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FABRICATOR 140, 180

OPERATION

 Manual 0-4992

4-12

Janua

r

y 25, 2008

4.14 Fabricator 180 Welding Setting Selection Guide

Stainless

Steel

Stainless

Steel

ER 308L

7.5% Ar

90% He 

35cfh

2.5 CO

2

.025” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

Aluminum

Aluminum

100% Ar

25cfh

.030” (0.8mm)

.035” (0.9mm)

Steel

Flux Core

E71T-GS

None

Required

.045” (1.2mm)

.030” (0.8mm)

.035” (0.9mm)

Steel

ER70S-6

Solid

 (or hard)

100% CO

2

25cfh

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

.035” (0.9mm)

75% Ar 

25cfh

CO

2

25%

92% Ar 

CO

2

8%

Material Type

Wire Type

Shielding Gas

and Flow Rate

Wire Size 

(Diameter)

Art # A-07959

Содержание Fabricator 140

Страница 1: ...Art A 07923 FABRICATOR PORTABLE MIG WELDING MACHINE 140 Service Manual Revision No AA Issue Date January 25 2008 Manual No 0 4992 Operating Features 180...

Страница 2: ......

Страница 3: ...Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2008 by Thermadyne Industries All rights reserved Reproduction of this work in whole or in part without written permission of...

Страница 4: ...2 1 2 04 General 2 2 2 05 Machine Specifications 2 3 2 06 Volt Amp Curves 2 4 2 07 Duty Cycle 2 5 2 08 Fabricator 180A MIG Gun 2 6 2 09 Installing a New Wire Liner 2 7 2 10 MIG Gun Maintenance 2 7 SEC...

Страница 5: ...on Guide 4 12 4 15 Gas Selection for Gas Metal Arc Welding 4 14 SECTION 5 BASIC TROUBLESHOOTING 5 1 5 01 Cleaning of the Unit 5 1 5 02 Cleaning of the Feed Rolls 5 1 5 03 Basic Troubleshooting 5 1 5 0...

Страница 6: ...05 Power Supply 7 4 7 06 Wire Feeder Parts 7 6 7 07 Feed Plate Parts 7 8 7 08 Accessories 7 10 APPENDIX 1 OPTIONS AND ACCESSORIES A 1 APPENDIX 2 FABRICATOR 180 SYSTEM SCHEMATIC A 2 APPENDIX 3 FABRICA...

Страница 7: ...ned 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 f...

Страница 8: ...quipment 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...

Страница 9: ...armful 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 f...

Страница 10: ...offer 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...

Страница 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...

Страница 12: ...i sous ten 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 talliqu...

Страница 13: ...vaillez dans 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...

Страница 14: ...urs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES...

Страница 15: ...ls anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correc...

Страница 16: ...e Intensit 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...

Страница 17: ...g to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part numb...

Страница 18: ...arc welding Does not require the use of a shielding gas As delivered from the factory the Fabricator 140 is set up for 024 0 6mm diameter solid wire and the Fabricator 180 is set up for 030 0 8mm dia...

Страница 19: ...4V 19 5 38V Output Current Range 30 140A 30 180A Duty Cycle Period Number of Output Voltage Values 4 6 Minimum Mains Circuit to suit factory fitted Plug Lead Weld Current Duty Cycle 15A 65A 40 21A 130...

Страница 20: ...36 38 40 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 V out I out Fabricator 140 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 0 10 20 30 40 50 60 70 80 90 100 110 120 1...

Страница 21: ...r 2 5 minutes out of every 10 minute period During the other 7 5 minutes of the 10 minute period the Fabricator 180 must idle and be allowed to cool The thermal cutout will operate if the duty cycle i...

Страница 22: ...ator 180A MIG Gun has an operating capacity in excess of the capacity of the FABRICATOR and can be expected to give trouble free service Item Description Part No Size 1 Nozzle 21 50 11 23 023 0 6mm 11...

Страница 23: ...or plug and the new raw end extends through the end of the conductor tube assembly 4 the outlet guide 10 in the connector plug must be securely tightened onto the liner to prevent its backward movemen...

Страница 24: ...FABRICATOR 140 180 INTRODUCTION Manual 0 4992 2 8 January 25 2008...

Страница 25: ...requires a 230VAC supply voltage The Fabricator 140 s power cord is equipped with a NEMA 5 15P plug and will only connect to a NEMA 5 15P receptacle The Fabricator 180 s power cord is equipped with a...

Страница 26: ...m falling over If an optional portable mounting arrangement is used follow the instructions that are provided with it 2 Remove Cylinder Cap Remove the large metal cap on top of the cylinder by rotatin...

Страница 27: ...ICATOR 140 180 January 25 2008 3 3 Manual 0 4992 1 Art A 07965 Cap 2 Shielding Gas Cracking 3 Shielding Gas Regulator and Flow Meter 4 Shielding Gas Shielding Gas 1 1 8 5 Gas Hose Figure 3 1 Gas Cylin...

Страница 28: ...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 Fi...

Страница 29: ...o the power source by first routing the switch lead through the access hole in the front panel followed by the gun cable see Figure 3 3 NOTE Turn the cable end to align the gas hose nipple on the conn...

Страница 30: ...polarity DCEP 1 Open the door to the machine 2 Remove the polarity terminal knobs 3 Set up the polarity as per Table 3 1 above by removing the leads from the terminals and reversing them if necessary...

Страница 31: ...n 3 09 Installing Wire Spool As delivered from the factory the unit is set for an 4 102mm spool Installation of 4 102mm Spool Assemble parts in sequence shown in Figure 3 6 from right to left 1 Spool...

Страница 32: ...turn the spool 3 10 Feedrolls A feedroll consists of two different sized grooves As delivered from the factory the drive roll is installed for 023 0 6mm for the Fabricator 140 and 030 035 0 8mm 0 9mm...

Страница 33: ...lines up with the hole in the spool When the spool of wire is in place replace the spool retaining pin NOTE The hub tension has been pre adjusted at the factory However if adjustment is required simp...

Страница 34: ...t the proper groove is being used Fig 3 11 5 Pass the wire into the Gun Liner of the Gun Cable End Fig 3 11 6 Close the Pressure Arm Fig 3 11 7 Close the Pressure Adjust Device Tighten it to a snug co...

Страница 35: ...Voltage Control Switch set to 1 0 1 2 3 4 5 6 OFF Art A 08338 Figure 3 13 Power ON 3 Set the wire feed speed to half way or 5 Art A 08339 Figure 3 14 Wire Speed Half way 4 Straighten the gun cable Re...

Страница 36: ...FABRICATOR 140 180 INSTALLATION Manual 0 4992 3 12 January 25 2008...

Страница 37: ...ctions and Warnings chapter included in this manual Neglect of these precautions may result in personal injury WARNING Make all connections to the power source including electrode and work cables as w...

Страница 38: ...feed motor 2 The Voltage Control Switch sets the voltage level to theweldingterminalsasitisrotatedintheclockwise direction There are 4 positions available in the Fabricator140and6positionsintheFabric...

Страница 39: ...ON FABRICATOR 140 180 January 25 2008 4 3 Manual 0 4992 Weldskill F A B R I C A T O R F A B R I C A T O R 180 80 0 1 2 3 4 5 6 OFF 1 2 4 3 5 6 8 9 Art A 07916 14 10 11 12 13 7 Figure 4 1 Fabricator Co...

Страница 40: ...roper lenses installed See Safety Instructions and Warnings chapter included in this manual Neglect of these precautions may result in personal injury Travel at a speed necessary to maintain a bead wi...

Страница 41: ...tal Molten Slag Solid Weld Metal Slag Art A 05104 Figure 4 3 FCAW Process 4 06 Basic Welding Technique General Two different welding processes are covered in this section with the intention of providi...

Страница 42: ...times Always wear the welding helmet with proper filter lenses CAUTION Do not pull the welding gun back when the arc is established This will create excessive wire extension stickout and make a very p...

Страница 43: ...n cause the desired change in the bead formation They are 1 Stickout distance between the end of the contact tube tip and the end of the electrode wire Keep this at about 3 8 10mm stickout as shown in...

Страница 44: ...structions and Warnings chapter included in this manual 4 11 Welding Procedure 1 Maintain the tip to work distance stickout at 5 16 to 3 8 8 to 9mm at all times 2 For transverse and longitudinal nozzl...

Страница 45: ...3 Leading 2 Increase 5 Larger 4 Ar CO2 mix Larger Bead 1 Increase 2 Decrease 3 Increase Smaller Bead 2 Decrease 2 Increase 3 Decrease Higher Narrower Bead 1 Decrease 2 Trailing 3 Increase Flatter Wid...

Страница 46: ...5 CO2 023 0 6mm 030 0 8mm 023 0 6mm 030 0 8mm 75 Ar 25 CO2 25cfh Aluminum Aluminum 100 Ar 25cfh 030 0 8mm 035 0 9mm Steel Flux Core E71T GS None Required 030 0 8mm 035 0 9mm Steel ER70S 6 Solid or har...

Страница 47: ...7 1 7 3 1 2 1 1 2 1 1 5 2 4 4 4 3 1 1 1 1 1 4 2 2 7 3 2 4 1 1 1 1 1 5 1 4 1 5 1 1 1 1 1 1 1 5 2 3 5 3 2 2 5 5 3 5 3 2 2 5 3 5 2 5 2 1 5 3 5 2 1 7 1 4 2 1 4 1 3 1 4 1 5 1 1 2 3 4 4 4 4 4 4 4 4 4 4 4 3...

Страница 48: ...CO2 025 0 6mm 030 0 8mm 035 0 9mm Aluminum Aluminum 100 Ar 25cfh 030 0 8mm 035 0 9mm Steel Flux Core E71T GS None Required 045 1 2mm 030 0 8mm 035 0 9mm Steel ER70S 6 Solid or hard 100 CO2 25cfh 023 0...

Страница 49: ...8 3 1 4 1 1 1 1 1 1 6 1 4 1 6 1 5 1 1 1 1 1 1 1 6 1 9 3 5 6 5 10 5 3 7 4 3 7 10 6 4 5 3 5 5 5 4 3 3 3 3 2 4 5 5 2 5 2 2 3 1 7 3 5 2 1 6 1 5 1 4 2 1 5 1 4 1 4 1 2 1 6 1 5 1 3 1 3 5 5 10 5 5 6 5 5 5 5 5...

Страница 50: ...our Good mechanical properties Greater than 3 32 See Note 1 Spray transfer 92 Argon 8 CO2 Flat HV Fillet Reduces undercutting Higher deposition rates and improved bead wetting Deep penetration and goo...

Страница 51: ...has not fractured and that it is connected to the MIG torch adaptor 4 Welding in a windy environment a Shield the weld area from the wind or increase the gas flow 5 Welding dirty oily painted oxidized...

Страница 52: ...utlet guides a Wire will rub against the misaligned guides and reduces wire feedability 5 Liner blocked with slag a Slag is produced by the wire passing through the feed roller if excessive pressure i...

Страница 53: ...Increase joint angle or gap C Shielding gas incorrect C Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase voltage by increasing voltage selection switch positio...

Страница 54: ...preheating part to be welded or cool slowly 7 Cold weld puddle A Faulty rectifier unit A Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component B Loose welding cable c...

Страница 55: ...lty control PCB B Have an Accredited THERMAL ARC Service Agent investigate the fault 4 Wire feeds when the MIG Gun trigger switch is depressed but arc can not be established Poor or no work lead conne...

Страница 56: ...FABRICATOR 140 180 BASIC TROUBLESHOOTING Manual 0 4992 5 6 January 25 2008...

Страница 57: ...from the positive Polarity Change Over terminal 5 Open the PRESSURE ADJUST DEVICE so the wire will not feed 6 With the Primary Line Disconnect in the OFF position plug the input power cord into the p...

Страница 58: ...mately 4 VDC to 20 VDC C Remove the jumper and the meter from J6 and re install MIG gun plug P6 This completes the Spool Gun Control Test If the above steps were correct proceed to the next section Ou...

Страница 59: ...terminals J3 to JFM If voltage measures at 120 VAC for Fabricator 140 or 230 VAC for Fabricator 180 replace the fan D Green AC LED is on fan turns OVERTEMP LED is on 1 The unit is overheated a Allow t...

Страница 60: ...the unit 2 Defective solenoid a Replace the solenoid C AC LED is on and the fan is on When the MIG gun switch is closed gas flows feed roll does not turn output voltage is measures 21 VDC 1 Defective...

Страница 61: ...side cover 1 Disconnect and isolate the black wire from the negative capacitor terminal A Refer to Figure 6 1 2 Disconnect and isolate the transformer wire from terminal AC1 Refer to Figure 6 1 3 Usin...

Страница 62: ...ion T1 Secondary Voltage 1 15 2 18 3 21 4 25 Fabricator 180 Voltage Control Switch SW1 position T1 Secondary Voltage 1 17 2 19 3 21 4 23 5 26 6 31 6 13 C1 C2 Test Procedure Use a Capacitor Tester if a...

Страница 63: ...illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts Most parts of the equipment are listed except commercially ava...

