ESAB Wire Speed Calibration for Motor Control PCB in all Fabricator Mig Welders Installation guide

Brand: ESAB

Model: Wire Speed Calibration for Motor Control PCB in all Fabricator Mig Welders

Type: Installation guide

September 29, 2006 1 0-4953_AC

General Information

This kit provides a field-installable Motor Control PCB

with installation and wire speed calibration instructions

for the Thermal Arc Fabricator MIG Welders listed below:

Fabricator 131

Fabricator 181

Fabricator 190

Fabricator 210

Fabricator 251

Fabricator 281

Manual No. 0-4953

Rev AC

Wire Speed Calibration for

Motor Control PCB 7977964

in all Fabricator MIG Welders

Installation Instructions

Recommended Tools

Method 1

• Contact tachometer with cone adapter

• Ratchet wrench with ½-inch and 5mm sockets or

equivalent nutdrivers

• Medium slip-joint pliers

• Miniature philips screwdriver

• Large flat-head screwdriver (Fabricator 131, 181

and 190)

NOTE

An assistant is also recommended in Method

1 to either hold and read the Tachometer or to

adjust the wire feed trim pots.

Method 2

• Tape measure

• Stop watch

• Ratchet wrench with ½-inch and 5mm sockets or

equivalent nutdrivers

• Medium slip-joint pliers and wire cutters

• Miniature philips screwdriver

• Large flat-head screwdriver (Fabricator 131, 181

and 190)

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermalarc.com

WARNING

Disconnect the Fabricator from the input

power supply voltage before disassembling.

WARNING

Never open the Power Source covers unless

the Mains Supply Voltage to the Power

Source is disconnected from the Mains

power point and the ON/OFF Power Switch

Indicator is off.

WARNING

There are extremely dangerous voltage and

power levels present inside this Power

Source. Do not attempt to diagnose or repair

unless you have had training in power

electronics measurement and

troubleshooting techniques.

NOTE

The new Motor Control PCB must be installed

in the Fabricator before the calibration

procedure can be made.

September 29, 2006 2 0-4953_AC

Installation

1. Shut down the Fabricator and disconnect it from

the Mains Supply Voltage.

CAUTION

See WARNINGS on the previous page.

2. Remove all of the 5mm sheet metal screws from

the hinged cover (N/A in Fabricator 190) and from

the stationary cover.

3. Remove both covers.

4. Locate the Motor Control PCB 7977964 in the

electronics side. Refer to Figure 1.

Motor Control PCB

Board Identiﬁcation # (7977964)

Art # A-07892

Figure 1: Typical Motor Board Location

5. Carefully disconnect the four (4) wire harnesses as

numbered in Figure 2.

6. Using slip-joint pliers, squeeze the nylon locking tab

of one of the PCB mounting posts while pulling that

corner of the board off of the post. Refer to Figure

2. Repeat this procedure on the other 3 posts and

remove the Motor Control PCB from the Fabricator.

Mounting Post (4)

123

Art # A-07893

Figure 2: Disconnect Motor Control PCB

September 29, 2006 3 0-4953_AC

7. Install the new Motor Control PCB by aligning the four mounting holes over the four nylon locking tabs and

press each corner down to lock in place. Re-connect the (4) wire harnesses as numbered in Figure 2.

ATTENTION

RE-USE JUMPER IN FABRICATOR 131, 181 & 190

If the Motor Control PCB is being replaced in a FABRICATOR 131, 181 or 190, remove the jumper

shown in Figure 3 from the old board and re-use it in the new board by installing it over the same two

pins (JD1 and JD2).

Jumper (Fabricator 131, 181, 190 Only) V MAX Trim Pot

V MIN Trim Pot

Mounting Holes (4)

Art ## A-07894

Figure 3: Location of Trim Pots and Jumper

Take note of the VMIN and VMAX trim pot locations on the Motor Control PCB.

September 29, 2006 4 0-4953_AC

4. Remove the drive roll retaining bolt with a ½-inch

socket. Leave drive roll in place. Refer to Figure 6.

NOTE:

Use a large flat-head screwdriver to remove

the drive roll retaining screw in the Fabricator

131, 181 & 190.

Art # A-07897

Figure 6: Remove Drive Roll Retaining Bolt

3. Jump pins 1 and 2 (may be marked as A and B in

some models) in the gun switch receptacle. This

may be easier to do from the inside of the Fabricator.

Refer to Figure 5.

Art # A-07896

Calibration Procedure

Method 1 - Tachometer

CAUTION

The Fabricator should still be disconnected

from the Mains Power Supply at this point.

1. Remove wire from feeder if present.

2. Set the voltage knobs on the front panel of the

Fabricator to their highest setting. Refer to Figure 4.

NOTE

The voltage knobs in Figure 4 are shown for

illustration purposes only.

The voltage knobs

on your Fabricator may vary.

13V - 16V

17V - 21V

22V - 31V

Art # A-07895

Figure 4: Typical Voltage Control Knobs

Figure 5: Typical Gun Switch Receptacle

September 29, 2006 5 0-4953_AC

5. Re-connect the Fabricator to the Mains Supply

Voltage.

WARNING

Do not make contact with any of the electrical

components on the side of the Fabricator

where the fixed protective cover has been

removed.

6. Set the wire speed knob on the front panel of the

Fabricator to its lowest setting. Refer to Figure 7.

Art # A-07898

Figure 7: Typical Wire Speed Knob Set Low

7. Engage the tachometer's cone adapter into the

vacant drive roll hole. Refer to Figure 8.

8. Turn on the Fabricator's main power switch. This

will actuate the wire feed drive.

WARNING

Secure loose hair or clothing and prevent

any foreign objects from entering the

spinning drive rolls.

Handheld contact tachometer

with cone adapter

Art # A-07899

Figure 8: Engage Tachometer into Wire Drive

September 29, 2006 6 0-4953_AC

9. Have an assistant adjust the VMIN trim pot on the Motor Control PCB to obtain a tachometer reading that is

within the Low RPM range in Table 1. Refer to Figure 3 for trim pot locations.

Tachometer Readings in IPM

Fabricator Model Low RPM Range High RPM Range

281 8 – 10 180 – 190

251 8 – 10 180 – 190

210 8 – 10 180 – 190

190 8 – 12 190 – 200

181 8 – 12 190 – 200

131 8 – 12 190 – 200

Table 1: RPM Calibration Settings

10.Set the wire speed knob on the front panel of the Fabricator to its highest setting. Refer to Figure 9.

Art # A-07900

Figure 9: Typical Wire Speed Knob Set High

11.Have an assistant adjust the VMAX trim pot on the Motor Control PCB to obtain a tachometer reading that is

within the High RPM range in Table 1. Refer to Figure 3 for trim pot locations.

12.Re-assemble covers to the Fabricator.

September 29, 2006 7 0-4953_AC

Calibration Procedure

Method 2 - Time and Measure

CAUTION

The Fabricator should still be disconnected

from the mains power supply at this point.

1. Disconnect the Gun Polarity Lead from the

terminal that it is connected to (positive or

negative). Also disconnect the work lead from the

terminal that it is connected to (positive or

negative). Refer to Figure 10.

WARNING

This method involves running wire through

the feeder on to the floor that will be

electrically "hot" if the Gun Polarity Lead is

not disconnected. DO NOT BEGIN THIS

CALIBRATION METHOD UNTIL THE GUN

POLARITY AND WORK LEADS ARE

DISCONNECTED.

2. Connect the torch lead. Refer to Figure 11.

a. Route the gun cable through the access hole in

the front panel.

b. Loosen the thumbscrew and insert the gun

cable end as far as it will go. Tighten the

thumbscrew.

c. Align the keyways of the Gun Switch Connector

with the receptacle below the gun cable and plug

them together. Secure by turning the locking

ring to the right (clockwise ).

Trigger Receptacle

Front Panel

Access Hole

Art # A-07902

Figure 11: Typical Torch Lead and Trigger Connection

Disconnect

Work Lead

Disconnect

Work Lead

Disconnect

Gun Polarity Lead

Disconnect

Gun Polarity Lead

Art # A-07901

Figure 10: Disconnect Gun Polarity and Work Leads

September 29, 2006 8 0-4953_AC

3. Install Wire Spool. The Fabricator 210 is shown.

Other models may vary slightly. Refer to Figure 12.

NOTE:

This is a trial and error method that will involve

discharging one foot of wire during each test

for the low speed calibration and four feet

during each test for the high speed calibration.

Therefore, be sure that there is a least 30 feet

of wire available on the spool in order to

complete this calibration procedure.

a. Remove Wire Spool Hub Nut by turning it

counter-clock wise (to the left).

b. Remove the spring from the hub.

c. Place a Wire Spool onto the hub, loading it so

that the wire will feed off the bottom of the spool

as the spool rotates counter-clockwise. Make

sure to align the spool alignment pin on the hub

with the mating hole in the wire spool.

d. If using a 10 lb. wire spool place the spring on

the exposed hub. Do not use the spring for larger

wire spools that cover the entire hub.

e. Replace the Wire Spool Hub Nut by turning it

clock wise (to the right).

Drive Pin

Art # A-07903

Wire Spool

Hub Nut

*Spring

Wire Spool

* The Spring is for use with

smaller 10 lb wire spools only

Figure 12: Wire Spool Installation

4. Insert wire into the feedhead. Refer to Figures 13

and 14.

a. Loosen the Spring Pressure Adjusting Knob

if needed and swing it down (first part of

Figure 13).

b. Move the Pressure (top) Roller Arm by swinging

it to the right (second part of Figure 13).

c. Make sure the end of the wire is free of any

burrs and is straight. Pass the end of wire

through the Inlet Wire Guide and over the

Feedroll. Make certain the proper groove is being

used (second part of Figure 13).

d. Pass the wire through the outlet guide and into

the Gun Liner of the Gun Cable (second part of

Figure 13).

e. Close the Pressure Roller Arm (Figure 14).

f. Swing the Spring Pressure Adjusting Knob back

into place (Figure 14).

g. Use the Spring Pressure Adjusting Knob to create

a “snug” condition; clockwise to tighten and

counter-clockwise to loosen (Figure 14).

h. Figure 15 shows the result with wire installed.

Continue to the next section for proper setting

of tension.

September 29, 2006 9 0-4953_AC

2 - Swing

Pressure arm

open

1 - Loosen

Adjuster and

swing down

3 - Feed wire

through here

4 - Feed wire

through here

Art # A-07143

Figure 13: Opening Pressure Arm and Inserting Wire

6 - Swing the

Adjuster back into

place.

7 - Adjust

the tension

Art # A-07144

5 - Swing

the Pressure

Arm closed

Figure 14: Closing Pressure Arm and Adjusting Tension

Art # A-07162

Wheel Brake Hex Head Bolt

Spool Hub Nut

Pressure Adjustment

Device

Figure 15: Wire Installed

September 29, 2006 10 0-4953_AC

5. Adjust Wirefeeder Drive Roller Pressure

The roller on the swing arm applies pressure to the

grooved roller via an adjustable tension devise. The

Tension Adjuster should be set to a minimum pressure

that will provide satisfactory wire feed without slippage.

If slipping occurs, and inspection of the wire out of the

MIG gun reveals no deformation or wear, the conduit

liner should be checked for kinks or clogging from metal

flakes. If this is not the cause of slipping, the feedroll

pressure can be increased by rotating the Tension

Adjusting Knob clockwise. The use of excessive

pressure may cause rapid wear of the feed roller, motor

shaft and motor bearings.

6. Adjust Wire Reel Hub Brake

The wire reel hub incorporates a friction brake which is

adjusted during manufacture for optimum braking. If it

is considered necessary, adjustment can be made by

turning the hex head bolt inside the open end of the

wire reel hub. Clockwise rotation will tighten the brake.

Refer to Figure 13.

CAUTION

Excessive tension on the brake will cause

rapid wear of mechanical wire feed parts,

over heating of electrical components and

possibly an increased incidence of wire

burnback into the contact tip.

NOTE

Correct adjustment will result in the wire reel

circumference continuing no further than

0.75" (20mm) after release of the Gun Trigger

Switch. The wire should be slack without

becoming dislodged from the reel.

7. Re-connect the Fabricator to the Mains Supply

Voltage and turn on the Power Switch.

WARNING

Do not make contact with any of the electrical

components on the side of the Fabricator

where the fixed protective cover has been

removed.

8. Remove the contact tip and nozzle from the end of

the torch and squeeze the torch trigger until several

inches of wire comes out of the conduit tube. Refer

to Figure 16.

9. Replace the contact tip and nozzle and trim off the

wire so it is flush with the end of the nozzle. Refer to

Figure 16.

Art # A-07904

Contact Tip

Diffuser

Trigger

Figure 16: Route Wire Through Torch

10.Set the wire speed knob on the front panel of the

Fabricator to its lowest setting. Refer to Figure 17.

Art # A-07898

Figure 17: Typical Wire Speed Knob Set Low

September 29, 2006 11 0-4953_AC

11.Set the voltage knobs on the front panel of the

Fabricator to their highest setting. Refer to Figure 18.

13V - 16V

17V - 21V

22V - 31V

Art # A-07895

Figure 18: Typical Voltage Control Knobs

12.Start the stopwatch and pull the torch trigger

simultaneously. At the end of exactly ONE (1)

MINUTE, release the trigger and measure the length

of wire that protrudes from the end of the torch

nozzle.

13.The protruded length should be within the LOW RPM

range in Table 2. Turn the VMIN trim pot on the

Motor Control board clockwise to increase the wire

length and counter-clockwise to reduce it. Refer to

Figure 3 for trim pot locations.

14.Trim off or re-coil the protruded wire to be flush

with the end of the nozzle. Repeat the 1 minute timed

discharge, measure the wire and re-adjust the trim

pot accordingly. Continue this process until the

discharged length is within the LOW RPM range in

Table 2.

15.Set the wire speed knob on the front panel of the

Fabricator to its highest setting. Refer to Figure 19.

Art # A-07900

Figure 19: Typical Wire Speed Knob Set High

16.Start the stopwatch and pull the torch trigger

simultaneously. At the end of exactly 15 SECONDS,

release the trigger and measure the length of wire

that protrudes from the end of the torch nozzle.

17.The protruded length should be within the HIGH RPM

range in Table 2. Turn the VMAX trim pot on the

Motor Control Board clockwise to increase the wire

length and counter-clockwise to reduce it. Refer to

Figure 3 for trim pot locations.

18.Trim off or re-coil the protruded wire to be flush

with the end of the nozzle. Repeat the 1 minute timed

discharge, measure the wire and re-adjust the trim

pot accordingly. Continue this process until the

discharge length is within the HIGH RPM range in

Table 2.

19.Re-assemble covers to the Fabricator.

Timed Wire Lengths (Inches)

Fabricator Model Low RPM Range High RPM Range

281 4

– 8 36 ½ – 39

251 4

– 8 36 ½ – 39

210 4

– 8 36 ½ – 39

190 4 ¾ – 7 27 – 29

181 4 ¾ – 7 27 – 29

131 4 ¾ – 7 27 – 29

Table 2: Wire Discharge Over Time

September 29, 2006 12 0-4953_AC

September 29, 2006 13 0-4953_AC

Thermadyne USA

2800 Airport Road

Denton, Tx 76207 USA

Telephone: (940) 566-2000

800-426-1888

Fax: 800-535-0557

Email: [email protected]

Thermadyne Canada

2070 Wyecroft Road

Oakville, Ontario

Canada, L6L5V6

Telephone: (905)-827-1111

Fax: 905-827-3648

Thermadyne Europe

Europe Building

Chorley North Industrial Park

Chorley, Lancashire

England, PR6 7Bx

Telephone: 44-1257-261755

Fax: 44-1257-224800

Thermadyne, China

RM 102A

685 Ding Xi Rd

Chang Ning District

Shanghai, PR, 200052

Telephone: 86-21-69171135

Fax: 86-21-69171139

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A

Rawang Integrated Industrial Park - Jln Batu Arang

48000 Rawang Selangor Darul Ehsan

West Malaysia

Telephone: 603+ 6092 2988

Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street

Preston, Victoria

Australia, 3072

Telephone: 61-3-9474-7400

Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L.

Via Benaco, 3

20098 S. Giuliano

Milan, Italy

Tel: (39) 02-98 80320

Fax: (39) 02-98 281773

Thermadyne International

2070 Wyecroft Road

Oakville, Ontario

Canada, L6L5V6

Telephone: (905)-827-9777

Fax: 905-827-9797

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

World Headquarters

Thermadyne Holdings Corporation

Suite 300, 16052 Swingley Ridge Road

St. Louis, MO 63017

Telephone: (636) 728-3000

Fascimile:

(636) 728-3010

Email: sales@thermalarc.com

www.thermalarc.com

ESAB Wire Speed Calibration for Motor Control PCB in all Fabricator Mig Welders Installation guide

Brand: ESAB

Model: Wire Speed Calibration for Motor Control PCB in all Fabricator Mig Welders

Type: Installation guide

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ESAB Wire Speed Calibration for Motor Control PCB in all Fabricator Mig Welders Installation guide

ESAB Wire Speed Calibration for Motor Control PCB in all Fabricator Mig Welders Installation guide

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