FABSTAR® 4030 Operating Manual
Contents
1. TROUBLESHOOTING REO LE _ 1068299 22 1 DUES e LIE LIO Jt Y 0 O z om 6 5 C rmm om R12 R13 E n passes 2 al el Lol 11 C OO LIT TTI J2 TEC XA ve O D O O cam T O co cim m dE cmn 000 b JP2 it d R68 TTY pol SERRE Figure 7 12 ADJUSTING TEST TEST POINTS POT VOLTAGE REMARKS 1 30 40 DC Checks positive supply voltage Checks R60 fuse to power sup ply TP1 TP3 15V 75V Checks voltage regulator TP4 TP3 Adjusts phase balance of all TP5 TP3 R12 Same as TP4 three phases TP6 R13 4 TP8 TP3 4002. I9VLIOA OLSNOILDINNOD ASWHd HIWHOASNVEL E SNL NO TINO a y 2 LDINNOD OLNMOHS 57 53 HOVLLY 007 SNOILDANNOD SLIOASLS 404 LIINNOD OLNMOHS SV S3ulM SLIOA09b 304 LDINNOD OLNMOHS SY 5 SLIOA0EZ LDINNOD OLNMOHS SV S38IM HIWHOASNVEL u3MOd 110 5 5 09 0 2 MOADNLLAN NO SH2018 1VNIWH3L OL SNOILDINNOD 3SVHd YIWYOISNVYL S S 09V 0 C SNOILDANNOD SLIOA 09 LDINNOD OLNMOHS SV 5 01 LDINNOD OLNMOHS SV S3uIM 002 123NNOD OLNMOHS SY S3YIM OA NO SH2018 IVNIWH3L JOVIIOA OLSNOLD3NNOD 3SVHd YIWWOISNVHL LL HIWHOASNVEL u3MOd 110 09 062 002 ay LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 LIMITED WARRANTY Thermal Arc Inc Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored insta
3. 9 1 April 20 2006 INTRODUCTION How To Use This Manual This Owner s Manual applies to just specification or part numbers listed on cover page 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 ANOTE 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 in your area listed in the inside back cover of this manual Include the Owner s Manual number and equipment identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com April 20 2006 430429 460 INTRODUCTION Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the rear panel In some cases the nameplate may be attached to the co
4. WELD position momen tarily approximately 1 2 second so the burnback circuit operates Burnback Operation When the gun switch is re leased the burnback circuit lowers the voltage to a value which is too low to maintain an arc The arc will go out If the wire continues to coast into the weld there is still enough power at the lower burn back voltage level to burn off the end of the wire This re moves the ball on the end of the wire and prepares it forthe next start It also prevents the wire from burn ing back to the tip or sticking in the weld puddle The burnbacktime and burnback voltageis selectable Jumpers on the Control Board control these val ues JP2 controls the burnback time and JP1 control the burnback voltage Selection is made by remov ing the Jumper Block and relocating Factory set tings are shown in Figure 5 1 The chart below shows some suggested settings for burnback time and voltage The gun must remain in the welding position after the gun switch is released to obtain the best results from the burnback circuit This method of burnback eliminates the need for a time adjustment and pre pares the wire for a good restart JP1 JP2 E 6v SHORT a a 18V 8 LONG Figure 5 8 c Turn off the gas at source JP1 Wire Wire JP2 Type Size Volts Time FACTORY SETTINGS 6 SHORT ER70S 3 035 6 Short ER70S 3 045 18 Short E71T 1 045 18 Short ER308L 035 6 Short ER4
5. Board 4 38 402037 9 Grommet Rubber 1 39 405362 2 Bushing Snap 2 40 203754 1 Panel Rear 1 All W 10080 5 Strain Relief 1 41 204375 Suppressor Surge Assembly 1 42 409870 Washer Insulator 4 All 43 203785 1 Bracket Mtg 2 All 44 409869 Bushing Insulator 4 All 45 203779 Heat Sink Top 1 All 46 404044 7 Thermostat Overload 1 All 47 201751 1 Bracket Mtg Fan Motor 1 All 48 830121 Bracket Mtg Fan Motor 1 All 49 12TW 595 1 Motor Fan 1 All 50 830120 Heat Sink Lower 1 All 51 402833 3 Diode Silicon Neg Base 1 All 51A W 10933 3 Diode Silicon Neg Base 3 All 52 409869 Grommet Mtg 4 All 52A 409870 Washer Insulator 4 All 53 405139 Rectifier Silicon Controlled 3 All 54 16DA 954 12 Pin Spring 3 All 55 405140 1 Clamp Mig 3 All 56 203776 1 Bar Bus 3 All 57 8RT 609 Fan 1 All 58 830887 Bar Bus 2 All 59 405278 13 Capacitor 3 All 60 361052 10 Clamp Mig 2 All 61 Deleted 62 830868 1 Base Mounting 1 All 63 830151 Panel Side Left 1 All 64 No Number 65 5CW 974 Bus Cable Stud 2 All 66 5CW 975 Bushing Insulator 2 All Not Illustrated 8 4 November 15 2000 430429 460 PARTS LIST Parts List for Figure 8 1 Part Description Qty Application No Number per Code Assy 67 5CW 976A Washer Insulating 4 All 68 No Number Washer FL ST 1 2 3 All 69 No Number Washer LK Std 1 2 4 All 70 No Number
6. April 20 2006 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial 430429 460 TABLE OF CONTENTS INTRODUCTION How To Use This 1 1 Equipment Identification 1 1 Receipt Of Equipment 1 1 Meanings Of Markings And Graphical Symbols 1 2 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 Gontrols and M eee GAG nb y a s 3 1 DULY CY Clee ad cr a 3 5 INSTALLATION 4 LOCATION artnet A A GS AA 4 1 4 1 Connection To Line Voltage 4 2 Input Connections To Power Source 4 3 Welding Esas o en RR o ee ER ARR ER Ra 4 3 OPERATION 5 MAINTENANCE Replacing SCRS x xd a A Me Ae Se 6 1 LUDTICA ION rs de e Rage 6 1 Inspection and Cleaning 6 1 TROUBLESHOOTING 7 Troubleshooting 11 7 1 Detailed Troubleshooting Instructions 7 4 PARTS LIST 8 Equipment Identification 8 1 How To Use This Parts 5 8 1 DIAGRAMS
7. Terminal 6 Pos 1 B 830904 Label Voltage Changeover 1 11 830152 Panel Side Right 1 12 408891 Label Ground 1 All 13 405362 1 Bushing Snap 1 All 14 83081 1 1 Panel Front Control 1 All 15 409623 2 Switch Power DPST 1 All 16 406806 3 Knob Control 1 All 17 402670 Receptacle Duplex 3 Wire 1 All 18 366826 1 Suppressor Assembly Mts on rear of Item 18 1 All 19 400254 Receptacle Box Solid Shell 1 All 20 203413 2 Door 1 21 203453 Hinge 2 22 368705 8 Capacitor W Leads Terminals 3 23 400707 3 Ammeter DC 1 All 24 409624 1 Voltmeter DC 1 All 25 400400 Switch SPST 1 All 26 401428 8 Potentiometer 1 All 27 405365 1 Switch SPST 1 All 28 203627 7 Circuit Breaker Pushbutton 1 All 29 830710 1 Diode Light Emitting 1 All 30 830709 1 Clip Retainer 1 All 31 830867 Choke Filter 1 All 32 830869 Transformer Main T1 1 A 830870 Transformer Main T1 1 B 830871 Transformer Main T1 1 C Not Illustrated November 15 2000 8 3 430429 460 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 33 203885 Choke Filter Input Assembly 1 All 34 830879 1 Bracket Mtg P C Board 1 All 35 830748 Label Voltage Changeover 1 A 830749 Label Voltage Changeover 1 B 830902 Label Voltage Changeover 1 C 36 203909B 4 Board P C Control 1 37 404460 1 Support
8. that is not exceeding 10 of nominal line voltage For example on a 460 volt 3 phase line the line voltage must not exceed 506 volts or be less than 414 volts Adjustments Preset at factory The follow ing describes the factory adjustments It is not in tended that the adjustments be made in the field Refer to Figure 7 4 for reference to P C Board 203909B 1 Balance Adjustment for Conduction Angle of SCRs Thepotentiometers R 12 R 13 areusedto adjust the balance 2 Arc Establish J 2 plug pins 1 and 6 The re mote Mega Con 3 Cable Kit H B P N 203972 the 19 pin receptacle pin J 2 plug 1 and Pin L J 2 plug Pin 6 Pin 6 is common ground Pin 1 will have 15 volts when the output amps is 50 amps R68 adjusts this or more and pin 1 will drop to 0 volts when with 20 amps or less November 15 2000 7 5 430429 460
9. AND METERS ELECTRODE LEAD PLUS WORK LEAD Weldin Curren 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet Amperes 15 2 M 30 5 M 45 7 M 61 0 M 76 2 M 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 90 194 F insulation 30 86 F ambient not over 4 5 volts lead drop Table 4 3 November 15 2000 4 3 430429 460 INSTALLATION WELDING VOLTAGE CONTROL TO SEMIAUTOMATIC WIRE FEEDER TO AUTOMATIC CONTROL To Wire Feeder Shown For Reverse Polarity DCEP Ground Cable and Clamp Work Piece Should Be Grounded Base Metal NOTE To change polarity reverse connections on power output terminals on power source Figure 4 4 Installation Diagram 4 4 November 15 2000 430429 460 OPERATION OPERATION Before operating this unit be sure that all installa tion instructions have been accomplished A thor ough knowledge of system cleaning as instructed in Maintenance chapter is required for consistently satisfactory results Also observe all applicable safety warnings listed in the Safety Instructions and Warnings chapter included in this manual and re lated instruction manual The operating instructions in this manual pertain only to the FAB
10. Screw 1 2 13 x 1 3 4 HHC ST 2 All 71 CW 1142A Shunt 50 MV 400 Amp 1 All 72 351505 Screw 1 2 13 x 1 3 4 HHC ST Drilled for Item 73 1 All 73 No Number Screw 6 32 x 1 2 Rd Hd MH ST 1 All 74 No Number Screw 1 2 13 x 1 HHC ST 1 All 75 DW 458 Washer 1 All 76 204821 Resistor 2 All 77 204893 Bar Bus 1 All Not Illustrated November 15 2000 8 5 430429 460 PARTS LIST This page intentionally left blank 8 6 November 15 2000 430429 460 DIAGRAMS DIAGRAMS e Note the model and specification number shown on the equipment nameplate e Locate these numbers in the model and specification number columns below e Use only those diagrams and instructions that are applicable VOLTAGE MODEL SPECIFICATION CONNECTION SCHEMATIC CHANGEOVER NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM FABSTAR 100010A 1 2 4 3 830877 830877 830877 4030 SHEET 1 SHEET 2 SHEET 3 November 15 2000 9 1 430429 460 This page intentionally left blank 9 2 November 15 2000 LL80 8 gaor 1335 NOLID3NNOD WWE GuVOS GIBEVSEHS Y Los esl GUY OS 1OYINO NO MIDS OND 133HS 335 SNOLDINNOD 18 YIMOd L33HS 335 SNOLLDINNOD ABVWIMd H3WHOJSNVAL GU
11. codes it is the re sponsibility of the user to comply with all applicable rules and regulations Where no state or local codes 20 30 Ibs 9 1 13 6 kg Soil Treating Material copper sulphate magnesium sulphate or rock sait placed in circular trench and covered with earth Grounding Conductor te ip ASS P3722 LE AA ground ciamp E Approx 305 mm 18 Inches 457 mm Not less than 8 Ft 2438 mm Approx P Ground Rod Figure 4 1 Outside Ground asten Grounding Conductor to the rod with an approved 6 Inches 152 mm Approx exist itis recommended that the National Electrical Code be followed Referto Table 4 1 forwire sizes The work or work table must also be grounded by using a conductor attached to a driven ground or wa ter pipe as described below See Figures 4 1 and 4 2 The requirements and recommendations for grounding apply to rubber tire mounted equipment In addition to the usual function of protecting person nel againstthe hazard of electrical shock due to fault inthe equipment grounding serves to discharge the static electrical charges which tend to build up on the surfaces of tire mounted equipment These static 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 ment Use an input power cable assembly w