Страница 64: ...i Part Number Helvi Part Number Helvi Part Number 1 1 Bezel Front Molding F140 180 W7004018 2 1 Bushing Torch F140 180 W7004016 3 1 Panel Front Fab140 W7004044 3 1 Panel Front Fab180 W7004045 4 1 Clam...

Страница 65: ...iption Description Part Number Part Number Part Number Part Number Part Number 1 1 Clamp Cable D20 F140 180 W7004003 1 1 Clamp Cable M25X1 5 Fab180 W7004013 2 1 Bezel Rear Molding F140 180 W7004019 3...

Страница 66: ...8 Rectifier 140A Fab140 W7004032 4 1 D1 D8 Rectifier 180A Fab180 W7004033 5 1 Panel Top Side F140 180 W7004042 6 1 SOL 1 Solenoid Valve 110V60Hz Fab140 W7004036 6 1 SOL 1 Solenoid Valve 230V60Hz Fab18...

Страница 67: ...PARTS LISTS FABRICATOR 140 180 January 25 2008 7 5 Manual 0 4992 1 2 3 4 5 6 7 8 9 10 11 12 Art A 08258...

Страница 68: ...014 2 1 Handle F140 180 W7004012 3 1 Panel Internal F140 180 W7004048 4 1 Drive Roll 023 030 035 0 6 0 8 0 9mm 7977036 5 1 Wire Feed Plate Fab140 W7004054 5 1 Wire Feed Plate Fab180 W7004055 6 1 Screw...

Страница 69: ...PARTS LISTS FABRICATOR 140 180 January 25 2008 7 7 Manual 0 4992 1 2 3 4 5 6 7 8 9 11 12 10 13 Art A 08259...

Страница 70: ...Part Number Part Number 1 1 Motor Pinion F140 180 W7004200 2 1 Arm Pressure F140 180 W7004201 3 1 Pressure Roll F 140 180 W7004202 4 1 Key Drive Spacer F140 180 W7004203 5 1 Screw Fix Drive Roll F140...

Страница 71: ...PARTS LISTS FABRICATOR 140 180 January 25 2008 7 9 Manual 0 4992 Art A 08276_AB 1 8 8 8 8 See Appendix 1 and 4 for more options 4 7a 7b 7c 7d 7e 6 6 10 11 11 11 12 3 5 12 12 12 2 2 4 7...

Страница 72: ...Ref Ref Des Des Des Des Des Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number 1 1 Alternative Firepower Regulator 0781 9851 2 1 T...

Страница 73: ...2723 Medalist 1400 Series HRF Flowmeter Regulator Argon Argon CO2 mix gases Victor Regulator Flowmeter CO2 0781 2725 Medalist 1400 Series HRF Flowmeter Regulator CO2 gas CONSUMABLES Feedroll Kits Feed...

Страница 74: ...AC 1PH 60Hz SW1 FAN V V M M TS1 COM COM GUN SW YELLOW GREEN B1 B TS1 T1 TS1 T1 WIRE SPEED WIRE SPEED TS1 DIODE HEATSINK 3 TS1 DIODE HEATSINK 3 CB1 CB1 SOL1 SOL1 GND GND OVERTEMP OVERTEMP J4 J4 T1 T1 1...

Страница 75: ...4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC INDUSTRIAL PARK 2 WEST LEBANON NH 03784 603 298 5711 A THERMADYNE COMPANY RevCode Tuesday July 24 200...

Страница 76: ...V V M M TS1 COM COM GUN SW FAN 120 VAC 60Hz SW1 PCB1 WHT BLK GRN YELLOW GREEN AC AC J3 J3 J5 J5 1 2 3 4 5 6 7 8 OVERTEMP OVERTEMP CB1 CB1 SW1 SW1 R L1 4 3 2 1 L1 L1 T1 T1 1 2 3 4 J2 J2 A1 A B1 B F1 F1...

Страница 77: ...4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC INDUSTRIAL PARK 2 WEST LEBANON NH 03784 603 298 5711 A THERMADYNE COMPANY RevCode Tuesday July 24 200...

Страница 78: ...35 045 0 9 1 2mm Hard Wire 7977731 Feed Roll 030 035 0 8 0 9mm Soft Wire 7977732 Feed Roll 030 035 0 8 0 9mm Cored Wire 7977264 704277 Feed Roll 045 1 16 1 2 1 6mm Cored Wire W7004022 Size visible whe...

Страница 79: ......

Страница 80: ...herwise 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 change this warranty in any way or grant any othe...

Страница 81: ...d components including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150 Original Main Power Magnetic...

Страница 82: ......

Страница 83: ...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 84: ...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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