Professional Documents
Culture Documents
Doclib 8270 DocLib 2967 0-4992 AA
Doclib 8270 DocLib 2967 0-4992 AA
Doclib 8270 DocLib 2967 0-4992 AA
FABRICATOR
180 PORTABLE MIG WELDING MACHINE
Art # A-07923
Service Manual
Revision No: AA
Operating Features:
Issue Date: January 25, 2008 Manual No.: 0-4992
! WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgment,
the Manufacturer assumes no liability for its use.
Published by:
Thermadyne Industries
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2008 by
Thermadyne Industries
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ...................................................................................... 1-1
1.02 Principal Safety Standards ............................................................................. 1-4
1.03 Symbol Chart ................................................................................................. 1-5
1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6
1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6
1.06 Principales Normes De Securite ..................................................................... 1-9
1.07 Graphique de Symbole ................................................................................. 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 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
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Location ......................................................................................................... 3-1
3.02 Safety ............................................................................................................. 3-1
3.03 Grounding ...................................................................................................... 3-1
3.04 Electrical Input Requirements ........................................................................ 3-1
3.05 Requirements for Maximum Output ............................................................... 3-2
3.06 Installation of Shielding Gas (GMAW) Process .............................................. 3-2
3.07 Attaching the Gun and Cable Assembly to the Power Source ......................... 3-5
3.08 Polarity Changeover ....................................................................................... 3-6
3.09 Installing Wire Spool ...................................................................................... 3-7
3.10 Feedrolls ......................................................................................................... 3-8
3.11 Install Wire into the Feedhead ........................................................................ 3-9
3.12 Install Wire into the Welding Gun ................................................................. 3-11
TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 General Safety Precautions ............................................................................ 4-1
4.02 Fabricator Controls ......................................................................................... 4-2
4.03 Gas Metal Arc Welding (GMAW) .................................................................... 4-4
4.04 Flux Cored Arc Welding (FCAW) ..................................................................... 4-4
4.05 Shutdown Procedures .................................................................................... 4-4
4.06 Basic Welding Technique ................................................................................ 4-5
4.07 Welding Gun Positions ................................................................................... 4-6
4.08 MIG Welding (GMAW) Variables .................................................................... 4-7
4.09 Establishing the Arc and Making Weld Beads ................................................. 4-8
4.10 Pre-Weld Procedure ....................................................................................... 4-8
4.11 Welding Procedure ......................................................................................... 4-8
4.12 Reference Tables ............................................................................................ 4-9
4.13 Fabricator 140 Welding Setting Selection Guide ........................................... 4-10
4.14 Fabricator 180 Welding Setting Selection 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
5.04 Solving Problems Beyond the Welding Terminals .......................................... 5-1
5.05 Welding Problems .......................................................................................... 5-3
5.06 Power Source Problems ................................................................................. 5-5
SECTION 6:
ADVANCED TROUBLESHOOTING .................................................................. 6-1
6.01 Pre Power-Up Checks ..................................................................................... 6-1
6.02 Initial Setup Conditions .................................................................................. 6-1
6.03 Primary Power Test ........................................................................................ 6-1
6.04 Logic & Control Test ....................................................................................... 6-1
6.05 Spool Gun Control Test .................................................................................. 6-2
6.06 Output Voltage Test ........................................................................................ 6-2
6.07 Wire Feed & Weld Test ................................................................................... 6-2
6.08 Primary Power Problems ............................................................................... 6-3
6.09 Logic & Control Problems .............................................................................. 6-4
6.10 Wire Feed and Weld Problems ....................................................................... 6-5
6.11 Rectifier Assembly Test Procedure ................................................................. 6-5
6.12 T1 Transformer Test Procedure ...................................................................... 6-6
6.13 C1 & C2 Test Procedure ................................................................................. 6-6
TABLE OF CONTENTS
SECTION 7:
PARTS LIST .......................................................................................... 7-1
7.01 Equipment Identification ................................................................................. 7-1
7.02 How To Use This Parts List ............................................................................ 7-1
7.03 Front Panel ..................................................................................................... 7-2
7.04 Rear Panel ...................................................................................................... 7-3
7.05 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
LIMITED WARRANTY
WARRANTY SCHEDULE
! WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards 7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
1. Do not touch live electrical parts. 15. Keep all panels and covers securely in place.
6. Turn off all equipment when not in use. Disconnect power to 1. Wear a welding helmet fitted with a proper shade of filter (see
equipment if it will be left unattended or out of service. ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
2. If inside, ventilate the area and/or use exhaust at the arc to remove 4. Be alert that welding sparks and hot materials from welding can
welding fumes and gases. easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator. 5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
manufacturer’s instruction for metals, consumables, coatings, and can cause fire on the hidden side.
cleaners.
7. Do not weld on closed containers such as tanks or drums.
5. Work in a confined space only if it is well ventilated, or while
8. Connect work cable to the work as close to the welding area as
wearing an air-supplied respirator. Shielding gases used for
practical to prevent welding current from traveling long, possibly
welding can displace air causing injury or death. Be sure the
unknown paths and causing electric shock and fire hazards.
breathing air is safe.
9. Do not use welder to thaw frozen pipes.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to 10. Remove stick electrode from holder or cut off welding wire at
form highly toxic and irritating gases. contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
! WARNING WARNING
3. Allow pressure to escape before completely removing cap. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
LEAD WARNING Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
This product contains chemicals, including lead, or oth-
erwise produces chemicals known to the State of Cali- Safe Practices for Occupation and Educational Eye and Face Protection,
fornia to cause cancer, birth defects and other repro- ANSI Standard Z87.1, from American National Standards Institute,
ductive harm. Wash hands after handling. (California 1430 Broadway, New York, NY 10018.
Health & Safety Code § 25249.5 et seq.) Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to 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 taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
Continuous Weld
Circuit Breaker
X Duty Cycle
Mode
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
Protective Earth
Fault Indication
(Ground) IPM Inches Per Minute
! MISE EN GARDE
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.05 Dangers relatifs au soudage à l’arc 6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
AVERTISSEMENT
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
L’ELECTROCUTION PEUT ETRE MORTELLE.
9. N’enroulez pas de câbles électriques autour de votre corps.
Une décharge électrique peut tuer ou brûler gravement. 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
L’électrode et le circuit de soudage sont sous tension la pièce à souder.
dès la mise en circuit. Le circuit d’alimentation et les 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
circuits internes de l’équipement sont aussi sous ten- soudage (terre).
sion dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou 12. N’utilisez que des équipements en bon état. Réparez ou remplacez
la bobine de fil, le logement des galets d’entrainement aussitôt les pièces endommagées.
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
inadéquatement installé ou inadéquatement mis à la terre de courant alternatif, à moins qu’il soit muni d’un réducteur de
est dangereux. tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
AVERTISSEMENT AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons Le soudage dégage des vapeurs et des fumées
ultraviolets intenses, susceptibles de brûler les yeux et dangereuses à respirer.
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe. 1. Eloignez la tête des fumées pour éviter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour ou que les fumées et les vapeurs sont aspirées à l’arc.
vous protéger le visage et les yeux lorsque vous soudez ou que 3. Si la ventilation est inadequate, portez un respirateur à adduction
vous observez l’exécution d’une soudure. d’air approuvé.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux 4. Lisez les fiches signalétiques et les consignes du fabricant rela-
sont recommandés. tives aux métaux, aux produits consummables, aux revêtements
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger et aux produits nettoyants.
les autres des coups d’arc ou de l’éblouissement; avertissez les 5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
observateurs de ne pas regarder l’arc. portez un respirateur à adduction d’air. Les gaz protecteurs de
4. Portez des vêtements en matériaux ignifuges et durables (laine et soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
cuir) et des chaussures de sécurité. malaises ou la mort. Assurez-vous que l’air est propre à la respi-
ration.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé. 6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
AVERTISSEMENT
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSER
EXPLOSION Les bouteilles contiennent des gaz protecteurs sous
L’arc produit des étincellies et des projections. Les haute pression. Des bouteilles endommagées peuvent
particules volantes, le métal chaud, les projections de exploser. Comme les bouteilles font normalement partie
soudure et l’équipement surchauffé peuvent causer un du procédé de soudage, traitez-les avec soin.
