Tweco 190-MIG User Manual

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190

FABRICATOR

MIG WELDING MACHINE

Art # A-07329

Operating Manual

Revision No: AI Issue Date: July 29, 2009 Manual No.: 0-4838 Operating Features:

190

230

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 ser vice 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 P potential hazards that may exist when working with this product.

recautions. They will help you to avoid

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 marketleading, dependable 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 develop 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.

Fabricator 190 MIG Welding Machine Instruction Manual Number 0-4838 for: Package System Part Number W1001500 Power Source Part Number 707559

Published by: Thermadyne Industries, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

Reproduction of this work, in whole or in part, without written permission of the publisher 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.

Original Publication Date: March 17, 2006 Revision AI Date: July 29, 2009

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 Principal Safety Standards ............................................................................. 1-4

1.03 Symbol Chart ................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc.................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.06 Principales Nor mes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole ................................................................................. 1-10

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 General Information ....................................................................................... 2-2

2.05 Safety ............................................................................................................. 2-2

2.06 Pr otective Filter Lenses .................................................................................. 2-2

2.07 Welding Protection ......................................................................................... 2-2

2.08 User Responsibility ........................................................................................ 2-3

2.09 Duty Cycle ...................................................................................................... 2-3

2.10 MIG Gun Specifications .................................................................................. 2-3

2.11 Options and Accessories ................................................................................ 2-3

2.12 Power Supply Specifications .......................................................................... 2-4

2.13 Wire Drive Specifications ............................................................................... 2-5

2.14 Fabricator 190 Package System Contents ...................................................... 2-5

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Environment ................................................................................................... 3-1

3.02 Location ......................................................................................................... 3-1

3.03 Ventilation ...................................................................................................... 3-1

3.04 Mains Supply Voltage Requirements .............................................................. 3-2

3.05 Alternative Mains Supply Voltages ................................................................. 3-2

3.06 Quick Set Up ................................................................................................... 3-3

3.07 Installation of Shielding Gas (GMAW) Process .............................................. 3-4

3.08 Attaching the Gun and Cable Assembly to the Power Source ......................... 3-6

3.09 Feed

3.10 Installing Wire Spool ...................................................................................... 3-9

3.11 Inserting Wire into the Feedhead and Welding Gun ...................................... 3-10

3.12 Polarity Changeover ..................................................................................... 3-12

rolls......................................................................................................... 3-8

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 Inside Panel .................................................................................................... 4-1

4.02 Power Supply Front Panel ............................................................................. 4-2

4.03 TWECO Weldskill MIG Gun ............................................................................. 4-4

4.04 Installing A New Wire Conduit ........................................................................ 4-5

4.05 MIG Gun Maintenance .................................................................................... 4-6

4.06 Basic Welding Technique................................................................................ 4-7

4.07 Technical Tips................................................................................................. 4-9

4.08 Spot Welding Operation ................................................................................. 4-9

4.09 Welding Setting Selection Guide .................................................................. 4-10

SECTION 5:

SERVICE .............................................................................................. 5-1

5.01 Routine Maintenance & Inspection ................................................................. 5-1

5.02 Basic Troubleshooting .................................................................................... 5-3

5.03 Solving Problems Beyond the Welding Terminals .......................................... 5-3

5.04 Welding Problems .......................................................................................... 5-5

5.05 Power Supply Problems ................................................................................. 5-7

APPENDIX 1: OPTIONS AND ACCESSORIES ........................................................... A-1

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM ................................................... A-2

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

FABRICATOR 190 WELDING MACHINE

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

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 past 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 Z49.1 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.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically 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.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

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

r touch other people with the holder or electrode.

time o

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. 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.

14. Wear a safety harness to prevent falling if working above floor level.

15. Keep all panels and covers securely in place.

WARNING

4. 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.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

Manual No. 0-4838 1-1 SAFETY

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 hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

FABRICATOR 190 WELDING MACHINE

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

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.

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. 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.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. 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.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS/ANSI Z49.1:1999

Welding or Cu tting

Operation

Torch Soldering All 2 Gas Tungsten Arc Weldin Torch Brazing All 3 or 4 Light Under 50 Amp Oxygen Cutting

Light Under 1 in., 25 mm 3 or 4 Heavy Medium 1 – 6 in., 25 – 150 mm 4 or 5Atomic Hydro g en Weld in Heavy Over 6 in., 150 mm 5 or 6Carbon Arc Welding

Gas Welding

Light Under 1/8 in., 3 mm 4 or 5Light 12 Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Heavy 14 Heavy Over 1/2 in., 12 mm 6 or 8

Shield ed Metal-Arc Welding (Stick) Electrodes

Light Under 5/32 in., 4 mm 10 Light 20 to 100 Amp 10 Medium Heavy

Gas Metal Arc Welding

Light Under 60 Amp 7 Light Under 300 Amp 9 Light Medium Heavy

Electrode Size Metal

Thickness or Welding

Under 5/32 to ¼ in., 4 to 6.4m Over ¼ in., 6.4 mm

60 to 160 Amp 11 Medium 300 to 400 Amp 12 160 to 250 Amp 12 Heavy 400 to 800 Amp 14 250 to 500 Amp 14

Filter

Shade

12 14

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. 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.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

Welding or Cu tting

Operation

Medium

Carbon Arc Gouging

Plasma Arc Weld in g

Light Under 20 Amp 6 to 8

Medium 100 to 400 Amp 12 Heavy 400 to 800 Amp 14

Plasma Arc Cutting

Electrode Size Metal

Thickness or Welding

50 to 150 Amp 12

150 to 500 Amp 14

All 12 All 14

Filter

Shade

SAFETY 1-2 Manual No. 0-4838

WARNING

FABRICATOR 190 WELDING MACHINE

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

1. 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.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch 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.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

Manual No. 0-4838 1-3 SAFETY

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

FABRICATOR 190 WELDING MACHINE

1.02 Principal Safety Standards

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 escape before completely removing cap.

WARNING

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 & Safety code Sec.

25249.5 et seq.)

NOTE

Safety in Welding and Cutting, ANSI Standard Z49.1, 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, American 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 P1, 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 Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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 & Magnetic Fields - Background Paper, OTA-BP-E63 (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 and 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

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

taping them.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

SAFETY 1-4 Manual No. 0-4838

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.

FABRICATOR 190 WELDING MACHINE

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

Manual No. 0-4838 1-5 SAFETY

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

FABRICATOR 190 WELDING MACHINE

1.04 Precautions De Securite En Soudage A L’arc

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 procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” p Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.05 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccor même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

résente les pratiques sécuritaires à suivre.

dés à deux sources de courant en

3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen

de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez 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’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

SAFETY 1-6 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’ arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés

rsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir 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 á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

mince moins de 1 po. (25 mm) 2 ou 3

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

épais plus de 6 po. (150 mm) 5 ou 6

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtr e oculair e

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtr e oculair e

Manual No. 0-4838 1-7 SAFETY

FABRICATOR 190 WELDING MACHINE

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêche inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

r le courant de suivre un long parcours

1. Por tez un écran facial ou des lunettes protectr ices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans 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’échappement nocifs.

SAFETY 1-8 Manual No. 0-4838

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

FABRICATOR 190 WELDING MACHINE

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez 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’ôter.

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN

1.06 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding 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 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

Manual No. 0-4838 1-9 SAFETY

FABRICATOR 190 WELDING MACHINE

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Sous Tension

Hors Tension

Tension dangereuse

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Fusible

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Distant

Facteur de Marche

Pourcentage

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)

Soudage á L’arc Avec Electrode Non Fusible (GTAW)

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Torch de

Purge Du Gaz

Soudure Par Point

Duréc du Pulse

Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.

Durée de Pré-Dèbit

Durée de Post-Dèbit

Soudage

Mode Continu de Soudure

Détente à 2-Temps

Détente à 4-Temps

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

115V 15A

SAFETY 1-10 Manual No. 0-4838

Classement de PriseSource Auxiliaire

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Probléme de Terre

Pouces Par Minute

Mètres Par Minute

Art # A-07639

FABRICATOR 190 WELDING MACHINE

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page i.

