Thermal Arc Fabricator 210 Owner's Manual
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Thermal Arc Fabricator 210 Owner's Manual

Mig power supplies
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See also: Service Manual , Operating Manual
FAB RI CA TOR 210/250
MIG Power Sup plies
For the Fol low ing Specs:
• 100047A-1
• 100048A-2
OWNER'S MAN UAL Num ber 430429-478 (Rev AA)
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
Fab ri ca tor 210
Fab ri ca tor 250
Re vised Oc to ber 23, 2000

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  • Page 1 • 100048A-2 Fab ri ca tor 250 OWNER’S MAN UAL Num ber 430429-478 (Rev AA) Re vised Oc to ber 23, 2000 IMPORTANT: Read these instructions before installing, operating, or servicing this system. THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

  • Page 2: Table Of Contents

    430429-478 TABLE OF CONTENTS IN TRO DUC TION How To Use This Man ual........1-1 Equip ment Iden ti fi ca tion .
  • Page 3 430429-478 TABLE OF CONTENTS TWECO MIG GUN BA SIC WELDING TECH NIQUE Set ting Of The Power Sup ply....... . 9-1 Po si tion of MIG Gun .

  • Page 4: In Tro Duc Tion

    430429-478 IN TRO DUC TION How To Use This Man ual This Owner’s Man ual usu ally ap plies to just the op er a tion of the sys tem. Notes will be un der lined spec i fi ca tion or part num bers listed on shown in ital ics.
  • Page 5 430429-478 This page in ten tion ally left blank. July 10, 2000...

  • Page 6: Arc Welding Safety In Struc Tions And Warn Ings

    ARC WELDING SAFETY IN STRUC TIONS AND WARN INGS In struc tion 830001 ARC WELDING SAFETY IN STRUC TIONS AND WARN INGS ARC WELDING can be haz ard ous. PROTECT YOUR SELF AND OTHERS FROM POS SI BLE SE RI OUS IN JURY OR DEATH. KEEP CHILDREN AWAY. PACE MAKER WEARERS KEEP AWAY UN TIL CON SULTING YOUR DOC TOR.
  • Page 7 ARC WELDING SAFETY IN STRUC TIONS AND WARN INGS In struc tion 830001 FUMES AND GASES can be haz ard ous 4. Read the Ma te rial Safety Data Sheets (MSDSs) and the man u - to your health. fac turer’s in struc tion for met als, consumables, coat ings, and clean ers.
  • Page 8 ARC WELDING SAFETY IN STRUC TIONS AND WARN INGS In struc tion 830001 ENGINE FUEL can cause fire or 2. Do not add fuel while smok ing or if unit is near any sparks or open ex plo sion. flames. 3.
  • Page 9 ARC WELDING SAFETY IN STRUC TIONS AND WARN INGS In struc tion 830001 This page in ten tion ally left blank. May 8, 1996...
  • Page 10 PRE CAU TIONS DE SECURITE EN SOUDAGE A L'ARC In struc tion 830002 PRE CAU TIONS DE SECURITE EN SOUDAGE A L’ARC LE SOUDAGE A L′ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAIS SEZ PAS LES EN FANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 11 PRE CAU TIONS DE SECURITE EN SOUDAGE A L'ARC In struc tion 830002 SE LEC TION DES NU ANCES DE FILTRES OCULAIRES POUR LA PRO TEC TION DES YEUX EN COUPAGE ET SOUDAGE ( selon AWS A 8.2-73 ) Opération Di men sion d’électrode ou Nu ance de Epaisseur de métal ou...
  • Page 12 PRE CAU TIONS DE SECURITE EN SOUDAGE A L'ARC In struc tion 830002 LE SOUDAGE PEUT CAUSER UN 4. Méfiez-vous des pro jec tions brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures INCENDIE OU UNE EX PLO SION ou fis sures.
  • Page 13 PRE CAU TIONS DE SECURITE EN SOUDAGE A L'ARC In struc tion 830002 DES PIECES EN MOUVEMENT 3. Seules des personnes qualifiées doivent démonter des PEUVENT CAUSER DES BLESSURES. protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire. Des pièces en mouvement, tels des ventilateurs, des 4.

  • Page 14: Gen Eral In For Ma Tion

    430429-478 GEN ERAL IN FOR MA TION The Fab ri ca tor 210 and 250 are semi-automatic viii) Do not stand on damp ground when weld ing. Gas Metal Arc Welders (GMAW-commonly MIG) ix) For more com plete safety ad vice please read with ei ther in te grated or sep a rate wire feed unit.

  • Page 15: Duty Cy Cle

    430429-478 Figure 3-1 Fabricator Duty Cycle Curves ken, miss i n g , p l a i n l y w o r n , d i s torted o r Duty Cy cle con tam i nated, should be re placed im me di ately. The rated duty cy cle of a weld ing Power Sup ply is Should such re pairs or re place ments be come nec - the op er at ing time it may be used at its rated out put...

  • Page 16: Spec I Fi Ca Tions

    430429-478 SPEC I FI CA TIONS MIG Gun Spec i fi ca tions Gun Cat a log Num ber 830788 Gun Type TWECO 250A (Spraymaster Con sum ables) Gun Ca ble Length 3.6 me ters (12 ft) Ma chine Spec i fi ca tions Fab ri ca tor 210 Fab ri ca tor 250 Com pact...

  • Page 17: Wire Drive Spec I Fi Ca Tions

    430429-478 Fab ri ca tor 210 Fab ri ca tor 250 Com pact Com pact 100% Duty Cy cle Out put Rat ing 127A 127A 180A 180A Duty Cy cle Pe riod 10 min utes Num ber Of Out put Volt age Values Wire Size Range 0.6mm (.024") - 0.9mm (.035") Hard (Fab ri ca tor 210) 0.6mm (.024") - 1.2mm (.045") Hard (Fab ri ca tor 250)

  • Page 18: Op Tional Ac Ces Sories

    430429-478 Fab ri ca tor 210 Fab ri ca tor 250 ü ü Reg u la tor/Flowmeter ü ü TWECO MIG Gun 250A ü ü Feed Roller 0.6/0.8 Hard ü ü Feed Roller 0.9/1.2 Hard ü ü Feed Roll, 1.0/1.2 - 1.4/1.6 Flux Cored ü...
  • Page 19 430429-478 This page in ten tion ally left blank. October 23, 2000 Revised...

  • Page 20: In Stal La Tion Rec Om Men Da Tions

    430429-478 IN STAL LA TION REC OM MEN DA TIONS En vi ron ment e) Place at a dis tance of 30cm (1ft)or more from The Fab ri ca tors are NOT de signed for use in en vi - walls or sim i lar that could re strict nat u ral air ron ments with in creased haz ard of elec tric shock.

  • Page 21: Al Ter Na Tive In Put Power Sup Ply Volt Ages

    Al ter na tive In put Power Sup ply Volt ages Figure 5-2 Voltage Settings For Fabricator 210 & The Power Sup plies are suit able for the fol low ing In put Power sup ply volt ages:...

  • Page 22: Set Up For Com Pact Fab Ri Ca Tors

    430429-478 SET UP FOR COM PACT FAB RI CA TORS a) Re move all pack ag ing ma te ri als. and 1.2mm (.045") flux cored wires. Se lect the roller re quired with the cho sen wire size CAU TION : To ob tain ad e quate air flow mark ing fac ing out wards.
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  • Page 24: Power Supply Con Trols, In Di Ca Tors And Fea Tures

    430429-478 POWER SUPPLY CON TROLS, IN DI CA TORS AND FEA TURES Figure 7-3 Compact Fabricator Controls Figure 7-4 Internal Fabricator Controls July 10, 2000...

  • Page 25: Standby Switch With In-Built In Di Ca Tor Light

    430429-478 Fig ure 7-5 Ex am ples Of The Dig i tal Read Outs Standby Switch With In-built (5% tol er ance) of weld ing cur rent and volt me ter to fa cil i tates pre cise weld ing con di tion ad just ment. In di ca tor Light Re fer to Im proved Cur rent Ac cu racy Cal i bra tion The in di ca tor light is pro vided to in di cate when the...

  • Page 26: Spool Gun Con Trol Socket

    430429-478 Spool Gun Con trol Socket The SPOOL GUN 14 pin re cep ta cle is used to con - nect a (Tweco Spool Mas ter) spool gun to the weld - ing power Sup ply cir cuitry: To make con nec tions, align keyway, in sert plug, and ro tate threaded col lar fully clock wise.

  • Page 27: Ther Mal Over Load

    430429-478 & bot tom plates to gether to Ther mal Over load form a nug get be tween The crit i cal com po nent for ther mal pro tec tion is them. The spot time pe riod the rec ti fier stack, which is fit ted with a ther mal over - is set by the SPOT TIME load cut out de vice.

  • Page 28: Spool Gun/Stan Dard Switch

    430429-478 spec tion of the wire con tact tip re veals no wear, dis - Burnback time is ad justed by plac ing a flat bladed tor tion or burn-back jam, the con duit liner should be screw driver into the Burnback ad just ment ac cess checked for kinks and clog ging by metal flakes and hole and ad just ing the trim po ten ti om e ter.
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  • Page 30: Tweco Mig Gun

    430429-478 TWECO MIG GUN TWECO MIG GUN Re fer to TWECO gun man ual for gun main te nance in struc tion and parts list for spare part num bers. July 10, 2000...
  • Page 31 430429-478 TWECO MIG GUN This page in ten tion ally left blank. July 10, 2000...

  • Page 32: Ba Sic Welding Tech Nique

    430429-478 BA SIC WELDING TECH NIQUE Set ting Of The Power Sup ply The set ting of the Fab ri ca tor re quires some prac - tice by the op er a tor, the weld ing Power Sup ply hav - ing two con trol set tings that have to bal ance.

  • Page 33: Stitch Welding Op Er A Tion

    430429-478 Figure 9-7 Wire Penetration Comparison de sired weld or ‘ON’ time while stitch weld - This dem on strates that where the up per limit of ing. cur rent is lim ited by ma chine ca pac ity and duty cy - cle, higher de po si tion rates and there fore greater d) Dwell Time pro duc tiv ity will be achieved by us ing smaller elec -...

  • Page 34: Main Te Nance & In Spec Tion

    430429-478 MAIN TE NANCE & IN SPEC TION Im proved Cur rent Ac cu racy Cal i bra tion Pro ce dure For The Dig i tal Me ter The only rou tine main te nance re quired for the Fab ri ca tor is a thor ough clean ing and in spec tion, with the fre quency de pend ing on the us age and WARNING: This cal i bra tion pro -...
  • Page 35 430429-478 vii) De ter mine the out put cur rent as given by xiii ) Con firm the min i mum DIG I TAL METER the DC AM ME TER. read ing is within ±2% of DC AMMEER. viii ) Ad just SHUNT CAL. po ten ti om e ter on xiv) If the above is not met, off set the DIG I TAL METER to read iden ti cally SHUNT CAL.

  • Page 36: Trou Ble Shooting

    430429-478 TROU BLE SHOOTING The ba sic level of trou ble shoot ing is that which can be per formed with out spe cial equip ment or knowl edge, and with out re mov ing the cov ers from the Power Sup ply. If ma jor com po nents are faulty, then the Power Sup ply should be re turned to an Ac credited THER MAL ARC Ser vice Agent for re pair.
  • Page 37 430429-478 b) In con sis tent wire feed Wire feed ing prob lems can be re duced by check ing the fol low ing points: 1. Wire spool brake is too tight. -Feed roller driven by mo tor in the cab i net will slip.

  • Page 38: Welding Prob Lems

    430429-478 Welding Prob lems FAULT CAUSE REM EDY 1 Un der cut. A Welding arc volt age too high. A Re duce volt age by re duc ing the volt age se lec tion switches po si tion or in crease the wire feed speed.

  • Page 39: Power Sup Ply Prob Lems

    430429-478 FAULT CAUSE REM EDY 6 Weld crack ing. A Weld beads too small A De crease travel speed B Weld pen e tra tion nar row and B Re duce cur rent and volt age deep and in crease Mig gun travel speed or se lect a lower pene tration shield ing gas.
  • Page 40 430429-478 FAULT CAUSE REM EDY 4 In put power sup ply volt age is Gun trig ger switch leads Re con nect. ON and In di ca tor light is lit but are dis con nected. when the gun trig ger switch is de pressed noth ing hap pens.
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  • Page 42: Parts List

