Академический Документы
Профессиональный Документы
Культура Документы
FABSTAR
TRANSFORMER-RECTIFIER
WELDING MACHINE
Operating Manual
Version No: 1 Issue Date: April 20, 2006 Manual No.: 430429-460
Operating Features:
Read and understand this entire Manual and your employers safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
Copyright 2006 by
Thermadyne Industries Inc.
Reproduction of this work, in whole or in part, without written permission of the pub-
lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
i
430429-460
TABLE OF CONTENTS
INTRODUCTION 1
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Meanings Of Markings And Graphical Symbols: . . . . . . . . . . . . . . . . . . . . . . 1-2
DESCRIPTION OF EQUIPMENT 3
Controls and Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
INSTALLATION 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Connection To Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Input Connections To Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Welding Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
OPERATION 5
MAINTENANCE 6
Replacing SCRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TROUBLESHOOTING 7
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Detailed Troubleshooting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
PARTS LIST 8
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
How To Use This Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
DIAGRAMS.........................................................................................................9-1
WARRANTY
Continuous Weld
Circuit Breaker
X Duty Cycle
Mode
Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)
! 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.
Arc Welding Hazards 7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
1. Do not touch live electrical parts. 15. Keep all panels and covers securely in place.
6. Turn off all equipment when not in use. Disconnect power to 1. Wear a welding helmet fitted with a proper shade of filter (see
equipment if it will be left unattended or out of service. ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
April 20, 2006 2-1
FABSTAR 4030
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
WARNING contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
2. If inside, ventilate the area and/or use exhaust at the arc to remove 4. Be alert that welding sparks and hot materials from welding can
welding fumes and gases. easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator. 5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
manufacturers instruction for metals, consumables, coatings, and can cause fire on the hidden side.
cleaners.
7. Do not weld on closed containers such as tanks or drums.
5. Work in a confined space only if it is well ventilated, or while
8. Connect work cable to the work as close to the welding area as
wearing an air-supplied respirator. Shielding gases used for
practical to prevent welding current from traveling long, possibly
welding can displace air causing injury or death. Be sure the
unknown paths and causing electric shock and fire hazards.
breathing air is safe.
9. Do not use welder to thaw frozen pipes.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to 10. Remove stick electrode from holder or cut off welding wire at
form highly toxic and irritating gases. contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
! WARNING WARNING
2. Wear gloves and put a rag over cap area when removing cap. National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
3. Allow pressure to escape before completely removing cap.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
! WARNING
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
This product, when used for welding or cutting, produces Boulevard, Rexdale, Ontario, Canada M9W 1R3.
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some Safe Practices for Occupation and Educational Eye and Face Protec-
cases, cancer. (California Health & Safety code Sec. tion, ANSI Standard Z87.1, from American National Standards Insti-
25249.5 et seq.) tute, 1430 Broadway, New York, NY 10018.
NOTE Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
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:
! MISE EN GARDE
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
SAPPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QUILS NAIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL DOPERATION OU LES INSTRUCTIONS AVANT DINSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procds de soudage peuvent sauser des blessures graves ou la mort, de mme que des dommages au reste du matriel et la
proprit, si lutilisateur nadhre pas strictement toutes les rgles de scurit et ne prend pas les prcautions ncessaires.
En soudage et coupage, des pratiques scuritaires se sont dveloppes suite lexprience passe. Ces pratiques doivent tre apprises par
tude ou entranement avant dutiliser lequipement. Toute personne nayant pas suivi un entranement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les quipements raccords aux lignes dalimentation alors que dautres sadressent aux
groupes lectrognes.
La norme Z49.1 de lAmerican National Standard, intitule SAFETY IN WELDING AND CUTTING prsente les pratiques scuritaires suivre.
Ce document ainsi que dautres guides que vous devriez connatre avant dutiliser cet quipement sont prsents la fin de ces instructions de
scurit.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX DINSTALLATION, DE REPARATION, DENTRETIEN ET DESSAI.
Dangers Relatifs au Soudage lArc 6. Arrtez tout quipement aprs usage. Coupez lalimentation de
lquipement sil est hors dusage ou inutilis.
7. Nutilisez que des porte-lectrodes bien isols. Ne jamais plonger
les porte-lectrodes dans leau pour les refroidir. Ne jamais les
laisser traner par terre ou sur les pices souder. Ne touchez
pas aux porte-lectrodes raccords deux sources de courant en
mme temps. Ne jamais toucher quelquun dautre avec llectrode
ou le porte-lectrode.
AVERTISSEMENT
8. Nutilisez pas de cbles lectriques uss, endommags, mal
pisss ou de section trop petite.
LELECTROCUTION PEUT ETRE MORTELLE.
9. Nenroulez pas de cbles lectriques autour de votre corps.
Une dcharge lectrique peut tuer ou brler gravement. 10. Nutilisez quune bonne prise de masse pour la mise la terre de
Llectrode et le circuit de soudage sont sous tension la pice souder.
ds la mise en circuit. Le circuit dalimentation et les 11. Ne touchez pas llectrode lorsquen contact avec le circuit de
circuits internes de lquipement sont aussi sous ten- soudage (terre).
sion ds la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou 12. Nutilisez que des quipements en bon tat. Rparez ou remplacez
la bobine de fil, le logement des galets dentrainement aussitt les pices endommages.
et toutes les pices mtalliques en contact avec le fil de
soudage sont sous tension. Un quipement 13. Dans des espaces confins ou mouills, nutilisez pas de source
inadquatement install ou inadquatement mis la terre de courant alternatif, moins quil soit muni dun rducteur de
est dangereux. tension. Utilisez plutt une source de courant continu.
14. Portez un harnais de scurit si vous travaillez en hauteur.
1. Ne touchez pas des pices sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vtements isolants, secs et non trous.
3 Isolez-vous de la pice souder et de la mise la terre au moyen
de tapis isolants ou autres.
4. Dconnectez la prise dalimentation de lquipement ou arrtez le
moteur avant de linstaller ou den faire lentretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
lalimentation afin dviter une mise en marche accidentelle.
5. Veuillez installer cet quipement et le mettre la terre selon le
manuel dutilisation et les codes nationaux, provinciaux et locaux
applicables.
AVERTISSEMENT AVERTISSEMENT
LE RAYONNEMENT DE LARC PEUT BRLER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER LOUIE. POUR LA SANTE.
Larc de soudage produit une chaleur et des rayons Le soudage dgage des vapeurs et des fumes
ultraviolets intenses, susceptibles de brler les yeux et dangereuses respirer.
la peau. Le bruit caus par certains procds peut
endommager loue. 1. Eloignez la tte des fumes pour viter de les respirer.
1. Portez une casque de soudeur avec filtre oculaire de nuance 2. A lintrieur, assurez-vous que laire de soudage est bien ventile
approprie (consultez la norme ANSI Z49 indique ci-aprs) pour ou que les fumes et les vapeurs sont aspires larc.
vous protger le visage et les yeux lorsque vous soudez ou que 3. Si la ventilation est inadequate, portez un respirateur adduction
vous observez lexcution dune soudure. dair approuv.
2. Portez des lunettes de scurit approuves. Des crans latraux 4. Lisez les fiches signaltiques et les consignes du fabricant rela-
sont recommands. tives aux mtaux, aux produits consummables, aux revtements
3. Entourez laire de soudage de rideaux ou de cloisons pour protger et aux produits nettoyants.
les autres des coups darc ou de lblouissement; avertissez les 5. Ne travaillez dans un espace confin que sil est bien ventil; sinon,
observateurs de ne pas regarder larc. portez un respirateur adduction dair. Les gaz protecteurs de
4. Portez des vtements en matriaux ignifuges et durables (laine et soudage peuvent dplacer loxygne de lair et ainsi causer des
cuir) et des chaussures de scurit. malaises ou la mort. Assurez-vous que lair est propre la respi-
ration.
5. Portez un casque antibruit ou des bouchons doreille approuvs
lorsque le niveau de bruit est lev. 6. Ne soudez pas proximit doprations de dgraissage, de
nettoyage ou de pulvrisation. La chaleur et les rayons de larc
peuvent ragir avec des vapeurs et former des gaz hautement
toxiques et irritants.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE 1. Portez un cran facial ou des lunettes protectrices
EXPLOSION approuves. Des crans latraux sont recommands.
Larc produit des tincellies et des projections. Les 2. Portez des vtements appropris pour protger la peau.
particules volantes, le mtal chaud, les projections de
soudure et lquipement surchauff peuvent causer un
incendie et des brlures. Le contact accidentel de
llectrode ou du fil-lectrode avec un objet mtallique
AVERTISSEMENT
peut provoquer des tincelles, un chauffement ou un
incendie.
LES BOUTEILLES ENDOMMAGEES PEUVENT
1. Protgez-vous, ainsi que les autres, contre les tincelles et du EXPLOSER
mtal chaud.
Les bouteilles contiennent des gaz protecteurs sous
2. Ne soudez pas dans un endroit o des particules volantes ou des haute pression. Des bouteilles endommages peuvent
projections peuvent atteindre des matriaux inflammables. exploser. Comme les bouteilles font normalement partie
du procd de soudage, traitez-les avec soin.
3. Enlevez toutes matires inflammables dans un rayon de 10, 7
mtres autour de larc, ou couvrez-les soigneusement avec des
bches approuves. 1. Protgez les bouteilles de gaz comprim contre les sources de
chaleur intense, les chocs et les arcs de soudage.
4. Mfiez-vous des projections brulantes de soudage susceptibles
de pntrer dans des aires adjacentes par de petites ouvertures 2. Enchainez verticalement les bouteilles un support ou un cadre
ou fissures. fixe pour les empcher de tomber ou dtre renverses.
5. Mfiez-vous des incendies et gardez un extincteur porte de la 3. Eloignez les bouteilles de tout circuit lectrique ou de tout soudage.
main.
4. Empchez tout contact entre une bouteille et une lectrode de
6. Noubliez pas quune soudure ralise sur un plafond, un plancher, soudage.
une cloison ou une paroi peut enflammer lautre ct.
5. Nutilisez que des bouteilles de gaz protecteur, des dtendeurs,
7. Ne soudez pas un rcipient ferm, tel un rservoir ou un baril. des boyauxs et des raccords conus pour chaque application
spcifique; ces quipements et les pices connexes doivent tre
8. Connectez le cble de soudage le plus prs possible de la zone maintenus en bon tat.
de soudage pour empcher le courant de suivre un long parcours
inconnu, et prvenir ainsi les risques dlectrocution et dincendie. 6. Ne placez pas le visage face louverture du robinet de la bouteille
lors de son ouverture.
9. Ne dgelez pas les tuyaux avec un source de courant.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
10. Otez llectrode du porte-lectrode ou coupez le fil au tube-con- lorsque raccord pour utilisation.
tact lorsquinutilis aprs le soudage.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
11. Portez des vtements protecteurs non huileux, tels des gants en comprim et aux quipements connexes, ainsi que la publication
cuir, une chemise paisse, un pantalon revers, des bottines de P-1 de la CGA, identifie dans la liste de documents ci-dessous.
scurit et un casque.
AVERTISSEMENT
AVERTISSEMENT Safe Practices for Occupation and Educational Eye and Face Protec-
tion, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN Cutting and Welding Processes, norme 51B NFPA, National Fire Pro-
ACCUMULATEUR; LELECTROLYTE DUN ACCUMU- tection Association, Batterymarch Park, Quincy, MA 02269.
LATEUR PEUT BRULER LA PEAU ET LES YEUX.
2-8 April 20, 2006
430429-460
DESCRIPTION OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
This unit is a constant voltage, transformer rectifier 6. Feeder Control Receptacle Connection
type DC welding machine that provides volt-ampere point for a remote voltage control type wire feeder
characteristic curves that are basically flat. control (19-pin).
This unit is recommended to be used with gas 7. Local/Remote Switch Selects voltage con-
metal arc welding (MIG) and flux core arc welding trol function for either local or remote operation.
(with or without shielding gas) applications. This unit
has to be used with a wire feeder. All Thermal Arc
feeder models can be used with this unit. In some 8. Circuit Breaker (10 amps) Protects the
cases an adapter cable may be required. 115-V AC control circuitry and the 115-volt recepta-
cles.
3. Voltmeter Monitors open circuit voltage and 11. Overload Indicator Yellow L.E.D., when
welding voltages any time secondary cir cuit is lighted, indicates that machine has shut down as a
closed. r e s u l t of am p e r a g e o v e r load o r r e c ti fier
4. Am me ter Mon i tors the cur rent flow ing overtemperature (S2).
through the welding arc.
12. Stability Control Switch When the switch
5. Positive Terminal (+) Serves as a connec- is in the mild steel (forceful), provides the user with
tion point for the lead to the wire feeder when re - a forceful arc. When the switch is in the stainless
verse polarity (DCEP) is desired. (smooth), provides the user with a smooth arc.
FABSTAR 4030 FABSTAR 4030
ITEM 100010A-1 and -2 100010A-3
Duty Cycle
(Figure 3-5)
Duty cycle is the percentage of each ten-minute pe-
riod of time that the welding machine may be oper-
ated under rated load conditions. For example, a
duty cycle of 60% means that the machine can be
operated at rated load for an average of 6 minutes of
each 10 minute period of operation. During the re-
maining 4 minutes, the machine must idle to permit
proper cooling. Figure 3-6 enables the operator to
determine the duty cycle at various welding amper-
ages.
INPUT
POWER
SWITCH
S1
PRIMARY VOLTAGE
SELECTION
FAN CHANGEOVER
MOTOR PANEL
FORM FACTOR
IMPROVEMENT PINS PINS PINS AMPHENOL
115 VAC CHOKE E/F/G A/B H/J/K CONNECTOR
L2
ARC STABILIZER
CHOKE
L1
WELDING
OUTPUT
POWER
INSTALLATION
exist, it is recommended that the National Electrical
Location Code be followed. Refer to Table 4-1 for wire sizes.
For best operating characteristics and longest unit The work or work table must also be grounded by
life, take care in selecting an installation site. Avoid using a conductor attached to a driven ground or wa-
locations exposed to high humidity, dust, high ambi- ter pipe as described below. See Figures 4-1 and
ent temperature or corrosive fumes. Moisture can 4-2.
condense on electrical components, causing corro-
sion or shorting of circuits. Dirt on components helps The re q u i r e m e n t s and rec o m m e n d a t i o n s for
retain this moisture. grounding apply to rubber tire mounted equipment.
In addition to the usual function of protecting person-
Adequate air circulation is needed at all times in or- nel against the hazard of electrical shock due to fault
der to assure proper operation. Provide a minimum in the equipment, grounding serves to discharge the
of 12 inches (305 mm) of free air space at both front static electrical charges which tend to build up on the
and rear of the unit. Make sure that the ventilator surfaces of tire mounted equipment. These static
openings are not obstructed. charges sometimes cause painful shock to person-
nel, and in some instances, lead to the erroneous
conclusion that an electrical fault exists in the equip-
Grounding ment.