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.

2.02 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 control 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. Record these numbers on the bottom of page i for future reference.

2.03 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.

NOTE

A NOTE 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

Manual No. 0-4838 2-1 INTRODUCTION

FABRICATOR 190 WELDING MACHINE

2.04 General Information

The Fabricator 190 is a semiautomatic Gas Metal Arc Welder (GMAW/FCAW-commonly MIG) with an integrated wire feed unit. The Fabricator 190 is designed and manufactured to meet the requirements of CSA and IEC 60974-1 standards.

The Fabricator 190 gives excellent performance on mild steel, stainless steel, aluminum, silicon bronze and some hard facing wires with Argon based shielding gases. The Power Supply also gives excellent results on mild steel using Carbon Dioxide shielding gas.

The Fabricator 190 is supplied as a complete, ready-toweld package including a wheel base, cylinder tray, MIG gun, work lead, and flow regulator. The following instructions detail how to correctly set up the welder and give guidelines on gaining the best production efficiency from the Power Supply. Please read these instructions thoroughly before using your Fab

ricator welder.

2.05 Safety

The following basic safety rules should always be followed:

2.06 Protective Filter Lenses

Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infrared, ultraviolet radiation and a percentage of the visible light. Such filter lenses are incorporated within face shields. To prevent damage to the filter lenses from molten or hard particles an additional hard clear glass or special plastic external cover lens should be used. This cover lens should always be kept in place and replaced before the damage impairs your vision while welding.

2.07 Welding Protection

Filter lens

Approximate range of

welding current

Up to 150 Shade 10

150-250 Shade 11 250-300 Shade 12 300-350 Shade 13

Over 350 Shade 14

required for

MIG

Ensure the machine is correctly installed, if necessary, by a qualified electrician.

Ensure the Power Supply is gr ounded correctly (electrically) in accordance with local regulations.

Excessive heat in the welding cables may cause fire. Never weld with poor electrical connections, damaged welding cables or exceed the welding cable current rating as this will produce excessive heat and may cause a fire.

Always wear the correct protective clothing for protection from sparks, molten particles and arc rays.

When welding in confined spaces, always ensure adequate ventilation and constant observation of the operator.

Keep combustible materials away from the welding area. Have a suitable fire extinguisher handy.

Never watch the welding arc with naked eyes. Always use and wear

Do not stand on damp ground when welding. For more complete safety advice, please read Section 1.

a welding mask fitted with the correct filter lens.

Filter Lens Size Versus Welding Current

It is recommended to use a welding helmet, conforming to the local relevant Standards when electric arc welding. Use a welding helmet in serviceable condition with the correct filter lens. Refer to Table 2-1 above and AWS table in Section 1.01 of this manual.

INTRODUCTION 2-2 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

2.08 User Responsibility

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment (including welding leads) should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Thermal Arc. Advice in this regard can be obtained by contacting Thermal Arc.

This equipment or any of its parts should not be altered from standard specification without prior wr of Thermal Arc. The purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc.

itten approval

2.10 MIG Gun Specifications

MIG Gun Specifications

Gun Catalog Number 10217P Gun Type TWECO Weldskill 200 Amp Gun Cable Length 10ft (3m)

2.11 Options and Accessories

Refer to the Appendix section of this manual for the list of available options and accessories for this product.

2.09 Duty Cycle

Duty Cycle is the amount of arc-on time (actual welding or cutting time) during any 10 minute period that a machine can operate at it’s rated output without damaging internal components. For example, the Fabricator 190 is designed for 15% duty cycle at 190 amps. This means that it has been designed and built to provide the rated amperage, 190 amps, for 1 minute and 30 seconds out of every 10 minute period. During the other 8 minutes 30 seconds of the 10 minute period the Fabricator 190 must idle and be allowed to cool. The thermal cutout will operate if the duty cycle is exceeded.

100

Duty Cycle (%)

Safe

Oper ating

ZONE

0 20 40 60 80 10 0 120 140 160 180

Wel di ng Curr en t ( Am ps )

Art # A-07598

Figure 2-1: Fabricator 190 Duty Cycle Curve

Manual No. 0-4838 2-3 INTRODUCTION

FABRICATOR 190 WELDING MACHINE

2.12 Power Supply Specifications

Package System Part Number W1001500 Power Source Part Number 707559 Power Source Weight 123lb (56kg) Power Source Dimensions HxWxD

(including wheels and cylinder carrier) Number of Phases

Frequency 60 Hz Flexible Supply Cable Size 10ft (3m) 10AWG x 3 Supply Plug NEMA 6-50P Nominal Input Voltage Rated Input Current @ 100% Duty Cycle * 11A Rated kVA @ 100% Duty Cycle * 2.5 kVA Maximum Input Current @ 190A Output @230V 34A Generator Requirements 10 kVA Supply VA @ Maximum Output 7.9 kVA Recommended Primary Circuit Size 50A Recommended Minimum Primary Fuse Size ** 30A Open Circuit Voltage Range 26 – 60V DC Welding Arc Voltage Range 15.8 – 25V DC Output Current Range 30 – 190A DC

33 x 16.3 x 34.7”

(838 x 414 x 866mm)

1∅

± 10%

230V

Rated Output Duty Cycle 190A/23.4V @ 15% 100% Duty Cycle Output Rating 85A DC at 19V Duty Cycle Period 10 minutes Number of Output Voltage Values 8 Electrode Wire Type and Diameter

Mild / Stainless Steel Aluminum Flux Cored

Wire Feed Speed Range 80 – 700 ipm (2 – 18 m/min ) Wire Spool Size Diameter 8” / 12” (200mm / 300mm) Burn-back Timer Range

Burn-back Time Factory Set to: Spot Timer Range 0.5 – 4.5 seconds Thermal Protection Self-resetting thermostat fitted to

Operating Temperature Range 32° to 104°F (0° to 40°C)

* The Rated Input Current should be used for the determination of cable size & supply

requirements.

.023” (0.6mm) – .035” (0.9mm) .030” (0.8mm) – .045” (0.9mm) .030” (0.8mm) – .045” (1.2mm)

0 – 0.6 seconds

rectifier and transformer

0.16 seconds

INTRODUCTION 2-4 Manual No. 0-4838

2.13 Wire Drive Specifications

Control Circuit Supply 30VA @ 24VAC Wire Drive Motor Supply 40VA @ 2 to 24VDC (Intermittent Duty) Wire Speed Range 80 to 700 IPM

Wire Diameters

Material

Mild Steel • • •

Stainless Steel • • •

Aluminum • •

Flux Cored • • •

Wire Spool Capacity 44 lb, 33 lb, 10 lb, 8” and 12” wire spool sizes

FABRICATOR 190 WELDING MACHINE

Wire Drive Specifications

(2 to 18 m/min)

.023”

(0.6mm)

.030”

(0.8mm)

.035”

(0.9mm)

.045”

(1.2mm)

2.14 Fabricator 190 Package System Contents

Fabricator 190 Package System Contents

Fabricator 190 Power Source with Integrated Wirefeeder Factory Fitted Wheeling Kit Factory Fitted Single Cylinder Rack Factory Fitted Primary Power Cable 10 AWG, 10ft (3m) with Plug

NEMA 6-50P Work Lead 10ft (3m) with work clamp Regulator/Flowmeter – Argon Mix Gases Tweco Weldskill MIG Gun 200 Amp, 10ft (3m) Fitted Feed Roll for .023” - .030” (0.6 – 0.8mm) solid wire

Manual No. 0-4838 2-5 INTRODUCTION

FABRICATOR 190 WELDING MACHINE

INTRODUCTION 2-6 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

SECTION 3:

INSTALLATION

3.01 Environment

The Fabricator 190 is NOT designed for use in environments with increased hazard of electric shock.

Examples of environments with increased hazard of electric shock are:

In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts;

In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator, or

In wet or damp hot locations wher e humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.02 Location

Be sure to locate the Power Supply according to the following guidelines:

In areas, free from moisture and dust. In areas, free from oil, steam and corrosive gases. In areas, not subjected to abnormal vibration or shock. In areas, not exposed to direct sunlight or rain. Place at a distance of 1ft (300mm) or more from walls or

similar that could restrict natural air flow for cooling. The minimum ground clearance for these products is 5.5"

(140mm).

3.03 Ventilation

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

Manual No. 0-4838 3-1 INSTALLATION

FABRICATOR 190 WELDING MACHINE

3.04 Mains Supply Voltage Requirements

The Mains supply voltage should be within ± 10% of the rated Mains supply voltage. Too low a voltage may cause poor welding performance or the wirefeeder malfunction. Too high a supply voltage will cause components to overheat and possibly fail. The Fabricator 190 is supplied with a 10 AWG x 3 supply lead.

Install a power outlet for each Power Supply and fit fuses as per the machine specifications.

WARNING

Thermal Arc advises that your Fabricator be electrically connected by a qualified electrical trades-person.

The Fabricator 190 Power Supply is factory connected for the following input power supply voltage:

Input Power

Supply Lead Size

10 AWG x 3 40 Amps 10ft (3m) 230V 190A @ 15%

Table 3-1: Factory Fitted Input Power Supply Leads Fitted to the Fabricator 190

Lead Current

Rating

Lead

Length

Machine

Voltage Setting Duty Cycle

3.05 Alternative Mains Supply Voltages

WARNING

The Fabricator 190 input power supply lead should be replaced with leads as specified in Table 3-2 when the Fabricators input power supply voltage is changed.

The Power Supply is suitable for use on the following input power supply voltages:

Input Power Supply

Voltage Setting

208V 1ø 10AWG (5mm2) 3M 50 Amps 45 Amp 250A @ 30% 230V 1ø 10AWG (5mm2) 3M 50 Amps 45 Amp 250A @ 30%

Table 3-2: Mains Supply Lead Sizes for Alternative Mains Supply Voltages

Primary Input

Power Lead Size Lead Length

Input Power

Outlet Size Fuse Size Duty Cycle

National Electrical Code Standards permit the rating of the fuse or thermal circuit breaker protecting the circuit conductors to be double the standard rating for any circuit used exclusively for an electric arc welder. Check local requirements for your situation in this regard.

Changing the Voltage Selection

1. Disconnect the power supply from the main power source.

2. Refe

INSTALLATION 3-2 Manual No. 0-4838

r to Figure 3-1. The power supply comes wired for 230V. Locate the black input power wire secured to the input voltage selection block. Loosen the set screw for both voltage locations.

3. Remove the black wire from the current location and Insert the uninsulated wires into the new voltage location. Secure by tightening the set screw onto the uninsulated portion of the wires. Secure the first set screw as well.

Art # A-08417

Figure 3-1: Voltage selections for Fabricator 190

FABRICATOR 190 WELDING MACHINE

3.06 Quick Set Up

CAUTION

To obtain adequate air flow and cooling for the Power Supply components, the four wheels must be fitted. Alternatively, the Power Supply may be raised 5.5" (140 mm)from the floor using supports that do not restrict airflow.

NOTE

The steps in this subsection are intended for individuals experienced in the set up of this type welder. More detailed setup instructions are in the 3.06 and following subsections.

1. Connect the work lead to the negative (-) socket (positive + for Self Shielded Flux Cored Wire)

2. Connect the (negative - for Self Shielded Flux Cored Wire)

GUN

lead to the positive (+) socket

7. Fit the electrode wire spool to the wire reel hub located behind the electrode wire compartment door.

8. Fit the TWECO Weldskill MIG gun and trigger wires through/to the front of the unit.

9. Remove the contact tip from the gun.

10.With the gun lead reasonably straight, feed the wire through the wire drive rolls and gun.

11. Fit the app and nozzle.

ropriate contact tip and replace insulator

NOTE

See Section 3.11 "Polarity Changeover" for more detail and exceptions!

3. Position a gas cylinder on the rear tray and secure to the Power Supply cylinder bracket with the chain provided. If this arrangement is not used then ensure that the gas cylinder is secured to a building pillar, wall bracket or otherwise securely fixed in an upright position.

WARNING

If the gas cylinder is not secured to the cylinder tray, the power supply must be kept from moving to avoid over-extending the gas hose which can result in personal injury, damage to the power supply, flowmeter and gas cylinder.

4. Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts provided.

5. Fit the gas Regulator/Flowmeter to the gas cylinder and connect the gas hose from the rear of the Power Supply to the Flowmeter outlet.

6. The machine is fitted with a .023"/.030” vee groove feed roll suited for hard wire. Change this feed roll if required to fit your chosen wire size.

Manual No. 0-4838 3-3 INSTALLATION

FABRICATOR 190 WELDING MACHINE

3.07 Installation of Shielding Gas (GMAW) Process

Refer to Figure 3-2.

NOTE

Shielding Gas is not required if the unit is used self shielded FCAW (flux cored arc welding) wires

Cylinder positioning

Chain the cylinder to a wall or other support to prevent the cylinder from falling over. If an optional portable mounting is used, follow the instructions provided with it.

Cracking

Remove the large metal cap on top of the cylinder by rotating counter clockwise. Next remove the dust seal.

Position yourself so the valve is pointed away from you and quickly open and close the valve for a burst of gas. This is called “Cracking” and is done to blow out any foreign matter that may be lodged in the fitting. (Fig 3-2.)

CAUTION

Adjusting Regulator

Adjust control knob of regulator to the required flow rate, indicated on gauge dial. (Refer to Figure 3-1 and data charts Approx. 20 CFH.

The gas flow rate should be adequate to cover the weld zone to stop weld porosity. Excessive gas flow rates may cause turbulence and weld porosity.

Argon or argon based gas flow rates:

- Workshop welding: 20-30 CFH

- Outdoors welding: 30-40 CFH Helium based or CO2 gas flow rates:

- Workshop welding: 30-40 CFH

- Outdoors welding: 40-50 CFH

NOTE

All valves downstream of the regulator must he opened to obtain a true flow rate reading on the outlet gauge. (Welding power source must be triggered) Close the valves after the pressure has been set.

Never “crack” a fuel gas cylinder valve near other welding works, sparks or open flames. Ensure surrounding area is well ventilated

Regulators – fitting to cylinders

Screw the regulator into the appropriate cylinder. The nuts on the regulator and hose connections are right hand (RH) threaded and need to be turned in a clockwise direction in order to tighten. Tighten with a wrench.

CAUTION

Match regulator to cylinder. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.

Regulators – fitting to welder.

Blow out the hose before connecting to the regulator and rear of welding power source – to remove dust, talc, etc.

The nut on the hose connection is right hand (RH) threaded and needs to be turned in a clockwise direction in order to tighten.

Art # A-07280

Figure 3-1: Adjusting Flow Rate

Refer to section 4.10 for suggested gas / filler metal combinations.

NOTE

The regulator/flow meters used with argon based and carbon dioxide shielding gases are different. The regulator/flow meter supplied is for argon based shielding gases. If carbon dioxide is to be used a suitable carbon dioxide regulator/flow meter will need to be fitted.

INSTALLATION 3-4 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

“Cracking”

Cap

Shielding Gas

Regulator and Flow Meter

Shielding Gas

Gas Hose

Shielding Gas

Art # A-07401

Figure 3-2: Gas Cylinder Installation

Manual No. 0-4838 3-5 INSTALLATION

FABRICATOR 190 WELDING MACHINE

3.08 Attaching the Gun and Cable Assembly to the Power Source

The Fabricator 190 is supplied with a Tweco Weldskill gun 190 10217 air-cooled torch. The Weldskill gun is designed with an ergonomic handle and fewer parts to cause performance problems. The Weldskill gun uses standard readily available Tweco consumable parts.

