THERMADYNE C. IHERMAL FABRICATOR WELDER Models 210 and 250 CV/DC MIG Power Supplies OPERATING MANUAL OWNERS MANUAL Number 430429-448 September 17, 1999Pan No. [SSE Tgs77 | 598 A vicins Read and understand this entire Operating Manual and your employer's safety practices before installing, operating, or servicing the equioment. A oo While the information contained in this manual represents our best judgement, Thermal Arc assumes no lability for its use. ‘Thermal Arc™ Fabricator Welder Model Operating Manual Published by: ‘Thermal Arc 2200 Corporate Drive Troy, Ohio, USA 45373 (937) 440-0196 Copyright 1998, Thermal Arc All rights reserved. Reproduction of this work, in whole or in part, without writen 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 the Thermal Arc™ Fabricator Welder Operating Manual, whether such error results from negligence, accident, or any other cause. Page iiFabricator 210, 250 TABLE OF CONTENTS Page 1, INTRODUCTION.. 1.1 Notes, Cautions and Warnings. 1.2 Important Safety Precaution 1.3 Publications... 1.4 Note, Attention et Avertissement. 1.5 Precautions De Securite Important... 1.6 Documents De Reference. 1.7 Statement of Warranty 2. GENERAL INFORMATION 2.1 Safety 2.2 Protective Filter Lenses. 2.3 Welding Protection .. 2.4 User Responsibility... 2.5 Duty Cycle... 3, SPECIFICATIONS. 3.1 MIG Torch Specifications. 3.2 Machine Specifications.. 3.3 Wire Drive Specifications. 3.4 Power Supply Contents.. 3.5 Optional Access0Ti€5...nrsnenmne . 4, INSTALLATION RECOMMENDATIONS. 4.1 Environment. 4.2 Location .. 43 Ventilation 4.4 Mains Supply Voltage Requirements 4.5 Alternative Mains Supply Voltages... 5. SET UP FOR COMPACT FABRICATORS 6. POWER SUPPLY CONTROLS, INDICATORS AND FEATURE: 6.1 Standby switch with in-built Indicator Light. 6.2. Coarse Voltage Control Switch and Fine Voltage Control Switch. 6.3 Digital Ammeter and Voltmeter (Optional). 6.4 Torch Polarity Lead «um —— 6.5 Positive and Negative Welding Terminals 6.6 Spool Gun Control Socket 6.7 Thermal Overload 6.8 Choice of Inductance Setting... 6.9 Wirespeed Control. Page fiFabricator 210, 250 TABLE OF CONTENTS Page 6.10 Mode Selector Switch... 6.11 Spot Timer. 6.12 Dwell Timer... 6.13 Burnback Control . 6.14 Spool Gun / Standard Switch ..u.nsmnnn 6.15 Wirefeeder Drive Roller Pressure Adjustment. 6.16 Wire Reel Brake 7. TWECO MIG TORCH (Cat No 7.1 Introduction 7.2 MIG Torch Components 7.3 Torch Consumable Parts... 7.4 Installing A New Wire Conduit ee 27 7.5 MIG Torch Maintenance ns 8. BASIC WELDING TECHNIQUE.. 8.1 Setting of the Power Supply... (0-6105 where supplied)... 8.2 Position of MIG Torch. . 29 8.3 Distance from the MIG Torch Nozzle to the Work Piece.. 29 8.4 Travel Speed. 7 29 8.5 Electrode Wire Size Selection. 29 30 8.6 Stitch Welding Operation. 8.7 Spot Welding Operation ...nmm 9, ROUTINE MAINTENANCE & INSPECTION 9.1 Improved Current Accuracy Calibration Procedure for the Digital Meter... 10, BASIC TROUBLESHOOTING 10.1 Solving Problems Beyond the Welding Terminals... 10.2 Welding Problems... 10.3 Power Supply Problems 10.4 Key Spare Parts... 11. VOLT/AMP GRAPHS.. 12, FABRICATOR 210 AND 250 POWER SUPPLY CIRCUIT DIAGRAM. 13. PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM.. Page ivFabricator 210, 250 TABLES Page Table 1 - Filter lens size verses welding current. Table 2 - Factory fitted Mains supply leads fitted to the Fabricator Power Supplies Table 3 - Mains supply lead sizes for altemative Mains supply voltages Table 4 - Mig Torch components Table 5 - ig torch gas diffusers... Table 6 - Mig torch contact tips. Table 7 - Mig torch nozzles Table 8 - Mig torch conduits... Table 9 - 0.9mm (.035)/1.2mm (.045”) wire deposition rate, FIGURES Figure 1 - Fabricator duty eycle curves... Figure 2 - Voltage settings for Fabricator 210 & 250..... 19 Figure 3 - Compact Fabricator controls.... Figure 4 - Internal Fabricator controls... Figure 5 - Examples of the digital read outs. Figure 6 - Spool Gun 14 pin receptacle... Figure 7 - Exploded view of MIG torch... Figure 8 - Conduit trim length... Figure 9 - MIG Torch angle .. Figure 10 - Wire penetration comparison Figure 11 - Volt/Amp curves of the Fabricator 210 Figure 12 - Volv/Amp curves of the Fabricator 250... Figure 13 - Power Supply schematic for Fabricator 210 and 250.. Figure 14 - Circuit diagram for control PCB 705946.... PagevFabricator 210, 250 This page intentionally left blank Page vi44 4.2 Fabricator 210, 250 INTRODUCTION Notes, Cautions and Warnings ‘Throughout this manual, notes, cautions, and warnings are used to highlight important information. ‘These highlights are categorized as follows: NOTE ‘An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. umm CAUTION A procedure which, if not properly followed, may cause damage to the equipment. Accu ‘A procedure which, if not properly followed, may cause injury to the operator or others in the operating area. Important Safety Precautions Avowe OPERATION AND MAINTENANCE OF WELDING ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. To prevent possible injury, read, understand and follow all wamings, safety precautions and instructions before using the equipment. Call 1-603-298-8711 or your local distributor if you have any questions. Page 1Fabricator 210, 250 AB GASES AND FUMES Gases and fumes produced during the welding process can be dangerous and hazardous to your health, Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. ‘© Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. ‘© The kinds of fumes and gases from the welding are depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following: Antimony Beryllium Cobalt Manganese Selenium Arsenic Cadmium Copper ‘Mercury Silver Barium Chromium Lead Nickel Vanadium * Always read the Material Safety Data Sheets (MSD's) that should be supplied with the material you are using. These MSDS’s will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. + For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.3, Publications in this manual. # Use special equipment, such as water or down draft cutting tables, to capture fumes and gases. * Do not use the welding torch in an area where combustible or explosive gases or materials are located * Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. A ELECTRIC SHOCK Electric Shock can injure or kill. The welding are process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. ‘© Never touch any parts that are electrically “live” or “hot.” © Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. Repair or replace all worn or damaged parts. ‘© Extra care must be taken when the workplace is moist or damp. ‘Install and maintain equipment according to NEC code, refer to item 4 in Subsection 1.3, Publications, + Disconnect power supply before performing any service or repairs Read and follow all the instructions in the Operating Manual. Page 2Fabricator 210, 250 A FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the welding are. * Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. ‘* Ventilate all flammable or explosive vapors from the workplace. ‘© Do not cut or weld on containers that may have held combustibles. # Provide a fire watch when working in an area where fire hazards may exist. © Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion, NOISE Noise can cause permanent hearing loss, Plasma are processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. * To protect your hearing from loud noise, wear protective ear plugs and/or ear mufis. Protect others in the workplace. * Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels. © For information on how to test for noise, see item ] in Subsection 1.3, Publications, in this manual, ARC RAYS Are Rays can injure your eyes and burn your skin. The welding are process produces very bright ultra violet and infra red light. These are rays will damage your eyes and burn your skin if you are not properly protected. To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. ‘* Wear welding gloves and suitable clothing to protect your skin from the are rays and sparks. « Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dity. ‘Protect others in the work area from the are rays, Use protective booths, screens or shields. ‘Use the shade of lens as recommended in the Operating Manual Page 3Fabricator 210, 250 13 Publications Refer to the following standards or their latest revisions for more information: 1, OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard 249.