140
®
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.
Fabricator 140 and 180 MIG Welding Machine
Service Manual Number 0-4992 for :
Fabricator 140
Catalog Number W1002500
Fabricator 180
Catalog Number W1002600
Published by:
Thermadyne Industries
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2008 by
Thermadyne Industries
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of 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.
Publication Date: January 25, 2008
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
i
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
Arc Welding Hazards ...................................................................................... 1-1
Principal Safety Standards ............................................................................. 1-4
Symbol Chart ................................................................................................. 1-5
Precautions De Securite En Soudage A L’arc .................................................. 1-6
Dangers relatifs au soudage à l’arc ................................................................. 1-6
Principales Normes De Securite ..................................................................... 1-9
Graphique de Symbole ................................................................................. 1-10
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01
2.02
2.03
2.04
2.05
2.06
2.07
2.08
2.09
2.10
How To Use This Manual ................................................................................ 2-1
Equipment Identification................................................................................. 2-1
Receipt Of Equipment ..................................................................................... 2-1
General ........................................................................................................... 2-2
Machine Specifications ................................................................................... 2-3
Volt - Amp Curves .......................................................................................... 2-4
Duty Cycle ...................................................................................................... 2-5
Fabricator 180A MIG Gun ............................................................................... 2-6
Installing a New Wire Liner ............................................................................ 2-7
MIG Gun Maintenance .................................................................................... 2-7
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
3.11
3.12
Location ......................................................................................................... 3-1
Safety ............................................................................................................. 3-1
Grounding ...................................................................................................... 3-1
Electrical Input Requirements ........................................................................ 3-1
Requirements for Maximum Output ............................................................... 3-2
Installation of Shielding Gas (GMAW) Process .............................................. 3-2
Attaching the Gun and Cable Assembly to the Power Source ......................... 3-5
Polarity Changeover ....................................................................................... 3-6
Installing Wire Spool ...................................................................................... 3-7
Feedrolls ......................................................................................................... 3-8
Install Wire into the Feedhead ........................................................................ 3-9
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
APPENDIX 2: FABRICATOR 180 SYSTEM SCHEMATIC ............................................... A-2
APPENDIX 3: FABRICATOR 140 SYSTEM SCHEMATIC ............................................... A-4
APPENDIX 4: FEED ROLL KITS ........................................................................... A-6
LIMITED WARRANTY
WARRANTY SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
SAFETY INSTRUCTIONS
FABRICATOR 140, 180
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
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
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.
Arc Welding Hazards
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
WARNING
10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill.
11. Do not touch electrode while in contact with the work (ground)
circuit.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power
is on. In semi-automatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
WARNING
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch
open, or remove line fuses so power cannot be turned on
accidentally.
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
1. Wear a welding helmet fitted with a proper shade of filter (see
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.
January 25, 2008
1-1
Manual 0-4991
FABRICATOR 140, 180
SAFETY INSTRUCTIONS
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
WARNING
FUMES AND GASES can be hazardous to your health.
1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
2. Do not weld where flying sparks can strike flammable material.
1. Keep your head out of the fumes. Do not breath the fumes.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
4. Be alert that welding sparks and hot materials from welding can
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
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
Manual 0-4992
Electrode Size
Filter
Welding or cutting
2
3 or 4
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
4 or 5
5 or 6
6 or 8
10
12
14
Electrode Size
Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
1-2
Filter
11
12
12
12
12
12
12
14
9
12
14
January 25, 2008
SAFETY INSTRUCTIONS
FABRICATOR 140, 180
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Wear approved face shield or safety goggles. Side shields
recommended.
1. Stop engine before checking or adding fuel.
2. Wear proper body protection to protect skin.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
WARNING
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged.
4. Do not overfill tank — allow room for fuel to expand.
Shielding gas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
WARNING
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
MOVING PARTS can cause injury.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
3. Keep cylinders away from any welding or other electrical circuits.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
6. Turn face away from valve outlet when opening cylinder valve.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
!
WARNING
WARNING
Engines can be dangerous.
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
WARNING
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.
4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas.
5. Observe correct polarity (+ and –) on batteries.
January 25, 2008
1-3
Manual 0-4991
FABRICATOR 140, 180
SAFETY INSTRUCTIONS
1.02
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
LEAD WARNING
This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
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.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
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:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
Manual 0-4992
1-4
January 25, 2008
SAFETY INSTRUCTIONS
1.03
FABRICATOR 140, 180
Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
January 25, 2008
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
Voltage Input
Art # A-04130
1-5
Manual 0-4991
FABRICATOR 140, 180
1.04
SAFETY INSTRUCTIONS
Precautions De Securite En Soudage A L’arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
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
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
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.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension
dès la mise en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou
la bobine de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement
inadéquatement installé ou inadéquatement mis à la terre
est dangereux.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
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.
Manual 0-4992
1-6
January 25, 2008
SAFETY INSTRUCTIONS
FABRICATOR 140, 180
AVERTISSEMENT
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de
soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
malaises ou la mort. Assurez-vous que l’air est propre à la respiration.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
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.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
Soudage aux gaz
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
Opération de coupage
ou soudage
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
mince
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais
Soudage á l'arc avec
électrode enrobees
(SMAW)
4 ou 5
Gougeage Air-Arc avec
électrode de carbone
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
épais
14
moins de 5/32 po. (4 mm)
10
5/32 á 1/4 po. (4 á 6.4 mm)
12
mince
moins de 300 amperès
9
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 á 400 amperès
12
plus de 400 amperès
14
Coupage á l'arc Plasma (PAC)
épais
January 25, 2008
1-7
Manual 0-4991
FABRICATOR 140, 180
SAFETY INSTRUCTIONS
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
soudage.
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou un
incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
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
projections peuvent atteindre des matériaux inflammables.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
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
ou fissures.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
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.
LES MOTEURS PEUVENT ETRE DANGEREUX
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
Manual 0-4992
1-8
January 25, 2008
SAFETY INSTRUCTIONS
FABRICATOR 140, 180
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
AVERTISSEMENT
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION. Le carburant est hautement inflammable.
AVERTISSEMENT
1. Arrêtez
le moteur avant de vérifier le niveau e
carburant ou de faire le plein.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
PLOMB AVERTISSEMENT
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
Ce produit contient des produits chimiques, comme le
plomb, ou engendre des produits chimiques, reconnus
par l’état de Californie comme pouvant être à l’origine
de cancer, de malformations fœtales ou d’autres
problèmes de reproduction. Il faut se laver les mains
après toute manipulation. (Code de Californie de la
sécurité et santé, paragraphe 25249.5 et suivants)
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
1.06
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
AVERTISSEMENT
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
January 25, 2008
Principales Normes De Securite
1-9
Manual 0-4991
FABRICATOR 140, 180
1.07
SAFETY INSTRUCTIONS
Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Mono Phasé
Déroulement du Fil
Hors Tension
Trois Phasé
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Tri-Phase Statique
Tension dangereuse
Fréquence Convertisseur
Transformateur-Redresseur
Torch de Soudage
Augmentez/Diminuer
Distant
Purge Du Gaz
Facteur de Marche
Mode Continu de
Soudure
Pourcentage
Soudure Par Point
Disjoncteur
Source AC Auxiliaire
X
%
Fusible
Panneau/Local
Intensité de Courant
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Tension
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Hertz (cycles/sec)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Fréquence
Decoupe Arc Carbone
(CAC-A)
t
Duréc du Pulse
Durée de Pré-Dèbit
t1
t2
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Détente à 4-Temps
Courant Constant
Négatif
Positif
Tension Constante
Ou Potentiel Constant
Courant Continue (DC)
Haute Température
Terre de Protection
Amorçage de L’arc au
Contact (GTAW)
Connexion de la Ligne
115V 15A
Manual 0-4992
t
Probléme de Terre
IPM
Pouces Par Minute
MPM
Mètres Par Minute
Force d'Arc
Ligne
Source Auxiliaire
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Inductance Variable
V
Tension
Classement de PriseSource Auxiliaire
Art # A-07639
1-10
January 25, 2008
INTRODUCTION
FABRICATOR 140, 180
2.02 Equipment Identification
SECTION 2:
INTRODUCTION
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
nameplate attached to the rear panel. In some cases, the
nameplate may be attached to the control panel.
Equipment which does not have a name plate such as
gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
i for future reference.
2.01 How To Use This Manual
This Service Manual applies to just specification or catalog
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as
follows:
!
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
claim. Furnish complete information concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.
WARNING
A WARNING gives information regarding
possible personal injury.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
in your area listed in the inside back cover of this manual.
Include the Service Manual number and equipment
identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
January 25, 2008
2-1
Manual 0-4992
FABRICATOR 140, 180
INTRODUCTION
2.04 General
The Thermal Arc Fabricator 140 / 180 Machines are both
single-phase input welding machine and come equipped
with the following:
1. Built-in Wire Feeder and Wire Spool Hub
2. Quick Connect Welding Gun and Cable (10 Foot
Length)
3. Work Cable and Clamp
4. Regulator/Flow Meter
5. Input Cord
6. Spare Parts Kit (4 contact tips)
7. Operational Manual
8. 0.5 lb Spool of Wire
The welding system is designed for use with the following
processes:
1. GMAW – Gas metal arc welding (MIG). Requires
the use of a shielding gas and regulator.
2. FCAW – Flux-cored arc welding – Does not require
the use of a shielding gas.
As delivered from the factory, the Fabricator 140 is set
up for .024" (0.6mm) diameter solid wire and the
Fabricator 180 is set up for .030” (0.8mm) diameter solid
wire.
The feed roll can be reversed in either machine which will
set up the Fabricator 140 for .030” (0.8mm) diameter
solid wire and the Fabricator 180 for .024" (0.6mm)
diameter solid wire.
Optional feedrolls, contact tips and gun liners are available
to convert the gun and feed system to use the following
wires.
1. .023” - .035" (0.6mm – 0.9mm) Solid Wire (Mild
Steel and Stainless Steel)
2. .030" - .035” (0.8mm – 0.9mm) Self-Shielding Wire
3. .030" (0.8mm) Aluminum Wire
Refer to section 3.10 Feedrolls and Appendix 4 for more
information.
Also refer to OPTIONAL EQUIPMENT LIST and 180A MIG
Gun sections included in this manual.
Manual 0-4992
2-2
January 25, 2008
INTRODUCTION
FABRICATOR 140, 180
2.05 Machine Specifications
Description
Package System Part Number
Power Source Weight
Power Source Dimensions HxWxD
Number of Phases
Frequency
Flexible Supply Cable Size
Supply Lead Plug Type
Nominal Input Voltage
Rated Input Current
Rated kVA @ 100% Duty Cycle
Rated Input Current
Maximum Input Current
Generator Requirements
Supply VA @ max. output
Open Circuit Voltage Range
Output Current Range
Duty Cycle Period
Number of Output Voltage Values
Minimum Mains Circuit to suit factory fitted Plug
& Lead (Weld Current @ Duty Cycle)
Maximum Mains Circuit to suit factory fitted Plug
& Lead (Weld Current @ Duty Cycle)
Wire Size Range
Steel
Stainless Steel
Flux Core
Aluminum
Fabricator 140
Fabricator 180
W1002500
W1002600
64 lb (29 kg)
80 lb (36 kg)
15.8 x 10.0 x 21.3”
400 x 255 x 540mm
1
60Hz
7 ft (2.3 m) 14AWG
8 ft (2.5 m) 12AWG
5-15P
6-50P
120V AC
230V AC
^ 15A
^ 21A
1kVA
1.9kVA
15A (65A@40%)
21A (130A@25%)
24A (90A@20%)
31A (180A@15%)
# 6kVA
# 8.5kVA
# 5.1kVA
# 7kVA
20.5 – 34V
19.5 – 38V
30 – 140A
30 – 180A
10 Minutes
4
6
(+) 15A (65A@40%)
(+) 21A (130A@25%)
(+) 24A (90A@20%)
(+) 31A (180A@15%)
.023” - .030” - .035"
(0.6 - 0.8 - 0.9mm)
.023” - .030”
.023” - .030” - .035"
(0.6 - 0.8mm)
(0.6 - 0.8 - 0.9mm)
.030” - .035”
.030” - .035” - .045"
(0.8 - 0.9mm)
(0.8 - 0.9 - 1.2mm)
.030” - .035” (0.8 - 0.9mm)
^ 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.
Table 2-1: Specifications
January 25, 2008
2-3
Manual 0-4992
FABRICATOR 140, 180
INTRODUCTION
2.06 Volt - Amp Curves
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
Figure 2-1: Volt/Amp curves of the Fabricator 140
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
Figure 2-2: Volt/Amp curves of the Fabricator 180
Manual 0-4992
2-4
January 25, 2008
INTRODUCTION
FABRICATOR 140, 180
2.07 Duty Cycle
Duty Cycle is the amount of arc-on time (actual welding time) during any 10 minute period that a machine can operate
at it’s rated output without damaging internal components. For example, the Fabricator 180 is designed for 25% duty
cycle at 130 amps. This means that it has been designed and built to provide the rated amperage, 130 amps, for 2.5
minutes out of every 10 minute period. During the other 7.5 minutes of the 10 minute period, the Fabricator 180 must
idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.
The Fabricator 140 is designed for 20% duty cycle at 90 Amps.
The Fabricator 180 is designed for 25% duty cycle at 130 Amps
If the unit overheats and the thermostat opens, wait 15 minutes for unit to cool.
Fabricator 140 at Rated Duty Cycle
0
1
2
3
4
5
6
Minutes
7
8
9
10
Art # A-07889
Fabricator 180 at Rated Duty Cycle
0
1
2
3
4
5
6
Minutes
7
8
9
10
Figure 2-3: Duty Cycle of Fabricator 140 and Fabricator 180
January 25, 2008
2-5
Manual 0-4992
FABRICATOR 140, 180
INTRODUCTION
2.08 Fabricator 180A MIG Gun
The Fabricator 180A MIG Gun (Figure 2-4) fitted to the FABRICATOR 140 and 180 offers robust construction, unparalleled
reliability and easy replacement of consumable parts. The Fabricator 180A MIG Gun has an operating capacity in
excess of the capacity of the FABRICATOR and can be expected to give trouble free service.
2
1
3
4
Item
Description
Part No.
1
Nozzle
21-50
2
Contact Tip
11-23
11-30
11-35
3
Gas Diffuser
35-50
4
Conductor Tube
Assembly 180 Gun
W7004068
5
Handle Torch Black
W7004069
6
Switch Trigger
180Gun
W7004070
7
Cable Assembly,
180Gun
W7004071
8
Wire Liner
35-40-15
9
Gas Inlet Nipple
N/A
10
Guide, Outlet,
F140/180
W7004023
11
Connector Plug
N/A
12
Gun Switch Lead
N/A
Connector 6-pin
180SG/180Gun
W7004067
5
6
7
Art # A-07956
Size
.023” (0.6mm)
.030” (0.8mm)
.040” (1.0mm)
8
9
11
10
12
Figure 2-4: Exploded View of Fabricator 180A MIG Gun
Manual 0-4992
2-6
January 25, 2008
INTRODUCTION
FABRICATOR 140, 180
2.09 Installing a New Wire Liner
1. Be sure that the Fabricator 180A MIG Gun cable is arranged in a straight line and free from twists when installing
or removing a wire liner (8). Remove the old liner by first removing the gun’s nozzle (1), contact tip (2) and gas
diffuser (3). Then remove the outlet guide (10) from the connector plug and pull the old wire liner out of the cable
assembly from the connector plug end.
2. To install a new wire liner, first inspect the o-ring gas seal on the liner for cuts or damage. Start from the connector
plug end of the assembly and begin pushing the liner through the connector plug, cable assembly (7), and into the
gun handle (5). If the liner should lodge along the way, gently whip or work the cable assembly (7) to aid forward
movement.
3. When the wire liner meets the end of the connector plug and the new raw end extends through the end of the
conductor tube assembly (4), the outlet guide (10) in the connector plug must be securely tightened onto the liner
to prevent its backward movement.
NOTE
When the liner assembly is fully inserted into the cable assembly and the liner stop is firmly against the
connector plug, the “raw end” of the liner will protrude out of the open end of the gun conductor tube. Trim
the wire liner so that it protrudes past the end of the conductor tube assembly (4) by approximately the
length of the gas diffuser (3); 1 1/16" ± 1/16" (27mm ± 1.5mm). See Figure 2-5. The trimmed end which seats
in the gas diffuser (3) must be filed and reamed smooth on the inside and outside radii so wire feed will not
be obstructed.
4. Replace gas diffuser (3), contact tip (2) and nozzle (1).
Gas Diffuser
Wire Liner
x
x
Art # A-08333
Figure 2-5: Trim Wire Liner to Length Of Gas Diffuser
2.10 MIG Gun Maintenance
Remove dust and metallic particles from the gun conduit by forcing clean, dry compresses air into the conduit once a
week. This will minimize wire feeding problems.
January 25, 2008
2-7
Manual 0-4992
FABRICATOR 140, 180
Manual 0-4992
INTRODUCTION
2-8
January 25, 2008
INSTALLATION
FABRICATOR 140, 180
SECTION 3:
INSTALLATION
The Fabricator 180’s power cord is equipped with a NEMA
6-50P plug and will only connect to a NEMA 6-50P
receptacle.
CAUTION
3.01 Location
For best operating characteristics and longest unit life,
take care in selecting the installation site. Avoid locations
exposed to high humidity, dust, high ambient temperature,
or corrosive fumes. Moisture can condense on electrical
components, causing corrosion or shorting of circuits.
Dirt on components will retain this moisture and also
increases wear on moving parts.
Consult the nameplate for proper input voltage
and input amperage. The method of
installation, conductor size, and over-current
protection shall conform to the requirements
of the local electrical code. All installation
wiring and machine connection shall be done
by a competent electrician.
Adequate air circulation is needed at all times in order to
assure proper operation. Provide a minimum of 12”
(300mm) of free air space at both the front and rear of
the unit. Make sure that the ventilation openings are not
obstructed.
The National Electrical Code (Article 630B) provides
standards for amperage handling capability of supply
conductors based on the duty cycle of the welding power
source. The Fabricator 140 has a 20% duty cycle (2
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
standards. Ensure that the building supply and receptacle
comply with NEC standards and any additional state and
local codes.
CAUTION
The Fabricator is not suitable for use in rain.
3.02 Safety
NOTE
The supply wiring for the welding power
source must be capable of handling a
minimum of 20 amperes. The welding power
source must be the only load connected to
the supply circuit. Poor unit performance or
frequently opening line fuses or circuit
breakers can result from an inadequate or
improper supply.
Refer to additional installation instructions under the
SAFETY INSTRUCTIONS AND WARNINGS (Section 1) in
this manual.
3.03 Grounding
The internal frame of this welding machine should be
grounded for personal safety. Where grounding is
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,
it is recommended that the National Electrical Code be
followed.
CAUTION
Do not connect the Fabricator 140 to an input
power supply with a rated voltage that is
greater than 132 +10% VAC. Do not remove
the power cord ground prong.
3.04 Electrical Input Requirements
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
requires a 120VAC supply voltage and the Fabricator 180
requires a 230VAC supply voltage.
CAUTION
Do not connect the Fabricator 180 to an input
power supply with a rated voltage that is
greater than 255 + 10% VAC. Do not remove
the power cord ground prong.
The Fabricator 140’s power cord is equipped with a NEMA
5-15P plug and will only connect to a NEMA 5-15P
receptacle.
January 25, 2008
3-1
Manual 0-4992
FABRICATOR 140, 180
3.05 Requirements for Maximum Output
In order to obtain the maximum output capability of the
Fabricator 140, a branch circuit capable of 20 amperes at
115 to 125 Volts 60 Hz is required. In order to obtain the
maximum output capability of the Fabricator 180, a branch
circuit capable of 30 amperes at 230 to 250 Volts 60 Hz is
required. This generally applies when welding steel that
is equal to or greater than 12 gauge (0.105” 2.5mm) in
thickness.
The rated output with this installation is 90 amperes, 18
Volt, 20% duty cycle (2 minutes out of every 10 minutes
used for welding) for the Fabricator 140, and 130 amperes,
20 Volt, 25% duty cycle (2.5 minutes out of every 10
minutes used for welding) for the Fabricator 180.
INSTALLATION
3.06 Installation of Shielding Gas
(GMAW) Process
Refer to Figure 3-1.
NOTE
Shielding Gas is not required if the unit is using
self-shielded FCAW (flux cored arc welding)
wires.
1. Cylinder Positioning: Chain the cylinder to a wall or
other support to prevent the cylinder from falling over.
If an optional portable mounting arrangement is used,
follow the instructions that are provided with it.
2. Remove Cylinder Cap: Remove the large metal cap
on top of the cylinder by rotating counter clockwise.
Next remove the dust seal.
3. Cracking: Position yourself so the valve is pointed
away from you and quickly open and close the valve
for a burst of gas. This is called “Cracking” and is
done to blow out any foreign matter that may be
lodged in the fitting.
CAUTION
KEEP FACE WELL AWAY FROM THE
CYLINDER VALVE DURING “CRACKING” .
Never “crack” a fuel gas cylinder valve near
other welding works, sparks or open flames.
Ensure that the surrounding area is well
ventilated.
4. Fit Regulator/Flowmeter to Cylinders:
Screw the regulator into the appropriate cylinder. The
nuts on the regulator and hose connections are right
hand (RH) threaded and need to be turned in a
clockwise direction in order to tighten. Tighten with a
wrench.
CAUTION
Match regulator to cylinder. NEVER CONNECT
a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
5. Attach Supplied Gas Line: Attach supplied gas line
between the regulator output and the desired input
at the rear of the power supply depending on Spool
Gun or MIG Gun use.
Manual 0-4992
3-2
January 25, 2008
INSTALLATION
FABRICATOR 140, 180
Cap
2
1
Shielding
Gas
3
4
Regulator and
Flow Meter
/8”
“Cracking”
11
Shielding
Gas
Shielding
Gas
5
Shielding
Gas
Art # A-07965
Gas Hose
Figure 3-1 Gas Cylinder Installation
January 25, 2008
3-3
Manual 0-4992
FABRICATOR 140, 180
INSTALLATION
Adjusting Regulator
Adjust control knob of regulator to the required flow rate,
indicated on gauge dial. (Refer to Figure 3-2 and data
charts Approx. 20 CFH)
The gas flow rate should be adequate to cover the weld
zone to stop weld porosity. Excessive gas flow rates may
cause turbulence and weld porosity.
