ESAB fabricator 141i Service Manual

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Page 1

ESAB Fabricator® 141i

3-IN-1 Multi Process Welding Systems

Service Manual

3163339

Révision : AA Issue Date: September 17, 2015 Manual No.: 0-5448

esab.com

Page 2

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency, visit us on the web at www.esab.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, 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 developing technologically advanced products to achieve a safer working environment within the welding industry.

Page 3

WARNING

Plasma Cutting Power Supply ESAB Fabricator® 141i 3-in-1 Multi Process Welding Systems™ Service Manual: 0-5448

Published by:

ESAB 2800 Airport Rd. Denton, TX 76208

www.esab.com

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.

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: September 17, 2015 Revision Date:

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________

Purchase Date:__________________________________ __________

Power Supply Serial #:___________________________ __________

Torch Serial #:___________________________________ __________

Page 4

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility

designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

PROTECT YOURSELF AND OTHERS!

OPERATING.

Page 5

TABLE OF CONTENTS

SECTION 1: SAFETY .................................................................................................... 1-1

1.0 Safety Precautions....................................................................................................... 1-1

SECTION 2:

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

2.03 Receipt of Equipment .................................................................................................. 2-1

2.04 Description .................................................................................................................. 2-1

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

2.05 Transportation Methods .............................................................................................. 2-2

2.06 User Responsibility ..................................................................................................... 2-2

2.07 Fabricator 141i Portable System Package (Part No. W1003141) ................................ 2-2

SECTION 3:

SAFETY AND INSTALLATION .................................................................................. 3-1

3.01 Duty Cycle ................................................................................................................... 3-1

3.02 Speciﬁcations .............................................................................................................. 3-2

3.03 Environment ................................................................................................................ 3-3

3.04 Location ...................................................................................................................... 3-3

3.05 Ventilation ................................................................................................................... 3-4

3.06 Electricity Supply Voltage ............................................................................................ 3-4

3.07 Electromagnetic Compatibility ..................................................................................... 3-5

3.08 Victor Flowmeter/ Regulator ........................................................................................ 3-6

3.09 Volt-Ampere Curves .................................................................................................... 3-8

SECTION 4:

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

4.01 Power Source Controls, Indicators and Features ......................................................... 4-1

4.02 Attaching the Fusion 140A MIG Gun ........................................................................... 4-7

4.03 Inserting Wire into the Wire Feed Mechanism ............................................................. 4-8

4.04 Installing 4" (100mm) Diameter Spool ....................................................................... 4-9

4.05 Installing 8" (200mm) Diameter Spool ........................................................................ 4-9

4.06 Feed Roller Pressure Adjustment .............................................................................. 4-10

4.07 Changing the Feed Roll .............................................................................................. 4-11

4.08 Wire Reel Brake ......................................................................................................... 4-11

4.09 Flowmeter/ Regulator Operation ................................................................................ 4-12

4.10 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire .................................. 4-13

4.11 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire ................................ 4-14

4.12 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire ............. 4-15

4.13 Setup for LIFT TIG (GTAW) Welding .......................................................................... 4-15

4.14 Setup for STICK (SMAW) Welding .......................................................................... 4-17

4.15 Torch Adapter Thumb Screw Replacement ................................................................ 4-18

SECTION 5:

THEORY OF OPERATION ....................................................................................... 5-1

5.01 Inverter Design ................................................................................................................... 5-1

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TABLE OF CONTENTS

SECTION 6:

TROUBLESHOOTING ............................................................................................ 6-1

6.01 Pre-Power Up Checks.................................................................................................. 6-1

6.02 Tools Needed for Troubleshooting and Servicing ........................................................ 6-1

6.03 Troubleshooting .......................................................................................................... 6-1

6.04 Case Removal .............................................................................................................. 6-4

6.05 Clear protective Sheet Removal ................................................................................... 6-5

6.06 Visually Inspect ........................................................................................................... 6-5

6.07 Preliminary DC Bus Measurement of the Main PCB1 .................................................. 6-6

6.08 Check Main ON / OFF Switch ....................................................................................... 6-7

6.09 Check Main Input Rectiﬁer .......................................................................................... 6-8

6.10 DC Bus Voltage Measurement ..................................................................................... 6-8

6.11 PCB Connectors .......................................................................................................... 6-9

6.12 DIP Switch Settings, Control PCB2 ........................................................................... 6-18

6.13 Calibration ................................................................................................................. 6-19

6.14 Main Circuit Description ............................................................................................ 6-22

6.15 Circuit Diagram ......................................................................................................... 6-24

SECTION 7:

DISASSEMBLY PROCEDURE ................................................................................... 7-1

7.01 Safety Precautions for Disassembly ............................................................................ 7-1

7.02 Control PCB2 Removal ................................................................................................ 7-1

7.03 Display PCB3 Removal ................................................................................................ 7-3

7.04 Front Panel Assembly Removal ................................................................................... 7-5

7.05 Rear Panel Removal .................................................................................................... 7-6

7.06 ON/ OFF Switch SW1 and Power Cord Removal .......................................................... 7-7

7.07 Base Panel Removal and Main PCB1 Disassembly ...................................................... 7-8

SECTION 8:

ASSEMBLY PROCEDURES ..................................................................................... 8-1

8.01 Installing Base panel.................................................................................................... 8-1

8.02 Installing Rear panel .................................................................................................... 8-2

8.03 Installing Front Panel ................................................................................................... 8-3

8.04 Installing Control PCB2 and Clear Protective Sheet ..................................................... 8-4

8.05 Installing Case ............................................................................................................. 8-6

SECTION 9: KEY SPARE PARTS ...................................................................................... 9-1

9.01 Tweco Fusion 140A MIG Gun Parts ............................................................................. 9-1

9.02 Power Source .............................................................................................................. 9-2

9.03 Hardware List .............................................................................................................. 9-4

SECTION 10:

OPTIONS AND ACCESSORIES ................................................................................10-1

10.01 Options and Accessories ........................................................................................... 10-1

REVISION HISTORY ...................................................................................................10-2

INTERNATIONAL CONTACT INFORMATION ............................................................. REAR COVER

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ESAB FABRICATOR 141i

SECTION 1: SAFETY

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ﬂame proof clothing, safety gloves.

- Do not wear loose ﬁtting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualiﬁed electrician.

- Appropriate ﬁre extinguishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility. As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations. For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary cutting protection and accessories.

Manual 0-5448 1-1 SAFETY INSTRUCTIONS AND WARNINGS

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ESAB FABRICATOR 141i

WARNING

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area.

ARC R AYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and ﬁlter lens and wear protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause ﬁre. Make sure therefore that there are no inﬂammable materials nearby.

Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmuffs or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERAT-

ING.

PROTECT YOURSELF AND OTHERS!

Do not use the power source for thawing frozen pipes.

WARNING

CAUTION

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difﬁculties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

This product is solely intended for metal removal. Any other use may result in personal injury and / or equipment damage.

CAUTION

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5448

Read and understand the instruction manual before installing or operating.

Page 9

SECTION 2:

INTRODUCTION

ESAB FABRICATOR 141i

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, DANGER, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

NOTE!

An operation, procedure, or background information which requires additional emphasis or is helpful in efﬁcient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

WARNING

Gives information regarding possible electrical shock injury. Warnings will be enclosed in a box such as this.

DANGER

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

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. Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

2.04 Description

The ESAB Fabricator 141i is a self contained single phase multi process welding system that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding processes. The Power Source is equipped with an integrated wire feed unit, digital voltage and amperage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional. The Power Source is also fully compliant to Standard CSA E60974-1-00 and UL 60974.1. The Fabricator 141i MIG provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efﬁciency and quality from the Power Source. Please read these instructions thoroughly before using this equipment.

Additional copies of this manual may be purchased by contacting ESAB at the address and phone number in your area listed on 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 ESAB web site listed below

http://www.esab.com

Manual 0-5448 2-1 INTRODUCTION

Page 10

ESAB FABRICATOR 141i

Comes Complete With:

• Fabricator 141i Power Source

• 140 Amp MIG Gun

• Regulator/Flowmeter & Hose

• ESAB Electrode Holder & Ground Clamp

• Drive Rolls & Contact Tips

• Sample Electrodes & Shoulder Strap

• 20A to 15A Power Cord Adapter

• Operator Manual & CD

A-12917

2.05 Transportation Methods

WARNING

2.06 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 ESAB. Advice in this regard can be obtained by contacting an Accredited ESAB Distributor. This equipment or any of its parts should not be altered from standard speciﬁcation without prior written approval of ESAB. The user 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 ESAB.

2.07 Fabricator 141i Portable System Package (Part No. W1003141)

Disconnect input power conductors from de-energized supply line before moving the welding Power Source. Lift Power Source with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, secure the Power Source on a proper skid before transporting.

INTRODUCTION 2-2 Manual 0-5448

Page 11

ESAB FABRICATOR 141i

Fabricator 141i

SECTION 3:

SAFETY AND INSTALLATION

3.01 Duty Cycle

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 100 amperes at 19 volts. This means that it has been designed and built to provide the rated amperage (100 A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes is 2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool.

100

Duty Cycle (percentage)

0102030405060708090100 110120 130140 150

Safe

Operating

Region

STICK (SMAW)/ MIG (GMAW/ FCAW)

TIG (GTAW)

Art # A-11276_AB

Welding Current (amps)

Figure 3-1: Fabricator 141i Duty Cycle

Manual 0-5448 3-1 SAFETY AND INSTALLATION

Page 12

ESAB FABRICATOR 141i

3.02 Speciﬁcations

DESCRIPTION FABRICATOR 141i MULTI PROCESS 3 IN 1 WELDER

Power Source Part No. W1003140

Power Source Dimensions H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm)

Power Source Weight 32.2lb(14.6kg)

Cooling Fan Cooled

Welder Type Multi Process Welding System

Output Terminal Type DinseTM 25

Standards CSA E60974-1-00 / UL60974-1 / IEC 60974-1

Number of Phases Single Phase

Nominal Supply Voltage 115V AC

Supply Voltage Range 95-140V AC

Supply Frequency 50/60Hz

Welding Current Range (MIG Mode) 10- 90A Welding Current Range (LIFT TIG Mode) 10- 140A Welding Current Range (STICK Mode) 10- 90A

Wirefeed Speed Range 95-390 IPM MIG Welding Voltage Range 10-19V DC Nominal OCV 53V DC

Breaker Size 20A

Effective Input Current (I

MIG (GMAW/FCAW)

1eff

)

16.8A

(Requires updated Power Cord and Plug)

30A

16.1A*

STICK (SMAW)

TIG (GTAW) Maximum Input Current (I

MIG (GMAW/FCAW)

STICK (SMAW)

TIG (GTAW)

1max

)

16.8A

11.0A

26.2A

28.4A

24.7A

11.8A*

14.3A*

41.5A*

30.5A*

37A*

Single Phase Generator Requirement 5 KW 6 KW*

MIG (GMAW/FCAW) Welding Output

STICK (SMAW) Welding Output

LIFT TIG (GTAW) Welding Output

90A@20%, 18.5V 60A@60%, 17.0V

45A@100%, 16.25V

80A@35%, 23.2V 60A@60%, 22.4V

45A@100%, 21.8V 100A@20%, 14.0V

60A@60%, 12.4V

45A@100%, 11.8V

140A@15%, 19V*

60A@60%, 17.6V*

45A@100%, 16.8V*

90A@15%, 23.0V* 60A@60%, 22.8V*

45A@100%, 22.2V* 140A@15%, 15.6V*

60A@60%, 12.8V*

45A@100%, 12.2V*

Protection Class IP23S

Table 3-1: Fabricator 141i Speciﬁcation

SAFETY AND INSTALLATION 3-2 Manual 0-5448

Page 13

ESAB FABRICATOR 141i

NOTE!

* indicates data tested by ESAB Group, Inc.

