A-12919
3163339
ESAB Fabricator® 181i
3-IN-1 Multi Process
Welding Systems
Operating
Manual
180
Révision : AA Issue Date: September 9, 2015 Manual No.: 0-5421
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.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood
the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working
environment within the welding industry.
WARNING
!
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.
Plasma Cutting Power Supply
ESAB Fabricator® 181i 3-in-1 Multi Process Welding Systems™
Operating Manual Number 0-5421
Published by:
ESAB
2800 Airport Rd.
Denton, TX 76208
www.esab.com
Copyright 2015 by ESAB
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.
Original Publication Date: September 9, 2015
Revision Date:
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________
Purchase Date:__________________________________ __________
Power Supply Serial #:___________________________ __________
Torch Serial #:___________________________________ __________
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar
with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc
Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to
install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be
sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be
used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service
advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,
faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
SECTION 1: SAFETY ........................................................................................ 1-1
1.0 Safety Precautions .......................................................................................... 1-1
SECTION 2 SYSTEM:
INTRODUCTION ..................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05 Transportation Methods .................................................................................. 2-1
2.06 User Responsibility ......................................................................................... 2-2
2.07 Fabricator 181i Portable System Package (Part No. W1003181) .................... 2-2
2.08 Duty Cycle ....................................................................................................... 2-3
2.09 Specifications ................................................................................................. 2-3
2.10 Options and Accessories ................................................................................ 2-5
SECTION 3:
INSTALLATION, OPERATION AND SETUP ........................................................ 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location .......................................................................................................... 3-1
3.03 Ventilation ....................................................................................................... 3-1
3.04 Electricity Supply Voltage .............................................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-3
3.06 Victor Regulator .............................................................................................. 3-4
3.07 Leak Testing the System ................................................................................. 3-5
3.08 When You Finish Using the Regulator ............................................................. 3-5
3.09 Storage of the Regulator ................................................................................. 3-5
3.10 Power Source Controls, