ESAB Fabricator 181i Service Manual

A-12919

3163339

ESAB Fabricator® 181i

3-IN-1 Multi Process Welding Systems

Service Manual

Révision : AA Issue Date: September 18, 2015 Manual No.: 0-5449

180

esab.com

WE APPRECIATE YOUR BUSINESS!

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

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

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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® 181i 3-in-1 Multi Process Welding Systems™ Operating Manual Number 0-5449

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 18, 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

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

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

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

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

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

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

2.07 Fabricator 181i Portable System Package (Part No. W1003181) .................... 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 Volt-Ampere Curves ........................................................................................ 3-7

SECTION 4:

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

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

4.02 Attaching the Tweco Fusion 180A Gun ............................................................ 4-7

4.03 Torch Adapter Thumb Screw Replacement .................................................... 4-8

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

4.05 Installing 8" (200mm) Diameter Spool .......................................................... 4-10

4.06 Inserting Wire into the Wire Feed Mechanism .............................................. 4-11

4.07 Feed Roller Pressure Adjustment .................................................................. 4-12

4.08 Changing the Feed Roll ................................................................................. 4-12

4.09 Wire Reel Brake ............................................................................................ 4-13

4.10 Gas Regulator Operation ............................................................................... 4-13

4.11 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 4-14

4.12 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire .................... 4-15

4.13 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 4-17

4.14 Setup for LIFT TIG (GTAW) Welding ............................................................. 4-17

4.15 Setup for STICK (SMAW) Welding .............................................................. 4-19

4.16 Leak Testing the System ............................................................................... 4-20

SECTION 5:

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

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

TABLE OF CONTENTS

SECTION 6:

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

6.01 Basic Troubleshooting-Power Source Faults ................................................... 6-1

6.02 Checking Unit Before Applying Power ............................................................ 6-2

6.03 Tools Needed for Troubleshooting and Servicing ............................................ 6-2

6.04 Case Removal ................................................................................................. 6-3

6.05 Clear Cover Sheet Removal ............................................................................. 6-4

6.06 Visually Inspect ............................................................................................... 6-4

6.07 Preliminary DC Bus Measurement of the Main Inverter Board ........................ 6-4

6.08 Preliminary Check of the Main Inverter Board ................................................ 6-5

6.09 Check Main On / Off Switch ............................................................................ 6-7

6.10 Check Main Input Rectiﬁer .............................................................................. 6-7

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

6.12 PCB Connectors .............................................................................................. 6-9

6.13 DIP Switch Settings, Control PCB ................................................................. 6-14

6.14 Calibration .................................................................................................... 6-15

6.15 Main Circuit Description ............................................................................... 6-18

6.16 Circuit Diagram ............................................................................................. 6-20

SECTION 7:

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

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

7.02 Control Board Removal ................................................................................... 7-1

7.03 Front Panel Assembly Removal ...................................................................... 7-3

7.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal ....................... 7-5

7.05 Back Panel Removal ....................................................................................... 7-6

7.06 Power Switch S1 and Power Cord Removal ................................................... 7-7

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

SECTION 8:

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

8.01 Installing Base Board ...................................................................................... 8-1

8.02 Installing Back Panel ....................................................................................... 8-2

8.03 Installing Front Panel ...................................................................................... 8-4

8.04 Installing Main Control Panel and Clear Cover Sheet ...................................... 8-6

8.05 Installing Case ................................................................................................ 8-7

SECTION 9:

KEY SPARE PARTS ................................................................................... 9-1

9.01 Tweco WeldSkill 180A MIG Gun (Used until February 2013) .......................... 9-1

9.02 Tweco Fusion 180A MIG Gun Parts ................................................................ 9-2

9.03 Power Source ................................................................................................. 9-3

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 181i

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 0-5449 1-1 SAFETY INSTRUCTIONS AND WARNINGS

ESAB FABRICATOR 181i

WARNING

ELECTRIC SHOCK - Can kill.

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

cable standards.

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

ing.

- 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 RAYS - 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 0-5449

Read and understand the instruction manual before installing or operating.

!

SECTION 2:

!

INTRODUCTION

ESAB FABRICATOR 181i

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

!

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 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.

2.02 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

The ESAB Fabricator 181i 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 181i 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 0-5449 2-1 INTRODUCTION

ESAB FABRICATOR 181i

!

2.05 Transportation Methods

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.

WARNING

Disconnect input power conductors from de-energized supply line before moving the welding Power Source.

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 181i Portable System Package (Part No. W1003181)

INTRODUCTION 2-2 Manual 0-5449

A-12920

ESAB FABRICATOR 181i

Duty Cycle (percentage)

100

Welding Current (amps)

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, 180 amperes at 23 volts. This means that it has been designed and built to provide the rated amperage (180 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.

90

80

70

60

50

40

30

20

Safe

Operating

Region

TIG (GTAW)

MIG (GMAW/FCAW)

STICK (SMAW)

10

0

20 40 60

80 100

120 140 160 180

A-10352

Figure 3-1: Fabricator 181i Duty Cycle

Manual 0-5449 3-1 SAFETY AND INSTALLATION

ESAB FABRICATOR 181i

3.02 Speciﬁcations

DESCRIPTION FABRICATOR 181i MULTI PROCESS 3 IN 1 WELDER

Power Source Part No. W1003180

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

Power Source Mass 32.2lb(14.6kg)

Cooling Fan Cooled

Welder Type Multi Process Welding System

Output Terminal Type DinseTM 50

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

Number of Phases Single Phase

Nominal Supply Voltage 230V AC

Supply Voltage Range 208-265V AC

Supply Frequency 50/60Hz

Welding Current Range (MIG Mode) 10-180A

Wirefeed Speed Range 100 - 650 IPM

MIG Welding Voltage Range 14.5 - 23V DC

Nominal OCV 62V DC

Effective Input Current (I for MIG (GMAW/FCAW) for LIFT TIG (GTAW) for STICK (SMAW)

Maximum Input Current (I for MIG (GMAW/FCAW) for LIFT TIG (GTAW) for STICK (SMAW)

1eff

)

1max

15.9 Amps

14.3 Amps

17.2 Amps

)

35.6 Amps

28.6 Amps

35.7 Amps

Single Phase Generator Requirement 9 KVA

MIG (GMAW/FCAW) Welding Output at 104°F (40°C)

180A @ 20%, 23V 113A @ 60%, 19.7V 88A @ 100%, 18.4V

STICK (SMAW) Welding Output at 104°F (40°C).

175A @ 20%, 27V

101A @ 60%, 24V 78A @ 100%, 23.1V

LIFT TIG (GTAW) Welding Output at 104°F (40°C).

175A @ 25%, 17V 113A @ 60%, 14.5V 88A @ 100%, 13.5V

Protection Class IP23S

SAFETY AND INSTALLATION 3-2 Manual 0-5449

Table 3-1: Fabricator 181i Speciﬁcation

ESAB FABRICATOR 181i

NOTE!

The recommended time delay fuse or circuit breaker size is 50 amp. An individual branch circuit capable of carrying 50 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) Tweco 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 0-5449 3-3 SAFETY AND INSTALLATION

ESAB FABRICATOR 181i

!

3.05 Ventilation

WARNING

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

3.06 Electricity Supply Voltage

WARNING

!

The Fabricator 181i must be electrically connected by a qualiﬁed electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 265 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.

ventilated.

WARNING

The Electricity Supply voltage should be within 208-265V 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 3-2.

