T.L. FAHRINGER FW-200 HPA Owner'S Manual Download

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FW-200 HPA

FLASH-BUTT WELDER

OWNER’S MANUAL

T. L. Fahringer Co.

P.O. Box 1412

Brandon, FL 33509-1412

Toll Free: 800-237-3829

Local: 813-681-2373

Web: www.fahringer.com

Summary of Contents for FW-200 HPA

Page 1: ...FW 200 HPA FLASH BUTT WELDER OWNER S MANUAL T L Fahringer Co P O Box 1412 Brandon FL 33509 1412 Toll Free 800 237 3829 Local 813 681 2373 Web www fahringer com ...

Page 2: ...IMPORTANT PLEASE READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE OPERATING THIS MACHINE PERFORMING IMPROPER PROCEDURES MAY VOID THE WARRANTY ON THIS MACHINE AND COULD CAUSE SERIOUS INJURY TO THE OPERATOR ...

Page 3: ...lamping Pressure Distribution Adjustment 2 6 Blade Guide Alignment Back Edge 2 7 Blade Guide Alignment Tooth Edge 2 7 Forge Pressure Switch Calibration 2 8 Weld Setup 2 9 Manual Welding Procedure 2 9 Anneal Setup 2 10 Manual Annealing Procedure 2 10 Obtaining New Anneal Settings 2 11 Automatic Welding and Annealing Procedure 2 11 Settings Chart 2 12 Section 3 Maintenance Care and Maintenance of We...

Page 4: ...Section 1 INSTALLATION ...

Page 5: ...the auto switching outlet 100 psi air supply and air hose with standard female quick disconnect fitting Oil 30 weight or heavier Water cooling pump to accept 1 4 I D water cooling hose and tank to hold at least 15 U S gallons of water i e LITTLE GIANT model 2E N pump Dial or digital calipers 4 6 ITEMS REQUIRED FOR OPERATING THE FW 200 HSA 3 16 T handle allen wrench at least 3 long Ratchet wrench w...

Page 6: ... wires are already attached the order does not matter 9 Attach the green Ground wire to MAIN POWER block at the input where the green ground wires are already attached 10 If desired plug the female end of an extension cord to the male receptacle attached to the auto switching outlet on the back of the welder and plug the other end of the extension cord into a standard 115 VAC powered outlet The au...

Page 7: ...Section 2 OPERATING INSTRUCTIONS ...

Page 8: ...FW 200 HPA Rev 4 2 1 ...

Page 9: ...e WELD VOLTAGE SWITCH P2 ANNEAL HEAT 2 KNOB Adjusts the anneal heat for the Soak Stage Heat Range 100 999 100 0 volts 999 Max Weld Voltage as set by the WELD VOLTAGE SWITCH T1 ANNEAL TIMER 1 Sets the amount of time Anneal Heat 1 is applied for the Ramp Stage Set the time by pressing the button below the display that corresponds with the position of the number you want to change T2 ANNEAL TIMER 2 S...

Page 10: ... clamps simultaneously M1 WELD VOLTAGE METER Indicates the output voltage level at the jaws M2 LINE VOLTAGE METER Indicates the voltage level powering the machine L1 POWER LIGHT Indicates the main power is turned ON R1 FORGE PRESSURE REGULATOR Adjusts the amount of pressure applied to the sliding carriage assembly during forging CW Adjusts the pressure higher CCW Adjusts the pressure lower R2 FOLL...

Page 11: ... POSITION INDICATOR Indicates the current position of weld current cut off JAWS Clamp the blade to be welded or annealed between the upper and lower jaws BLADE GUIDES Guides to align the blade horizontally Guides to align either the back edge or tooth edge of the blade are available Positions 1 4 on the tooth edge guides are for smaller to larger tooth sizes respectively ...

Page 12: ...O EXIT SETUP Just press the ANNEAL BUTTON at any time WHILE IN SETUP The WELD BUTTON acts as a toggle ON OFF for the cam motor The ADVANCE BUTTON acts as a jog for the cam motor The cam motor speed is set at the rapid feed rate when the mode switch is set to WELD ONLY The cam motor speed is set by the FLASHING SPEED SWITCH when the mode switch is set to NORMAL Clamping is disabled JAW GAP DISTANCE...

Page 13: ...ps and look at the impressions of the jaws on the white paper They should be an even color from front to back This denotes even clamping pressure If the impressions are not even the points of darkest color and greatest width indicate the areas of heavier clamping pressure Follow the procedure below to adjust how the clamping pressure is distributed PLEASE NOTE It is normal for the upper jaw impres...

Page 14: ...aws push it against the inside guides and clamp it in place 7 Pull the outside guides against the straightedge and tighten them in place 8 Unclamp and remove the straightedge from the machine TOOTH EDGE GUIDE CALIBRATION 1 Mount the inner guides to the front of the carriages making sure the mating surfaces are clean and smooth and rotate them to setting 4 Note Make sure the front of the lower jaws...

Page 15: ...the timing mark toward the drop off until the machine beeps then stop immediately 6 The cam follower should be lined up with the cam about 1 16 above the drop off right when the machine beeps See Cam Diagram a If the forge pressure is calibrated proceed to step 12 b Otherwise proceed to step 7 7 Remove the top cover from the machine 8 Adjust the trip position if necessary by loosening the set scre...

Page 16: ...E REGULATOR to the desired setting SELECT FLASHING SPEED Set the FLASHING SPEED SWITCH to a position 1 6 SET BLADE GUIDES Adjust the BLADE GUIDES to accommodate the blade s tooth size ADJUST CLAMPING PRESSURE DISTRIBUTION Check the clamping pressure distribution and adjust if necessary MANUAL WELDING PROCEDURE 1 Select MANUAL or WELD ONLY mode 2 Setup for the desired blade size See WELD SETUP 3 Se...

Page 17: ...heck the clamping pressure distribution and adjust if necessary MANUAL ANNEALING PROCEDURE 1 Set the mode switch to MANUAL 2 Setup for the desired blade size See ANNEAL SETUP 3 Advance to the ANNEAL position a Both clamps must be UP b Press the ADVANCE BUTTON until the red anneal light comes on 4 Load a welded blade a With both clamps UP insert the blade with the weld burr between the jaws and the...

Page 18: ...the machine if necessary a The welder is out of calibration if the green light does not come on and a second beep sounds at the weld start position b With both clamps UP press the ADVANCE BUTTON to re calibrate 5 Select the desired clamping mode 6 Adjust air blow off hoses Adjust the air blow off hoses so they are aimed at the center of the blade where it meets the outer jaws 7 Advance to the weld...

Page 19: ... 6 2 3 0 3 6 2 10 280 310 002 010 1 2 5 6 4 8 3 5 1 3 6 3 10 300 325 005 010 2 3 4 6 6 10 3 5 2 3 6 3 10 325 350 005 015 2 3 4 6 15 25 4 6 3 4 8 5 10 350 400 010 040 3 4 4 6 25 40 4 6 4 4 10 5 10 400 475 020 050 4 5 4 6 35 45 5 8 5 5 10 5 20 475 550 030 075 4 6 3 5 35 55 7 10 7 5 15 10 25 500 575 035 125 5 6 3 5 40 60 7 10 10 5 15 10 30 1 1 1 4 1 1 2 2 1 4 3 8 1 2 3 4 WELD SETTINGS RAMP STAGE SOAK...

Page 20: ...ADE SIZE TYPE JAW GAP in TIMING in WELD VOLTAGE FLASHING SPEED FORGE PRESSURE psi FOLLOW PRESSURE psi DELAY TIME sec ANNEAL HEAT 1 ANNEAL TIME 1 ANNEAL HEAT 2 ANNEAL TIME 2 WELD SETTINGS RAMP STAGE SOAK STAGE ANNEAL SETTINGS ...

Page 21: ...Section 3 MAINTENANCE ...

Page 22: ...0 of material to restore the finish on the welding side of the jaws The bottom beveled side of the jaws also need to be surface ground to clean in order to maintain parallelism and to remove warping The upper steel jaws also need to be reground periodically though not as often due to the better wear qualities of steel These jaws must also be ground together for the same reasons as the lower jaws b...

Page 23: ... has been completed Check the oil level in the hydraulic pump reservoir and add oil if necessary A drop in the oil level would indicate a leak in the system and should be corrected as soon as possible Hydraulic Oil Type AW68 Check the oil level in the air lubricator and add oil as needed It is normal for the air lubricator to loose oil and should need filling once every month or so If it is not lo...

Page 24: ... the allen wrench inserted into one of the mount screws to keep the slide from falling out when removing the block 5 Using a flat blade screwdriver pry the clamp block pushrod down until there is about a 1 32 gap between the clamp block and the carriage 6 Pull the clamp block straight out REMOVING THE LOWER JAWS Remove the two lower jaw mount screws to remove the jaws See Diagram REMOVING THE GUID...

Page 25: ...reads but do not tighten them 7 Install the spring retainer assembly and tighten the screw down 8 Now tighten the clamp block mount screws down all the way 9 Make sure the spring retainer is not tightened down on the slide by turning the adjustment screw back and forth The clamp block should move freely If it does not loosen the assembly and adjust to fix the problem CAUTION It is very important t...

Page 26: ...arranty repair After the first 90 days the customer is responsible for all freight charges to and from T L Fahringer Company s plant All warranty returns must be authorized by T L Fahringer Co in advance Furthermore any further damage that occurs to equipment during shipment back to T L Fahringer Co will not be covered under warranty It is the sender s responsibility to package the equipment prope...

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