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Valley FABRICATOR 251, Service Manual

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Valley FABRICATOR 251 Service Manual Download Page 30

3-8

August 22, 2008

FABRICATOR 251

SERVICE MANUAL

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Summary of Contents for FABRICATOR 251

Page 1: ...208 208 V V 230 230 V V 60 60HZ FABRICATOR MIG WELDING MACHINE 251 Service Manual Revision AB Issue Date August 22 2008 Manual No 0 5099 Operating Features Art A 08561 ...

Page 2: ......

Page 3: ...695 5292 or 304 232 1542 http www vngas com Copyright 2008 by Valley National Gases LLC All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligen...

Page 4: ...ibility 2 2 2 08 Duty Cycle 2 3 2 09 Specifications 2 3 2 10 Included Items 2 5 2 11 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 Mains Supply Voltage Requirements 3 2 3 05 Alternative Mains Supply Voltages 3 2 3 06 Quick Setup 3 4 3 07 Installation of Shielding Gas GMAW Process 3 4 3 08 Attaching the Gun and Cable Assembly to...

Page 5: ...1 Basic Troubleshooting 6 1 6 02 Solving Problems Beyond the Welding Terminals 6 2 6 03 Welding Problems 6 4 6 04 Power Supply Problems 6 6 SECTION 7 ADVANCED TROUBLESHOOTING 7 1 7 01 Preliminary Checks 7 1 7 02 Initial Setup Conditions 7 2 7 03 Primary Power Test 7 2 7 04 Logic and Control Tests 7 3 7 05 Spool Gun Control J1 Test 7 4 7 06 Output Voltage Test 7 5 7 07 Wire Feed Weld Test 7 6 7 08 ...

Page 6: ...ernal Replacement Parts 9 2 9 04 Internal Replacement Parts 1 9 4 9 05 Major Electrical and Mechanical Replacement Parts 9 6 9 06 Internal Replacement Parts 2 9 7 9 07 Internal Replacement Parts Spool Assembly 9 8 9 08 Internal Replacement Parts Wire Feeder 9 9 9 09 Wire Feeder Replacement Parts 9 10 APPENDIX 1 FEEDROLL KITS A 1 APPENDIX 2 POWER SUPPLY CIRCUIT DIAGRAM A 2 APPENDIX 3 MAIN PCB CIRCU...

Page 7: ...ed spaces 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 level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet...

Page 8: ...uipment 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 weld where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert...

Page 9: ...rmful exhaust 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 explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before ...

Page 10: ...ffer clear science 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 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKE...

Page 11: ...Welding 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 Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow Tim...

Page 12: ...on dès 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 pièces métalliques en contact avec le fil de soudage sont sous tension Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux 1 Ne touchez pas à des pièces sous tension 2 Portez des gants et des vête...

Page 13: ...ce confiné que s il est bien ventilé sinon portez un respirateur à adduction d air Les gaz protecteurs de soudage peuvent déplacer l oxygène de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre à la respi ration 6 Ne soudez pas à proximité d opérations de dégraissage de nettoyage ou de pulvérisation La chaleur et les rayons de l arc peuvent réagir avec des vapeurs et ...

Page 14: ...non huileux tels des gants en cuir une chemise épaisse un pantalon revers des bottines de sécurité et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules métalliques volantes En refroidissant la soudure peut projeter du éclats de laitier 1 Portez un écran facial ou des lunettes protectrices approuvées D...

Page 15: ...nti étincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule 5 Utilisez la polarité correcte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut être brûlant e...

Page 16: ...Intensité de Courant Tension Hertz cycles sec Fréquence Négatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639 115V 15A t t1 t2 X IPM MPM t Fusible Déroulement du Fil Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Durée de Pré Dèbit Durée de Post Dèbit Duréc du Pulse Soudure Par Point Ap...

Page 17: ... manual Include the Service Manual number and equipment identification numbers 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the rear panel In some cases the nameplate may be attached to the control panel Equipment which does not have a name plate such as gun and cable assemblies is iden...

Page 18: ...nd when welding For more complete safety advice please read section 1 2 06 Protective Filter Lenses Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infrared ultraviolet radiation and a percentage of the visible light Such filter lenses are incorporated within face shields To prevent damage to the filter lenses from molten or ha...

Page 19: ...very 10 minute period 60 of 10 minutes is 6 0 minutes During the other 4 0 minutes of the 10 minute period the Power Supply must idle and be allowed to cool The thermal cutout will operate if the duty cycle is exceeded 2 09 Specifications Gun Catalog Number 43340VNG Gun Type Valley National Gases 400 Amp Gun Cable Length 15 ft 4 5m MIG Gun Specifications Table 2 2 MIG Gun Specifications Control Ci...

Page 20: ...imum Duty Cycle 300A 31 7V 40 300A 31 7V 40 100 Duty Cycle Output Rating 195A DC at 24V 195A DC at 24V Duty Cycle Period Number of Output Voltage Values Mild Stainless Steel Aluminum Flux Cored Wire Feed Speed Range Wire Spool Size Diameter Burn Back Timer Range Burn Back Time Factory Set to Spot Timer Range Dwell Timer Range Stitch Weld Time Weld Stitch Time Dwell non weld Time Thermal Protection...

Page 21: ...yFittedPrimaryPowerCable8AWG 10ft 3m withPlugNEMA6 50P WorkLead10ft 3m CableStowageHooks Regulator FlowMeter ArgonMixGases ValleyNationalGasesaircooledMIGGun 400Amp 15ft 4 5m FittedFeedRollfor 035 045 0 9 1 2mm solidwire Table 2 5 System Contents 2 11 Optional Accessories Refer to the Appendix section of this manual for the list of available options and accessories ...

Page 22: ...FABRICATOR 251 SERVICE MANUAL 2 6 August 22 2008 NOTES ...

Page 23: ... considerably 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 conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the Power Supply according to the following guidelines In area...

Page 24: ...uty Cycle 8 AWG 40 Amps 10ft 3m 230V 250A 60 Table 3 1 Factory Fitted Input Power Supply Leads Fitted to the Fabricator 251 3 05 Alternative Mains Supply Voltages WARNING The Fabricator 251 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 suppl...

Page 25: ...es where they are secured to the input voltage selection block Loosen the set screw for both voltage locations 3 Remove the blue wires from the current location and insert them into the new voltage location Secure by tightening the set screw onto the uninsulated portion of the wires Secure the other voltage set screw as well 230V connection 208V connection Art A 07332 Figure 3 1 Voltage Selections...

Page 26: ... your chosen wire size 7 Fit the electrode wire spool to the wire reel hub located behind the electrode wire compartment door 8 Fit the Valley National Gases MIG gun and trigger wires through to the front of the unit 9 Remove the contact tip from the gun 10 With the gun lead reasonably straight feed the wire through the wire drive rolls and gun 11 Fit the appropriate contact tip and replace insula...

Page 27: ... 3 5 SERVICE MANUAL FABRICATOR 251 Regulator and Flow Meter Cap Cracking 1 2 3 4 5 Gas Hose Art A 07278 Shielding Gas Shielding Gas Stowage Hook Shielding Gas Shielding Gas 1 1 8 Figure 3 2 Gas Cylinder Installation ...

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 triggered Close the valves after the pressure has been set Art A 07280 Figure 3 3 Adjusting Flow Rate Refer to section 4 09 for suggested gas filler metal combinations NOTE The regulator flow meters ...

Page 29: ...ard and up to open Art A 07142_AB 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 2 Route the gun cable through the access hole in the front panel Refer to Figures 3 5 and 3 6 3 Loosen the thumbscrew and insert the gun cable end as far as it will go Tighten thumbscrew Refer to Figure...

Page 30: ...VICE MANUAL Trigger Receptacle Front Panel Access Hole Art 0 7148 Figure 3 5 Route Gun Cable Through Front Panel Access Hole and Connect Trigger Loosen Thumbscrew Art A 07149 Tighten Thumbscrew Figure 3 6 Mount Gun Cable to Adapter Socket ...

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 A 07150 The size that is visible when fitting the feedroll is the groove size in use 045 1 2 045 1 2mm Stamping Figure 3 8 Feedroll Example NOTE All grooved feed rolls have their wire size or range st...

Page 32: ...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 Replace the Wire Spool Hub Nut by turning clock wise to the right NOTE The Hub tension has been pre adjusted at the factory However if adjustment is required refer to Section 3 12 and Figure 3 12 CAUTION Use care in handli...

Page 33: ...e 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 Swing the Spring Pressure Adjusting Knob back into place Figure 3 11 7 Use the Spring Pressure Adjusting Knob to create a snug condition Clockwise to tighten and Counter Clockwise to loosen Figure 3 11 8...

Page 34: ...se rapid wear of the feed roller motor shaft and motor bearings NOTE Genuine Valley National Gases contact tips and liners should be used Many non genuine liners use inferior materials which can cause wire feed problems 3 14 Wire Reel Hub Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking If it is considered necessary adjustment can be ma...

Page 35: ...le and gas hose 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 Socket Spool Gun Gas Outlet Connection Art A 08573 Figure 3 13 Spool Gun Connections NOTE When the SPOOL GUN is properly attached and the trigger is depressed the system automatically dis...

Page 36: ...W 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 Gasless Flux Cored electrode wire 2 D C Electrode Negative DCEN Straight Polarity 2 Connected to Neg output terminal 2 Connected to Pos output terminal CABLE CONNECTIONS PROCESS POLARITY Exception Contac...

Page 37: ...4 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 terminal e Replace both terminal knobs and tightly secure them to ensure good electrical connections CAUTION Ensure terminal knobs are tightly secured and that there is no connection between positiv...

Page 38: ...3 16 August 22 2008 FABRICATOR 251 SERVICE MANUAL NOTES ...

Page 39: ...ures Weldskill 13V 16V 17V 21V 22V 31V A V Thermal Overload Indicator Wire Feed Speed Control Power On Off Switch Coarse Voltage Selector Switch Fine Voltage Selector Switch Spool Gun Gas Outlet Spool Gun Interface Amphenol Receptacle Gun Polarity Lead Digital Display Voltage Amp Selection Button Gun Switch Amphenol Receptacle Front Panel Access Hole Torch Art A 08562 Positive Welding Terminal Neg...

Page 40: ...ctrical components are at Mains voltage potential Digital Display The Digital Display allows for accurate monitoring 5 tolerance of welding current and voltage to facilitate precise welding condition adjustments Value displayed for 157 Amp Value displayed for 21 9 Volts Art A 07279 Figure 4 2 Digital Display The Digital Meter will display both welding current or arc voltage To toggle between the c...

Page 41: ... 275 300 325 Current Amps Wire Speed IPM 030 STEEL 035 STEEL 045 STEEL 0 2 3 S T E E L Art A 07451 STEEL Figure 4 3 Steel AMP to IPM Conversion 0 100 200 300 400 500 600 700 800 900 25 50 75 100 125 150 175 200 225 250 275 300 325 Current Amps Wire Speed IPM 023 SS 030 SS 035 SS 045 SS Art A 07452 STAINLESS STEEL Figure 4 4 Stainless Steel AMP to IPM Conversion ...

Page 42: ...ed within its duty cycle the thermal overload will not activate Refer to section 2 09 for an explanation of duty cycle and section 2 10 for the power supply specifications Wirespeed Control The Wirespeed Control knob controls the welding current via the electrode wire feed rate i e the speed of the wire feed motor Coarse Voltage Control Switch The Coarse Voltage Control sets the voltage level to t...

Page 43: ...n receptacle is used to connect the two wires from the torch gun to the Fabricator 251 Only pins 1 and 2 are used for this To make connections align keyway insert plug and rotate threaded collar fully clockwise 1 2 Art A 07171 Figure 4 6 Gun Switch Receptacle Spool Gun Interface Amphenol Connector The Spool Gun Interface 10 pin connector is used to connect a spool gun to the Fabricator 251 refer t...

Page 44: ...ith a continuous 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 Figure 4 9 For Reference only SPOT This mode of welding is used to weld two plates together at a desired location by melting the top bottom plates together to form a nugget between them Th...

Page 45: ...t position the Weld Spot Stitch knob 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 MIN MIN 4 1 3 2 WELD WELD SPOT STITCH SPOT STITCH t Art A 07429 Figure 4 13 Weld Spot Stitch Control Dwell Stitch DWELL STITCH CONTROL KNOB When the Weld Mode control is in the Stitch ...

Page 46: ...FABRICATOR and can be expected to give trouble free service Art A 08563 1 2 3 5 4 6 7 Figure 4 16 Valley National Gases 43340VNG Air Cooled MIG Gun Item Description Part No Qty 1 NOZZLE VNG24A 62 1 2 NOZZLE INSULATOR VNG34A 1 3 CONTACT TIP VNG14 35 1 4 GAS DIFFUSER VNG54A 1 5 CONDUCTOR TUBE WM63J 50 1 6 HANDLE ASSY WM480 1 7 TRIGGER ASSY WM92 1 Original Parts Installed Table 4 2 Original Consumabl...

Page 47: ...d of the connector plug and the new raw end extends through the end of the conductor tube on the welding gun tighten the Allen screw in the connector plug onto the conduit to prevent its backward movement CONDUCTOR TUBE CONDUIT LINER CONDUIT LINER 1 1 16 27mm Art A 08565 REMOVE CONSUMABLES ALLEN SCREW O RINGS ALLEN SCREW CONNECTOR PLUG Figure 4 17 Conduit Trim Length NOTE When the conduit is fully...

Page 48: ...ctrode wire needs more Wire Speed to achieve the same current level A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the work piece If the Wire Speed 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 nor...

Page 49: ...enetration required The deposition rate required The bead profile desired The position of welding and Cost of the electrode wire Weld metal deposition rate is proportional to current density Current density is defined as the current per cross sectional area of the electrode wire and is normally expressed as amps per mm2 An example is in Table 4 3 below Electrode Wire Size Current Amps Current Dens...

Page 50: ...S 1240 1550 1 Bore Inside Corner Arc Spot 24A 75 IAS 1240 1531 3 4 Bore Outside Corner Arc Spot 24A 75 IAS 1240 1532 3 4 Bore Automotive Stud Nozzle N A Table 4 4 Spot Welding Nozzles 4 08 Spot Welding Operation Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations Refer to the Spot Welding Nozzle table The Fabricator 251 will operate effectively using 030 0 8mm...

Page 51: ... Greater than 3 32 See below Spray transfer 92 Argon 8 CO2 or minimum 80 Argon 20 O2 Flat HV Fillet Reduces undercutting Higher deposition rates and improved bead wetting Deep penetration and good mechanical properties Greater than 14 gauge 075 See below Short Circuit 98 Argon 2 CO2 All Position Welding Good control of melt through and distortion Used also for spray arc welding Pool fluidity somet...

Page 52: ...023 0 6mm 030 0 8mm 035 0 9mm 045 1 2mm 030 0 8mm 035 0 9mm 045 1 2mm Aluminum Aluminum 4043 ER 5183 ER 5356 ER 100 Ar 25cfh 030 0 8mm 035 0 9mm Stainless Steel Stainless 7 5 Ar 90 He 2 5 CO2 35cfh ER308LSi ER309LSi ER316LSi Shielding Gas and Flow Rate Wire Size Diameter 1 16 1 6mm 030 0 8mm 045 1 2mm 035 0 9mm 045 1 2mm 1 16 1 6mm Steel 100 CO2 25cfh None Flux Core E71T 11 E71T GS E71T 1 Art A 07...

Page 53: ...5 H 4 5 5 H 4 3 H 4 6 5 H 5 7 H 5 3 25 H 5 7 25 H 7 7 5 H 6 3 5 2 25 1 25 L 8 4 L 7 3 25 M 2 4 25 L 8 4 5 M 5 5 M 5 4 5 H 1 7 H 2 6 75 H 2 3 5 M 6 3 H 3 7 75 H 4 5 H 5 5 75 H 6 6 25 M 2 1 5 M 3 1 5 M 5 1 75 M 4 2 M 7 2 H 1 5 H 2 3 5 H 3 6 H 3 3 5 H 4 8 5 H 5 7 25 H 5 4 25 H 7 4 5 M 2 M 3 2 5 M 3 2 M 4 3 M 4 2 5 M 7 5 M 6 3 5 H 1 6 5 H 1 4 5 H 6 6 H 1 6 H 7 6 5 H 5 6 H 6 6 5 1 5 M 6 2 H 1 1 5 M 7 2...

Page 54: ...4 16 August 22 2008 FABRICATOR 251 SERVICE MANUAL NOTES ...

Page 55: ...low 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 clean the Power Supply 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 Supply should also be wiped clean If n...

Page 56: ... check 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 and use a vacuum to carefully clean the interior Maintain more often if used under severe conditions Gas lines Art A 07269 Clean exterior of power supply ...

Page 57: ...pair unless you have had training in electronic measurement and trouble shooting techniques 6 01 Basic Troubleshooting 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 Valley National Gases Service Age...

Page 58: ...gas leaks between the reulator flowmeter connection and in the gas hose to the power supply 3 Internal gas hose in the power supply a The hose from the solenoid valve to the MIG torch adaptor may be fractured or disconnected from the MIG torch adaptor Return to an Accredited Valley National Gases Service Agent for repair 4 Welding in a windy environment a Shield the weld area from the wind or incr...

Page 59: ...ster Slag can also be produced by the wire passing through an incorrect feed roller groove shape or size Slag is fed into the liner where it accumulates thus reducing wire feedability 6 Incorrect or worn contact tip a The contact tip transfers the weld current to the electrode wire If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the electrode w...

Page 60: ...es 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 speed 1 Voltage too high a Lower voltage by reducing the voltage selection switch or increase wirespeed control D Excessive spatter 2 Voltage too low a Raise voltage by increasing the voltage select...

Page 61: ...eed 1 Faulty rectifier unit a Have an Accredited Valley National Gases Service Agent to test then replace the faulty component 2 Loose welding cable connection a Check all welding cable connections B Cold weld puddle 3 Low Primary Voltage a Contact supply authority 4 Weld speed too fast a Reduce weld speed 1 The MIG torch has been connected to the wrong polarity on the front panel a Connect the MI...

Page 62: ... is depressed 2 Faulty control PCB or Tweco Gun a Have an Accredited Valley National Gases 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 work lead connection a Clean work clamp area and ensure good electrical contact G Wire continues to feed when the gun trigger switch is released 1 The Weld Mode Switch has bee...

Page 63: ...UTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit 1 Check general machine completeness 2 Check tightness of mounting and STRUCTURAL HARDWARE and all terminations and ELECTRICAL FITTINGS 3 NO DEFORMATION present to detract from machine s appearance or performa...

Page 64: ...ALS 11 Connect Work cable to NEGATIVE OUTPUT WELDING TERMINAL 12 Disengage PRESSURE ADJUST DEVICE so wire will not feed See figure 3 10 7 03 Primary Power Test A Close primary disconnect device and observe the following 1 Green Indictor Lamp inside ON OFF Switch illuminates B Set ON OFF Switch to ON position and observe the following 1 Fan turns on 2 Digital Display turns on The meter has two disp...

Page 65: ...V F Set WELD MODE SELECTOR SWITCH to position 2T Set BURNBACK CONTROL potentiometer to maximum position Depress Gun Switch and observe the following 1 Gas flows 2 Contactor energizes 3 Feed roll turns 4 Display reads approx 15 0 V G Release Gun Switch 1 Feed Roll stops immediately 2 Display reads 15 0 V 2 After 1 seconds a Gas flow stops b Contactor de energizes c Display reads 0 0 V H Set BURNBAC...

Page 66: ...approx 4VDC up to approx 27 VDC M Set COARSE VOLTAGE SELECTOR SWITCH to position H Set FINE VOLTAGE SELECTOR SWITCH to position 8 N Connect voltmeter probes to JB 6 and J6 8 Depress the gun trigger and vary the WIRE SPEED CONTROL potentiometer from minimum to maximum The voltage should vary from approx 2VDC up to approx 25 VAC O Set WIRE SPEED CONTROL to 4 P Set COARSE VOLTAGE SELECTOR SWITCH to p...

Page 67: ...READING MUST BE INCREASING IN VALUE COARSE VOLTAGE SELECTOR SWITCH SETTING FINE VOLTAGE SELECTOR SWITCH SETTING VOLTAGE 1 1 15 3 1 2 15 9 1 3 16 2 1 4 16 9 2 1 17 4 2 2 18 1 2 3 18 5 2 4 19 3 3 1 20 4 3 2 21 4 3 3 22 1 3 4 23 1 4 1 24 1 4 2 25 3 4 3 26 2 H 1 29 9 H 2 32 1 H 3 33 5 H 4 35 9 H 5 38 2 H 6 41 5 H 7 43 5 H 8 47 4 F Set COARSE VOLTAGE SELECTOR SWITCH to position L G Set FINE VOLTAGE SEL...

Page 68: ...is connected If incorrect check wiring in plug and continuity of primary input cable 3 Circuit breaker CB1 tripped a Reset breaker 4 Defective or improperly wired input power cable or plug a Measure for primary voltage at the Input Terminal Block between terminals 1 2 for 208 VAC input or between terminals 1 3 for 230VAC input see Input Terminal Block Figure 7 1 B Green Indicator in ON OFF Switch ...

Page 69: ...voltage is not present replace PCB 1 7 Faulty MIG TIMER PCB PCB 2 a See Section 7 15 8 Faulty MAIN PCB 1 a Measure between JB 4 to JB 11 at PCB 1 for approx 30 VAC when gun switch is closed If voltage is not present replace PCB 9 Faulty SPOOL GUN PCB PCB 3 a Measure at PCB1 between JB 5 to JA 2 for 21VDC If voltage is not present replace PCB3 C When gun switch is closed gas flows contactor does no...

Page 70: ...r per test procedure page XXX G When Gun Switch is closed gas flows contactor closes feed roll turns but display shows 0 volts 1 Open wire between shunt and PCB4 a Check wire continuity and replace if open 2 PCB 4 is defective a Measure voltage between X1 3 to X1 1 for 32VAC If voltage is correct replace PCB4 7 10 Spool Gun Control J1 Problem A Gas does not flow when jumper is connected between J1...

Page 71: ... work cable a Clean contact point check continuity of cable and cable to clamp connection Replace if work cable if required B Wire feed and welding problems Refer to sections 6 03 6 03 7 13 Terminal Block Voltage Test Line 1 208 V 230 V Fan Fan Main Transformer Fan Primary Note Voltage Tolerance 5V BLK WHT 208V 230V 230V Art A 07541 Figure 7 1 Input Terminal Block Diagram ...

Page 72: ...ITCH 10C RED 9 BLK 8 BRN 10A RED 10B RED 8A BRN 4 BLK 4A BLK Art A 08568 13A PUR 11 GRY WIRE No S TERMINAL No S TERMINAL No S WIRE No S 3 7 11 15 1 5 9 13 10B RED 7B BLK 7C BLK TOP OF SWITCH WIRE No S TERMINAL No S TERMINAL No S WIRE No S 2 6 10 14 12A BRN 4 8 12 16 BOTTOM OF SWITCH 17 BLK 12 BRN 17A BLK 13 PUR 16 WHT 19 23 17 21 10C RED 18 22 20 24 11A GRY 16A WHT Art A 08569 Figure7 2 3 Position...

Page 73: ... 8 9 7 11 10 12 SWITCH 2 COARSE SWITCH POSITION 1 2 3 X X X X X X 1 2 6 5 4 3 8 9 7 11 10 12 SWITCH 3 FINE 5 6 4 X X 7 X 8 X X X X X X X X X X X X X 13 14 18 17 16 15 20 21 19 23 22 24 X X X X X X X X X X Art A 08570 Figure 7 5 SW3 SW4 Continuity 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 fi...

Page 74: ...ops to 0VDC when Gun Switch is released STITCH 10 VDC for durations of STICH TIME 3 3VDC for durations of DWELL TIME Drops to 0VDC when Gun Switch is released 4T 14VDC at 1st Gun Switch closure Drops to 0VDC at second Gun Switch closure If the voltages are not found to be correct replace PCB2 To confirm the rest of the circuitry is working disconnect JC connector from Main PCB and place a jumper b...

Page 75: ...connector from MAIN PCB 1 4 Using a meter check the diode readings between the following points Forward biased diode junction Positive meter probe on rectifier plates 2 and 3 to plates 1 4 Negative meter probe on rectifier plates 1 4 to plates 2 3 Art A 07575 1 2 3 4 Remove and isolate from rectifier assembly Figure 7 3 Rectifier Assembly Test Double forward biased junction Positive meter probe on...

Page 76: ...voltage between the two transformer output connections as follows COARSE VOLTAGE SELECTION FINE VOLTAGE SELECTOR VOLTAGE AC approx SWITCH SETTING SWITCH SETTING L 1 11 8 L 2 12 2 L 3 12 5 L 4 12 9 L 5 13 2 L 6 13 8 L 7 14 0 L 8 14 6 M 1 15 3 M 2 16 0 M 3 16 5 M 4 17 3 M 5 17 9 M 6 18 9 M 7 19 5 M 8 20 6 H 1 22 1 H 2 23 6 H 3 24 7 H 4 26 4 H 5 28 0 H 6 30 2 H 7 31 8 H 8 34 8 ...

Page 77: ...ltage is then fed to a zener regulator to provide the 15VDC supply for the electronics on the circuit board Inputs to the Control PCB CONNECTOR JA Terminal JA 1 trigger input 40VDC trigger open approx 20VDC trigger closed reference JA 5 Terminal JA 2 trigger input 0VDC trigger open approx 20VDCV trigger closed reference JA 5 Terminal JA 3 spot timer pot 12VDCV trigger closed 0VDC trigger open refe...

Page 78: ...l 0VDC to 24VDC with speed pot reference JB 6 Terminal JB 9 positive welding voltage Terminal JB 10 return for 32VAC supply from auxiliary winding on M1 reference JB 5 Terminal JB 11 relay contact to control SOL1 W1 closes to complete circuit to JB 10 reference JB 4 CONNECTOR JB Torch circuit jumper installed 8 02 Circuit Operation Of The MIG Timer PCB 7977965 This board is connected by way of a 6...

Page 79: ...common connects to wirespeed potentiometer input of 7977964 PCB measure 0 to 5VDC depends on wire speed setting wrt 7977964 JA 5 Terminal X2 3 wirespeed relay normally closed connects to main wirespeed pot wiper measure 0 to 5VDC depends on wire speed setting wrt 7977964 JA 5 in normal setting Terminal X2 4 trigger relay connects to trigger input of 7977964 PCB Terminal X2 5 trigger relay connects...

Page 80: ...8 4 August 22 2008 FABRICATOR 251 SERVICE MANUAL NOTES ...

Page 81: ... illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show p...

Page 82: ...ut Terminal Fabs 2 8 871992VN Panel Front Fab251 1 9 705937PKD Molding Front Fab210 251 281 1 10 871011PKD Bushing Torch 1 11 707259VN Panel Side LH Fab210 251 1 12 SEE NOTE 1 Screw Hex HD M5x13mm Self Tap 41 13 7977683PKD Latch Slide Door Latch 2 14 704883PKD PCB Digital Meter Fab251 281 PCB4 1 15 871988VN Door Fab210 251 1 16 707305PKD Harness Control Wiring Fab251 1 17 707304PKD Harness Power W...

Page 83: ...August 22 2008 9 3 SERVICE MANUAL FABRICATOR 251 Art A 08572 1 2 3 4 22 5 6 7 8 10 11 9 12 13 14 15 19 20 17 16 23 24 21 18 ...

Page 84: ...PCB Control Fabricators PCB1 1 3 203627 001 Circuit Breaker 5A CB2 1 4 7978041PKD Circuit Breaker 2A CB1 1 5 401840 003 Cable Power Cable Fab251 281 1 6 707206PKD Gas Hose 5 8 BSP Fabricators 1 7 7978001PKD Contactor 32A 3 Pole 24VAC W1 1 8 7976580 Terminal Block 6 Way 110A 1 9 707204PKD Solenoid Assy Fabricators SOL1 1 10 707204PKD Solenoid Assy Fabricators SOL2 1 11 7977951 Switch 32A 3 Pos Fab2...

Page 85: ...August 22 2008 9 5 SERVICE MANUAL FABRICATOR 251 11 13 7 15 8 9 10 14 12 1 2 3 4 5 6 Art A 07516 ...

Page 86: ...51 281 1 2 See Note 1 Screw Hex HD M8x12mm Self Tap 2 3 7978035PKD Wheel 5 8 IDx10 OD 2 4 871046PKD Clip Retaining 5 8 ID 2 5 707256WBLKPKD Panel Base Fab210 251 281 1 6 7977566 Castor Swivel 5 Wheel 2 7 870921WBLKPKD Bracket Front Wheels 1 8 7977974 Terminal Output Fabricators 2 9 7977962 Rectifier 300A Fab251 281 BR1 1 10 707308PKD Transformer Fab251 281 T1 1 11 7977832PKD Switch Thermostat 207 ...

Page 87: ... REF DESIGNA REF DESIGNA REF DESIGNA REF DESIGNATION TION TION TION TION QTY QTY QTY QTY QTY 1 871048PKD Hub Spool Assy Fab210 251 1 2 870734 Knob Control 1 4 IDx 57 4 3 871051PKD Label Int Controls Fab210 251 1 4 7977965PKD PCB Timer Fab210 251 A2281 PCB2 1 5 871010PKD Feed Plate Assy 2 Roll 210 251 1 6 707265WBLK Panel Internal Fab210 251 1 7 203627 001 Circuit Breaker 5A CB2 1 8 7978041PKD Circ...

Page 88: ... 16x3 4 STZP 1 2 170459 001 Plunger Spring Nut Hub 2 3 405377 Nut Wire Spool Hub 1 4 374552 001 Spacer Spool Hub 1 5 374551 Washer 3 4 Flat Keyed Hub 1 6 400562 027 Spring Spool Hub 1 7 707251PKD Shaft Wire Spool Hub 1 8 405448 Washer 1 1 64 Flat Nylon Hub 1 9 405376 Hub Wire Spool 1 10 See Note Washer 1 2 IDx1 45 OD Flat 2 11 707197WBLKPKD Bracket Wire Spool Fab210 251 1 12 See Note Nut Hex 1 2 1...

Page 89: ...late 1 2 871010PKD Feed Plate Assy 2 Roll 210 251 1 3 870082 Knob Control 1 4 ID x 3 4 1 4 10 6187 Knob Torch Locking 1 5 871173PKD Adapter Tweco 4 2R Plate 1 6 See Note Screw Skt Set M4 0 7x 4mm 1 7 871012WBLKPKD Bracket Feed Plate Fab210 251 1 8 870891PKD Motor Wire Drive 3 2A 20VDC 1 9 See Note Screw PHCR M6 1x20mm STZP 3 10 See Note Screw PHCR M4 0 4x10mm STZP 2 11 See Note Screw Hex HD M8 1 2...

Page 90: ...re Arm 2R M C WF 870679PKD 3 1 Gear Idler Assembly WF 871001PKD 4 2 Screw M4x10 Pan Head WF See note 5 3 Screw M6x1 30 MM long WF See note 6 1 Retainer Drive Gear 2R Plate 870733PKD 7 1 Gear Drive Roll 2R Plate 870560PKD 8 2 Screw M8 X 16 Hex Head WF See note 9 1 Screw M6x1 35MM Long WF See note 10 1 Clamp MIG gun 2R Plate 171362 11 1 Feedplate 2 Roll WF 870558PKD 12 1 Insulator Motor 2R Plate 870...

Page 91: ...inum Wire Size 024 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 375980 030 045 1 2mm 375980 002 375980 004 375980 092 375980 022 3 64 1 2mm 375980 011 375980 033 052 1 3mm 375980 090 375980 012 052 1 16 1 3 1 6mm 375980 017 375980 023 Notes 1 One Kit 375980 028 is suppl...

Page 92: ...LK 9 BLK 10 10A RED 10 RED 10C RED 11 11A GRY 14 14A BLU 208VAC 15 15A ORN 230VAC 4B BLUE 1D RED 1C RED 1B RED J E 1 J E 2 2 2A PNK BURNBACK 100K TS1 TEMP LED1 J A 2 J A 1 FABRICATOR 251 3 ORN 30 BRN 30 A BRN 31 ORN 31 A ORN 32 WHT 33 BLU 34 BLU 35 WHT 36 GRY 37 ORN 39 RED 38 A WHT 38 WHT 54 BLK 56 RED 24 23 12 11 11 GRY 12 12A BRN 18 17 6 5 12 BRN 16 16A WHT 22 21 10 9 16 WHT 13 13A VIO 14 13 2 1...

Page 93: ...52 BRN 52 A BRN 53 WHT 57 VIO 55 BLK T1 TRANS 251US COIL T3 T4 SWITCH POSITION 1 2 3 X X X X X X 1 2 6 5 4 3 8 9 7 11 10 12 SWITCH 3 FINE 5 6 4 X X 7 X 8 X X X X X X X X X X X X X 13 14 18 17 16 15 20 21 19 23 22 24 X X X X X X X X X X X1 1 X1 3 X1 2 X2 3 X2 2 X2 1 X3 4 X3 3 SHUNT PCB 4 704883 X1 6 X1 5 X1 4 X1 3 DIG METER X1 1 21 ORN 22 VIO 23 GRY 30C BRN 31D ORN A B C D E F G H I J J1 18 1SF Art...

Page 94: ...FABRICATOR 251 A 4 August 22 2008 APPENDIX 3 MAIN PCB CIRCUIT DIAGRAM 30 VAC Art A 08574 ...

Page 95: ...FABRICATOR 251 August 22 2008 A 5 DESCRIPTION FABRICATOR MAIN PCB 7977964 Art A 08574 _ ...

Page 96: ...FABRICATOR 251 A 6 August 22 2008 APPENDIX 4 SPOT TIMER CIRCUIT DIAGRAM Art A 08575 ...

Page 97: ...FABRICATOR 251 August 22 2008 A 7 DESCRIPTION CODE DESIGN FABRICATOR SPOT TIMER 7977965 Art A 08575 ...

Page 98: ...n C8 100n 13 12 14 U3D LM324 Q4 BC337 40 14Vdc R14 22K R17 22K R21 22K R24 100K R23 22K 14Vdc D17 1N4004 D16 1N4004 C10 100n 9 10 8 U3C LM324 Q3 BC337 40 6 5 7 U3B LM324 2 3 1 4 11 U3A LM324 1 2 3 4 5 6 X3 CON6 SPOOL TRIG NORM TRIG 24VAC_1 Vin 3 ADJ 1 Vout 2 U1 LM317T D12 1N4004 D13 1N4004 D10 1N4004 D11 1N4004 C4 100n C1 470u 50V C5 22u 50V C3 100n R9 2K7 R10 270R 14Vdc D2 1N4004 24VAC_2 35Vdc D ...

Page 99: ...5Vdc 35Vdc D6 1N4148 D8 1N4148 D7 1N4148 D14 1N4004 R3 560R 1 2W Q2 BC337 40 R12 22K R5 22K Q1 BC337 40 K4 AZ945 K1 AZ945 K3 AZ945 K2 AZ945 C7 22u 50v 1 2 3 4 5 6 X1 CON6 1 2 3 4 5 6 X2 CON6 MOT COM MOT LOC MOT SPOOL GV COM GV LOC GV SPOOL POT COM POT LOC POT SPOOL TRIG N C TRIG D1 1N4004 1 2 J1 JUMPER Install jumper for use with MILLER spool gun which has no speed pot on the spool gun R1 560R 1 2...

Page 100: ...ing negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of the Manufacturer is authorized to change this warranty in any way or grant any other warranty and the Manufacturer shall not be bound by any such attempt Correction of non conformities in the manner and time provided...

Page 101: ...i conductors 3 years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources 90 days Nil Replacement repair parts 90 days Nil MIG TIG and Plasma welding tor...

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