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique 1. Protégez les bouteilles de gaz comprimé contre les sources de
peut provoquer des étincelles, un échauffement ou un chaleur intense, les chocs et les arcs de soudage.
incendie.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud. 3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
2. Ne soudez pas dans un endroit où des particules volantes ou des 4. Empêchez tout contact entre une bouteille et une électrode de
projections peuvent atteindre des matériaux inflammables. soudage.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7 5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
mètres autour de l’arc, ou couvrez-les soigneusement avec des des boyauxs et des raccords conçus pour chaque application
bâches approuvées. spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures 6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
ou fissures. lors de son ouverture.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la 7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
main. lorsque raccordé pour utilisation.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, 8. Lisez et respectez les consignes relatives aux bouteilles de gaz
une cloison ou une paroi peut enflammer l’autre côté. comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie. AVERTISSEMENT
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con- LES MOTEURS PEUVENT ETRE DANGEREUX
tact lorsqu’inutilisé après le soudage. LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
11. Portez des vêtements protecteurs non huileux, tels des gants en ETRE MORTELS.
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque. Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
AVERTISSEMENT
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
LES ETINCELLES ET LES PROJECTIONS BRULANTES des prises d’air du bâtiment.
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
6. Réinstallez les capots ou les protecteurs et fermez les portes après Recommended Safe Practices for the Preparation for Welding and
des travaux d’entretien et avant de faire démarrer le moteur. Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
AVERTISSEMENT
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Com-
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN pressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU- Arlington, VA 22202.
LATEUR PEUT BRULER LA PEAU ET LES YEUX.
Code for Safety in Welding and Cutting, norme CSA W117.2 Associa-
Les accumulateurs contiennent de l’électrolyte acide et tion canadienne de normalisation, Standards Sales, 276 Rexdale Bou-
dégagent des vapeurs explosives. levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protec-
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
tion, norme ANSI Z87.1, American National Standards Institute, 1430
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles Broadway, New York, NY 10018.
d’accumulateur.
Cutting and Welding Processes, norme 51B NFPA, National Fire Pro-
3. N’utilisez que des outils anti-étincelles pour travailler sur un tection Association, Batterymarch Park, Quincy, MA 02269.
accumulateur.
January 25, 2008 1-9 Manual 0-4991
FABRICATOR 140, 180 SAFETY INSTRUCTIONS
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Tri-Phase Statique
Tension dangereuse Fréquence Convertisseur Torch de Soudage
Transformateur-Redresseur
Mode Continu de
Disjoncteur
X Facteur de Marche
Soudure
Amorçage de L’arc au
Ligne
Contact (GTAW)
MPM Mètres Par Minute
^ 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. Check local requirements for
your situation in this regard.
# Generator Requirements at the Maximum Output Duty Cycle.
Fabricator 140
36
[V out]
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
[I out]
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
FABRICATOR 180
40
[V out]
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
[I out]
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
Art # A-07888
0 1 2 3 4 5 6 7 8 9 10
Minutes
Art # A-07889
0 1 2 3 4 5 6 7 8 9 10
Minutes
2 1
3
4
Switch Trigger
6 W7004070
180Gun
Cable Assembly,
7 W7004071
180Gun
11 10
12
Figure 2-4: Exploded View of Fabricator 180A MIG Gun
Gas Diffuser
Wire Liner
x x
Art # A-08333
For best operating characteristics and longest unit life, Consult the nameplate for proper input voltage
take care in selecting the installation site. Avoid locations and input amperage. The method of
exposed to high humidity, dust, high ambient temperature, installation, conductor size, and over-current
or corrosive fumes. Moisture can condense on electrical protection shall conform to the requirements
components, causing corrosion or shorting of circuits. of the local electrical code. All installation
Dirt on components will retain this moisture and also wiring and machine connection shall be done
increases wear on moving parts. by a competent electrician.
Adequate air circulation is needed at all times in order to The National Electrical Code (Article 630B) provides
assure proper operation. Provide a minimum of 12” standards for amperage handling capability of supply
(300mm) of free air space at both the front and rear of conductors based on the duty cycle of the welding power
the unit. Make sure that the ventilation openings are not source. The Fabricator 140 has a 20% duty cycle (2
obstructed. minutes of every 10 minutes can be used for welding)
and the Fabricator 180 has a 25% duty cycle. The power
cords supplied with these units comply with these
CAUTION
standards. Ensure that the building supply and receptacle
comply with NEC standards and any additional state and
The Fabricator is not suitable for use in rain. local codes.
3.02 Safety NOTE
Refer to additional installation instructions under the The supply wiring for the welding power
SAFETY INSTRUCTIONS AND WARNINGS (Section 1) in source must be capable of handling a
this manual. minimum of 20 amperes. The welding power
source must be the only load connected to
3.03 Grounding the supply circuit. Poor unit performance or
frequently opening line fuses or circuit
The internal frame of this welding machine should be breakers can result from an inadequate or
grounded for personal safety. Where grounding is improper supply.
mandatory under state or local codes, it is the
responsibility of the user to comply with all applicable
rules and regulations. Where no state or local codes exist, CAUTION
it is recommended that the National Electrical Code be
followed. Do not connect the Fabricator 140 to an input
power supply with a rated voltage that is
3.04 Electrical Input Requirements greater than 132 +10% VAC. Do not remove
the power cord ground prong.
Plug the input cord into a properly grounded and protected
(by fuse or circuit breaker) mains receptacle capable of
handling a minimum of 20 Amperes. The Fabricator 140 CAUTION
requires a 120VAC supply voltage and the Fabricator 180
requires a 230VAC supply voltage. Do not connect the Fabricator 180 to an input
The Fabricator 140’s power cord is equipped with a NEMA power supply with a rated voltage that is
5-15P plug and will only connect to a NEMA 5-15P greater than 255 + 10% VAC. Do not remove
receptacle. the power cord ground prong.
CAUTION
CAUTION
Cap
1
Shielding
Gas
Regulator and
4
3 “Cracking” Flow Meter
/8”
Shielding
11
5 Art # A-07965
Gas Hose
Art # A-07280
Art # A-08335
Gas Nipple
Keyway
! WARNING
ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not
plug machine in until told to do so in these instructions
As delivered from the factory, the output polarity is connected as DCEP (reverse polarity). The output terminals are
located on the interior panel of the welding power source.
2
3 Art # A-07905
6
1
Art # A-07906
2
3
3.10 Feedrolls
A feedroll consists of two different sized grooves. As
delivered from the factory, the drive roll is installed for
.030
.023” (0.6mm) for the Fabricator 140, and .030” / .035”
(0.8mm / 0.9mm) for the Fabricator 180.
The groove size visible when fitting the feedroll is the 0.8
groove size in use.
The groove closest to the motor is the one to thread.
Art # A-07963
! WARNING
ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not
plug machine in until told to do so in these instructions.
CAUTION
Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the
end of the wire firmly and do not let go of it. Make sure that the end of the wire is free of any burrs and is
straight.
Art # A-07911
Wire
Art # A-07913
Spool Wire Guide Feedroll
Art # A-07915
! WARNING
If ground connection clamp is in place on the
workpiece the electrode wire is electrically
ELECTRIC SHOCK CAN KILL! With the gun “hot” when the gun switch is activated.
switch (located on the gun) activated, welding
power is applied to the output terminals, 5. Activate the gun switch until the wire feeds out past
feedroll, ground clamp, gun cable connection the gun nozzle.
and welding wire. Do not touch these parts
with the gun switch activated.
Nozzle
2. Turn the welding machine ON with the front panel Contact Tip
Voltage Control Switch set to "1".
OFF 0
Wire
1 Gun Switch
6 2
5 3
4 Art # A-08340
Art # A-08338
Art # A-08339
! WARNING
Be sure to put on proper protective clothing and eye safeguards (welding coat, apron, gloves, and welding
helmet, with proper lenses installed). See Safety Instructions 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 well as remote
control cables, with the power source turned off. These connections could be electrically live with the
power switch ON.