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 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 qualiﬁed 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 t 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.

50 / 60 Hz Single Phase Supply

Supply Voltage 230V AC

Input Current at Maximum Output 35.7 Amps

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

Minimum Recommended Input Cable Size 12 AWG

Maximum Recommended Input Conductor Length 50 ft (15m)

Minimum Recommended Grounding Conductor Size 12 AWG

50 Amps

SAFETY AND INSTALLATION 3-4 Manual 0-5449

Table 3-2: Electrical Service Guide

ESAB FABRICATOR 181i

!

NOTE! Arc outages may occur while welding on 208 VAC or using Extension cords in Stick mode.

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 265V AC or higher is applied to the Primary Power Cord.

Model

Fabricator 181i

Primary Supply

Cord Size

(Factory Fitted)

12 AWG (3.3mm²)

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

Minimum Primary

Current Circuit Size

(Vin/Amps)

MIG (GMAW/

FCAW)

Current & Duty Cycle

STICK (SMAW)

LIFT TIG

(GTAW)

208-230V/40A 180A @ 20% 175A @ 20% 208-230V/25A 175A @ 25%

3.07 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding 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 Trouble-some.

NOTE!

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorised 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).

Source is used in a domestic situation.

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 pace-makers 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 immunity 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.

Manual 0-5449 3-5 SAFETY AND INSTALLATION

ESAB FABRICATOR 181i

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. Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interfer-

ence occurs, it may be necessary to take additional precautions such as ﬁltering of the mains 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 its 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 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 recommendation

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 Work Piece

Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g.

ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct connection to the work piece, 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 interfer-

ence. Screening the entire welding installation may be considered for special applications.

SAFETY AND INSTALLATION 3-6 Manual 0-5449

ESAB FABRICATOR 181i

Art # A-11296

3.08 Volt-Ampere Curves

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

Manual 0-5449 3-7 SAFETY AND INSTALLATION

Figure 3-2: Fabricator 181i Volt-Ampere Curves

ESAB FABRICATOR 181i

This Page Intentionally Blank

SAFETY AND INSTALLATION 3-8 Manual 0-5449

SECTION 4:

1

2

3

4

5

7

8

11

12

13

14

A-13038

6

9

10

15

16

18

OPERATION

4.01 Power Source Controls, Indicators and Features

ESAB FABRICATOR 181i

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

19

Figure 4-3: Wire Feed Compartment Control

Art #

20

21

A-10355

Manual 0-5449 4-1 INTRODUCTION

ESAB FABRICATOR 181i

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 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 Adaptor (Tweco Style)

The MIG Gun adaptor is the connection point for the Tweco Gun. Connect the MIG Gun by pushing the MIG Gun connector into the brass MIG Gun Adaptor ﬁrmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment to secure the Tweco MIG Gun in position. Failure to properly lock the Tweco MIG Gun into the MIG Gun Adapter will result in the Tweco MIG Gun being pushed out of the MIG Gun Adapter 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 this heavy duty bayonet type terminal. It is essential, however, that the male plug is 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 bayonet terminal.

INTRODUCTION 4-2 Manual 0-5449

ESAB FABRICATOR 181i

W/FCAW) mode

Remote Amps in LIFT TIG (GTAW) mode

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 male plug is 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 this heavy duty bayonet type terminal. It is essential, however, that the male plug is 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 bayonet terminal.

CAUTION

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

8. Remote Control and Spool Gun Socket

The 8 pin socket is used to connect the Tweco 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

2

1

5

4

8

7

Art # A-10421_AC

1 2

3 4

3

6

Figure 4-4: Remote Control Socket

5

6

7

8

Remote Wirespeed in MIG (GMA

Trigger Switch

WV

Function

Remote Volts in MIG (GMAW/FCAW)

Negative

Spool Gun Motor

Positive

1 Spool gun motor (0V)

2

3

Trigger Switch Input

4

5

6

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.

7

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

8

Manual 0-5449 4-3 INTRODUCTION

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

Table 4-1

ESAB FABRICATOR 181i

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.

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.

INTRODUCTION 4-4 Manual 0-5449

ESAB FABRICATOR 181i

!

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!

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. Thermal Overload 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. Should the thermal overload 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.

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 MIG (FCAW/GMAW) set up details.

WARNING

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

Manual 0-5449 4-5 INTRODUCTION

ESAB FABRICATOR 181i

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

17. Intelligent Fan Control

The Fabricator 181i 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 (Control No. 8). 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).

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 functionality and Spool Gun functionality

21. 10A Fuse

The 10A fuse is used to protect the spool gun motor.

INTRODUCTION 4-6 Manual 0-5449

ESAB FABRICATOR 181i

Art #

A-10356_AB

MIG Gun Adaptor

MIG Gun Connector

Thumb Screw

8 pin socket

8 pin plug

4.02 Attaching the Tweco Fusion 180A Gun

Fit the Tweco Fusion MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adaptor 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 0-5449 4-7 INTRODUCTION

ESAB FABRICATOR 181i

A-12958

Screws

Securing Block

Art # A-11483

Art # A-11484

Pressure Arm

Tension Knob

Art # A-11485_AB

Thumb Screw Fully Exposed

Push Upward

4.03 Torch Adapter Thumb Screw Replacement

1. Place unit on its back.

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

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

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

INTRODUCTION 4-8 Manual 0-5449

ESAB FABRICATOR 181i

Art # A-11486

Art #

A-10357

Friction Washer

4”（100mm） Diameter spool

Nut with Nylon Insert

Spring

Plastic Spacer

Brass Flat Washer

Flat Washer

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

6. To reassemble, reverse steps 1 through 4.

4.04 Installing 4" (100mm) Diameter Spool

As delivered from the factory, the Power Source is ﬁtted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to ﬁt a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 4-6. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake. The brake is correctly adjusted when the spool stops within 3/8(10mm) to 3/4(20mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without becoming dislodged from the spool.

CAUTION

!

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

Manual 0-5449 4-9 INTRODUCTION

Figure 4-6: 4" (100mm) Diameter Spool Installation

ESAB FABRICATOR 181i

Art #

A-10358

Spring

Nut with Nylon Insert

8” (200mm) diameter spool

Spool Hub Nut

Alignment pin

Brass Flat Washer

Wire Spool Hub

Friction Washer

Plastic Spacer

Flat Washer

Alternate Alignment Pin Position

4.05 Installing 8" (200mm) Diameter Spool

As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool. In order to re-ﬁt a 8" (200mm) spool assemble parts in the sequence shown below in Figure 4-7. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake. The Brake is correctly adjusted when the spool stops within 3/8" (10mm) to 3/4" (20mm) (measured at the outer edge of the spool) after MIG Gun trigger is released. Wire should be slack without becoming dislodged from the spool.

CAUTION

!

NOTE!

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

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

Figure 4-7: 8" (200mm) Diameter Spool Installation

INTRODUCTION 4-10 Manual 0-5449

ESAB FABRICATOR 181i

Art #

A-10359_AB

Outlet Guide

Inlet Guide

Wire Drive Tension Screw

Pressure Roller Arm

4.06 Inserting Wire into the Wire Feed Mechanism

Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in an counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 4-8). With the MIG welding wire feeding from the bottom of the spool (Figure 4-9) 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 4-8). Remove the 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 make sure the Electricity Supply is switched off. 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..

Figure 4-8: Wire Drive Assembly Components

Art #

MIG Welding Wire

Figure 4-9: MIG Welding Wire - Installation

A-10360

Manual 0-5449 4-11 INTRODUCTION

ESAB FABRICATOR 181i

4.07 Feed Roller Pressure Adjustment

The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal ﬂakes and swarf. If it is not the cause of slipping, the feed roll pressure can be increased by rotating the pressure screw clockwise.

WARNING

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

CAUTION

!

4.08 Changing the Feed Roll

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

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

GROOVE “B”GROOVE “A”

GROOVE “B” SIZE

Figure 4-10: Dual Groove Feed Roller

Feed Roll

Retaining Screw

Feed Roll

GROOVE “A” SIZE

Art #

A-09584_AC

A-09583

INTRODUCTION 4-12 Manual 0-5449

Figure 4-11: Changing the Feed Roll

ESAB FABRICATOR 181i

Wire Reel Brake Adjustment Nut

Art #

A-10361

4.09 Wire Reel Brake

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

CAUTION

!

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

Figure 4-12: Wire Reel Brake

4.10 Gas Regulator Operation

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

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

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

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

Adjusting Flow Rate

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

1. Adjust the gas ﬂow rate. The recommended rate for MIG welding is 28-46 CFH. The recommended rate for LIFT TIG welding is 10-28 CFH.

NOTE!

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

Shutdown

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

1. Close cylinder or upstream valve tightly.

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

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

4. Before transporting cylinders that are not secured on a cart designed for such purposes, remove regulators.

Manual 0-5449 4-13 INTRODUCTION

ESAB FABRICATOR 181i

!

Art #

A-10362

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

connection

Primary Cord

Work Lead

Negative Welding Terminal (-)

Positive Welding Terminal (+)

MIG Gun Polarity Lead

MIG Gun

8 pin Plug

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

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

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

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

turer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Fit the MIG Gun to the Power Source. (Refer to section Attaching the Tweco Fusion 180A Gun).

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

current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

E. Fit the gas regulator/ﬂow gauge to the shielding gas cylinder (refer to Section 4.09) then connect the shielding gas hose

from the rear of the Power Source to the regulator/ﬂow gauge outlet.

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

G. Switch the LOCAL/REMOTE switch inside the

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

H. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

!

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched off. Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

CAUTION

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

INTRODUCTION 4-14 Manual 0-5449

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

ESAB FABRICATOR 181i

!

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

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

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

turer. Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

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

current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

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

E. Switch the LOCAL/REMOTE switch inside the

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

F. Switch the MIG GUN/SPOOL GUN switch inside

the wire feed compartment to MIG GUN.

WARNING

Before connecting the work clamp to the work make sure the Electricity Supply is switched off.

CAUTION

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

Manual 0-5449 4-15 INTRODUCTION

ESAB FABRICATOR 181i

(+)

Positive Welding Terminal

MIG Gun

Negative Welding Terminal (-)

8 pin Plug

MIG Gun Polarity Lead.

Work Lead

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

A-09587_AD

INTRODUCTION 4-16 Manual 0-5449

ESAB FABRICATOR 181i

Art #

A-10363

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

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

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

2. Open side panel and loosen thumb screw.

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

4. Tighten thumb screw and replace side panel.

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

6. Align Control Plug to panel ﬁtting and tighten securely.

4.14 Setup for LIFT TIG (GTAW) Welding

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

B. Connect the TIG Torch to the negative welding terminal (-). Welding current ﬂows from the Power Source via heavy duty

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

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

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

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

TIG torch will require a trigger switch to weld in LIFT TIG Mode.

NOTE!

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

E. Fit the gas regulator/ﬂow gauge to the shielding gas cylinder (refer to Section 4.09) then connect the shielding gas hose

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

Manual 0-5449 4-17 INTRODUCTION

ESAB FABRICATOR 181i

!

Art #

A-10364

MIG Gun polarit not connected

providing remote control of the weld current.

(+)

WARNING

F. Switch the LOCAL/REMOTE switch inside the

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

Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure the Electricity Supply is switched off. Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

CAUTION

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

Positive welding terminal

y lead

.

Work lead

.

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

TIG Torch

Figure 4-15: Setup for TIG Welding

turn the weld current on/o as well as

Connect to shielding gas regulator/ow gauge. Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

Negative welding terminal (- ).

INTRODUCTION 4-18 Manual 0-5449

ESAB FABRICATOR 181i

!

Art #

A-10365

Negative Welding Terminal (-)

Positive Welding Terminal

(+)

Work Lead

Electrode Holder

MIG Gun polarity lead not connected.

4.15 Setup for STICK (SMAW) Welding

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

Welding current ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

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

rent ﬂows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

WARNING

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

C. Switch the LOCAL/REMOTE switch inside the wire

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

holder make sure the Electricity Supply is switched off

CAUTION

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

Manual 0-5449 4-19 INTRODUCTION

Figure 4-16: Setup for Manual Arc Welding.

ESAB FABRICATOR 181i

!

4.16 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 regulator to deliver the maximum required delivery ﬂow rate.

3. Close the cylinder valve. Watch to see if the high pressure or contents gauge drops, if it does you have a leak in the connection between the regulator and the cylinder.

4. 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..

INTRODUCTION 4-20 Manual 0-5449

ESAB FABRICATOR 181i

SECTION 5:

THEORY OF OPERATION

5.01 Inverter Design

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

Inverter Technology - Summary

Rectiﬁer Filter IGBT Transformer Rectiﬁer Inductor

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

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

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

Art # A-09846

Manual 0-5449 5-1 THEORY OF OPERATION

ESAB FABRICATOR 181i

This Page Intentionally Blank

THEORY OF OPERATION 5-2 Manual 0-5449

SECTION 6:

TROUBLESHOOTING

6.01 Basic Troubleshooting-Power Source Faults

The following table is a guide for analysing problems and making repairs to the Power Source.

FAULT CAUSE REMEDY

1 Electricity Supply is

ON, power indicator is illuminated however the Power Source will not commence welding.

A Power Source is not in the

correct mode of operation.

B Faulty torch trigger. B Repair or replace torch trigger

ESAB FABRICATOR 181i

A Set the Power Source to the

correct mode of operation with the process selection switch.

switch/lead.

2 Fault Indicator is

illuminated and the Power Source will not commence welding.

3 The Power Source will not

feed wire in MIG mode.

4 Welding wire continues to

feed when torch trigger is released.

5 Welding arc cannot be

established in MIG mode.

Duty cycle of Power Source has been exceeded.

A Electrode wire stuck in conduit

liner or contact tip (burn-back jam).

B MIG GUN/SPOOL GUN switch

is switched to SPOOL GUN.

A Trigger mode selection switch

is in 4T latch mode.

B Torch trigger leads shorted. B Repair or replace torch trigger

A MIG Gun polarity lead is not

connected into a welding output terminal.

Leave the Power Source switched ON and allow it to cool. Note that fault indicator must be extinguished prior to commencement of welding.

A Check for clogged / kinked MIG

Gun conduit liner or worn contact tip. Replace faulty components.

B Switch the MIG GUN/SPOOL GUN

switch to MIG GUN.

A Change the trigger mode selection

switch from 4T latch mode to 2T normal mode.

switch/lead.

A Connect the MIG Gun polarity

lead to either the positive welding output terminal or the negative welding output terminal as required.

6 Inconsistent wire feed. A Worn or dirty contact tip. A Replace if necessary.

7 No gas ﬂow in MIG mode. A Gas hose is damaged. A Replace or repair.

Manual 0-5449 6-1 TROUBLESHOOTING

B Poor or no work lead contact. B Clean work clamp area and ensure

good electrical contact.

