ESAB Fabricator 141i 3-IN-1 Multi Process Welding Systems Instruction manual

ESAB Fabricator® 141i
3-IN-1 Multi Process Welding Systems
Operating Manual
3163339
Révision : AA Issue Date: September 10, 2015 Manual No.: 0-5420
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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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WARNING
!
Plasma Cutting Power Supply ESAB Fabricator® 141i 3-in-1 Multi Process Welding Systems™ Operating Manual Number 0-5420
Published by:
ESAB 2800 Airport Rd. Denton, TX 76208
www.esab.com
Copyright 2015 by ESAB
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.
All rights reserved.
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 10, 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
OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
SECTION 1: SAFETY ........................................................................................ 1-1
1.0 Safety Precautions .......................................................................................... 1-1
SECTION 2 SYSTEM:
INTRODUCTION ..................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Description ..................................................................................................... 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
2.08 Duty Cycle ............................................................................................................. 2-3
2.09 Specifications ....................................................................................................... 2-3
SECTION 3: INSTALLATION, OPERATION AND SETUP ................................................ 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Electricity Supply Voltage .............................................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-3
3.06 Victor Flowmeter/ Regulator ........................................................................... 3-4
3.07 Leak Testing the System ................................................................................. 3-5
3.08 When You Finish Using the Flowmeter/ Regulator ..........................................................3-5
3.09
3.10 Power Source Controls, Indicators and Features ............................................ 3-6
3.11 Attaching the Fusion 140A MIG Gun ............................................................. 3-11
3.12 Inserting Wire into the Wire Feed Mechanism .............................................. 3-11
3.13 Installing 4" (100mm) Diameter Spool ......................................................... 3-12
3.14 Installing 8" (200mm) Diameter Spool .......................................................... 3-13
3.15 Feed Roller Pressure Adjustment .................................................................. 3-14
3.16 Changing the Feed Roll ................................................................................. 3-14
3.17 Wire Reel Brake ............................................................................................ 3-14
Storage of the Flowmeter/ Regulator ..................................................................... 3-5
3.18 Flowmeter/ Regulator Operation ................................................................... 3-14
3.19 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 3-15
3.20 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire .................... 3-16
TABLE OF CONTENTS
3.21 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 3-17
3.22 Setup for LIFT TIG (GTAW) Welding ............................................................. 3-18
3.23 Setup for STICK (SMAW) Welding .............................................................. 3-19
3.24 Torch Adapter Thumb Screw Replacement ................................................... 3-20
SECTION 4: BASIC WELDING GUIDE .................................................................... 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5
4.03 Stick (SMAW) Basic Welding Technique ......................................................... 4-9
4.04 Effects of Stick Welding Various Materials ...................................................... 4-9
4.05 Stick (SMAW) Welding Troubleshooting ....................................................... 4-16
4.06 TIG (GTAW) Basic Welding Technique .......................................................... 4-18
4.07 TIG (GTAW) Welding Problems ..................................................................... 4-20
SECTION 5:
POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS .................... 5-1
5.01 Power Source Problems ................................................................................. 5-1
5.02 Routine Service............................................................................................... 5-2
5.03 Cleaning the Welding Power Source ............................................................... 5-3
5.04 Cleaning the Feed Rolls ................................................................................... 5-3
5.05 Volt-Ampere Curves ........................................................................................ 5-4
SECTION 6: KEY SPARE PARTS .......................................................................... 6-1
6.01 Tweco Fusion 140A MIG Gun Parts ................................................................ 6-1
6.02 Power Source ................................................................................................. 6-2
6.03 Hardware List ................................................................................................. 6-4
APPENDIX ................................................................................................... A-1
APPENDIX: FABRICATOR 141I CIRCUIT DIAGRAM .................................................... A-2
REVISION HISTORY ........................................................................................ A-4
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 0-5420 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
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 0-5420
Read and understand the instruction manual before installing or operating.
!
ESAB FABRICATOR 141i
SECTION 2 SYSTEM:
INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part num­bers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, 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.
2.02 Equipment Identification
The unit’s identification number (specification or part num­ber), model, and serial number usually appear on a data tag attached to the rear panel. Equipment which does not have a data tag such as torch and cable assemblies are identi­fied only by the specification or part number printed on loosely attached card or the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual. Include all equipment identification numbers as described above along with a full description of the parts in error. 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

WARNING
!
!
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
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.
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.
Manual 0-5420 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 0-5420
ESAB FABRICATOR 141i
Fabricator 141i
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

2.08 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
90
80
70
60
50
40
30
Duty Cycle (percentage)
20
10
0
0102030405060708090100 110120 130140 150
2.09 Specifications
Safe
Operating
Region
STICK (SMAW)/ MIG (GMAW/ FCAW)
Welding Current (amps)
TIG (GTAW)
Art # A-11276_AB
Figure 2-1: Fabricator 141i Duty Cycle
Manual 0-5420 2-3 INTRODUCTION
ESAB FABRICATOR 141i
This Page Intentionally Blank
INTRODUCTION 2-4 Manual 0-5420
ESAB FABRICATOR 141i
SECTION 3: INSTALLATION,
OPERATION AND SETUP

3.01 Environment

This Power Source is 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 have been insulated.

3.02 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.

3.03 Ventilation

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

3.04 Electricity Supply Voltage

CAUTION
!
SHUT DOWN welding Power Source, disconnect input power employing lockout/tagging procedures. Lock-out/tagging pro­cedures consist 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
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 quali­fied electrician.
• Correctly earthed (electrically) in accor­dance with local regulations.
• Connected to the correct size power point
and fuse as per the Specifications on page 2-4.
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.
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electri­cal parts.
Manual 0-5420 3-1 INSTALLATION, OPERATION AND SETUP
ESAB FABRICATOR 141i
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 3-1. Refer to Table 3-1.
WARNING
An electrical shock or fire hazard is probable if the following electrical service guide recommendations
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
are not followed. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the Welding Power Source.
50 / 60 Hz Single Phase Supply
115V AC
28.4 Amps
30 Amps
30 Amps
Table 3-1: 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 Power Control Assembly (PCA) will turn on after the input capacitors have charged to operating voltage (after approximately 5 seconds)
NOTE!
Damage to the PCA 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 3-2: Primary Circuit Sizes to Achieve Maximum Current
INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5420
ESAB FABRICATOR 141i

3.05 Electromagnetic Compatibility

WARNING
!
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the weld-
ing equipment according to the manufacturer’s instruc­tions. If electromagnetic 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.
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
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of industrial
5. The health of people around, e.g. the use of pacemak-
6. Equipment used for calibration and measurement.
7. The time of day that welding or other activities are to
Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.
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)..
telephone cables; above, below and adjacent to the welding equipment.
equipment.
ers and hearing aids.
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 Elec-
tricity 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 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 main-
tained 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 pos-
sible 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
electrical 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
Manual 0-5420 3-3 INSTALLATION, OPERATION AND SETUP
ESAB FABRICATOR 141i
A-09414_AC
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.

3.06 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.
conform 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. .
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.
Figure 3-1: Victor CS Flowmeter/ Regulator
WARNING
!
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.
1. Note the maximum inlet pressure stamped on the 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.
2. The flowmeter/ regulator body will be stamped “IN” or “HP” at the inlet port. Attach the inlet port to the system supply pressure connection.
3. If gauges are to be attached to the flowmeter/ regula­tor 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
WARNING
!
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
Figure 3-2: Flowmeter/ Regulator to Cylinder Valve
6. Before opening the cylinder valve, turn the flowmeter/ regulator adjusting screw counterclockwise until there is no pressure on the adjusting spring and the screw turns freely.
7. Relief Valve (where provided): The relief valve is designed 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.
INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5420
ESAB FABRICATOR 141i
Art # A-09828
WARNING
!
!
8. Slowly and carefully open the cylinder valve (Figure
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!
3-3) until the maximum pressure shows on the high pressure gauge.
b) If the low-pressure gauge drops, there is a leak
in the down stream equipment, hose, hose fitting, outlet fitting or low-pressure gauge. Check for leaks using an approved leak detector solution.
c) If the high-pressure gauge drops and the low-
pressure gauge increases at the same time, there is a leak in the flowmeter/ regulator seat.
d) If the flowmeter/ regulator requires service or
repair, take it to a qualified repair technician.
5. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed.
WARNING
!
If a leak has been detected anywhere in the system, dis continue use and have the system repaired. DO NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pressure.

3.08 When You Finish Using the Flowmeter/ Regulator

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

3.07 Leak Testing the System

Leak test the system before putting into operation.
1. Be sure that there is a valve in the downstream equip­ment to turn off the gas flow.
2. With the cylinder valve open, adjust the Flowmeter/ regulator to deliver the maximum required delivery pressure.
3. Close the cylinder valve.
4. Turn the adjusting screw/knob counterclockwise one turn. a) If the high-pressure gauge reading drops, there is
a leak in the cylinder valve, inlet fitting, or high­pressure gauge.
1. Close the cylinder valve.
2. Open the valve on the downstream equipment. This drains all pressure from the system.
3. Close the valve on the downstream equipment.
4. Turn the adjusting screw counterclockwise to release the ten sion on the adjusting spring.
5. Check the gauges after a few minutes for verification that the cylinder valve is closed completely.
3.09
When the regulator is not in use and has been removed from the cylinder, it should be stored in an area where it will be pro­tected from dust, oil, and grease. The inlet and outlet should be capped to protect against internal contamination and prevent insects from nesting.

Storage of the Flowmeter/ Regulator

Manual 0-5420 3-5 INSTALLATION, OPERATION AND SETUP
ESAB FABRICATOR 141i
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A-13037
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Art #
A-10355

3.10 Power Source Controls, Indicators and Features

Figure 3-4: Front Panel
Figure 3-5: Rear Panel
INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5420
Figure 3-6: Wire Feed Compartment Control
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.
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.
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.
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
Manual 0-5420 3-7 INSTALLATION, OPERATION AND SETUP
!
CAUTION
Loose welding terminal connections can cause overheating and result in the male
plug being fused in the Dinse connector..
ESAB FABRICATOR 141i
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.
CAUTION
!
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.
Loose welding terminal connections can cause overheating and result in the male plug be­ing fused in the Dinse connector..
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Art # A-10421_AC
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Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Trigger Switch
WV
Remote Volts in MIG (GMAW/FCAW)
Negative
Spool Gun Motor
Positive
Figure 3-7: Remote Control Socket
Socket Pin
1 Spool gun motor (0V)
2
3
4
5
6
7
8
Trigger Switch Input
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.
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Function
Table 3-3
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!
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.
INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5420
ESAB FABRICATOR 141i
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.
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 3.20 or 3.21 for MIG (GMAW/ FCAW) set up details, section 3.22 for LIFT TIG (GTAW) set­up details or section 3.23 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.
Manual 0-5420 3-9 INSTALLATION, OPERATION AND SETUP
ESAB FABRICATOR 141i
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.
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 3.19 to 3.20 for MIG (FCAW/GMAW) set up details.
WARNING
!
Only Welding Shielding Gases specifically designed for arc welding applications should be used.
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 and the internal elec­trical components are at Mains voltage potential.
17. Intelligent Fan Control
When Power Supply is first turned on it will default in MIG Mode. The Fan will operate for approximately 10 seconds, then shut down.
When triggered in MIG mode, fan will not turn on until Power Supply reaches temperatures in which cooling is required. When in Lift TIG mode, as soon as output is enabled, the fan will come on immediately and will not shut down until welding has ceased and Power Supply is at proper operat­ing temperature. When set to Stick mode, fan will turn on immediately and will not turn off until welding has ceased and Power Supply is at proper operating temperature.
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).
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 the spool gun motor and internal motor.
INSTALLATION, OPERATION AND SETUP 3-10 Manual 0-5420
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