Argon or argon based gas flow rates:
- Workshop welding: 20-30 CFH
- Outdoors welding: 30-40 CFH
Helium based or CO2 gas flow rates:
- Workshop welding: 30-40 CFH
- Outdoors welding: 40-50 CFH
NOTE
All valves downstream of the regulator must
be opened to obtain a true flow rate reading
on the outlet gauge. (Welding power source
must be triggered) Close the valves after the
pressure has been set.
Art # A-07280
Figure 3-2: Adjusting flow rate
Refer to section 4.15 for suggested gas / filler metal
combinations.
NOTE
The regulator/flowmeters used with argon
based and carbon dioxide shielding gases are
different. The regulator/flow meter supplied is
for argon based shielding gases. If carbon
dioxide is to be used a suitable carbon dioxide
regulator/flow meter will need to be fitted.
Two types of gas are generally used with Gas Metal Arc
Welding (GMAW) of thin gauge sheet steel. A mixture of
75% Argon and 25% Carbon Dioxide (CO2) is
recommended, Carbon Dioxide (CO2) can also be used.
Manual 0-4992
3-4
January 25, 2008
INSTALLATION
FABRICATOR 140, 180
3.07 Attaching the Gun and Cable
Assembly to the Power Source
The Fabricator 140/180 is supplied with a 180A MIG gun.
The 180A MIG gun is designed with an ergonomic handle
and fewer parts to eliminate performance problems. The
180A MIG gun uses standard readily available TWECO
consumable parts.
Front Panel Access Hole
Art # A-08334
1. Open the door to the machine.
2. Connect the gun cable to the power source by first
routing the switch lead through the access hole in
the front panel followed by the gun cable (see
Figure 3-3).
NOTE:
Turn the cable end to align the gas hose nipple
on the connector plug with the keyway located
in the bottom of the front panel access hole.
Gas Hose Nipple
Art # A-08335
Gas Nipple
Keyway
3. Loosen the thumbscrew and insert the gun cable end as
far as it will go. Tighten thumbscrew (see Figure 3-3).
Thumbscrew
4. Insert the gun switch plug into the gun switch socket
(see Figure 3-3).
Hose
Clamp
5. If shielding gas is being used, push the gas hose. on
to the gas hose nipple and secure it with the hose
clamp.
6. To remove the gun, simply reverse these directions.
Gas
Hose
CAUTION
When disconnecting gun switch leads from
the machine, grab the connectors and pull. Do
not pull on the wires.
Gun Switch
Socket
Gun Switch Plug
Figure 3-3: Attaching Gun and Cable
January 25, 2008
3-5
Manual 0-4992
FABRICATOR 140, 180
INSTALLATION
3.08 Polarity Changeover
!
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.
PROCESS
POLARITY
CABLE CONNECTIONS
CABLE TO GUN
CABLE TO WORK
1. GMAW* – Solid Wire &
1. DCEP – Reverse Polarity* 1. Connected to (+) 1. Connected to (-)
flux cored with shielding gas
Pos. output terminal Neg. output terminal
2. FCAW* – Self-shielding
2. DCEN – Straight Polarity* 2. Connected to (-) 2. Connected to (+)
Wire – no Shielding Gas
Neg. output terminal Pos. output terminal
* Exception: Contact your filler metal supplier for recommended polarity.
Table 3-1: Process Cable Connections
Connection for GMAW (reverse polarity DCEP)
1. Open the door to the machine.
Polarity
Terminal
Knobs
2. Remove the polarity terminal knobs.
3. Set up the polarity (as per Table 3-1 above) by
removing the leads from the terminals and
reversing them if necessary. Refer to Figure 3-4.
Polarity
Terminal
Leads
4. Replace the polarity terminal knobs.
NOTE
Ensure that the polarity terminal knobs are
tightly secured and that there is no connection
between positive and negative terminals.
Gas Hose
Normally
Connected
Art # A-08336
Figure 3-4: Connection for GMAW (reverse polarity DCEP)
Connection for FCAW (straight polarity DCEN)
1. Open the door to the machine.
2. Remove the polarity terminal knobs.
3. Set up the polarity (as per Table 3-1 above) by
removing the leads from the terminals and
reversing them if necessary. Refer to Figure 3-5.
Polarity
Terminal
Knobs
Gas Hose
Normally
Disconnected
4. Replace the polarity terminal knobs.
NOTE
Polarity
Terminal
Leads
Ensure that polarity terminal knobs are tightly
secured and that there is no connection
between positive and negative terminals.
Art # A-08337
Figure 3-5: Connection for FCAW (straight polarity DCEN)
Manual 0-4992
3-6
January 25, 2008
INSTALLATION
FABRICATOR 140, 180
3.09 Installing Wire Spool
As delivered from the factory, the unit is set for an 4”
(102mm) spool.
Installation of 4” (102mm) Spool
Assemble parts in sequence (shown in Figure 3-6 from
right to left).
1. Spool 4” (102mm)
2. "D" Washer
3. Retaining Spring
4. Nut
NOTE
Nut is tightened until a slight force is required
to turn the spool\
1
2
3
Art # A-07905
4
Figure 3-6: 4" Spool Installation
January 25, 2008
3-7
Manual 0-4992
FABRICATOR 140, 180
INSTALLATION
Installation of 8” (203mm) spool
Assemble parts in sequence (shown in Figure 3-7).
1. Spool 8” (203mm)
2. "D" Washer
3. Retaining Spring
4. Nut
5. Spool Adapter Hub
6. Drive Pin
NOTE
Nut is tightened until a slight force is required
to turn the spool
5
6
1
Art # A-07906
2
3
4
Figure 3-7: 8" Spool Installation
3.10 Feedrolls
A feedroll consists of two different sized grooves. As
delivered from the factory, the drive roll is installed for
.023” (0.6mm) for the Fabricator 140, and .030” / .035”
(0.8mm / 0.9mm) for the Fabricator 180.
.030
0.8
The groove size visible when fitting the feedroll is the
groove size in use.
The groove closest to the motor is the one to thread.
Art # A-07963
This also applies to optional feedrolls which are available
for this machine.
Manual 0-4992
Figure 3-8: Feedroll Example
3-8
January 25, 2008
INSTALLATION
FABRICATOR 140, 180
3.11 Install Wire into the Feedhead
!
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.
Load the Wire Spool
Slide the wire spool onto the hub, loading it so that the wire will feed off the spool as the spool rotates counterclockwise.
Make sure that the locating pin on the spool hub lines up with the hole in the spool.
When the spool of wire is in place, replace the spool retaining pin.
NOTE
The hub tension has been pre-adjusted at the factory. However if adjustment is required, simply turn the
spool nut counter-clockwise to reduce tension, and clockwise to increase tension.
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.
Pressure Adjust Device
Pressure Arm
Gun Cable End
Art # A-07911
Wire Spool
Inlet Wire Guide
Feedroll
Figure 3-9: Wire Feeder Components
January 25, 2008
3-9
Manual 0-4992
FABRICATOR 140, 180
INSTALLATION
Route the Wire Through the Feedhead
Pressure Adjust Device
1. Loosen Pressure Adjust Device (Fig. 3-10).
2. Open Pressure Adjust Device (Fig. 3-10).
Pressure Arm
Art # A-07912
3. Open Pressure Arm (Fig. 3-10).
4. Place the end of the wire into the Inlet Wire Guide,
feeding it over the Feedroll. Make certain that the
proper groove is being used (Fig. 3-11).
5. Pass the wire into the Gun Liner of the Gun Cable End
(Fig. 3-11).
6. Close the Pressure Arm (Fig. 3-11).
7. Close the Pressure Adjust Device. Tighten it to a “snug”
condition (Fig. 3-11).
Figure 3-10: Opening Pressure Arm
8. Figure 3-12 shows the result with the wire installed.
Pressure Adjust Device
Pressure Arm
Gun Cable End
Wire
Spool
Wire Guide
Feedroll
Art # A-07913
Figure 3-11: Inserting Wire
Art # A-07915
Figure 3-12: Wire Installed
Manual 0-4992
3-10
January 25, 2008
INSTALLATION
FABRICATOR 140, 180
3.12 Install Wire into the Welding Gun
1. Plug the Welding Power Source into the 120VAC
receptacle for the Fabricator 140, and into the 230VAC
receptacle for the Fabricator 180.
!
4. Straighten the gun cable. Remove the nozzle and
contact tip from the MIG welding gun (see Section
2.08).
!
WARNING
ELECTRIC SHOCK CAN KILL! With the gun
switch (located on the gun) activated, welding
power is applied to the output terminals,
feedroll, ground clamp, gun cable connection
and welding wire. Do not touch these parts
with the gun switch activated.
If ground connection clamp is in place on the
workpiece the electrode wire is electrically
“hot” when the gun switch is activated.
5. Activate the gun switch until the wire feeds out past
the gun nozzle.
Nozzle
Contact Tip
2. Turn the welding machine ON with the front panel
Voltage Control Switch set to "1".
OFF
WARNING
Wire
0
Gun Switch
1
6
2
5
3
Art # A-08340
4
Art # A-08338
Figure 3--13: Power ON
Figure 3-15: Feed Wire Through Gun
3. Set the wire feed speed to half-way or "5".
6. Deactivate the gun switch and replace the contact tip
and nozzle. Cut the wire within ¼” (6mm) from the
nozzle.
7. Set the Voltage Control Switch to "0 / OFF" and unplug
the supply cord.
Art # A-08339
Figure 3-14: Wire Speed Half-way
January 25, 2008
3-11
Manual 0-4992
FABRICATOR 140, 180
Manual 0-4992
INSTALLATION
3-12
January 25, 2008
OPERATION
FABRICATOR 140, 180
SECTION 4:
OPERATION
4.01 General Safety Precautions
Read and understand the safety instructions at the beginning of this manual prior to operating this machine.
!
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.
January 25, 2008
4-1
Manual 0-4992
FABRICATOR 140, 180
OPERATION
NOTE
4.02 Fabricator Controls
Genuine TWECO contact tips and liners should
be used. Many non-genuine liners use inferior
materials which can cause wire feed problems.
Refer to Figure 4-1
(1) The Wire Speed Control knob controls the welding
current via the electrode wire feed rate (i.e. the
speed of the wire feed motor).
(9) The Gun Adaptor connects the MIG Gun to the
feedhead assembly.
(2) The Voltage Control Switch sets the voltage level to
the welding terminals as it is rotated in the clockwise
direction. There are 4 positions available in the
Fabricator 140 and 6 positions in the Fabricator 180.
The OFF switch position disconnects the power
from the controls.
(10) The Gun Switch Connector is provided for
connection of the Gun Switch Leads.
(11) 32A Primary Circuit Breaker.
(12) Negative (-) Welding Terminal.
(13) Positive (+) Welding Terminal.
CAUTION
CAUTION
The Voltage Control Switch MUST NOT BE
SWITCHED during the welding process. Some
internal electrical components are at Mains
voltage potential with this switch in the OFF
position.
Loose welding terminal connections can cause
overheating and result in the cables being
fused to the welding terminals.
(14) 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 ¾” (20mm) after release of the
Torch Trigger Switch. The wire should be slack
without becoming dislodged from the reel.
(3) MIG Gun cable end and Gun Switch Leads are
routed through this opening.
(4) The Work Cable & Clamp connects to the item
being welded.
(5) The gas inlet nipple is used to connect the gas
hose to the gas regulator for GMAW or FCAW.