B Worn feed roll. B Replace.

C Excessive brake tension on

wire reel hub.

D Worn, kinked or dirty conduit

liner

B Gas passage contains

impurities.

C Gas regulator turned off. C Turn on regulator.

D Empty gas cylinder. D Replace gas cylinder.

C Reduce brake tension on spool

hub

D Clean or replace conduit liner

B Disconnect gas hose from the rear

of Power Source and blow out impurities.

ESAB FABRICATOR 181i

!

8 Gas ﬂow continues after

the torch trigger switch has been released (MIG mode).

9 Power indicator will not

illuminate and welding arc cannot be established.

10 TIG electrode melts when

arc is struck.

11 Arc ﬂutters during TIG

welding.

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

The mains supply voltage has exceeded voltage limits of the Power Source.

TIG Torch is connected to the (+) weld terminal.

Tungsten electrode is too large for the welding current.

Table 6-1 Power Source Faults

6.02 Checking Unit Before Applying Power

WARNING

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

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

Have an accredited ESAB service provider repair or replace gas valve.

Ensure that the mains supply voltage is within 208/230VAC ±15%

Connect the TIG Torch to the (-) VE terminal.

Select the correct size of tungsten electrode. Refer to Table 4-7 in the operating manual.

WARNING

Check DC bus voltage according to Section 6.07 after removing case.

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

6.03 Tools Needed for Troubleshooting and Servicing

Art # A-09849

TROUBLESHOOTING 6-2 Manual 0-5449

6.04 Case Removal

Lossen Screws Front & Rear

1

2

Art # A-10457_AB

CAUTION

!

1. Cover

Read and follow safety information in Section 6.02 before proceeding.

ESAB FABRICATOR 181i

Remove Screws

Art # A-10456

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

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

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

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

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

2. Ground screw

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

Manual 0-5449 6-3 TROUBLESHOOTING

ESAB FABRICATOR 181i

1

Art # A-10458

!

6.05 Clear Cover Sheet Removal

CAUTION

!

1. Clear protective sheet

Take out clear protective sheet.

Read and follow safety information in Section 6.02 before proceeding.

6.06 Visually Inspect

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

a) Loose or broken wires or connectors.

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

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

If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components used in the Power Source. Locate the faulty component(s) then replace where necessary.

6.07 Preliminary DC Bus Measurement of the Main Inverter Board

Read and follow safety information in Section 6.02 before proceeding.

DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF

Upper capacitor bank

Lower capacitor bank

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

Positive meter lead to testpoint 3

Negative meter lead to testpoint 4

Table 6-2 DC BUS, Multimeter set to measure DC volts

0 VDC

TROUBLESHOOTING 6-4 Manual 0-5449

6.08 Preliminary Check of the Main Inverter Board

4

3

1

2

5

6

7

8

10

9

12

11

14

13

16

15

17

18

19

20

21

22

A-09988

CAUTION

!

Read and follow safety information in Section 6.02 before proceeding.

ESAB FABRICATOR 181i

Output Diode Testing Multimeter Lead Placement Diode Voltage

Left Output Diodes

Right Output Diodes

Table 6-3 Output Diodes, Multimeter set to measure Diode Voltage

IGBT Testing Multimeter Lead Placement Diode Voltage

IGBT 1

IGBT 2

IGBT 3

IGBT 4

Manual 0-5449 6-5 TROUBLESHOOTING

Positive meter lead to testpoint 5

Negative meter lead to testpoint 6

Positive meter lead to testpoint 7

Negative meter lead to testpoint 8

Positive meter lead to testpoint 9

Negative meter lead to testpoint 10

Positive meter lead to testpoint 11

Negative meter lead to testpoint 12

Positive meter lead to testpoint 13

Negative meter lead to testpoint 14

Positive meter lead to testpoint 15

Negative meter lead to testpoint 16

Table 6-4 IGBT’s, Multimeter set to measure Diode Voltage

0.2 – 0.8 VDC

ESAB FABRICATOR 181i

4

3

1

2

5

6

7

8

10

9

12

11

14

13

16

15

17

18

19

20

21

22

A-09988

IGBT Testing Multimeter Lead Placement Impedance

IGBT 1

IGBT 2

IGBT 3

IGBT 4

Positive meter lead to testpoint 17

Negative meter lead to testpoint 9

Positive meter lead to testpoint 18

Negative meter lead to testpoint 11

Positive meter lead to testpoint 19

Negative meter lead to testpoint 13

Positive meter lead to testpoint 20

Negative meter lead to testpoint 15

Table 6-5 IGBT’s, Multimeter set to measure ohms (Ω)

150 to 350 Ω

Inrush PTC Multimeter Lead Placement Impedance

PTC

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

TROUBLESHOOTING 6-6 Manual 0-5449

Positive meter lead to testpoint 21

Negative meter lead to testpoint 22

0 to 100 Ω

6.09 Check Main On / Off Switch

ESAB FABRICATOR 181i

24

23

2526

Art # A-10459

Power Switch Testing Multimeter Lead Placement Impedance

Switch ON

Switch OFF

Table 6-7 Power Switch, Multimeter set to measure ohms (Ω)

6.10 Check Main Input Rectiﬁer

Input Rectiﬁer Testing Multimeter Lead Placement Diode Voltage

AC1 to DC+

AC2 to DC+

AC1 to DC-

AC2 to DC-

Table 6-8 IGBT’s, Multimeter set to measure Diode Voltage

Positive meter lead to testpoint 23

Negative meter lead to testpoint 24

Positive meter lead to testpoint 25

Negative meter lead to testpoint 26

Positive meter lead to testpoint 23

Negative meter lead to testpoint 24

Positive meter lead to testpoint 25

Negative meter lead to testpoint 26

Positive meter lead to AC1

Negative meter lead to testpoint DC+

Positive meter lead to AC2

Negative meter lead to testpoint DC+

Positive meter lead to testpoint DC-

Negative meter lead to testpoint AC1

Positive meter lead to testpoint DC-

Negative meter lead to testpoint AC2

0 to 1 Ω

> 1k Ω

0.2 – 0.8 VDC

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

Manual 0-5449 6-7 TROUBLESHOOTING

ESAB FABRICATOR 181i

4

3

1

2

5

6

7

8

10

9

12

11

14

13

16

15

17

18

19

20

21

22

A-09988

6.11 DC Bus Voltage Measurement

Apply voltage to the Power Source.

WARNING

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

DC Bus Testing Multimeter Lead Placement Voltage with Supply Voltage OFF

Upper capacitor bank

Lower capacitor bank

Overall capacitor bank

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

Positive meter lead to testpoint 3

Negative meter lead to testpoint 4

Positive meter lead to testpoint 1

Negative meter lead to testpoint 4

Table 6-9 DC BUS, Multimeter set to measure DC volts

Note: These DC voltages are at nominal mains supply voltage of 230VAC.