The recommended time delay fuse or circuit breaker size is 20 amp. An individual branch circuit capable of carrying 20 amperes and protected by fuses or circuit breaker is recommended for this application. Fuse size is based on not more than 200 percent of the rated input amperage of the welding Power Source (Based on Article 630, National Electrical Code)

ESAB continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speci ﬁcations or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

The values speciﬁed in the table above are optimal values, your values may differ. Individual equipment may differ from the above speciﬁcations due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components, installation location and conditions and local power grid supply conditions.

The thermal protection switch is rated at 80°C.

3.03 Environment

These units are designed for use in environments with increased hazard of electric shock.

A. Examples of environments with increased hazard of electric shock are:

1. 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.

2. 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.

3. In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories.

B. 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.

3.04 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 32 to 104° F (0 to 40° C).

C. In areas, free from oil, steam and corrosive gases.

D. In areas, not subjected to abnormal vibration or shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 12"(300mm) or more from walls or similar that could restrict natural air ﬂow for cooling.

G. The enclosure design of this Power Source meets the requirements of IP23S as outlined in EN 60529. This provides adequate

protection against solid objects (greater than 1/2", 12mm), and direct protection from vertical drops. Under no circumstances should the Power Source be operated or connected in a micro environment that will exceed the stated conditions. For further information please refer to EN 60529.

H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal

surface in the upright position when in use.

WARNING

This equipment should be electrically connected by a qualiﬁed electrician.

Manual 0-5448 3-3 SAFETY AND INSTALLATION

Page 14

ESAB FABRICATOR 141i

3.05 Ventilation

WARNING

3.06 Electricity Supply Voltage

WARNING

The Fabricator 141i must be electrically connected by a qualiﬁed electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 140 VAC or higher is applied to the Primary Power Cable.

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

CAUTION

The Electricity Supply voltage should be within 95-140V AC. Too low a voltage may cause poor welding performance in STICK mode. Too high a supply voltage will cause components to overheat and possibly fail. The Welding Power Source must be:

• Correctly installed, if necessary, by a qualied electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point and fuse as per the Specications on page 3-2.

WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts.

SHUT DOWN welding Power Source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging procedures con-

sist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirements

Operate the welding Power Source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power source whenever necessary to inspect or service the unit.

Do not connect an input (WHITE or BLACK) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal.

• Correctly installed, if necessary, by a qualied electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point, fuse and primary supply lead based on Table 3-2. Refer to Table 3-2.

WARNING

An electric shock or ﬁre hazard is probable if the following electrical service guide recommendations are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding Power Source.

SAFETY AND INSTALLATION 3-4 Manual 0-5448

Page 15

ESAB FABRICATOR 141i

50 / 60 Hz Single Phase Supply

Supply Voltage

Input Current at Maximum Output

Maximum Recommended Fuse* or Circuit Breaker Rating *Time Delay Fuse, UL class RK5. Refer to UL248 Maximum Recommended Fuse^ or Circuit Breaker Rating ^Normal Operating , UL class K5. Refer to UL248

Single Phase Generator Requirement 5 KW

Minimum Recommended Input Cable Size 12AWG

Maximum Recommended Input Cable Length 10ft (3m)

Minimum Recommended Grounding Cable Size 12AWG

Table 3-2: Electrical Service Guide

NOTE!

Welding arc outs may be experienced if an extension cord is used when STICK welding when operating the Power Source on 95 VAC due to the lack of DC voltage at the STICK electrode.

Input Power

Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors. A relay in the Main PCB1 will turn on after the input capacitors have charged to operating voltage (after approximately 5 seconds)

115V AC

28.4 Amps

30 Amps

NOTE!

Damage to the Main PCB1 could occur if 140V AC or higher is applied to the Primary Power Cord.

Model

Fabricator

Primary Supply

Cord Size

(Factory Fitted)

12AWG (3.3mm2) 115V/20A 90A@20% 80A@35% 100A@20%

Minimum Primary

Current Circuit Size

(Vin/Amps)

MIG (GMAW/

FCAW)

Current & Duty Cycle

STICK (SMAW)

LIFT TIG

(GTAW)

141i

10AWG (5mm2) 115V/30A 140A@15% 90A@15% 140A@15%

Table 3-3: Primary Circuit Sizes to Achieve Maximum Current

3.07 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If elec-

tromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input ﬁlters. In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer troublesome.

Manual 0-5448 3-5 SAFETY AND INSTALLATION

Page 16

ESAB FABRICATOR 141i

LOW PRESSURE GAUGE (DELIVERY)

HIGH PRESSURE GAUGE (SUPPLY)

INLET

CONNECTION

OUTLET

CONNECTION

PRESSURE

ADJUSTING

SCREW

A-09414_AC

NOTE!

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment. Further guidance is given in EN 60974-13 Arc Welding Equipment - Installation and use (under preparation).

B. Assessment of Area

Before installing welding equipment, the user shall make an

assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account

1. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pacemakers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The compatibility of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will

depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Electricity Supply

Welding equipment should be connected to the Electric-

ity Supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as ﬁltering of the Electricity Supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout it’s length. The shielding should be connected to the

SAFETY AND INSTALLATION 3-6 Manual 0-5448

Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained

according to the manufacturer’s recommendations. All

access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modiﬁed in any way except for those changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

3. Welding Cables The welding cables should be kept as short as possible

and should be positioned close together, running at or close to the ﬂoor level.

4. Equipotential Bonding Bonding of all metallic components in the welding

installation and adjacent to it should be considered. However. Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing of the Workpiece Where the workpiece is not bonded to earth for electri-

cal safety, nor connected to earth because of it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding Selective screening and shielding of other cables

and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

3.08 Victor Flowmeter/ Regulator

Flowmeter/ Regulator (Figure 3-1) attached to the cylinder valve reduces high cylinder pressures to suitable low working pressures for welding, cutting, and other applications.

Figure 3-1: Victor CS Flowmeter/ Regulator

Page 17

ESAB FABRICATOR 141i

WARNING

1. Note the maximum inlet pressure stamped on the

2. The ﬂowmeter/ regulator body will be stamped “IN” or

3. If gauges are to be attached to the ﬂowmeter/ regulator

Use the ﬂowmeter/ regulator for the gas and pressure for which it is designed. NEVER alter a ﬂowmeter/ regulator for use with any other gas.

NOTE!

Flowmeters/ Regulators supplied with 5/8" -18 standard inert gas connections. Flowmeters/ Regulators purchased with open 1/8”, 1/4”, 3/8”, or 1/2” NPT ports must be assembled to their intended system.

ﬂowmeter/ regulator. DO NOT attach the ﬂowmeter/ regulator to a system that has a higher pressure than the maximum rated pressure stamped on the ﬂowmeter/ regulator.

“HP” at the inlet port. Attach the inlet port to the system supply pressure connection.

and the ﬂowmeter/ regulator is stamped and listed by a third party (i.e. “UL” or “ETL”). The following requirements must be met: a) Inlet gauges over 1000 PSIG (6.87 mPa) shall con-

form with the requirements of UL 404, “Indicating Pressure Gauges for Compressed Gas Service.”

b) Low pressure gauges must be UL recognized for

the class of ﬂowmeter/ regulator they are being used on according to UL252A.

WARNING

DO NOT use a ﬂowmeter/ regulator that

delivers pressure exceeding the pressure rating of the downstream equipment unless pro visions are made to prevent over-pressurization (i.e. system relief valve). Make sure the pressure rating of the down stream equipment is compatible with the maximum delivery pressure of the ﬂowmeter/ regulator.

WARNING

Figure 3-2: Flowmeter/ Regulator to Cylinder Valve

6. Before opening the cylinder valve, turn the ﬂowmeter/

7. Relief Valve (where provided): The relief valve is de-

DO NOT attach or use the ﬂowmeter/ regulator if oil, grease, ﬂamma ble substances or damage is present! Have a qualiﬁed repair technician clean the ﬂowmeter/ regulator or repair any damage.

A-09845_AB

regulator adjusting screw counterclockwise until there is no pressure on the adjusting spring and the screw turns freely.

signed to protect the low pressure side of the ﬂowmeter/ regulator from high pres sures. Relief valves are not intended to protect down stream equipment from high pressures.

WARNING

DO NOT tamper with the relief valve or remove it from the ﬂowmeter/ regulator.

WARNING

Stand to the side of the cylinder opposite the ﬂowmeter/ regulator when opening the cylinder valve. Keep the cylinder valve between you and the ﬂowmeter/ regulator. For your safety, NEVER STAND IN FRONT OF OR BEHIND A FLOWMETER/ REGULATOR WHEN OPENING THE CYLINDER VALVE!

4. Be sure that the ﬂowmeter/ regulator has the correct pressure rating and gas service for the cylinder used.

5. Carefully inspect the ﬂowmeter/ regulator for damaged threads, dirt, dust, grease, oil, or other ﬂammable substances. Remove dust and dirt with a clean cloth. Be sure the inlet swivel ﬁlter is clean and in place. Attach the ﬂowmeter/ regulator (Figure 3-2) to the cylinder valve. Tighten securely with a wrench.

Manual 0-5448 3-7 SAFETY AND INSTALLATION

8. Slowly and carefully open the cylinder valve (Figure 3-3) until the maximum pressure shows on the high pressure gauge.

Page 18

ESAB FABRICATOR 141i

Art # A-09828

Figure 3-3: Open Cylinder Valve

9. On all cylinders, open the valve completely to seal the valve packing. On gaugeless ﬂowmeters/ regulators, the indicator will register the cylinder contents open.

CAUTION

10. Attach the desired downstream equipment.

3.09 Volt-Ampere Curves

Keep the cylinder valve wrench, if one is required, on the cylinder valve to turn off the cylinder quickly, if necessary.

Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown.

Output Voltage (Volts)

0102030405060708090 100 110 120 130 140 150

MIG (GMAW/ FCAW)

Fabricator 141i

STICK (SMAW)

Welding Current (Amps)

TIG (GTAW)

Art # A-11807

Figure 3-2: Fabricator 141i Volt-Ampere Curves

SAFETY AND INSTALLATION 3-8 Manual 0-5448

Page 19

Notes

ESAB FABRICATOR 141i

Manual 0-5448 3-9 SAFETY AND INSTALLATION

Page 20

ESAB FABRICATOR 141i

This Page Intentionallly Blank

SAFETY AND INSTALLATION 3-10 Manual 0-5448

Page 21

SECTION 4:

A-13037

OPERATION

4.01 Power Source Controls, Indicators and Features

ESAB FABRICATOR 141i

Figure 4-1: Front Panel Figure 4-2: Rear Panel

Art #

A-10355

Figure 4-3: Wire Feed Compartment Control

Manual 0-5448 4-1 OPERATION

Page 22

ESAB FABRICATOR 141i

1. Power Indicator

The power indicator is illuminated when the Electricity Supply is applied to the Power Source and when the ON/OFF switch located on the rear panel is in the ON position.

2. Digital Wirespeed/Amperage Meter (Left Digital Display)

This digital meter displays preview Wirespeed in MIG mode only then actual amperage (weld current) once an arc has been established. It also displays preview amperage in both the STICK and LIFT TIG modes only then actual amperage (weld current) once an arc has been established.

At times of non-welding, the amperage meter will display a preview value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Wire speed / Amperage potentiometer (Control No. 3). At times of non-welding, the amperage meter will preview a wirefeed speed value (Inches Per Minute) in MIG mode only. This can be identiﬁed as preview wirefeed speed by a decimal point at the lower right hand side of the display.

When welding, the amperage meter will display actual amperage (weld current) in all modes.

At the completion of welding, the amperage meter will hold the last recorded amperage value for a period of approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the Power Source will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the Power Source will return to preview mode.

NOTE!

The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.

3. Wirespeed/Amperage Control

In MIG mode, the Wirespeed/Amperage control knob adjusts the speed of the wire feed motor (which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc). The optimum wire speed depends upon the material type and the welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required settings for a basic range of MIG (GMAW/FCAW) welding applications.

In STICK and LIFT TIG modes, the Wirespeed/Amperage control knob adjusts the amount of amperage (weld current) delivered to the welding arc by the Power Source. It directly adjusts the Power Source to deliver the desired level of weld current.

