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Thermal Arc Fabricator 180 - User Manual

Thermal Arc Fabricator 180
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Art # A-07923
FABRICATOR
®
PORTABLE MIG WELDING MACHINE
140
Service Manual
Revision No: AA Issue Date: January 25, 2008 Manual No.: 0-4992
Operating Features:
180

Table of Contents

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Do you have a question about the Thermal Arc Fabricator 180 and is the answer not in the manual?

Summary

Safety Instructions and Warnings

Arc Welding Hazards

Discusses hazards of electric shock, arc rays, and noise.

Principal Safety Standards

Lists ANSI, OSHA, NFPA, and other safety standards.

Symbol Chart

Explains various symbols used in the manual.

Safety Precautions in Arc Welding

Details safety measures and precautions for arc welding.

Hazards Related to Arc Welding

Explains dangers associated with arc welding processes.

Principal Safety Standards (French)

Lists principal safety standards for welding.

Symbol Chart (French)

Provides a chart of common welding symbols.

Introduction

How To Use This Manual

Guides users on how to navigate and understand the manual.

Equipment Identification

Explains how to identify the welding unit's specifications.

Receipt Of Equipment

Instructions for checking and handling received equipment.

General Information

Provides an overview of the welding system and its processes.

Machine Specifications

Details technical specifications for Fabricator 140 and 180.

Volt - Amp Curves

Displays voltage-ampere characteristics of the machines.

Duty Cycle

Explains the arc-on time capacity of the welding machines.

Fabricator 180 A MIG Gun

Describes the MIG gun and its replaceable parts.

Installing a New Wire Liner

Step-by-step guide for replacing the wire liner.

MIG Gun Maintenance

Recommends cleaning procedures for the MIG gun.

Installation

Location

Guidance on selecting an optimal installation site for the unit.

Safety

Refers to essential safety instructions for installation.

Grounding

Explains the importance and procedure for grounding the machine.

Electrical Input Requirements

Details voltage, amperage, and receptacle requirements.

Requirements for Maximum Output

Specifies branch circuit requirements for maximum output.

Installation of Shielding Gas (GMAW) Process

Step-by-step guide for installing shielding gas for GMAW.

Attaching the Gun and Cable Assembly to the Power Source

Instructions for connecting the MIG gun to the power source.

Polarity Changeover

Explains how to change the output polarity for different processes.

Installing Wire Spool

Procedure for installing wire spools of different sizes.

Feedrolls

Information on feedroll types and selection for wire feeding.

Install Wire into the Feedhead

Steps for loading wire into the feedhead assembly.

Install Wire into the Welding Gun

Procedure for feeding wire through the welding gun.

Operation

General Safety Precautions

Emphasizes safety measures before operating the machine.

Fabricator Controls

Identifies and explains the function of each control on the machine.

Gas Metal Arc Welding (GMAW)

Describes the GMAW process and operational steps.

Flux Cored Arc Welding (FCAW)

Outlines the FCAW process and its operational procedures.

Shutdown Procedures

Provides steps for safely shutting down the welding machine.

Basic Welding Technique

Covers fundamental concepts for semi-automatic welding.

Welding Gun Positions

Illustrates optimal gun angles for various welding positions.

MIG Welding (GMAW) Variables

Explains variables affecting GMAW process quality.

Establishing the Arc and Making Weld Beads

Guidance on creating practice welds and establishing the arc.

Pre-Weld Procedure

Steps to take before starting the welding process.

Welding Procedure

Details the steps for performing a welding procedure.

Reference Tables

Provides tables for welding parameters and gas selection.

Fabricator 140 Welding Setting Selection Guide

Recommended settings for the Fabricator 140 based on material.

Fabricator 180 Welding Setting Selection Guide

Recommended settings for the Fabricator 180 based on material.

Gas Selection for Gas Metal Arc Welding

Advises on appropriate gas selection for GMAW.

Basic Troubleshooting

Cleaning of the Unit

Instructions for periodically cleaning the welding unit's interior.

Cleaning of the Feed Rolls

Procedure for cleaning the wire feed rolls to ensure proper function.

Basic Troubleshooting

Basic troubleshooting steps that don't require special tools.

Solving Problems Beyond the Welding Terminals

Addresses common GMAW problems like porosity and gas issues.

Welding Problems

A table listing welding faults, causes, and remedies.

Power Source Problems

Identifies common power source issues and their solutions.

Advanced Troubleshooting

Pre Power-Up Checks

Essential checks before powering up the unit for operation.

Initial Setup Conditions

Guides on setting initial conditions for troubleshooting.

Primary Power Test

Procedures to test the primary power circuit of the unit.

Logic & Control Test

Tests the logic and control functions of the welding machine.

Spool Gun Control Test

Checks the functionality of the spool gun control circuit.

Output Voltage Test

Measures and verifies the output voltage levels.

Wire Feed & Weld Test

Verifies the wire feed and welding arc functionality.

Wire Feed and Weld Problems

Addresses issues related to wire feeding and arc transfer.

Rectifier Assembly Test Procedure

Step-by-step guide to test the rectifier assembly.

T1 Transformer Test Procedure

Procedure to test the T1 transformer secondary voltage.

C1 & C2 Test Procedure

Guide for testing capacitors C1 and C2.

Parts Lists

Equipment Identification

Information on identifying equipment for ordering parts.

How To Use This Parts List

Explains how to use the parts list to find components.

Front Panel Parts

Lists and illustrates parts for the front panel assembly.

Rear Panel Parts

Lists and illustrates parts for the rear panel assembly.

Power Supply Parts

Details components of the power supply unit.

Wire Feeder Parts

Lists and illustrates parts specific to the wire feeder.

Feed Plate Parts

Details components related to the feed plate assembly.

Accessories

Lists optional accessories available for the welding machine.

Appendix 1: Options and Accessories

Guns and Accessories

Lists available gun assemblies and accessories like regulators.

Consumables

Details various consumables such as feedrolls, contact tips, nozzles.

Appendix 2: Fabricator 180 System Schematic

Fabricator 180 System Schematic Diagram

Provides a system schematic diagram for the Fabricator 180.

Appendix 3: Fabricator 140 System Schematic

Fabricator 140 System Schematic Diagram

Provides a system schematic diagram for the Fabricator 140.

Appendix 4: Feed Roll Kits

Feed Roll Installation & Parts Guide

Illustrates feed roll installation and lists available feed roll parts.

Limited Warranty

Warranty Terms and Conditions

Outlines the terms, limitations, and exclusions of the product warranty.

Warranty Schedule

Warranty Periods for Equipment Types

Details warranty periods for different types of welding equipment.

Global Customer Service Contact Information

Thermal Arc Service Locations

Provides contact information for global customer service centers.

Thermal Arc Fabricator 180 Specifications

General IconGeneral
Input Voltage230 V
Input Frequency50/60 Hz
Output Current Range10-180 A
Input PhaseSingle Phase
Duty Cycle at 180A20%
Welding ProcessesMIG
Protection ClassIP23

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