ESAB fabricator 141i Service Manual

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

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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.

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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.

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 #:___________________________________ __________

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.

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

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

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

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.

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

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

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

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

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

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

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

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

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.

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

Notes

ESAB FABRICATOR 141i

Manual 0-5448 3-9 SAFETY AND INSTALLATION

ESAB FABRICATOR 141i

This Page Intentionallly Blank

SAFETY AND INSTALLATION 3-10 Manual 0-5448

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

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

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

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

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.

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

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

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

+ 64 hidden pages

ESAB fabricator 141i Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual