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FABRICATOR 210

June 19, 2006

6-1

SECTION 6:

TROUBLESHOOTING

WARNING

Disconnect the Fab

icato

om the Input powe

supply voltage befo

e disassembling.

WARNING

Do not attempt to diagnose o

epai

unless you have had t

aining in elect

onic measu

ement and t

ouble-

shooting techniques.

6.01 Basic Troubleshooting

The basic level of t

oubleshooting is that which can be pe

med without special equipment o

knowledge, and

without

emoving the cove

s f

om the Powe

Supply.

If majo

components a

e faulty, then the Powe

Supply should be

etu

ned to an Acc

edited The

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Содержание A-07360

Страница 1: ...208 208 V V 230 230 V V 60 60HZ 250 250 FABRICATOR MIG WELDING MACHINE 210 Service Manual Revision AE Issue Date June 19 2006 Manual No 0 4879B Operating Features Art A 07360...

Страница 2: ......

Страница 3: ...784 603 298 5711 www thermalarc com Copyright 2006 2007 2008 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher...

Страница 4: ...2 4 2 10 Specifications 2 4 2 11 Included Items 2 6 2 12 Optional Accessories 2 6 SECTION 3 INSTALLATION 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Ventilation 3 1 3 04 Input Power Requirements 3...

Страница 5: ...ESHOOTING 6 1 6 01 Basic Troubleshooting 6 1 6 02 Solving Problems Beyond the Welding Terminals 6 2 6 03 Welding Problems 6 4 SECTION 7 ADVANCED TROUBLESHOOTING 7 1 7 01 Preliminary Checks 7 1 7 02 In...

Страница 6: ...ajor Electrical and Mechanical Replacement Parts 9 4 9 05 Internal Replacement Parts 1 9 5 9 06 Internal Replacement Parts 2 9 6 9 07 Internal Replacement Parts Spool Assembly 9 7 9 08 Internal Replac...

Страница 7: ...cations 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 al...

Страница 8: ...ires 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...

Страница 9: ...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 Eng...

Страница 10: ...ce 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 t...

Страница 11: ...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 contact avec l...

Страница 12: ...e 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 Assurez vous qu...

Страница 13: ...ez 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 curit et un c...

Страница 14: ...U 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 moteur avant de c...

Страница 15: ...pies 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 Service Manual number and equipme...

Страница 16: ...cuit 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 Powe...

Страница 17: ...n damp ground when welding For more complete safety advice please read section 1 2 07 Protective Filter Lenses Protective filter lenses are provided to reduce the intensity of radiation entering the e...

Страница 18: ...10 minute period 30 of 10 minutes is 3 0 minutes During the other 7 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 cycl...

Страница 19: ...ty Cycle 250A 26 2V 30 250A 26 2V 30 100 Duty Cycle Output Rating 137A DC at 21V 137A DC at 21V Duty Cycle Period Number of Output Voltage Values Mild Stainless Steel Aluminum Flux Cored Wire Feed Spe...

Страница 20: ...e 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 035 045 0 9mm 1...

Страница 21: ...bly 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...

Страница 22: ...ctory 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 be replaced with leads as specified...

Страница 23: ...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 More detailed...

Страница 24: ...els of the unit so it cannot roll Carefully stand the cylinder on the tray and with one foot press against the bottom of the cyl inder to assure it is against the back of the unit Chain the cylinder i...

Страница 25: ...ATOR 210 June 19 2006 3 5 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 Cylinder Instal...

Страница 26: ...hop 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 triggere...

Страница 27: ...Set up Chart Art A 07392 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 com pound or equivalent or Thermal Arc 903910...

Страница 28: ...06 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 Moun...

Страница 29: ...hat 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...

Страница 30: ...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...

Страница 31: ...g 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 Sp...

Страница 32: ...e 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 wire feed proble...

Страница 33: ...e 10 pin socket and the Spool Gun Gas Outlet on the front of the unit Refer to Figure 3 13 Front Panel Rear Panel Art A 07371 Spool Gun Gas Input Connection Main Gun Gas Input Connection Spool Gun 10...

Страница 34: ...ainless 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...

Страница 35: ...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...

Страница 36: ...FABRICATOR 210 3 16 June 19 2006 NOTES...

Страница 37: ...s and Features 13V 16V 17V 21V 22V 31V 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...