1) Remove the door panel to the machine by inserting your left and right index fingers into the two holes marked with arrows in Figure 3-3 and firmly pull it towards you.

2) Route the gun cable through the access hole in the front panel. Refer to Figure 3-4.

3) Loosen the thumbscrew and insert the gun cable end as far as it will go. Tighten thumbscrew. Refer to Figure 3-5.

4) Insert the trigger plug into its receptacle and thread its retainer on securely by hand.

NOTE

Lubricate the O-ring on the quick-connect fitting with grease (Dow company #4 compound or equivalent).

4) To remove the gun, reverse these directions.

Figure 3-3: Door Panel Removal

Art # A-07363

INSTALLATION 3-6 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

Art # A-07339

Front Panel Access Hole

Trigger Receptacle

Figure 3-4: Route Gun Cable Through Access Hole and Connect Trigger

Art: A-07601

Loosen Thumbscrew

Tighten Thumbscrew

Figure 3-5: Mount Gun Cable to Adapter Socket

Manual No. 0-4838 3-7 INSTALLATION

FABRICATOR 190 WELDING MACHINE

3.09 Feedrolls

A feedroll consists of two different sized grooves. As delivered from the factory, the feedroll is installed for .023” (0.6mm).

When the feedroll is installed, the visibly marked size refers to the groove which will be in use.

The groove closest to the motor is the one to thread the wire through.

This also applies to optional feedrolls which are available for this machine.

(0.6mm) Stamping

. 023”

.023

0.6

. 023”

(0.6mm) Groove

The size that is visible when ﬁtting the feedroll is the groove

Art # A-07187

Figure 3-6: Feedroll Example

Refer to the Options and Accessories list in the Appendix section of this manual for information on additional feed

roll kits.

size in use.

INSTALLATION 3-8 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

3.10 Installing Wire Spool

Installation of 8” (203mm) spool

1. Remove the spool retaining pin (6) from spool hub (7).

2. Fit the spool (5) onto the spool hub (7).

3. Ensure that the drive pin engages the mating hole in the spool.

4. Push the spool retaining pin (6) into place in the spool hub (7).

NOTE

Nut is tightened until a slight force is required to turn the spool

Installation of 12” (300mm) spool

Installation of a 12" (300mm) spool is the same as the 8” (203mm) spool except that the Spool Retaining Pin will go into the outer holes of the Spool Hub.

1. Nut

2. Flat Washer (X3)

3. Wave Washer (X2)

4. Spool 8” (203mm)

5. Spool Retaining Pin

6. Spool Hub (using inner holes)

7. Friction Washer

Outer holes used for 12” (300mm) spool

Drive Pin

Art # A-07474_AB

Figure 3-7: Spool Installation

Manual No. 0-4838 3-9 INSTALLATION

FABRICATOR 190 WELDING MACHINE

3.11 Inserting Wire into the Feedhead and Welding Gun

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions

Slide the wire spool onto the hub, loading it so that the wire will feed off the spool as the spool rotates counter clockwise.

Make sure the drive pin on the spool hub lines up with the hole in the spool.

When the spool of wire is in place, replace the spool retaining pin.

NOTE

CAUTION

Use care in handling the spooled wire as it will tend to “unravel” when loosened from the spool. Grasp the end of the wire firmly, and don’t let go of it. Make sure the end of the wire is free of any burrs and is straight.

1. Loosen Pressure Adjust Device knob (Fig. 3-8)

2. Open Pressure Adjust Device (Fig. 3-9)

3. Open Pressure Arm (Fig. 3-9)

4. Place end of wire into the Inlet Wire Guide, feeding it over the Feedroll. Make certain the proper groove is being used. (Fig. 3-10)

5. Pass the wire into the outlet guide then into the MIG Gun. (Fig. 3-10)

6. Close the Pressure Arm. (Fig. 3-9)

7. Close the Pressure Adjust Device. Tighten the Pressure Adjust Device knob to a “snug” condition. (Fig. 3-9)

8. Figure 3-10 shows the result with wire installed.

The Hub tension has been pre-adjusted at the factory. However is adjustment is required, simply turn the spool nut counter clockwise to reduce tension, and clockwise to increase tension

Spool

Art # A-07569

Pressure Arm

Pressure Adjust Device

Gun Cable EndFeedrollWire GuideWire

Figure 3-8: Inner Workings of Device

INSTALLATION 3-10 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

Art # A-07568

Figure 3-9: Opening Pressure Arm and Inserting Wire

Feedroll kit consists of idler roll and drive roll

Art # A-07570

Wire Threaded Through Feedroll

Figure 3-10: Wire Installed

Manual No. 0-4838 3-11 INSTALLATION

FABRICATOR 190 WELDING MACHINE

3.12 Polarity Changeover

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the machine is unplugged from the power receptacle. Do not plug machine in until told to do so in these instructions

As delivered from the factory, the output polarity is connected for DCEP (reverse polarity).

PROCESS POLARITY

1. GMAW* – Steel, Stainless Steel, Aluminum & gas shielded Flux Cored electrode wires

2. FCAW* – Gasless Flux Cored electrode wire

* Exception: Contact your filler metal supplier for the recommended polarity.

1. D.C. Electrode Positive (DCEP) – Reverse Polarity

2. D.C. Electrode Negative (DCEN) – Straight Polarity

1. Connected to (+) Pos. output terminal

2. Connected to (-) Neg. output terminal

CABLE CONNECTIONS

CABLE TO GUN CABLE TO WORK

1. Connected to (-) Neg. output terminal

2. Connected to (+) Pos. output terminal

Table 3-4: Process Cable Connections

Changing polarity process.

a. Locate the two terminal knobs at the bottom of the machine. Refer to Figure 3-11. b. Remove both terminal knobs by rotating counter-clockwise. Refer to Figure 3-11. c. Set up the desired lead polarity as per Table 3-4 and as shown in Figure 3-12 by placing the loose end of the

polarity cable on the appropriate terminal. d. Connect (or re-connect) the work cable to the vacant terminal e. Replace both terminal knobs.

NOTE

Ensure terminal knobs are tightly secured and that there is no connection between positive and negative terminals.

INSTALLATION 3-12 Manual No. 0-4838

Terminal Knob

Figure 3-11: Remove Terminal Knobs

FABRICATOR 190 WELDING MACHINE

Art # A-07571

Art # A-07340

DCEN Polarity Terminal

Connect the work cable to the vacant terminal

Figure 3-12: Terminal Polarity Setting

DCEP Polarity Terminal

Terminal Polarity Cable

Manual No. 0-4838 3-13 INSTALLATION

FABRICATOR 190 WELDING MACHINE

INSTALLATION 3-14 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

SECTION 4:

OPERATION

WARNING

The electrode wire will be at welding voltage potential while it is being fed through the system.

4.01 Inside Panel

1. Burnback Control Knob: Burnback time is the difference between the wirefeed motor stopping and switching off of

the welding current. The Burnback time allows the electrode wire to burn out of the molten metal weld pool. The Burnback time is factory set for optimum performance. Turn the Burnback knob clockwise to increase the time and counter-clockwise to decrease it. The adjustable range is 0 to .6 seconds. Refer to Figure 4-1.

2. Wirefeeder Drive Roller Pressure Adjustment: The idler roll applies pressure to the drive roll via screw adjustable spring pressure. The pressure adjust device should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn-back jam, the conduit line the cause of slipping, the feedroll pressure can be increased by rotating the pressure adjust device clockwise. The use of excessive pressure may cause rapid wear of the feed roll, motor shaft and motor bearings.

r should be checked for kinks and clogging by metal flakes and slag. If this is not

3. Wire Reel Brake: The spool hub incorporates a friction brake which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the spool hub. Clockwise rotation will tighten the brake. Correct adjustment will result in the spool circumference continuing no further than ¾” (20mm) after release of the Gun trigger switch. The wire should be slack without becoming dislodged from the spool.

