Thermal Arc Fabricator 250C III User manual

FABRICATOR
MIG Power Supplies
Operation Manual
Version No: AW-02Issue Date: July 13th, 2012
Operating Features
250C III
320C III
320S III C/W VFE 4C III
400S III C/W VFE 4C III
500S III C/W VFE 4C HS III
250
AMP 320
AMP 400
AMP
CC
500
AMP
DC

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud to
have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate
your nearest distributor or service agency call Thermadyne
Customer Service on (44) 01257 224824.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid
potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for
Thermadyne Industries. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.
We distinguish ourselves from our competition through market-
leading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.

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 judgement, the Manufacturer assumes no
liability for its use.
Fabricator 250C III MIG Welding Machine, Part Number - FAB250C
Fabricator 320C III MIG Welding Machine, Part Number - FAB320C
Fabricator 320S III MIG Welding Machine, Part Number - FAB320S
Fabricator 400S III MIG Welding Machine, Part Number - FAB400S
Fabricator 500S III MIG Welding Machine, Part Number - FAB500S
Published by:
Thermadyne Industries Ltd
Chorley North Industrial Park
Chorley
Lancashire
PR6 7BX
England
www.thermadyne.com
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: March 1th, 2012
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
Record the following information for Warranty purposes:

TABLE OF CONTENTS
SECTION 1: SAFETY PRECAUTIONS 1
1.01 Safety Instructions and Warning 1
1.02 Declaration of Conformity 5
1.03 Statement of Warranty 6
71.04 Symbol Legend
SECTION 2: INTRODUCTION AND DESCRIPTION 8
2.01 How to use this Manual 8
2.02 Equipment Identification 8
2.03 Receipt of Equipment 8
2.04 Description 9
2.05 Safety 9
2.06 Transporting Methods 9
2.07 Protected Filter Lenses 9
2.08 User Responsibility 10
2.09 Duty Cycle 10
SECTION 3: INSTALLATION RECOMMENDATIONS 11
3.01 Environment 11
3.02 Location 11
3.03 Electrical Input Connections 11
3.04 Electrical Input Requirements 12
3.05 Input Power 13
3.06 Specifications 14
SECTION 4: OPERATOR CONTROLS 16
4.01 Fabricator Layout 250C & 320C 16
4.02 Fabricator Layout 320S & 400S 18
4.03 Fabricator Layout 500S 22
SECTION 5: UNDERSTANDING AND SETTING UP FOR WELDING 25
5.01 Power Source Features 25
5.02 Basic Control Panel - Overview
5.03 Digital Control Panel - Overview
26
5.04 Digital Control Panel - Description
5.05 Wire Feeder Motor & Feedroll Assembly
5.06 Wire Feed Rollers
27
28
30
31
31
5.05 Spool holder description
32
SECTION 6: GETTING STARTED
32
6.01 Torch Connection
32
6.02 How to connect the work lead
32
6.03 Where to connect the work clamp
33
6.04 How to connect to the mains
33
6.05 How to fit the wire spool
33
6.06 Inserting the wire
35
6.07 How to connect the gas cylinder
35
6.08 How to configure the machine for aluminium welding

SECTION 7: OPERATION 36
367.01 Setting welding current and voltage
7.02 Welding modes 36
7.03 Secondary parameters 36
7.04 Two stroke 37
37
7.05 Four stroke
7.06 Spot and stitch welding 38
SECTION 8: BASIC WELDING TECHNIQUE 39
8.01 Setting of the Power Source 39
8.02 Position of MIG Torch 39
8.03 Distance of the MIG Torch Nozzle to the Work Piece 39
8.04 Travel Speed 39
8.05 Electrode Wire Size Selection 39
8.06 Stitch Welding Operation 40
8.07 Spot Welding Operation 40
SECTION 9: ROUTINE MAINTENANCE & INSPECTION 41
SECTION 10: BASIC TROUBLESHOOTING 42
10.01 Porosity 42
10.02 Inconsistent wire feed 43
10.03 Welding Problems 44
10.04 Power Source Problems 45
SECTION 11: SPARE PARTS 48
11.01 Parts description Fabricator 250C & 320C 48
4911.01 Spare part numbers Fabricator 250C & 320C
11.02 Parts description Fabricator 320S & 400S 51
11.02 Spare part numbers Fabricator 320S & 400S 52
11.04 Spare part numbers Fabricator 500S 57
11.05 VFE 4C HS WFU Description + Spare Part Numbers 59
11.06 Water Cooler Parts Description + Spare Parts List 61
SECTION 12: MACHINE SCHEMATICS 62
12.01 Schematic for the FAB 250C & 320C 62
12.02 Schematic for the FAB 320S & 400S
12.03 Schematic for the FAB 500S
63
12.04 Wire Feed Unit Schematic
64
65
SECTION 13: Optional accessories 66
11.03 VFE 4C WFU Description + Spare Part Numbers 54
11.04 Parts description Fabricator 500S 56