4. MIG Gun Adapter (ESAB Style)

The MIG Gun adapter is standard ESAB connection with an 8 pin gun trigger for the Fusion MIG Gun. Connect the MIG Gun by pushing the MIG Gun connector into the brass MIG Gun Adapter ﬁrmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment to secure the Fusion MIG Gun in position. Failure to properly lock the Fusion MIG Gun into the MIG Gun Feedplate will result in the MIG Gun being pushed out of the MIG Gun Feedplate by the MIG welding wire or lack of shielding gas (porosity in the weld) at the weld zone.

5. Positive Welding Output Terminal

The positive welding terminal is used to connect the welding output of the Power Source to the appropriate welding accessory such as the MIG Gun (via the MIG Gun polarity lead), electrode holder lead or work lead. Positive welding current ﬂows from the Power Source via 25mm Dinse style connector. It is essential, however, that the Dinse adapter and male plug are inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the Dinse connector.

OPERATION 4-2 Manual 0-5448

Page 23

ESAB FABRICATOR 141i

6. MIG Gun Polarity Lead

The polarity lead is used to connect the MIG Gun to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminum electrode wire. When using ﬂux cored (gasless) wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt, consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the Dinse adapter and male plug are inserted and turned securely to achieve a sound electrical connection.

CAUTION

7. Negative Welding Output Terminal

The negative welding terminal is used to connect the welding output of the Power Source to the appropriate welding accessory such as the MIG Gun (via the MIG Gun polarity lead), TIG Torch or work lead. Negative welding current ﬂows to the Power Source via 25mm Dinse style connector. It is essential, however, that the Dinse adapter and male plug are inserted and turned securely to achieve a sound electrical connection.

Loose welding terminal connections can cause overheating and result in the male plug being fused in the Dinse connector.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the Dinse connector.

8. Remote Control and Spool Gun Socket

The 8 pin socket is used to connect the Fusion MIG Gun, remote control device or spool gun plug to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Socket Pin

Art # A-10421_AC

1 2

3 4

Figure 4-4: Remote Control Socket

Remote Wirespeed in MIG (GMAW/FCAW) mode

Remote Amps in LIFT TIG (GTAW) mode

Trigger Switch

Function

Remote Volts in MIG (GMAW/FCAW)

Negative

Spool Gun Motor

Positive

1 Spool gun motor (0V)

Trigger Switch Input

Spool gun motor (+24V DC)

5k ohm (maximum) connection to 5k ohm remote control potentiometer.

Zero ohm (minimum) connection to 5k ohm remote control potentiometer.

Wiper arm connection to 5k ohm potentiometer for the remote control of the Wirespeed in MIG mode.

Wiper arm connection to 5k ohm potentiometer for the remote control of the Amperage (Weld Current) in LIFT TIG mode.

Manual 0-5448 4-3 OPERATION

Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.

Table 4-1

Page 24

ESAB FABRICATOR 141i

Note that the Local/ Remote Switch (Control No. 18) located in the wirefeed compartment should be set to Remote for remote amperage/voltage controls to operate.

9. Multifunction Control - Voltage, Down Slope & Arc Force

The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc Force (STICK Mode) depending on the welding mode selected.

NOTE!

When MIG Mode is Selected

In this mode the control knob is used to adjust the MIG welding voltage of the Power Source. The welding voltage is increased by turning the knob clockwise or decreased by turning the knob counterclockwise. The optimum voltage level required will depend on the type of welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications.

When STICK Mode is Selected

In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneﬁcial in providing the operator the ability to compensate for variability in joint ﬁt-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob counterclockwise.

When LIFT TIG Mode is Selected

In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time of the amperage at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufﬁciently.

Note that when in 2T normal mode (Control No. 11), the Power Source will enter down slope mode as soon as the trigger switch is released (ie if the multifunction control knob is set to 5, the Power Source will ramp down from the present welding current to zero over 5 seconds). If no down slope time is set then the welding output will cease immediately. If the Power Source is set to 4T latch mode, to enter down slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output will cease immediately.

10. Arc Control (Inductance)

The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance.

11. Trigger Mode Control (MIG and LIFT TIG Mode only)

The trigger mode control is used to switch the functionality of the of the MIG or TIG Trigger Switch between 2T (normal) and 4T (latch mode)

2T (Normal Mode)

In this mode, the MIG or TIG Trigger Switch must remain depressed for the welding output to be active. Press and hold the MIG or TIG Trigger Switch to activate the Power Source (weld). Release the MIG or TIG Trigger Switch to cease welding.

OPERATION 4-4 Manual 0-5448

Page 25

ESAB FABRICATOR 141i

4T (Latch Mode)

This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the MIG or TIG Trigger Switch and the output will remain active. To deactivate the Power Source, the trigger switch must again be depressed and released, thus eliminating the need for the operator to hold the MIG or TIG Trigger Switch

Note that when operating in LIFT TIG mode, the Power Source will remain activated until the selected Downslope time has elapsed (refer Control No. 9).

12. Process Selection Control

The process selection control is used to select the desired welding mode. Three modes are available, MIG, LIFT TIG and STICK modes. Refer to section 4.10 through 4.12 for MIG (GMAW/FCAW) set up details, section 4.13 for LIFT TIG (GTAW) set-up details or section 4.14 for STICK (SMAW) set-up details.

Note that when the Power Source is powered off the mode selection control will automatically default to MIG mode. This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the Power Source and mistakenly be in contact with the work piece during power up.

13. Digital Voltage Meter (Right Digital Display)

The digital voltage meter is used to display the both the preview voltage (MIG mode only) and actual output voltage (all modes) of the Power Source.

At times of non-welding, the voltage meter will display a preview value in MIG mode. This value can be adjusted by varying the multifunction control knob (Control No. 9). Note that in STICK and LIFT TIG modes, the voltage meter will not preview welding voltage but will display Open Circuit Voltage in STICK mode and 0V in LIFT TIG mode.

When welding, the voltage meter will display actual welding voltage in all modes.

At the completion of welding, the digital voltage meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the Power Source will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the Power Source will return to preview mode.

NOTE!

14. Fault Indicator

This welding Power Source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the Power Source has been exceeded or if a fault is detected in the Inverter. Should the Fault Indicator illuminate the output of the Power Source will be disabled. Once the Power Source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the power switch should remain in the on position such that the fan continues to operate thus allowing the Power Source to cool sufﬁciently. Do not switch the Power Source off should a thermal overload condition be present. If the fault condition does not extinguish, then the Power Supply will need to be taken to an authorized repair center for analysis.

15. Gas Inlet (MIG mode only for MIG Gun or Spool Gun operation)

The Gas Inlet connection is used to supply the appropriate MIG welding gas to the Power Source. Refer to section 4.10 to 4.11 for MIG (FCAW/GMAW) set up details.

WARNING

Manual 0-5448 4-5 OPERATION

Only Welding Shielding Gases speciﬁcally designed for arc welding applications should be used.

Page 26

ESAB FABRICATOR 141i

16. On / Off Switch

This switch is used to turn the Power Source on/off.

WARNING

When the front digital displays are lit, the machine is connected to the Mains supply voltage

17. Intelligent Fan Control

The Fabricator 141i is designed with an intelligent fan control. It automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the Power Source.

Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required.

Note in STICK mode the fan operates continuously.

18. Local / Remote Switch (located in wirefeed compartment)

The local/ remote switch is used only when a remote control device (such as a TIG Torch with remote current control) is ﬁtted to the Power Source via the remote control socket (8 Pin Remote Socket). When the local/remote switch is in the remote position, the Power Source will detect a remote device and work accordingly. When in the local mode, the Power Source will not detect the remote device and will operate from the Power Source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local remote switch (ie in both local and remote modes).

and the internal electrical components are at Mains voltage potential.

Should a remote device be connected and the local/ remote switch set to remote, the maximum setting of the Power Source will be determined by the respective front panel control, irrespective of the remote control device setting. As an example, if the output current on the Power Source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output from the Power Source will be 50%. Should 100% output be required, the respective front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output.

19. Burnback Control (located in wirefeed compartment)

The Burnback control is used to adjust the amount of MIG wire that protrudes from the MIG Gun after the completion of MIG welding (commonly referred to as stick-out). To decrease the Burnback time (or lengthen the amount of wire protruding from the MIG Gun at the completing of welding), turn the Burnback control knob counterclockwise. To increase the Burnback time (or shorten the amount of wire protruding from the MIG Gun at the completing of welding), turn the Burnback Control knob clockwise.

20. MIG Gun & Spool Gun Switch

The MIG Gun / Spool Gun switch is used to switch welding mode between MIG Gun function and Spool Gun function.

21. 10A Fuse

The 10A fuse is used to protect both spool gun motor and internal motor.

OPERATION 4-6 Manual 0-5448

Page 27

ESAB FABRICATOR 141i

Art #

A-10356_AB

MIG Gun Adaptor

MIG Gun Connector

Thumb Screw

8 pin socket

8 pin plug

4.02 Attaching the Fusion 140A MIG Gun

Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter. Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position.

Figure 4-5: Attaching MIG Gun

Manual 0-5448 4-7 OPERATION

Page 28

ESAB FABRICATOR 141i

4.03 Inserting Wire into the Wire Feed Mechanism

Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in a counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm. With the MIG welding wire feeding from the bottom of the spool (Figure 4-7) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the MIG Gun. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly (Figure 4-6). Remove the nozzle and contact tip from the MIG Gun. With the MIG Gun lead reasonably straight, feed the wire through the MIG Gun by depressing the trigger switch. Fit the appropriate contact tip.

WARNING

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so premature arcing will not occur. The electrode wire will be at welding voltage potential while it is being fed through the system. Keep MIG Gun away from eyes and face.

Wire Drive Tension Screw

Art #

A-10359_AB

Pressure Roller Arm

Outlet Guide

Inlet Guide

Figure 4-6: Wire Drive Assembly Components

Figure 4-7: MIG Welding Wire - Installation

OPERATION 4-8 Manual 0-5448

MIG Welding Wire

Art #

A-10360

Page 29

ESAB FABRICATOR 141i

Art #

A-10357

Friction Washer

4”（100mm） Diameter spool

Nut with Nylon Insert

Spring

Plastic Spacer

Brass Flat Washer

Flat Washer

4.04 Installing 4" (100mm) Diameter Spool

As delivered from the factory, the Power Source is ﬁtted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to ﬁt a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 4-8. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake. The brake is correctly adjusted when the spool stops within 4" (100mm) to 8" (200mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without becoming dislodged from the spool.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical components and possibly an increased incidence of electrode wire Burnback into contact tip.

Figure 4-8: 4" (100mm)Diameter Spool Installation

4.05 Installing 8" (200mm) Diameter Spool

As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool. In order to re-ﬁt a 8" (200mm) spool assemble parts in the sequence shown below in Figure 4-9. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake. The Brake is correctly adjusted when the spool stops within 3/8" (10mm) to 3/4" (20mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without becoming dislodged from the spool.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical components and possibly an increased incidence of electrode wire Burnback into contact tip. Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 8" (200mm) diameter spool.

NOTE!

This alignment pin can be removed by unscrewing in an counterclockwise direction and locating in the appropriate position.

Manual 0-5448 4-9 OPERATION

Page 30

ESAB FABRICATOR 141i

Alignment pin

Alternate Alignment Pin Position

8” (200mm) diameter spool

Spool Hub Nut

Plastic Spacer

Spring

Friction Washer

Flat Washer

Nut with Nylon Insert

Brass Flat Washer

Wire Spool Hub

Art #

A-10358

Figure 4-9: 8" (200mm) Diameter Spool Installation

4.06 Feed Roller Pressure Adjustment

The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices 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 liner should be checked for kinks and clogging by metal ﬂakes and debris. If it is not the cause of slipping, the feed roll pressure can be increased by rotating the pressure screw clockwise.

WARNING

Before changing the feed roller ensure that the Electricity Supply to the Power Source is switched off.

CAUTION

The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.