CAUTION

Excessive tension on the brake will cause rapid wear of mechanical wire feed parts, overheating of electrical components and possibly an increased incidence of wire Burnback into the contact tip.

Art # A-07397

Wire Spool Brake Drive Roller Pressure Adjustment

Figure 4-1: Inside Panel

Manual No. 0-4838 4-1 OPERATION

FABRICATOR 190 WELDING MACHINE

4.02 Power Supply Front Panel

123

Weldskill

Art # A-07476

Figure 4-2: Fabricator 190 Front Panel

OPERATION 4-2 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

1. Handle Bar

2. Thermal Overload Indicator: The critical component

for thermal protection are the rectifier stack and the transformer, which are fitted with thermal overload protection devices. If the overload is activated then the machine should be left to cool for approximately 15 minutes before resuming welding. If the Power Source is operated within its duty cycle, the thermal overload will not activate. Refer to section 2.10 for an explanation of duty cycle and section 2.13 for the power supply specifications.

WARNING

When the On/Off Power Switch Indicator is lit, the machine is connected to the primary input supply voltage and the internal electrical components are at primar y input voltage potential.

3. On/Off Power Switch: The indicator light is provided to indicate when the Fabricator 190 is connected to the Input Power Supply Voltage. With the switch in

the Off position are turned off and the switch is illuminated to indicate

that the primary power is still present.

4. Wirespeed Control: The Wirespeed Control knob controls the wire feed speed which is adjustable from 80 to 800 IPM.

the auxiliary power and the fan

7. Output Voltage Control Switch: The Output Voltage Control Switch sets the voltage level to the welding terminals. The output voltage is increased when the switch is rotated in the clockwise direction.

CAUTION

The Output Voltage Control switch MUST NOT BE SWITCHED during the welding process.

8. Positive Welding Current Terminal: Welding current flows from the Power Supply via this heavy duty terminal. Shown with terminal knob removed. The knob must be firmly secured before attempting to weld.

9. Gun Polarity Lead: This lead selects the welding voltage polarity of the electrode wire. Attach it to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire . Attach the Gun Polarity Lead to the negative welding terminal ( - ) when using gasless flux cor ed electrode wire. If in doubt, consult the manufacturer of the electrode wire for the correct polarity.

10.Positive and Negative Welding Terminal Knobs

Welding current flows from the Power Supply via the heavy duty terminals. The knobs must be firmly secured before attempting to weld.

CAUTION

5. Spot Timer Control: The spot time duration is set by

the Spot Timer Control knob, and is only activated with the mode selector switched to Spot position. When the Mode Selector switch is switched to the Spot position, the Spot Timer Control knob controls the duration of a single spot weld. The timer is adjustable from .5 to 4.5 seconds.

6. Mode Selector Switch: The Mode Selector switch selects the method of welding.

CONTINUOUS: This mode of welding is used to weld two or more components together with a continuous weld. When the MIG gun trigger switch is depressed welding commences. When the MIG gun trigger switch is released welding ceases.

SPOT: This mode of welding is used to weld two plates together at a desired location by melting the top & bottom plates together to for between them. The spot time period is set by the Spot Timer Control knob.

m a nugget

Loose welding terminal connections can cause overheating and r esult in failure of the terminals.

11.Negative Welding Current Terminal: Welding current flows from the Power Supply via this heavy duty terminal. Shown with terminal knob removed. The knob must be firmly secured before attempting to weld.

12.Gun Connector: This is the receptacle into which the MIG gun is connected. It accepts a #4 Tweco style gun.

13.Gun Trigger Switch Amphenol Receptacle: The Gun Trigger 4-pin receptacle is used to connect the two wires from the MIG gun to the Fabricator 190. Only pins A and B are used for this. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Refer to Figure 4-3.

Manual No. 0-4838 4-3 OPERATION

FABRICATOR 190 WELDING MACHINE

13.Torch Trigger Receptacle (continued)

Art # A-07602

Socket Pin Function

A Gun Switch

Gun Switch (contact closure provided between

B C Not Used

pins A and B to energize the contactor).

D Not Used

Figure 4-3: Torch Trigger Receptacle Pin-out

4.03 TWECO Weldskill MIG Gun

The TWECO Weldskill MIG Gun fitted to the FABRICATOR 190 offers robust construction, unparalleled reliability and easy replacement of consumable parts. The TWECO Weldskill MIG Gun has an operating capacity in excess of the capacity of the FABRICATOR and can be expected to give trouble free service.

Art # A-07344

Figure 4-4: TWECO Weldskill MIG Gun

TWECO Weldskill 150A Fabgun MIG Gun — Original Parts Installed

Item Des cription "P" Series Part No.

1 NOZZLE 1/2" WS21-50 2 CONTACT TIP .035" WS11-35 3 NOZZLE INSULA TO R 63J-3 4 GAS DIFFUSER WS51 5 CONDUCTOR TUBE WM150J45 6 HANDLE ASSEMBLY TA1-80 7 TRIGGER SWITCH ASSEMBLY WM91

OPERATION 4-4 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

TWECO MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO. Not only will this give greater

reliability (and hence greater productivity) but it will reduce stockholding of consumable parts.

Contact your Thermal Arc distributor to order TWECO replacement parts, options and accessories. For

assistance in locating a Thermal Arc distributor, contact the Thermadyne office listed in the inside rear cover that is nearest to you.

Gun Consumable Parts

Refer to the appendix section of this manual for the list of consumable items, including nozzles, contact tips, gas diffusers and conductor tubes.

4.04 Installing A New Wire Conduit

Removal

1. Be sure the MIG gun cable is arranged in a straight line and free from twists when installing or removing a wire conduit.

2. Unscrew and remove the MIG Gun Nozzle and Contact Tip using a pair of slip-joint pliers. Remove the Insulator.

3. Unscrew the Gas Diffuser from the Conductor Tube using a 7/16-inch (11mm) open end wrench across the flats.

Installation

1. Inspect the two O-ring gas seals on the Connector Plug for cuts or damage.

2 Start from the Connector Plug end of the assembly

and begin pushing the Wire Conduit through the Connector Plug, cable assembly and into the gun. If the Wire Conduit should lodge along the way, gently whip or work the cable assembly to aid forward movement.

3. When the Wire Conduit stop meets the end of the Connector Plug and the new raw end extends through the end of the Conductor Tube on the welding gun, the allen screw in the Connector Plug must be securely tightened onto the Wire Conduit to prevent its backward movement.

NOTE

When the Wire Conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug, the “raw end” of the Wire Conduit will protrude out of the open end of the gun Conductor Tube. Trim the Wire Conduit as shown in Figure 4-5. The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed.

4. Loosen the allen screw in the Connector Plug using a 5/64-in. allen wrench and pull the old Wire Conduit out of the cable assembly from the connector plug end.

Manual No. 0-4838 4-5 OPERATION

FABRICATOR 190 WELDING MACHINE

3. Replace the Gas Diffuser and Insulator.

4. Replace the Contact Tip and Nozzle.

CAUTION

Do not over-tighten the allen screw as this will distort the Wire Conduit and lead to wire feedability problems.

CONDUCTOR TUBE

CONDUIT LINER

ALLEN SCREW

REMOVE CONSUMABLES

CONDUIT LINER

1 1/16" (27mm)

Art # A-07330

O-RINGS

ALLEN SCREW

CONNECTOR PLUG

Figure 4-5: Conduit Installation and Trim Length

4.05 MIG Gun Maintenance

Remove dust and metallic particles from the gun conduit by forcing clean, dry compressed air into the conduit once a week. This will minimize wire feeding problems.

OPERATION 4-6 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

4.06 Basic Welding Technique

Setting of the Power Supply

The setting of the Fabricator requires some practice by the operator, the welding Power Supply having two control settings that have to balance. These are the Wire Speed control and the Voltage Control switches. The welding current is determined by the Wire Speed control, the current will increase with increased Wire Speed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the arc. Increasing the welding voltage hardly alters the welding current level, but lengthens the arc. By decreasing the voltage, a shorter arc is obtained with little change in welding current.

