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Thermal Arc A-07360 User Manual

Thermal Arc A-07360
102 pages
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FABRICATOR
®
MIG WELDING MACHINE
210
Service Manual
Revision: AE Issue Date: June 19, 2006 Manual No.: 0-4879B
Operating Features:
Art # A-07360

Table of Contents

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Thermal Arc A-07360 Specifications

General IconGeneral
BrandThermal Arc
ModelA-07360
CategoryWelding System
LanguageEnglish

Summary

Safety Instructions and Warnings

Arc Welding Hazards

Details hazards related to arc welding, including electric shock and fumes.

Principal Safety Standards

Lists key safety standards and organizations relevant to welding.

Precautions De Securite En Soudage A L’arc

Provides safety precautions for arc welding in French.

Dangers Relatifs Au Soudage à L’arc

Outlines dangers associated with arc welding in French.

Principales Normes De Securite

Lists principal safety standards and their sources in French.

Introduction

How To Use This Manual

Explains how to use the service manual and interpret its special annotations.

Equipment Identification

Describes how to identify the unit using its nameplate and part numbers.

Symbol Chart

Displays common symbols used on the welding machine and their meanings.

General Information

Provides general information about the Fabricator 210 welder, its design, and applications.

Safety

Lists fundamental safety rules to be followed when operating the equipment.

Protective Filter Lenses

Recommends appropriate filter lens shades for welding current ranges.

User Responsibility

Outlines the purchaser's responsibility for proper operation and maintenance.

Duty Cycle

Explains the concept of duty cycle and its application to the power supply.

Specifications

Lists detailed technical specifications for the machine and its components.

Included Items

Lists all items included in the Fabricator 210 package system.

Optional Accessories

Refers to the appendix for a list of available optional accessories.

Installation

Environment

Describes environments where the welder should not be used due to increased electric shock hazard.

Location

Provides guidelines for selecting a suitable location for the power supply.

Ventilation

Emphasizes the need for adequate ventilation in the welding area.

Input Power Requirements

Details the required main supply voltage and connection requirements.

Alternative Mains Supply Voltages

Specifies lead sizes for alternative input power supply voltages.

Quick Setup

Provides essential steps for a quick setup of the welder.

Installation of Shielding Gas (GMAW) Process

Details the process of installing shielding gas for GMAW.

Attaching the Gun and Cable Assembly to the Power Source

Guides on how to connect the welding gun and cable assembly to the power source.

Input And Output Wire Guide Installation

Instructions for installing the input and output wire guides.

Selection and Installation of Feedrolls

Explains how to select and install the correct feedrolls for wire.

Installing Wire Spool

Step-by-step guide for installing a wire spool onto the machine.

Inserting Wire into the Feedhead

Instructions on how to insert welding wire into the feedhead.

Wirefeeder Drive Roller Pressure Adjustment

Details how to adjust the drive roller pressure for optimal wire feed.

Wire Reel Hub Brake

Explains the adjustment of the wire reel hub brake.

Spool Gun Attachment

Instructions for attaching a spool gun to the power supply.

Polarity Changeover

Details the process for changing the welding polarity (cable to gun/work).

Operation

Power Supply Controls, Indicators and Features

Identifies and explains the various controls and indicators on the power supply.

Weld Mode Selector

Describes the weld mode selector switch and its functions.

TWECO Weldskill 250 AMP Weld Gun

Introduces the TWECO Weldskill 250 AMP MIG gun and its features.

Installing A New Wire Conduit

Provides instructions for installing a new wire conduit.

MIG Gun Maintenance

Details routine maintenance procedures for the MIG gun.

Basic Welding Technique

Covers fundamental welding techniques, including power supply settings and gun angle.

Stitch Welding Operation

Explains how to perform stitch welding operations.

Spot Welding Operation

Details how to perform spot welding operations, including nozzle selection.

Gas Selection for Gas Metal Arc Welding

Provides a guide for selecting shielding gas based on metal type and thickness.

Welding Setting Selection Guide

Offers guidance on selecting welding settings for various materials and wire sizes.

Maintenance

Routine Maintenance & Inspection

Outlines routine cleaning and inspection procedures for the equipment.

Troubleshooting

Basic Troubleshooting

Covers basic troubleshooting steps that can be performed without special tools.

Solving Problems Beyond the Welding Terminals

Addresses common problems like porosity and their solutions.

Welding Problems

Lists various welding problems and their corresponding causes and remedies.

Advanced Troubleshooting

Preliminary Checks

Lists initial checks and cleaning procedures before advanced troubleshooting.

Initial Setup Conditions

Specifies initial setup conditions for testing the power supply.

Primary Power Test

Details the procedure for testing the primary power input to the unit.

Logic and Control Tests

Outlines tests for various logic and control functions of the welder.

Spool Gun Control (J1) Test

Describes tests for the spool gun control interface and its voltage outputs.

Output Voltage Test

Details how to test the output voltage across different control settings.

Wire Feed & Weld Test

Covers tests for wire feed functionality and arc establishment.

Primary Power Problems

Lists potential primary power issues and their diagnostic steps.

Logic and Control Problems

Identifies common logic and control problems and their solutions.

Spool Gun Control (J1) Problem

Addresses issues related to spool gun control and gas solenoid.

Output Voltage Problem

Discusses problems related to low output voltage and switch issues.

Wire Feed and Weld Problems

Outlines problems related to inconsistent arc transfer or wire feed.

Terminal Block Voltage Test

Explains how to perform voltage tests on the input terminal block.

SW3 Coarse and SW4 Fine Rotary Switch Test

Details continuity testing procedures for the coarse and fine rotary switches.

MIG Timer PCB (PCB2) Test

Describes testing procedures for the MIG timer PCB.

Rectifier Assembly Test

Outlines diode testing procedures for the rectifier assembly.

Main Transformer Test

Details how to measure output voltage from the main transformer secondary.

Circuit Operation

Circuit Operation Of The Control PCB 7977964

Explains the circuit operation of the control PCB and its inputs.

Circuit Operation Of The MIG Timer PCB 7977965

Describes the MIG Timer PCB and its connections.

Circuit Operation Of The Digital Volt/Amp PCB 704883

Explains the circuit operation of the digital volt/amp PCB.

Circuit Operation Of The Spool Gun PCB 7978034

Details the circuit operation of the spool gun PCB and its terminals.

Parts List

Equipment Identification

Explains how to identify equipment and provide information for ordering parts.

How To Use This Parts List

Guides on how to use the parts list to find and order components.

External Replacement Parts

Lists external replacement parts with their part numbers and descriptions.

Major Electrical and Mechanical Replacement Parts

Lists major electrical and mechanical replacement parts for the unit.

Internal Replacement Parts (1)

Lists internal replacement parts, including PCBs, switches, and fans.

Internal Replacement Parts (2)

Lists additional internal replacement parts, including knobs and circuit breakers.

Internal Replacement Parts-Spool Assembly

Lists replacement parts specific to the spool assembly.

Internal Replacement Parts-Wire Feed

Lists replacement parts for the wire feed mechanism.

Wire Feeder Replacement Parts

Lists replacement parts for the wire feeder assembly.

Appendix 1: Optional Accessories and Consumables

Appendix 3: Feed Roll Kits

Appendix 4: Power Supply Circuit Diagram

Appendix 5: Main PCB Circuit Diagram

Appendix 6: Spot Timer Circuit Diagram

Limited Warranty

Warranty Schedule

Global Customer Service Contact Information

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