OPERATION 4-10 Manual 0-5448

Page 31

ESAB FABRICATOR 141i

Art #

A-09584_AC

4.07 Changing the Feed Roll

To change feed roll remove the feed roll retaining screw by turning in an counterclockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions. A dual groove feed roller is supplied as standard. It can accommodate 023"(0.6mm) -.030" (0.8mm) diameter hard wires. Select the roller required with the chosen wire size marking facing outward.

GROOVE “B”GROOVE “A”

GROOVE “B” SIZE

Figure 4-10: Dual Groove Feed Roller

Feed Roll

Retaining Screw

Figure 4-11: Changing the Feed Roll

Feed Roll

GROOVE “A” SIZE

A-09583

4.08 Wire Reel Brake

The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking. If it is considered necessary, adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 3/8" (10mm) - 3/4" (20mm) after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.

Manual 0-5448 4-11 OPERATION

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical components and possibly an increased incidence of electrode wire Burnback into contact tip.

Page 32

ESAB FABRICATOR 141i

Wire Reel Brake Adjustment Nut

Art #

A-10361

Figure 4-12: Wire Reel Brake

4.09 Flowmeter/ Regulator Operation

With the ﬂowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows:

1. Stand to one side of ﬂowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal parts.

2. With valves on downstream equipment closed, adjust ﬂowmeter/ regulator to approximate working pressure. It is recommended that testing for leaks at the ﬂowmeter/ regulator connection points be carried out using a suitable leak detection solution or soapy water.

3. Purge air or other unwanted welding grade shielding gas from equipment connected to the ﬂowmeter/ regulator by individually opening then closing the equipment control valves. Complete purging may take up to ten seconds or more, depending upon the length and size of the hose being purged.

Adjusting Flow Rate

With the ﬂowmeter/ regulator ready for operation, adjust working ﬂow rate as follows:

1. Adjust the gas ﬂow rate. The recommended rate for MIG welding is 15-25 CFH. The recommended rate for LIFT TIG welding is 10-25 CFH.

NOTE!

It may be necessary to re-check the shielding gas ﬂowmeter/ regulator ﬂow rate following the ﬁrst weld sequence due to back pressure present within shielding gas hose assembly.

Shutdown

Close cylinder valve whenever the ﬂowmeter/ regulator is not in use. To shut down for extended periods (more than 30 minutes).

1. Close cylinder or upstream valve tightly.

2. Open downstream equipment valves to drain the lines. Bleed gas into a well ventilated area and away from any ignition source.

3. After gas is drained completely, disengage adjusting screw and close downstream equipment valves.

4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove ﬂowmeters/ regulators. Put caps on all cylinders that do not have ﬂowmeters/ regulators on them.

OPERATION 4-12 Manual 0-5448

Page 33

ESAB FABRICATOR 141i

Art #

A-10362

Shielding Gas Hose Fitted with 5/8"-18 UNF

connection

Primary Cord

Work Lead

Negative Welding Terminal (-)

Positive Welding Terminal (+)

MIG Gun Polarity Lead

MIG Gun

8 pin Plug

Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

4.10 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire

A. Select MIG mode with the process selection control. (Refer to Section 4.01 for further information)

B. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.

Welding current ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Fit the MIG Gun to the Power Source. (Refer to Section 4.02 Attaching the Fusion 140A MIG Gun).

D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding

current ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

E. Fit the ﬂowmeter/ regulator to the shielding gas cylinder then connect the shielding gas hose from the rear of the Power

Source to the ﬂowmeter/ regulator outlet.

F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

G. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the Power Sources Wirespeed and Voltage controls.

H. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

WARNING

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so premature arcing will not occur. Secure the shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

Manual 0-5448 4-13 OPERATION

Figure 4-13: Setup for MIG Welding with Gas Shielded MIG Wire

Page 34

ESAB FABRICATOR 141i

(+)

4.11 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire

A. Select MIG mode with the process selection control (refer to Section 4.01.12 for further information).

B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.

Welding current ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. Welding

current ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

E. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the Power Sources Wirespeed and Voltage controls.

F. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

WARNING

Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so premature arcing will not occur.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal. Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

Positive Welding Terminal

MIG Gun

8 pin Plug

MIG Gun Polarity Lead.

Negative Welding Terminal (-)

Work Lead

Figure 4-14: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire

OPERATION 4-14 Manual 0-5448

A-09587_AD

Page 35

ESAB FABRICATOR 141i

Art #

A-10363

4.12 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire

Set the Process Selection Control to MIG for Spool Gun welding. For setup and operation of the spool gun, please refer to the spool gun operations manual. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to SPOOL GUN. Connect the Argon shielding gas to the Shielding Gas Inlet on the rear panel of the Power Source.

1. Make sure the welding power source is turned OFF before connecting the welding gun.

2. Open side panel and loosen thumb screw.

3. Insert the back end of the Spool gun into the gun receiving bushing.

4. Tighten thumb screw and replace side panel.

5. Connect gas supply ﬁtting and tighten with a wrench.

6. Connect the 8 pin plug by aligning the keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwise to lock the plug into position.

4.13 Setup for LIFT TIG (GTAW) Welding

A. Select LIFT TIG mode with the process selection control (refer to Section 4.01.12 for further information).

B. Using the supplied 50mm to 25mm DINSE adapter, connect the TIG torch to the negative welding terminal (-). Welding

current ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the positive welding terminal (+). Welding current ﬂows from the Power Source via Dinse style

terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the Power Source. The TIG torch will

require a trigger switch to weld in LIFT TIG Mode.

NOTE!

A ESAB 17V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a ESAB Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current. Please refer to "2.10 Options and Accessories".

E. Fit the ﬂowmeter/ regulator to the shielding gas cylinder (refer to Section 3.08) then connect the shielding gas hose from

the TIG torch to the ﬂowmeter/ regulator outlet. Note that the TIG torch shielding gas hose is connected directly to the ﬂowmeter/ regulator. The Power Source is not ﬁtted with a shielding gas solenoid to control the gas ﬂow in LIFT TIG mode therefore the TIG torch will require a gas valve.

Manual 0-5448 4-15 OPERATION

Page 36

ESAB FABRICATOR 141i

Art # A-11576_AB

WARNING

Secure the shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source. Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

F. Switch the LOCAL/REMOTE switch inside the

wire feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage using a Foot Control.

Positive Welding Terminal (+)

MIG Torch polarity lead not connected

Work Lead

Connect to shielding gas regulator/ﬂow gauge.

Negative welding terminal (-)

50mm- 25mm Adaptor

Note: A Tweco 17V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Tweco Foot Control with an 8 pin plug must be used to turn the

TIG Torch

weld current on/off as well as providing remote control of the weld current.

Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

Figure 4-15: Setup for TIG Welding

OPERATION 4-16 Manual 0-5448

Page 37

ESAB FABRICATOR 141i

Art #

A-10365

Negative Welding Terminal (-)

Positive Welding Terminal

(+)

Work Lead

Electrode Holder

MIG Gun polarity lead not connected.

4.14 Setup for STICK (SMAW) Welding

A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

Welding current ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer. Welding cur-

rent ﬂows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode

C. Switch the LOCAL/REMOTE switch inside the wire

feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage control using a Hand Pendant Control.

holder make sure the Electricity Supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

Manual 0-5448 4-17 OPERATION

Figure 4-16: Setup for Stick Welding(SMAW)

Page 38

ESAB FABRICATOR 141i

4.15 Torch Adapter Thumb Screw Replacement

WARNING

All power to unit should be removed.

1. Place unit on its back.

A-12958

2. Remove 2 screws in bottom of the front panel. A securing block will become detached and fall free from the front panel as you turn each screw out. Set these aside for reassembly. Leave screws sitting in the pockets of the panel.

Screws

Art # A-11483

Securing Block

OPERATION 4-18 Manual 0-5448

Page 39

ESAB FABRICATOR 141i

3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang downwardly.

Tension Knob

Pressure Arm

Art # A-11484

4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed.

Thumb Screw Fully Exposed

Art # A-11485_AB

5. Remove damaged thumb screw and replace with new one.

Art # A-11486

6. To reassemble, reverse steps 1 through 4.

Push Upward

Manual 0-5448 4-19 OPERATION

Page 40

ESAB FABRICATOR 141i

This Page Intentionally Blank

OPERATION 4-20 Manual 0-5448

Page 41

ESAB FABRICATOR 141i

SECTION 5:

THEORY OF OPERATION

5.01 Inverter Design

What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply. The AC is then rectiﬁed to extremely smooth DC. The diagram to the below shows the basic electrical wiring of a DC output inverter power supply.

Inverter Technology - Summary

Rectiﬁer Filter IGBT Transformer Rectiﬁer Inductor

AC -50/60Hz DC -Rippled DC -Smooth AC -23KHz AC -23K Hz DC - Rippled DC -Smooth

High Vo ltage High Vo ltage High voltage High Vo ltage Low Vo ltage Low Vo ltage Low Voltage

Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage

Art # A-09846

Manual 0-5448 5-1 THEORY OF OPERATION

Page 42

ESAB FABRICATOR 141i

Notes

THEORY OF OPERATION 5-2 Manual 0-5448

Page 43

ESAB FABRICATOR 141i

SECTION 6:

TROUBLESHOOTING

6.01 Pre-Power Up Checks

It is best to perform the following Pre-Power Up test procedures in order to prevent blowing Primary Line Fuses or causing further damage to the power supply.

Checking Unit Before Applying Power

CAUTION

With switch SW1 in OFF position, push and release the two push button switches. Each should have a recognizable tactile on/off position. If either switch does not switch properly, check that the appropriate switch activators located behind the overlay are aligned properly. Turn the three potentiometer knobs. All of the three knobs should turn in both directions smoothly and have two stop positions.

The following safety information shall be read before starting troubleshooting and servicing:

1. Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.

2. Signiﬁcant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing case.

3. Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.

4. STATIC (ESD) can damage PC boards.

6.02 Tools Needed for Troubleshooting and Servicing

6.03 Troubleshooting

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair it unless you are an accredited service provider and you have had training in power electronics measurement and troubleshooting techniques.

Power Up Problems

NOTE!

In the event that either an individual indicator will not come on,or if a segment on the either Digital Display will not light, yet the unit is otherwise fully functional, the Display PCB3 should be changed.

Before changing any PCB, check that the PCB in question has the appropriate input power supply voltage as listed in PCB CONNECTORS section 6.11.

Art # A-09849

Manual 0-5448 6-1 TROUBLESHOOTING

Page 44

ESAB FABRICATOR 141i

A. Unit is completely inactive: No lights come on; Displays

do not come on, Fan does not operate.

1. Primary Voltage Supply problem

a) Measure for 115VAC (+/- 15%) at Primary Sup-

ply Voltage outlet/breaker.

2. Defective primary line cord/plug

a) Measure for 115VAC on the ON/OFF Switch

(SW1) between wires from the input power cable. If voltage is low or not present repair or replace cord/plug.

3. Defective ON/OFF Switch (SW1)

a) Measure for 115VAC at SW1 between two wires

from SW1 to Main PCB1. If voltage is low or not present, Replace SW1

4. Defective rectiﬁer bridge BR1 and BR2

a) Measure for 162VDC on PCB1 connector DCOUT

between Pin 3 to 1. If the voltage is less than 130V or missing, replace BR1 and BR2.

5. Defective Main PCB1

a) Replace Main PCB1

6. Defective ribbon cable / poor connection

a) Reseat or replace ribbon cable

STICK Process Problem

A. PROCESS switch will not change welding process.

1. Defective Display PCB3

a) Replace Display PCB3.

2. Defective Control PCB2

a) Replace Control PCB2.

3. Defective ribbon cable / poor connection

a) Reseat or replace ribbon cable.

B. Preset current can’t be adjusted.

1. Defective Display PCB3

a) Replace Display PCB3.

2. Defective Control PCB2

a) Replace Control PCB2.

3. Defective ribbon cable / poor connection

a) Reseat or replace ribbon cable.

C. Arc force can’t be adjusted.

1. Defective Display PCB3

a) Replace Display PCB3.

2. Defective Control PCB2

a) Replace Control PCB2.

3. Defective ribbon cable / poor connection

a) Reseat or replace ribbon cable.

D. Preset current can be adjusted, but when welding the

welding current is different from preset value.

1. Defective Control PCB2 a) Replace Control PCB2.

2. Defective Current sensor

a) Replace current sensor.

E. No open circuit voltage

1. Defective Main PCB1

a) Replace Main PCB1.

2. Broken wire in machine

a) Check and replace.

3. Defective Control PCB2

a) Replace Control PCB2.

F. Once the electrode touches the work piece, the fault

indicate illuminates and arc can’t be established.

1. Defective Current sensor

a) Replace current sensor.

2. Poor connection between current sensor and Control PCB2

a) Check and replace.

3. Defective Control PCB2

a) Replace Control PCB2.

G. Fan doesn’t run

1. Defective fan

a) Measure the voltage between pin 1 and pin 2 of

Funs connectors. If voltage is 20-24V, replace the fan.

2. Defective Control PCB2

a) Measure the voltage between pin 1 and pin 2

of Funs connectors. If voltage is not present,

replace Control PCB2. H. The fault indicator illuminates and no output voltage. The fault indicator can be indication of either over tem-

perature or over current.

1. Over temperature

a) Allow unit to remain ON with the fan running for

1 to minutes, until fault indicator turns off.

2. Defective thermal sensor

a) There is a negative temperature coefﬁcient

(NTC) resistor sensor attached to the heat sink,

if the fault indicator is still ON after fan runs for

5-10 minutes, disconnect IGBT OT connector

from Control PCB2 and measure the resistance.

It should be about 47K at 25℃ ambient tempera-

ture, if it is less than 20K, replace it.

3. Over current

a) With SW1 OFF, disconnect the Driver connec-

tor from Control PCB2 and turn SW1 on. If fault

indicator turns off, replace Main PCB1.

b) With SW1 OFF, disconnect the Driver connec-

tor from Control PCB2 and turn SW1 on. If fault

indicator is still ON, replace Control PCB2.

MIG Process Problem

A. Trigger switch does not switch between 2T and 4T.

1. Defective Display PCB3

a) Replace Display PCB3.

2. Defective Control PCB2

a) Replace Control PCB2.

3. Defective ribbon cable / poor connection

a) Reseat or replace ribbon cable.

B. The power source does not feed wire when torch trigger

is depressed.

TROUBLESHOOTING 6-2 Manual 0-5448

Page 45

ESAB FABRICATOR 141i

1. Defective torch trigger

a) Check the torch trigger switch and replace it.

2. 8pin gun connector not connected

a) Connect 8 pin gun connector.

3. MIG GUN/SPOOL GUN switch is switched to SPOOL GUN.

a) Turn the switch to MIG GUN.

4. When torch trigger is depressed, the output voltage measured is about 14-24 VDC,but the motor doesn’t run.

a) Measure the signal between pin 1 and pin 2

of PWM connector on Control PCB2, if it is not present, replaces Control PCB2.

b) Measure the voltage between pin 1 and pin 2 of

MD connector on primary power PCB. It should be 5-16VDC. If it is not present, replace Main PCB1.

c) Measure the voltage between pin 3 and pin 4 of

M1/S in spool gun PCB6. It should be 5-16VDC. If it is not present, replace spool gun PCB6.

d) Check and replace the wire if it is broken.

e) Replace the motor if it is faulty.

C. Welding wire continues to feed when torch trigger is

released.

1. Trigger mode selection switch is in 4T mode position

a) Turn the trigger mode to 2T mode.

2. Faulty Torch trigger switch

a) Replace torch trigger switch.

3. Torch trigger leads short circuit

a) Repair trigger leads.

D. Welding arc cannot be established.

1. MIG gun polarity lead is not connected to a welding output terminal

a) Connect the MIG gun polarity lead to either posi-

tive welding output terminal or negative welding output terminal as appropriate.

2. Poor or no work lead contact

a) Clean work clamp area and ensure good electri-

cal contact.

E. Inconsistent wire feed.

1. Fouled contact tip

a) Replace contact tip if necessary.

2. Drive roll tension not tight enough

a) Tighten drive roll tension.

3. Worn feed roll

a) Replace feed roll.

4. Excessive brake tension on wire reel hub

a) Reduce brake tension on spool hub.

5. Worn, kinked or dirty conduit liner

a) Clean or replace conduit liner.

F. No gas ﬂow

1. Empty gas cylinder

a) Replace gas cylinder.

2. Flow meter/regulator turned off

a) Turn on ﬂow meter/ regulator.

3. Gas passage contains debris

a) Disconnect gas hose from the rear of Power

Source and blow out debris.

4. Gas hose is damaged

a) Replace gas hose

5. Defective gas valve

a) Depress the trigger switch, measure the voltage

between pin 4 and pin 5 of DY1 connector on Main PCB1. If it is 20-24VDC,but the gas valve is not active, replace the gas valve.

6. If there is no voltage present between pin 4 and pin 5 of DY1 connector on Main PCB1, replace Control PCB2.

F. Gas ﬂow continues after the torch trigger switch has

been released.

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

a) Repair or replace the gas valve.

LIFT TIG Process Problem

A. TIG electrode melts when arc is struck.

1. TIG Torch is connected to the (+) polarity terminal

a) Connect the TIG Torch to the (-) polarity terminal.

2. No argon gas protects the electrode

a) Make sure the argon gas is applied.

NOTE!

For other problems, please refer to "STICK Process Problem" Section.

Manual 0-5448 6-3 TROUBLESHOOTING

Page 46

ESAB FABRICATOR 141i

6.04 Case Removal

WARNING

1. Cover

Read and follow safety information in Section 6.02 before proceeding.

Lossen Screws Front & Rear

Remove Screws

Art # A-10456

a) Remove the two top screws from the front & rear mouldings.

b) Remove the centre screws from the front & rear mouldings.

c) Loosen slightly the two bottom screws from the front & rear mouldings.

d) Remove the three bottom screws and the two top screws securing the cover panel.

e) Gently lever apart the front & rear mouldings & remove the cover panel.

2. Ground screw

- Carefully lift the case to access and remove the screw which connects the ground wire to the cover.

TROUBLESHOOTING 6-4 Manual 0-5448

Art # A-12169

Page 47

6.05 Clear protective Sheet Removal

WARNING

1. Clear protective sheet Take out clear protective sheet.

Read and follow safety information in Section 6.02 before proceeding.

ESAB FABRICATOR 141i

Art # A-12170

6.06 Visually Inspect

Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectiﬁer when a failure occurs. Carefully inspect all components within these units. Look in particular for the following:

a) Loose or broken wires or connectors.

b) Burned or scorched parts or wires or evidence of arcing.

c) Any accumulation of metal dust or ﬁlings that may have caused shorting or arcing.

If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components used in the Power Source.

Locate the faulty component(s) then replace where necessary.

Manual 0-5448 6-5 TROUBLESHOOTING

Page 48

ESAB FABRICATOR 141i

6.07 Preliminary DC Bus Measurement of the Main PCB1

WARNING

Read and follow safety information in Section 6.02 before proceeding.

6 8

Art # A-12171

DC Bus Testing Multimeter Lead Placement Voltage with SW1 OFF

Buck CAPACITOR

Negative meter lead to testpoint1 Positive meter lead to testpoint2

Table 6-1 DC BUS, Multimeter set to measure DC volts

Output Diode Testing Multimeter Lead Placement Diode Voltage

Left Output Diodes

Right Output Diodes

Positive meter lead to testpoint 5

Negative meter lead to testpoint 6

Positive meter lead to testpoint 7

Negative meter lead to testpoint 8

0.2 – 0.8 VDC

Table 6-2 Output Diodes, digital meter set to measure Diode Voltage

IGBT Testing Multimeter Lead Placement Diode Voltage

IGBT 1

IGBT 2

IGBT 4

IGBT 5

Positive meter lead to testpoint 9

Negative meter lead to testpoint 10

Positive meter lead to testpoint 11

Negative meter lead to testpoint 12

Positive meter lead to testpoint 13

Negative meter lead to testpoint 14

Positive meter lead to testpoint 15

Negative meter lead to testpoint 16

0.2 – 0.8 VDC

Table 6-3 IGBT’s, digital meter set to measure Diode Voltage

TROUBLESHOOTING 6-6 Manual 0-5448

Page 49

ESAB FABRICATOR 141i

IGBT Testing Multimeter Lead Placement Impedance

IGBT 1

IGBT 2

IGBT 4

IGBT 5

Table 6-4 IGBT’s, Multimeter set to measure ohms (Ω)

Inrush PTC Multimeter Lead Placement Impedance

Positive meter lead to testpoint 17 Negative meter lead to testpoint 9

Positive meter lead to testpoint 18

Negative meter lead to testpoint 11

Positive meter lead to testpoint 19

Negative meter lead to testpoint 13

Positive meter lead to testpoint 20

Negative meter lead to testpoint 15

150 to 350 Ω

PTC

Table 6-5 Inrush PTC, Multimeter set to measure ohms (Ω)

6.08 Check Main ON / OFF Switch

Positive meter lead to testpoint 21

Negative meter lead to testpoint 22

80 to 120 Ω

2526

Power Switch Testing Multimeter Lead Placement Impedance

Switch ON

Switch OFF

Manual 0-5448 6-7 TROUBLESHOOTING

Art # A-10459

Positive meter lead to testpoint 23

Negative meter lead to testpoint 24

Positive meter lead to testpoint 25

Negative meter lead to testpoint 26

Positive meter lead to testpoint 23

Negative meter lead to testpoint 24

Positive meter lead to testpoint 25

Negative meter lead to testpoint 26

Table 6-6 Power Switch, Multimeter set to measure ohms (Ω)

0 to 1 Ω

> 1k Ω

Page 50

ESAB FABRICATOR 141i

6.09 Check Main Input Rectiﬁer

Input Rectiﬁer Testing Multimeter Lead Placement Diode Voltage

AC1 to DC+

AC2 to DC+

Positive meter lead to AC1

Negative meter lead to testpoint DC+

Positive meter lead to AC2

Negative meter lead to testpoint DC+

0.2 – 0.8 VDC

AC1 to DC-

AC2 to DC-

Positive meter lead to testpoint DC-

Negative meter lead to testpoint AC1

Positive meter lead to testpoint DC-

Negative meter lead to testpoint AC2

0.2 – 0.8 VDC

Table 6-7 IGBT’s, Multimeter set to measure Diode Voltage

Measurements may be made directly onto the main input rectiﬁer. AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position.

6.10 DC Bus Voltage Measurement

Apply voltage to the Power Source.

WARNING

There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present. Do not touch any live parts.

6 8

Art # A-12171

TROUBLESHOOTING 6-8 Manual 0-5448

Page 51

ESAB FABRICATOR 141i

DY2

NTCS

DC Bus Testing Multimeter Lead Placement

Buck CAPACITOR

Negative meter lead to testpoint1 Positive meter lead to testpoint2

Table 6-8 DC BUS, Multimeter set to measure DC volts

Note: These DC voltages are at nominal mains supply voltage of 115VAC.