When changing to a different electrode wire diameter, different control settings are requi needs more Wire Speed to achieve the same current level.

A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the work piece.

If the Wire Speed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If, however, the welding voltage is too high, large drops will form on the end of the electrode wire, causing spatter. The correct setting of voltage and Wire Speed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound.

Travel Speed

Speed at which a weld travels influences the width of the weld and penetration of the welding run.

Position of MIG gun

The angle of MIG gun to the weld has an effect on the width of the weld run. Refer to Figure 4-6.

Forehand

Art # A-05148

Vertical

red. A thinner electrode wire

Figure 4-6: MIG Gun Angle

Manual No. 0-4838 4-7 OPERATION

FABRICATOR 190 WELDING MACHINE

Distance from the MIG Gun Nozzle to the Work Piece

The electrode stick out from the MIG gun nozzle should be between 5/64”(2.0mm) to 13/64”(5.0mm). This distance may vary depending on the type of joint that is being welded.

Art # A-07186

1/4” (6.4mm)

.023”

(.6mm)

Solid Wire

5/16” (7.9mm)

.030”

(.8mm)

3/8” (9.5mm)

.035”

(.9mm)

Flux Cored Wire

9/16”

(14.3mm)

.035”

(.9mm)

11/16”

(17.5mm)

Figure 4-9: Optimum Contact Tip to Work Distances

Electrode Wire Size Selection

The choice of electrode wire size in conjunction with shielding gas used depends on:

- Thickness of the metal to be welded,

- Type of joint,

- Capacity of the wire feed unit and power supply,

- The amount of penetration required,

Tip

Contact

Distance: ±1/16”

.045”

(1.1mm)

Gas

Nozzle

Wire Diameter

- The deposition rate required,

- The bead profile desired,

- The position of welding and

- Cost of the electrode wire.

Advantages of MIG welding forehand:

• Allows superior visibility of the weld zone

• Flatter weld bead

• Shallower penetration

Forehand

Vertical

Backhand

Art # A-07185

Figure 4-7: Advantages of forehand welding

OPERATION 4-8 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

4.07 Technical Tips

Reduce Porosity in the Weld Metal

• Weld in still air to ensure gas coverage

• Clean the dirty, oil, paint, oxidization or grease from

the metal to be welded

• Eliminate any gas leaks in the hose

• Make sure the gas cylinder is not empty with a flow

rate of about 25cfh

Electrode Wire Burns Back to the Contact Tip

•Wire feed speed is too low

• MIG gun liner is blocked with dust or metallic dust

• Bent MIG gun liner

• Damage or worn inlet or outlet wire guides in the wire

drive system

Irregular Weld Beard Shape

• Incorrect or worn feed roller size

Output Voltage Control Switch to 8 Wirespeed Control to between 5 to 8

Mode Selector Switch to

Adjust the Spot Time control knob for the desired

weld penetration

Voltage Selector Switches and Wirespeed Control

Select higher Voltage Selector switch positions and set the Wirespeed Control between 354 to 590 ipm (9 to 15 meters/minute) for maximum penetration.

Mode Selector Switch

Set the MODE SELECTOR switch to SPOT.

Spot Time

Adjust the SPOT TIME control shaft for the desired weld or ‘ON’ time for spot welding.

Spot

• Incorrect size or worn contact tip

• Bad work lead contact to work piece

No Strength in the Weld Joint

•Wire feed speed (welding current) is too low

• Incorrect gas for the material being welded

• Joint preparation too narrow or gap too tight

Cracks Develop in the Weld Metal

•Arc voltage is too high

• The weld cooling r

• The stresses in the welded metal are too high

• Weld penetration is too narrow and deep

ate is too fast

4.08 Spot Welding Operation

Fit an optional spot welding nozzle to the MIG gun for consistent spot welding operations. Refer to Figure 4-8 and the Spot Welding Nozzles table below. The Fabricator will operate effectively using .030” (0.8mm) electrode wire when spot welding. Penetration depth is limited when using .023”(0.6mm) electrode wire for spot welding. Set the controls as follows for maximum penetration when spot welding:

21-62-FAS

Art # A-07675

Figure 4-8: Spot Welding Nozzle

SPOT WELDING NOZZLES

TYPE MINI & NO. 1 150 AMP

Flat Arc Spot

Inside Corner Arc Spot N/A

Outside Corner Arc Spot N/A

Automotive Stud Nozzle 21-62 SAS

21-62-FAS 1210-1520 (5/8" Bore)

1210-1524

Manual No. 0-4838 4-9 OPERATION

FABRICATOR 190 WELDING MACHINE

4.09 Welding Setting Selection Guide

Material T ype

Art # A-07448

Steel

Wire T ype

Solid

(or hard)

ER70S-6

Shielding Gas

and Flow Rate

100% CO

25cfh

75% Ar

225%

25cfh

92% Ar

Wire Size

(Diameter)

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

.023” (0.6mm)

Steel

Aluminum

Stainless

Steel

Flux Core

E71 T- 1 1

E71 T- GS

Aluminum

4043 ER 5183 ER 5356 ER

Stainless

Steel

ER 308

ER 308L

ER 308LSi

8% CO

25cfh

None

Required

100% Ar

25cfh

90% He

7.5% Ar

2.5 CO

35cfh

.030” (0.8mm)

.035” (0.9mm)

.030” (0.8mm)

.035” (0.9mm)

.030” (0.8mm)

.035” (0.9mm)

.023” (0.6mm)

.030” (0.8mm)

.035” (0.9mm)

OPERATION 4-10 Manual No. 0-4838

Voltage Step

Wire Speed

FABRICATOR 190 WELDING MACHINE

THICKNESS

22 ga. (0.8mm)

20 ga. (0.9mm)

2.25

2.5

1.25

2.5

1.25

18 ga. (1.2mm)

2.75

1.5

16 ga. (1.6mm)

2.25

3.25

2.5

3.25

2.5

1/8” (3.2mm)

2.75

2.5

3.75

2.75

6.25

4.25

3/16” (5.0mm)

1/4” (6.4mm) 5/16” (8.0mm)

4.75

4.25

6.25

4.5

6.5

4.5

7.5

4.75

2.25

2.5

1.5

Manual No. 0-4838 4-11 OPERATION

2.5

1.5

1.75

1.5

2.25

1.25

2.75

1.75

2.75

2.5

3.5

2.75

3.5

3.75

4.5

3.75

5.75

3.25

5.5

4.75 5.5

6.25

5.75

FABRICATOR 190 WELDING MACHINE

NOTES

OPERATION 4-12 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

SECTION 5:

SERVICE

5.01 Routine Maintenance & Inspection

The only routine maintenance required for the Fabricator is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

WARNING

Disconnect the Fabricator from the Input power supply voltage before disassembling.

Special maintenance is not necessary for the control unit parts in the Power Supply. If these parts are damaged for any reason, replacement is recommended.

CAUTION

Do not blow air into the Power Supply during cleaning. Blowing air into the Power Supply can cause metal particles to interfere with sensitive electronic components and cause damage to the Power Supply.

To clean the Power Supply, disconnect it from the mains supply voltage then open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The Power Supply should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.

Troubleshooting and repairing the Fabricator should be carried out only by those who are familiar with electrical equipment.

WARNING

Do not attempt to diagnose or repair unless you have had training in electr onic measurement and tr oubleshooting techniques.

Manual No. 0-4838 5-1 MANUAL GMAW WELDING

FABRICATOR 190 WELDING MACHINE

Warning!

Disconnect input power before maintaining.