Figures Description
Figure No Description
Figure 1 Colour Picture of Fabricator Family Front page
Figure 2 Symbol Legend 7
Figure 3 Electrical Input Connections 12
Figure 4 Fabricator Layout 250III / 320 Compact 16
Figure 7 Basic Control Panel - Overview 26
Figure 8 Digital Control Panel - Overview 27
Figure 9 Digital Control Panel Description 28
Figure 10 Wire Feed Motor Assembly - 2 & 4 Roll 30
Figure 11 Feed Roll Rollers Information 31
Figure 12 Spool Holder Description 31
Figure 13 Torch Connection 32
Figure 14 Connection of Work Lead 32
Figure 15 Connection on Work Clamp 33
Figure 16 Spool Holder Description 33
Figure 17 Wire Feed Description 34
Figure 18 Pressure Roll Tension 34
Figure 19 Aluminium Liner Information 35
Figure 20 Two Stroke Description 37
Figure 21 Four Stroke Description 37
Figure 22 Spot & Stitch Description 38
Figure 23 Spot & Stitch Description 38
Figure 24 Position of MIG Torch 39
Figure 25 Wire Size Penetration Comparison 40
Figure 26 Parts Description Fab 250C & 320C 48
Figure 27 Parts Description Fab 320S & 400S 51
Figure 28 VFE 4C III W.F.U. Parts Description + Spare Part No 54
Figure 29 Parts Description Fab 500S 56
Figure 30 VFE 4C 4S III W.F.U. Parts Description + Spare Part No 59
Figure 31 Water Cooler Parts description + Spare Parts List 61
Figure 32 Power Source Schematic for Fab 250C & 320C 62
Figure 33 Power Source Schematic for Fab 320S & 400S 63
Figure 6 Fabricator Layout 500III Seperate 22
Figure 5 Fabricator Layout 320III / 400III Seperate 18
Figure 34 Power Source Schematic for Fab 500S 64
Figure 35 Wire Feed Unit Schematic 65

SECTION 1: Safety Instructions and Warnings
WARNING
ARC WELDING can be hazardous.
Protect yourself and others from possible serious injury or death. Keep children away. Pace maker 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. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain
practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are out lined 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.
ELECTRIC SHOCK can kill.
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 terminal
circuits are also live when power is on. In
semiautomatic 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.
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.
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.
5. Properly install and ground this equipment according to its
Owner's Manual and national, state, and 10 cal codes.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
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, under sized or poorly spliced cables.
9. Do not wrap cables around your body.
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. 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.
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. Wear a welding helmet fitted with a proper shade of filter (see
ANSI 249.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved earplugs or earmuffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
Welding or Cutting
operation
Electrode size Metal Thickness or
Welding Current
Filter
shade
no.
Welding or Cutting operation Electrode size Metal
Thickness or Welding
Current
Filter
shade no.
Torch soldering All 2 Gas metal arc welding
Torch brazing All 2 or 3 Non Ferrous base metal All 11
Oxygen cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12
Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen welding All 12
Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc welding All 12
Gas welding Plasma arc Welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Carbon Arc Gouging
Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Light 12
Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14
Shielded metal-arc welding (stick) electrodes Plasma arc cutting
Under 5/32 in., 4 mm 10 Light Under 300 Amp 9
Under 5/32 to ¼ in., 4 to 6.4mm 12 Medium 300 to 400 Amp 12
Over ¼ in., 6.4 mm 14 Heavy Over 400 Amp 14
1

FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not
breathe the fumes.
2. If inside, ventilate the area and/or use 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 (MSDS) and the
manufacturer's instruction for metals, consumables, coatings, and
cleaners.
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 vapours 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 re moved 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.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work
piece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, over
heating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material
Remove all flammables within 35ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
3. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4. Watch for fire, and keep a fire extinguisher nearby.
5. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
6. Do not weld on closed containers such as tanks or drums.
7. Connect work cable to the work as close to the welding area as
practical to prevent welding current from travelling long, possibly
unknown paths and causing electric shock and fire hazards.
8. Do not use welder to thaw frozen pipes.
9. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Flying sparks and hot metal can
cause Injury
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
CYLINDERS can explode if damaged.
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 carefuIIy.
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 or equipment cylinder rack to prevent falling
or tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
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.
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 air intakes.
2

ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near
any sparks or open flames.
3. Allow engine to cool before fuelling. If possible, check and add fuel
to cold engine before beginning job.
4. Do not overfill tank - allow room for fuel to expand away from any
building air intakes.
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 or connecting unit.
3. Have only qualified people remove guards or covers 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. Re-install panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
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.
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
To reduce magnetic fields in the work place, use the following procedures:
1. Keep cables close together by twisting or taping them. 2. Do not coil or drape cables around the body.
3. Arrange cables to one side and away from the operator. 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.
3

Page left blank intentionally
4

1.02 DECLARATION OF CONFORMITY
Manufacturer and Merchandiser of Quality Consumables and Equipment: Thermal Arc
Address: Thermadyne Europe
Europa Building
Chorley North Industrial Park
Chorley
Lancashire
England
PR6 7BX
Description of equipment:
Welding Equipment (GMAW) Thermal Arc Fabricator 250C III, 320CIII, 320S III, 400S III
& 500S III and associated accessories.
The equipment described in this manual conforms to all applicable aspects and regulations
of the “Low Voltage Legislation“ (Low Voltage Directive (LVD) 2006/95/EC ) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of
the “Electromagnetic Compatibility (EMC) Legislation” (Directive 2004/108/EC) and to the
National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts
used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications:
The product is designed and manufactured to a number of standards and technical requirements.
Among them are:
• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
• ISO/IEC.60974-1 (BS.638-PT10) (EN.60.974-1) (EN50192) (EN50078) applicable to welding
equipment and associatedaccessories.
• For environments with increased hazard of electrical shock, Power Supplies bearing the
'S' mark conform to EN50192 when used in conjunction with hand torches with exposed cutting
tips, if equipped with properly installed standoff guides.
• Extensive product design verificatio is conducted at the manufacturing facility as part of the
routine design and manufacturing process. This is to ensure the product is safe, when used
according to instructions in this manual and related industry standards, and performs as
specifed. Rigorous testing is incorporated into the manufacturing process to ensure the
manufactured product meets or exceeds all design specifications.
Thermadyne has been manufacturing products for more than 30 years, and will continue to
achieve excellence in our area of manufacture.
Manufacturers responsible representative:
Steve Ward
Operations Director,
Thermadyne Europe,
Europa Building,
Chorley N Industrial Park,
Chorley, Lancashire,
England, PR6 7BX.
5