! WARNING
ELECTRIC SHOCK CAN KILL! Do not operate the machine with the door open.
CAUTION
Do not pull the machine with the gun. Damage can occur to the gun, gun liner and machine. Avoid bending
the gun cable with a sharp radius. Damage can occur to the gun liner.
1
3
5
OFF 0
1
6 2
5 3
2
4
180
80 FABRICATOR
Weldskill
Art # A-07916
4
6
10
11
14 13 12
!
to the workpiece with proper wire stick-out. Lower your
WARNING
welding helmet and pull the gun trigger switch.
Art: A-05104
! WARNING
Follow these instructions only after referring to the Safety Instructions and Warnings chapter of this manual,
and the instructions in the Installation chapter
CAUTION
Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stickout)
and make a very poor weld.
The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed on the
seam or joint prior to lowering the helmet.
5º to 15º 5 to 15º
Longitudinal Longitudinal Angle
Angle 30 to 60º
Direction of Transverse Angle
90º Travel
Transverse Direction of
Angle Travel Art: A-05107
Art: A-05105
Figure 4-4: Butt and Horizontal Welds Figure 4-6: Horizontal Fillet Weld
Art: A-05106
Direction of Travel Figure 4-7: Overhead
Key: (1) First Choice, (2) Second Choice, (3) Third Choice, (4) Fourth Choice, (5) Fifth Choice
NOTE
Same adjustment is required for wire feed speed.
* When these variables are changed, the wire feed speed must be adjusted so that the welding current remains
constant. See DEPOSITION RATE in the WELDING VARIABLES section. This change is especially helpful on materials
of 20 gauge (.04” 1mm approximately) and smaller in thickness.
.023” (0.6mm)
100% CO2 .030” (0.8mm)
25cfh
Solid .035” (0.9mm)
Steel (or hard)
ER70S-6 .023” (0.6mm)
75% Ar
25% CO2 .030” (0.8mm)
25cfh
.035” (0.9mm)
.030” (0.8mm)
*** Aluminum
Aluminum 100% Ar
25cfh .035” (0.9mm)
OFF
ARRÊT 0
1
Voltage
2
Step Wire THICKNESS
3
Speed
4
22 ga. (0.8mm) 20 ga. (0.9mm) 18 ga. (1.2mm) 1/16” (1.6mm) 1/8” (3mm) 3/16” (4.5mm)
1 1 2 3 4 4
1.5 1.5 2 3 5 5
1 1 2 3 4 4
1.4 1.4 1.4 2 3 3
3 4 4
1.5 2.2 2.2
1 1 2 3 4 4
1.5 1.5 2 3.5 5 5.5
1 1 2 3 4 4
1 1 1.4 2 3.5 3.5
1 2 3 4 4
1 1.3 1.7 2.5 2.5
1 1 2 3 4 4
1.2 1.2 1.5 2 2.5 3.2
1 1 2 3 4 4
1 1 1.4 1.7 2.7 2.7
1 2 3 4 4
2.5 3.2 4 5 5
1 3 4 4
2.4 4 4.5 5.2
2 2 3 4
2 2 3.5 6
2 2 3 4
1.8 1.8 2.5 3.5
2 2 3 4
2 2 3.5 7
2 2 3 4
1.5 1.5 2.3 3.5
.023” (0.6mm)
100% CO2 .030” (0.8mm)
25cfh
Solid .035” (0.9mm)
Steel (or hard)
ER70S-6 .023” (0.6mm)
75% Ar
25% CO2 .030” (0.8mm)
25cfh
.035” (0.9mm)
92% Ar .035” (0.9mm)
8% CO2
.030” (0.8mm)
Flux Core None
Steel E71T-GS .035” (0.9mm)
Required
.045” (1.2mm)
.025” (0.6mm)
Stainless 90% He
Stainless Steel 7.5% Ar
Steel .030” (0.8mm)
ER 308L 2.5 CO2
35cfh .035” (0.9mm)
Art # A-07959
OFF
ARRÊT 0
1
Voltage
Step
6 2 Wire THICKNESS
5 3
Speed
4
22 ga. (0.8mm) 20 ga. (0.9mm) 18 ga. (1.2mm) 1/16” (1.6mm) 1/8” (3mm) 3/16” (4.5mm) 1/4” (6.4mm)
