Thermal Arc Fabricator 281 Service Manual
  1. Manuals
  2. Brands
  3. Thermal Arc Manuals
  4. Welding System
  5. 281 FABRICATOR
  6. Service manual

Thermal Arc Fabricator 281 Service Manual

Mig welding machine
Hide thumbs Also See for Fabricator 281:
Table of Contents

Advertisement

Quick Links

See also: Operating Manual
281

Service Manual

fabricator
MiG WeldinG Machine
Version No: AG
Issue Date: December 16 , 2010
Operating Features:
®
Art # A-09904
Manual No.: 0-4880B
208
1
Hz
V

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Fabricator 281 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Thermal Arc Fabricator 281

Summary of Contents for Thermal Arc Fabricator 281

  • Page 1: Service Manual

    ® fabricator MiG WeldinG Machine Art # A-09904 Service Manual Version No: AG Issue Date: December 16 , 2010 Manual No.: 0-4880B Operating Features:...
  • Page 2 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.
  • Page 3 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...

  • 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 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: Section 1: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.
  • Page 8 FABRICATOR 281 5. Use approved ear plugs or ear muffs if noise level is high. WARNING WELDING can cause fire or explosion. WARNING Sparks and spatter fly off from the welding arc. FUMES AND GASES can be hazardous to your health.
  • Page 9 FABRICATOR 281 WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. ENGINE FUEL can cause fire or explosion. Chipping and grinding cause flying metal. As welds Engine fuel is highly flammable. cool, they can throw off slag. 1. Stop engine before checking or adding fuel.

  • 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. 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 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 DANGERE- LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES USES POUR LA SANTE. YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’ Le soudage dégage des vapeurs et des fumées dan- OUIE.
  • Page 13 FABRICATOR 281 ces éléments peuvent dégager des fumées toxiques au moment du soudage. AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEUVENT EX- AVERTISSEMENT PLOSER LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE Les bouteilles contiennent des gaz protecteurs sous EXPLOSION haute pression. Des bouteilles endommagées peuvent L’arc produit des étincellies et des projections.

  • Page 14: Principales Normes De Securite

    FABRICATOR 281 2. Ne faites pas le plein en fumant ou proche d’une source d’étin- celles ou d’une flamme nue. 3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soud- age.

  • Page 15: Section 2:Introduction

    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 Manual No. 0-4880B...

  • Page 16: Symbol Chart

    FABRICATOR 281 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

    • Keep combustible materials away from the welding area. Have a suitable fire extinguisher handy. The Fabricator 281 is a 208-230 Volt MIG machine with a best in class performance of 300 Amp maximum • Never watch the welding arc with naked eyes.

  • Page 18: User Responsibility

    5.0 minutes out of every 10 minute period (50% of 10 approved by Thermal Arc Advice in this regard can be minutes is 5.0 minutes). During the other 5.0 minutes obtained by contacting Thermal Arc.
  • 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...

  • Page 20: Included Items

    FABRICATOR 281 2.10 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...

  • Page 21: Section 3:Installation

    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

    3.05 Alternative Primary Input Voltages WARNING The Fabricator 281 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 Secure the other voltage set screw as well. 208V connection 230V connection Art # A-07332 Figure 3-1: Voltage selections for Fabricator 281 (Wired for 230V) Manual No. 0-4880B INSTALLATION...

  • Page 24: Quick Setup

    3.07 and following subsections. 1. Mount the A2281 wire feeder unit on top of the Fabricator 281 power supply. 2. Connect the work lead to the negative (-) socket (positive + for Self Shielded Flux Cored Wire) 3.

  • Page 25: Mount The A2281 Wire Feeder

    Figure 3-3. 1. Mount the A2281 wire feeder unit on top of the 26ft (8m) Interconnection Cable Assembly Fabricator 281 power supply by engaging its swivel receptacle into the turret on top of the Fabricator 281. Refer to Figure 3-2.
  • Page 26 FABRICATOR 281 tray and with one foot press against the bottom of Argon or argon based gas flow rates: the cylinder to assure it is against the back of the - Workshop welding: 20-30 CFH unit. Chain the cylinder in place. (Refer to Figure 3-5...
  • Page 27 FABRICATOR 281 Shielding Regulator and Flowmeter “Cracking” Shielding Shielding Shielding To A2281 Wire Art # A-07964 Feeeder Gas Inlet Stowage Hook Gas Hose Figure 3-5 Gas Cylinder Installation Manual No. 0-4880B INSTALLATION...

