Thermal Arc FABRICATOR 190

Other manuals for Thermal Arc FABRICATOR 190

Service Manual90 pages

Questions and Answers

N
Noah AndersonAug 14, 2025
How to fix porosity in Thermal Arc FABRICATOR 190?
- A
  allencodyAug 14, 2025
  To reduce porosity in your Thermal Arc Welding System, you can try the following: * Check the gas cylinder contents and flow meter. * Inspect for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Source. * Ensure the hose from the solenoid valve to the MIG torch adaptor is intact and properly connected. * Shield the weld area from wind or increase the gas flow. * Minimize the distance between the MIG torch nozzle and the workpiece. * Ensure the gas holes are not blocked and gas is exiting the torch nozzle. * Prevent spatter buildup inside the MIG torch nozzle to avoid restricting gas flow. * Check the MIG gun O-rings for damage.
P
Patrick HendersonAug 20, 2025
What to do if Thermal Arc FABRICATOR 190 Welding System has jerky wire feed?
- J
  James PalmerAug 20, 2025
  If the Thermal Arc Welding System's wire feed is jerky, this may help: * Replace a worn or dirty contact tip. * Replace a worn feed roll. * Reduce brake tension on the spool hub if there's excessive back tension from the wire reel hub roll. * Clean or replace a worn, kinked, or dirty conduit liner. * Increase the Swing Arm pressure if it is low.
S
Sandra WilkersonAug 25, 2025
Why is my Thermal Arc FABRICATOR 190 producing a cold weld puddle?
- C
  Christina WilliamsAug 25, 2025
  A cold weld puddle in your Thermal Arc Welding System can be due to a few reasons. Check the following: * Loose welding cable connections: Ensure all connections are secure. * Low primary voltage: Contact your supply authority. * Faulty rectifier unit: Have an Accredited THERMAL ARC Service Agent test and replace the faulty component.
J
Jessica BartlettAug 27, 2025
What to do if gas flow continues after releasing the gun trigger switch on Thermal Arc Welding System?
- A
  Anthony StevensAug 27, 2025
  If gas continues to flow after releasing the gun trigger switch on your Thermal Arc Welding System, the gas valve may have jammed open due to impurities in the gas or the gas line. Have an Accredited Thermal Arc Service Agent repair or replace the gas valve.
S
Sarah SellersAug 30, 2025
Why does Thermal Arc Welding System arc not have a crisp sound?
- S
  Sonia HigginsAug 31, 2025
  If the arc from your Thermal Arc Welding System doesn't have a crisp sound, ensure the MIG torch is connected to the correct voltage polarity on the front panel. Connect the MIG torch to the positive (+) welding terminal for solid wires and gas-shielded flux-cored wires.
K
Kathy AlvarezSep 3, 2025
What to do if Thermal Arc Welding System wire feeds but arc can not be established?
- C
  cooperharoldSep 3, 2025
  If the Thermal Arc Welding System feeds wire when the gun trigger is depressed, but no arc is established, clean the work clamp area and ensure a good electrical contact.
J
jeffrey80Sep 6, 2025
What to do if Thermal Arc FABRICATOR 190 Welding System is ON but the welding arc can not be established?
- T
  Tina WardSep 6, 2025
  If the indicator light in the ON/OFF Power Switch is illuminated, but the welding arc cannot be established on your Thermal Arc Welding System, the ON/OFF Power Switch may be off. Switch the ON/OFF Power Switch on.
A
Amanda YatesSep 10, 2025
What to do if Thermal Arc FABRICATOR 190 gun trigger switch is depressed and nothing happens?
- K
  Kelly BrownSep 10, 2025
  If the primary input supply voltage is ON, the indicator light in the ON/OFF Power Switch is lit, but nothing happens when the gun trigger switch is depressed on your Thermal Arc Welding System: * Reconnect the gun trigger switch leads if they are disconnected. * Replace the gun trigger switch if it is defective.
R
Ryan WigginsNov 16, 2025
What to do if Thermal Arc Welding System has inconsistent wire feed?
- R
  Robert DaviesNov 16, 2025
  If you're experiencing inconsistent wire feed with your Thermal Arc Welding System, consider these points: * If the wire spool brake is too tight, the feed roller driven by the motor in the cabinet will slip. * If the wire spool brake is too loose, the wire spool can unwind and tangle. * Worn or incorrect feed roller size can cause issues. Use the correct ‘U’, ‘V’, or ‘knurled V’ groove drive feed roller matched to your wire type. * Misalignment of inlet/outlet guides causes the wire to rub, reducing feedability. * A liner blocked with slag can cause issues, as can excessive pressure applied to the pressure adjustment device. * Using an incorrect or worn contact tip can cause problems. Use a contact tip designed for soft electrode wires. * Poor work lead contact to the workp...

Summary

Safety Instructions and Warnings

Arc Welding Hazards

Details hazards associated with electric shock, arc rays, noise, and fumes during welding operations.

Principal Safety Standards

Lists relevant safety standards and codes for welding and cutting operations.

Symbol Chart

Provides a visual guide to common symbols used in welding equipment and operations.

Introduction to the Fabricator 190

How to Use This Manual

Guides users on how to effectively navigate and understand the manual's structure and content.

Equipment Identification

Details how to locate and identify the welding unit's specification, model, and serial number.

Receipt Of Equipment

Provides instructions for inspecting the equipment upon receipt for completeness and shipping damage.

General Information

Overview of the Fabricator 190, its features, and compliance with industry standards.

Safety Precautions

Outlines fundamental safety rules to be followed during operation and installation.

Protective Filter Lenses

Explains the function and importance of filter lenses for eye protection from welding radiation.

Welding Protection

Provides guidance on selecting appropriate filter lens shades for welding current ranges.

User Responsibility

Defines the user's role in proper installation, operation, maintenance, and repair of the equipment.

Duty Cycle Explained

Explains the concept of duty cycle and its impact on machine operation and longevity.

MIG Gun Specifications

Lists the specifications for the TWECO Weldskill MIG gun used with the Fabricator 190.

Options and Accessories

Refers to the appendix for a list of available optional equipment and accessories.

Power Supply Specifications

Details technical specifications for the welding power supply, including electrical and physical parameters.

Wire Drive Specifications

Outlines the specifications for the wire drive system, including wire diameter and speed.

Package System Contents

Lists all components included in the complete Fabricator 190 welding package.

Installation Guide

Environment Requirements

Specifies suitable environmental conditions for operating the welder, avoiding electric shock hazards.

Location Selection

Provides guidelines for selecting an appropriate installation location, considering air flow and environmental factors.

Ventilation Needs

Emphasizes the importance of adequate ventilation to remove harmful welding fumes.

Mains Voltage Requirements

Details the required mains supply voltage and its tolerance for optimal welder performance.

Alternative Mains Voltages

Explains how to change voltage selection and required lead sizes for different supply voltages.

Quick Setup Procedure

Provides a streamlined process for initial setup and connection of the welding equipment.

Shielding Gas Installation (GMAW)

Guides the installation and setup of shielding gas cylinders, regulators, and flow rates.

Attach Gun and Cable Assembly

Details the procedure for connecting the MIG gun and cable assembly to the main power source unit.

Feedroll Installation

Explains the function and installation of feedrolls for guiding welding wire, including size selection.

Installing Wire Spool

Provides instructions for mounting the welding wire spool onto the machine's spool hub.

Insert Wire into Feedhead and Gun

Guides the process of feeding the welding wire through the machine and into the MIG gun.

Polarity Changeover

Explains how to change the output polarity settings for different welding processes (GMAW/FCAW).

Operation Guide

Inside Panel Controls

Details the controls and features located on the inside panel of the welding machine.

Front Panel Controls

Identifies and describes the controls and indicators on the front panel of the power supply.

TWECO Weldskill MIG Gun

Describes the TWECO Weldskill MIG gun, its features, and consumable parts.

Install New Wire Conduit

Provides step-by-step instructions for removing and installing a new wire conduit in the MIG gun.

MIG Gun Maintenance

Outlines recommended maintenance procedures for the MIG gun to ensure optimal performance.

Basic Welding Technique

Explains how to set up power supply controls and use basic welding techniques for optimal results.

Technical Tips for Welding

Offers advice on troubleshooting common welding problems like porosity, wire feed issues, and weld shape.

Spot Welding Operation

Details how to set up and perform spot welding operations using the appropriate nozzle.

Welding Setting Selection Guide

Provides a guide for selecting appropriate welding settings based on material type, wire, and gas.

Service and Maintenance

Routine Maintenance and Inspection

Describes routine cleaning and inspection procedures for the welding equipment.

Basic Troubleshooting

Covers basic troubleshooting that can be performed without special equipment or knowledge.

Troubleshooting Welding Terminals

Addresses common GMAW problems like porosity and inconsistent wire feed.

Welding Problems and Solutions

Lists common welding faults (e.g., undercut, lack of penetration) with their causes and remedies.

Power Supply Problems

Troubleshoots issues related to the power supply, such as indicator lights, wire feed, and gas flow.

Options and Accessories

Power Supply Circuit Diagram

Limited Warranty Information

Global Customer Service Contacts

Thermal Arc FABRICATOR 190 Specifications

General

Input Frequency	50/60 Hz
Output Amperage Range	10-190 A
Duty Cycle	30% @ 190 A
Welding Processes	MIG, Stick, TIG
Wire Feed Speed Range	50-700 IPM
Wire Diameter Range	0.023 - 0.045 in
Input Phase	Single Phase
Weight	68 lbs. (31 kg)