    430429-478 TROUBLESHOOTING Parts List Equip ment Iden ti fi ca tion All iden ti fi ca tion num bers as de scribed in the In tro - found on the name plate at tached to the equip - duc tion chap ter must be fur nished when or der ing ment.
  • Page 43 430429-478 TROUBLESHOOTING Figure 11-1 11-8 October 23, 2000 Revised...
  • Page 44 430429-478 TROUBLESHOOTING Parts List for Figure 11-1 Item Part De scrip tion Ap pli ca tion Num ber Code Assy 100047A-1 Fab ri ca tor 210 (CSA Ver.) 100048A-2 Fab ri ca tor 250 (CSA Ver.) 830616-1 Base, Welder 830614-1 Door, L.
  • Page 45 430429-478 TROUBLESHOOTING Figure 11-2 October 23, 2000 Revised 11-10...
  • Page 46 430429-478 TROUBLESHOOTING Parts List for Figure 11-2 Item Part De scrip tion Ap pli ca tion Num ber Code Assy 830913 Drive Mo tor Assy 10-6039 Adap tor, Gun Assy 10-6187 Screw, Locking Mig Torch 10-6040 Out put Liner 10-6144 In put Guide See Op tional Chart Page 4-3...
  • Page 47 430429-478 TROUBLESHOOTING Figure 11-3 October 23, 2000 Revised 11-12...
  • Page 48 430429-478 TROUBLESHOOTING Parts List for Figure 11-3 Item Part De scrip tion Ap pli ca tion Num ber Code Assy 830619-2 Panel, Rear 830619-1 Panel, Rear 600049-1 Fan, Assy 600045 Valve, Gas — 401840-4 Ca ble, In put Power — 401840-3 Ca ble, In put Power —...
  • Page 49 430429-478 TROUBLESHOOTING Figure 11-4 October 23, 2000 Revised 11-14...
  • Page 50 430429-478 TROUBLESHOOTING Parts List for Figure 11-4 Item Part De scrip tion Ap pli ca -tion Num ber Code Assy 830852-1 Panel, In te rior 830617-1 Bracket, Reel, Lug 830496 Washer, Fric tion 10-6018 Hub, Spool 830534 Clip, Re taining W11242-27 Washer, Flat 10-6132...
  • Page 51 430429-478 TROUBLESHOOTING Figure 11-5 October 23, 2000 Revised 11-16...
  • Page 52 430429-478 TROUBLESHOOTING Parts List for Figure 11-5 Item Part De scrip tion Ap pli ca -tion Num ber Code Assy W-11166-10 Fuse, AGC - 3 Amp 402658 Holder, Fuse 600093 Re sis tor 600042 Contactor 600037 Trans former, Aux 830612-1 Panel, Baf fle 600041 Board, PC Con trol...
  • Page 53 430429-478 TROUBLESHOOTING Figure 11-6 October 23, 2000 Revised 11-18...
  • Page 54 430429-478 TROUBLESHOOTING Parts List for Figure 11-6 Item Part De scrip tion Ap pli ca -tion Num ber Code Assy 830665 Trans former, Power Assy, 250 830648 Trans former, Power Assy, 210 10-6131 Ca pac i tor, Electrolitic 400828-3 Tie, Ca ble 830589 Bar, Bus 10-6127...
  • Page 55 430429-478 TROUBLESHOOTING This page in ten tion ally left blank. October 23, 2000 Revised 11-20...

  • Page 56: Volt/Amp Graphs

    430429-478 VOLT/AMP GRAPHS Figure 12-8Volt/Amp Curves Of The Fabricator 210 Figure 12-9 Volt/Amp Curves Of The Fabricator 250 July 10, 2000 12-1...
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  • Page 58: Fab Ri Ca Tor 210 And 250 Power Supply Cir Cuit Di A Gram

    430429-478 FAB RI CA TOR 210 AND 250 POWER SUPPLY CIR CUIT DI A GRAM July 10, 2000 13-1...
  • Page 61 430429-478 This page in ten tion ally left blank. 13-4 July 10, 2000...

  • Page 62: Printed Cir Cuit Board Cir Cuit Di A Gram

    430429-478 PRINTED CIR CUIT BOARD CIR CUIT DI A GRAM Figure 14-10 Circuit Diagram For Control PCB 705946 July 10, 2000 14-1...
  • Page 63 430429-478 This page in ten tion ally left blank. 14-2 July 10, 2000...

  • Page 64: Pub Li Ca Tions

    Pub li ca tions Re fer to the fol low ing stan dards or their lat est re vi sions for more in for ma tion: 1. OSHA, SAFETY AND HEALTH STAN DARDS, 29CFR 1910, ob tain able from the Su per in ten dent of Doc u ments, U.S.

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