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

    FABRICATOR 281 3.09 Attaching the Gun and Cable Assembly to the Remote Feeder The Fabricator 281 is supplied with a Tweco Weldskill 300 AMP air-cooled gun. The Weldskill gun is designed Art # A-07458_AB with an ergonomic handle and fewer parts to cause per formance problems.

  • Page 29: Selection And Installation Of Feedrolls

    FABRICATOR 281 Thumbscrew Art # A-07459 Figure 3-8: Mount Gun Cable to Adapter Socket 3.10 Selection and Installation of Feedrolls A Feedroll consists of two different sized grooves. As delivered from the factory the feedroll is installed for .035” / .045”...

  • Page 30: Input And Output Wire Guide Installation

    NOTE 3.12 Installing Wire Spool on the Remote Installation of all styles of feed rolls for the Fabricator 281 are identical. As delivered from the factory, the unit is set for a 33/44 lb. or 12" (300mm) spool. WARNING...
  • Page 31 FABRICATOR 281 3. Place Wire Spool onto the hub, loading it so that the wire will feed off the bottom of the spool as Wire Spool Hub Nut the spool rotates counter clockwise. Make sure to align the spool alignment pin on the hub with Alignment Pin the mating hole in the wire spool.

  • 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.

  • 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 3.14 Wirefeeder Feedroll Pressure 3.15 Wire Spool Hub Brake 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.
  • Page 35 FABRICATOR 281 The output terminals are located on the front panel of the welding power source. CABLE TO WIREFEEDER CABLE TO WORK CABLE CONNECTIONS PROCESS POLARITY CABLE TO A2281 CABLE TO WORK 1. GMAW* – Steel, Stainless Steel, 1. Connected to (+) 1.
  • 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.

  • Page 37: Section 4:Operation

    Weldskill 17V - 21V 13V - 16V 22V - 31V Coarse Voltage Selector Switch Fine Voltage Selector Switch Wirefeeder Interface Amphenol Receptacle Negative Welding Terminal Positive Welding Terminal Art # A-07462_AB Figure 4-1: Fabricator 281 Controls OPERATION Manual No. 0-4880B...
  • 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.
  • 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 Manual No. 0-4880B...
  • 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. Only pins 1 and 2 are used for this. plug or cable to interface with the SPOOL GUN 10-pin receptacle.
  • Page 42 FABRICATOR 281 Wirefeeder Interface Amphenol Receptacle The Wirefeeder 7 pin receptacle is used to connect the A2281 Wirefeeder to the welding Power Source. 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) his mode of welding is used to weld two plates WELD (SPOT / STITCH) together at a desired location by melting the top & bottom plates together to form a nugget between them. The spot time period is set by the Weld (Spot/ Stitch) timer control located in the electrode wire compartment.

  • Page 45: Tweco Weldskill 300 Amp Weld Gun

    4.03 TWECO Weldskill 300 AMP Weld Gun The TWECO Weldskill 300 AMP gun fitted to the Fabricator 281 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 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.

  • Page 47: Mig Gun Maintenance

    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. 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 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.
  • Page 49 FABRICATOR 281 Advantages of MIG welding forehand: • Allows superior visibility of the weld zone • Flatter weld bead • Shallower penetration Forehand Vertical Backhand Art # A-07185 Figure 4-15: MIG Gun Angle Manual No. 0-4880B 4-1 OPERATION...

  • 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 for consistent spot welding operations. Refer to weld bead.

  • Page 51: Gas Selection For Gas Metal Arc Welding

    FABRICATOR 281 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 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% ,25cfh Solid .035”...
  • Page 53 FABRICATOR 281 Coarse Voltage THICKNESS Fine Voltage 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...
  • Page 54 FABRICATOR 281 NOTES OPERATION 4-18 Manual No. 0-4880B...

