Thermal Arc FABRICATOR 210 Operating Manual Download Page 1

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208

208
V

230

230
V

250

FABRICATOR

MIG WELDING MACHINE

210

Operating Manual

Revision:

Issue Date:

November 13, 2009

Manual No.:

0-4855

Operating Features:

t # A-07360

Summary of Contents for FABRICATOR 210

Page 1: ...208 208 V V 230 230 V V 60 60HZ 250 250 FABRICATOR MIG WELDING MACHINE 210 Operating Manual Revision AH Issue Date November 13 2009 Manual No 0 4855 Operating Features Art A 07360...

Page 2: ...tions 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...

Page 3: ...03 298 5711 www thermalarc com Copyright 2006 2007 2008 2009 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher...

Page 4: ...07 Duty Cycle 2 3 2 08 Specifications 2 3 2 09 Included Items 2 5 2 10 Optional Accessories 2 5 SECTION 3 INSTALLATION 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Input Power...

Page 5: ...Welding Operation 4 12 4 10 Gas Selection for Gas Metal Arc Welding 4 13 4 11 Welding Setting Selection Guide 4 14 SECTION 5 MAINTENANCE TROUBLESHOOTING 5 1 5 01 Routine Maintenance Inspection 5 1 5...

Page 6: ......

Page 7: ...s or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above floor leve...

Page 8: ...can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire 1 Protect yourself and others from flying sparks and hot metal 2 Do not...

Page 9: ...xhaust gases 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes WARNING ENGINE FUEL can cause fire or e...

Page 10: ...e based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arra...

Page 11: ...GMAW Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Lin...

Page 12: ...n sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliques en con...

Page 13: ...ans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Ass...

Page 14: ...rode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage 11 Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s c...

Page 15: ...RULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 1 Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteu...

Page 16: ...t de Courant Tension Hertz cycles sec Fr quence N gatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639...

Page 17: ...dditional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual Include the manual number and equ...

Page 18: ...stand on damp ground when welding For more complete safety advice please read section 1 2 05 Protective Filter Lenses Protective filter lenses are provided to reduce the intensity of radiation enteri...

Page 19: ...f every 10 minute period 25 of 10 minutes is 2 5 minutes During the other 7 5 minutes of the 10 minute period the Power Supply must idle and be allowed to cool The thermal cutout will operate if the d...

Page 20: ...aximum Duty Cycle 250A 25 0V 25 250A 25 0V 25 100 Duty Cycle Output Rating 115A DC at 20V 115A DC at 20V Duty Cycle Period Number of Output Voltage Values Mild Stainless Steel Aluminum Flux Cored Wire...

Page 21: ...rimary Power Cable 10 AWG 10ft 3m with Plug NEMA 6 50P Y Work Lead 10ft 3m with clamp Y Cable Stowage Hook Y Regulator Flowmeter Argon Mix Gases Y TWECO Weldskill MIG gun 250A 15 4 5m Y Drive Roll for...

Page 22: ...FABRICATOR 210 INTRODUCTION 2 6 Manual No 0 4855...

Page 23: ...onsiderably reduces the skin resistance of the human body and the insulation properties of accessories Environments with increased hazard of electric shock do not include places where electrically con...

Page 24: ...10ft 3m 230V 1 250A 25 Table 3 1 Factory Fitted Input Power Supply Leads Fitted to the Fabricator 210 3 05 Alternative Mains Supply Voltages WARNING The Fabricator 210 input power supply lead should b...

Page 25: ...upply may be raised 5 5 140 mm from the floor using supports that do not restrict airflow NOTE The steps in this subsection are intended for individuals experienced in the set up of this type welder M...

Page 26: ...the wheels of the unit so it cannot roll Carefully stand the cylinder on the tray and with one foot press against the bottom of the cylinder to assure it is against the back of the unit Chain the cyl...

Page 27: ...Manual No 0 4855 3 5 INSTALLATION Regulator and Flow Meter Cap Cracking 1 2 3 4 5 Gas Hose Art A 07374 Shielding Gas Shielding Gas Shielding Gas Shielding Gas Stowage Hook 1 1 8 Figure 3 2 Gas Cylinde...

Page 28: ...tes Workshop welding 30 40 CFH Outdoors welding 40 50 CFH NOTE All valves downstream of the regulator must be opened to obtain a true flow rate reading on the outlet gauge Welding power source must be...

Page 29: ...to open Art A 08661 Set up Chart Figure 3 4 Door Panel Opening NOTE Lubricate the O ring on the quick connect fitting of the gun cable with grease Dow company 4 compound or equivalent or Thermal Arc...

Page 30: ...No 0 4855 Trigger Receptacle Front Panel Access Hole Art A 08662 Loosen Thumbscrew Art A 08672 Tighten Thumbscrew Figure 3 5 Route Gun Cable Through Front Panel Access Hole and Connect Trigger Figure...

Page 31: ...ounted that will be the groove closest to the motor and the one to thread To ensure proper wire feed the groove closest to the motor must match the electrode wire size being used 045 1 2mm Groove Art...

Page 32: ...pin on the hub with the mating hole in the wire spool 4 If using a 10 lb wire spool place the spring on the exposed hub Do not use the spring for larger wire spools that cover the entire hub 5 Replac...

Page 33: ...is being used Second part of Figure 3 10 4 Pass the wire through the outlet guide and into the Gun liner of the Gun Cable Second part of Figure 3 10 5 Close the Pressure Roller Arm Figure 3 11 6 Swin...

Page 34: ...ressure may cause rapid wear of the feed roller motor shaft and motor bearings NOTE Genuine TWECO contact tips and liners should be used Many non genuine liners use inferior materials which can cause...

Page 35: ...e to the 10 pin socket and the Spool Gun Gas Outlet on the front of the unit Refer to Figure 3 13 Front Panel Rear Panel Spool Gun Gas Input Connection Main Gun Gas Input Connection Spool Gun 10 Pin S...

Page 36: ...Steel Stainless Steel Aluminum gas shielded Flux Cored electrode wires 1 D C Electrode Positive DCEP Reverse Polarity 1 Connected to Pos output terminal 1 Connected to Neg output terminal 2 FCAW Gasl...

Page 37: ...and 3 15 b Remove both terminal knobs by rotating counterclockwise c Set up the desired lead polarity as per Table 3 3 and as shown in Figures 3 14 or 3 15 d Place the Work Lead cable on the opposite...

Page 38: ...FABRICATOR 210 INSTALLATION 3 16 Manual No 0 4855 NOTES...

Page 39: ...ols Indicators and Features Thermal Overload Indicator Wire Feed Speed Control Power ON OFF Switch Coarse Voltage Switch Selector Fine Voltage Switch Selector Spool Gun Gas Outlet Spool Gun Interface...

Page 40: ...be left to cool for approximately 15 minutes before resuming welding If the Power Source is operated within its duty cycle the thermal overload will not activate Refer to section 2 09 for an explanat...

Page 41: ...e is used to connect the two wires from the torch gun to the Fabricator 210 Only pins 1 and 2 are used for this To make connections align keyway insert plug and rotate threaded collar fully clockwise...

Page 42: ...weld When the MIG gun trigger switch is depressed welding commences When the MIG gun trigger switch is released welding ceases WELD MODE WELD MODE 2T 2T SPOT SPOT STITCH STITCH 4T 4T Art A 07427_AB Fi...

Page 43: ...b controls the duration of a single spot weld WELD MODE STITCH When the Weld Mode control is in the Stitch position the Weld Spot Stitch knob controls the length of the stitch weld on time Art A 07429...

Page 44: ...guished 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 D...

Page 45: ...ZZLE 1 2 WS22 50 WS22 50 2 NOZZLE INSULATOR WS32 WS32 3 CONTACT TIP 035 WS14 35 WS14 35 4 GAS DIFFUSER WS52 WS52 5 CONDUCTOR TUBE WM62J 50 WM62J 50 6 HANDLE ASSEMBLY WM1 80 TA1 80 7 TRIGGER SWITCH ASS...

Page 46: ...work the cable assembly to aid forward movement 3 When the Wire Conduit Liner stop meets the end of the Connector Plug and the new raw end extends through the end of the Conductor Tube on the welding...

Page 47: ...n changing to a different electrode wire diameter different control settings are required A thinner electrode wire needs more Wire Speed to achieve the same current level A satisfactory weld cannot be...

Page 48: ...e Selection The choice of electrode wire size in conjunction with shielding gas used depends on Thickness of the metal to be welded Type of joint Capacity of the wire feed unit and power supply The am...

Page 49: ...with the Stitch weld bead It will also reduce heat distortion in thin plate Coarse Fine Voltage Selector Switches and Wire Speed Control Set these controls to obtain the desired welding conditions fo...

Page 50: ...Switches and Wirespeed Control Select higher Voltage Selector switch positions and set the Wirespeed Control between 354 to 590 ipm 9 to 15 m min for maximum penetration Mode Selector Switch Set the...

Page 51: ...r Good mechanical properties Greater than 3 32 See below Spray transfer 92 Argon 8 CO2 or 80 Argon 20 O2 Flat HV Fillet Reduces undercutting Higher deposition rates and improved bead wetting Deep pene...

Page 52: ...23 0 6mm 030 0 8mm 035 0 9mm 045 1 2mm 023 0 6mm 030 0 8mm 035 0 9mm 045 1 2mm 030 0 8mm 035 0 9mm 045 1 2mm 045 1 2mm 030 0 8mm 035 0 9mm 045 1 2mm 030 0 8mm 035 0 9mm 100 CO2 Stainless Steel Aluminu...

Page 53: ...4 1 2 2 1 2 3 1 5 2 2 75 2 4 2 25 2 3 1 25 3 1 3 5 3 1 2 25 3 2 3 5 3 2 2 75 3 4 5 5 3 4 3 5 3 4 6 25 4 1 4 75 4 4 1 3 1 25 1 3 75 2 1 2 25 1 4 1 25 1 4 1 2 2 3 75 2 2 2 2 2 1 5 2 2 1 5 4 1 8 25 4 2 5...

Page 54: ...FABRICATOR 210 OPERATION 4 16 Manual No 0 4855 NOTES...

Page 55: ...not blow air into the Power Supply during cleaning Blowing air into the Power Supply can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Supply To...

Page 56: ...ck of torch Consumable parts Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads Replace as needed 3 Months 6 Months Replace all broken parts Visually check an...

Page 57: ...USE REMEDY 1 Gas cylinder contents and flow meter a Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 25CFM 15 litres per minute 2 Gas leaks a Check for gas leaks b...

Page 58: ...plied 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 reducin...

Page 59: ...higher penetration 4 Weld speed too fast a Reduce weld speed C Lack of fusion 1 Voltage too low a Increase voltage by increasing voltage selection switch position 2 Weld speed too fast a Reduce weld s...

Page 60: ...a Check compatability to base metal B 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 connection...

Page 61: ...Faulty control PCB or Tweco Gun a Have an Accredited Thermal Arc Service Agent investigate the fault F Wire feeds when the gun trigger switch is depressed but arc can not be established 1 Poor or no...

Page 62: ...FABRICATOR 210 SERVICE 5 8 Manual No 0 4855 NOTES...

Page 63: ...sembly with 25ft cable 200 Amp 60 Spool Gun 25ft 90906 Gun assembly with 25ft cable 300 Amp 60 ACCESSORIES Victor Regulator Flow Meter Mixed Gases 0781 2723 Medalist 1400 Series HRF Flow Meter Regulat...

Page 64: ...X X X X X X X X X X X X X 1 2 6 5 4 3 8 9 7 11 10 14 16 13 12 15 SWITCH 3 COARSE AND SWITCH 4 FINE 2A CB1 FABRICATOR 210 3 VIO 31C ORN COARSE FINE SW3 SW4 Art A 08666 TB 4 5 Fan motor 24V Aux Y1 Solen...

Page 65: ...ORN COARSE FINE SW3 SW4 Art A 08666_AB NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL BR1 Wire Feeder Motor J B 7 J B 9 J B 6 J B 8 WIRESPEED 1K RI M2 J B 1 J B 2 J B 3 43 BLK 43A BLK 44 BRN 46 RED...

Page 66: ...t Aluminum Wire Size 023 0 6mm 375980 031 030 035 0 8 0 9mm 375980 001 375980 003 375980 010 030 035 045 0 8 0 9 1 2mm 375980 028 375980 029 035 0 9mm 375980 040 375980 032 035 045 3 64 0 9 1 2 1 2mm...

Page 67: ......

Page 68: ...urchaser for service interruption The rem edies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract or anything done in connection therewith su...

Page 69: ...300MST 400MSTP Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards Power Switch Semi Conductors 3 years 3 years All Other Original Circuits and Components...

Page 70: ......

Page 71: ...trict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Eh...

Page 72: ...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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