12. de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux pum uu 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provincia
13. est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ve travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Brassage terdre toutes conditions 2 au chalumeau Brassage fort toutes conditions 3 ou 4 au chalumeau moins de 1 po 25 mm 2ou3 moyen de 46 po 25 150 mm 4ou5 plus de 6 po 150 mm 5 ou 6 moins de 1 8 po 3 mm 4ou5 de 1 8 1 2 3412 5ou6 pais plus de 1 2 po 12 mm 6 ou 8 Soudage l arc avec lectrode enrobees SMAW Nuance de filtre oculaire Op ration de coupage ou soudage moins de 5 32 po
14. laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin A AAA Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e da
15. left unattended out of service April 20 2006 Wear welding helmet fitted with a proper shade of filter see ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended FABSTAR 4030 3 2 2 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high t2 WARNING e FUMES AND GASES be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 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 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapor
16. the fan blades clean Check and tighten all electrical connections as necessary to eliminate unnecessary losses and to avoid subsequent trouble from overheating or open circuits Check for broken wiring or damaged insula tion on wiring WARNING Disconnect line volt age from the unit before at tempting any servicing inside unit Turn off fused disconnect switch that supplies power to welding machine and remove its fuses CAUTION The flow of air through the welding machine is carefully directed by baffles Never operate the welding machine with any of the side or top pan els removed or open as serious dam age to the rectifiers might result November 15 2000 6 1 430429 460 MAINTENANCE This page intentionally left blank 6 2 November 15 2000 430429 460 TROUBLESHOOTING 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
17. to one side and away from the operator Do not coil or drape cable around the body ES D 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 2 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion ANSI Standard 287 1 from American Nation
18. water pipe that enters the ground not more than 10 feet 3 048 mm from the machine Refer to the Wire and Fuse Size Chart Ta ble 4 1 for selection of the proper grounding con ductor NOTE The grounding conductor must be as short as possible in order to produce the most efficient installation Treating An Outside Ground The soil treating materials are placed in a circular trench around the rod but not in direct contact The crystals are gradu ally dissolved by surface waters and the solution is carried into the most useful area of earth surround ing the electrode rod Flood the trench several times when making original installation See Figure 4 1 Treating An Inside Ground Reduce the diameter of the hole to 6 inches 152 mm pour soil treating material in and around the rod Add enough water to dissolve 8 pounds 4 0 kg of soil treating material Flood the hole every 6 months and replace the soil treating material when it is all dissolved See Figure 4 2 Connection To Line Voltage Refer to Table 4 1 for wire sizes required CAUTION Conductor size shall be se lected to meet NEC CE Code and local codes and shall be modified as required for line voltage drop and ambient tem perature This welding machine operates on a three phase AC input See nameplate of the machine to deter mine required input voltage and frequency Make certain that the welding machine is connected for the power supply voltage
19. with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use eee Light Under 300 Amp 9 April 20 2006 AR WARNING FLYING SPARKS AND HOT METAL can cause injury NY Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin WARNING 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 carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a statio
20. 043 3 64 6 Short NOTE These recommendations are based on overall performance Specific applications may require different settings November 15 2000 5 1 November 15 2000 430429 460 MAINTENANCE MAINTENANCE Replacing SCRs Replacing SCRis a critical task but it can be ac complished the field by following the instructions in the Detailed Troubleshooting Instructions section lo cated in the Troubleshooting chapter of this manual Lubrication The fan motor incorporates sleeve bearings You 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 ofthe motor The following tablewill furnish a recom mended guide as to the frequency of this lubrication if desired NOTE Apply 1 12 drops of 20W non detergent oil at each end of bearing TYPE OF DUTY LUBRICATION INTERVAL Light up to 6 hrs day Every 12 mo Moderate 7 to 15 Every 6 mo hrs day Every Heavy 16 to 24 hrs day Inspection and Cleaning For uninterrupted satisfactory service from this welding machine it is necessary to keep the ma chine clean dry and well ventilated At least every three months or more often as necessary wipe and blow out all dirt from the machine s internal compo nents with air pressure of not over 25 psi 172 kPa Be sure to wipe
21. 15 V AC control circuitry and the 115 volt recepta cles 9 115 V AC Receptacles Provides auxiliary power for wire feeders water pumps etc 10 amps max at 100 duty cycle 10 Negative Terminal Serves as a connec tion point for the lead from workpiece for reverse polarity DCEP 11 Overload Indicator Yellow L E D when lighted indicates that machine has shut down as a result of amperage overload or rectifier overtemperature S2 12 Stability Control Switch When the switch is in the mild steel forceful provides the user with a forceful arc When the switch is in the stainless smooth provides the user with a smooth arc Figure 3 1 Control Panel for FABSTAR 4030 November 15 2000 3 1 430429 460 DESCRIPTION OF EQUIPMENT FABSTAR 4030 FABSTAR 4030 ITEM 100010A 1 and 2 100010A 3 Rated Output Amperage 400A 375A 300A Rated Output Voltage 32V 33 V 29V Rated Duty Cycle 60 60 100 Maximum Open Circuit Voltage 41V Auxiliary Power AC 1 1 KVA 115 10 Rated Input Voltage Frequency 100010 1 200 230 460V 60 Hz 400V 50 60 Hz 100010A 2 230 460 575V 60 Hz Input Phase 3 Phase 3 Phase Input Amperage 200V 55 44 At Rated Outputs 230V 48 38 And Line Voltage 400V m 27 24 Connections 460V 24 19 575V 19 16 Table 3 1 Machine Specifications 1 25 N FABSTAR 4030 Wei
22. 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com 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 JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 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 5 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 World Headquarters THERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com
23. 4 mm 5 32 4 1 4 po 4 4 6 4 mm 12 plus de 1 4 po 6 4 mm 14 2 6 Op ration de coupage Soudage l arc sous gaz avec fil plein GMAW Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec I toutes conditions 12 Gougeage Air Arc avec lectrode de carbone Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Nuance de ou soudage filtre oculaire toutes conditions toutes conditions mince April 20 2006 Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE O UNE EXPLOSION produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endr
24. ARRANTY SCHEDULE April 2006 ENGINE DRIVEN WELDERS Scout Raider Explorer Original Main Power Stators and Inductors Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW MIG WELDING EQUIPMENT Fabricator 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors PLASMA WELDING EQUIPMENT Ultima 150 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors Welding Console Wel
25. Amps 5 V Checks shunt amplifier 10 Table 7 4 7 6 November 15 2000 430429 460 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for com mercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to another part The part descriptions may be indented to show part relationships SPECIFICATION NUMBER 100010A 1 100010A 2 100010A 3 To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifica tions and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts List applies to all Specificati
26. CTION Symbol Chart Note that only some of these symbols will appear on your model Single Phase Wire Feed Function Wire Feed Towards 3 NU Three Phase Workpiece With Output Voltage Off Three Phase Static Frequency Converter Welding Gun Transformer Rectifier Purging Of Gas Continuous Weld Duty Cycle Mode Panel Local Spot Time Shielded Metal Gas Metal Arc Gas Tungsten Arc 2 Step Trigger Welding GTAW 6 Operation Press to initiate wirefeed Air Carbon Arc welding release to stop Cutting CAC A Constant Current a Hu y Press and hold for preflow release Constant Voltage to start arc Press to stop arc and Or Constant Potential hold for preflow High Temperature Burnback Time Disturbance In Fault Indication Ground System Touch Start GTAW Receptacle Rating Auxiliary Power Art A 04130 1 2 April 20 2006 FABSTAR 4030 SAFETY INSTRUCTIONS AND WARNINGS 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 p
27. IHERMAL 4030 FABSTAR TRANSFORMER RECTIFIER WELDING MACHINE Operating Manual Version No Issue Date April 20 2006 Manual No 430429 460 Operating Features Ey Be JHERMAL ARC SK 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 1 800 752 7621 or visit us on the web at www thermalarc com 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 Inc 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