1.03 STATEMENT OF WARRANTY
In accordance with the warranty periods stated below, Thermadyne guarantees the proposed
product to be free from defects in material or workmanship when operated in accordance with the
written instructions as defined in this operating manual.
Thermadyne welding products are manufactured for use by commercial and industrial users and
trained personnel with experience in the use and maintenance of electrical welding and cutting
equipment.
Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due
to defects in material or workmanship within the warranty period. The warranty period begins on
the date of sale to the end user.
Thermal Arc Fabricator 250C III, 320C III, 320S III, 400S III & 500S III
Component Warranty Period
Power Source 2 Years
Wire Feed Unit 2 Years
Optional Cooler 2 Years
If warranty is being sought, Please contact your Thermadyne product supplier for the warranty
repair procedure.
Thermadyne warranty will not apply to:
• Equipment that has been modified by any other party other than Thermadyne’s own service
personnel or with prior written consent obtained from Thermadyne Service Department.
• Equipment that has been used beyond the specifications established in the operating
manual.
• Installation not in accordance with the installation/operating manual.
• Any product that has been subjected to abuse, misuse, negligence or accident.
• Failure to clean and maintain (including lack of lubrication, maintenance and protection),
the machine as set forth in the operating, installation or service manual.
Within this operating manual are details regarding the maintenance necessary to ensure trouble
free operation.
This manual also offers basic troubleshooting, operational and technical details including
application usage.
You may also wish to visit our web site www.thermadyne.com select your product class and then
select literature. Here you will find documentation including:
• Operator manuals
• Service manuals
• Product guides
Alternatively please contact your Thermadyne distributor and speak with a technical
representative.
NOTE
Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne
distributor or an Authorised Service Agent approved by the Company
January 2012
6

1.04 SYMBOL LEGEND
Figure 2.
7

SECTION 2: INTRODUCTION AND DESCRIPTION
2.01 How to use this Manual
This Operator owner’s manual applies to Part Numbers: FAB250C III, FAB320CIII,
FAB320S III, FAB400S III & FAB500S III
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:
WARNING
A WARNING gives information regarding possible personal injury
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 given below:
Thermadyne Customer Service
Thermadyne Industries Ltd
Europa Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7BX.
Phone: [phone]
Fax: [phone]
Include the Owner’s Manual number and equipment identification numbers.
Electronic copies of this manual can also be emailed to you at no charge in
Acrobat PDF format by contacting Thermadyne Customer Service on (44) 01257 261755.
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial
number appear on a nameplate fixed to the rear panel. In some cases, equipment
which does not have a control panel such as gun and cable assemblies is identified
only by the specification or part number printed on the shipping container.
Record the number for future reference.
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
distributor you purchased the equipment from.
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 unpacking the unit. Use care to
avoid damaging the equipment when using bars, hammers, etc, to unpack the unit.
8

2.04 Description
The Thermal Arc Fabricators are 400Volt 3 phase MIG machines which offer great
performance, A 250A & 320Amp option also a 420Amp output @ 30% duty cycle unit and
a 530Amp maximum output @ 25% duty cycle with 30 voltage steps along with separate
WFU's, digital meters and cylinder racks. The wire feed unit system has an option of up to
10m interconnection cables. The Wirefeeder has touch panel control pad incorporating
spot/stitch timers. The Wirefeeder also benefits from fitted wheels and conveniently
fits on a swivel mount on top of the power source or can be lifted off the pivot and
carried up on top of equipment or machinery up to 10m away. The Thermal Arc
Fabricator range are extremely versatile all round performers that offer excellent
performance on mild steel, stainless steel, aluminium, silicon bronze and some hard
facing wires with Argon based shielding gases. The Fabricators also gives excellent
results on mild steel using Carbon Dioxide shielding gas.
The following instructions detail how to correctly set up the welder and give guidelines
on gaining the best production efficiency from the Fabricator. Please read these
instructions thoroughly before using your Fabricator welder.
2.05 Safety
The following basic safety rules should always be followed:
• Ensure the machine is correctly installed, if necessary, by a qualified
electrician.
• Ensure the Power Supply is grounded correctly (electrically) in accordance with
local regulations.
• Excessive heat in the welding cables may cause fire. Never weld with poor
electrical connections, damaged welding cables or exceed the welding cable
current rating as this will produce excessive heat and may cause a fire.
• Always wear the correct protective clothing for protection from sparks, molten
particles and arc rays.
• When welding in confined spaces, always ensure adequate ventilation and
constant observation of the operator.
• Keep combustible materials away from the welding area. Have a suitable fire
extinguisher close by.
• Never watch the welding arc with naked eyes. Always use and wear a welding
mask fitted with the correct filter lens.
• Do not stand on damp ground when welding. For more complete safety advice
please read section 1.
2.06 Transporting Methods
These units are equipped with handles mounted on the front panel of power source.
If using a fork lift vehicle, place and secure unit on a suitable pallet before transporting.
If using an overhead crane, ensure correct slings are used before lifting.
2.07 Protective Filter Lenses
Protective filter lenses are provided to reduce the intensity of radiation entering the
eye thus filtering out harmful infrared, ultraviolet radiation and a percentage of the
visible light. Such filter lenses are incorporated within face shields. To prevent damage
to the filter lenses from molten or hard particles an additional hard clear glass or
special plastic external cover lens should be used. This cover lens should always be
kept in place and replaced before the damage impairs your vision while welding.
9