6.11 PCB Connectors

1. Main PCB1

AC1

AC2

CIN1

CU3

CY1

CU4

AC OUT

DC+

DC-



R24



DY1

R29

QF/FJ



R28

Voltage with Supply Voltage ON

161 VDC +/-10%



GAS

PWM



W05

TR8

OUT+

T13-1

COUT1

R25

T20-1

R101

C100

T16-1T17-1

T14-1T15-1

R100R102

IN Header Pin Pin Function Signal

1 +15V +15 VDC 2 IGBT 1, 4 PWM Driver Signal 5 VDC Vpk 3 IGBT 2, 5 PWM Driver Signal 5 VDC Vpk 4 IGBT 2, 5 PWM Driver Signal 5 VDC Vpk

5 IGBT 1, 4 PWM Driver Signal 5 VDC Vpk

6 Rectiﬁed Secondary of Current Transformer TR8 -6 VDC 7 Common of +15V 0 VDC

Table 6-9 IN Header Pin Function (Connects to DRIVE header on Control PCB2)

OUT-

COUT2

Art # A-12172



PWM Header Pin Pin Function Signal

1 PWM Common 0 VDC 2 Motor PWM Driver signal 5 V Vpk

Table 6-10 PWM Header Pin Function (Connects to PWM header on Control PCB2)

Manual 0-5448 6-9 TROUBLESHOOTING

Page 52

ESAB FABRICATOR 141i

MD Header Pin Pin Function Signal

1 Motor positive 0-24V between Pin 1 and Pin 2, depending on wire

2 Motor negative

Table 6-11 MD Header Pin Function (Connects to MT header on Spool Gun PCB6)

NTCS Header Pin Pin Function Signal

1 Power source for NCT circuitry 12VDC between Pin 1 and Pin 2 2 Power source for NCT circuitry

Table 6-12 NTCS Header Pin Function (Connects to NTCS header on Control PCB2)

DY2 Header Pin Pin Function Signal

1 +24V power source +21~25VDC 2 Common of +24VDC and -24VDC 0V 3 -24V power source -21~25VDC

Table 6-13 DY2 Header Pin Function (Connects to SOURCE header on Control PCB2)

DY1 Header Pin Pin Function Signal

1 Not used n/c 2 Not used n/c 3 Not used n/c 4 Solenoid Positive +23~25VDC

5 Solenoid negative (/GAS)

speed

0V@ solenoid ON,

+23~25VDC@ solenoid OFF

Table 6-14 DY1 Header Pin Function (Connects to Solenoid)

QF/FJ Header Pin Pin Function Signal

1 Not used n/c

2 Solenoid negative

3 +24V power source for solenoid +23V~25VDC 4 Common of +24V power source for solenoid 0V

0V@Solenoid ON,

+23~25VDC@ solenoid OFF

Table 6-15 QF/FJ Header Pin Function (Connects to QF/DY header on Control PCB2)

TROUBLESHOOTING 6-10 Manual 0-5448

Page 53

2 Control PCB2

SW0



ESAB FABRICATOR 141i

WVIN

QF/DY

GUN

IGBTOT



WVF

PWM

Vmin



Imin

Imax

NTCS FUNs CR SOURCE DRIVE

GUN Header Pin Pin Function Signal

1 +24V Trigger positive

2 Trigger Common 0V

Table 6-16 GUN Header Pin Function (Connects to GUN1 header on Remote Interface PCB4)

+23V~25VDC (0V when

Trigger closed)

IFB

Art # A-12173

PWM Header Pin Pin Function Signal

1 PWM Common 0VDC 2 Motor PWM Driver signal 5V Vpk

Table 6-17 PWM Header Pin Function (Connects to PWM header on Main PCB1)

QF/DY Header Pin Pin Function Signal

1 Not used n/c 2 Solenoid negative (/GAS) 0VDC@Solenoid ON,

+23~25VDC@ solenoid OFF 3 +24V power source for solenoid

4 Common of +24V power source for solenoid 0V

Table 6-18 QF/FJ Header Pin Function (Connects to QF/FJ header on Main PCB1)

FUNs Header Pin Pin Function Signal

1 Fan Positive +20V~24VDC 2 Fan negative (/FAN) 0v@ Fan ON, +20V~24VDC@ Fan OFF

+23V~25VDC

Table 6-19 FUNs Header Pin Function (connects to Fan)

Manual 0-5448 6-11 TROUBLESHOOTING

Page 54

ESAB FABRICATOR 141i

DRIVE Header Pin Pin Function Signal

1 +15V +15 VDC

2 IGBT1 ,4 PWM Driver Signal 5VDC Vpk 3 IGBT2 ,5 PWM Driver Signal 5VDC Vpk 4 IGBT2 ,5 PWM Driver Signal 5VDC Vpk 5 IGBT1 ,4 PWM Driver Signal 5VDC Vpk

6 Rectiﬁed Secondary of Current Transformer TR8 -6VDC

7 Common of +15V 0VDC

Table 6-20 DRIVE Header Pin Function (Connects to IN header on Main PCB1)

WVIN Header Pin Pin Function Signal

1 Negative welding terminal Negative welding voltage 2 Not used n/c 3 Positive welding terminal Positive welding voltage

Table 6-21 WVIN Header Pin Function (Connects to welding terminals)

IFB Header Pin Pin Function Signal

1 +15V power source +15VDC 2 -15V power source -15VDC 3 Current sensor signal 4V/ 300A 4 0V 0V

Table 6-22 IFB Header Pin Function (Connects to welding output current sensor)

SOURCE Header Pin Pin Function Signal

1 +24V power source +21~25VDC 2 Common of +24V and -24V 0V

3 -24V power source -21~25VDC

Table 6-23 SOURCE Header Pin Function (Connects to DY2 header on Main PCB1)

CR Header Pin Pin Function Signal

1 Burn back potentiometer Min 0V 2 Burn back potentiometer wiper 0-5VDC 3 Burn back potentiometer Max +5VDC

Table 6-24 CR Header Pin Function (Connects to CR header on Burnback PCB5)

IGBT OT Header Pin Pin Function signal

0V-5V

1 NTC temperature sensor

2 NTC temperature sensor 0V

Overtemperature when voltage less

than 0.9v.

Table 6-25 IGBT OT Header Pin Function (Connects to 47K NTC resistor)

NTCS Header Pin Pin Function Signal

1 Power source for NCT circuitry 2 Power source for NCT circuitry

12VDC between Pin 1 and pin 2

Table 6-26 NTCS Header Pin Function (Connects to NTCS header on Main PCB1)

TROUBLESHOOTING 6-12 Manual 0-5448

Page 55

ESAB FABRICATOR 141i

MB Header Pin Pin Function Signal

1 Serial display date& EPROM (D-IN) 5VDC digital 2 Serial display data(LOAD) 5VDC digital 3 Serial display data (CLK) 5VDC digital 4 2T/4T push button 0VDC 5 Serial display EPROM (D-OUT) 5VDC digital

6 Not used n/c

7 Chip select 5VDC digital 8 MODEpush button 0VDC 9 +15VDC 15VDC

10 Not used n/c

11 Inductance pot terminal 2

12 Volts set point 0-5VDC

13 Inductance pot terminal 1

14 Amps set point 0-5VDC 15 5VDC 5VDC 16 Common 0VDC

Table 6-27 MB Header Pin Function (Connects to J12 header on Remote Interface PCB4)

0-10 kΩ between

pin 11 and 13

0-10 kΩ between

pin 11 and 13

3. Display PCB3

Inductance

Volts/Downslope /Arcforce

Amps

Art # A-12174

Manual 0-5448 6-13 TROUBLESHOOTING

Page 56

ESAB FABRICATOR 141i

GUN1

REMOTE

J1 Header Pin Pin Function Signal

1 Serial display date& EPROM (D-IN) 5VDC digital 2 Serial display data(LOAD) 5VDC digital 3 Serial display data (CLK) 5VDC digital 4 2T/4T push button 0VDC 5 Serial display EPROM (D-OUT) 5VDC digital 6 Not used n/c 7 Chip select 5VDC digital 8 MODEpush button 0VDC 9 +15VDC 15VDC

10 Not used n/c

11 Inductance pot terminal 2

12 Volts set point 0-5VDC

13 Inductance pot terminal 1

14 Amps set point 0-5VDC 15 5VDC 5VDC 16 Common 0VDC

Table 6-28 J1 Header Pin Function (Connects to J11 header on Remote Interface PCB4)

0-10 kΩ between

pin 11 and 13

0-10 kΩ between

pin 11 and 13

4. Remote Interface PCB4

J11

GUN1 Header Pin Pin Function Signal

1 +24V trigger positive (/Torch Switch)

2 0VDC 0V

Table 6-29 GUN1 Header Pin Function (Connects to GUN header on Control PCB2)

REMOTE Header Pin Pin Function Signal

1 2

Table 6-30 REMOTE Header Pin Function (Connects to SW2 Local/ Remote switch)

J12

15V

Local/ Remote switch

GUN

SGM

R-

Art # A-12175

+23~25VDC

0V@Trigger closed,

Closed when Remote

Mode selected

15V Header pin Pin Function Signal

1 +15V power source +15VDC 2 0V 0V

Table 6-31 15V Header Pin Function (Connects to 15V header on Spool Gun PCB6)

TROUBLESHOOTING 6-14 Manual 0-5448

Page 57

ESAB FABRICATOR 141i

R-G Header Pin Pin Function Signal

1 Spool Gun motor negative

2 +24V trigger positive

3 Trigger switch RTN 0V

4 Spool Gun motor positive

5 -12VDC Pot Max -12VDC 6 +12VDC Pot Min +12VDC

7 Remote Amps Pot Wiper -12V~+12VDC

8 Remote Vots Pot Wiper -12V~+12VDC

Table 6-32 R-G Header Pin Function (Connects to front panel 8 pin remote socket)

J12 Header Pin Pin Function Signal

10 Not used n/c

11 Inductance pot terminal 2

12 Volts set point 0-5VDC

13 Inductance pot terminal 1

14 Amps set point 0-5VDC 15 5VDC 5VDC 16 Common 0VDC

Table 6-33 J12 Header Pin Function (Connects to MB header on Control PCB2)

0-24V between

pin 1 and 4

+23V-25VDC,

0V@ trigger

closed

0-24V between

pin 1 and 4

0-10 kΩ between

pin 11 and 13

0-10 kΩ between

pin 11 and 13

Manual 0-5448 6-15 TROUBLESHOOTING

Page 58

ESAB FABRICATOR 141i

J11 Header Pin Pin Function Signal

1 Serial display date& EPROM (D-IN) 5VDC digital 2 Serial display data(LOAD) 5VDC digital 3 Serial display data (CLK) 5VDC digital 4 2T/4T push button 0VDC 5 Serial display EPROM (D-OUT) 5VDC digital 6 MIG/ LIFT TIG/ STICK Selection Button 0V when depressed 7 Chip select 5VDC digital 8 MODEpush button 0VDC 9 +15VDC 15VDC

10 Not used n/c

11 Inductance pot terminal 2

12 Volts set point 0-5VDC

13 Inductance pot terminal 1

14 Amps set point 0-5VDC 15 5VDC 5VDC 16 Common 0VDC

Table 6-34 J11 Header Pin Function (Connects to J11 header on Display PCB3)

0-10 kΩ between pin

11 and 13

0-10 kΩ between pin

11 and 13

SGM Header Pin Pin Function Signal

5. Burnback PCB5

Spool Gun Motor connector 0-24VDC

Table 6-35 SGM Header Pin Function (Connects to SGM header on Spool Gun PCB6)

Art # A-12176

CR Header Pin Pin Function Signal

1 Burn back potentiometer max +5VDC

2 Burn back potentiometer min 0V

3 Burn back potentiometer wiper 0V~5VDC

Table 6-36 CR Header Pin Function (Connects to CR header on Control PCB2)

TROUBLESHOOTING 6-16 Manual 0-5448

Page 59

6. Spool Gun PCB6

ESAB FABRICATOR 141i

Art # A-12177

FUSE Header Pin Pin Function Signal

Table 6-37 FUSE Header Pin Function (Connects to 10A Motor Fuse)

PP Header Pin Pin Function Signal

Local/ Remote switch connector

Table 6-38 PP Header Pin Function (Connects to SW2 Local/ Remote switch)

15V Header Pin Pin Function Signal

1 +15V power source +15VDC

2 0V 0V

Table 6-39 15V Header Pin Function (Connects to 15V header on Remote Interface PCB4)

10A Fuse connector Closed

Closed when Remote

Mode selected

SGM Header Pin Pin Function Signal

Spool Gun Motor connector 0-24VDC

Table 6-40 SGM Header Pin Function (Connects to SGM header on Remote Interface PCB4)

MT Header Pin Pin Function Signal

1 Motor positive input voltage

2 Motor negative input voltage

3 Motor negative output voltage

4 Motor positive output voltage

0-24VDC between pin

1 and 2

0-24VDC between pin

1 and 2

Table 6-41 MT Header Pin Function (Connects to MD header on Main PCB1 and Motor)

Manual 0-5448 6-17 TROUBLESHOOTING

Page 60

ESAB FABRICATOR 141i

SW0



6.12 DIP Switch Settings, Control PCB2

1 DIP Switch SW0, Control PCB2

WVIN

QF/DY

GUN

IGBTOT



WVF

PWM

Vmin

IFB



NTCS FUNs CR SOURCE DRIVE

Imin

Imax

Art # A-12173

Art # A-12221

SW0 position Function

1 Set to OFF for Fabricator 141i

2 Set to OFF for Fabricator 141i 3 Set to OFF for Fabricator 141i 4 Set to OFF for Fabricator 141i

Table 6-41 SW0 Dip Switch functions

TROUBLESHOOTING 6-18 Manual 0-5448

Page 61

6.13 Calibration

Vmin

WVF

SW0

1 Calibration

ESAB FABRICATOR 141i

Imax

Imin

Set SW0-1 to ON, SW0-2 to ON, SW0-3 to ON, SW0-4 to OFF to allow calibration of output volts & amps, and calibration of wire feed speed.

2 Output Current Calibration

Select STICK mode on the front panel. Measure open circuit voltage and adjust WVF potentiometer so Volts display reads within 0.2V of the measured value. Connect a load to the output terminals. The load should be of a resistance to give 25V at 250A. Set front panel AMPS potentiometer to minimum. Adjust Imin trimpot until output amps is 10A +/- 0.2A Set front panel AMPS potentiometer to maximum. Adjust Imax trimpot until output amps is 90A +/- 1A Recheck settings Set front panel AMPS potentiometer to maximum. Adjust A potentiometer so Amps display reads within 0.5A of the measured value.

3 Output Voltage Calibration

Select MIG mode on the front panel. Remove the load from the output terminals. Set front panel VOLTS potentiometer to minimum. Adjust Vmin trimpot until output volts is 10.0V +/- 0.2V Set front panel VOLTS potentiometer to maximum. Adjust W2 trimpot until output volts is 19V +/- 0.2V Recheck settings

4 Wire Speed Calibration

Art # A-12224

NOTE!

These adjustments are on the wiring side of the Main PCB1.

Manual 0-5448 6-19 TROUBLESHOOTING

Page 62

ESAB FABRICATOR 141i

W05 MAX SPEED

W0 2MIN SPEED

U0 2pin 6

U0 1pin 1

U0 1pin 2

U0 1pin 3

0V for wiredrive circuit (R017)

Art # A-12178

Select MIG mode on the front panel. Remove the load from the output terminals. Set front panel WIRESPEED (AMPS) potentiometer to minimum. AMPS display should read “30” Adjust W02 trimpot until motor volts is 4.5V +/- 0.2V Set front panel WIRESPEED (AMPS) potentiometer to maximum. AMPS display should read “100” Adjust W05 trimpot until motor volts is 15V +/- 0.2V Recheck settings Set SW0-1 to OFF, SW0-2 to OFF, SW0-3 to OFF, SW0-4 to OFF to disable calibration of output volts & amps, and calibration of wire feed speed and return to normal operation.

5 Wire Speed Testpoint Waveforms

Select MIG mode on the front panel and remove the load from output terminals.

Adjust the wirespeed control knob to the max and the digital amperage meter will display a preview value 390.

Now you can measure below waveforms according to different test points.

TROUBLESHOOTING 6-20 Manual 0-5448

Page 63

TEST POINT “A” 5V/div TEST POINT “B” 5V/div

ESAB FABRICATOR 141i

TEST POINT “C” 5V/div TEST POINT “D” 5V/div

TEST POINT “E” and “F” 5V/div TEST POINT “G” 5V/div

Art # A-11231

Manual 0-5448 6-21 TROUBLESHOOTING

Page 64

ESAB FABRICATOR 141i

DC+

6.14 Main Circuit Description

WARNING

Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage.

DC-

C16 C18 C18-1

BR2

BR1

PTC

R102

R100

C100

T13-1

OUT+

4 3 2 1

HallSensor

COUT1

T14-1

T15-1

TRANSFORMER

T16-1

NTC

C102

T17-1

EA RTH

T18-1

TR8

COUT2

C101

R101

OUT-

Art # A-12179

R103

CY1

CIN1

AC2

T1 T2

CU4 CU3

AC1

EA RTH

DC+

T5 T4

DC-

TROUBLESHOOTING 6-22 Manual 0-5448

Page 65

ESAB FABRICATOR 141i

The mains supply voltage is connected via a double pole switch to the input rectiﬁer BR1 &BR2. Overvoltage protection is provided by varistor CY1. The rectiﬁer output charges the main capacitor bank (C16, C18, C18-1) to high voltage. Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds. The primary igbt transistors (T1, T2, T4, and T5) switch the transformer primary at high frequency and varying duty cycle. Secondary output voltage from the transformer is rectiﬁed by the output diodes (T13-1, T14-1, T15-1, T16-1, T17-1, T18-1) to DC. This DC is controlled by the PWM of the primary side igbt transistors, and is ﬁltered by an inductor before connecting to the welding output terminals. A thermal overload device (thermistor) is ﬁxed to the rectiﬁer heatsink. When an over temperature occurs, the control circuit inhibits the trigger, gas solenoid, wire drive system and the welding output. The thermal overload indicator LED on the front panel is illuminated. The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current, and also detect transformer saturation. The Hall effect current sensor is powered from regulated + & - 15VDC supplies and provides a voltage signal proportional to the output DC welding current to allow the control circuit to regulate welding current.

Manual 0-5448 6-23 TROUBLESHOOTING

Page 66

ESAB FABRICATOR 141i

Art # A-11792 _AC

J24J10

CONNECTOR

LAYOUT

DIAGRAM

J19

J13

J16

J15

J18

DRIV

PWM

WVIN

IFB

SOURCE

GUN

QF /DY

O T

FUNSCRNTCS

123

6.15 Circuit Diagram

TROUBLESHOOTING 6-24 Manual 0-5448

Page 67

SECTION 7:

DISASSEMBLY PROCEDURE

7.01 Safety Precautions for Disassembly

WARNING

Unplug unit before beginning Disassembly procedure.

7.02 Control PCB2 Removal

Read and follow safety information in Section 6.02 before proceeding.

WARNING

STATIC (ESD) can damage PC boards.

ESAB FABRICATOR 141i

WARNING

Remove case (refer to 6.04) before removing Control PCB2.

1. M4 Screw. Remove 4 screws from Control panel.

2 Disconnect DRIVE harness from DRIVE connector.

3. Disconnect SOURCE harness from SOURCE connector.

4. Disconnect CR harness from CR connector.

5. Disconnect FUNs harness from FUNs connector.

6. Disconnect NTCS harness from NTCS connector.

7. Disconnect IGBT OT harness from IGBT OT connector.

8. Disconnect GUN harness from GUN connector.

9. Disconnect QF/DY harness from QF/DY connector.

10. Disconnect WVIN harness from WVIN connector.

11 Disconnect MB harness from MB connector.

12. Disconnect PWM harness from PWM connector.

Read and follow safety information in Section 6.02 before proceeding with disassembly.

13. Disconnect IFB harness from IFB connector.

Ensure to unplug all harness from the Control PCB2.

Manual 0-5448 7-1 DISASSEMBLY PROCEDURE

Page 68

ESAB FABRICATOR 141i

Art # A-12180

WVIN

QF/DY

GUN

IGBT OT

NTCS

FUNs

PWMMB

SOURCE

IFB

DRIVE

A-10018

DISASSEMBLY PROCEDURE 7-2 Manual 0-5448

Page 69

7.03 Display PCB3 Removal

WARNING

1. Remove Control Panel screws.

2. Disconnect the harness from the connectors.

3 Remove Display PCB3.

4. Remove Remote Interface PCB4.

Read and follow safety information in Section 6.02 before proceeding with disassembly.

ESAB FABRICATOR 141i

A-12929

Manual 0-5448 7-3 DISASSEMBLY PROCEDURE

Page 70

ESAB FABRICATOR 141i

Art # A-12181

DISASSEMBLY PROCEDURE 7-4 Manual 0-5448

Page 71

7.04 Front Panel Assembly Removal

CAUTION

1. Remove the ﬁve screws on front panel.

2 Unscrew Negative output terminal bolts.

3. Unscrew torch cable terminal bolts.

4. Unscrew output terminal bolts.

Read and follow safety information in Section 6.02 before proceeding with disassembly.

ESAB FABRICATOR 141i

A-12930

Manual 0-5448 7-5 DISASSEMBLY PROCEDURE

Page 72

ESAB FABRICATOR 141i

A-12931

7.05 Rear Panel Removal

CAUTION

1. Remove the rear panel screws.

2. Disconnect the gas tube.

3. Disconnect Input Cord ground wire.

4. Disconnect the four wires from the switch.

5. Disconnect FUNS Harness from the control PCB2.

Read and follow safety information in Section 6.02 before proceeding with disassembly.

DISASSEMBLY PROCEDURE 7-6 Manual 0-5448

Page 73

ESAB FABRICATOR 141i

A-12932

7.06 ON/ OFF Switch SW1 and Power Cord Removal

CAUTION

1. Gas inlet. Remove gas inlet from rear panel.

2. SW1 locking tabs

Squeeze the locking tabs and push SW1 out from the rear panel.

3. Strain relief screws

Remove the two screws from the strain relief.

4. Remove Fan.

5. Pull the Input Power Cord out. It may be necessary to use a ﬂat blade screw driver against the strain relief

Read and follow safety information in Section 6.02 before proceeding with disassembly.

tabs, prying outward (Internal side if strain relief) to help remove the cord.

Manual 0-5448 7-7 DISASSEMBLY PROCEDURE

Art # A-12223

Page 74

ESAB FABRICATOR 141i

7.07 Base Panel Removal and Main PCB1 Disassembly

CAUTION

1. Remove Wire Feeder Screws.

2. Remove Inductor Screws.

3. Remove Central Panel Screws.

4. Remove Main PCB1 assembly Screws.

5. Remove Rectiﬁers.

6. Remove the feet of Main PCB1 assembly.

7. Heatsink on Main PCB1 assembly.

8. Main PCB1 assembly.

Read and follow safety information in Section 6.02 before proceeding with disassembly.

DISASSEMBLY PROCEDURE 7-8 Manual 0-5448

Page 75

8.01 Installing Base panel

1. Main PCB1 assembly.

2. Heatsink on Main PCB1 assembly.

3. Install the feet of Main PCB1 assembly.

4. Install Rectiﬁers (torque 15 kgfcm).

5. Install Inductor.

6. Install Main PCB1 assembly screws.

7. Install Central Panel Screws.

8. Install Wire Feeder Screws.

ESAB FABRICATOR 141i

SECTION 8:

ASSEMBLY PROCEDURES

Art # A-12089

Manual 0-5448 8-1 ASSEMBLY PROCEDURES

Page 76

ESAB FABRICATOR 141i

A-12933

8.02 Installing Rear panel

1. Install gas inlet.

2. Install ON/OFF switch

3. Install wire cord and 2 screws.

4. Reconnect Input Wire on the ON/OFF switch.

5. Install fan.

6. Install plastic inserts into rear panel feet and install panel screws.

ASSEMBLY PROCEDURES 8-2 Manual 0-5448

Art # A-12222

Page 77

8.03 Installing Front Panel

A-12934

1. Reinstall output terminals on front panel with 27mm wrench.

2. Place Display PCB3 and Remote Interface PCB4 assembly into front panel and install screws.

ESAB FABRICATOR 141i

3. Reconnect torch polarity cable to the torch connector.

4. Reconnect positive output terminal bolts and tighten with 17mm wrench. ( Note: reconnect wires, pay attention to the wire color.)

5. Reconnect negative output terminal bolts and tighten with 17mm wrench. (Note: reconnect wires and pay attention to the wire color.)