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Goverment Printing Office, Washington, D.C. 20402 4, ANSI Standard 287.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018 6. ANSI Standard 249.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard 46.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8, NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9, NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10.NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12.CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 13.NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 14,American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N,W. LeJeune Rd, Miami, FL 33126 15.ANSI Standard 288.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from ‘American National Standards Institute, 1430 Broadway, New York, NY 10018 Page 4Fabricator 210, 250 14 15 Note, Attention et Avertissement Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations & caractére important. Ces mises en relief sont classifiées comme suit : NOTE Toute opération, procédure ou renseignement général sur lequel il importe diinsister davantage ou qui contribue a lefficacité de fonctionnement du systéme. meme 47 TENTION Toute procédure pouvant résulter 'endommagement du matériel en cas de non-respect de fa procédure on queston AM osecerssenen Toute procédure pouvant provoquer des blessures de opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question. Precautions De Securite Importantes M osresssenenr OPERATION ET LA MAINTENANCE DU MATERIEL DE SOUDAGE A L'ARC AU JET DE PLASMA PEUVENT PRESENTER DES RISQUES ET DES DANGERS DE SANTE. I faut communiquer aux opérateurs et au personne! TOUS les dangers possibles. Afin d'éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d'utlliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions. Page 5Fabricator 210, 250 A FUMEE et GAZ La fumée et les gaz produits par le procédé de jet de plasma peuvent dangers de santé. * Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre téte hors de la plume de fumée provenant du chalumeau. enter des risques et des © Utilisez un appareil respiratoire alimentation en air si l'aération fournie ne permet pas @'Gliminer la fumée et les gaz. © Les sortes de gaz et de fumée provenant de I’arc de soudage dépendent du genre de métal utilisé, des revétements se trouvant sur le métal et des différents procédés. Vous devez. prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants: antimoine baryum chrome mangantse —_plomb argent béryllium cobalt mercure sélénium arsenic cadmium cuivre nickel vanadium © Lisez toujours les fiches de données sur la sécurité des matiéres (sigle américain “MSDS”), celles-ci devraient étre fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant & la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé. © Pour des informations sur la maniére de tester la fumée et les gaz de votre lieu de travail, consultez l'article 1 et les documents cités & la page 8 © Utilisez un équipement spécial tel que des tables de coupe A débit d’eau ou & courant descendant pour capter la fumée et les gaz. # N’utilisez pas le chalumeau au jet de soudage dans une zone ott se trouvent des matiéres ou des ‘gaz. combustibles ou explosits. «Le phosgene, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée, A CHOC ELECTRIQUE Les choes électriques peuvent blesser ou méme ter. Le procédé au jet de soudage requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l'opérateur et les autres personnes sur le lieu de travail ‘© Ne touchez. jamais une piéce “sous tension” ou “vive”; portez. des gants et des vétements secs. Isolez-vous de la pice de travail ou des autres parties du circuit de soudage. © Réparez ou remplacez toute piéce usée ou endommagée. © Prenez des soins particuliers lorsque la zone de travail est humide ou moite. * Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page ¥, article 9.) © Débranchez lalimentation électrique avant tout travail d’entretien ou de réparation. « Lisez et respectez toutes les consignes du Manuel de consignes. Page 6Fabricator 210, 250 A INCENDIE ET EXPLOSION Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de I'are de soudage. Le procédé & I’are de soudage produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matiéres combustibles ou provoquer l’explosion de fumées inflammables. ‘+ Soyez certain qu’aucune matiére combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matiére qu'il est impossible de retirer de la zone de travail. * Procurez une bonne aération de toutes les fumées inflammables ou explosives. * Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matigres combustibles. * Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers incendie. * Le gas hydrogéne peut se former ou s’accumuler sous les pices de travail en aluminium Jorsqu’elles sont coupées sous l'eau ou sur une table d’eau, NE PAS couper les alliages en aluminium sous V’eau ou sur une table d'eau A moins que le gas hydrogéne peut s’échapper ou se dissiper. Le gas hydrogéne accumulé explosera si enflammé RAYONS D’ARC DE PLASMA Les rayons provenant de I’arc de soudage peuvent blesser vos yeux et briler votre peau. Le procédé are de soudage produit une lumiére infra-rouge et des rayons ultra-violets tés forts. Ces rayons are nuiront a vos yeux et brileront votre peau si vous ne vous protégez pas correctement. * Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parvis latérales ou des lunettes de protection ou une autre sorte de protection oculaire. * Portez des gants de soudeur et un vétement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de Par. * Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure. * Protégez. les autres personnes se trouvant sur la zone de travail contre les rayons de Pare en foumissant des cabines ou des écrans de protection. + Respectez le teint de lentille recommandé dans le manuel de consignes. BRUIT Le bruit peut provoquer une perte permanente de Voute. Les procédés de soudage a l’are de soudage peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous diidez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de Voute. * Pour protéger votre ouie contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires, Protégez également les autres personnes se trouvant sur Je lieu de travail, * Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux stirs, * Pour des renseignements sur la maniére de tester le bruit, consultez l'article 1, page 8 Page 7Fabricator 210, 250 1.6 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites @ celles-ci pour de plus amples renseignements : 1, OSHA, NORMES DE SECURITE DU TRAVAIL ET DE PROTECTION DE LA SANTE, 29CFR 1910, disponible auprés du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 . Norme ANSI 249.1, LA SECURITE DES OPERATIONS DE COUPE ET DE SOUDAGE, disponible auprés de la Société Ameéricaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd,, Miami, FL 33126 3. NIOSH, LA SECURITE ET LA SANTE LORS DES OPERATIONS DE COUPE ET DE SOUDAGE A L’ARC ET AU GAZ, disponible auprés du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4, Nome ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l'Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018 . Nome ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprés de I’ American National Standards Institute, 1430 Broadway, New York, NY 10018 6. Norme ANSI Z49.2, PREVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCEDES DE COUPE ET DE SOUDAGE, disponible auprés de I’American National Standards Institute, 1430 Broadway, New York, NY 10018 7. Norme A6.0 de I’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT. RENFERME DES PRODUITS COMBUSTIBLES, disponible auprés de la American Welding Society, 550 N.W. Leleune Rd., Miami, FL 33126 8. Norme 51 de I’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES A GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCEDES ASSOCIES, disponible auprés de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprés de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10.Norme 51B de la NFPA, LES PROCEDES DE COUPE ET DE SOUDAGE, disponible auprés de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES EN CYLINDRES, disponible auprés de I’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12.Norme CSA W117.2, CODE DE SECURITE POUR LE SOUDAGE ET LA COUPE, disponible auprés de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3 13.ivret NWSA, BIBLIOGRAPHIE SUR LA SECURITE DU SOUDAGE, disponible auprés de T’Association Nationale de Foumitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103 14.Norme AWSF4.1 de l'Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PREPARATION A LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX , disponible auprés de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 nw Page 817 Fabricator 210, 250 15.Norme ANSI 288.