1 1 1 3 5 5 5
1.6 1.6 1.9 3.5 6.5 10 10
1 1 1 3 4 5 6
1.4 1.4 1.5 2.3 3 5.3 7.4
1 2 3 4 5 5
1.2 1.4 1.7 2.4 3.5 3.7
1 1 1 3 4 4 5
1.6 1.6 2 3.5 5.5 5.5 10
1 1 1 2 3 4 5
1.5 1.5 1.5 2 2.5 4.3 6
1 1 2 3 4 5
1.3 1.4 1.6 2 3.3 4.5
6 6
4.2 4.2
1 2 4 5 6
1.6 1.9 4.3 6 10
1 2 4 5 6
1.4 1.6 3 5.5 6
3 4 4 6
1.8 2 2.5 3.5
3 4 5 6
3.5 4.5 6 10
3 4 5 5
3.5 4.7 6.2 6.2
2 2 4 5 5
2.6 3 3.6 5.7 5.7
2 2 3 5
2 2 2.5 3.7
2 2 3 5
2 2 2.5 3
Carbon Greater than ER70S-X Short 100% CO2 All Position High welding speeds. Good
Steel 22 gauge Circuit Welding penetration and pool control.
(.030”)
Greater than ER70S-X Short 75% Argon All Position Suitable for high-current and high-
22 gauge Circuit 25% CO2 Welding speed welding.
(.030”)
Greater than ER70S-X Short 92% Argon All Position Higher deposition rates without melt-
22 gauge Circuit 8% CO2 Welding through. Minimum distortion and
(.030”) spatter. Good pool control for out-of-
position welding.
Greater than ER70S-X Spray 92% Argon Flat & HV Good arc stability, weld soundness,
10 gauge (1/8”) Transfer 8% CO2 Fillet and increasing width of fusion.
Low Alloy Greater than See Note 1 Short 75% Argon All Position High welding speeds. Good
and 22 gauge Circuit 25% CO2 Welding penetration and pool control.
High Alloy (.030”) Globular Applicable for out-of-position welds.
Steel Suitable for high-current and high-
speed welding.
Greater than See Note 1 Short 92% Argon All Position Good coalescence and bead contour.
22 gauge Circuit 8% CO2 Welding Good mechanical properties.
(.030”)
Greater than See Note 1 Spray 92% Argon Flat & HV Reduces undercutting. Higher
3/32” transfer 8% CO2 Fillet deposition rates and improved bead
wetting. Deep penetration and good
mechanical properties.
Greater than See Note 1 Short 98% Argon All Position Good control of melt-through and
14 gauge Circuit 2% CO2 Welding distortion. Used also for spray arc
(.075”) welding. Pool fluidity sometimes
sluggish depending on the base alloy.
Stainless Greater than ER308-X Short 90% Helium All Position Low CO2 percentages in Helium mix
Steel 22 gauge ER309-X Circuit 7.5% Argon Welding minimizes carbon pickup, which can
(.030”) ER316-X 2.5% CO2 cause intergranular corrosion with
or some alloys. Helium improves wetting
81% Argon action and contour. CO2 percentages
18% Helium above 5% should be used with caution
1 % CO2 on some alloys.
Greater than ER308-X Spray 90% Helium Flat & HV Good arc stability. Produces a fluid
3/32” ER309-X Transfer 7.5% Argon Fillet but controllable weld pool, good
ER316-X 2.5% CO2 coalescence, and bead contour.
or Minimizes undercutting on heavier
81% Argon thickness.
18% Helium
1 % CO2
Aluminum Greater than ER4043 Spray Argon All Position Excellent cleaning action. Provides
18 gauge ER5356 Transfer Welding more stable arc than helium-rich
(.045”) mixtures.
