Thermal Arc C/W VFE 4C HS III Operation Manual Download Page 1

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FABRICATOR

MIG Power Supplies

Operation Manual

Version No:

Issue Date:

July

201

Operating Features

250C III

320C III

320S III

C/W VFE 4C III

400S III

C/W VFE 4C III

500S III

C/W VFE 4C HS III

250

AMP

320

AMP

400

AMP

500

AMP

Summary of Contents for C/W VFE 4C HS III

Page 1: ...Supplies Operation Manual Version No AW 02 Issue Date July 13th 2012 Operating Features 250C III 320C III 320S III C W VFE 4C III 400S III C W VFE 4C III 500S III C W VFE 4C HS III 250 AMP 320 AMP 40...

Page 2: ...They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Glob...

Page 3: ...Number FAB400S Fabricator 500S III MIG Welding Machine Part Number FAB500S Published by Thermadyne Industries Ltd Chorley North Industrial Park Chorley Lancashire PR6 7BX England www thermadyne com R...

Page 4: ...put Power 13 3 06 Specifications 14 SECTION 4 OPERATOR CONTROLS 16 4 01 Fabricator Layout 250C 320C 16 4 02 Fabricator Layout 320S 400S 18 4 03 Fabricator Layout 500S 22 SECTION 5 UNDERSTANDING AND SE...

Page 5: ...02 Inconsistent wire feed 43 10 03 Welding Problems 44 10 04 Power Source Problems 45 SECTION 11 SPARE PARTS 48 11 01 Parts description Fabricator 250C 320C 48 49 11 01 Spare part numbers Fabricator 2...

Page 6: ...4 Figure 19 Aluminium Liner Information 35 Figure 20 Two Stroke Description 37 Figure 21 Four Stroke Description 37 Figure 22 Spot Stitch Description 38 Figure 23 Spot Stitch Description 38 Figure 24...

Page 7: ...of service 7 Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the...

Page 8: ...ch for fire and keep a fire extinguisher nearby 5 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 6 Do not weld on closed containers such as tanks or d...

Page 9: ...ATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery 2 Stop engine before disconnecting...

Page 10: ...Page left blank intentionally 4...

Page 11: ...s designed and manufactured to a number of standards and technical requirements Among them are CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN...

Page 12: ...ied by any other party other than Thermadyne s own service personnel or with prior written consent obtained from Thermadyne Service Department Equipment that has been used beyond the specifications es...

Page 13: ...1 04 SYMBOL LEGEND Figure 2 7...

Page 14: ...and equipment identification numbers Electronic copies of this manual can also be emailed to you at no charge in Acrobat PDF format by contacting Thermadyne Customer Service on 44 01257 261755 2 02 Eq...

Page 15: ...y electrically in accordance with local regulations Excessive heat in the welding cables may cause fire Never weld with poor electrical connections damaged welding cables or exceed the welding cable c...

Page 16: ...ch results from improper use or unauthorized modification from standard specification faulty maintenance damage or improper repair by anyone other than appropriately qualified persons approve by Therm...

Page 17: ...r according to the following guidelines In areas free from moisture and dust Ambient temperature between 0 degrees C and 40 degrees C In areas free from oil steam and corrosive gases In areas not subj...

Page 18: ...ted at the welding power source end for three phase electrical input power Do not connect an input BROWN BLUE or RED conductor to the ground terminal Do not connect the ground YELLOW GREEN conductor t...

Page 19: ...ding power source and will void the manufactures warranty NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and...

Page 20: ...ange switched steps 10 12 WIRE FEEDER Supply voltage N A 24Vac Speed 1 19 m min 1 19 m min Number of feed rolls 2 4 Spool Spool weight max 300mm 18 kg max 300mm 18 kg Dimensions H x W x D N A 510 x 27...

Page 21: ...e 100 Selection range switched steps 2 10 3 10 WIRE FEEDER Supply voltage 24Vac 24Vac Speed 1 19 m min 1 25 m min Number of feed rolls 4 4 Spool Spool weight max 300 mm 18 kg max 300mm 18 kg Dimension...

Page 22: ...SECTION 4 OPERATOR CONTROLS 4 01 Fabricator Layout 250C III 320C III Compact Unit Figure 4 Power Source Front Power Source Back Power Source WFU Side 16...

Page 23: ...rity output from the Power Source that offers two inductances of different values to the Metal plate via an earth lead It is essential that the male plug is inserted and turned securely to achieve a s...

Page 24: ...4 02 Fabricator Layout 320S III 400S III C W VFE 4C III Wire Feed Unit Figure 5 Power Source Front Power Source Back Power Source Connection Side Power Source WFU Side 18...

Page 25: ...urce that offers two inductances of different values to the Metal plate via an earth lead It is essential that the male plug is inserted and turned securely to achieve a sound electrical connection ma...

Page 26: ...trol Socket inlet This male 7 pin receptacle is used to connect a Wirefeeder from the welding power source circuitly A17 Gas inlet The Gas Inlet connections a quick fit connector supplied via the gas...