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprés de l’American National Standards Institute, 1430 Broadway, New York, NY 10018 ‘Statement of Warranty LIMITED WARRANTY: Thermal Are, A Thermadyne Company, warrants that its products will be free of defects in workmanship or material, Should any failure to conform to this warranty appear within the time period applicable to the Thermal Are products as stated below, Thermal Are shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, comect such defects by suitable repair or replacement, at Thermal Are’s sole option, of any components or parts of the product determined by Thermal Arc to be defective, THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of ‘Thermal Are with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Are is authorized to change this warranty in any way or grant any other warranty. THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDEGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT. THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Aro’s authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Are delivers the product to the authorized distributor. Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period ‘extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor. Page 9Fabricator 210, 250 PLASMA WELDING POWER SUPPLIES EABRICATOR/GENERATORS INVERTERS LABOR MAIN POWER MAGNETICS 3 YEARS 2YEARS 1 YEAR (STATIC & ROTATING) ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2YEARS —«1YEAR CONTROL PC BOARD 3 YEARS 2YEARS 1 YEAR ALL OTHER CIRCUITS AND 1 YEAR 1 YEAR 1 YEAR COMPONENTS INCLUDING BUT NOT LIMITED TO, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, POWER SWITCHING SEMICONDUCTORS ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTORS WARRANTY FOR DETAILS. CONSOLES, CONTROL EQUIPMENT, 1 YEAR 1 YEAR 1 YEAR HEAT EXCHANGES, AND ACCESSORY EQUIPMENT ‘TORCH AND LEADS 180 DAYS I80DAYS 180 DAYS. REPATR/REPLACEMENT PARTS 90 DAYS: 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal ‘Are by an authorized Thermal Are® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All retumed goods shall be at the customer's risk and expense. This warranty supersedes all previous Thermal Arc warranties. ‘Thermal Arc® is a Registered Trademark of Thermadyne... Effective May 1, 1997 Page 10Fabricator 210, 250 2,_GENERAL INFORMATION ‘The Fabricator 210 and 250 are semi-automatic Gas Metal Arc Welders (GMAW-commonly MIG) with either integrated or separate wire feed unit. The Power Supplies are designed to meet the broad operating needs of the metal fabrication industry where production efficiency is vital. They are designed and manufactured in Australia to Australian Standard AS1966.1-1985, IEC974-1 and CE. The Fabricator range gives excellent performance on mild steel, stainless steel, aluminium, silicon bronze and some hard facing wires with Argon based shielding gases. The Power Supplies also give excellent results on mild stee! using Carbon Dioxide shielding gas. The Fabricator range is supplied as a complete package ready to weld (apart from gas cylinder and electrode wire). The following instructions detail how to correctly set up the welder and give guidelines on gaining the best production efficiency from the Power Supply. Please read these instructions thoroughly before using your Fabricator welder. 24 Safety The following basic safety rules should always be followed: i) Ensure the machine is correctly installed, if necessary, by a qualified electrician ii) Ensure the Power Supply is earthed correctly (electrically) in accordance with local regulations. iii) Excessive heat in the welding cables may cause fire. Never weld with poor electrical connections, damaged welding cables or exceed the welding cable current rating as, this will produce excessive heat and may cause a fire. iv) Always wear the correct protective clothing for protection from sparks, molten particles and are rays. v) When welding in confined spaces, always ensure adequate ventilation and constant observation of the operator. vi) Keep combustible materials away from the welding area, Have a suitable fire extinguisher handy, vii)_Never watch the welding are with naked eyes. Always use and wear a welding mask fitted with the correct filter lens. viii) Do not stand on damp ground when welding. ix) For more complete safety advice please read the safety literature included with the equipment before starting to weld. 2.2 Protective Filter Lenses Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infra-red, ultra-violet 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 hard particles an additional hard clear glass or special plastic external cover lens should be used. This cover lens should always be kept in place and replaced before the damage impairs your vision while welding. Page 11Fabi ator 210, 250 23 2.4 25 Welding Protection oS It is recommended to use a welding Approximate range of Filter lens helmet, conforming to the local velevane welding current | required for MIG Standards when electric are welding. Up to 150 Shade 10 Use a welding helmet in serviceable condition with the correct filter Jens ae Slade fitted as per Table 1. 250-300 Sade 12} 300-350 Shade 13 User Responsibility ‘Over 350 Shade 14 This equipment will perform as per the information contained herein when Table I Filfer lens size verses welding cunent installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly wom, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be earried out by appropriately qualified persons approved by THERMAL ARC. Advice in this regard can be obtained by contacting THERMAL ARC. This equipment or any of its parts should not be altered from standard specification without prior written approval of THERMAL ARC. The purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorised modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by THERMAL ARC. Duty Cycle Duty Cycle (percentage) The rated duty cycle of a 1m welding Power Supply is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts, To explain the ten minute duty cycle period the following example is used. Suppose a welding Power Supply is designed to operate 2 40 eo 80 100 120 140 180 180 200 220 m0 at 50% duty cycle, 250 Wetcing Curent amps) 70 2m amperes at 27 volts. This Figure 1 - Fabricator duty cycle curves, means that it has been designed and built to provide the rated amperage (250A) at the rated load voltage (27V), for 5.0 minutes out of every 10 minute period (50% of 10 minutes is 5.0 minutes). During the other 5.0 minutes of the 10 minute period the Power Supply must idle and be allowed to cool. The thermal cut-out will operate if the duty cycle is exceeded, Page 12Fabricator 210, 250 3._SPECIFICATIONS 3.1 MIG Torch Specifications [Torch Catalog Number 10-6105 (Torch Type TWECO 250A (Eliminator Consumables) ‘Torch Cable Length 3.6 metres (12 ft) Page 13Fabricator 210, 