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YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
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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 210 MIG Welding Machine Instruction Manual Number 0-4855 for: Package System Part Number 100047B-001 Power Source Part Number 707519...
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-4 1.03 Symbol Chart ....................1-5 1.04 Precautions De Securite En Soudage à L’arc ..........1-6 1.05 Dangers Relatifs au Soudage à L’arc .............. 1-6 1.06 Principales Normes De Securite ..............
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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 MIG Gun Identification ................... 4-6 4.04 TWECO Weldskill 250A MIG Gun ..............4-7 4.05 Installing A New Wire Conduit ................
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. 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.
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FABRICATOR 210 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. WELDING can cause fire or explosion. 5.
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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. ENGINE FUEL can cause fire or explosion.
FABRICATOR 210 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S.
FABRICATOR 210 1.03 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage Transformer-Rectifier Purging Of Gas Increase/Decrease...
FABRICATOR 210 1.04 Precautions De Securite En Soudage à L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS.
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FABRICATOR 210 AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons dangereuses à...
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FABRICATOR 210 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.
FABRICATOR 210 Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur. fumées d’échappement doivent être envoyées à...
FABRICATOR 210 1.07 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage Torch de Tension dangereuse Fréquence Convertisseur Transformateur-Redresseur...
Include the manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature link: http://www.thermalarc.com Manual No. 0-4855...
• Never watch the welding arc with naked eyes. Al- from standard specification without prior written approval ways use and wear a welding mask fitted with the of Thermal Arc. The purchaser of this equipment shall correct filter lens. have the sole responsibility for any malfunction which •...
FABRICATOR 210 2.07 Duty Cycle The rated duty cycle of a welding Power Supply is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts. To explain the ten minute duty cycle period the following example is used.
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FABRICATOR 210 Fabricator 210 Package System Part Number 100047B-001 Power Source Part Number 707519 Power Source Weight 190lb (86kg) 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% 230V ±10% Number of Phases...
FABRICATOR 210 3.02 Location SECTION 3: INSTALLATION Be sure to locate the Power Supply according to the following guidelines: In areas, free from moisture and dust. 3.01 Environment In areas, free from oil, steam and corrosive gases. The Fabricator 210 is NOT designed for use in In areas, not subjected to abnormal vibration or shock.
Install a power outlet for each Power Supply and fit fuses as per the machine specifications. WARNING Thermal Arc advises that your Fabricator 210 be electrically connected by a qualified electrical trades- person. The Fabricator 210 Power Supply is factory connected for the following input power supply voltage:...
FABRICATOR 210 Changing the Voltage Selection 1. Disconnect the power supply from the main power source. 2. Refer to Figure 3-1. The power supply comes wired for 230V. Locate the black input power wire secured to the input voltage selection block. Loosen the set screw for both voltage locations. 3.
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 NOTE cylinder and connect the gas hose from the rear of the Power Supply to the Flow Meter outlet.
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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. 0-4855 INSTALLATION...
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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.
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 3-5 and -3-6.
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FABRICATOR 210 Art # A-08662 Front Panel Access Hole Trigger Receptacle Figure 3-5: Route Gun Cable Through Front Panel Access Hole and Connect Trigger Loosen Thumbscrew Art # A-08672 Tighten Thumbscrew Figure 3-6: Mount Gun Cable to Adapter Socket INSTALLATION Manual No.
FABRICATOR 210 3.09 Input And Output Wire Guide To ensure proper wire feed, the groove closest to the motor must match the electrode wire size being used. Installation Refer to Figure 3-7. .045” (1.2mm) Stamping Install the input wire guide (the longer one) by loosening .045 the input guide lockscrew and inserting the guide into the hole in the feedhead assembly.
FABRICATOR 210 3.11 Installing Wire Spool As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool. Installation of wire spool 1. Remove Wire Spool Hub Nut by turning counter clock wise (to the left). 2.
FABRICATOR 210 3.12 Inserting Wire into the Feedhead WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions. 1.
FABRICATOR 210 Wheel Brake Hex Head Bolt Pressure Adjustment Device Art # A-08651 Wire Spool Hub Retaining Pin 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.
FABRICATOR 210 3.15 Spool Gun Attachment A spool gun can readily be used with the Fabricator 210 power supply. 1. Attach appropriate input gas to the Spool Gun input gas connection on the rear of the unit. (Refer to Figure. 3- 2.
FABRICATOR 210 3.16 Polarity Changeover WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power supply before proceeding. Do not reattach the input power until told to do so in these instructions. The output terminals are located on the front panel of the welding power source. CABLE TO GUN, CABLE TO WORK CABLE CONNECTIONS PROCESS...
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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. b.
FABRICATOR 210 SECTION 4: OPERATION WARNING DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding voltage potential. 4.01 Power Supply Controls, Indicators and Features Thermal Overload Indicator Wire Feed Speed Control Power ON/OFF Switch Weldskill Coarse Vo ltage Switch Selector...
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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. 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.
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FABRICATOR 210 Positive and Negative Welding Current Terminals Spool Gun Interface Amphenol Connector Refer back to Figure 4-1. Both terminals located at The Spool Gun Interface 10 pin connector is used to the bottom of the unit are shown without the terminal connect a spool gun to the Fabricator 210 (refer to knob.
FABRICATOR 210 4.02 Weld Mode Selector The Weld Mode Selector switch selects the method of welding mode. WELD MODE WELD DWELL (STITCH) (SPOT / STITCH) SPOT STITCH Art # A-07183_AB Figure 4-4: Internal Welding Controls This mode of welding is used to weld two plates 2T (Continuous Welding): together at a desired location by melting the top &...
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FABRICATOR 210 This mode of welding is used to weld two or more Dwell Stitch components together with a stitch weld. The WELD DWELL (STITCH) TIMER CONTROL (Spot/Stitch) shaft controls the welding or ‘ON’ time When the Weld Mode control is in the Stitch position, the and the "DWELL (Stitch)"...
FABRICATOR 210 4.03 MIG Gun Identification The FABRICATOR 210 comes with one of two versions of the TWECO Weldskill 210A MIG gun. The two guns can be easily distinguished from one another by their several obvious physical differences as depicted below. Be sure to identify which version you have before ordering the replacement parts listed on the following page.
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. Additional MIG Gun Parts See Appendix at the back of this manual.
FABRICATOR 210 4.05 Installing A New Wire Conduit 3. When the Wire Conduit Liner stop meets the end of the Connector Plug and the new raw end extends Removal through the end of the Conductor Tube on the welding gun, the allen screw in the connector plug must be 1.
FABRICATOR 210 4.06 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. 4.07 Basic Welding Technique 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.
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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. Flux Cored Wire Solid Wire Art # A-07186...
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 4-17: MIG Gun Angle 4.08 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.
FABRICATOR 210 4.09 Spot Welding Operation Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to Figure 4-18 and the Spot Welding Nozzle table below. The Fabricator 210 will operate effectively using .030” (0.8mm) electrode wire when spot welding.
FABRICATOR 210 4.10 Gas Selection for Gas Metal Arc Welding Suggested Base Plate Filler Transfer Welding Metal Type Shielding Comments Thickness Metal Mode Positions Greater than 22 ER70S-X Short High welding speeds. Good Carbon 100% CO gauge (.030”) Circuit Position penetration and pool control.
FABRICATOR 210 To clean the Power Supply, disconnect it from the mains SECTION 5: supply voltage then open the enclosure and use a vacuum MAINTENANCE & cleaner to remove any accumulated dirt and dust. The Power Supply should also be wiped clean. If necessary, TROUBLESHOOTING solvents that are recommended for cleaning electrical apparatus may be used.
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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.
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.
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FABRICATOR 210 WARNING Disengage the drive roll when testing for gas flow by ear. 2. Inconsistent wire feed FAULT CAUSE REMEDY 1. Wire spool brake is too a. Feed roller driven by motor in the cabinet will slip. tight. 2. Wire spool brake is too a.
FABRICATOR 210 5.04 Welding Problems FAULT CAUSE REMEDY A. Undercut. 1. Welding arc voltage a. Reduce voltage by reducing the voltage too high. selection switch position or increase the wire feed speed. 2. Incorrect torch a. Adjust angle angle 3. Excessive heat a.
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Check compatability to base metal B. Cold weld puddle. 1. Faulty rectifier unit a. Have an Accredited Service Thermal Arc Agent to test then replace the faulty component. 2. Loose welding cable a. Check all welding cable connections. connection.
B. Mains supply voltage is ON. 1. Primary fuse is blown. a. Replace primary fuse. Indicator light is not lit and 2. Broken connection in a. Have an Accredited Thermal Arc welding arc can not be primary circuit. Service Agent check primary established.
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FABRICATOR 210 NOTES SERVICE Manual No. 0-4855...
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, correct...
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year Engines and Associated Components are NOT Warranted by Thermal Arc®, See the Engine Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE Manufacturers’...
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 Telephone: 603+ 6092 2988 Fax: 800-535-0557...
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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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