Note 1: Contact your Filler Metal Supplier for recommended filler metal for the base metal to be welded.
Manual 0-4992 4-14 January 25, 2008
BASIC TROUBLESHOOTING FABRICATOR 140, 180
SECTION 5:
BASIC TROUBLESHOOTING
The basic level of troubleshooting is that which can be 1. Gas cylinder contents and flow meter.
performed without special equipment or knowledge, and a. Ensure that the gas cylinder is not empty and
without removing the covers from the Power Source. the flow meter is correctly adjusted to 20CFM
If major components are faulty, then the Power Source (15 liters per minute).
should be returned to an Accredited THERMAL ARC 2. Gas leaks
Service Agent for repair.
a. Check for gas leaks between the regulator/
cylinder connection and in the gas hose to the
Power Source.
3. Internal gas hose in the Power Source.
a. Ensure the hose from the solenoid valve to the
MIG torch adaptor 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 or greasy
plate.
a. Clean contaminates off the plate.
6. Distance between the MIG torch nozzle and the
work piece.
a. Keep the distance between the MIG torch nozzle
and the work piece to a minimum.
! WARNING
the wire when heated. A contact tip designed
for soft electrode wires should be used.
Disengage the drive roll when testing for gas 7. Poor work lead contact to work piece.
flow by ear. a. If the work lead has a poor electrical contact to
the work piece, then the connection point will
2. Inconsistent wire feed heat up and result in a reduction of power at
the arc.
Wire feeding problems can be reduced by checking the
following points: 8. Bent liner.
1. Wire spool brake is too tight. a. This will cause friction between the wire and
the liner thus reducing wire feedability
a. Feed roller driven by motor in the cabinet will
slip.
2. Wire spool brake is too loose.
a. Wire spool can unwind and tangle.
3. Worn or incorrect feed roller size.
a. Use ‘U’ groove drive feed roller matched to the
aluminum 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.
4. Misalignment of inlet/outlet 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 is applied
to the pressure roller adjuster. Slag can also
be produced by the wire passing through an
incorrect feed roller groove shape or size. Slag
is fed into the liner where it accumulates, thus
reducing wire feedability.
2. Perform C1 & C2 Test Procedure Section 6.13. 1. Unit should remain off, nothing happens.
3. Check the F1 fuse. Replace if open. B. Turn VOLTAGE CONTROL SWITCH to position 1 and
observe the following:
6.02 Initial Setup Conditions 1. Green AC LED turns on.
This section is to help isolate the defective circuit before 2. Fan turns on.
troubleshooting, identify symptoms, and test the unit for
proper operation. Follow the instructions as given to 3. OVERTEMP LED is off.
identify the possible symptom(s) and the defective circuit. 4. Output Voltage measures 0 VDC.
After repairs are complete, run the following tests again
to verify that the unit is fully operational. This completes the Primary Power Test. If the above steps
were correct, proceed to the next section, Logic and
A. Connect the gas supply to the rear of the Power Supply. Control Test. If the unit does not function as detailed
B. Adjust the inlet pressure to approximately 20 CFH. above, note the symptom and proceed to Section 6.08
Refer to page 3-4 "Adjusting Regulator". Primary Power Problems.
C. Set the power supply controls as follows: 6.04 Logic & Control Test
1. VOLTAGE CONTROL SWITCH SW1 to Position 0. A. Close the MIG gun switch.
2. WIRE SPEED CONTROL Potentiometer to 0 (Fully 1. Gas flows.
Counter Clockwise).
2. Feed roll turns slowly.
3. Connect work cable to negative (-) Polarity Change
Over terminal. 3. Output Voltage measures 21 VDC.
4. Disconnect the wire from the Feed Head assembly B. Release the MIG Gun Switch.
from the positive (+) Polarity Change Over 1. Gas flow stops.
terminal.
2. Feed roll stops turning.
5. Open the PRESSURE ADJUST DEVICE so the wire
will not feed. 3. Output Voltage slowly decreases to 0 VDC.
6. With the Primary Line Disconnect in the OFF C. Disconnect one of the wires connected to the
position, plug the input power cord into the temperature switch located on the rectifier heat sink:
primary line outlet.
1. Yellow OVERTEMP LED turns on.
D. Close the MIG gun switch and observe the following:
1. Gas does not flow.
2. Feed roll does not turn.
3. Output Voltage measures 0 VDC.
C. Remove the jumper and the meter from J6 and re- 2. Wire feeds out.
install MIG gun plug P6. 3. Welding arc established.
This completes the Spool Gun Control Test. If the above This completes the Wire Feed & Weld Test. If the above
steps were correct, proceed to the next section, Output steps were correct, the system is functioning properly. If
Voltage Test. If the unit does not function as detailed the unit does not function as detailed above, note the
above, check the wire harness connections from the PCB symptom and proceed to Section 6.10 Wire Feed and Weld
to J6. Problems.
A +OUT -OUT
Art # A-08255
AC1 AC2
Fabricator 140
Voltage Control Switch (SW1) position # 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
CATALOG NUMBERS:
W1002500 Fabricator 140
W1002600 Fabricator 180
Art # A-08256
1 8
2
7
5 6
Manual 0-4992 7-2 January 25, 2008
PARTS LISTS FABRICATOR 140, 180
7.04 Rear Panel
Item Qty Ref
Ref.. Des. Description 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 1 Nipple,Gas Inlet,1/8",F140/180 W7004038
4 1 Panel,Rear,Fab140 W7004046
4 1 Panel,Rear,Fab180 W7004047
5 1 Cord,3xAWG14,FP90/120/130-F140 1444-0433
5 1 Cord,3XAWG12,8ft,Fab180 W7004011
Art # A-08257
2
1
1 2 3 4 5
Art # A-08258
12 11 10 9 8 7 6
1 2 3 4 5 6
Art # A-08259
13 12 11 10 9 8 7
1
6
8 8 2
4
7e
7d
8
8
7c
7b
7a
11
12
6 12
10
Art # A-08276_AB
12 12
11 11
4
Art # A-08260
4 3
PCB1 T1
CB1 1 1
J4 J1
L1 A1 A R/L1 2 2
D
230 VAC 1PH SW1 3 3
60Hz SW1
L2 B1 B
4 4
S/L2
5 5
GND
SOL1
M1
F1 JFM
FAN
J3
C J2
J5
V+
1
V-
2
M+
3
M- 4
TS1 5
COM 6
COM TS1 (DIODE HEATSINK)3 TS1 (T1)
7
GUN SW 8
B
OVERTEMP AC
WIRE SPEED
YELLOW GREEN
Art # A-07918_AB
5 4 3
2 1
+ POS
D1 D2 D3 D4
RV1 D
C1 + C2 + R1
D5 D6 D7 D8
L3
- NEG
INDUCTOR
J6 P6 P6
SW3 SW4
M2 1 1 1
2 2 2
3 3 3
- WFM + 4 4 4
5 5 5
6 6 6
J6 RECEPTACLE
FRONT VIEW B
O
1
D D
4
2
O O
5
3
D 6
2 1
D T1
CB1
PCB1 SW1
1 1
J4 J1
2 2
L1 A1 A R/L1
BLK 3 3
120 VAC SW1
4 4
60Hz
L2 B1 B
WHT
SOL1
GND
GRN
M1
F1 JFM
FAN
J3
C J2
J5
V+
1
V-
2
M+
3
M- 4
TS1 5
COM 6
COM TS1 (DIODE HEATSINK)
7
GUN SW 8
OVERTEMP AC
B WIRE SPEED
YELLOW GREEN
Art # A-07919_AB
5 4 3
2 1
+ POS D
D1 D2 D3 D4
RV1
C1 + C2 + R1
D5 D6 D7 D8
L3
- NEG
INDUCTOR
J6 P6 P6
SW3 SW4
M2 1 1 1
2 2 2
3 3 3
- WFM + 4 4 4
5 5 5
6 6 6
B
J6 RECEPTACLE
FRONT VIEW
O
1
D D
4
2
O O
5
3
D 6
2 1
July 2007
July 2007