The frame of this weld i n g mac h i n e should be Use an in put-power ca ble as s e m b l y which in-
grounded for personnel safety. Where grounding is cludes a grounding conductor to connect this equip-
mandatory under state or local codes, it is the re - ment to the input power supply. When included in the
sponsibility of the user to comply with all applicable cable assembly, the grounding conductor will be
rules and regulations. Where no state or local codes green or green with a yellow stripe, or bare. Connect
Ground
Line Input Wire Size Wire Size
Voltage (AWG)* (AWG)* Lag Fuse Rating
200 8 8 50
230 8 8 60
460 12 12 30
575 12 12 30
* Input conductor sizes are based on allowable ampacities of insulated copper conductors, with not
more than three conductors in a raceway or cable.
Input Connections To Power As shipped from the factory, the input terminal board
Source voltage links are set up for the highest line voltage.
Refer to the voltage change over diagram at the back
of this manual for correct voltage selection connec-
WARNING: The fused discon- tions.
nect switch: Open or place in the 3. Thread the input conductor cables from the wall
OFF position and remove the disconnect switch through the hole in the rear panel
and through the hole in the yoke to the input power
fuses. To avoid an accident, switch on the front panel. Connect the conductors to
make the electric power connec- terminals on the input power switch using UL listed
tions to the welding machine pressure wire connectors. Connect the ground wire
to the grounding stud provided on the lifting yoke
first, then to the fused discon- near the changeover board.
nect switch. This will prevent an
accidental application of power WARNING: It is of the utmost im-
while the machine is being con- portance that the chassis be
nected. connected to an approved elec-
1. A line (wall) disconnect switch, with fuses or cir- trical ground to prevent acci-
cuit breakers should be provided at the main power dental shocking. Take care not
panel. The primary power input must have four insu- to connect the ground wire to
lated copper conductors (three power leads and one
ground wire). The wires may be heavy rub- any of the primary leads.
ber-covered cable or may be run in a solid or flexible
conduit. Do not connect the input conductors until 4. Recheck all connections to make sure that they
step 3. are tight, well insulated, and that the proper connec-
tion has been made.
2. For access to input terminal board, remove the
screws which secure the right side panel of the
power supply. The input terminal board is clearly
marked to show the available primary voltage con- Welding Leads
nections which may be used. Set the voltage links, Use Table 4-2 for selection of the proper size cop-
on this board, to match your actual incoming voltage. per welding leads.
100 #4 #4 #2 #1 #1
150 #2 #2 #1 #1/0 #2/0
200 #1 #1 #1/0 #2/0 #3/0
250 #1/0 #1/0 #2/0 #3/0 #4/0
300 #2/0 #2/0 #3/0 #4/0 2 #2/0
350 #3/0 #3/0 #4/0 2 #2/0 2 #3/0
400 #4/0 #4/0 #4/0 2 #2/0 2 #3/0
NOTE: Lead size shown is for 90C (194F) insulation, 30C (86F) ambient, and not over 4.5 volts
lead drop.
Table 4-3
OPERATION
Before operating this unit, be sure that all installa- b. Keep the gun in the WELD position momen-
tion instructions have been accomplished. A thor - tarily (ap prox i mately 1/2 sec ond) so the
ough knowledge of system cleaning as instructed in burnback circuit operates.
Maintenance chapter is required for consistently
satisfactory re sults. Also observe all applicable Burnback Operation When the gun switch is re-
safety warnings listed in the Safety Instructions and leased, the burnback circuit lowers the voltage to a
Warnings chapter included in this manual and re - value which is too low to maintain an arc. The arc will
lated instruction manual. go out. If the wire continues to coast into the weld,
there is still enough power at the lower burn-back
The operating instructions in this manual pertain voltage level to burn off the end of the wire. This re-
only to the FABSTAR welding machine, but refer- moves the ball on the end of the wire and prepares it
ence is made to other items of equipment not in - for the next start. It also prevents the wire from burn-
cluded as part of the FABSTAR . Before operating, ing back to the tip or sticking in the weld puddle. The
consult technical manuals related to specific wire burnback time and burnback voltage is selectable.
(electrode) feeders and welding guns usually used
with this unit. Jumpers on the Control Board control these val-
ues. JP2 controls the burnback time and JP1 control
1. Perform all preset operations on welding gun the burnback voltage. Selection is made by remov-
and wire feeder. ing the Jumper Block and relocating. Factory set-
2. Check installation (refer to Installation Dia- tings are shown in Figure 5-1.
gram, Figure 4-4) to be certain all connections are The chart below shows some suggested settings
tight and proper controls, gas, and torches are in - for burnback time and voltage.
stalled.
The gun must remain in the welding position after
3. Set Voltage Control on the unit to the desired the gun switch is released to obtain the best results
welding voltage. from the burnback circuit. This method of burnback
eliminates the need for a time adjustment and pre-
4. Turn on gas supply at gas cylinder.
pares the wire for a good restart.
5. Turn control power switch to ON position. The
cooling fan should now start.
NOTE: A thermostatically controlled fan
motor is optional (Fan Turn-on Thermostat
Kit 200155A), which may be incorporated Figure 5-8
into the system that stops and starts auto- c. Turn off the gas at source.
matically when a predetermined tempera-
ture has been reached.
JP1
6. Adjust the gas supply to the desired flow rate. Wire Wire JP2
Type Size Volts Time
7. Place the welding gun in proximity of the work. (FACTORY SETTINGS) 6 SHORT
8. Activate the gun switch. Open circuit voltage
will appear, welding gas will flow, and the arc will initi- ER70S-3 .035 6 Short
ate.
9. Readjust any controls as necessary. ER70S-3 .045 18 Short
CAUTION: Once a welding arc is estab- E71T-1 .045 18 Short
lished, power should not be removed
from the weld ing machine, and the ER308L .035 6 Short
IN-PUT POWER ON/OFF SWITCH
should not be turned OFF. ER4043 3/64 6 Short
10. To terminate welding, proceed in the following
manner: NOTE: These recommendations are based
a. Deactivate the gun switch. Gas will stop on overall performance. Specific applications
flowing. may require different settings.
MAINTENANCE
Replacing SCRs three months, or more often as necessary, wipe and
Replacing an SCR is a critical task but it can be ac- blow out all dirt from the machines internal compo-
complished in the field by following the instructions in nents, with air pressure of not over 25 psi (172 kPa).
the Detailed Troubleshooting Instructions section lo- Be sure to wipe the fan blades clean.
cated in the Troubleshooting chapter of this manual. Check and tighten all electrical connections as
necessary to eliminate unnecessary losses and to
avoid subsequent trouble from overheating or open
Lubrication circuits. Check for broken wiring or damaged insula-
The fan motor incorporates sleeve bearings. You tion on wiring.
can expect the life of this motor to exceed 50,000
hours without relubrication. Periodically cleaning the
motor and lubricating the bearings will extend the life WARNING: Disconnect line volt-
of the motor. The following ta ble will furnish a recom- age from the unit be fore at-
mended guide as to the frequency of this lubrication tempting any servicing inside
if desired.
unit. Turn off fused disconnect
NOTE: Ap p l y 1 - 1 2 d r o p s o f 2 0 W switch that supplies power to
non-detergent oil at each end of bearing. welding machine, and remove
its fuses.
TROUBLESHOOTING
The following chart contains information which can be used to diagnose and correct unsatisfactory operation
or failure of the various components of the welding machine. Each symptom of trouble is followed by a list of
probable causes and the procedure necessary to correct the problem.
See Wire Feeder or Welding Gun Manual for troubleshooting information on the Wire Feeder or the Welding
Gun.
Troubleshooting Guide
Welding machine will not start.
Power switch OFF
Place power switch in ON position.
Overtemperature thermostat has tripped. (Yellow indicator on)
Allow machine to cool to reset thermostat. (Yellow indicator will go out)
Power lines dead
Check voltage.
Broken input power lead
Repair.
Wrong line voltage
Check line voltage.
Incorrect input power connections at welding machine
Check connections against wiring diagram.
Tripped circuit breaker or fuse on input lines
Reset circuit breaker or replace fuses.
Ventilation blocked
Solid-state contactor operates, but welding machine will not deliver welding cur-
rent, and open circuit voltage is present at the output when gun switch is de-
pressed.
No ground connections at work
Make connections.
Welding cables not connected
Make connections.
Fan not operating (also see causes and remedies under Welding machine will
not start)
Tripped circuit breaker on front panel of welding machine
Reset circuit breaker; 115-volt receptacle may be overloaded.
Broken lead or connection to fan motor
Repair wiring.
Defective fan control thermostat (If equipped)
Replace thermostat.
Motor failed
Replace motor.
Inconsistent welding
Irregular wire feed speed
See wire feeder and/or welding gun manuals for wire feeding problems.
Inadequate shielding of arc
Adjust shielding gas flow for best results.
Wire feed rate or voltage set improperly
See filler metal charts for recommended wire feeds and voltage settings.
Incorrect polarity
Make sure polarity is correct for filler metal being used.
Loose cable connections
Check for loose or overheated connections and tighten.
Welding contact tube (tip) on wire feeder makes poor contact with electrode
TROUBLESHOOTING
Detailed Troubleshooting
Instructions
The FABSTAR 4030 machine is a solid-state
welding machines. The method of troubleshooting is
different, but it is not more difficult than troubleshoot-
ing a conventional unit. Do not overlook the obvious.