250 3.2 Machine Specifications Fabricator 210 Fabricator 250 Compact Compact Plant Assembly 706105 706112 [Plant Mass 93kg (209bs) 103kg (227Ibs) Plant Dimensions (including 1 910mm x W 365mm x D 900mm iwheels and cylinder carrier) (35.8" x W 14.4"x D 35.5”) [Power Supply 706081 706088 Power Supply Mass 85kg (187Ibs) 93kg (205Ibs) | [Power Supply Dimensions (inclu- 800mm x W 355mm x D 820mm | jing wheels and cylinder carrier) (H31.5” x W 14.0" D323”) [Primary input voltage 208V 2300. I 208V 230V {umber of Phases 1D [Frequency | 60 Hz [Rated Input Current @ 100% V20A an ¥36A aan (Duty Cycle [Rated kVA @ 100% Duty Cycle SKVA SKVA SRVA SKVA [Maximum Input Current 390A 36 35 50A (Generator Requirements OKVA OKVA Be IDKVA IDKVA ‘Supply VA @ no load 1020 VA 930 VA 1170 VA 1060 VA ‘Supply Watts @ no load 550W. 550W 660W 660W ISupply VA @ max. output B.IKVA B.IKVA TLSKVA T1SKVA Supply Watts @ max. output 7060W 7060W 9450W 9450W [Machine Efficiency @ max 5% 3% 58% 58% yutput [Power Factor @ max. output 0.85 085 0.85 0.85 [Recommended Mains Outlet Size 30A 304, 404 40a | [Recommended Fuse Size + 60A + 608 + 80A + 804 [Open Circuit Voltage Range 18910340V | 186t0352V | 17.91043.1V | 18.8t042.9V (Ouiput Current Range 30 to 210A 30 t0 210A 30 t0 250, 30 to 250A [Rated Output Duty Cycle 210A@ 40% | 210A@40% | 250A@50% | 250A@ 50% 100% Duty Cycle Output Rating 127A 127A 180A 180A [Duty Cycle Period 10 minutes jumber of Output Voltage Values 16 16 Wire Size Range 0.6mm (.024”) - 0.9mm (.035”) Hard (Fabricator 210) 0.6mm (.024”)- 1.2mm (.045") Hard (Fabricator 250) 0.9mm (.035")- 1.2mm (.043") Soft 0.8mm (,030”) - 1.2mm (.045”) Fluxcored VY The Rated Input Current should be used for the determination of cable size & supply requirements. + Motor start fuses or thermal circuit breakers are recommended for this application. Australian Standard AS3000 permits the rating of the fuse or thermal circuit breaker protecting the circuit conductors, to be Page 14Fabricator 210, 250 double the outlet current rating for any circuit used exclusively for an electric are welder, Check local requirements for your situation in this regard. + Generator Requirements at the Rated Output Duty Cycle. Page 15Fabricator 210, 250 3.3, Wire Drive Specifications Motor Supply Voltage 36VAC Motor Supply VA 216VA, Control Supply Voltage 24VAC Control Supply VA 30VA Minimum Wire Speed Im per minute (3.3 ft per minute) Maximum Wire Speed 20m per minute (65.6 ft per minute) Wire Diameter Mild Steel: Aluminium: Flux Cored: Stainless Steel: (0.6mm (.024”), 0.8mm (.030"), 0.9mm (.035") 1.0mm (,040"), 1.2mm (.045") 0.8mm (.030"), 0.9mm (.035”) 0.9mm (.035”), 1.0mm (.040"), 1.2mm 045") 0.8mm (.030"), 0.9mm (.035”), 1.2mm (.045") Wire Spool Size 15Kg G31b)Maximum Spot Time Range to 4.0 Seconds Stiteh ‘on’ Time 0 to 4.0 Seconds Stitch ‘off’ Time Oto 4.0 Seconds Burnback Time Range 0 to 0.40 Seconds 3.4 Power Supply Contents Fabricator 210 | Fabricator 250 Vheeling Kit ‘oll on Cylinder Carrier [Power Supply )perating Instructions Metre (L0ft) Work Lead Cable Stowage Hook egulator / Flowmeter [TWECO MIG torch 250A, ‘eed Roller 0.6/0.8 Hard [Feed Roller 0.9/1.2 Hard [Feed roll, 1.0/1.2 - 1.4/1.6 Flux cored Set of Contact T SISISISISISISISISI SSIS SISISISISISISISISI SITS Page 16Fabricator 210, 250 3.5 Optional Accessories Catalogue Description Fabricator 210 | Fabricator 250 ‘Number 706135 _ [Digital Meter Kit v v 10-6103 [250A Fliminator torch (fits Fabricator adaptor) v v [ELC4123545) 150A Eliminator torch (fits Fabricator adaptor) v v 10-6021 _ [Work lead Gm) v v 10-6120 [Feed roll, 0.6/0.8 Hard Wire v v 10-6151 [Feed roll, 0.9/1.2 Hard Wire v v 10-6121 [Feed roll, 1.0/1.2 Hard Wire v v 10-6179 [Feed roll, 0.8/0.9 Soft Wire v v 10-6134 _|Feed roll, 1.0/1.2 Sof Wire v v 10-6180 [Peed roll, 0.8/0.9 Flux cored v v 10-6022 [Feed roll, 1.0/1.2 - 1.4/1.6 Flux cored v v ELC94L [Eliminator Mig Torch trigger lock v v 4. INSTALLATION RECOMMENDATIONS 44 4.2 Environment The Fabricators are NOT designed for use in environments with increased hazard of electric shock. a) Examples of environments with increased hazard of electric shock are - i) Inlocations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive part ii) In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or iii) In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories. b) 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. Location Be sure to locate the Power Supply according to the following guidelines: a) In areas, free from moisture and dust. b) Inareas, free from oil, steam and corrosive gases. ¢) _ Inareas, not subjected to abnormal vibration or shock. 4d) Inareas, not exposed to direct sunlight or rain. e) Place ata distance of 30cm (1fiJor more from walls or similar that could restrict natural air flow for cooling. f) The minimum ground clearance for these products is 140mm (5.5) Page 17Fabricator 210, 250 + 4.3, Ventilation Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated. 4.4 Mains Supply Voltage Requirements ‘The Mains supply voltage should be within + 10% of the rated Mains supply voltage. Too low a voltage may cause poor welding performance or the wirefeeder malfunction. Too high a supply voltage will cause components to overheat and possibly fail. The Fabricator is supplied with an input lead to which an appropriate plug should be fitted. Install a power outlet for each Power Supply and fit fuses as per the Machine Specifications. A vce: THERMAL ARC advises that your Fabricator be electrically connected by a qualified electrical trades- person. ‘The Fabricator Power Supplies are factory connected for the following Mains supply voltages: Machine | Mains Supply | Lead Current | Lead Machine | Duty Lead Size Rating Length _ | Voltage Setting | Cycle Fabricator 210 3 metre 3 210A @ ostety 10 AWG 30 Amps aon 230V aa Fabricator 250 3 metre 250A @ es 8AWG 40 Amps aon 230V eae Table 2 - Factory fitted Mains supply leads fitted to the Fabricator Power Supplies A vicsnc: The Fabricator Mains supply leads should be replaced with leads as specified in section 4.5 when the Fabricators Mains supply voltage is changed. 4.5 Alternative Mains Supply Voltages ‘The Power Supplies are suitable for the following Mains supply voltages: ‘Mains Supply | MainsSupply | Mains [Fuse Size| Machines Voltage Setting | Lead Size _| Outlet Size Duty Cycle Fabricator 210 6.0mm" (10AWG) (706081) See Figure 2 6.0mm? (10AWG) Fabricator 250 208V 8.0mm*(8AWG) | 40Amp [+80Amp| 250A 706088) See Figure 2 230V 8.0mm'(8AWG) | 40Amp |+80Amp| @50% “Table 3 - Mains supply lead sizes for alternative Mains supply voltages Motor start fuses or thermal circuit breakers are recommended for this application. Australian Standard AS3000 permits the rating of the fuse or thermal circuit breaker protecting the circuit Page 18Fabricator 210, 250 ‘conductors to be double the outlet current rating for any circuit used exclusively for an electric are welder. Check local requirements for your situation in this regard. INPUT VOLTAGE SELECTION 208V 230V [pos -gemeage | [zoey] zaoy) “YPN aaov i= See (rosy ix geasegome fs he ar, | any Sasser | Figure 2 - Voltage settings for Fabricator 210 & 250, 5. SETUP FOR COMPACT FABRICATORS a) Remove all packaging materials. -= CAUTION 1 To obtain adequate air flow and cooling for the Power Supply components, the four wheels must be fitted. Alternatively, the Power Supply may be raised 140mm (5.5") from the floor using supports that do not restrict airfow. b) Connect the work lead to the negative (~) socket (positive + for Flux Cored Wire) c) Connect the TORCH lead to the positive (+) socket (negative — for Flux Cored Wire) 4) Position a gas cylinder on the rear tray and lock securely to the Power Supply cylinder bracket with the chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position, Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts provided. €) Fit the gas Regulator/Flowmeter to the gas cylinder. f) Connect the gas hose from the rear of the Power Supply to the Flowmeter outlet. g) Three dual groove feed rollers are supplied as standard with the Power Supply. These can accommodate 0.6mm (.024”), 0.8mm (.030"), 0.9mm (,035") and 1.2mm (.045”) diameter hard wires as well as 1.0mm (,040") and 1.2mm (.045") flux cored wires. Select the roller required with the chosen wire size marking facing outwards. 1h) Fit the electrode wire spool to the wire reel hub located behind the electrode wire compartment door. Ensure that the drive dog-pin engages the mating hole in the wire spool. Push the'R' clip into place to retain the wire spool securely. The wire should feed from the bottom of the spool. i) Fit the TWECO MIG torch to the wire feed unit by releasing the torch locking screw in the brass torch adaptor and pushing in the torch fitting until the plastic torch casing meets the brass adaptor. Tighten the torch locking screw securely. Remove the contact tip from the torch. J) Connect the two black torch trigger leads to the torch trigger terminals. k) Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the torch. 1) Lower the pressure lever and with the torch lead reasonably straight, feed the wire through the torch. Fit the appropriate contact tip. Page 19The electrode wire will be at welding voltage potential whilst itis being fed through the system. 6. POWER SUPPLY CONTROLS, INDICATORS AND FEATURES ‘Thermal overtoad light Optional meter Standby switch & indicator light | | Coarse vottage swite = 3 7 oe" SL irespeed cont FABRICATOR’ 210 Brass torch adaptor \ |_spoot gun r ) 2 control socket Negative welding current terminal ©- 5 6+6 sin polarity ead Post 7 npoteiy ead sitive welding current terminal Figure 3 - Compact Fabricator controls Burnback control BREAK, ‘Spool gun switch aN MODE SELECTOR SWITCH spor src m a he oe | Spot timer contro aw a oT ow. t SPOT (s) 7 Dwell timer control Mode selector switch Figure 4 - Internal Fabricator controls Page 2061 6.2 6.3 6.4 6.5 Fabricator 210, 250 ‘Standby switch with in-built Indicator Light The indicator light is provided to indicate when the Fabricator is connected to the Mains supply voltage. With the switch in the STANDBY position, the auxiliary power and the fan are tumed off. A iris When the light is lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential Coarse Voltage Control Switch and Fine Voltage Control Switch The Coarse Voltage Control sets the voltage level to the welding terminals as it is rotated in the clockwise direction. The Fine Voltage Control switch increases the voltage (in smaller increments than the Coarse switch) as itis rotated in the clockwise direction, CAUTION 2 The Coarse & Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process. Digital Ammeter and Voltmeter (Optional) Where fitted an average reading ammeter and voltmeter is provided to allow accurate monitoring (5% tolerance) of welding current and voltmeter to facilitates precise welding condition adjustment. Refer to section 9.1 on page 31 for the Improved Current Accuracy Calibration Procedure for the Digital Meter. Value displayed for 157 Amp Value displayed for 23.4 Volts IS TA osu Figure 5 - Examples of the digital read outs The Digital Meter will display both welding current and voltage. To toggle between the current and voltage readings depress the push button switch mounted below the meters display. See Figure 5 for an example of current and voltage display. ‘The Digital Meter will hold the last reading at completion of welding for 10 seconds to allow for easy operator setup. Torch Polarity Lead This lead selects the welding voltage polarity of the electrode wire. Plug it into the positive welding terminal (+) when using steel, stainless steel or aluminium electrode wire. Plug the Torch Polarity Lead into the negative welding terminal ( — ) when using gasless electrode wire. If in doubt, consult the manufacturer of the electrode wire for the correct polarity. Positive and Negative Welding Terminals Welding current flows from the Power Supply via heavy duty DINSE terminals. It is essential, however, that the male plug is inserted and tumed securely to achieve a sound electrical connection. Page 21Fabricator 210, 250 ‘mE CAUTIONS Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal. 6.6 Spool Gun Control Socket The SPOOL GUN 14 pin receptacle is used to connect a spool gun to the welding power Supply circuitry: To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. The socket information is included in the event the supplied cable is not suitable and it is necessary to wire a plug or cable to interface with the SPOOL GUN 14-pin receptacle. Figure 6 - Spool Gun 14 pin receptacle Socket Pin Function A Tnput Supply 24VAG 1,0A with respect to Socket G (cireuit common), B ‘Output to energize the power supply contactor, 24VAC (Contact closure is provided between socket pins A and B to energize the contactor). c Not Used. D ‘Not Used. E Not Used. F ‘Not Used. c 24 circuit common, H Not Used. ui Not Used. J Not Used. K Not Used. L Not Used. M Not Used N Not Used, Page 2267 Thermal Overload The critical component for thermal protection is the rectifier stack, which is fitted with a thermal overload cut out device, If the overload operates then the machine should be left to cool for approximately 15 minutes before resuming welding. The thermal overload will not operate and there will be no danger of transformer damage if the Power Supply is operated within its duty cycle, refer to section 1.5 for an explanation of duty cycle and section 3 for the specifications. 6.8 Choice of Inductance Setting The Fabricator 210 & 250 have two inductance settings. These inductance terminals are the positive welding terminals. Inductance selection can effect the spatter level and penetration characteristics of the weld. The correct choice depends upon the shielding gas, transfer mode and the material type. CO, (High Inductance) is used for: © Carbon Dioxide shielded welding, © Dip transfer with 1.2mm (.045") wires (Carbon Dioxide or mixed gas). © Gives a hotter weld in DIP transfer. MIXED GASES (Low Inductance) is used for: © Spray transfer © Aluminium and Flux Cored wires. © Gives a cooler weld in DIP transfer. NOTE {fin doubt, use the high inductance setting 6.9 Wirespeed Control The Wirespeed Control knob controls the welding current via the electrode wire feed rate. ie the speed of the wire feed motor. 6.10 Mode Selector Switch ‘The Mode Selector switch selects the method of welding mode. 4) CONTINUOUS This mode of welding is used to weld two or more components together CD with a continuous weld. b) 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. The spot time period is set by the SPOT TIME control shaft located in the electrode wire compartment. NOTE 2 A spot nozzle should be used on the MIG torch to obtain consistent spot welds. ©) STITCH This mode of welding is used to weld two or more components together with a stitch weld. The SPOT TIME shaft controls the welding or 'ON' time whilst the DIVELL TIME shaft controls the interval or 'OFF" time for stitch welding, Page 23Fabricator 210, 250 ® LATCH This mode of welding is mainly used for long weld runs, as the operator aD need only press the trigger to activate the weld, then press the trigger again to stop. This obviates the need for the operator to depress the trigger for the complete length of the weld run, 6.11 Spot Timer With the MODE SELECTOR switch is switched to the SPOT position, the SPOT TIME shaft controls the duration of a single spot weld. With the MODE SELECTOR switch is switched to the STITCH position, the SPOT TIME shaft controls the welding or ‘ON’ time whilst stitch welding. 6.12 Dwell Timer The DELL TIME shaft controls the terval or 'OFF" time whilst stitch welding. 