs NB2157 Cup, Retaining, 1/2" ID 871067PKD Axle,1/2"...

  • Page 88: Remote Parts (3)

    FABRICATOR 281 WELDING MACHINE 9.08 Remote Parts (3) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 204036 Label,Precautions,Arc Equip 831247PKD Label, Mode Select, Fab281 871081PKD Shroud Wrfdr A2281 377941...

  • Page 89: Remote Electrical Components (1)

    FABRICATOR 281 WELDING MACHINE 9.09 Remote Electrical Components (1) ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 7977965PKD PCB,Timer,Fab210/251/A2281 PCB2 871003PKD Solenoid Assy,24VAC, A2281 Y1,Y2 7978034PKD PCB,Spool Gun,Fab251/281...

  • Page 90: Remote Wire Feeder Parts

    FABRICATOR 281 WELDING MACHINE 9.10 Remote Wire Feeder Parts ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNATION TION...
  • Page 91 FABRICATOR 281 WELDING MACHINE Art # A-07562 9-11 June 9, 2006...

  • Page 92: Mig Torch

    FABRICATOR 281 WELDING MACHINE 9.11 MIG Torch ITEM ITEM ITEM ITEM ITEM P P P P P AR ART NUMBER T NUMBER T NUMBER T NUMBER T NUMBER DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION 43340 Weldskill MIG Gun, 280A 15FT Note Refer to Appendix 1 for individual components.

  • Page 93: Appendix 1: Optional Accessories And Consumables

    FABRICATOR 281 APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES For Tweco/Victor Inquiries and Orders: Call 1-800-318-6819 Consumable Parts Management Group GUNS Tweco® WeldSkill 15ft 43340 Gun assembly with 15ft cable (supplied with package), 300 Amp @ 30% Tweco® No. 4 12ft 412-3545 Gun assembly with 12ft cable, 400 Amp @ 60% Tweco®...

  • Page 94: Appendix 2: Power Supply Circuit Diagram

    FABRICATOR 281 APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM • Note the model and specification number shown on the equipment nameplate 4 BLK COARSE FABRICATOR 281 4A BLK 8&8A BRN (10) 8 BRN 9&9A BLK (12) (11) 9 BLK 10&10A RED Input Terminal Block 1 RED K1\3...
  • Page 95 FABRICATOR 281 SWITCH 2 COARSE SWITCH 3 FINE SWITCH SWITCH POSITION POSITION Bridge Rectifier POSITIVE OUTPUT Inductor TERMINAL PLUGSOCKET 21 ORN PCB 4 X1/6 22 VIO X1/5 + C1 - C4 704883 Varistor 23 GRY X1/4 DIG METER 30A BRN X1/3 31B BLK X1/1...

  • Page 96: Appendix 3: Main Pcb Circuit Diagram

    FABRICATOR 281 APPENDIX 3: MAIN PCB CIRCUIT DIAGRAM 30 VAC Art # A-07520 June 9, 2006...
  • Page 97 FABRICATOR 281 82 BENNING SREET WEST LEBANON, NH 03784, USA DESCRIPTION: FABRICATOR MAIN PCB 7977964 Art # A-07520 June 9, 2006...

  • Page 98: Appendix 4: Spot Timer Circuit Diagram

    FABRICATOR 281 APPENDIX 4: SPOT TIMER CIRCUIT DIAGRAM Art # A-07521 June 9, 2006...
  • Page 99 FABRICATOR 281 82 BENNING SREET WEST LEBANON, NH 03784, USA DESCRIPTION: FABRICATOR SPOT TIMER 7977965 CODE DESIGN: Art # A-07521 June 9, 2006...
  • Page 100 FABRICATOR 281 APPENDIX 5: SPOOL GUN PCB +14Vdc +35Vdc +14Vdc 1N4004 100n +Vout 1N4004 1N4004 LM317T 270R 22u 50V 100n 100n 470u 50V 4013 1N4004 1N4004 +14Vdc +14Vdc +14Vdc 100K 100n 1N4004 LM324 100n LM324 1N4004 +14Vdc 24VAC_1 100n 24VAC_2 SPOOL TRIG NORM TRIG BC337-40...

  • Page 101: Appendix 5: Spool Gun Pcb

    FABRICATOR 281 MOT SPOOL MOT COM MOT LOC GV SPOOL GV COM GV LOC CON6 +35Vdc +35Vdc +35Vdc Install jumper for use with MILLER spool gun which has no speed pot on the spool gun 560R 1/2W 560R 1/2W 560R 1/2W AZ945 AZ945 AZ945...

  • Page 102: Appendix 6: Feedroll Kits

    FABRICATOR 281 APPENDIX 6: FEEDROLL 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 Double Smooth Double Bottom Smooth "V"...

  • Page 103: Appendix 7: Wire Feeder Terminal Block Diagram

    FABRICATOR 281 APPENDIX 7: WIRE FEEDER TERMINAL BLOCK DIAGRAM orange 31 gray 36 white 38 & 38A brown 30 white 32 & 32A gray 47 orange 48 FRONT OF WIRE FEEDER June 9, 2006 A-11...

  • Page 104: 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 105: 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 107: 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 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 108 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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