As in the case of all electrical equipment, loose con-
nections are the primary cause of malfunction both
internal and external to the welding machine. Do not
overlook bad grounds, worn contact tubes (tips),
dirty cable liners, shorted control cables, wrong set-
tings, blown fuses, worn contactors, misconnections
from feeding equipment, misapplication, etc. The
only equipment needed to properly detect a problem
on this welding machine is a simple volt-ohmmeter,
al though an oscil lo scope is the best method to
quickly see the problem.
Control Circuit Board Malfunction If a board
mal func tion oc curs, the following situ a tions will
probably result: Figure 7-9
1. Loss of arc completely.
2. Very noticeable, rough, sputtering, arc. Examples:
3. Loss of control and burnback.
4. Minor starting problems.
Mounting Procedure for SCRs
1. Thoroughly clean heat sink surface to eliminate
any dirt or contamination.
2. Ap ply a thin coat of Alcoa #2 com pound to
cleaned surface. Alcoa #2 is available from Thermal
Arc, part number 903870.
3. Positively locate the SCR in place in the heat
sink. A small spring pin in the extruded heat sink will
locate the SCR.
4. Place the clamp in position with the bolts through
the holes in the heat sink, and proceed in following
manner.
5. Tighten the nuts evenly until finger tight. Less than rated Correct Excessive force.
force. Tighten rated force. Loosen both nuts
6. Tighten each bolt in 1/4 turn increments using nuts al ternately and start over.
correct size hex key. 1/4 turn at a time NEVER ad just
7. Place the Force Indicator Gauge (903878) firmly until points coin- force by backing
against the springs as shown. Be sure both ends and cide. off the nuts. Fric -
the center are in firm contact with the springs. The tion will produce a
gauge notch location will indicate the spring deflec- false reading. Al-
tion or force. Correct mounting force is indicated as ways start from
shown below. Step 1.
Figure 7-11
Figure 7-12
ADJUSTING
TEST TEST POINTS POT VOLTAGE REMARKS
1 TP2 (+) TP3 30 10% DC Checks positive supply voltage
Checks R60 fuse to power sup -
ply
2 TP1 (+) TP3 15 V .75 V Checks voltage regulator
3 TP4 (+) TP3 Adjusts phase balance of all
TP5 (+) TP3 R12 Same as TP4 three phases
TP6 (+) TP3 R13
4 TP8 (+) TP3 400 Amps = 5 V Checks shunt amplifier
10%
Table 7-4
PARTS LIST
100010A-1 A
100010A-2 B
100010A-3 C
Not Illustrated
Not Illustrated
8-4 November 15, 2000
430429-460
PARTS LIST
Parts List for Figure 8-1
Not Illustrated
DIAGRAMS
Note the model and specification number shown on the equipment nameplate.
Locate these numbers in the model and specification number columns below.
VOLTAGE
MODEL SPECIFICATION CONNECTION SCHEMATIC CHANGEOVER
NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM
2
2
30
17
30
10
15
17
H 43 BR H
CONTROL BOARD 30 35 RD
31
57 BR
31A
10 WT
20 WT
37 WT
11 BK
21 BK
12 BK
39 BK
40 BK
103 104
36 109
101
9 BK 11 BK C6 3
3
12 L2
- - 101 111 5 CR4
- R2 5 8 22 YL
M1 M2
3 30
1 2 46 YL
24 RD 26
+ +
6 30 105 14
110 23 WT WT TOP
40 BK R11 30 4A
10 WT 3 14
8 RD 3 52 RD 37 WT 11 108
G 27 27 3 8 CR1 4C G
14 GY SCR1
6 BR 4B 54 BK TOP 105 109
23 8
64 BK
9
C
62 GY 15 YL 104
B
30 30 36 12
49 BK 47 RD
A
17 53 WT X1 26
N
9 R11 23 16 39 BK 3
M
V
R1 S4 4A X2 S2
J4 55 GN-YL 15
S
7 WT
U
CW 48 BL 7 28 L1 41 BL
7 17 30
L
G
5 BL 50 OR 20
H
25 YL
K
6 BR 30 17 19
7 42 YL 30
J
58 BL 30 50 OR CR2 45 YL
7 BOTTOM 26 WT WT 26
31A 7 WT 49 BK + - 106 30
9 21 21 B1 106 19
56 RD 7
27 S3 48 BL 21 C1 27 RD
9A 9 TOP
TOP 30 4B
38 RD
16 30 BOTTOM
12 BK 51 OR X3 33 YL SCR2
F 3 30 30 4A F
CB1 T1
BK X4 34 OR
30 17 BK 21
10 DS1 X1 4 BK 17 23
4A 23 + - 18 WT
4B X5 31 BL C2 25 23
13 RD RD 30 13
30
28
CR3
17
20
X6 14 GY
28
17
29 107 SCR3
TOP
4C
53 WT
18 WT
16 GN-YL
TOP 25
19 GN-YL
C5
27 29 WT WT 44 YL
- 30 26
56 RD X2 +
9A 36 BK 28 YL
C3 31 30
J5
S1 52 RD 28 X1
E 17 29 E
102
16 GN-YL
4C
RV1
+
8 RD 23
1 19 GN-YL
23
4 BK
32 GN-YL
17 BK
FOR POWER CABLE AND 30
VOLTAGE CHANGEOVER 55 GN-YL BOTTOM 108
54 BK
GND SCREW 17 8
CONNECTIONS SEE SHEET 3.
16
20
ON BASE
17
61 BK
31 -
44 YL
29 A
45 YL R10 R9 R8
21 B
46 YL
C11
C12
34 OR 1 8 C
4B
32 GN-YL 47 RD
D 28 2 36 + C10 C7 D
33 YL J1
4B 3
3
21 BK
4
30 26 C9 C8
KEY R6 R5 R4
20 WT
3 6
13 RD
10 7
43 BR
12
12 8 CONTROL BOARD
15 YL 9
17
31 BL 10
4B 31A
57 BR
R12
38 RD
63 BK
17 1 J2
42 YL 2
7
C C
9A
62 GY 3
7
9 5 BL 4
J3
KEY
KEY
58 BL
51 OR 1 2 3 4 5 6 7 9 10 11
17 6 35 RD
12
8
22 YL 30 RD
29
31
61 BK
23 WT 29 WT R7 26
8 29
36 BK
24 RD 28 YL 13
8 29
59 BR
41 BL
15 170 11-00
25 YL
21
26 WT
B 21 B
27 RD R3
21
60 RD
OUTSIDE DISTR.
DISTRIBUTION TABLE
830877S1 3-26-01
MATERIAL NO. QUANTITY-U.M. COMM. CLS.
REVISION CHART UNLESS OTHERWISE SPECIFIED
REV ECN NO. DATE SHEETS AFFECTED DIMENSIONS ARE IN INCHES/MILLIMETERS
MATERIAL SPEC.
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS. TITLE
CHANGEOVER BOARD FRACT. DIAGRAM, CONNECTION
INCH ~ ANGLES 3
DESCRIPTIVE DATA
DECIMAL-INCH METRIC
FABSTAR 4030
GROUND SCREW .0 .1 0. 1.0mm DESIGNED DRAWN DATE SCALE
12 11 10 9 8 7 6 5 4 3 2 1
430429-460
LEGEND
PRIMARY VOLTAGE CHANGEOVER
SEE SHEET 3 FOR INFORMATION
B1 FAN MOTOR
H T1 H
C1-3 CAPACITOR 67,000 MFD 35V DC.
C5-9 CAPACITOR .047 MFD 400V DC
INPUT
C10-12 CAPACITOR .01 MFD 400V DC
CABLE
C10
CB1 CIRCUIT BREAKER 15 AMP
C7 R7
R8 R4 STAINLESS CR1-4 DIODE, NEG BASE
S3
DS1 LIGHT EMITTING DIODE (YELLOW)
K TO
MILDSTEEL
CR1 G CONTROL J1 RECEPTACLE 10 PIN CONTROL BOARD
SCR1
A
} BOARD J2 RECEPTACLE 6 PIN CONTROL BOARD
G G
J3 RECEPTACLE 11 PIN CONTROL BOARD
L2 L1 J4 RECEPTACLE 19 PIN
POSITIVE J5 RECEPTACLE OUTPUT 120V AC
C11 (+)
R3 R12 C5
L1 CHOKE
R9 C8 R5 L2 INPUT CHOKE
S1 C3 + C2 + C1 +
L1 CR4 M1 METER VOLTS 0-50V DC
M2 METER AMMETER 0-400 AMPS
K TO
CR2 G CONTROL
SCR2 R1 POTENTIOMETER 5K OHM 2W
L2 A
} BOARD
F R2 SHUNT 400 AMP 50MV F
R3 & R12 RESISTOR 10 OHM 100W
R2 (R12 NOT USED ON UNITS PRIOR TO JAN. 2000)
L3
NEGATIVE R4-6 RESISTOR 4.7 OHM 1W
R11 (-) R7 RESISTOR 2 OHM 100W
- + C6 R8-10 RESISTOR 680 OHM 3.25W
R11 RESISTOR, 49.9 KOHM, 1/4 WATT
D D
J1-3
X3
J1-2
J4 T1 24V
J1-1
X4 J1-4
A
B Y
J1-6
C DS1 J1-7
D J1-8
E J1-10 CONTROL BOARD
C X5 C
J1-9
F T1 24V
G X6
H
J2-1
J J2-2
K CB1 RV1 S2 J2-3
J2-4
L
X1
M T1
J2-6
J5 B1 170 11-00
N X2
P A J3-1 J3-11 K
120V TO TO
B G J3-2 J3-10 G B
R NO X2 SCR3
CONNECTIONS SCR1 { }
S5 S4 K J3-3 J3-9 A
S OUTSIDE DISTR.
T1 (OPT.) J3-4
T LOCAL DISTRIBUTION TABLE
X1 CHANGE RECORD
A J3-5 FINISH CODE PER 800001 NONE
U
V
} CW
TO
SCR2
G J3-6
E.C. No. DATE
FILE NAME
830877S2
PLOT DATE
11-14-00
ACTIVITY REPLACED BY REPLACES
CONFIDENTIAL: This drawing, including all information SIZE DWG. NO. SHEET 2
contained thereon, is the exclusive and confidential property of
R
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others, A THERMADYNE Company R
D 830877
in whole or in part, except with express written permission.
TROY, OHIO 45373 , U.S.A.
12 11 10 9 8 7 6 5 4 3 2 1
430429-460
CONNECTIONS FOR 200/230/460 VOLT CONNECTIONS FOR 230/460/575 VOLT CONNECTIONS FOR 400 VOLT
1 2 3 4 5 6 1 2 3 4 5 6
H INPUT INPUT H
SWITCH 2B RD SWITCH 2B RD
INPUT
1 BK 1B BK ATTACH WIRES 1 BK 1B BK ATTACH WIRES SWITCH
L1 (BK) L1 (BK)
1A BK AS SHOWN TO 1A BK AS SHOWN TO ATTACH WIRES
S1 S1 L1 (BK) 1 BK
L2 (RD) 2 RD CONNECT FOR L2 (RD) 2 RD CONNECT FOR AS SHOWN TO
2A RD 2A RD S1
200 VOLTS 230 VOLTS L2 (RD) 2 RD CONNECT FOR
L3 (WT) 3 WT L3 (WT) 3 WT
3A WT 3A WT 400 VOLTS
3B WT 3B WT L3 (WT) 3 WT
GND (GN) GND (GN)
GND SCREW GND SCREW GND (GN)
ON LIFTING ON LIFTING
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 GND SCREW
INPUT YOKE INPUT YOKE
ON LIFTING
CABLE CABLE INPUT YOKE 1 2 3
CABLE
G G
1 2 3 4 5 6 1 2 3 4 5 6
INPUT INPUT
SWITCH SWITCH 1B
1 BK 1B BK 2B RD ATTACH WIRES 1 BK BK ATTACH WIRES
L1 (BK) L1 (BK)
1A BK AS SHOWN TO 1A BK AS SHOWN TO
S1 2 RD S1 2 RD
L2 (RD) CONNECT FOR L2 (RD) CONNECT FOR
2A RD 2A RD
3 WT
230 VOLTS 3 WT 460 VOLTS
L3 (WT) L3 (WT) T1
3A WT 3B WT 3A WT
GND (GN) GND (GN) 2B RD 3B WT
1A
GND SCREW GND SCREW
F ON LIFTING ON LIFTING F
INPUT YOKE 1 2 3 4 5 6 7 8 9 INPUT YOKE 1 2 3 4 5 6
T1 T1 400 V COIL B
1A 1A 1B
1A
2A
5A
1B
1A
5A
1B
4A
3A
3A
2A
3B
200 V 230 V
6C
2A
5A
6A
6C
4A
6A
COIL B
D TRANSFORMER PHASE 2A TRANSFORMER PHASE 2A 2B D
CONNECTIONS TO 2A CONNECTIONS TO
VOLTAGE CHANGEOVER 30 V VOLTAGE CHANGEOVER 2B
3A 3A
TERMINAL BLOCKS COIL A TERMINAL BLOCKS 115 V COIL A
(ON LIFTING YOKE) 4A (ON LIFTING YOKE) 4A 1C
30 V
5A 1C
5A 5A
200 V 230 V
COIL C
2C
6A 6A
2B
5B
6B
2C
4B
6B
4C
400 V
4B
3B
4C
3C
5C
5C
2B
3C
2C
COIL C
2B
5B
1C
2C
5B
1C
5C
1B 1B
C C
400 VOLT
200 V 230 V
POWER
2B 2B TRANSFORMER
T1
2B
1A 30 V 2C
2A 1A 3B
3B
2A COIL B 2A 115 V COIL B
3A 4B 3A
30 V 4B
4A COIL A 4A COIL A
5B
5A 5A
5A 5B 6A 5B
6A 170 11-00
200 V 230 V
B 6B 6B B
1B
2B 1B
1C 1C OUTSIDE DISTR.
200/230/460 VOLT 2B 230/460/575 VOLT 2B
DISTRIBUTION TABLE
POWER 3B POWER 3B
4B COIL B 200 V 4B COIL B 230 V CHANGE RECORD FINISH CODE PER 800001 NONE
TRANSFORMER TRANSFORMER E.C. No. DATE
5B 5B FILE NAME PLOT DATE ACTIVITY REPLACED BY REPLACES
T1 5B 2C T1 6B 2C 830877S3 12-1-01
6B MATERIAL NO. QUANTITY-U.M. COMM. CLS.
UNLESS OTHERWISE SPECIFIED
2C
DIMENSIONS ARE IN INCHES/MILLIMETERS
30 V 3C TOLERANCES BELOW APPLY EXCEPT FOR MATERIAL SPEC.
3C VENDOR DESIGNED PARTS AND ITEMS.
COIL C 115 V COIL C PRODUCED TO RECOGNIZED STANDARDS. TITLE
12 11 10 9 8 7 6 5 4 3 2 1
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
April 2006