Thermal Arc 281 FABRICATOR Bedienungsanleitung

208

V230

FABRICATOR®

MIG WELDING MACHINE

281

Service

Manual

Version No: AE.01 Issue Date: June 9, 2006 Manual No.: 0-4880B

Operating Features:

Art # A-07447

WARNINGS

Read and understand this entire Manual and youremployer’s safety practices before installing,

operating, orservicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement,

the Manufacturerassumes no liability forits use.

Fabricator281 MIG Welding Machine

Service Manual Number0-4880B for:

Package System Part NumberW1001600

PowerSource Part Number707300

Published by:

Thermadyne Inc.

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermalarc.com

Thermadyne Industries Inc.

Reproduction of this work, in whole orin part, without written permission of the pub-

lisheris prohibited.

The publisherdoes not assume and hereby disclaims any liability to any party forany

loss ordamage caused by any errororomission in this Manual, whethersuch error

results from negligence, accident, orany othercause.

Publication Date: June 9, 2006

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 Principal Safety Standards ............................................................................. 1-4

1.03 Precautions De Securite En Soudage A L’arc .................................................. 1-5

1.04 Dangers relatifs au soudage à l’arc................................................................. 1-5

1.05 Principales Normes De Securite ..................................................................... 1-8

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 General Information ....................................................................................... 2-3

2.06 Safety ............................................................................................................. 2-3

2.07 Protective FilterLenses .................................................................................. 2-3

2.08 UserResponsibility ........................................................................................ 2-4

2.10 Specifications ................................................................................................. 2-4

2.09 Duty Cycle ...................................................................................................... 2-4

2.11 Included Items ............................................................................................... 2-6

2.12 Optional Accessories ...................................................................................... 2-6

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location ......................................................................................................... 3-1

3.03 Ventilation ...................................................................................................... 3-1

3.04 Primary Input Voltage Requirements ............................................................. 3-2

3.05 Alternative Primary Input Voltages ................................................................. 3-2

3.06 Quick Setup .................................................................................................... 3-4

3.07 Mount the A2281 Wire Feeder........................................................................ 3-5

3.08 Installation of Shielding Gas (GMAW) Process .............................................. 3-6

3.09 Attaching the Gun and Cable Assembly to the Remote Feeder....................... 3-8

3.10 Selection and Installation of Feedrolls .......................................................... 3-10

3.11 Input And Output Wire Guide Installation ..................................................... 3-10

3.12 Installing Wire Spool on the Remote ............................................................ 3-11

3.13 Inserting Wire into the Feedhead.................................................................. 3-12

3.14 WirefeederFeedroll Pressure Adjustment .................................................... 3-13

3.15 Wire Spool Hub Brake .................................................................................. 3-13

3.16 Spool Gun Attachment ................................................................................. 3-14

3.17 Polarity Changeover..................................................................................... 3-15

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:

OPERATION ........................................................................................... 4-1

4.01 PowerSupply Controls, Indicators and Features ............................................ 4-1

4.02 Internal Controls of A2281 Remote ................................................................ 4-7

4.03 TWECO Weldskill 300 AMP Weld Gun ............................................................ 4-9

4.04 Installing A New Wire Conduit ...................................................................... 4-10

4.05 MIG Gun Maintenance .................................................................................. 4-11

4.06 Basic Welding Technique .............................................................................. 4-11

4.07 Stitch Welding Operation.............................................................................. 4-14

4.08 Spot Welding Operation ............................................................................... 4-14

4.09 Gas Selection forGas Metal Arc Welding ..................................................... 4-15

4.10 Welding Setting Selection Guide .................................................................. 4-16

SECTION 5:

MAINTENANCE ....................................................................................... 5-1

5.01 Routine Maintenance & Inspection................................................................. 5-1

SECTION 6:

TROUBLESHOOTING ................................................................................ 6-1

6.01 Basic Troubleshooting .................................................................................... 6-1

6.02 Solving Problems Beyond the Welding Terminals .......................................... 6-1

6.03 Welding Problems .......................................................................................... 6-3

6.04 PowerSupply Problems ................................................................................. 6-5

6.05 Wire FeederProblems .................................................................................... 6-6

SECTION 7:

ADVANCED TROUBLESHOOTING .................................................................. 7-1

7.01 Preliminary Checks......................................................................................... 7-1

7.02 Initial Setup Conditions .................................................................................. 7-2

7.03 Primary PowerTest ........................................................................................ 7-2

7.04 Logic and Control Tests .................................................................................. 7-3

7.05 Spool Gun Control (J1) Test ........................................................................... 7-4

7.06 Output Voltage Test ........................................................................................ 7-5

7.07 Wire Feed & Weld Test .................................................................................. 7-6

7.08 Primary PowerProblems ............................................................................... 7-6

7.09 Logic and Control Problems ........................................................................... 7-7

7.10 Spool Gun Control (J1) Problem .................................................................... 7-8

7.11 Output Voltage Problem ................................................................................. 7-8

7.12 Wire Feed and Weld Problems ....................................................................... 7-9

7.13 Terminal Block Voltage Test............................................................................ 7-9

7.14 SW3 Coarse and SW4 Fine Rotary Switch Test ............................................ 7-10

7.15 MIG TimerPCB (PCB2) Test ......................................................................... 7-12

7.16 RectifierAssembly Test ............................................................................... 7-13

7.17 Main TransformerTest ................................................................................. 7-14

TABLE OF CONTENTS

SECTION 8:

CIRCUIT OPERATION ................................................................................ 8-1

8.01 Circuit Operation Of The Control PCB 7977964 .............................................. 8-1

8.02 Circuit Operation Of The MIG TimerPCB 7977965......................................... 8-2

8.03 Circuit Operation Of The Digital Volt/Amp PCB 704883 .................................. 8-2

8.04 Circuit Operation Of The Spool Gun PCB 7978034 ......................................... 8-3

SECTION 9:

PARTS LIST .......................................................................................... 9-1

9.01 Equipment Identification................................................................................. 9-1

9.02 How To Use This Parts List ............................................................................ 9-1

9.03 PowerSupply External Replacement Parts (1) ............................................... 9-2

9.04 PowerSupply External Replacement Parts (2) ............................................... 9-4

9.05 PowerSupply Electrical Replacement Parts ................................................... 9-5

9.06 Remote Parts (1) ............................................................................................ 9-6

9.07 Remote Parts (2) ............................................................................................ 9-7

9.08 Remote Parts (3) ............................................................................................ 9-8

9.09 Remote Electrical Components (1) ................................................................. 9-9

9.10 Remote Wire FeederParts............................................................................ 9-10

9.11 MIG Torch .................................................................................................... 9-12

APPENDIX 1: OPTIONAL ACCESSORIES AND CONSUMABLES ...................................... A-1

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM ................................................... A-2

APPENDIX 3: MAIN PCB CIRCUIT DIAGRAM ........................................................... A-4

APPENDIX 4: SPOT TIMER CIRCUIT DIAGRAM ....................................................... A-6

APPENDIX 5: SPOOL GUN PCB .......................................................................... A-8

APPENDIX 6: FEEDROLL KITS .......................................................................... A-10

APPENDIX 7: WIRE FEEDER TERMINAL BLOCK DIAGRAM ......................................... A-11

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

1-1

June 9, 2006

FABRICATOR 281

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is electrically

live wheneverthe output is on. The input powercircuit

and machine internal circuits are also live when power

is on. In semiautomatic orautomatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts

touching the welding wire are electrically live. Incorrectly

installed orimproperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Weardry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats

orcovers.

4. Disconnect input powerorstop engine before installing or

servicing this equipment. Lock input powerdisconnect switch

open, orremove line fuses so powercannot be turned on

accidentally.

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 powerto

equipment if it will be left unattended orout of service.

7. Use fully insulated electrode holders. Neverdip holderin waterto

cool it orlay it down on the ground orthe work surface. Do not

touch holders connected to two welding machines at the same

time ortouch otherpeople with the holderorelectrode.

8. Do not use worn, damaged, undersized, orpoorly spliced cables.

9. Do not wrap cables around yourbody.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground)

circuit.

12. Use only well-maintained equipment. Repairorreplace damaged

parts at once.

13. In confined spaces ordamp locations, do not use a welderwith

AC output unless it is equipped with a voltage reducer. Use

equipment with DC output.

14. Weara safety harness to prevent falling if working above floor

level.

15. Keep all panels and covers securely in place.

WARNING

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.

1. Weara welding helmet fitted with a propershade of filter(see

ANSI Z49.1 listed in Safety Standards) to protect yourface and

eyes when welding orwatching.

2. Wearapproved safety glasses. Side shields recommended.

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 ordeath, ordamage to otherequipment orproperty, if the operatordoes 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 powerlines; otherpractices 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.

1-2 June 9, 2006

FABRICATOR 281

3. Use protective screens orbarriers to protect others from flash

and glare; warn others not to watch the arc.

4. Wearprotective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

5. Use approved earplugs orearmuffs if noise level is high.

WARNING

FUMES AND GASES can be hazardous to yourhealth.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to yourhealth.

1. Keep yourhead out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/oruse exhaust at the arc to remove

welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction formetals, consumables, coatings, and

cleaners.

5. Work in a confined space only if it is well ventilated, orwhile

wearing an air-supplied respirator. Shielding gases used for

welding can displace aircausing injury ordeath. Be sure the

breathing airis safe.

6. Do not weld in locations neardegreasing, cleaning, orspraying

operations. The heat and rays of the arc can react with vapors to

form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the

weld area, the area is well ventilated, and if necessary, while

wearing an air-supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause fire orexplosion.

Sparks and spatterfly 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 orwelding wire to metal objects

can cause sparks, overheating, orfire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly coverthem with approved covers.

4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

5. Watch forfire, and keep a fire extinguishernearby.

6. Be aware that welding on a ceiling, floor, bulkhead, orpartition

can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks ordrums.

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 welderto thaw frozen pipes.

10. Remove stick electrode from holderorcut off welding wire at

contact tip when not in use.

Welding orcutting Electrode Size FilterWelding orcutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or4Non-ferrous base metal All 11

Oxygen Cutting Ferrous base metal All 12

Light Under1 in., 25 mm 3 or4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or5 (TIG) All12

Heavy Over6 in., 150 mm 5 or6Atomichydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under1/8 in., 3 mm 4 or5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or6 Carbon arc air gouging

Heavy Over1/2 in., 12 mm 6 or8 Light 12

Shielded metal-arc Under5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over1/4 in., 6.4 mm 14 Light Under300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over400 Amp 14

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

1-3

June 9, 2006

FABRICATOR 281

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool,

they can throw off slag.

1. Wearapproved face shield orsafety goggles. Side shields

recommended.

2. Wearproperbody protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas underhigh pressure.

If damaged, a cylindercan explode. Since gas cylinders

are normally part of the welding process, be sure to treat

them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical

shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining

them to a stationary support orequipment cylinderrack to prevent

falling ortipping.

3. Keep cylinders away from any welding orotherelectrical circuits.

4. Neverallow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed forthe specific application; maintain them and

associated parts in good condition.

6. Turn face away from valve outlet when opening cylindervalve.

7. Keep protective cap in place overvalve except when cylinderis in

use orconnected foruse.

8. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away

from any building airintakes.

WARNING

ENGINE FUEL can cause fire orexplosion.

Engine fuel is highly flammable.

1. Stop engine before checking oradding fuel.

2. Do not add fuel while smoking orif unit is nearany sparks or

open flames.

3. Allow engine to cool before fueling. If possible, check and add

fuel to cold engine before beginning job.

4. Do not overfill tank — allow room forfuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands

and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and

securely in place.

2. Stop engine before installing orconnecting unit.

3. Have only qualified people remove guards orcovers for

maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect

negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving

parts.

6. Reinstall panels orguards and close doors when servicing

is finished and before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE;

BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always weara face shield when working on a battery.

2. Stop engine before disconnecting orconnecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welderto charge batteries orjump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

1-4 June 9, 2006

FABRICATOR 281

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn

face, eyes, and skin.

The coolant in the radiatorcan be very hot and under

pressure.

1. Do not remove radiatorcap when engine is hot. Allow engine to

cool.

2. Weargloves and put a rag overcap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

This product, when used forwelding orcutting, produces

fumes orgases which contain chemicals know to the

State of California to cause birth defects and, in some

cases, cancer. (California Health & Safety code Sec.

25249.5 et seq.)

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 Ef-

fects of PowerFrequency 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 cellularlevel and from studies

with animals and people which clearly establish that low frequency

magnetic fields and 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 orto offerclearscience-based advice on

strategies to minimize oravoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures.

1. Keep cables close togetherby twisting ortaping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil ordrape cable around the body.

4. Keep welding powersource and cables as faraway from

body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally

recommended forpacemakerwearers. Consult your

doctorforcomplete information.

1.02 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 forthe Preparation forWelding 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 P-

1, from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code forSafety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices forOccupation 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.

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