TROUBLESHOOTING 6-8 Manual 0-5449

161 VDC +/-10%

322 VDC +/-10%

6.12 PCB Connectors

AC1

AC2

CIN1

TR1

CIN2

CY1

CU3

CU4

T2

T1

R24

R25

IN

DY2

DY1

R29

R28

T5

T4

NTCS

PWM

W05

W02

MD

C21

C20

C17

C23

C16

C18

C24

C19

COUT2

COUT1

OUT-

OUT+

T20-1

T13-1

T14-1T15-1

R100R102

C100

T16-1

T17-1

T18-1T19-1

R101R103

C101

PTC

DC+

DC-

J1

TR8

QF/FJ

GAS

A-09990

1 Inverter PCB

ESAB FABRICATOR 181i

IN Header Pin Pin function Signal

1 +15V 15 VDC 2 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk 3 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk 4 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk 5 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk

6 Rectiﬁed secondary of current transformer TR8 15 VDC pk 7 0V 0 VDC

Table 6-10 IN Header pin function (connects to DRIVE header on control PCB)

PWM Header Pin Pin function Signal

1 0VDC 0 VDC 2 Motor pwm drive signal 5 VDC pk

Table 6-11 PWM Header pin function (connects to PWM header on control PCB)

MD Header Pin Pin function Signal

1 Motor positive 24 VDC

2 Motor negative 0 VDC

Table 6-12 MD Header pin function (connects to motor)

Manual 0-5449 6-9 TROUBLESHOOTING

ESAB FABRICATOR 181i

Imin

IFB

PWM

Vmin

MB

GUN

QF/DY

WVIN

IGBT OT

NTCS

FUNs

SOURCE CRSOURCE

DRIVE

Imax

W2

WVF

A

SW0

A-09991

NTCS Header Pin Pin function Signal

1 +24V 24 VDC 2 0V 0 VDC

Table 6-13 NTCS Header pin function (connects to NTCS header on control PCB)

DY2 Header Pin Pin function signal

1 +24V 24 VDC 2 0V 0 VDC 3 -24V -24 VDC

Table 6-14 DY2 Header pin function (connects to SOURCE header on control PCB)

DY1 Header Pin Pin function signal

1 +24V (solenoid positive) 24 VDC 2 0V 0V 3 No connection n/c 4 +24V (solenoid positive) 24 VDC 5 Solenoid negative 0 VDC

Table 6-15 DY1 Header pin function

QF/FJ Header Pin Pin function signal

GAS Header Pin Pin function signal

2 Control PCB

1 +24V (VRD positive, South Paciﬁc Version Only) 24 VDC 2 Solenoid negative 0 VDC 3 +24V (solenoid positive) 24 VDC 4 0V 0 VDC

Table 6-16 QF/FJ Header pin function (Connects to QF/DY header on control PCB)

1 +24V (solenoid positive) 24 VDC 2 Solenoid negative 0 VDC

Table 6-17 GAS Header pin function (connects to Solenoid)

TROUBLESHOOTING 6-10 Manual 0-5449

ESAB FABRICATOR 181i

GUN Header Pin Pin function Signal

1 +24V trigger positive (0V when trigger closed) 24 VDC 2 0VDC 0 VDC

Table 6-18 GUN Header pin function (connects to GUN header on display PCB)

PWM Header Pin Pin function Signal

1 0VDC 0 VDC 2 Motor pwm drive signal 5 VDC pk

Table 6-19 PWM Header pin function (connects to PWM header on inverter PCB)

QF/DY Header Pin Pin function Signal

1 +24V (VRD positive, South Paciﬁc Version Only) 24 VDC 2 Solenoid negative 0 VDC 3 +24V (solenoid positive) 24 VDC 4 0V 0 VDC

Table 6-20 QF/FJ Header pin function (Connects to QF/FJ header on inverter PCB)

FUNs Header Pin Pin function Signal

1 +24V (Fan positive) 24 VDC 2 0V (Fan negative) when fan is on 0 VDC

Table 6-21 FUNs Header pin function (not used)

DRIVE Header Pin Pin function Signal

1 +15V 15 VDC 2 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk 3 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk 4 IGBT 2 pwm drive signal, 15V p-p square wave 15 VDC pk 5 IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk 6 Rectiﬁed secondary of current transformer TR8 15 VDC pk 7 0V 0 VDC

Table 6-22 DRIVE Header pin function (connects to IN header on inverter PCB)

WVIN Header Pin Pin function Signal

1 Positive welding terminal positive VDC 2 No connection n/c 3 Negative welding terminal 0 VDC

Table 6-23 WVIN Header pin function

IFB Header Pin Pin function Signal

1 +15V 15 VDC 2 -15V -15 VDC 3 Current sensor signal 4 0V 0 VDC

Table 6-24 IFB Header pin function (Connects to welding output current sensor)

Manual 0-5449 6-11 TROUBLESHOOTING

ESAB FABRICATOR 181i

J12

Volts/Downslope / Arcforce

GUN1

GUN

R-G

J11

REMOTE

Amps

Inductance

JC

J1

A-09992

SOURCE Header Pin Pin function Signal

1 +24V 24 VDC 2 0V 0 VDC 3 -24V -24 VDC

Table 6-25 SOURCE Header pin function (connects to DY2 header on control PCB)

CR Header Pin Pin function Signal

1 +5V 5 VDC 2 Wiper 10k Burnback potentiometer 0 – 5 VDC 3 0V 0 VDC

Table 6-26 CR Header pin function (connects to 10k Burnback potentiometer)

IGBT OT Header Pin Pin function signal

1 Igbt thermostat (0VDC when thermostat closed) VDC 2 0V 0 VDC

Table 6-27 IGBT OT Header pin function (connects to igbt thermostat)

NTCS Header Pin Pin function Signal

1 +24V 24 VDC 2 0V 0 VDC

Table 6-28 NTCS Header pin function (connects to NTCS header on inverter PCB)

MB Header Pin Pin function Signal

3 Display PCB

1 Serial display data & eprom (D-IN) 5 VDC digital 2 Serial display data (LOAD) 5 VDC digital 3 Serial display data (CLK) 5 VDC digital 4 2T/4T pushbutton (0V when button pushed) 0VDC 5 Serial display eprom (D-OUT) 5 VDC digital 6 Stick mode (used for remote / local) 7 Chip select 5 VDC digital 8 MODE pushbutton (0V when button pushed) 0VDC

9 15VDC 15 VDC 10 Remote / Local switch 11 Inductance pot terminal 2 12 Volts setpoint 0 – 5 VDC 13 Inductance pot terminal 1 14 Amps setpoint 0 – 5 VDC 15 5VDC 5 VDC 16 0V 0 VDC

Table 6-29 MB Header pin function (connects to J12 header on display PCB)

TROUBLESHOOTING 6-12 Manual 0-5449

ESAB FABRICATOR 181i

GUN Header Pin Pin function Signal

1 +24V trigger positive (0V when trigger closed) 24 VDC 2 0VDC 0 VDC

Table 6-30 GUN Header pin function (connects to GUN header on control PCB)

GUN1 Header Pin Pin function Signal

1 +24V trigger positive (0V when trigger closed) 24 VDC 2 0VDC 0 VDC

Table 6-31 GUN Header pin function (connects to front panel torch trigger terminals)

REMOTE Header Pin Pin function Signal

1 Remote switch 2 Remote switch

Table 6-32 REMOTE Header pin function (connects to remote switch)

J1 & J11 Header Pin Pin function Signal

1 Serial display data & eprom (D-IN) 5 VDC digital 2 Serial display data (LOAD) 5 VDC digital 3 Serial display data (CLK) 5 VDC digital 4 2T/4T pushbutton (0V when button pushed) 0VDC 5 Serial display eprom (D-OUT) 5 VDC digital 6 Stick mode (used for remote / local) 7 Chip select 5 VDC digital 8 MODE pushbutton (0V when button pushed) 0VDC