Art # A-12182

6. Reconnect the harness to the connectors on Display PCB3 and Remote Interface PCB4.

Manual 0-5448 8-3 ASSEMBLY PROCEDURES

Page 78

ESAB FABRICATOR 141i

8.04 Installing Control PCB2 and Clear Protective Sheet

Art # A-12183

1. Install 4 screws.

2 Plug harness into DRIVE connector.

3. Plug harness into SOURCE connector.

4. Plug harness into CR connector.

5. Plug harness into FUNs connector

6. Plug harness into NTCs connector.

7. Plug harness into IGBT OT connector .

8. Plug harness into GUN connector.

9. Plug harness into QF/DY connector.

10. Plug harness into WVIN connector.

11 Plug harness into MB connector.

12. Plug harness into PWM connector.

13. Plug harness into IFB connector.

Verify harness connections with the system schematic to ensure all connections are correct.

14. Install clear protective sheet.

ASSEMBLY PROCEDURES 8-4 Manual 0-5448

Page 79

ESAB FABRICATOR 141i

Art # A-12184

Manual 0-5448 8-5 ASSEMBLY PROCEDURES

Page 80

ESAB FABRICATOR 141i

8.05 Installing Case

1. Install Case.

2. Install Ground Screw, which connects the ground wire to the cover.

3. Install Screws. Tighten screws.

Tighten Screws Front & Rear

Install Screws

Art # A-12092

ASSEMBLY PROCEDURES 8-6 Manual 0-5448

Page 81

Notes

ESAB FABRICATOR 141i

Manual 0-5448 8-7 ASSEMBLY PROCEDURES

Page 82

ESAB FABRICATOR 141i

Notes

ASSEMBLY PROCEDURES 8-8 Manual 0-5448

Page 83

SECTION 9: KEY SPARE PARTS

9.01 Tweco Fusion 140A MIG Gun Parts

ESAB FABRICATOR 141i

Torch Part No: 1017-1321

Art# A-11672_AB

Item

No.

1 Velocity Nozzle**

4 Conduit Assembly* WS42-3035-15 1420-1140

5B Tweco Control Wire 35K-350-1 2000-2352

Description Part No.

VNS-50 1220-1201

VNS-50F 1220-1200

VNS-62 1220-1203

VNS-62F 1220-1202

VNS-37 1220-1206

VNS-37F 1220-1204

VNS-75FAS 1220-1205

VTS-23 1110-1308

VTS-30 1110-1309

VTS-35 1110-1310

VTS-40 1110-1311

Velocity Contact Tip**

Handle / Trigger Repair Kit

Tweco Rear Connector

Tweco Control Wire & Plug

VTS-45 1110-1312

VTS-52 1110-1314

VTS-116 1110-1315

VTSA-116 1110-1317

VTSA-364 1110-1313

VTS-564 1110-1316

F8 2020-2025

350-174H 2035-2110

WS-354-TA-LC 2060-2141

Table 9-1: Tweco Fusion 140A MIG Gun Parts

Figure 9-1

Manual 0-5448 9-1 KEY SPARE PARTS

** Patent Pending

* Refer to ESAB Catalog No. 64-2103 for additional options.

Page 84

ESAB FABRICATOR 141i

9.02 Power Source

A-11811_AB

Art #

KEY SPARE PARTS 9-2 Manual 0-5448

Figure 9-2

Page 85

ESAB FABRICATOR 141i

FABRICATOR 141i POWER SOURCE SPARE PARTS

ITEM PART NUMBER DESCRIPTION

1 W7006216 PCB,Power,141i 2 W7006227 PCB,Control,141i 3 W7003033 Solenoid,Valve,24VDC 4 W7006226 PCB, Remote Interface Integrated with Display, 141i 5 W7006209 Wiredrive Assy,w/ Motor,141i 6 W7004906 Feedroll retaining thumb screw 7 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed 8 W7004947 Fan,24VDC,4.75"x4.75"x1",141i

9 W7003010 Rectiﬁer Bridge,1000V,50A 10 W7003215 Connector,Gas Inlet,5/8"-18UNF 11 W7006210 Dinse,Socket,141i 12 W7004983 Shoulder strap, 141i (not shown) 13 W7006224 Input Power Cable (not shown) 14 W7004942 Socket,8 Pin,w/ Harness 15 W7003053 Switch,On/Off,250V 16 W7004911 CT Sensor,Output,141i 17 W7004912 Wire Hub Assy,141i 18 W7006220 Panel, Front 19 W7006223 Panel, Rear 20 W7004922 Handle,141i 21 W7006222 Side and Top Panels (not shown) 22 W7004966 Adapter,ESAB 4,141i 23 W7004925 Guide,Inlet,.023-.045,141i 24 W7004967 Guide,Outlet,.023-.045,141i 25 W7006221 Panel,Door (not shown) 26 W7006208 Panel,Base,141i 27 870734 Knob,1/4" IDx.72" ODx.9" H 28 W7004972 Knob,1/4" IDx1" ODx0.9" H 29 W7006211 Panel,Front Control,141i 30 W7004953 Push Button Actuator 31 OTWAK/1S Screw,Locking,MIG Gun 32 W7004961 Thermistor,NTC,K45 47K,141i 33 W7004940 PCB Burnback Potentiometer 34 W7006214 PCB,Spool Gun,141i 35 W7004979 Fuse Holder,141i 36 W7006217 Fuse,10 Amp 37 W7006218 Label,Setup Chart,141i,English (not shown) 38 W7006219 Label,Setup Chart,141i,French (not shown) 39 W7006212 Inductor,141i (not shown) 40 W7004951 Spool Hub,141i 41 W7004943 Remote/Local and MIG/ Spool Gun Switch 42 W4017500 Dinse Adapter, 50mm- 25mm (not shown)

Table 9-2

Manual 0-5448 9-3 KEY SPARE PARTS

Page 86

ESAB FABRICATOR 141i

9.03 Hardware List

ITEM DESCRIPTION Torque WHERE USED Qty

1 Nut Lock, M20 ≥ 50 kgfcm 25mm Dinse 2

2 Screw Hexagon, M10 × 1.5-20 ST ZP ≥ 50 kgfcm 25mm Dinse 2

3 Washer, M4, ET Lock 15 ± 1 kgfcm Handle 2

Side Panel 3

4 SC PHCR M4 × 0.7-10 ST ZP 15 ± 1 kgfcm Handle 2

Rear Panel 2

Front Panel 3

Side Panel 3

Door Assy 2

5 SC PHCR M4 × 0.7-16 ST BK 15 ± 1 kgfcm Front Panel 2

Rear Moulding 2

6 SC PHCR ST 6G × 3/8 STBK 10 ± 1 kgfcm 8 Pin Remote Socket 2

Front PCB 4

7 Nut Hexagon M4 × 0.7 ST ZP 15 ± 1 kgfcm Fan 4

8 SC PHSL M4 × 0.7-30 ST ZP 15 ± 1 kgfcm Fan 4

9 Nut Hexagon M12 × 1.75 ST ZP ≥ 50 kgfcm Gas Adaptor Inlet 1

10 Washer Flat, 7.91 D (M8) ≥ 50 kgfcm Wirefeeder Plate 2

11 Washer Spring, 7.91 D N/A Wirefeeder Plate 2

12 Screw Hexagon M8 × 1.25-30 ST ZP ≥ 50 kgfcm Wirefeeder Plate 2

13 Nut Hexagon M8 × 1.25 ST ZP ≥ 50 kgfcm Wirefeeder Plate 2

14 Screw Hexagon HD 9/32 × 16 ×19 48 ± 1 kgfcm Wirefeeder Plate 2

15 Screw Skt Set M4 × 0.7 15 ± 1 kgfcm ESAB No. 4 Torch Adaptor 1

16 Screw Hexagon M6 × 1.0-10 ST ZP 48 ± 1 kgfcm ESAB No. 4 Torch Adaptor 1

17 Nut Hexagon M10 × 1. 5 ST ZP ≥ 50 kgfcm ESAB No. 4 Torch Adaptor 1

Table 9-3

NOTE!

All the hardware can be purchased from local store.

KEY SPARE PARTS 9-4 Manual 0-5448

Page 87

ESAB FABRICATOR 141i

SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL

SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL

5 2

1 2

2 2

4 1

8 4

7 4

4 1

3 1

4 1

3 1

4 1

3 1

4 1

3 1

4 1

6 4

6 2

9 1

SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL

SCREW ITEM 4, 2 OFF USED TO SECURE DOOR ASSY TO BASE PANEL

1111101

13 2

4 1

5 2

Art # A-11932_AB

Manual 0-5448 9-5 KEY SPARE PARTS

Figure 9-3

Page 88

ESAB FABRICATOR 141i

Notes

KEY SPARE PARTS 9-6 Manual 0-5448

Page 89

ESAB FABRICATOR 141i

SECTION 10:

OPTIONS AND ACCESSORIES

10.01 Options and Accessories

DESCRIPTION PART NUMBER

Fusion 140A MIG Gun, 10ft (3.0m) Length

ESAB Spool Gun 160A,12ft (3.6M) Length, suits 4" (100mm) spools for aluminium welding

TIG Torch, 17V, 12.5 ft, 8 pin and accessory kit with 1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina nozzle; short back cap; long back cap

Fabricator 141i- 181i Carry Bag Basic 4 Wheel Cart Foot Control for remote amperage control when TIG welding ESAB WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)

Drive Roll .023" - .035" (0.6-0.9mm) V groove for steel & stainless steel Drive Roll .023"- .030" (0.6-0.8mm) V groove for steel & stainless steel wires

[Fitted] Drive Roll .035"/.045" (0.9/1.2mm) V groove for steel & stainless steel wires Drive Roll .030"-.035" (0.8-0.9mm) U grooved for aluminum wires Drive Roll .040"-.045" (1.0-1.2mm) U grooved for aluminum wires Drive Roll .030"-.035" (0.8-0.9mm) V knurled groove for ﬂux cored wires Drive Roll .045" (1.2mm) V knurled groove for ﬂux cored wire STICK KIT, 25mm DINSE

WTL ground clamp with 16 mm2 lead and 25 mm2 dinse, 10ft (3.1m) long

F140TA-10-3035 1017-1321

SG160TA-12-3035 1027-1390

W4013802

W4015301 W4014700

600285 4100-1004 W4014800

7977036

7977660 7977731 7977264 7977732

704277

W4009401

WTL electrode clamp with 16 mm2 lead and 25 mm2 dinse, 13ft (4m) long

Victor Argon Flowmeter/ Regulator Accessory Kit for TIG Torch with 1/16", 3/32", 1/8" thoriated tungstens; 1/16",

3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina nozzle; short back cap; long back cap

Power Adapter, 115V, 20A- 15A

Table 10-1: Fabricator 141i Options and Accessories List

0781-4169

P062900010

W4013300

Manual 0-5448 10-1 ACCESSORIES

Page 90

ESAB FABRICATOR 141i

Date Rev Description

09/17/2015 AA Manual release

REVISION HISTORY

ACCESSORIES 10-2 Manual 0-5448

Page 91

Page 92

ESAB subsidiaries and representative ofﬁces

Europe

AUSTRIA

ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V. Heist-op-den-Berg Tel: +32 70 233 075 Fax: +32 15 257 944

BULGARIA

ESAB Kft Representative Ofﬁce Soﬁa Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03 ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Bareggio (Mi) Tel: +39 02 97 96 8.1 Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL Bucharest Tel: +40 316 900 600 Fax: +40 316 900 601

RUSSIA

LLC ESAB Moscow Tel: +7 (495) 663 20 08 Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22 ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC Kiev Tel: +38 (044) 501 23 24 Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

Asia/Pacific

AUSTRALIA

ESAB South Paciﬁc Archerﬁeld BC QLD 4108 Tel: +61 1300 372 228 Fax: +61 7 3711 2328

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 6622

INDIA

ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Paciﬁc Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd Durbanvill 7570 - Cape Town Tel: +27 (0)21 975 8924

Distributors For addresses and phone numbers to our distributors in other countries, please visit our home page www.esab.eu

www.esab.eu

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