6.13 Burnback Control Bumback time is the difference between the wirefeed motor stopping and switching off of the welding current. The Bumback time allows the electrode wire to burn out of the molten metal weld pool. The Bumback time is factory set for optimum performance. Bumback time is adjusted by placing a flat bladed screwdriver into the Bumback adjustment access hole and adjusting the trim potentiometer. Clockwise adjustment increases Bumback time. 6.14 Spool Gun / Standard Switch ‘The PRINCE Spool Gun can readily be used with the Fabricator 210 and 250 power supplies. ‘The Fabricator 210 and 250 come ready with a “STANDARD / SPOOL GUN” selector switch which is located inside the wire drive compartment of the power supply. This switch allows either the in-built wire drive system (‘STANDARD” mode) or the PRINCE Spool Gun (“SPOOL GUN" mode) to operate. NOTE3 When in the SPOOL GUN mode the internal gas contro! and the internal wire feed system of the power supply are disabled. 6.15 Wirefeeder Drive Roller Pressure Adjustment The moveable roller applies pressure to the grooved roller via screw adjustable spring pressure. The adjustable spring screw should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or bum-back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf. If this is not the cause of slipping, the feedroll pressure can be increased by rotating the adjustable spring screw clockwise. The use of excessive pressure may ‘cause rapid wear of the feed roller, motor shaft and motor bearings. NOTE 4 Genuine TWECO contact tips and liners should be used, Many non-genuine liners use inferior ‘materials which can cause wire feed problems. Page 246.16 Wire Reel 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 made by turning the large nut inside the ‘open end of the wire reel hub. Clockwise rotation will tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 20mm (0.75”) after release of the Torch trigger switch. The wire should be slack without becoming dislodged from the reel CAUTION 4 Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, overheating of ‘electrical componentry and possibly an increased incidence of wire Burnback into the contact tip. TWECO MIG TORCH (Cat N 7.4 Introduction The TWECO 250A gun fitted to the Fabricator offers robust construction, unparalleled reliability and easy replacement of consumable parts. The TWECO 250A has an operating capacity in excess of the capacity of the Fabricators and can be expected to give trouble fiee service. TWECO MIG Torches may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO. Not only will this give greater reliability (and hence greater productivity), but it will reduce stockholding of consumable parts. See your THERMAL ARC distributor for details. 0-6105 where su! Figure 7 - Exploded view of MIG torch 7.2 MIG Torch Components tem Part No. Description ay T = Nozzle (refer to Table 7) 1 2 = Contact tip ((efer to Table 6) 7 3 = Gas diffuser (refer to Table 5) 7 a WMG3a5 ‘Conductor tbe T 3 458 ‘O-Ring, Gun Handle i 6 0721 “Handle kit (includes items 7, 8, 9, 22 & 23) T a = Insert & screw __(Fefer to item 6) 2 3 = Hlandle cap (refer to tem 6) i Page 25Fabricator 210, 250 o — ‘Support (refer to item 6) T 10 ELCs Trigger Lever T i ELOMB Trigger Blades 1 2 = Butt Splice (insulated crimp link 1-Smn") 2 3B LCOS, ‘Cap serew T 4 9072110 Cable assembiy T 15 24 ‘O-Ring, Connector Plug z Texel wc Set screw 852 UNC T 17 350178 Connector plug 1 18 = Conduit (refer to Table &) 1 2 = Gun hanger (refer to item 6) i 3 i Tanger sorew _(referto item 6) i 24 ELOAL, Locking Trigger (not shown) (option) = 73 Table 4 - Mig Torch components Torch Consumable Parts NOTES “denotes parts that are supplied as standard with TWECO torch Cat No: 10-6105 a) Gas Diffusers Part No. Part No. * ELS2 (slide on nozzles) ELS2CT (screw on nozzles) b) Contact Tips Table 5 - Mig torch gas diffusers STANDARD TAPERED Wire Size Part No. Wire Size Part No. (0.6mm (.024") not available (0.6mm (.024") ELI6T23 0.8mm (.030") EL1630 (0.8mm (030") ELI6T30 0.9mm (.035") * ELI635 (0.9mm (.035") ELIOTS5 1.0mm (.040") EL1640 1.0mm (.040") ELI6T40 1.2mm (.045") ELI64S 1.2mm (045°) ELI6TAS 1.2mm (,045") Alum | ELI6A364 1.2mm (.045) Alum | _ELI6AT364 ©) Nozzles Table 6 - Mig torch contact tips Page 26Fabricator 210, 250 74 Bore Size Part No. Bore Size Part No. 9.5mm 3/8") EL22A37 [95mm Gis”) EL22CT37 9.5mm (3/8") ARTE 9.5mm (3/8") EL22CT37F, 1 12.7mm (1/2") EL22A50 12.7mm (1/2") EL22CT50 127mm (1/2”) EL22A50F 12.7mm (12”) EL22CTSOF 12.7mm (1/2”) EL22150P 12.7mm (172") EL22CTSOP 15.9mm 5/8") EL22A62 15.9mm 6/8") EL22CTS2, 15.9mm 6/8") _| EL22A62F 15.9mm 5/8") EL220CT62F 15.9mm (5/8") * EL22162P 15.9mm (S/8") EL22CT62P_ 19.1mm Gi") EL22A75 19.1mm (3/4") EL2CT75_| 19.1mm (3/4) EL2A7SF [9.1mm G4") EL2CTISF J 15.9mm (5/8") EL22162FAS CT = Coarse Thread P= Protruding Tip (Spot Nozzle) F=Flush Tip Table 7 - Mig torch nozzles 4) Conduits HARD ELECTRODE WIRE SOFT ELECTRODE WIRE Wire Size Part No. Wire Size Part No. 0.6mm (.024") 42/23 or 44/23 0.6mm (.024”) Alum | not available 0.8mm (.030") 42/3035 or 44/3035 0.8mm (.030") Alum | _ not available 0.9mm (.035") * 42/3035 or 44/3035 0.9mm (.035") Alum | __42N/3545 1.0mm (040") 42/4045 or 44/4035 1.0mm (,040") Alum aNrasas | 1.2mm (.043") “42/4045 or 44/4035 1.2mm (045°) Alum | 42N/3545 Table 8 - Mig torch conduits Installing A New Wire Conduit a) Be sure the MIG Torch cable is arranged in a straight line, free from twists, when installing or removing a wire conduit, Remove the old conduit by first removing the MIG Torches nozzle, contact tip and gas diffuser. Then loosen Allen screws in the conductor tube and connector plug and pull the old wire conduit out of the cable assembly from the connector plug end. b) To install a new wire conduit, first inspect the o-ring gas seal on the conduit for cuts or damage. Start from the connector plug end of the assembly and begin pushing the conduit through the connector plug, cable assembly and into the gun. If the conduit should lodge along the way, gently whip or work the cable assembly to aid forward movement. ©) When the wire conduit stop meets the end of the connector plug and the new raw end extends through the end of the conductor tube, the Allen screw in the connector plug must be securely tightened onto the conduit to prevent its backward movement. Page 27Fabricator 210, 250 Conductor tube , Figure 8 - Conduit trim length NOTE 6: When the conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug, the “raw end' of the conduit will protrude out of the open end of the gun conductor tube. Trim the conduit as shown in Figure 8. The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radi so wire feed will not be obstructed. 4) Replace Gas Diffuser, Contact Tip, and Nozzle. ©) Tighten the Allen screw in the conductor tube. s) CAUTION 5 ‘Do not over tighten the conductor tube screw as this action will result in the distortion of the conduit and will if ’ lead to wire feedability problems. |e} 7.5 MIG Torch Maintenance Forehand Verical Remove dust and metallic particles from the torch [-—*— fecsene) conduit by forcing clean, dry compressed air into the 5 a conduit once a week. This will minimise wire feeding Figure 9 - MIG Torch angle problems, 8. BASIC WELDING TECHNIQUE 8.1 Setting of the Power Supply The setting of the Fabricator requires some practice by the operator, the welding Power Supply having two control settings that have to balance. These are the Wirespeed control and the Voltage Control switches. The welding current is determined by the Wirespeed control, the current will inerease with increased Wirespeed, resulting in a shorter are. Less wire speed will reduce the current and lengthen the are. Increasing the welding voltage hardly alters the welding current level, but lengthens the are. By decreasing the voltage, a shorter arc is obtained with litle change in welding current. When changing to a different electrode wire diameter, different control settings are required. A thinner electrode wire needs more Wirespeed to achieve the same current level. A satisfactory weld cannot be obtained if the wirespeed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the workpiece. Page 288.2 8.3 8.4 85 Fabricator 210, 250 Tf the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion, If, however, the welding voltage is too high, large drops will form on the end of the electrode wire, causing