28. RIMARY VOLTAGE SELECTION FAN CHANGEOVER MOTOR PANEL LINE VOLTAGE AUXILIARY MAIN 3 PHASE CONTROL CIRCUIT TRANSFORMER POWER OVERLOAD BREAKER T1 THERMOSTAT VOLTAGE VOLTAGE WELDING POWER VOLTAGE VOLTAGE OUTPUT RECTIFIER Boe BOARD a 115 VOLT ASSEMBLY di RECEPTACLE DIODES CR1 CR4 SCR S SCR1 SCR3 FORM FACTOR 115 vac IMPROVEMENT L2 PINS PINS PINS AMPHENOL E F G A B H J K CONNECTOR 115 VAC CONTACTOR REMOTE VOLTAGE FILTER POWER CONTROL CONTROL FROM CAPACITORS TO FROM GUN WIREFEEDER 01 03 WIREFEEDER SWITCH OPTIONAL THROUGH WIREFEEDER ARC STABILIZER CHOKE L1 WELDING OUTPUT POWER 3 6 November 15 2000 430429 460 INSTALLATION INSTALLATION Location For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high ambi ent temperature or corrosive fumes Moisture can condense on electrical components causing corro sion or shorting of circuits Dirt on components helps retain this moisture Adequate air circulation is needed at all times in or der to assure proper operation Provide a minimum of 12 inches 305 mm of free air space at both front and rear of the unit Make sure that the ventilator openings are not obstructed Grounding The frame of this welding machine should be grounded for personnel safety Where grounding is mandatory under state or local
29. STAR welding machine but refer ence is made to other items of equipment not in cluded as part of the FABSTAR Before operating consult technical manuals related to specific wire electrode feeders and welding guns usually used with this unit 1 Perform all preset operations on welding gun and wire feeder 2 Check installation refer to Installation Dia gram Figure 4 4 to be certain all connections are tight and proper controls gas and torches are in stalled 3 Set Voltage Control on the unit to the desired welding voltage 4 Turn on gas supply at gas cylinder 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 into the system that stops and starts auto matically when a predetermined tempera ture has been reached 6 Adjustthe gas supply to the desired flow rate 7 Place the welding gun in proximity of the work 8 Activate the gun switch Open circuit voltage will appear welding gas will flow and the arc will initi ate 9 Readjust any controls as necessary CAUTION Once a welding arc is estab lished power should not be removed from the welding machine and the IN PUT POWER ON OFF SWITCH should not be turned OFF 10 To terminate welding proceed in the following manner a Deactivate the gun switch Gas will stop flowing b Keep the gun in
30. T LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d ter compl tement le bouchon Principales Normes de Securite Safety in Welding and Cutting norme ANSI 749 1 American Weld ing Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 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 Cu
31. Y OS TONINOD 430429 460 This page intentionally left blank 9 4 November 15 2000 uo 3NAQVWHBHL V lr epu SNOLID3NNO ON 1OHLNOD HIMOd VINYOISNVAL M TOUNDD 9 oL Q3TIONINOD NOUS IVNOILdO 1WISOWYHL HOLIMS SIOA 310W38 1V201 OYINO ONIZITIAVLS HOLIMS QVOTH3AO IVLSOWY3HL 35VHd B3MOd H2LIMS MOSS3uddns L NHON 665 40151534 WHO 089 80151534 MOOL WHO 290151538 MLWHO 2790151533 3AUND3N 00027 OL YOIYd SLINN NO 5 LON ZLY MOOL WHO OL HOISIS3H ANOS dWv 005 INNHS Y quvog ME WHO XS S313WOLLN31Od SAW 00 0 Y3LIWWY HAL A05 0 SNOAYILIW bud DOHI DWAOZL 11410 310v1d3538 AALLISOd Nid 61 3DV1d3538 TOULNOD Nid LL 310v1d3538 IOHLNOD 9 3721 83238 auvog 2 TOHLNOD Nid OL TVLADAY E 34010 9NLLLIWa SL INDIO QW 10 HOLIDVAVD QW 270 HOLIDVAVD ASE Q3W 00 9 HOLIDVAVD 133H5 335 430429 460 This page intentionally left blank 9 6 November 15 2000 Kuedujo 3NAQVWH3HL Y YIWYOHSNYYL u3MOd 00 OA ONILAN NO TWNIWYAL
32. 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 Unit delivers welding current but soon shuts down Overtemperature thermostat has tripped Yellow indicator on Allow machine to cool to reset thermostat Yellow indicator will go out Welding machine overloaded Reduce load overload can be carried only for a short time Duty cycle too high Do not operate continually at overload currents Power leads too long or too small in cross section Replace with larger diameter cable Ambient temperature too high Operate at reduced loads when temperature exceeds 104 40 Ventilation blocked November 15 2000 7 1 430429 460 TROUBLESHOOTING Check air intake and exhaust openings for obstructions to air flow See installation section Location paragraph Fan not operating See Fan not operating below 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 Voltage control does not control welding voltage Voltage local remote
33. al Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 518 from National Fire Protection Association Batterymarch Park Quincy MA 02269 April 20 2006 FABSTAR 4030 Precautions de Securite en Soudage l Arc A MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entra nement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 249 1 de l American National Standard intitu
34. ast 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 249 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 Are 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 WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can Kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks or 12 Use only well maintained equipment Repair or replace damaged m gt severe burns The electrode and work circuit is electricall
35. available The input power ca bles should be connected to the power supply through a fused disconnect switch furnished by the customer Refer to the identification nameplate to determine the rating of the machine then consultthe local power company for wire and fuse size code If no code exists use the size of wire fuses listed in Ta ble 4 1 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 Table 4 2 Recommended Wire and Fuse Sizes November 15 2000 430429 460 INSTALLATION Input Connections To Power Source WARNING The fused discon nect switch Open or placeinthe OFF position and remove the fuses To avoid an accident make the electric power connec tions to the welding machine first then to the fused discon nect switch This will prevent an accidental application of power while the machine is being con nected 1 A line wall disconnect switch with fuses or cir cuit breakers should be provided at the main power panel The primary power input must have four insu lated copper conductors three power leads and one ground wire The wires may be heavy rub ber covered cable or may be run in a Solid or flexible conduit Do
36. ch attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in thermal arc s sole judgment impaired the safety or performance of any thermal arc product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc W
37. d Controller Weld Timer All other original circuits and components including but not limited to relays Switches contactors solenoids fans electric motors Coolant Recirculator SMAW Stick WELDING EQUIPMENT Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays Switches contactors solenoids fans power switch semi conductors 1605 3005 4005 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT Water Recirculators Plasma Welding Torches Gas Regulators Supplied with power sources MIG and TIG Torches Supplied with power sources Replacement repair parts MIG TIG and Plasma welding torch consumable items This information applies to Thermal Arc products that were purchased in the USA and Canada WARRANTY PERIOD LABOR 3 years 3 years 1 year See the Engine Manufactures Warranty for Details WARRANTY PERIOD 3 years 3 years 1 year WARRANTY PERIOD 5 years TR 1 year LABOR 1 year 1 year 1 year 3 years 3 years 1 year LABOR 1 year 180 days Nil Nil Nil Nil IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA
38. ght 280 Lbs 127 kg 648 mm A 25 4 2 271 32 695 mm 24 1 2 Figure 3 2 Dimensions Weight Information 3 2 November 15 2000 430429 460 DESCRIPTION OF EQUIPMENT VOLTS DC Be NOSE OG 100 150 200 250 300 350 400 EN VOLTAGE POT MIN AMPS DC Figure 3 3 Volt Amp Curves November 15 2000 430429 460 DESCRIPTION OF EQUIPMENT FABSTAR 4030 AVERAGE INPUT LINE CURRENT 200 VOLT 230 VOLT E 2 te 5 440 VOLT y 460 VOLT 575 VOLT 1 1 0 100 200 500 400 WELDING CURRENT Figure 3 4 Input Line Current Chart 3 4 November 15 2000 430429 460 DESCRIPTION OF EQUIPMENT 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 100 a 90 9 W o gt 80 o gt 2 70 60 1 100 200 500 400 WELDING CURRENT Figure 3 5 Duty Cycle Chart November 15 2000 3 5 430429 460 DESCRIPTION OF EQUIPMENT LINE VOLTAGE INPUT POWER P
39. h 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 Reinstall panels or guards and close doors when servicing is finished and before starting engine ne WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases Do not use welder to charge batteries or jump start vehicles 1 Use equipment outside in open well ventilated areas Observe correct polarity and on batteries April 20 2006 2 3 FABSTAR 4030 WARNING 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 e
40. hich in cludes a grounding conductor to connect this equip menttothe input power supply When included in the cable assembly the grounding conductor will be green orgreen with a yellow stripe or bare Connect Fasten Grounding Conductor to the rod with an approved ground clamp Grounding Conductor Removable Cover Not less than 8 Ft 2438 mm Soil Figure 4 2 Inside Ground November 15 2000 4 1 430429 460 INSTALLATION the grounding conductor to the equipment ground ing terminal if provided and if not to the equipment frame taking care to see that good electrical contact is made between conductor and frame Connect the other end of the grounding conductor to the system ground If for any reason an input cable which does in clude a grounding conductor is used the equipment may be grounded with a separate conductor if per mitted under applicable code or by special permis sion of the jurisdictional body responsible for enforcement of the code Minimum size and color coding requirements must be in accordance with any applicable state or local code or the National Electrical Code If metallic armored cable or conduit is used the metal sheathing or conduit must be effectively grounded as required by state or local code or the National Electrical Code Ifa system ground is not available the welding ma chine must be connected to a driven ground rod see Figures 4 1 and 4 2 or to a
41. ions 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 although an oscilloscope is the best method to quickly see the problem Control Circuit Board Malfunction If a board malfunction occurs the following situations will probably result 1 Loss of arc completely 2 Very noticeable rough sputtering arc 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 Apply a thin coat of Alcoa 2 compound 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 6 Tighten each bolt in 1 4 turn increments using correct size hex key 7 Place the Force Indicator Gauge 903878 firmly against the springs as shown Be sure both ends and the center are in firm co