Use the hose clamp to secure the has hose to the
gas nipple.
(6) Main Power Cable (Fabricator 140 shown)
CAUTION
(7) The FABRICATOR 180A MIG gun has an operating
capacity in excess of the capacity of the
FABRICATOR and may be fitted to many different
types of MIG welding power supplies.
Excessive tension on the brake will cause rapid
wear of mechanical wire feed parts,
overheating of electrical components and
possibly an increased incidence of wire
burnback into the contact tip.
(8) The moveable tension knob 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 burn-back jam, the
conduit liner should be checked for kinks and
clogging by metal flakes and slag. 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.
Manual 0-4992
4-2
January 25, 2008
OPERATION
FABRICATOR 140, 180
®
1
3
5
OFF
0
1
6
2
5
2
3
4
180
80
Weldskill
FABRICATOR
Art # A-07916
4
6
7
8
9
10
11
14
13
12
Figure 4-1: Fabricator Controls
January 25, 2008
4-3
Manual 0-4992
FABRICATOR 140, 180
4.03 Gas Metal Arc Welding (GMAW)
See Welding Guidelines included in this manual.
Make all necessary connections as instructed in the
INSTALLATION chapter.
Place the WELD VOLTAGE RANGE SWITCH at the desired
setting.
OPERATION
Travel at a speed necessary to maintain a bead width from
1
/8" to ¼" (3mm to 6mm) depending on the thickness of
the material. For material that may require larger
weldments, either change to a larger diameter filler wire
or use multi pass beads. On some applications, it may be
necessary to adjust the voltage range to stabilize the arc.
Upon completion of the weld, release the gun trigger
switch, raise the welding helmet, and visually examine
the weld.
CAUTION
NOTE
To help you overcome any problems that might
arise, you will find useful information in section
4.08 Basic Welding Techniques.
Do not turn the WELD VOLTAGE RANGE
SWITCH clockwise past position 4, as damage
to the switch may occur.
Rotate the WIRE SPEED control to the desired setting.
4.04 Flux Cored Arc Welding (FCAW)
Plug the supply cord into a 120 VAC 20 Ampere receptacle
for the Fabricator 140, and into a 230 VAC 30 Ampere
receptacle for the Fabricator 180.
Follow the same general procedure as with the GMAW
process above. Shielding gas is not required for self
shielded type wires. For differences in the process see
section 4.06 Basic Welding Techniques. Also included is
information to solve any problem related to the FCAW
process.
Open the gas cylinder valve to supply shielding gas to the
gun.
Connect the WORK CLAMP to the workpiece (material to
be welded).
4.05 Shutdown Procedures
Extend wire from the gun, and cut to proper stick-out for
that type of wire (when welding always maintain this
distance).
Close the cylinder valve (GMAW process only). Press gun
switch to vent gas line (GMAW process only). Place the
POWER ON/OFF SWITCH in the OFF position.
Position gun to where it is at approximately right angles
to the workpiece with proper wire stick-out. Lower your
welding helmet and pull the gun trigger switch.
!
!
WARNING
After releasing the gun switch, the electrode
wire will remain electrically “hot” for several
seconds.
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.
Manual 0-4992
4-4
January 25, 2008
OPERATION
4.06 Basic Welding Technique
General
Two different welding processes are covered in this
section, with the intention of providing the very basic
concepts in using the semi-automatic mode of welding.
In this mode, the welding gun is hand-held. The electrode
(welding wire) is then fed into a weld puddle and the arc
is shielded by a gas or gas mixture.
Setting of the Power Supply
The settings of the Fabricator requires some practice by
the operator in that the welding Power Supply has two
control settings that need to balance. These are the Wire
Speed control and the Voltage Control switches. The
welding current is determined by the Wire Speed control
(i.e., the current will increase with increased wire speed,
resulting in a shorter arc). Slower wire speed will reduce
the current and lengthen the arc. Increasing the welding
voltage hardly alters the welding current level, but
lengthens the arc. By decreasing the voltage, a shorter
arc is obtained with little change in welding current.
When changing to a different electrode wire diameter,
different control settings are required. A thinner electrode
wire needs more wire speed to achieve the same current
level.
A satisfactory weld cannot be obtained if the wire speed
and voltage switch settings are not adjusted to suit the
electrode wire diameter and dimensions of the work piece.
If the wire speed is too high for the welding voltage,
“stubbing” will occur as the wire dips into the molten
pool and does not melt. Welding in these conditions
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 wire speed can be seen
in the shape of the weld deposit and heard by a smooth
regular arc sound.
FABRICATOR 140, 180
GAS METAL ARC WELDING (GMAW)
This process, also known as MIG welding, CO2 welding,
Micro Wire Welding, short arc welding, dip transfer
welding, wire welding etc., is an electric arc welding
process which fuses together the parts to be welded by
heating them with an arc between a solid, continuous,
consumable electrode and the work. Shielding is obtained
from an externally supplied gas or gas mixture. The
process is normally applied semi-automatically; however
the process may be operated automatically and can be
machine operated. The process can be used to weld thin
and fairly thick steels, and some non-ferrous metals in all
positions.
Shielding Gas
Weld Metal
Solidified Weld
Metal
Nozzle
Electrode
Arc
Base Metal
Art: A-05103
Figure 4-2: GMAW Process
FLUX CORED ARC WELDING (FCAW)
This process also known as Dual-Shielded, Innershield,
FAB Shield, FabCO, etc., is an electric arc welding process
which fuses together the parts to be welded by heating
them with an arc between a continuous flux filled electrode
wire and the work. Shielding is obtained through
decomposition of the flux within the tubular wire.
Additional shielding may or may not be obtained from an
externally supplied gas or gas mixture. The process is
normally applied semi-automatically; however the process
may be applied automatically or by machine. It is
commonly used to weld large diameter electrodes in the
flat and horizontal position and small electrode diameters
in all positions. The process is used to a lesser degree for
welding stainless steel and for overlay work.
Gas (optional)
Molten Metal
Solid Weld
Metal Molten
Slag
Slag
Nozzle (optional)
Flux Cored
Electrode
Arc
Art: A-05104
Figure 4-3: FCAW Process
January 25, 2008
4-5
Manual 0-4992
FABRICATOR 140, 180
OPERATION
!
WARNING
Follow these instructions only after referring to the Safety Instructions and Warnings chapter of this manual,
and the instructions in the Installation chapter
Check List Before Starting
POLARITY – DCEP (Direct Current Electrode Positive) or DCEN (Direct Current Electrode Negative)
WIRE FEED SPEED – 1 to 10
VOLTAGE RANGE SWITCH SETTING – 1 to 4
GAS FLOW RATE – 15 to 25 CFH
ELECTRODE WIRE STICK-OUT – approx 3/8” (10mm)
4.07 Welding Gun Positions
The welding gun should be held at an angle to the weld joint (see Secondary Adjustment Variables in Section 4.08).
Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses.
CAUTION
Do not pull the welding gun back when the arc is established. This will create excessive wire extension (stickout)
and make a very 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
Longitudinal
Angle
5 to 15º
Longitudinal Angle
90º
Transverse
Angle
Direction of
Travel
Direction of
Travel
30 to 60º
Transverse Angle
Art: A-05107
Art: A-05105
Figure 4-6: Horizontal Fillet Weld
Figure 4-4: Butt and Horizontal Welds
10º Longitudinal Angle
Direction of Travel
10 to 20º Longitudinal
Angle
30 to 60º
Transverse Angle
30º to 60º
Transverse
Angle
30 to 60º
Transverse
Angle
5 to 15º
Longitudinal
Angle
Art: A-05108
Art: A-05106
Direction of Travel
Figure 4-7: Overhead
Figure 4-5: Vertical Weld
Manual 0-4992
4-6
January 25, 2008
OPERATION
FABRICATOR 140, 180
2. Wire Feed Speed. Increase in wire feed speed
increases weld current. Decrease in wire feed speed
decreases weld current.
4.08 MIG Welding (GMAW) Variables
Most of the welding done by all processes is on carbon
steel. The following items describe the welding variables
in short-arc welding of 24 gauge (0.024”, 0.6mm) to ¼”
(6.4mm) mild sheet or plate. The applied techniques and
end results in the GMAW process are controlled by these
variables.
3. Nozzle Angle. (Figures 4-9 and 4-10) This refers to
the position of the welding gun in relation to the
joint. The transverse angle is usually one half the
included angle between plates forming the joint. The
longitudinal angle is the angle between the center
line of the welding gun and a line perpendicular to
the axis of the weld. The longitudinal angle is
generally called the Nozzle Angle and can be either
trailing (pulling) or leading (pushing). Whether the
operator is left-handed or right-handed has to be
considered to realize the effects of each angle in
relation to the direction of travel.
Pre-selected Variables
Pre-selected variables depend upon the type of material
being welded, the thickness of the material, the welding
position, the deposition rate and the mechanical
properties. These variables are:
1. Type of electrode wire
2. Size of electrode wire
Transverse
Angle
3. Type of gas (not applicable to self-shielding wires
FCAW)
4. Gas flow rate (not applicable to self-shielding wires
FCAW)
Primary Adjustable Variables
Longitudinal
Angle
These control the process after Pre-selected Variables
have been found. They control the penetration, bead width,
bead height, arc stability, deposition rate and weld
soundness. They are:
Axis of Weld
Art: A-05110
1. Arc Voltage
2. Welding Current (wire feed speed)
Figure 4-9: Transverse and Longitudinal Nozzle Axes
3. Travel Speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable
variables which in turn cause the desired change in the
bead formation. They are:
Direction of Gun Travel
1. Stickout—distance between the end of the
contact tube (tip) and the end of the electrode
wire. Keep this at about 3/8” (10mm) stickout
(as shown in Figure 4-8).
Gas Nozzle
Tip to Work
Distance
Art # A-05111
Leading or "Pushing"
Angle (Forehand)
Trailing or "Pulling"
Angle (Backhand)
Figure 4-10: Nozzle Angle, Right-Handed Operator
Contact Tip (Tube)
Electrode Wire
Actual Stickout
Average Arc Length
90º
Art: A-05109
Figure 4-8: Electrode Stick-Out
January 25, 2008
4-7
Manual 0-4992
FABRICATOR 140, 180
4.09 Establishing the Arc and Making
Weld Beads
OPERATION
4.11 Welding Procedure
1. Maintain the tip to work distance (stickout) at 5/16”
to 3/8” (8 to 9mm) at all times.
Before attempting to weld on a finished piece of work, it
is recommended that practice welds be made on a sample
metal of the same material as that of the finished piece.
2. For transverse and longitudinal nozzle angles, see
section 4.07 Welding Gun Positions.
3. Hold the gun about 3/8” (9mm) from the work, lower
the helmet by shaking your head and squeeze the
trigger to start the wire feeding, and establish the
arc.
NOTE
The easiest MIG welding procedure for the beginner to
experiment with, is the flat position. This equipment is
capable of flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 or
18 gauge (0.06” 1.5mm or 0.08” 2.0mm) mild steel plate
6” x 6” (150 x 150mm). Use 0.024” (0.6mm) wire and
CO2 shielding gas.
Get in the habit of shaking the helmet down,
rather than using the hands. One hand must
hold the gun, and the other is often needed to
hold pieces to be tacked or positioned.
4.10 Pre-Weld Procedure
1. Check the OPERATION chapter of this manual for
details on this equipment.
4. Make a single down-hand (pulling) stringer weld
bead.
2. Set the welding voltage range switch at position 1
or 2.
5. Practice welding beads. Start at one edge and weld
across the plate to the opposite edge.
NOTE
3. Set the wire feed speed control to about the 2.5
setting. Readjust as necessary.
When the equipment is properly adjusted, a
rapidly cracking or hissing sound of the arc is
a good indicator of correct arc length.
4. Adjust the gas flow rate to about 20 cubic feet per
hour (15 - 20 lpm).
5. Review standard safe practice procedures in
ventilation, eye and face protection, fire, compressed
gas and preventative maintenance. See Safety
Instructions and Warnings chapter included in this
manual.
6. Practice stopping in the middle of the plate, restarting
into the existing weld crater and continuing the weld
bead across the plate.
NOTE
When the gun trigger is released after welding,
the electrode forms a ball on the end. To the
new operator, this may present a problem in
obtaining the penetration needed at the start
of the next weld. This can be corrected by
cutting the ball off with wire cutters.
Manual 0-4992
4-8
January 25, 2008
OPERATION
FABRICATOR 140, 180
4.12 Reference Tables
The following tables are provided as user aids when performing MIG or FLUX CORED welding.
Type of Gas
Carbon Dioxide (CO2)
Argon (Ar) - Carbon Dioxide (CO2)
Argon (Ar)
Typical Mixtures
Primary Uses
Mild and low alloy steels
75% Ar – 25% CO2 Mild and low alloy steels, Stainless Steel
Aluminum
Result Desired
Welding Variable
Travel Nozzle Angle
Speed
Arc
Welding Current
Voltage (wire speed)
Deeper
Penetration
1
Shallower
Penetration
1
Larger Bead
1
Increase
2
Decrease
3
Smaller Bead
2
Decrease
2
3
1
Higher
Decrease
Narrower Bead
Flatter Wider 1Increase
Bead
Faster
Deposition Rate
Slower
Deposition Rate
3
Stick out
Increase
Trailing Max
25°
3
Decrease
Leading
2
Wire
size
Decrease
5
2
5
Increase
Smaller
(*)
Gas
Type
4
CO2
Larger 4Ar CO2
mix
Increase
(*)
Increase
Trailing
Decrease
(*)
3
Increase
2
3
2
90° or
Leading
Decrease
1
Increase
2
Increase
(*)
3
1
Decrease
2
Decrease
(*)
3
Smaller
Larger
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.
January 25, 2008
4-9
Manual 0-4992
FABRICATOR 140, 180
OPERATION
4.13 Fabricator 140 Welding Setting Selection Guide
Material Type
Wire Type
Shielding Gas
and Flow Rate
Wire Size
(Diameter)
.023” (0.6mm)
100% CO2
25cfh
Steel
.030” (0.8mm)
Solid
(or hard)
.035” (0.9mm)
ER70S-6
.023” (0.6mm)
75% Ar
25% CO2
25cfh
.030” (0.8mm)
.035” (0.9mm)
Steel
Flux Core
E71T-GS
*** Aluminum
Aluminum
Stainless
Steel
Stainless
Steel
ER 308L
Art # A-07960
Manual 0-4992
4-10
None
Required
100% Ar
25cfh
75% Ar
25%CO2
25cfh
90% He
7.5% Ar
2.5 CO2
35cfh
.030” (0.8mm)
.035” (0.9mm)
.030” (0.8mm)
.035” (0.9mm)
.023” (0.6mm)
.030” (0.8mm)
.023” (0.6mm)
.030” (0.8mm)
January 25, 2008
OPERATION
FABRICATOR 140, 180
4.13 Fabricator 140 Welding Setting Selection Guide (con't)
OFF
ARRÊT
0
Voltage
Step
Wire
Speed
1
2
3
THICKNESS
4
22 ga. (0.8mm) 20 ga. (0.9mm) 18 ga. (1.2mm) 1/16” (1.6mm)
1
1
1.5
1.4
1
1
1.5
1.4
2
2
2
1.4
3
3
3
1
1
1.5
1
1
1
1
1
1
1.2
1
1
1
1
1.5
1
1
1.2
1
2.5
2
2
2
2
2
2
1
2
2
2
2
January 25, 2008
2
1.8
2
1.5
2
2
2
2
2
1.4
1.3
1.5
1.4
3.2
2.4
2
1.8
2
1.5
3
3
3
3
3
3
3
3
3
3
3
4-11
3
2
1.5
3.5
2
1.7
2
1.7
4
4
3.5
2.5
3.5
2.3
1/8” (3mm)
4
4
4
4
4
4
4
4
4
4
4
4
4
4
5
3
2.2
5
3.5
2.5
2.5
2.7
5
4.5
3/16” (4.5mm)
4
4
4
4
4
4
4
4
4
4
5
3
2.2
5.5
3.5
2.5
3.2
2.7
5
5.2
6
3.5
7
3.5
Manual 0-4992
FABRICATOR 140, 180
OPERATION
4.14 Fabricator 180 Welding Setting Selection Guide
Material Type
Wire Type
Shielding Gas
and Flow Rate
Wire Size
(Diameter)
.023” (0.6mm)
100% CO2
25cfh
Steel
.030” (0.8mm)
Solid
(or hard)
.035” (0.9mm)
ER70S-6
.023” (0.6mm)
75% Ar
25% CO2
25cfh
.030” (0.8mm)
.035” (0.9mm)
92% Ar
8% CO2
.035” (0.9mm)
.030” (0.8mm)
Steel
Flux Core
E71T-GS
None
Required
.035” (0.9mm)
.045” (1.2mm)
Aluminum
Aluminum
100% Ar
25cfh
.030” (0.8mm)
.035” (0.9mm)
Stainless
Steel
Stainless
Steel
ER 308L
Art # A-07959
Manual 0-4992
4-12
90% He
7.5% Ar
2.5 CO2
35cfh
.025” (0.6mm)
.030” (0.8mm)
.035” (0.9mm)
January 25, 2008
OPERATION
FABRICATOR 140, 180
4.14 Fabricator 180 Welding Setting Selection Guide (con't)
OFF
ARRÊT
0
Voltage
Step
Wire
Speed
1
6
2
5
3
THICKNESS
4
22 ga. (0.8mm) 20 ga. (0.9mm) 18 ga. (1.2mm) 1/16” (1.6mm)
1
1
1.6
1.4
1
1
1
1
1
1.6
1.5
1
1
1
1.6
1.4
1.2
1.6
1.5
1.3
1
1
2
1
1
1
1.9
1.5
1.4
2
1.5
1.4
3
3
3
3
2
2
3.5
2.3
1.7
3.5
2
1.6
1/8” (3mm)
5
4
4
4
3
3
6.5
3
2.4
5.5
2.5
2
3/16” (4.5mm) 1/4” (6.4mm)
5
5
5
4
4
4
6
1
1
1.6
1.4
2
2
3
3
3
2
2
2
January 25, 2008
2.6
2
2
2
2
2
1.9
1.6
1.8
3.5
3.5
3
2
2
4-13
4
4
4
4
4
4
3
3
4.3
3
2
4.5
4.7
3.6
2.5
2.5
5
5
4
5
5
5
5
5
10
5.3
3.5
5.5
4.3
3.3
4.2
6
5.5
2.5
6
6.2
5.7
5
6
5
5
5
5
6
6
6
6
6
5
5
10
7.4
3.7
10
6
4.5
4.2
10
6
3.5
10
6.2
5.7
3.7
3
Manual 0-4992
FABRICATOR 140, 180
OPERATION
4.15 Gas Selection for Gas Metal Arc Welding
Metal Type
Carbon
Steel
Base Plate
Thickness
Filler
Metal
Greater than
22 gauge
(.030”)
ER70S-X
Short
Circuit
100% CO2
All Position High welding speeds. Good
Welding penetration and pool control.
Greater than
22 gauge
(.030”)
ER70S-X
Short
Circuit
75% Argon
25% CO2
All Position Suitable for high-current and highWelding speed welding.
Greater than
22 gauge
(.030”)
ER70S-X
Short
Circuit
92% Argon
8% CO2
All Position Higher deposition rates without meltWelding through. Minimum distortion and
spatter. Good pool control for out-ofposition welding.
Spray
Transfer
92% Argon
8% CO2
Greater than ER70S-X
10 gauge (1/8”)
Low Alloy
and
High Alloy
Steel
Stainless
Steel
Aluminum
Transfer Suggested
Mode Shielding Gas
Welding
Positions
Flat & HV
Fillet
Comments
Good arc stability, weld soundness,
and increasing width of fusion.
Greater than
22 gauge
(.030”)
See Note 1
Short
Circuit
Globular
75% Argon
25% CO2
All Position High welding speeds. Good
Welding penetration and pool control.
Applicable for out-of-position welds.
Suitable for high-current and highspeed welding.
Greater than
22 gauge
(.030”)
See Note 1
Short
Circuit
92% Argon
8% CO2
All Position Good coalescence and bead contour.
Welding Good mechanical properties.
Greater than
3/32”
See Note 1
Spray
transfer
92% Argon
8% CO2
Greater than
14 gauge
(.075”)
See Note 1
Short
Circuit
98% Argon
2% CO2
All Position Good control of melt-through and
Welding distortion. Used also for spray arc
welding. Pool fluidity sometimes
sluggish depending on the base alloy.
Greater than
22 gauge
(.030”)
ER308-X
ER309-X
ER316-X
Short
Circuit
90% Helium
7.5% Argon
2.5% CO2
or
81% Argon
18% Helium
1 % CO2
All Position Low CO2 percentages in Helium mix
Welding minimizes carbon pickup, which can
cause intergranular corrosion with
some alloys. Helium improves wetting
action and contour. CO2 percentages
above 5% should be used with caution
on some alloys.
Greater than
3/32”
ER308-X
ER309-X
ER316-X
Spray
Transfer
90% Helium
7.5% Argon
2.5% CO2
or
81% Argon
18% Helium
1 % CO2
Greater than
18 gauge
(.045”)
ER4043
ER5356
Spray
Transfer
Argon
Flat & HV
Fillet
Flat & HV
Fillet
Reduces undercutting. Higher
deposition rates and improved bead
wetting. Deep penetration and good
mechanical properties.
Good arc stability. Produces a fluid
but controllable weld pool, good
coalescence, and bead contour.
Minimizes undercutting on heavier
thickness.
All Position Excellent cleaning action. Provides
Welding more stable arc than helium-rich
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
5.01 Cleaning of the Unit
5.04 Solving Problems Beyond the
Welding Terminals
Periodically remove the right side panel (after
disconnecting the supply cord from the receptacle) and
blow out the interior with clean, dry, compressed air of
not more than 25 PSI air pressure. Do not strike any
components with the air hose nozzle.
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:
5.02 Cleaning of the Feed Rolls
1. Porosity
Clean the wire groove on the feed roll at frequent intervals.
This cleaning operation can be done by using a small wire
brush. To clean the wire groove, loosen the pressure
device and lift the feedroll pressure arm. Remove all wire
from the feedhead. Wipe off the bearing roll (the “top”
roll in the feedhead).
5.03 Basic Troubleshooting
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.
The basic level of troubleshooting is that which can be
performed without special equipment or knowledge, and
without removing the covers from the Power Source.
a. Ensure that the gas cylinder is not empty and
the flow meter is correctly adjusted to 20CFM
(15 liters per minute).
If major components are faulty, then the Power Source
should be returned to an Accredited THERMAL ARC
Service Agent for repair.
2. Gas leaks
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.
January 25, 2008
5-1
Manual 0-4992
FABRICATOR 140, 180
BASIC TROUBLESHOOTING
7. Maintain the MIG torch in good working order.
6. Incorrect or worn contact tip.
a. Ensure that the gas holes are not blocked and
gas is exiting out of the torch nozzle. Refer to
WARNING below.
a. The contact tip transfers the weld current to
the electrode wire. If the hole in the contact tip
is too large, then arcing may occur inside the
contact tip resulting in the electrode wire
jamming in there. When using soft electrode
wire such as aluminum, the wire 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.
b. Do not restrict gas flow by allowing spatter to
build up inside the MIG torch nozzle.
!
WARNING
7. Poor work lead contact to work piece.
Disengage the drive roll when testing for gas
flow by ear.
a. 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 arc.
2. Inconsistent wire feed
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.
Manual 0-4992
5-2
January 25, 2008
BASIC TROUBLESHOOTING
FABRICATOR 140, 180
5.05 Welding Problems
FAULT
1 Undercut.
2 Lack of penetration.
CAUSE
A Welding arc voltage
too high.
REMEDY
A Reduce voltage by reducing the voltage
selection switch position or increase the
wire feed speed.
B Adjust angle
B Incorrect torch
angle
C Excessive heat input C Increase the torch travel speed and/or
reduce welding current by reducing the
voltage selection switch position or
reducing the wire feed speed.
A Welding current too A Increase welding current by increasing
low
wire feed speed and increasing voltage
selection switch position.
B Joint preparation
B Increase joint angle or gap
too narrow or gap
i h gas
C Shielding
C Change to a gas which gives higher
incorrect
Voltage too low
penetration
3 Lack of fusion.
Increase voltage by increasing voltage
selection switch position.
4 Excessive spatter.
A Voltage too high
A Lower voltage by reducing the voltage
selection switch or increase wirespeed
control.
B Voltage too low
B Raise voltage by increasing the voltage
selection switch or reduce wirespeed
control.
A Adjust voltage and current by adjusting
5 Irregular weld shape. A Incorrect voltage
the voltage selection switch and the
and current settings.
wirespeed control.
Convex = voltage too
low. Concave =
voltage too high.
B Wire is wandering
B Replace contact tip
C Incorrect shielding C Check shielding gas
gas
D Insufficient or
D Adjust the wirespeed control or the
excessive heat input
voltage selection switch
Table 5-1a: Welding Problems
January 25, 2008
5-3
Manual 0-4992
FABRICATOR 140, 180
CAUSE
FAULT
6 Weld cracking
BASIC TROUBLESHOOTING
A Weld beads too small
B Weld penetration
narrow and deep
C Excessive weld
stresses
D Excessive voltage
E
7 Cold weld puddle
Cooling rate too fast
A Faulty rectifier unit
REMEDY
A Decrease travel speed
B Reduce current and voltage and increase MIG
torch travel speed or select a lower penetration
shielding gas.
C Increase weld metal strength or revise design
D Decrease voltage by reducing the voltage
selection switch.
E Slow the cooling rate by preheating part to be
welded or cool slowly.
A Have an Accredited THERMAL ARC Service
Agent to test then replace the faulty
component.
B Check all welding cable connections.
B Loose welding cable
connection.
C Low Primary Voltage
C Contact supply authority
8 Arc does not have a crisp
The MIG torch has been
Connect the MIG torch to the positive (+)
sound that short arc
connected to the wrong
welding terminal for solid wires and gas
exhibits when the
voltage polarity on the
shielded flux cored wires. Refer to the electrode
wirefeed speed and
front panel.
wire manufacturer for the correct polarity.
voltage are adjusted
correctly.
Table 5-1b: Welding Problems Continued
Manual 0-4992
5-4
January 25, 2008
BASIC TROUBLESHOOTING
FABRICATOR 140, 180
5.06 Power Source Problems
FAULT
1 Primary line voltage is
ON. Welding arc can not
be established.
CAUSE
A Primary fuse is blown.
REMEDY
A Replace primary fuse.
B Broken connection in primary B Have an Accredited THERMAL ARC Service Agent check
circuit.
primary circuit.
MIG Gun trigger switch leads
Reconnect.
are disconnected.
2 Primary line voltage is
ON but when the MIG
Gun trigger switch is
depressed nothing
happens.
3 Primary line voltage is
A Electrode wire stuck in wire
A Check for clogged / kinked MIG Gun wire liner or worn
contact tip. Replace faulty component(s).
ON, no wire feed but gas
liner or contact tip (burn-back
flows from the MIG Gun
jam).
when the torch trigger
switch is depressed.
B Faulty control PCB
B Have an Accredited THERMAL ARC Service Agent
investigate the fault.
4 Wire feeds when the MIG
Poor or no work lead
Clean work clamp area and ensure good electrical contact.
Gun trigger switch is
connection.
depressed but arc can
not be established.
5 Jerky wire feed
A Worn or dirty contact tip
A Replace
B Worn feed roller.
B Replace
C Excessive back tension from C Reduce brake tension on spool hub
wire reel hub.
D Worn, kinked or dirty conduit D Clean or replace conduit liner
liner
6 No gas flow
A Gas hose is cut.
A Replace or repair.
B Gas passage contains
B Disconnect gas hose from the rear of FABRICATOR then
impurities.
raise gas pressure and blow out the impurities.
C Gas regulator turned off.
C Turn on.
7 Gas flow continues after
Gas valve has jammed open
Have an Accredited THERMAL ARC Service Agent repair or
the MIG Gun trigger
due to impurities in the gas or
replace gas valve.
switch has been
the gas line.
released.
Table 5-2: Power Source Problems
January 25, 2008
5-5
Manual 0-4992
FABRICATOR 140, 180
Manual 0-4992
BASIC TROUBLESHOOTING
5-6
January 25, 2008
ADVANCED TROUBLESHOOTING
FABRICATOR 140, 180
SECTION 6:
ADVANCED TROUBLESHOOTING
6.01 Pre Power-Up Checks
6.03 Primary Power Test
1. Perform Rectifier Assembly Test Procedure section
6.11.
A. Close the Primary Line Disconnect and observe the
following:
1. Unit should remain off, nothing happens.
2. Perform C1 & C2 Test Procedure Section 6.13.
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
This section is to help isolate the defective circuit before
troubleshooting, identify symptoms, and test the unit for
proper operation. Follow the instructions as given to
identify the possible symptom(s) and the defective circuit.
After repairs are complete, run the following tests again
to verify that the unit is fully operational.
1. Green AC LED turns on.
2. Fan turns on.
3. OVERTEMP LED is off.
4. Output Voltage measures 0 VDC.
B. Adjust the inlet pressure to approximately 20 CFH.
Refer to page 3-4 "Adjusting Regulator".
This completes the Primary Power Test. If the above steps
were correct, proceed to the next section, Logic and
Control Test. If the unit does not function as detailed
above, note the symptom and proceed to Section 6.08
Primary Power Problems.
C. Set the power supply controls as follows:
6.04 Logic & Control Test
A. Connect the gas supply to the rear of the Power Supply.
1. VOLTAGE CONTROL SWITCH SW1 to Position 0.
A. Close the MIG gun switch.
2. WIRE SPEED CONTROL Potentiometer to 0 (Fully
Counter Clockwise).
1. Gas flows.
2. Feed roll turns slowly.
3. Connect work cable to negative (-) Polarity Change
Over terminal.
4. Disconnect the wire from the Feed Head assembly
from the positive (+) Polarity Change Over
terminal.
3. Output Voltage measures 21 VDC.
B. Release the MIG Gun Switch.
1. Gas flow stops.
2. Feed roll stops turning.
5. Open the PRESSURE ADJUST DEVICE so the wire
will not feed.
6. With the Primary Line Disconnect in the OFF
position, plug the input power cord into the
primary line outlet.
3. Output Voltage slowly decreases to 0 VDC.
C. Disconnect one of the wires connected to the
temperature switch located on the rectifier heat sink:
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.
January 25, 2008
6-1
Manual 0-4992
FABRICATOR 140, 180
E. Release the MIG gun switch. Reconnect the wire to
the temperature switch. Close the MIG gun switch and
observe the following:
1. Gas flows.
ADVANCED TROUBLESHOOTING
6.06 Output Voltage Test
A. Connect a voltmeter to the Positive and Negative
Polarity Change Over terminals. Close the MIG gun
switch and record the voltage displayed.
2. Feed roll turns slowly.
1. Repeat the check for each of the VOLTAGE
CONTROL SWITCH settings. The voltages should
measure approximately as outlined in the
following charts:
3. Output Voltage measures 21 VDC.
F. Release the MIG gun switch.
1. Gas flow stops.
2. Feed roll stops turning.
3. Output Voltage reading slowly decreases to 0 VDC.
G. Connect a DC Voltmeter to the two wires connected
to the Wire Feed Motor (M2). Close the MIG gun switch
and vary the WIRE SPEED CONTROL Potentiometer
from minimum "0" to maximum (10) setting.
1. Feed roll speed will increase with potentiometer
increase.
2. Motor voltage should vary from approximately 2
VDC to 19VDC.
This completes the Logic & Control Test. If the above
steps were correct, proceed to the next section, Spool
Gun Control Test. If the unit does not function as detailed
above, note the symptom and proceed to Section 6.09
Logic & Control Problems.
6.05 Spool Gun Control Test
A. Remove the MIG gun plug P6 from receptacle J6.
Install a jumper between J6-2 and J6-5.
1. Gas flows.
2. Wire Feed Motor does not turn.
B. Set WIRE SPEED CONTROL potentiometer to "0"
position. Measure the voltage between J6-1 to J6-3
while adjusting the WIRE SPEED CONTROL
potentiometer from minimum to maximum setting.
1. Voltage should vary from approximately 4 VDC
to 20 VDC.
Manual 0-4992
Voltage
21
24
28
34
FABRICATOR 180
Voltage Control Switch SW1 Setting
1
2
3
4
5
6
Voltage
21
23
26
30
35
41
This completes the Output Voltage Test. If the above steps
were correct, proceed to the next section, Wire Feed &
Weld Test. If the unit does not function as detailed above,
note the symptom and proceed to Section 6.12 T1
Transformer Test.
6.07 Wire Feed & Weld Test
A. Reconnect the wires to the Polarity Change Over
terminals for Reverse Polarity (GAS). Close the
PRESSURE ADJUST DEVICE.
B. Position the gun for welding and close the MIG gun
switch.
1. Gas Flows.
2. Wire feeds out.
C. Remove the jumper and the meter from J6 and reinstall MIG gun plug P6.
This completes the Spool Gun Control Test. If the above
steps were correct, proceed to the next section, Output
Voltage Test. If the unit does not function as detailed
above, check the wire harness connections from the PCB
to J6.
FABRICATOR 140
Voltage Control Switch SW1 Setting
1
2
3
4
3. Welding arc established.
This completes the Wire Feed & Weld Test. If the above
steps were correct, the system is functioning properly. If
the unit does not function as detailed above, note the
symptom and proceed to Section 6.10 Wire Feed and Weld
Problems.
6-2
January 25, 2008
ADVANCED TROUBLESHOOTING
6.08 Primary Power Problems
FABRICATOR 140, 180
D. Green AC LED is on, fan turns, OVERTEMP LED is on.
1. The unit is overheated.
A. AC LED and fan are on, but VOLTAGE CONTROL
SWITCH SW1 is in Position "0".
a. Allow the unit to remain on with the fan running
to cool. See section 2.07 for duty cycle
information.
1. SW1 is defective.
B. Nothing happens when the VOLTAGE CONTROL
SWITCH (SW1) is turned to position "1". Green AC
LED is off and the fan does not turn.
2. Defective Temperature Switch TS1 (for Fabricator
180 the TS2 may also be defective).
a. Measure continuity of Temperature switch(es)
and replace if open.
1. Circuit Breaker (CB1) is tripped..
a. Reset CB1.
3. Open wire is temperature switch circuit.
2. Fuse F1 open.
a. Install a jumper on PCB between J5-5 to J5-6.
If the OVERTEMP LED goes out, the fault is in
the Temperature switch wiring.
a. Remove F1 and check continuity. Replace if
open.
3. Defective VOLTAGE CONTROL SWITCH (SW1).
4. Defective PCB.
a. Check continuity of SW1.
a. Install a jumper on the PCB between J5-5 to
J5-6. If the OVERTEMP LED does not go out,
replace the PCB.
4. Primary line breaker / fuse is open.
a. Measure voltage at the primary receptacle. If
voltage is not present, reset breaker / replace
the fuse.
E. Gas flows and feed roll turns without closing the MIG
gun switch.
1. MIG gun switch is shorted.
5. Primary line voltage to the unit is low.
a. Unplug MIG gun plug P6 from the CONTROL
RECEPTACLE J6.
a. Measure the voltage at the VOLTAGE
CONTROL SWITCH (SW1) between terminals
A1 to B1. Voltage should measure 120 VAC
for Fabricator 140 or 230 VAC for Fabricator
180. If the voltage is low at the unit but
measures correctly at the primary line outlet,
the primary line cord is too long or too small
to support the unit.
b. If the gas turns off and the feed roll stops
turning, the fault is in the MIG gun.
2. Defective PCB.
a. Unplug and isolate the J5 connector from the
PCB.
NOTE
b. If gas flows and the feed roll continues to turn,
replace the PCB.
Be sure to remove any extension cords and
plug the unit directly into a wall outlet.
3. Short in the wire harness.
C. Green AC LED comes on but the fan is not turning.
a. If unplugging J5 in the previous step causes
the gas and feed roll to stop, there is a short
in the wires going from J5 to J6.
1. Defective fan.
a. Measure voltage on PCB terminals J3 to JFM.
If voltage measures at 120 VAC for Fabricator
140 or 230 VAC for Fabricator 180, replace
the fan.
F. AC LED is on, fan is on, gas is off, feed rolls do not
turn but output voltage is present.
1. Defective PCB.
a. Replace PCB.
January 25, 2008
6-3
Manual 0-4992
FABRICATOR 140, 180
6.09 Logic & Control Problems
A. AC LED is on and the fan is on. Gas does not flow and
the feed roll does not turn when the MIG gun switch
is closed.
ADVANCED TROUBLESHOOTING
D. AC LED is on and the fan is on. When the MIG gun
switch is closed, gas flows, the feed roll does not turn,
and the output voltage measures 0 VDC.
1. Defective VOLTAGE CONTROL SWITCH (SW1).
a. Check continuity - See truth table on system
schematic.
1. Defective MIG gun switch.
a. Check for continuity between P6-2 to P6-5
when the gun switch is closed.
2. Defective T1 Transformer.
a. Measure the T1 secondary voltage between
terminals AC1 and AC2. See section 6.12 T1
Transformer Test.
b. If no continuity is found, the fault is in the MIG
gun.
2. Defective PCB.
3. Defective Rectifier.
a. Install a jumper between J5-7 to J5-8.
a. Check diodes - See section 6.11 Rectifier
Assembly Test.
b. If gas does not flow and feed roll does not
turn, replace the PCB.
4. Defective Working Capacitors.
B. AC LED is on and the fan is on. When the MIG gun
switch is closed, gas does not flow but feed roll does
turn.
a. Check C1 & C2 - See section 6.13 C1& C2
Test Procedure.
1. Gas supply problem.
a. Make sure the cylinder is not empty, the valve
is turned fully on and that the flow meter
regulator is adjusted properly and the supply
hose is attached to the unit.
2. Defective solenoid.
a. Replace the solenoid.
C. AC LED is on and the fan is on. When the MIG gun
switch is closed, gas flows, feed roll does not turn,
output voltage is measures 21 VDC.
1. Defective Wire Feed Motor M2.
a. Measure for DC Voltage on the PCB between
J5-1 to J5-2. If there is voltage present, replace
M2.
2. Defective PCB.
a. Measure for 21VDC on the PCB between
terminals J5-1 to J5-2. If voltage is present
with the MIG gun switch closed, replace the
PCB.
Manual 0-4992
6-4
January 25, 2008
ADVANCED TROUBLESHOOTING
FABRICATOR 140, 180
6.10 Wire Feed and Weld Problems
6.11 Rectifier Assembly Test Procedure
A. Poor or inconsistent arc transfer or no arc transfer.
A. Remove the inside cover.
1. Poor work cable connection or open work cable.
1. Disconnect and isolate the black wire from the
negative capacitor terminal (A). Refer to Figure
6-1.
a. Clean contact point where the work cable
attaches to the work piece.
2. Disconnect and isolate the transformer wire from
terminal AC1. Refer to Figure 6-1.
b. Check continuity of the work cable.
B. Other welding problems.
3. Using a multimeter set to diode test scale, perform
the checks as indicated in the chart.
1. See Section 5.04 Solving Problems Beyond the
Welding Terminals.
METER (+)
-OUT
-OUT
-OUT
+OUT
AC1
AC2
+OUT
+OUT
AC1
AC2
METER (-)
+OUT
AC1
AC2
-OUT
-OUT
-OUT
AC1
AC2
+OUT
+OUT
INDICATION
Open
Open
Open
(2) Diode drop
Diode drop
Diode drop
Diode drop
Diode drop
Open
Open
B. Replace the Rectifier Assembly if shorted or open
diode is found. Reconnect wires previously removed
from terminals A and AC1.
A
+OUT
-OUT
Art # A-08255
AC1
AC2
Figure 6-1: Rectifier Connection Points
January 25, 2008
6-5
Manual 0-4992
FABRICATOR 140, 180
ADVANCED TROUBLESHOOTING
6.12 T1 Transformer Test Procedure
Disconnect and isolate the transformer secondary wire from the Rectifier Assembly Terminal AC1. Refer to
Figure 6-1. Connect the meter between the wire that was removed from terminal AC1 to terminal AC2. Close the
MIG gun switch and observe the voltage. Repeat this test for each position of the Voltage Control Switch.
Fabricator 140
Voltage Control Switch (SW1) position #
1
2
3
4
T1 Secondary Voltage
15
18
21
25
Fabricator 180
Voltage Control Switch (SW1) position #
1
2
3
4
5
6
T1 Secondary Voltage
17
19
21
23
26
31
6.13 C1 & C2 Test Procedure
Use a Capacitor Tester if available, otherwise visually check C1 & C2 for damage and make sure the relief valve is not
blown. Disconnect one of the wires connecting C1 & C2 to the rectifier assembly. Check continuity between the two
buss bars on C1 & C2. The meter should show a charging action. Reverse the polarity of the probes and you should
see the reading decrease to zero and then start a charging action again.
Replace the capacitors if a short or open is found. Reconnect wires that were previously removed.
Manual 0-4992
6-6
January 25, 2008
PARTS LISTS
FABRICATOR 140, 180
SECTION 7:
PARTS LIST
7.01 Equipment Identification
All identification numbers as described in the Introduction
chapter must be furnished when ordering parts or making
inquiries. This information is usually found on the
nameplate attached to the equipment. Be sure to include
any dash numbers following the Specification or Assembly
numbers.
7.02 How To Use This Parts List
The Parts List is a combination of an illustration and a
corresponding list of parts which contains a breakdown
of the equipment into assemblies, subassemblies, and
detail parts. Most parts of the equipment are listed except
commercially available hardware, bulk items such as wire,
cable, sleeving, tubing, etc., and permanently attached
items which are soldered, riveted, or welded to other parts.
The part descriptions may be indented to show part
relationships.
To determine the part number, description, quantity, or
application of an item, simply locate the item in question
from the illustration and refer to that item number in the
corresponding Parts List.
CATALOG NUMBERS:
W1002500
Fabricator 140
W1002600
Fabricator 180
January 25, 2008
7-1
Manual 0-4992
FABRICATOR 140, 180
PARTS LISTS
7.03 Front Panel
Item Qty Ref
Ref.. Des.
Description
Helvi Part Number
1
1
Bezel, Front Molding, F140/180
W7004018
2
1
Bushing, Torch, F140/180
W7004016
3
1
Panel, Front, Fab140
W7004044
3
1
Panel, Front, Fab180
W7004045
4
1
Clamp, Cable, D20, F140/180
W7004003
5
1
Lead, Work w/clamp, 10ft, Fab140
W7004007
5
1
Lead, Work w/clamp, 10ft, Fab180
W7004009
6
1
Work Clamp 300A, F140/180
W7004024
7
1
Knob, Switch, 38mm OD, F140/180
W7004004
8
1
Knob,Wire Speed,38mm,F140/180
W7004017
Art # A-08256
1
8
2
7
3
4
5
Manual 0-4992
6
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
3
4
5
January 25, 2008
7-3
Manual 0-4992
FABRICATOR 140, 180
PARTS LISTS
7.05 Power Supply
Item Qty Ref
Ref.. Des.
Description
1
1
PCB1
PCB,Control,115V,Fab140
W7004034
1
1
PCB1
PCB,Control,230V,Fab180
W7004035
2
2
R1
Resistor 470 Ohm 5W,F140/180
W7004029
3
1
TS1
Thermostat 100°C 10A,F140/180
W7004028
4
1
D1-D8
Rectifier 140A,Fab140
W7004032
4
1
D1-D8
Rectifier 180A,Fab180
W7004033
5
1
Panel Top&Side,F140/180
W7004042
6
1
SOL-1
Solenoid Valve,110V60Hz,Fab140
W7004036
6
1
SOL-1
Solenoid Valve,230V60Hz,Fab180
W7004037
7
1
M1
Fan,110V,FP120/130/160-F140
1444-0486
7
1
M1
Fan Assy,230V60Hz,Fab180
W7004008
8
2
T1
Transformer 110V60Hz,Al,Fab140
W7004051
8
2
T1
Transformer 230V60Hz,Al,Fab180
W7004050
9
2
C1
Capacitor 18000mF 63V,Fab140
W7004031
9
2
C1
Capacitor 22000mF 63V,Fab180
W7004030
10
1
C1, C2
Reactor,Al,Fab140
W7004053
10
1
C1, C2
Reactor,Al,Fab180
W7004052
11
1
M2
Motor + Gearbox,F140/180
W7004002
12
1
SW1
Switch,4P6PL,Fab140
W7004025
12
1
SW1
Switch,6P7PL,Fab180
W7004026
Manual 0-4992
Part Number
7-4
January 25, 2008
PARTS LISTS
FABRICATOR 140, 180
1
2
3
4
5
8
7
6
Art # A-08258
12
January 25, 2008
11
10
9
7-5
Manual 0-4992
FABRICATOR 140, 180
PARTS LISTS
7.06 Wire Feeder Parts
Item Qty Ref
Ref.. Des.
Description
1
2
Hinge Plastic,20x30,F140/180
W7004014
2
1
Handle,F140/180
W7004012
3
1
Panel Internal,F140/180
W7004048
4
1
Drive Roll .023”-.030”/.035” (0.6-0.8/0.9mm)
5
1
Wire Feed Plate,Fab140
W7004054
5
1
Wire Feed Plate,Fab180
W7004055
6
1
Screw,Torch Lock,M6x10,F140/180
W7004021
7
1
Circuit Breaker 32A,F140/180
W7004027
8
1
Knob, Polarity Board,F140/180
W7004020
9
1
Board,Polarity Conn.,F140/180
W7004006
10
1
Latch,Door,F140/180
W7004015
11
1
Spool Hub Assy,F140/180
W7004005
12
2
Panel Base,F140/180
W7004041
13
1
Panel Door,Fab140
W7004039
13
1
Panel Door,Fab180
W7004043
Manual 0-4992
Part Number
7-6
7977036
January 25, 2008
PARTS LISTS
FABRICATOR 140, 180
1
2
3
4
5
6
9
8
7
Art # A-08259
13
January 25, 2008
12
11
10
7-7
Manual 0-4992
FABRICATOR 140, 180
PARTS LISTS
7.07 Feed Plate Parts
Item
Qty Per Assy
Description
Part Number*
1
1
Motor & Pinion,F140/180
W7004200
2
1
Arm,Pressure,F140/180
W7004201
3
1
Pressure Roll,F/140/180
W7004202
4
1
Key Drive & Spacer,F140/180
W7004203
5
1
Screw Fix,Drive Roll,F140/180
W7004204
6
1
Guide,Inlet,023-035,F140/180
W7004022
7
1
Pressure Device,F140/180
W7004205
8
4
Hex Nut, M5
See Note 1
10
1
ST-CE Screw, M 4X4
See Note 1
11
3
TCI Screw, M 5X25
See Note 1
12
3
Insulating Washer
See Note 1
Note 1: This part is availabel at most hardware stores
Manual 0-4992
7-8
January 25, 2008
PARTS LISTS
FABRICATOR 140, 180
7
2
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
See Appendix 1 and 4 for more options
3
5
January 25, 2008
7-9
Manual 0-4992
FABRICATOR 140, 180
PARTS LISTS
7.08 Accessories
Item Qty Ref
Ref.. Des.
Description
Part Number
1
1
Alternative Firepower Regulator
0781-9851
2
1
Torch MIG,180A,Fab140/180,10ft
W4011400
3
1
.023" MILD-STEEL WIRE SPOOL
1440-0210
3
1
.030" MILD-STEEL WIRE SPOOL
1440-0215
4
1
Gas Hose,1/4"IDx59",F140/180
W7004040
1
2
Art # A-08260
4
Manual 0-4992
3
7-10
January 25, 2008
APPENDIX
FABRICATOR 140, 180
APPENDIX 1: OPTIONS AND ACCESSORIES
• Contact your Thermal Arc distributor to order options and accessories. For assistance in locating a Thermal Arc
distributor, contact the Thermadyne office listed in the inside rear cover that is nearest to you.
• Note the model and specification number shown on the equipment nameplate.
For Tweco/Victor Inquiries and Orders:
Call 1-800-318-6819 Consumable Parts Management Group
EQUIPMENT OPTIONS
PART NO
Description
W4011400
Gun Assembly with 10ft cable (supplied with package), 180
Amp @ 30%
GUNS
Tweco® WeldSkill 10ft
ACCESSORIES
Victor Regulator/Flowmeter Mixed Gases
0781-2723
Victor Regulator/Flowmeter CO2
CONSUMABLES
Feedroll Kits
Feedroll .023”-.030”/.035” (0.6-0.8/0.9mm)
Feedroll .035”-.045” (0.9-1.2mm)
Feedroll .030”-.035” (0.8-0.9mm)
Feedroll .040”-.045” (1.0-1.2mm)
Feedroll .030”-.035” (0.8-0.9mm)
Feedroll .045”-.1/16” (1.2-1.6mm)
Contact Tips
0781-2725
Medalist™ 1400 Series, HRF Flowmeter Regulator, ArgonArgon/CO2 mix gases
Medalist™ 1400 Series, HRF Flowmeter Regulator, CO2 gas
7977036
7977660
7977731
7977264
7977732
704277
V grooved for hard wire
V grooved for hard wire
U grooved for soft wire
U grooved for soft wire
V grooved knurl for cored wire
V grooved knurl for cored wire
11-23
11-30
11-35
11-40
11-45
.023” (0.6mm)
.030” (0.8mm)
.035” (.09mm)
.040” (1.0mm)
.045” (1.2mm)
21-37
21-50
21.62
3/8” (9.5mm)
1/2” (12.7mm)
5/8” (16mm)
42-23-15
42-3035-15
42-4045-15
42N-3545-15
51
.023”, 15 ft.(7.6m)
.030-.035”, 15ft. (4.5m)
.040-.045”, 15ft. (4.5m)
.035-3/64”, 15ft. (4.5m)
Nozzles
Wire Liners
Gas Diffuser
January 25, 2008
A-1
Manual 0-4992
FABRICATOR 140, 180
APPENDIX
APPENDIX 2: FABRICATOR 180 SYSTEM SCHEMATIC
4
5
CB1
L1
D
A1
230 VAC 1PH
60Hz
L2
3
T1
PCB1
J4
J1
R/L1
A
SW1
1
1
2
2
3
3
4
4
5
5
SW1
B1
B
S/L2
GND
SOL1
M1
JFM
F1
FAN
J3
C
J2
J5
V+
VM+
MTS1
COM
COM
GUN SW
B
OVERTEMP
1
2
3
4
5
6
7
8
TS1 (DIODE HEATSINK)3
TS1 (T1)
AC
WIRE SPEED
YELLOW
GREEN
A
Art # A-07918_AB
5
Manual 0-4992
3
4
A-2
January 25, 2008
APPENDIX
FABRICATOR 140, 180
2
1
GAS / NO GAS POLARITY
CHANGE OVER
+
D1
D2
D3
POS
D4
D
RV1
C1
D5
D6
D7
C2
+
+
R1
D8
L3
-
NEG
INDUCTOR
C
CONTROL
RECEPTACLE
MIG GUN
PLUG
J6
-
WFM
+
+
M3
-
P6
P6
1
2
3
4
5
6
M2
SPOOL GUN
PLUG
1
2
3
4
5
6
SW3
1
2
3
4
5
6
SW4
J6 RECEPTACLE
FRONT VIEW
2
3
Rev
D
O
D
Revisions
O
D
O
1
By
B
4
5
6
Date
<RevCode>
A THERMADYNE COMPANY
INDUSTRIAL PARK #2
WEST LEBANON, NH 03784
(603) 298-5711
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED 1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).
TITLE:
SCHEMATIC,
FABRICATOR 180
Last Modified: Tuesday, July 24, 2007
15:02:51
2
January 25, 2008
PCB No:
Assy No:
References
A
Scale
Supersedes
Monday, July 23, 2007
Drawn:
Date:
Sheet
1 of
Chk:
App:
Size
DWG No:
1
1
A-3
Manual 0-4992
FABRICATOR 140, 180
APPENDIX
APPENDIX 3: FABRICATOR 140 SYSTEM SCHEMATIC
4
5
3
D
T1
CB1
L1
BLK
A1
120 VAC
60Hz
L2
PCB1
J4
SW1
J1
SW1
WHT
1
2
2
3
3
4
4
R/L1
A
B1
1
B
SOL1
GND
GRN
M1
JFM
F1
FAN
J3
C
J2
J5
V+
VM+
MTS1
COM
COM
GUN SW
OVERTEMP
1
2
3
4
5
6
7
8
TS1 (DIODE HEATSINK)
AC
WIRE SPEED
B
YELLOW
GREEN
A
Art # A-07919_AB
5
Manual 0-4992
4
A-4
3
January 25, 2008
APPENDIX
FABRICATOR 140, 180
2
1
GAS / NO GAS POLARITY
CHANGE OVER
D1
D2
D3
+
POS
-
NEG
D
D4
RV1
C1
D5
D6
D7
C2
+
+
R1
D8
L3
INDUCTOR
C
CONTROL
RECEPTACLE
MIG GUN
PLUG
P6
J6
1
2
3
4
5
6
M2
-
WFM
+
SPOOL GUN
PLUG
+
M3
-
P6
SW3
1
2
3
4
5
6
1
2
3
4
5
6
SW4
B
J6 RECEPTACLE
FRONT VIEW
2
3
Rev
D
O
D
Revisions
O
D
O
1
By
4
5
6
Date
<RevCode>
A THERMADYNE COMPANY
INDUSTRIAL PARK #2
WEST LEBANON, NH 03784
(603) 298-5711
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED 1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF).
TITLE:
2
January 25, 2008
A
Scale
Supersedes
Monday, July 16, 2007
Drawn:
Date:
Chk:
SCHEMATIC,
FABRICATOR 140
Last Modified: Tuesday, July 24, 2007
15:56:58
PCB No:
Assy No:
References
Size
Sheet
1 of
DWG No:
App:
1
1
A-5
Manual 0-4992
FABRICATOR 140, 180
APPENDIX
APPENDIX 4: FEED ROLL KITS
FEED ROLL INSTALLATION & PARTS GUIDE
.030
0.8
Part No.
7977036
7977660
7977731
7977732
7977264
704277
W7004022
Description
Feed Roll .023/.030” (0.6 / 0.8mm) Hard Wire
Feed Roll .035/.045” (0.9 / 1.2mm) Hard Wire
Feed Roll .030/.035” (0.8 / 0.9mm) Soft Wire
Feed Roll .030/.035” (0.8 / 0.9mm) Cored Wire
Feed Roll .040/.045” (1.0-1.2mm) Soft Wire
Feed Roll .045/1/16” (1.2 / 1.6mm) Cored Wire
Guide, Inlet, 023-035
Size visible when
fitting the feedroll is
the groove size in use
Manual 0-4992
A-6
January 25, 2008
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
July 2007
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warranty
appear within the warranty period stated below, Thermal Arc 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 damage, correct such defects by suitable repair or
replacement, at Thermal Arc's sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of
merchantability, fitness for any particular purpose, or other warranty of
quality, whether express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special,
indirect, incidental, or consequential damages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc 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, tort, including negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warranty
are void if the product is sold to purchaser by unauthorized persons.
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.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned goods
shall be at the Purchaser's risk and expense. This warranty dated July 1st 2007
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
July 2007
ENGINE DRIVEN WELDERS
W ARRANTY P ERIOD
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
LABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer ............................................................. See the Engine Manufactures Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Fabricator 131, 181; 140; 180; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
PLASMA WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
1 year
SMAW (Stick) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
GENERAL ARC EQUIPMENT
W ARRANTY P ERIOD
LABOR
Water Recirculators ....................................................................................................................... 1 year
1 year
Plasma Welding Torches.............................................................................................................180 days
180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
Nil
Nil
MIG, TIG and Plasma welding torch consumable items................................................................... Nil
Nil
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX:
(636) 728-3010
Email: [email protected]
www.thermalarc.com