Страница 38: ...t 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 explanation of...

Страница 39: ...ed 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 1 2 Art...

Страница 40: ...ether with 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...

Страница 41: ...trols 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 MIN MIN 4 1 3 2...

Страница 42: ...led Table 4 2 MIG Gun Original Parts Consumables TWECO Weldskill MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO Weldskil...

Страница 43: ...RINGS ALLEN SCREW CONNECTOR PLUG Figure 4 13 Conduit Trim Length NOTE When the conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug the raw end...

Страница 44: ...ing 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 obtain...

Страница 45: ...oice 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 amount of penetratio...

Страница 46: ...he 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 for the w...

Страница 47: ...ed 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 WELD MODE switch to S...

Страница 48: ...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 penetration...

Страница 49: ...FABRICATOR 210 June 19 2006 4 13 THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK...

Страница 50: ...45 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 Aluminum Steel 75 Ar 25 CO2 25cfh Non...

Страница 51: ...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 25 4 2 4 25...

Страница 52: ...FABRICATOR 210 4 16 June 19 2006 NOTES...

Страница 53: ...to 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 Powe...

Страница 54: ...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...

Страница 55: ...less 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 equipm...

Страница 56: ...eaks 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 fractu...

Страница 57: ...warf 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 c...

Страница 58: ...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...

Страница 59: ...1 Faulty rectifier unit a Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component 2 Loose welding cable connection a Check all welding cable connections B Cold weld pudd...

Страница 60: ...FABRICATOR 210 6 6 June 19 2006...

Страница 61: ...ot 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 mac...

Страница 62: ...RNBACK CONTROL to minimum 10 Disconnect Isolate the GUN POLARITY LEAD from OUTPUT WELDING TERMINALS 11 Connect Work cable to NEGATIVE OUTPUT WELDING TERMINAL 12 Disengage PRESSURE ADJUST DEVICE so wir...

Страница 63: ...flows 2 Contactor energizes 3 Feed roll turns G Release Gun Switch 1 Feed Roll stops immediately 2 After 1 seconds a Gas flow stops b Contactor de energizes H Set BURNBACK CONTROL potentiometer to mi...

Страница 64: ...4 M 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 VA...

Страница 65: ...HES The voltages should measure approx as outlined below EACH SUCCESSIVE READING MUST BE INCREASING IN VALUE COARSE VOLTAGE SELECTOR SWITCH SETTING FINE VOLTAGE SELECTOR SWITCH SETTING VOLTAGE 1 1 17...

Страница 66: ...perly wired input power cable or plug a Measure for primary voltage at the terminal block where the input power cable is connected If incorrect check wiring in plug and continuity of primary input cab...

Страница 67: ...present replace PCB 1 7 Faulty MIG TIMER PCB PCB 2 a See Test Procedure 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...

Страница 68: ...bly a Check per the diode test procedure page 7 16 9 Defective Main transformer a Check main transformer per test procedure page 7 17 7 10 Spool Gun Control J1 Problem A Gas does not flow when jumper...

Страница 69: ...210 June 19 2006 7 9 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 Blo...

Страница 70: ...INAL TERMINAL WIRE 3 7 11 15 8A BRN 4 8 12 16 BOTTOM OF SWITCH 10 RED 8 BRN 10A RED 9 BLK 9A BLK Figure7 2 4 Position Rotary Switch Coarse 2 6 10 14 1 5 9 13 3 7 11 15 4 8 12 16 6 WHT 2A PINK 5 PNK 2...

Страница 71: ...check continuity of switch per figure 7 5 Knob Locking Collar Rotary Switch SW4 Fine Set Screw Retainer TRAN TAP SWITCH POSITION 1 2 3 4 T2 S2 T2 F2 T2 S2 T2 F2 X X X X X X X X X X X X X X X X 1 2 6 5...

Страница 72: ...DC 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 a...

Страница 73: ...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...

Страница 74: ...bridge and measure output voltage between the two transformer output connections as follows COARSE VOLTAGE SELECTION FINE VOLTAGE SELECTOR VOLTAGE AC approx SWITCH SETTING SWITCH SETTING 1 1 13 3 1 2...

Страница 75: ...hen fed to a zener regulator to provide the 15VDC supply for the electron ics on the circuit board Inputs to the Control PCB CONNECTOR JA Terminal JA 1 trigger input 40VDC trigger open approx 20VDC tr...

Страница 76: ...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 SO...

Страница 77: ...nects 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 wipe...

Страница 78: ...FABRICATOR 210 8 4 June 19 2006...

Страница 79: ...tration 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 avail...

Страница 80: ...abs 2 9 707321PKD Panel Front Fab210 1 10 705937PKD Molding Front Fab210 251 281 1 11 871011PKD Bushing Torch 1 12 707259CLAPKD Panel Side LH Fab210 251 1 13 See Note 1 Screw Hex HD M5x13mm Self Tap 4...

Страница 81: ...FABRICATOR 210 June 19 2006 9 3 Art A 07557 1 2 3 4 5 6 24 7 8 9 22 19 20 25 26 17 10 11 12 13 14 15 18 23 16 21...

Страница 82: ...w Hex HD M8x12mm Self Tap 2 3 7978035PKD Wheel 5 8 IDx10 OD 2 4 871046PKD Clip Retaining 5 8 ID 871046PKD 2 5 707256WBLKPKD Panel Base Fab210 251 281 1 6 7977566 Castor Swivel 5 Wheel 2 7 870921WBLKPK...

Страница 83: ...el Baffle Fab210 251 281 1 2 7977964 PCB Control Fabricators PCB1 1 3 203627 001 Circuit Breaker 5A CB2 1 4 7978041PKD Circuit Breaker 2A CB1 1 5 401840 004 Cable Power Cable Fab190 210 1 6 707206PKD...

Страница 84: ...GNA 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...

Страница 85: ...TZP 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 Sp...

Страница 86: ...71010PKD Feed Plate Assy 2 Roll 210 251 1 3 870082 Knob Control 1 4 IDx3 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 871012WBLKPK...

Страница 87: ...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...

Страница 88: ...FABRICATOR 210 9 10 June 19 2006...

Страница 89: ...assembly 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 Regul...

Страница 90: ...5CT 125 FAS 1250 1560 1 1 4 Bore 24A 75 FAS 1240 1530 3 4 Bore Flat Arc Spot 24A 100 FAS 1240 1550 1 Bore 25CT 162 FAS 1250 1570 1 5 8 Bore Inside Corner Arc Spot N A 22 62 IAS 1220 1521 5 8 Bore N A...

Страница 91: ...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 3...

Страница 92: ...1 GRY 12 DK BRN 13A VIO 1G BRN 1D BRN 1C BRN SW1 M1 INDL 2 1B BRN JE 1 JE 2 14 14A BLK 15 15A BLU TRAN TAP SWITCH POSITION 1 2 3 4 T2 S2 T2 F2 T2 S2 T2 F2 X X X X X X X X X X X X X X X X 1 2 6 5 4 3 8...

Страница 93: ...ED 11 11A GRY 12 12A BRN 13 13A VIO 14 14A BLK 15 15A BLU S7 F7 T2 M2 0V 208V 230V TH2 TEMP LED JA 4 JA 8 JA 3 WIRESPEED 1K MIG SPOOL MIG MIG SPOOL WHITE 4 JB 1 JB 2 JA 3 SPOOL JA 2 JA 1 36 GRY 37 ORN...

Страница 94: ...FABRICATOR 210 A 6 June 19 2006 APPENDIX 5 MAIN PCB CIRCUIT DIAGRAM 30 VAC Art A 07520...

Страница 95: ...FABRICATOR 210 June 19 2006 A 7 DESCRIPTION FABRICATOR MAIN PCB 7977964 82 BENNING SREET WEST LEBANON NH 03784 USA Art A 07520 _...

Страница 96: ...FABRICATOR 210 A 8 June 19 2006 APPENDIX 6 SPOT TIMER CIRCUIT DIAGRAM Art A 07521...

Страница 97: ...FABRICATOR 210 June 19 2006 A 9 82 BENNING SREET WEST LEBANON NH 03784 USA DESCRIPTION CODE DESIGN FABRICATOR SPOT TIMER 7977965 Art A 07521...

Страница 98: ...r 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 thermal arc is authorized to cha...

Страница 99: ...rs All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima...

Страница 100: ......

Страница 101: ...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...

Страница 102: ...World Headquarters Thermadyne Holdings Corporation Suite 300 16052 Swingley Ridge Road St Louis MO 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com...

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