spatter. The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound. Position of MIG Torch The angle of MIG torch to the weld has an effect on the width of the weld run. Refer to Figure 9, Distance from the MIG Torch Nozzle to the Work Piece The electrode stick out from the MIG Torch nozzle should be between 2.0mm (5/64”) to 5.0mm. (13/64”) This distance may vary depending on the type of joint that is being welded. Travel Speed Speed at which a weld travels influences the width of the weld and penetration of the welding run, Electrode Wire Size Selection The choice of electrode wire size in conjunction with shielding gas used depends on: a) Thickness of the metal to be welded, b) Type of joint, ©) Capacity of the wire feed unit and power supply, ) The amount of penetration required, e) The deposition rate required, f) The bead profile desired, g) The position of welding and h) 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 mm? An example is tabled below. Electrode Wire Size | Current Density Deposition Rate aa (Amps/mm’) (Ibs/hour) 0.9mm (.035") 200 314 7.0 1.2mm (.045") 200 177 62 Table 9 - 0.9mm (,035")/1.2mm (,045”) wire deposition rate This demonstrates that where the upper limit of current is limited by machine capacity and duty cycle, higher deposition rates and therefore greater productivity will be achieved by using smaller electrode wire, The Fabricator is a particularly efficient MIG welder with the 0.9mm steel wire in spray transfer mode. The savings from decreased welding time will more than cover the small cost penalty of 0.9 mm (.035") 1.2mm (045") Penetration comparison using the same current (200A) for both electrode Pabigas: 10 - Wire penetration comparisonFabricator 210, 250 8.6 a7 The smaller electrode wire sizes. (0.9mm (.035") wire cost approx. 10% more than T_2mm (045%), but is deposited approx. 15% faster, Higher current density (or smaller diameter wire) also gives deeper penetration as shown Figure 10. Stitch Welding Operation Stitch welding is normally used to bridge excessive gaps between panels or when welding very thin material to prevent heat build up and distortion, Set the controls as follows for stitch welding: a) Coarse & Fine Voltage Selector Switches and Wirespeed Control Set these controls to obtain the desired welding conditions for the wire and material being welded. b) Mode Selector Switch Set the MODE SELECTOR switeh to STITCH. c) Spot Time ‘Adjust the SPOT TIME control shaft for the desired weld or ‘ON’ time whilst stitch welding d) Dwell Time Adjust the DWELL TIME control shaft for the desired interval or 'OFF" time whilst stitch welding. ‘Spot Welding Operation Fita spot welding nozzle to the MIG Torch for consistent spot welding operations. The Fabricators will operate effectively using 0.8mm (,030”) electrode wire when spot welding. Penetration depth is limited when using 0.6mm (,024”) electrode wire for spot welding. Set the controls as follows for spot welding: a) Coarse & Fine Voltage Selector Switches and Wirespeed Control Select higher Voltage Selector switch positions and set the Wirespeed Control between 354 to 590 ipm (9 to 15 metres/minute) for maximum penetration. b) Mode Selector Switch Set the MODE SELECTOR switch to SPOT. ©) Spot Time ‘Adjust the SPOT TIME control shaft for the desired weld or 'ON' time for spot welding, @) Dwell Time ‘The DWELL TIME control shaft has no affect in this mode of operation. 9. ROUTINE MAINTENANCE & INSPECTION The only routine maintenance required for the Fabricator is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. A veces Disconnect the Fabricator from the Mains supply voltage before disassembling. Page 30Fabricator 210, 250 Special maintenance is not necessary for the control unit parts in the Power Supply. If these paris are damaged for any reason, replacement is recommended. (mam) CAUTION 6 Do 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 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, Ifnecessary, solvents that are recommended for cleaning electrical apparatus may be used. ‘Troubleshooting and repairing the Fabricator should be carried out only by those who are familiar with electrical equipment. A WARNING 6 Do not attempt to diagnose or repair unless you have had training in electronic measurement and troubleshooting techniques. 9.1 Improved Current Accuracy Calibration Procedure for the Digital Meter A vos This calibration procedure should be carried out by a qualified electrical tradesperson. The following procedure will give a current measurement accuracy of better than the factory standard of approximately 5%. Equipment Required: Fabricator 250 |DC Ammeter 250A 3004 (certified up to £1% accuracy) = oe LOAD RESISTANCE of 0.10 S5kW 8kW (Output Connecting Leads v v a) Procedure: i) With the Fabricator switched off, connect the LOAD RESISTANCE and DC AMMETER to the output terminals. ii) Open the wirefeeder compartment door or remove the left-hand side cover (when viewing the Fabricator from the front) iii) Select maximum voltage switch positions: Coarse 19-21V Fine 4 (Fabricator 210) Coarse 19-23V Fine 4 (Fabricator 250) iv) _ Switch the Mains supply voltage to the Fabricator ON. v) Ensure the DIGITAL METER is selected to read current. vi) Short circuit the TORCH TRIGGER terminals to energise output welding terminals. memes CAUTION 7 Do not allow the Fabricator to remain ON under load for more than ONE minute! vii) Determine the output current as given by the DC AMMETER. Page 31Fabricator 210, 250 viii) Adjust SHUNT CAL. potentiometer on DIGITAL METER to read identically with DC AMMETER. ix) Open circuit the TORCH TRIGGER terminals to deactivate output welding terminals. x) _ Select minimum voltage switch positions: Coarse 15-17V Fine 1(Fabricator 210) Course 15-17V Fine 1(Fabricator 250) xi) Short circuit the TORCH TRIGGER terminals to energise output welding terminals. Refer to CAUTION 8. xii) Determine output current as given by the DC AMMETER. xiii) Confirm the minimum DIGITAL METER reading is within 42% of DC AMMETER. xiv) Ifthe above is not met, offset the SHUNT CAL. potentiometer such that both the minimum and maximum values are within 42%. xv) The improved accuracy for DIGITAL METER is now complete. xvi) Where fitted, position the meter cover over the hexagonal brass spacers taking care not to trap loom wiring. xvii) Fit the M3 flat washers and M3x10 screws through the meter cover and into the hexagonal brass spacers. xviii) Close wire-feeder compartment or replace side panel. 10. 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 THERMAL ARC Service Agent for repair. 10.1 Solving Problems Beyond the Welding Terminals ‘The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW: a) Porosity When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points: 1, Gas cylinder contents and flow meter. - Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 15 litres per minute (0.5 Cubic Feet per minute). 2. Gas leaks = Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Supply. 3. Internal gas hose in the Power = Ensure the hose from the solenoid valve to Supply the Mig torch adaptor has not fractured and Page 32Fabricator 210, 250 Welding ina windy environment. - 5. Welding dirty, oily, painted, oxidised or greasy plate, 6. Distance between the MIG torch - nozzle and the work piece. 7. Maintain the MIG torch in good working order. That iis connected to the Mig torch adaptor. Shield the weld area from the wind or increase the gas flow. Clean contaminates off the plate Keep the distance between the MIG torch nozzle and the work piece to a minimum. Refer to section 8.3 on page 29. Ensure that the gas holes are not blocked and gas is exiting out of the toreh nozzle. Refer to WARNING 8 Do not restrict gas flow by allowing spatter to build up inside the Mig torch nozzle. Check that the MIG torch O-rings are not damaged. A WARNING 9 Disengage the drive roll when testing for gas flow by ear. Page 33Fabricator 210, 250 b) Inconsistent wire feed Wire feeding problems can be reduced by checking the following points: 1. Wire spool brake is too tight, 2. Wire spool brake is too loose. 