Approximate range of welding current Filter lens required for MIG
Up to 150 Shade 10
150-250 Shade 11
250-300 Shade 12
300-350 Shade 13
Over 350 Shade 14
2.08 User Responsibility
This equipment will perform as per the information contained herein when installed,
operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Defective equipment (including welding
leads) should not be used. Parts that are broken, missing, plainly worn, distorted or
contaminated, should be replaced immediately. Should such repairs or replacements
become necessary, it is recommended that such repairs be carried out by
appropriately qualified persons approved by Thermal Arc. Advice in this regard can be
obtained by contacting Thermal Arc.
This equipment or any of its parts should not be altered from standard specification
without prior written approval of Thermal Arc. The purchaser of this equipment shall
have the sole responsibility for any malfunction which results from improper use or
unauthorized modification from standard specification, faulty maintenance, damage or
improper repair by anyone other than appropriately qualified persons approve by
Thermal Arc.
2.09 Duty Cycle
The rated duty cycle of a welding Power Supply is the operating time it may be used at
its rated output current without exceeding the temperature limits of the insulation of the
component parts. To explain the ten minute duty cycle period the following example is
used. Suppose a welding Power Supply is designed to operate at 50% duty cycle, 250
amperes at 28 volts. This means that it has been designed and built to provide the
rated amperage (250A) at the rated load voltage (28V), for 5.0 minutes out of every 10
minute period (50% of 10 minutes is 5.0 minutes). During the other 5.0 minutes of the
10 minute period the Power Supply must idle and be allowed to cool. The thermal cut
out will operate if the duty cycle is exceeded.
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input
power conductors from de-energized supply line before moving the welding power
source.
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
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SECTION 3: INSTALLATION RECOMMENDATIONS
3.01 Environment
The Fabricator 250C III, 320C/S III, 400S III & Fabricator 500S III are NOT designed
for use in environments with increased hazard of electric shock.
Examples of environments with increased hazard of electric shock are:-
• Locations in which freedom of movement is restricted, so that the operator is
forced to perform the work in a cramped (kneeling, sitting or lying) position with
physical contact with conductive parts.
• Locations which are fully or partially limited by conductive elements, and in
which there is a high risk of unavoidable or accidental contact by the operator.
• Wet or damp hot locations where humidity or perspiration considerably
reduces the skin resistance of the human body and the insulation properties of
accessories.
3.02 Location
Be sure to locate the welder according to the following guidelines:
• In areas, free from moisture and dust.
• Ambient temperature between 0 degrees C and 40 degrees C.
• In areas, free from oil, steam and corrosive gases.
• In areas, not subjected to abnormal corrosive gases, vibration or shock.
• In areas, not exposed to direct sunlight or rain.
• Place at a distance of 300mm or more from the walls or similar that could
restrict natural air flow for cooling.
• The minimum ground clearance for these products is 130mm.
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3.03 Electrical Input Connections
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts
SHUT DOWN welding power source, disconnect input power employing
lockout/tagging procedures.
Lockout/tagging procedures consist of padlocking line disconnect switch in open
position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker
or other disconnecting device.
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3.04 Electrical Input Requirements
Operate the welding power source only from a three-phase 50/60 Hz, AC power
supply. The input voltage must match the electrical input voltage shown on the
input data label on the unit nameplate. Contact the local electric utility for information
about the type of electrical service available, how proper connections should be made,
and inspection required.
The line disconnect switch provides a safe and convenient means to completely
remove all electrical power from the welding power supply whenever necessary to
inspect or service the unit.
Note
This unit is equipped with a three-conductor with earth power cable that is connected
at the welding power source end for three-phase electrical input power.
Do not connect an input (BROWN, BLUE or RED) conductor to the ground terminal.
Do not connect the ground (YELLOW/GREEN) conductor to an input line terminal.
Refer to Figure 3:
1 Connect end of ground (YELLOW/GREEN) conductor to a suitable ground.
Use a grounding method that complies with all applicable electrical codes.
2 Connect primery power cable ends; line 1, line 2 and line 3 input conductors
to the de-energized line disconnect switch.
3 Use the below table as a guide to select line fuses for the disconnect
switch.
Input Voltage Fuse Size
3Phase 400 VAC 32 Amps
Electrical Input Connections
Note
Fuse size are based on not more than 200 percent of the rated input amperage of the
welding power source (please refer beck to the local Electrical Codes).
Figure 3.
Electrical Input Connections
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3.05 Input Power
Note
Note the available input power. Damage to the machine could occur if 460VAC or higher
is applied.
The following 400V Primary Current recommendations are required to obtain the
maximum welding current and duty cycle from this welding equipment:
WARNING
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Exceeding the duty cycle ratings will cause the thermal overload protection circuit to
become energized and shut down the output until the unit has cooled to normal
operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can cause damage to the welding power
source and will void the manufactures warranty.
NOTE
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Due to variations that can occur in manufactured products, claimed performance,
voltages, ratings, all capacities, measurements, dimensions and weights quoted are
approximate only. Achievable capacities and ratings in use and operation will depend
upon correct installation, use, applications, maintenance and service.
Model Primary Supply
Lead Size (Factory
Fitted)
Primary Current
Circuit Size
(Vin/Amps)
Max Current &
Duty Cycle
Fabricator 250C III 4 core 2.5mm sq 400 / 14A 250 @ 30%
Fabricator 320C III 4 core 2.5mm sq 400 / 17.5A 340 @ 25%
Fabricator 320S III 4 core 2.5mm sq 400 / 17.5A 340 @ 25%
Fabricator 400S III 4 core 4mm sq 400V / 24A 420 @ 30%
Fabricator 500S III 4 core 4mm sq 400V / 43A 530 @ 25%
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3.06 Specifications
FABRICATOR 250C III FABRICATOR 320C / 320S III
PRIMARY
Mains Input Voltage 3ph 400V 50Hz 3ph 400V 50Hz
Mains protection rating 16A slow blow 16A slow blow
Maximum power consumption 11.76 kVA 14.8 kVA
Power factor cos φ 0.9 0.9
SECONDARY
Current range I2 40A - 250A 40A - 340A
Open circuit voltage U20 19.4 - 45.4V 18.2 - 44.9V
Welding current l2 250A 340A
Output Voltage U2 26.5V
Duty
Cycle
30% 31V
Duty
Cycle
20%
Welding current l2 200A 230A
Output Voltage U2 24V
Duty
Cycle
60% 25.5V
Duty
Cycle
60%
Welding current l2 170A 200A
Output Voltage U2 22.5V
Duty
Cycle
100% 24V
Duty
Cycle
100%
Selection range (switched steps) 10 12
WIRE FEEDER
Supply voltage N/A 24Vac
Speed 1-19 m/min 1-19 m/min
Number of feed rolls 2 4
Spool + Spool weight max 300mm + 18 kg max 300mm + 18 kg
Dimensions H x W x D N/A 510 x 270 x 700 mm
SAFETY
Protection IP 23S IP 23S
Insulation class F F
Standards CE / EN 60 974-1 / EN 51099 CE / EN 60 974-1 / EN 51099
Weight 76kg C=99kg S=120kg
Dimensions H x W x D (fully assembled) 800 x 380 x 870 mm 800 / 1360 x 380 x 870 mm
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right
to change, improve or revise the specifications or design of this or any product without prior notice.
Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the
corresponding changes, updates, improvements or replacement of such items.
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