Page 27: ...This page has been left blank intentionally 21...

Page 28: ...4 03 Fabricator Layout 500S III C W VFE 4C III Wire Feed Unit Inc Cooler Option Figure 6 Power Source Front Power Source Back Power Source Connection Side Power Source WFU Side 22...

Page 29: ...or Feed Roll Assembly A9 Wire Spool Holder A10 Gas inlet The Gas Inlet connections is a 3 8 BSP male gas fitting supplied via the gas hose on the interconnecting lead A11 Primary Power Cable The input...

Page 30: ...red outlet Quick fit connections for water return from a water cooled MIG torch A27 Quick Fit water outlet Connector Female blue outlet Quick fit connections for water outlet for a water cooled MIG to...

Page 31: ...hanical damage Control Knob Encoder For the selected parameter rotating the knob clockwise or anticlockwise increases or decreases the parameter Digital Volt and Ammeter Displays selected weld paramet...

Page 32: ...chine On Off Switch V4 Voltage Control Switch 250II 10 Position switch V4 Voltage Control Switch 320III 12 Position switch V5 Wire Speed Dial V6 Spot Time Dial V7 Interval Time Dial V8 Power LED V9 Th...

Page 33: ...ntrol PCB C W Digital Display and Encoder V2 Machine ON OFF Switch V3 Voltage Control Switch Coarse 320C III N A V3 Voltage Control Switch Coarse 400S III 2 position switch V3 Voltage Control Switch C...

Page 34: ...RESET together with button X2 X2 Button Gas test Default RESET together with button X1 X3 Button Switches between 2T or 4T Press hold for 3 seconds this will initiate spot interval mode Enters second...

Page 35: ...tack welding s Int Time of interval s X9 LED Cooling circuit error if cooler system fitted X11 LED Thermal overheating Leave the machine on to cool down by means of the fans X12 Right Display Voltage...

Page 36: ...5 05 WIRE FEEDER MOTOR FEEDROLL ASSEMBLY Figure 10 Wire feed Assembles 4 rolls 2 rolls Pos Description E1 Fixing shaft E2 Pressure arm E3 Liner Feeder E4 EURO connector E5 Roll Plastic cup 30...

Page 37: ...1657 0 8 1 0 2188 2188 2150 1 0 1 2 2189 2189 2062 1 4 1 6 2176 2176 1656 1 2 1 6 2511 2511 1729 2 0 2 4 2512 2512 1842 0 8 1 0 2270 2270 2239 1 0 1 2 2269 2269 1829 1 4 1 6 2315 2315 2305 1 2 1 6 231...

Page 38: ...ect the coolant c onnections 5 of the torch with the sockets 3 and 4 Connect the red fitting together and the blue fittings together Figure 13 6 02 How to connect the work lead Connect the work lead 7...

Page 39: ...min 6 05 How to fit the wire spool Open the wire feed compartment lid on the machine or wire feed case and un screw the nut 11 from the wire support coil hub 9 Place wire spool on the hub 9 and ensur...

Page 40: ...rch cable out straight and press the inch button switch on the wire feed front panel Adjust the pressure at the pressure adjustment screws 12 so the wire feed rolls drive the wire consistently without...

Page 41: ...wire diameter x 10 l min 6 08 How to configure the machine for aluminium welding Change the feedrolls to U groove for aluminium wire Change the torch liner to a nylon or teflon liner Remove the capill...

Page 42: ...in four modes Continuous two stroke 2T Continuous four stroke 4T Spot welding Interval welding 7 03 Secondary parameters If necessary it is possible to change the secondary parameters Initial wire spe...

Page 43: ...on 7 05 Four stroke Press the button 3 2T 4T and select the LED 4 The four stroke mode is being used mostly for long welds when there is no need to hold the torch button pressed The welding procedure...

Page 44: ...ing mode is being used for welding short welds of the same length The pressing the torch button activates the time circuit that starts and end the welding procedure This mode is available in 2T or 4T...

Page 45: ...the work piece If the Wirespeed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool and does not melt Welding in these conditions normally produces a poor we...

Page 46: ...roductivity will be achieved by using smaller electrode wire The Fabricator is a particularly efficient MIG welder with 0 9mm steel wire in spray tranfer mode Higher current density or smaller diamete...

Page 47: ...Wirefeeder disconnect it from the mains supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The Power Source Wirefeeder should also be wiped clean I...

Page 48: ...uced by checking the following points 1 Gas cylinder contents and flow meter Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 15 litres per minute 2 Gas leaks Chec...

Page 49: ...applied to the pressure roller adjuster Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size Swarf is fed into the liner where it accumulates thus reduc...

Page 50: ...B Increase joint angle or gap C Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase voltage by increasing voltage selection switches position 4 Excessive spatter...

Page 51: ...e a crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG torch has been connected to the wrong voltage polarity on the front panel Connect the MIG tor...

Page 52: ...rea and ensure good electrical contact 7 Wire continues to feed when the torch trigger switch is released The Mode Selection has been set to 4T latch operation Set the Mode Selector Switch has been se...

Page 53: ...This page has been left blank intentionally 47...

Page 54: ...SECTION 11 SPARE PARTS 11 01 Parts Description Fabricator 250C 320C Figure 26 48...

Page 55: ...BV0318 Feeder Cover Plastic 1 18 FAB1627 Spool Holder Black 1 19 FABK910 Adapter up to 18 kg 2 20 FABV20206 3B Side cover left 1 21 FABV20210 3B Side cover right lower 1 22 FABV20216 5B Front panel An...

Page 56: ...FABT25 TERP Transformer 250 Switch TERMINAL 1 48 FABT32WSK TERP Transformer 320 Switch TERMINAL 1 49 FAB1195 1 Rectifier 250 1 49 FAB1538 1 Rectifier 320 1 50 FABV20009 1 Holder of choke galvanized 2...

Page 57: ...11 02 Parts Description Fabricator 320S 400S Figure 27 51...

Page 58: ...1 21 FABV20210 3B Lateral cover right lower 1 22 FABV20217 9B Front panel matt 1 22 FABV20221 3B Front panel Digital RAL matt 9005 1 23 FAB3598 Handle Holder L 1 24 FAB3599 Handle Holder R 1 25 FABV1...

Page 59: ...6 FABAO 20610 Quick Connector 35 70 Panel Socket 1 57 FABVM0344 Bundle clamp 1 58 FAB2115 Diode LED 10mm green 1 59 FAB4298 Packing 6 35 38mm 1 60 FAB2036 Switch VS16 400S 1 61 FAB4263 Knob arrow 34mm...

Page 60: ...connectors galvanized 1 4 FABV10002 3 Cover upper PS matt 1 5 FABV10006 4 Cover left Gloss 1 6 FABV10007 4 Cover right Gloss 1 7 FABVA0011 4A Facia panel matt 1 8 FABVA0004 15 Support vertical compact...

Page 61: ...k 2 23 FAB4121 Door Hinge 2 24 FABVM0112 YQ Bundle PS Y DIGITAL 1 25 FABBG 90625 Connector EURO Body 1 26 FAB3979 d Control PC Board Digital 1 27 FAB3505 Film PCB PANEL 1 28 FAB2917 1 Shunt 400A 60mV...

Page 62: ...11 04 Parts Description Fabricator 500S Figure 29 56...

Page 63: ...18 FAB3598 Handle Holder L 1 19 FAB3599 Handle Holder R 1 20 FABV10551 4N Handle bar galvanized 1 21 FABV10300 1A Carriage compact matt 1 22 FAB4273 Choke 500S 1 23 FABVM0353 Switch VS16 ON OFF 1 25...

Page 64: ...38mm 1 66 FAB1343 Knob arrow OM R 5 Red 1 67 FAB1141 Knob arrow OS C 6 Black 2 68 FAB4236 Filter FC 61113 R 1 69 FAB3252 Filter FZ 730 43 3 71 FABVM0370 Cables 500S 1 76 FABVM0104 Mains Cable 4x4mm 1...

Page 65: ...10004 6 Barrier of connectors galvanized 1 4 FABV10002 3 Cover upper PS matt 1 5 FABV10006 4 Cover left Gloss 1 6 FABV10007 4 Cover right Gloss 1 7 FABVA0011 4A Facia panel matt 1 8 FABVA0004 15 Suppo...

Page 66: ...22 FAB7 686 300 Door Lock 2 23 FAB4121 Door Hinge 2 24 FABVM0112 YQ Bundle PS Y DIGITAL 1 25 FABBG 90625 Connector EURO Body 1 26 FAB3979 d Control PCB 1 27 FAB3505 Film PCB PANEL 1 28 FAB2917 1 Shunt...

Page 67: ...VM0373 Tank Water cooling 1 7 FAB4172 Fan 500S Cooler 1 8 FAB4131 Heat Exchanger 1 9 FAB2546 Clamp 8 12 10 10 FAB3490 Fitting GES 8 R 1 4 2 11 FABVS040375 Adaptor FEMALE for flow sensor FL 2000 1 11 F...

Page 68: ...SECTION 12 MACHINE SCHEMATICS 12 01 Power Source Schematic Fabricator 250C III 320C III Figure 32 62...

Page 69: ...12 02 Power Source Schematic Fabricator 320S III 400S III Figure 33 63...

Page 70: ...12 03 Power Source Schematic Fabricator 500S III Figure 34 64...

Page 71: ...12 04 Wire Feed Unit Schematic VFE 4C III VFE 4C HS III WFU Figure 35 65...

Page 72: ...Water Cooled 500S 10M Interconnecting Cable Assy Water Cooled 500S Feed Rolls for Fabricator 250C 320C 320S 400S 0 6 0 8mm Hard Wire V Groove Feed Roll 1 0 1 2mm Hard Wire V Groove Feed Roll 1 2 1 6mm...

Page 73: ...This page has been left blank intentionally 67...

Page 74: ...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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