9 15VDC 15 VDC 10 Remote / Local switch 11 Inductance pot terminal 2 12 Volts setpoint 0 – 5 VDC 13 Inductance pot terminal 1 14 Amps setpoint 0 – 5 VDC 15 5VDC 5 VDC 16 0V 0 VDC

Table 6-33 J1 Header pin function (connects to J11 header on display PCB)

R-G Header Pin Pin function Signal

1

2 +24V trigger positive (0V when trigger closed) 24 VDC

3 0VDC 0 VDC

4

5 -12VDC -12 VDC

6 +12VDC +12 VDC

7 Remote amps -12 to +12 VDC

8 Remote volts -12 to +12 VDC

Table 6-34 R-G Header pin function (connects to front panel 8 pin remote socket)

Manual 0-5449 6-13 TROUBLESHOOTING

No connection Fabricator 181i

Spool gun motor negative for Fabricator 141i & 181i)

No connection Fabricator 181i

Spool gun motor positive for Fabricator 141i & 181i)

ESAB FABRICATOR 181i

Imin

IFB

PWM

Vmin

MB

GUN

QF/DY

WVIN

IGBT OT

NTCS

FUNs

SOURCE CRSOURCE

DRIVE

Imax

W2

WVF

A

SW0

A-09993

J1 Header Pin Pin function Signal

1 Serial display data & eprom (D-IN) 5 VDC digital 2 Serial display data (LOAD) 5 VDC digital 3 Serial display data (CLK) 5 VDC digital 4 2T/4T pushbutton (0V when button pushed) 0VDC 5 Serial display eprom (D-OUT) 5 VDC digital 6 Stick mode (used for remote / local) 7 Chip select 5 VDC digital 8 MODE pushbutton (0V when button pushed) 0VDC

9 15VDC 15 VDC 10 Remote / Local switch 11 Inductance pot terminal 2 12 Volts setpoint 0 – 5 VDC 13 Inductance pot terminal 1 14 Amps setpoint 0 – 5 VDC 15 5VDC 5 VDC 16 0V 0 VDC

Table 6-35 J1 Header pin function (connects to MB header on control PCB)

6.13 DIP Switch Settings, Control PCB

1 DIP Switch SW0, control PCB

TROUBLESHOOTING 6-14 Manual 0-5449

A-12583

6.14 Calibration

Imax

1 Calibration

ESAB FABRICATOR 181i

SW0 position Normal Calibration

1 OFF Set to ON for Fabricator 181i 2 OFF Set to ON for Fabricator 181i 3 OFF Set to ON for Fabricator 181i 4 OFF OFF

Table 6-36 SW0 Dip Switch functions

Imin

A

W2

A-09994

Vmin

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

2 Output Current Calibration

Select STICK mode on the front panel. Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0.2V of the measured value. Connect a load to the output terminals. The load should be of a resistance to give 25V at 250A. Set front panel AMPS potentiometer to minimum. Adjust Imin trimpot until output amps is 10A +/- 0.2A Set front panel AMPS potentiometer to maximum. Adjust Imin trimpot until output amps is 175A +/- 1A Recheck settings Set front panel AMPS potentiometer to maximum. Adjust A potentiometer so Amps display reads within 0.5A of the measured value.

3 Output Voltage Calibration

Select MIG mode on the front panel. Remove the load from the output terminals. Set front panel VOLTS potentiometer to minimum. Adjust Vmin trimpot until output volts is 14.0V +/- 0.2V Set front panel VOLTS potentiometer to maximum. Adjust W2 trimpot until output volts is 25V +/- 0.2V Recheck settings

SW0

WVF

Manual 0-5449 6-15 TROUBLESHOOTING

ESAB FABRICATOR 181i

A

B

U0 2pin 6

C

D

E

U0 1pin 1

F

U0 1pin 2

G

U0 1pin 3

0V for wiredrive circuit (R017)

W0 2MIN SPEED

W05MAX SPEED

A-09995

4 Wire Speed Calibration

NOTE: these adjustments are on the wiring side of the main inverter module circuit board.

Select MIG mode on the front panel. Remove the load from the output terminals. Set front panel WIRESPEED (AMPS) potentiometer to minimum. AMPS display should read “30” Adjust W02 trimpot until motor volts is 4.2V +/- 0.2V Set front panel WIRESPEED (AMPS) potentiometer to maximum. AMPS display should read “218” Adjust W05 trimpot until motor volts is 24.7V +/- 0.2V Recheck settings Set SW0-1 to OFF, SW0-1 to ON, SW0-3 to OFF, SW0-4 to ON to disable calibration of output volts & amps, and calibration of wire feed speed and return to normal operation.

5 Wire Speed Testpoint Waveforms

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

Adjust the wirespeed control knob to the max and the digital amperage meter will display a preview value 654.

Now you can measure below waveforms according to different testpoint when turn on the MIG torch trigger switch.

TROUBLESHOOTING 6-16 Manual 0-5449

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

Art # A-11231

ESAB FABRICATOR 181i

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

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

Manual 0-5449 6-17 TROUBLESHOOTING

ESAB FABRICATOR 181i

AC

1

AC

3

+

2

-

4

Q1

TR1

C19

C16 C17

R25

R24

R32

R33

T18-1

T16-1

T14-1

T17-1

T15-1

T13-1

R102

R100

R101

R103

C100

COUT1

COUT2

C18

TRANSFORMER

R39

C20

C21

R38

PRI-A

TR8

DC+

C23

C24

R39- 1

R38- 1

R104

C102

123

WVOUT

C101

R107

R106

123

WVOUT -1

PTC

J1

CIN1 CIN2

CU3CU4 R200

CY1

R200-1

DC-

DC+

AC2

AC1

T19-1

T20-1

OUT -

OUT+

T1

T2

R29

R28

R36

R37

T4

T5

A-09997

6.15 Main Circuit Description

CAUTION

!

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

TROUBLESHOOTING 6-18 Manual 0-5449

ESAB FABRICATOR 181i

The mains supply voltage is connected via a double pole switch to the input rectiﬁer Q1. Overvoltage protection is provided by varistor CY1.

The rectiﬁer output charges the main capacitor bank (C16, C17, C18, C19, C22 and C23) to high voltage. Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

The primary igbt transistors (T1, T2, T4, and T5) switch the transformer primary at high frequency and varying duty cycle. The transformer return wire is taken from the junction of the capacitors C20 and C21 (the voltage at this point is approximately half the DC bus voltage).

Secondary output voltage from the transformer is rectiﬁed by the output diodes (T13, T14, T15, T16, T17, T18, T19, and T20) to DC. This DC is controlled by the PWM of the primary side igbt transistors, and is ﬁltered by an inductor before connecting to the welding output terminals.

A thermal overload device (thermistor) is ﬁxed to the rectiﬁer heatsink. When an over temperature occurs, the control circuit inhibits the trigger, gas solenoid, wire drive system and the welding output. The thermal overload indicator LED on the front panel is illuminated.

The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current, and also detect transformer saturation. The Hall effect current sensor is powered from regulated + & - 15VDC supplies and provides a voltage signal proportional to the output DC welding current to allow the control circuit to regulate welding current.

Manual 0-5449 6-19 TROUBLESHOOTING

ESAB FABRICATOR 181i

CONNECTOR LAYOUT DIAGRAM

DRIVE

PWM

WV

I N

IFB

MB

SOURCE

GUN

QF/DY

OT

FUN

S

CRNTC

S

ON

4

123

Art # A-11230_AC

1 SPOOL GUN (0V)

2 TORCH SWITCH (+24VDC)

3 TORCH SWITCH RIN (0VDC)

4 SPOOL GUN (+24VDC)

5

6 REMOTE CONTROL IN (+15VDC)

7 (REMOTE AMPS/WIRESPEED) POT WIPER

8 (REMOTE VOLTAGE) POT WIPER

FUSE

BLACK

RED

POT1

1

RED

BLK

YEL

BURN BACK PCB 5

3 +24VDC1

1 +12VDC

2 RETURN

Current Sensor

1

6.16 Circuit Diagram

TROUBLESHOOTING 6-20 Manual 0-5449

SECTION 7:

DISASSEMBLY PROCEDURE

7.01 Safety Precautions for Disassembly

WARNING

!

Unplug unit before beginning Disassembly procedure.

7.02 Control Board Removal

!

Remove case (refer to 6.04) before remove control board.

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

Read and follow safety information in Section 6.02 before proceeding.

WARNING

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

ESAB FABRICATOR 181i

2 Disconnect DRIVE harness from DRIVE connector.

3. Disconnect SOURCE harness from SOURCE connector.

4. Disconnect CR harness from CR connector.

5. Disconnect FUNs harness from FUNs connector.

6. Disconnect NTCS harness from NTCS connector.

7. Disconnect IGBT OT harness from IGBT OT connector.

8. Disconnect GUN harness from GUN connector.

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

10. Disconnect WVIN harness from WVIN connector.

11 Disconnect MB harness from MB connector.

12. Disconnect PWM harness from PWM connector.

13. Disconnect IFB harness from IFB connector.

Ensure to unplug all harness from the main control PCB.

Manual 0-5449 7-1 DISASSEMBLY PROCEDURES

ESAB FABRICATOR 181i

7

4

32

1

11

12

10

9

8

13

WVIN

QF/DY

GUN

IGBT OT

6

5

PWMMB

NTCS

FUNs

CR

SOURCE

DRIVE

Art # A-10460

IFB

A-10018

DISASSEMBLY PROCEDURES 7-2 Manual 0-5449

7.03 Front Panel Assembly Removal

!

WARNING

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

1. Screws on front panel

2 Negative output terminal bolts. Unscrew Negative output terminal bolts.

3. Torch cable bolts. Unscrew torch cable terminal bolts.

4. Positive output terminal bolts. Unscrew output terminal bolts.

5. Unplug two red wire harness from PCB as shown in photo on following page.

ESAB FABRICATOR 181i

1

A-12941

3

2

Manual 0-5449 7-3 DISASSEMBLY PROCEDURES

4

ESAB FABRICATOR 181i

A-09965_AB

DISASSEMBLY PROCEDURES 7-4 Manual 0-5449

ESAB FABRICATOR 181i

!

1

A-12940

3

2

7.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal

WARNING

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

1. Remove Control Panel screws.

2 Front Panel PCB.

3. Remote control PCB.

Manual 0-5449 7-5 DISASSEMBLY PROCEDURES

Art # A-10463

ESAB FABRICATOR 181i

!

7.05 Back Panel Removal

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

1. Remove the rear panel screws.

2. Disconnect the gas tube.

3. Disconnect Input Cord ground wire.

4. Disconnect the four wires from the switch.

5. Disconnect FUNS Harness from the control PCB.

11

DISASSEMBLY PROCEDURES 7-6 Manual 0-5449

5

A-12939

ESAB FABRICATOR 181i

!

3

1

4

5

A-12938

A_10006

2

7.06 Power Switch S1 and Power Cord Removal

WARNING

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

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

2. SW1 locking tabs

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

3. Strain relief screws

Remove the two screws from the strain relief.

4. Remove Fan.

5 Input Power Cord ground wire ﬁlter.

Cut the tie-wrap and remove the Ferrite core from the ground wire.

6. Pull the Input Power Cord out. It may be necessary to use a ﬂat blade screw driver against the strain relief tabs, prying outward (Internal side if strain relief) to help remove the cord.

Manual 0-5449 7-7 DISASSEMBLY PROCEDURES

6

ESAB FABRICATOR 181i

!

3

7

8

6

5

4

7.07 Base Panel Removal and Main PCB Disassembly

WARNING

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

1. Remove Wire Feeder Screws.

2. Remove Main PCB assembly Screws.

3. Remove Central Panel Screws.

4. Remove Control PCB.

5. Remove Rectiﬁer.

6. Remove the feet of main PCB assembly.

7. Heatsink on main PCB assembly.

8. Main PCB assembly.

1

2

A-10007

Art # A-10465

DISASSEMBLY PROCEDURES 7-8 Manual 0-5449

8.01 Installing Base Board

4

5

1

1. Main Power PCB assembly.

2. Heatsink on main PCB assembly.

3. Install the feet of main PCB assembly.

4. Install Rectiﬁer.

5. Install Control PCB on main PCB assembly.

6. Install main PCB assembly screws.

7. Install Central Panel Screws.

8. Install Wire Feeder Screws.

ESAB FABRICATOR 181i

SECTION 8:

ASSEMBLY PROCEDURES

3

7

6

2

8

Art # A-11269

Manual 0-5449 8-1 ASSEMBLY PROCEDURES

ESAB FABRICATOR 181i

8.02 Installing Back Panel

1. Install gas inlet.

2. Install ON/OFF switch

3. Install wire cord and 2 screws.

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

5. Reinstall Ferrite core onto Ground Wire.

6. Install fan.

7. Reconnect power ON/OFF switch to terminals on Main Power PCB.

8. Reconnect Ground Wire to ﬁlter PCB.

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

1

4

2

5

3

6

ASSEMBLY PROCEDURES 8-2 Manual 0-5449

ESAB FABRICATOR 181i

7

8

Manual 0-5449 8-3 ASSEMBLY PROCEDURES

9

A-10114

ESAB FABRICATOR 181i

A-12936

8.03 Installing Front Panel

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

2. Place front panel PCB assembly into front panel and install screws.

3. Reconnect torch polarity cable to the torch connector.

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

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

6. Reconnect the red two wired plug into the PCB as shown in the photo on the following page.

A-10015

3

5

4

ASSEMBLY PROCEDURES 8-4 Manual 0-5449

ESAB FABRICATOR 181i

Manual 0-5449 8-5 ASSEMBLY PROCEDURES

A-09965_AB

ESAB FABRICATOR 181i

Art # A-11271

14

6

7

5

4

32

1

11

12

13

8

9

10

8.04 Installing Main Control Panel and Clear Cover Sheet

1. Install 4 screws.

2 Plug harness into DRIVE connector.

3. Plug harness into SOURCE connector.

4. Plug harness into CR connector.

5. Plug harness into FUNs connector

6. Plug harness into NTCs connector.

7. Plug harness into IGBT OT connector .

8. Plug harness into GUN connector.

9. Plug harness into QF/DY connector.

10. Plug harness into WVIN connector.

11 Plug harness into MB connector.

12. Plug harness into PWM connector.

13. Plug harness into IFB connector.

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

14. Install clear protective sheet.

ASSEMBLY PROCEDURES 8-6 Manual 0-5449

8.05 Installing Case

Art # A-10468_AB

1. Install Case.

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

3. Install Screws. Tighten screws.

1

Tighten Screws Front & Rear

ESAB FABRICATOR 181i

Install Screws

2

Manual 0-5449 8-7 ASSEMBLY PROCEDURES

ESAB FABRICATOR 181i

This Page Intentionally Blank

ASSEMBLY PROCEDURES 8-8 Manual 0-5449

ESAB FABRICATOR 181i

Art # A-10370_AB

9

87

6

5

4

3

2

1

SECTION 9:

KEY SPARE PARTS

9.01 Tweco WeldSkill 180A MIG Gun (Used until February 2013)

MIG Gun Part No: WS180TA-12-3035

ITEM PART NO. DESCRIPTION

1 1210-1112 Nozzle

2 1110-1101 Contact Tip

3 1510-1101 Gas Diffuser

4 2042-2053 Microswitch

5 2042-2054 Trigger Lever

6 2042-2055 Trigger Lever Spring

7 2035-2110 Tweco Rear Connector Plug

8 1420-1113 Conduit Assembly 9 WS-354-TA-LC 8- Pin Control Wire

Manual 0-5449 9-1 KEY SPARE PARTS

TWECO WELDSKILL 180A MIG GUN PARTS

ESAB FABRICATOR 181i

9.02 Tweco Fusion 180A MIG Gun Parts

Torch Part No: F180TA-12-3035

Art# A-11672_AB

Item

No.

1 Velocity Nozzle**

2 Velocity Contact Tip**

3 Handle / Trigger Repair Kit F80

4 Conduit Assembly* WS42-3035-15

5A Tweco Rear Connector 350-174H

5

5B Tweco Control Wire 35K-350-1

5C Tweco Control Wire & Plug WS-354-TA-LC

Description Part No.

VNS-50

VNS-50F

VNS-62

VNS-62F

VNS-37

VNS-37F

VNS-75FAS

VTS-23

VTS-30

VTS-35

VTS-40

VTS-45

VTS-364

VTSA-364

VTS-52

VTS-116

VTSA-116

VTS-564

KEY SPARE PARTS 9-2 Manual 0-5449

** Patent Pending

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

9.03 Power Source

ESAB FABRICATOR 181i

A-11243_AC

Art #

31

Manual 0-5449 9-3 KEY SPARE PARTS

ESAB FABRICATOR 181i

FABRICATOR 181i POWER SOURCE SPARE PARTS

ITEM PART NUMBER DESCRIPTION

1 W7004962 PCB,Power,181i 2 W7004963 PCB,Control,181i 3 W7003033 Solenoid,Valve,24VDC 4 W7004970 PCB,Display,181i 5 W7004969 PCB,Remote Interface,181i 6 W7004905 Wiredrive Assy,w/ Motor,181i 7 W7004906 Feedroll retaining thumb screw 8 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed

9 W7004947 Fan,24VDC,4.75"x4.75"x1",181i 10 W7003010 Rectiﬁer Bridge,1000V,50A 11 W7003215 Connector,Gas Inlet,5/8"-18UNF 12 W7004909 Dinse,Socket,181i 13 W7004955 Connector,Dinse,181i 14 W7004942 Socket,8 Pin,w/ Harness 15 W7003053 Switch,On/Off,250V 16 W7004911 CT Sensor,Output,181i 17 W7004912 Wire Hub Assy,181i 18 W7005552 Panel, Front 19 W7005555 Panel, Rear 20 W7004922 Handle,181i 21 W7005554 Side and Top Panels (not shown) 22 W7004966 Adapter,ESAB 4,181i 23 W7004925 Guide,Inlet,.023-.045,181i 24 W7004967 Guide,Outlet,.023-.045,181i 25 W7005553 Panel,Door (not shown) 26 W7004928 Panel,Base,181i 27 870734 Knob,1/4" IDx.72" ODx.9" H 28 W7004972 Knob,1/4" IDx1" ODx0.9" H 29 W7004957 Panel,Front Control,181i 30 W7004953 Push Button Actuator 31 26372003 Screw,Locking,MIG Gun 32 W7004961 Thermistor,NTC,K45 47K,181i 33 W7004940 PCB Burnback Potentiometer 34 W7004968 PCB,Spool Gun,181i 35 W7004979 Fuse Holder,181i 36 W7004982 Fuse,10 Amp 37 9-0025 Power Cord,12AWG,NEMA 6-50P (not shown) 38 W7005550 Label,Setup Chart,181i,English (not shown) 39 W7005551 Label,Setup Chart,181i,French (not shown) 40 W7004960 Inductor,181i (not shown) 41 W7004951 Spool Hub,181i 42 W7004943 Remote/Local Switch, Mig Gun/ Spool Gun Switch, 250V/2A,181i 43 W7004983 Shoulder strap, 181i (not shown)

KEY SPARE PARTS 9-4 Manual 0-5449

ESAB FABRICATOR 181i

SECTION 10:

Options and Accessories

10.01 Options and Accessories

DESCRIPTION PART NUMBER

Tweco WeldSkill 180A MIG Gun, 12ft (3.6m) Length

Tweco Fusion 180A MIG Gun, 12ft (3.6m) Length

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

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

Fabricator 141i-181i Carry Bag

Basic 4 Wheel Cart

Foot Control for remote amperage control when TIG welding

ESAB WeldSkill Auto-Darkening Helmet Skull & Fire (USA Only)

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

Drive Roll .023"- .030" (0.6-0.8mm) V groove for steel & stainless steel wires [Fitted]

Drive Roll .035"/.045" (0.9/1.2mm) V groove for steel & stainless steel wires

Drive Roll .030"-.035" (0.8-0.9mm) U grooved for aluminum wires

Drive Roll .040"-.045" (1.0-1.2mm) U grooved for aluminum wires

Drive Roll .030"-.035" (0.8-0.9mm) V knurled groove for ﬂux cored wires

Drive Roll .045" (1.2mm) V knurled groove for ﬂux cored wire

WS180TA-12-3035

F180TA-12-3035

SG160TA-12-3035

W4013802

W4015301

W4014700

600285

4100-1004

W4014800

7977036

7977660

7977731

7977264

7977732

704277

Stick Lead, 200A, 13ft, 50mm Dinse

Ground Lead, 200A,10ft, 50mm Dinse

Victor Argon Regulator/Flowgauge

Accessory Kit for TIG Torch with 1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina nozzle; short back cap; long back cap

Table 10-1: Fabricator 181i Options and Accessories List

WS200E13

WS200G10

0781-4169

P062900010

Manual 0-5449 10-1 ACCESSORIES

Date Rev Description

09/18/2015 AA Manual release

REVISION HISTORY

ESAB subsidiaries and representative ofﬁces

Europe

AUSTRIA

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

BELGIUM

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

BULGARIA

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

THE CZECH REPUBLIC

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

DENMARK

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

FINLAND

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

FRANCE

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

GERMANY

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

GREAT BRITAIN

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

HUNGARY

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

ITALY

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

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort

Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

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

POLAND

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

PORTUGAL

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

ROMANIA

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

RUSSIA

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

SLOVAKIA

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

SPAIN

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

SWEDEN

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

SWITZERLAND

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

UKRAINE

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

North and South America

ARGENTINA

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

BRAZIL

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

CANADA

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

MEXICO

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

USA

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

Asia/Pacific

AUSTRALIA

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

CHINA

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

INDIA

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

INDONESIA

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

JAPAN

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

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ

Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

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

SOUTH KOREA

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

UNITED ARAB EMIRATES

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

Africa

EGYPT

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

SOUTH AFRICA

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

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

www.esab.eu

Printed in China