  • Page 55: Section 5:Maintenance

    FABRICATOR 281 SECTION 5: MAINTENANCE To clean the Power Supply, disconnect it from the 5.01 Routine Maintenance & Inspection mains supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dirt and The only routine maintenance required for the Fabrica- 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.

  • Page 57: Section 6:Troubleshooting

    Ensure that the gas holes are not blocked and If major components are faulty, then the Power Supply gas is exiting out of the torch nozzle. Refer to should be returned to an Accredited Thermal Arc WARNING below Service Agent for repair.
  • Page 58 FABRICATOR 281 WELDING MACHINE 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. Slag can also be produced by the wire passing through an incorrect feed roll groove shape or size.

  • 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

    FABRICATOR 281 WELDING MACHINE 6.04 Power Supply Problems FAULT CAUSE REMEDY A. Indicator light in the ON/OFF Power 1. The ON/OFF Power Switch is Switch the ON/OFF Power Switch Switch is illuminated but welding arc off. can not be established.

  • Page 62: Wire Feeder Problems

    FABRICATOR 281 WELDING MACHINE 6.05 Wire Feeder Problems FAULT CAUSE REMEDY A 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.

  • Page 63: Section 7: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

    Set the power supply controls and connect cables as A. Close primary disconnect device and observe the follows: following: FABRICATOR 281 POWER SUPPLY 1. Green Indictor Lamp inside ON/OFF Switch (SW1) on the Power Supply illuminates 1. ON/OFF Switch to OFF Position B.

  • 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 Set WELD (SPOT/STITCH) TIMER CONTROL to above are all correct then proceed to paragraph 'C'. minimum. If the above 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 for 230VAC input (see Input Terminal Block 7.07 Wire Feed & Weld Test Figure 7.1). A. Close the PRESSURE ADJUST DEVICE. Connect the B. Green Indicator in ON/OFF Switch (SW1) on Power GUN POLARITY LEAD to the POSITIVE WELDING Supply is illuminated.

  • 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 is present, replace PCB 1 A. Nothing happens when gun switch is depressed; No gas flow, contactor does not energize, feed C.

  • Page 70: Spool Gun Control (J1) Problem

    FABRICATOR 281 3. Defective or faulty connection on Umbilical 2. PCB 4 is defective. Cable. a. Measure voltage between X1-3 to X1-1 for a. Measure between JB-7 to JB-9 for approx 32VAC. If voltage is correct, replace PCB4. 15VDC. If voltage is not correct, then check 7.10 Spool Gun Control (J1) Problem...

  • 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. Art # A-08568 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.
  • 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. Art # A-08571 Set Screw Knob Retainer Locking Collar Rotary Switch...

  • 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...

  • 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.

  • 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 be- tween the two transformer output connections as follows: COARSE VOLTAGE SELECTION FINE VOLTAGE SELECTOR VOLTAGE AC (approx.)

  • Page 77: Circuit Operation Of The Control Pcb 7978050

    FABRICATOR 281 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 PCB7978050 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 78 FABRICATOR 281 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 79 FABRICATOR 281 8.04 Circuit Operation Of The Spool Gun Terminal X2/4 trigger relay - connects to trigger input of PCB 7978034 7978050 PCB Terminal X2/5 CONNECTOR X1 trigger relay - connects to trigger input of Terminal X1/1 7978050 PCB motor relay "normally open" - connects to spool...
  • Page 80 FABRICATOR 281 CIRCUIT OPERATION Manual No. 0-4880B...

  • Page 81: Section 9:Parts List

    FABRICATOR 281 WELDING MACHINE 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 82: Power Supply External Replacement Parts (1)

    FABRICATOR 281 WELDING MACHINE 9.03 Power Supply External Replacement Parts (1) ITEM PART NUMBER DESCRIPTION REF. DES. 704883PKD PCB,Digital Meter,Fab251/281 PCB4 7977978 Knob,Output Terminal,Fabs 831270PKD Label,Weld Guide,Fab281 7977683PKD Latch, Slide,Door Latch 707273PKD Panel,Door-Side LH,Fab281 See Note 1 Nut, Hex, Nyloc, M8-1.25 705936PKD Handle Mount, Fabricator 705956PKD Handle Bar, Fab210/251/281 See Note 1 Screw,Hex HD,M5x13mm,Self Tap 707230WBLK Bracket,Cable Hanger,251/281 7978035PKD Wheel, 5/8" IDx10" OD 8 70921WBLKPKD Bracket,Front Wheels 7977566 Castor, Swivel, 5" Wheel...
  • Page 83 FABRICATOR 281 WELDING MACHINE Art # A-07534 Manual No. 0-4880B PARTS LIST...

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

    FABRICATOR 281 WELDING MACHINE 9.04 Power Supply External Replacement Parts (2) ITEM PART NUMBER DESCRIPTION 707282CLAPKD Panel,Top,Fab281 401840-003 Cable, Power Cable, Fab251/281 7 07256WBLKPKD Panel,Base,Fab210/251/281 See Note 1 Screw,Hex HD,M5x13mm,Self Tap 707276PKD Panel,Side RH,Fab281 871046PKD Clip, Retaining, 5/8" ID 7977953PKD Swivel, Top, Wirefeeder Note 1 These parts are available at most hardware stores. Art # A-07535 PARTS LIST Manual No.

  • Page 85: Power Supply Electrical Replacement Parts

    FABRICATOR 281 WELDING MACHINE 9.05 Power Supply Electrical Replacement Parts ITEM PART NUMBER DESCRIPTION REF DESIGNATION QTY 7977884PKD Switch,DPST,Grn,16A,250V SW1 7977950 Switch,32A,8 Pos,Fab251/281 SW2 7977951 Switch,32A,3 Pos,Fab251/281 SW3 707304PKD Harness,Control,Fab251 707308PKD Transformer,Fab251/281 7977832PKD Switch,Thermostat, 207°C TS1 7978038PKD Fan Assy, 208-230VAC,8",24Vac 7977974 Terminal, Output, Fabricators 704978PKD Suppressor Assy,Fab210/251/281 871088PKD Harness, Control, Fab281 10-6131...

  • Page 86: Remote Parts (1)

    FABRICATOR 281 WELDING MACHINE 9.06 Remote Parts (1) ITEM PART NUMBER DESCRIPTION REF DESIGNATION QTY 7977683PKD Latch, Slide,Door Latch 707293PKD Panel,Cover & Door,A2281 707278PKD Panel,Front,Fab281 7977884PKD Switch,DPST,Grn,16A,250V SW4 870696PKD Knob,Control,1/4" IDx1.6" 405376 Hub, Wire Spool 7977903PKD Wheel, 1/2" IDx5" OD 7977928PKD Castor, Swivel, 2" Wheel 7978029PKD Bushing, Snap, 1.69" ID 871011PKD Bushing Torch 870734 Knob,Control,1/4" IDx.57" 8 71070WBLKPKD Handle, Wrfdr A2281 See Note...

  • Page 87: Remote Parts (2)

    FABRICATOR 281 WELDING MACHINE 9.07 Remote Parts (2) ITEM PART NUMBER DESCRIPTION 7977978 Knob,Output Terminal,Fabs NB2157 Cup, Retaining, 1/2" ID 871067PKD Axle,1/2" Diax15.47",A2281 8 71068WBLKPKD Plate Mounting Castor Wrfdr 7977966PKD Swivel, Base, Wirefeeder 707288PKD Panel,Rear,A2281 7977948PKD Connector Plug, 7 Pin Art # A-07539 Manual No. 0-4880B PARTS LIST...

  • Page 88: Remote Parts (3)

    FABRICATOR 281 WELDING MACHINE 9.08 Remote Parts (3) ITEM PART NUMBER DESCRIPTION 204036 Label,Precautions,Arc Equip 831247PKD Label, Mode Select, Fab281 871081PKD Shroud Wrfdr A2281 377941 Guide,Input,.030-.045,2R Plate 405377 Nut, Wire Spool Hub 7 07289WBLKPKD Panel,Internal,A2281 Art # A-07561 PARTS LIST Manual No. 0-4880B...

  • Page 89: Remote Electrical Components (1)

    FABRICATOR 281 WELDING MACHINE 9.09 Remote Electrical Components (1) ITEM PART NUMBER DESCRIPTION 7977965PKD PCB,Timer,Fab210/251/A2281 PCB2 871003PKD Solenoid Assy,24VAC, A2281 Y1,Y2 7978034PKD PCB,Spool Gun,Fab251/281 PCB3 7978050 PCB, Control, Fabricators PCB1 7976754PKD Terminal Block,12 Way,25A Art # A-07538 Refer to Appendix 7 for Terminal Block Wiring Information Manual No. 0-4880B...

  • Page 90: Remote Wire Feeder Parts

    FABRICATOR 281 WELDING MACHINE 9.10 Remote Wire Feeder Parts ITEM PART NUMBER DESCRIPTION REF DESIGNATION QTY ALL 871079PKD Feed Drive Assy,2 Roll,Tweco#4 870891PKD Motor,Wire Drive,3.2A 20VDC 8 71064WBLKPKD Bracket, Feed Plate, A2281 871077PKD Plate,Adaptor,Motor,A2281 See Note 1 Screw,PHCR,M6-1x16mm, STZP 8 70695-001PKD Insulator, Motor, 2R Plate 870932PKD Feed Plate, 2 Roll,Tweco#4 375298 Gas Nipple, #10-32 UN,2R Plate 400562-048 Spring,Clamp,2R Plate 171374 Insulator,Screw mtg,2R Plate See Note 1 Screw,PHCR,M6-1x30mm, STZP 171362...
  • Page 91 FABRICATOR 281 WELDING MACHINE Art # A-07562 Manual No. 0-4880B -11 PARTS LIST...

  • Page 92: Mig Torch

    FABRICATOR 281 WELDING MACHINE 9.11 MIG Torch ITEM PART NUMBER DESCRIPTION 43340 Weldskill MIG Gun, 280A 15FT Note Refer to Appendix 1 for individual components. Art # A-07560 PARTS LIST -1 Manual No. 0-4880B...

  • 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...

  • 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 FABRICATOR 281 COARSE 4A BLK 8&8A BRN (10) 8 BRN 9&9A BLK (12) (11) 9 BLK 10&10A RED...
  • 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 704883 + C1 - C4 Varistor 23 GRY X1/4 DIG METER 30A BRN...

  • Page 96: Appendix 3: Main Pcb Circuit Diagram

    FABRICATOR 281 APPENDIX 3: MAIN PCB CIRCUIT DIAGRAM 30 VAC Art # A-07520 APPENDIX Manual No. 0-4880B...
  • Page 97 FABRICATOR 281 82 BENNING SREET WEST LEBANON, NH 03784, USA DESCRIPTION: FABRICATOR MAIN PCB 7978050 Art # A-07520_AB Manual No. 0-4880B APPENDIX...

  • Page 98: Appendix 4: Spot Timer Circuit Diagram

    FABRICATOR 281 APPENDIX 4: SPOT TIMER CIRCUIT DIAGRAM Art # A-07521 APPENDIX Manual No. 0-4880B...
  • Page 99 FABRICATOR 281 82 BENNING SREET WEST LEBANON, NH 03784, USA DESCRIPTION: FABRICATOR SPOT TIMER 7977965 CODE DESIGN: Art # A-07521 Manual No. 0-4880B APPENDIX...

  • Page 100: Appendix 5: Spool Gun Pcb

    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...
  • Page 101 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...

  • 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...

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

    FABRICATOR 281 APPENDIX 7: WIRE FEEDER TERMINAL BLOCK DIAGRAM Art # A-07599 orange 31 gray 36 white 38 & 38A brown 30 white 32 & 32A gray 47 orange 48 FRONT OF WIRE FEEDER Manual No. 0-4880B A-11 APPENDIX...
  • Page 104 FABRICATOR 281 APPENDIX A-1 Manual No. 0-4880B...

  • Page 106: 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 107: Warranty Schedule

    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’...
  • Page 108 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 •...

Table of Contents

Save PDF