Maintain more often if used under severe conditions

Each Use

Visual check of regulator and pressure

Visually inspect the torch body and consumables

Replace all broken parts

Visual check of torch Consumable parts

Weekly

Visually inspect the cables and leads. Replace as needed

3 Months

Gas and air lines

Visually inspect the Wire feed mechanisms

Clean exterior of power supply

6 Months

Visually check and use a vacuum to carefully clean the interior

Art # A-07362

MANUAL GMAW WELDING 5-2 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

5.02 Basic Troubleshooting

The basic level of troubleshooting is that which can be performed without special equipment or knowledge, and without removing the covers from the Power Supply.

If major components are faulty, then the Power Supply should be returned to an Accredited Thermal Arc Service Agent for repair.

5.03 Solving Problems Beyond the

Welding Terminals

The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW:

1. Porosity

When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal.

6. Distance between the MIG torch nozzle and the work piece.

a. Keep the distance between the MIG torch nozzle

and the work piece to a minimum.

7. Maintain the MIG torch in good working order.

a. Ensure that the gas holes are not blocked and

gas is exiting out of the torch nozzle. Refer to WARNING below

b. Do not restrict gas flow by allowing spatter to

build up inside the MIG torch nozzle.

c. Check that the MIG gun O-rings are not

damaged.

WARNING

Disengage the drive roll when testing for gas flow by ear.

Contaminants range from no gas around the welding arc to dirt on the work piece surface. Porosity can be reduced by checking the following points:

1. Gas cylinder contents and flow meter.

a. Ensure that the gas cylinder is not empty and

the flow meter is correctly adjusted to 2025CFM (15 litres per minute).

2. Gas leaks

a. Check for gas leaks between the regulator/

cylinder connection and in the gas hose to the Power Source.

3. Internal gas hose in the Power Source.

a. Ensure the hose from the solenoid valve to the

MIG torch adaptor has not fractured and that it is connected to the MIG torch adaptor.

4. Welding in a windy environment.

a. Shield the weld area from the wind or increase

the gas flow.

5. Welding dirty, oily, painted, oxidized or greasy plate.

a. Clean contaminates off the plate

Manual No. 0-4838 5-3 MANUAL GMAW WELDING

FABRICATOR 190 WELDING MACHINE

2. Inconsistent wire feed

Wire feeding problems can be reduced by checking the following points:

1. Wire spool brake is too tight.

a. Feed roller driven by motor in the cabinet will

slip.

2. Wire spool brake is too loose.

a. Wire spool can unwind and tangle.

3. Worn or incorrect feed roll size.

a. Use ‘U’ groove feed roll matched to the

aluminum wire size you are welding. Use ‘V’ groove feed roll matched to the steel wire size you are welding. Use ‘knurled V’ groove feed roll matched to the flux cored wire size you are welding.

4. Misalignment of inlet/outlet guides.

a. Wire will rub against the misaligned guides and

reduces wire feedability.

6. Incorrect or worn contact tip.

a. The contact tip transfers the weld current to

the electrode wire. If the hole in the contact tip is to large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the contact tip. When using soft electrode wire such as aluminum it may become jammed in the contact tip due to expansion of the wire when heated. A contact tip designed for soft electrode wires should be used.

7. Poor work lead contact to work piece.

a. If the work lead has a poor electrical contact to

the work piece then the connection point will heat up and result in a reduction of power at the arc.

8. Bent conduit.

a. This will cause friction between the wire and

the conduit thus reducing wire feedability.

5. Liner blocked with swarf.

a. Slag is produced by the wire passing through

the feed roll, if excessive pressure is applied to the pressure adjustement device. Slag can also be produced by the wire passing through an incorrect feed roll groove shape or size. Slag is fed into the conduit where it accumulates thus reducing wire feedability.

MANUAL GMAW WELDING 5-4 Manual No. 0-4838

5.04 Welding Problems

FAULT CAUSE REMEDY

A. Undercut. 1. Welding arc voltage

2. Incorrect torch

3. Excessive heat

4. Weld speed too fast Reduce weld speed.

too high.

angle

input

FABRICATOR 190 WELDING MACHINE

Reduce voltage by reducing the output voltage control switch position or increase the wire speed.

Adjust angle

Increase the torch travel speed and/or reduce welding current by reducing the output voltage control switch position or reducing the wire speed.

B. Lack of penetration. 1. Welding current too

low

2. Joint preparation too narrow or gap too tight

3. Shielding gas incorrect

4. Weld speed too fast Reduce weld speed.

C. Lack of fusion. 1. Voltage too low Increase voltage by increasing output

2. Weld speed too fast Reduce weld speed.

D. Excessive spatter. 1. Voltage too high Lower voltage by reducing the voltage

2. Voltage too low Raise voltage by increasing the output

3. Weld speed too fast Reduce weld speed.

E. Irregular weld

shape.

1. Incorrect voltage and current settings. Convex, voltage too low. Concave, voltage too high.

Increase welding current by increasing wire speed and increasing voltage selection switch position.

Increase joint angle or gap

Change to a gas which gives higher penetration

voltage control switch position.

selection switch or increase wire speed control.

voltage control switch or reduce wire speed control.

Adjust voltage and current by adjusting the voltage selection switch and the wire speed control.

2. Wire is wandering Replace contact tip

3. Incorrect shielding gas

4. Insufficient or excessive heat input

5. Weld speed too fast Reduce weld speed.

Check shielding gas.

Adjust the wire speed control or the output voltage control switch.

Table 5-1a: Welding Problems and Solutions

Manual No. 0-4838 5-5 MANUAL GMAW WELDING

FABRICATOR 190 WELDING MACHINE

FAULT CAUSE REMEDY

A. Weld cracking 1. Weld beads are too

small

2. Weld penetration narrow and deep

3. Excessive weld stresses

4. Excessive voltage Decrease voltage by reducing the

B. Cold weld puddle. 1. Faulty rectifier unit Have an Accredited Thermal Arc Service

4. Weld speed too fast Reduce weld speed.

C. Arc does not have a

crisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly.

5. Cooling rate too fast Slow the cooling rate by preheating part

6. Weld speed too fast Reduce weld speed.

2. Loose welding cable connection.

3. Low Primary Voltage Contact supply authority

1. The MIG torch has been connected to the wrong voltage polarity on the front panel.

2. Weld speed too fast Reduce weld speed.

Decrease travel speed

Reduce current and voltage and increase Mig torch travel speed or select a lower penetration shielding gas. Increase weld metal strength or revise design

voltage selection switch.

to be welded or cool slowly.

Agent to test then replace the faulty component. Check all welding cable connections.

Connect the MIG torch to the positive (+) welding terminal for solid wires and gas shielded flux cored wires. Refer to the electrode wire manufacturer for the correct polarity.

Table 5-1b: Welding Problems and Solutions (continued)

MANUAL GMAW WELDING 5-6 Manual No. 0-4838

5.05 Power Supply Problems

FAULT CAUSE REMEDY

A. Indicator light in the ON/OFF Power

Switch is illuminated but welding arc can not be established.

B. Primary input supply voltage is ON.

Indicator light in the ON/OFF Power Switch is not lit and welding arc can not be established.

C. Primary input indicator light in the

ON/OFF Power Switch is not lit and welding arc can be established.

D. Primary input supply voltage is ON

and indicator light in the ON/OFF Power Switch is lit but when the gun trigger switch is depressed nothing happens.

E. Primary input supply voltage is ON, no

wire feed but gas flows from the MIG Gun when the gun trigger switch is depressed.

F. Wire feeds when the gun trigger switch

is depressed but arc can not be established.

G. Wire feed and shielding gas ceases

but the MIG gun trigger switch is still depressed.

H. Jerky wire feed

I. No gas flow

J. Gas flow continues after the gun trigger

switch has been released.