42. l e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI Dangers Relatifs au Soudage l Arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 N enroulez pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement la pi ce souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit
43. les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX 2 8 Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 1 Porteztoujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur Wa P AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU E
44. lled operated and maintained accordance with Thermal specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective This warranty is exclusive and in lieu of any warranty of merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including but not limited to lost profits and business interruption The remedies of the purchaser set forth herein are exclusive and the liability of thermal arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of thermal arc is authorized to change this warranty in any way or grant any other warranty and thermal arc shall not be bound by any su
45. nary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards Engines can be dangerous 9 WARNING ENGINE EXHAUST GASES can kill 2 FABSTAR 4030 If used in a closed area vent engine exhaust outside and away from any building air intakes Vt y WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine E Y WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catc
46. not connect the input conductors until step 3 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 nections which may be used Set the voltage links onthis board to match your actual incoming voltage As shipped from the factory the inputterminal board voltage links are set up for the highest line voltage Refer to the voltagechangeover diagram atthe back of this manual for correct voltage selection connec tions 3 Thread the input conductor cables from the wall disconnect switch through the hole in the rear panel and through the hole in the yoke to the input power switch on the front panel Connect the conductors to terminals on the input power switch using UL listed pressure wire connectors Connect the ground wire to the grounding stud provided on the lifting yoke near the changeover board WARNING It is of the utmost im portance that the chassis be connected to an approved elec trical ground to prevent acci dental shocking Take care not to connect the ground wire to any of the primary leads 4 Recheck all connections to make sure that they are tight well insulated and that the proper connec tion has been made Welding Leads Use Table 4 2 for selection of the proper size cop per welding leads TOTAL LENGTH OF LEAD CIRCUIT IN FEET
47. ns la liste de documents ci dessous AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs 2 7 FABSTAR 4030 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent amp tre envoy es l ext rieur loin des prises d air du b timent y AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein 2 Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux
48. ntact with the springs The gauge notch location will indicate the spring deflec tion or force Correct mounting force is indicated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 All clamps to be set at 4 mark This corresponds to the VE3000 VE2500 section onthe gauge label Examples Less than rated force Tighten nuts alternately 1 4 turn at a time until points coin cide Figure 7 9 Correct rated force Figure 7 10 Force Gage shown position 903878 Clamp 405140 AM lt gt Heat Sink Sink 488 Excessive force Loosen both nuts and start over NEVER adjust force by backing off the nuts Fric tion will produce a false reading Al ways start from Step 1 November 15 2000 430429 460 TROUBLESHOOTING To Calibrate Force Gauge If the gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as shown below Testing Procedures Printed Circuit Board See Fiaure 7 4 True flat surface or straight edge FAP IPD PLL IL If the calibration edges do not line up calibrate the gauge by filing the bottom contact points Figure 7 11 Test point 3 3 is the common ground and the neg ative probe should be connected to this point unless otherwise specified All test readings are based on the line voltage supply being within specifications
49. ntrol panel Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container 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 location in your area listed in the inside back cover of this manual 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 un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit WARNING Falling ma chine due to lift ing eye fail ure may cause death or serious in jury Lifting device may fail when over loaded This lift ing device is designed to lift the power source ONLY If the machine is equipped with a trailer or accessories over 100 pounds DO NOT LIFT by lifting eyes Avoid sudden jerks drops or swinging Check lifting device components visually for loose ness and signs of metal fatigue Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade 430429 460 INTRODU
50. oit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque April 20 2006 FABSTAR 4030 4h B AVERTISSEMENT gt LES ETINCELLES LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de
51. ons or Assem blies the word ALL will be in the Application Code column Refer to the following list to deter mine the appropriate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification num ber is listed the use of an Application Code does not apply to this manual APPLICATION CODE November 15 2000 8 1 430429 460 PARTS LIST Figure 8 13 Fabstar Welder Model 4030 8 2 November 15 2000 430429 460 PARTS LIST Parts List for Figure 8 1 Description Qty Application No Number per Code Assy 100010 1 Welder Fabstar 4030 60 Hz 1 All 1 830150 Panel Top 1 All 2 12CW 2170 Boot Lifting Eye 1 All 3 204036 Label Precautionary 1 All 4 405154 6 Resistor Fixed 100 W 2 All 5 W 2974C Resistor 2 Ohm 100 W 1 All 6 400078 Bracket Mounting 6 All 7 830878 1 Yoke Lifting 1 8 830116 Label Ground 1 9 830885 1 Board Voltage Changeover 1 10 830815 1 Block Terminal 6 Pos 1 10A 830815 3 Block Terminal 3 Pos 1 830815 2 Block Terminal 9 Pos 1 830815 1 Block
52. 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 developing 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 Fabstar 4030 Transformer Rectifier Welding Machine Instruction Manual Number 430429 460 for the following part numbers 100010A 1 FABSTAR 4030 60 Hz 100010A 2 FABSTAR 4030 60 Hz 100010A 3 FABSTAR 4030 50 60 Hz 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 All rights reserved 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 Publication Date
53. s to form highly toxic and irritating gases 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 Torch soldering Cd Torch brazing y Under 1in 25mm Oxygen Cutting Under 1 in 25 mm Gas welding 1 8 to 1 2 in 3 12 mm EN 5 82 to 1 4in 12 Plasma arc cutting Or 64 mm 14 tien goggles or helmet from AWS A6 2 73 Filter 2 Ferrous base metal 12 Atomic hydrogen welding Plasma arc welding Carbon arc air gouging 1 to 6 in 25 150 mm TIG Over 6 in 150 mm 300 to 400 Amp Over 400 Amp WARNING WELDING can cause fire or explosion 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 contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them
54. scape before completely removing cap This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp 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 Arrange cables
55. switch set improperly Set to local or remote as required 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 7 2 November 15 2000 430429 460 TROUBLESHOOTING Check contact tube hole size and replace with proper tube November 15 2000 7 3 430429 460 TROUBLESHOOTING Detailed Troubleshooting Instructions The FABSTAR 4030 machine is a solid state welding method oftroubleshootingis different but itis not more difficult than troubleshoot ing a conventional unit Do not overlook the obvious As in the case of all electrical equipment loose con nect
56. tting and Welding Processes norme 51B NFPA National Fire Pro tection Association Batterymarch Park Quincy MA 02269 April 20 2006 430429 460 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT This unit is a constant voltage transformer rectifier type DC welding machine that provides volt ampere characteristic curves that are basically flat This unit is recommended to be used with gas metal arc welding MIG and flux core arc welding 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 cases an adapter cable may be required Controls and Outlets 1 Input Power On Off Switch The ON position energizes the power source and puts it in a ready state 2 Welding Voltage Control Adjusts arc weld ing output and open circuit voltage 3 Voltmeter Monitors open circuit voltage and welding voltages anytime secondary circuit is closed 4 Ammeter Monitors the current flowing through the welding arc 5 Positive Terminal Serves as a connec tion point for the lead to the wire feeder when re verse polaritv DCEP is desired 6 Feeder Control Receptacle Connection point for a remote voltage control type wire feeder control 19 pin 7 Local Remote Switch Selects voltage con trol function for either local or remote operation 8 Circuit Breaker 10 amps Protects the 1
57. ux et locaux applicables April 20 2006 2 5 FABSTAR 4030 3 AVERTISSEMENT els eo LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager _______________________________________________________________ 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer EEE Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage
58. y live whenever the output is on The input power circuit and machine internal 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers 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 parts at once 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 Wear a Safety harness to prevent falling if working above floor level Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage 5 Properly install and ground this equipment according to its Owner s haar Manual and national state and local codes caring EM 6 Turn off all equipment when not in use Disconnect power to 1 equipment if it will be
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