Thermal Arc FABRICATOR 190 User Manual

190
230
V
FABRICATOR
MIG WELDING MACHINE
190
Operating Manual
Revision No: AI Issue Date: July 29, 2009 Manual No.: 0-4838
Operating Features:
Art # A-07329

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)

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