3. Wom or incorrect feed roller size. 4, Mis-alignment of inleVoutlet guides. 5. Liner blocked with swarf. 6, Incorrect or worn contact tip. 7. Poor work lead contact to work piece. - 8. Bent liner. - Feed roller driven by motor in the cabinet will slip. ~ Wire spool can unwind and tangle, ~ Use 'U' groove drive feed roller matched to the aluminium wire size you are welding. Use 'V' groove drive feed roller matched to the steel wire size you are welding, Use ‘knurled V" groove drive feed roller matched to the flux cored wire size you are welding. ~ Wire will rub against the mis-aligned guides and reduces wire feedability. ~ Swarf is produced by the wire passing through the feed roller, if excessive pressure is applied to the pressure roller adjuster. Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size. ‘Swarf is fed into the liner where it accumulates thus reducing wire feedability. = The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is to large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip. ‘When using soft electrode wire such as aluminium it may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft electrode wires should be used. If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the are. ~ This will cause friction between the wire and the liner thus reducing wire feedability Page 34Fabricator 210, 250 10.2 Welding Problems FAULT. CAUSE, REMEDY heat input 1 Undercut. ‘A Welding arc voltage too [A Reduce voltage by reducing high, the voltage selection switches position or increase the wire feed speed. B Incorrect torch angle | B Adjust angle C Excessive heat input C Increase the torch travel speed and/or reduce welding current by reducing the voltage selection switches position or reducing the wire feed speed, 2 Lack of penetration. ‘A Welding current too low | A Increase welding current by increasing wire feed speed and increasing voltage selection switch position. B Joint preparation too | B_Increase joint angle or gap narrow or gap too tight C Shielding gas incorrect |C Change to a gas which gives higher penetration 3 Lack of fusion. Voltage too low Tncrease voltage by increasing voltage selection switches position, Excessive spatter. A Voltage too high ‘A Lower voltage by reducing the voltage selection switches or increase wirespeed control. B Voltage too low B Raise voltage by increasing the voltage selection switches or reduce wirespeed control. 3 Iregular weld shape. [A Incorrect voltage and [A Adjust voltage and current by current settings. adjusting the voltage Convex, voltage too low.| __ selection switches and the Coneave, voltage too wirespeed control. high, B Wire is wandering B Replace contact tip C Incorrect shielding gas | C Check shielding gas. D Insufficient or excessive |D Adjust the wirespeed control or the voltage selection switches. Page 35Fabricator 210, 250 Welding Problems (continued) FAULT. ‘CAUSE, REMEDY Weld beads too small Weld penetration narrow and deep Excessive weld stresses Excessive voltage Cooling rate too fast ‘Decrease travel speed Reduce current and voltage and increase Mig torch travel speed or select a lower penetration shielding gas. Increase weld metal strength or revise design Decrease voltage by reducing the voltage selection switches. Slow the cooling rate by preheating part to be welded or cool slowly. 7 Cold weld puddle. Faulty rectifier unit Have an Accredited THERMAL ARC Service Agent to test then replace the faulty component. voltage are adjusted correctly. C Loose welding cable Check all welding cable connection. connections. D Low Primary Voltage Contact supply authority B Are does not have a crisp] The MIG torch has been | Connect the MIG torch to the sound that short are connected to the wrong | positive (+) welding terminal exhibits when the voltage polarity on the for solid wires and gas wirefeed speed and front panel. shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity 10.3 Power Supply Problems FAULT CAUSE, REMEDY T Indicator light is ON but welding are can not be established. Voltage switch in standby position. Switch the voltage selection switches to a welding setting, not lit but welding are can be established. circuit. 2 Mains supply voltage is [A Primary fuse is blown. Replace primary fuse ON. Indicator light is not] B Broken connection in Have an Accredited lit and welding are can primary circuit. THERMAL ARC Service not be established. Agent check primary circuit. 3 Mains indicator light is | Indicator light is open Have an Accredited THERMAL ARC Service Agent replace Indicator light, Page 36Fabricator 210, 250 Power Supply Problems (continued) FAULT CAUSE REMEDY “4 Mains supply voltage is | Torch trigger switch Reconnect. ON and Indicator light is] leads are disconnected. lit but when the torch trigger switch is depressed nothing happens, 5 Mains supply voltage is [A Electrode wire stuck in [A Check for clogged / kinked ON, no wire feed but gas] conduit liner or contact | MIG Torch conduit or worn flows from the MIG tip (bum-back jam). contract tip. Replace faulty Torch when the torch components). trigger switch is B Faulty control PCB or |B Have an Accredited depressed. Tweco Torch THERMAL ARC Service Agent investigate the fault. 6 Wire feeds when the Poor or no work lead (Clean work clamp area and torch trigger switch is connection. ensure good electrical depressed but arc can not contact. be established. 7 Wire continues to feed | ‘The Mode Selector Set the Mode Selector Switch when the torch trigger Switch has been set to has been set to 2T (normal switch is released. 4T (latch operation). operation). 8 Jerky wire feed ‘A Wom or dirty contact tip [A Replace B Wom feed roll. B Replace C Excessive back tension |C Reduce brake tension on from wire reel hub, spool hub D Wom, kinked or dirty] Clean or replace conduit liner conduit liner 9” No gas flow ‘A Gas hose is cut. [A Replace or repair. B Gas passage contains |B Disconnect gas hose from the impurities. rear of Fabricator or then raise gas pressure and blow out the impurities. C Gas regulator turned off. }C_Tum on, 10 Gas flow continues after | Gas valve has jammed Have an Accredited the torch trigger switch | open due to impurities in] THERMAL ARC Service has been released. the gas or the gas line ‘Agent repair or replace gas valve. Page 37Fabricator 210, 250 10.4 Key Spare Parts Description Fabricator 210 | Fabricator =| [Main Transformer 706155PKD | _706156PKD Auxiliary Transformer 706130 706130 inductor Assembly 706145PKD | _706146PKD Rectifier 7977889 7977889 (Capacitor 22000uF 63V 10-6137 10-6131 (Control PCB (Compact Power Supply) 705946PKD_| _705946PKD [Contactor 7977878 7977878 |Wirespeed Knob 10-6177 10-6177 ‘Wirespeed Potentiometer 10-6026 10-6026 |Coarse Voltage Switch 7977666 7977666 [Fine Voltage Switch 7977666 7977666 Solenoid Vaive 7197867 7977867 [Wire Reel Lock Pin 10-6188 10-6188 Wire Reel Hub 10-6018 10-6018 ‘Thermal Overload Indicator Light 24VAC 7977882 7977882 Standby Switch 250VAC 7977884 7977884 [Resistor 22 ohm 20W en [Welding Current Terminals 10-6127 10-6127 Work Lead Plug 10-6128 10-6128 | Wire Drive Assembly 10-6150 10-6150 Wire Drive Motor 10-6172 10-6172 |Two roll wire drive system 10-6168 10-6168 [Fan Assembly 797880 7977880 Swivel Wheel 10-6146 10-6146 Fixed Wheel 7976759 7976759 (Cylinder chain 705620 705620 Regulator/Flowmeter 10-4209 10-4209 Tweco Torch 250 3.6m 10-6105 10-6105 Page 38Fabricator 210, 250 11. VOLT/AMP GRAPHS Vous Figure 11 - Volt/Amp curves of the Fabricator 210 | Fabricator 250 (230V) 3 sh ah--- al--- a al----h-- Fleas a af--- a : 8 g g Figure 12 - Volt/Amp curves of the Fabricator 250. Page 39Fabricator 210, 250 12. FABRICATOR 210 AND 250 POWER SUPPLY CIRCUIT DIAGRAM i | 3 xt PCH 705946 raz ea sat ral Page 40,Fabricator 210, 250 Figure 13 - Power Supply schematic for Fabricator 210 and 250 Page 41Fabricator 210, 250 13. PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM SE oy SIVTCHE MODE CONTROL. FOR CONTACTOR RELAYFabricator 210, 250 Figure 14 - Circuit diagram for control PCB 705946 Page 43