FABRICATOR 190 WELDING MACHINE

1. The ON/OFF Power Switch is off.

1. Primary fuses has blown or primary circuit breaker has tripped.

2. Two amp circuit breaker in the wirefeed compartment has tripped.

1. Indicator light is open circuit.

1. Gun trigger switch leads are disconnected.

1. Electrode wire stuck in conduit liner or contact tip (burn-back jam).

2. Faulty control PCB or Tweco Gun

1. Poor or no work lead connection.

1. The Mode Selector switch

is set to Spot

1. Worn or dirty contact tip Replace

2. Worn feed roll Replace

3. Excessive back tension from wire reel hub.roll.

4. Worn, kinked or dirty conduit liner

5. Low Swing Arm pressure Increase the Swing Arm pressure.

1. Gas hose is cut or pinched Replace or repair.

2. Gas passage contains impurities

3. Gas regulator turned off Turn on.

4. Empty Cylinder Refill cylinder.

1. Gas valve has jammed open due to impurities in the gas or the gas line.

Switch the ON/OFF Power Switch on.

Get a qualified electrician to replace the primary fuses or reset the circuit breakers.

Reset the circuit breaker in the wirefeed compartment.

Have an Accredited Thermal Arc Service Agent replace the ON/OFF Power Switch.

Reconnect gun trigger switch leads.

Check for clogged / kinked MIG Gun conduit or worn contract tip. Replace faulty component(s).

Have an Accredited Thermal Arc Service Agent investigate the fault. Clean work clamp area and ensure good electrical contact.

Set the Mode Selector switch is

set to Continuous

Reduce brake tension on spool hub

Clean or replace conduit liner

Disconnect gas hose from the rear of Fabricator then raise gas pressure and blow out the impurities.

Have an Accredited Thermal Arc Service Agent repair or replace gas valve.

Table 5-2: Power Supply Problems

Manual No. 0-4838 5-7 MANUAL GMAW WELDING

FABRICATOR 190 WELDING MACHINE

NOTES

MANUAL GMAW WELDING 5-8 Manual No. 0-4838

FABRICATOR 190 WELDING MACHINE

APPENDIX 1: OPTIONS AND ACCESSORIES

For Tweco/Victor Inquiries and Orders:

Call 1-800-318-6819 Consumable Parts Management Group

EQUIPMENT OPTIONS PART NO Description

GUNS

Tweco® WeldSkill 10ft 10217P Tweco® No. 2 10ft 210-3035 Gun Assembly with 10ft cable 250 Amp @ 60%

Tweco® No. 2 12ft 212-3035 Tweco® Spraymaster 10ft MS210-3545 Tweco® Spraymaster 12ft MS212-3545 ACCESSORIES MIG gun control lead & 4 pin plug MSAK-354

Victor Regulator/Flowmeter Mixed Gases 0781-2723 Victor Regulator/Flowmeter CO2 0781-2725 Medalist™ 1400 Series, HRF Flowmeter Regulator, CO2 gas

CONSUMABLES Drive Roll Kits Drive Roll .023”-.030”/.035” (0.6-0.8/0.9mm) 7977036 V grooved for hard wire Drive Roll .035”-.045” (0.9-1.2mm) 7977660 V grooved for hard wire Drive Roll .030”-.035” (0.8-0.9mm) 7977731 U grooved for soft wire Drive Roll .040”-.045” (1.0-1.2mm) 7977264 U grooved for soft wire Drive Roll .030”-.035” (0.8-0.9mm) 7977732 V grooved knurl for cored wire Drive Roll .045”-.1/16” (1.2-1.6mm) 704277 V grooved knurl for cored wire Contact Tips 11-23 .023” (0.6mm) 11-30 .030” (0.8mm) 11-35 .035” (.09mm) 11-40 .040” (1.0mm) 11-45 .045” (1.2mm) Nozzles

21-50 1/2” (12.7mm)

21.62 5/8” (16mm) Conduits 42-23-15 .023”, 15 ft.(7.6m) 42-3035-15 .030-.035”, 15ft. (4.5m) 42-4045-15 .040-.045”, 15ft. (4.5m) 42N-3545-15 .035-3/64”, 15ft. (4.5m) for Aluminum wire

21-37

Gun Assembly with 10ft cable (supplied with package), 200 Amp @ 30% (150 Amp @ 60%)

Gun Assembly with 12ft cable 250 Amp @ 60% Gun Assembly with 10ft cable 250 Amp @ 80% Gun Assembly with 12ft cable 250 Amp @ 80%

Connection lead between TWECO MIG guns & Fabricator 190 Medalist™ 1400 Series, HRF Flowmeter Regulator, Argon- Argon/CO2 mix gases

3/8” (9.5mm)

March 17, 2006

A-1

FABRICATOR 190 WELDING MACHINE

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM

A-2

NOTE: Re-use this jumper when replacing the 7978050 Control PCB

March 17, 2006

FABRICATOR 190 WELDING MACHINE

Wirespeed 1K

JB/3

Art # A-07406_AB

FABRICATOR 190 SYSTEM SCHEMATIC

SWITCH

POSITION

1 2 3 4 5 6 7 8

SWITCH 2

543

X X

7911

10 12

X X

March 17, 2006

A-3

LIMITED WARRANTY

This information applies to Thermal Arc products that were purchased in the USA and Canada.

March 2008

LIMITED WARRANTY: Thermal Arc®, Inc., A 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 warrant appear within the warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc's specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or damage, correct such defects by suitable repair o replacement, at Thermal Arc's sole option, of any components or parts of the produc determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o merchantability, fitness for any particular purpose, or other warranty o 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, whethe 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 b any such 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 warrant 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 supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered Trademark of Thermal Arc, Inc.

2006

WARRANTY SCHEDULE

This information applies to Thermal Arc products that were purchased in the USA and Canada.

March, 2008

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout, Raider, Explorer

Original Main Power Stators and Inductors.................................................................................. 3 years

Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine Manufactures Warranty for

Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 190, 210, 251, 281, 140, 180; Fabstar 4030; PowerMaster 350, 350P, 500, 500P; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors................................................................... 1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors.................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors................................................................... 1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors................. 3 years 3 years

Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR Dragster 85

Original Main Power Magnetics.....................................................................................................1 year 1 year

Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year 1 year

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year

160S, 300S, 400S

Original Main Power Magnetics....................................................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators ....................................................................................................................... 1 year 1 year

Plasma Welding Torches.............................................................................................................180 days 180 days

Gas Regulators (Supplied with power sources) ..........................................................................180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts............................................................................................................. 90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years

1 year

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

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 Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017

Telephone: (636) 728-3000 FAX: Email: sales@thermalarc.com

(636) 728-3010

www.thermalarc.com

Tweco 190-MIG User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Symbol Chart

1.06 Principales Normes De Securite

1.07 Graphique de Symbole

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 General Information

2.05 Safety

2.06 Protective Filter Lenses

2.07 Welding Protection

2.08 User Responsibility

2.10 MIG Gun Specifications

2.11 Options and Accessories

2.09 Duty Cycle

2.12 Power Supply Specifications

2.13 Wire Drive Specifications

2.14 Fabricator 190 Package System Contents

3.01 Environment

3.02 Location

3.03 Ventilation

3.04 Mains Supply Voltage Requirements

3.05 Alternative Mains Supply Voltages

3.06 Quick Set Up

3.07 Installation of Shielding Gas (GMAW) Process

3.08 Attaching the Gun and Cable Assembly to the Power Source

3.09 Feedrolls

3.10 Installing Wire Spool

3.11 Inserting Wire into the Feedhead and Welding Gun

3.12 Polarity Changeover

4.01 Inside Panel

4.02 Power Supply Front Panel

4.03 TWECO Weldskill MIG Gun

4.04 Installing A New Wire Conduit

4.05 MIG Gun Maintenance

4.06 Basic Welding Technique

4.07 Technical Tips

4.08 Spot Welding Operation

4.09 Welding Setting Selection Guide

5.01 Routine Maintenance & Inspection

5.02 Basic Troubleshooting

5.04 Welding Problems

5.05 Power Supply Problems

APPENDIX 1: OPTIONS AND ACCESSORIES

APPENDIX 2: POWER SUPPLY CIRCUIT DIAGRAM

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION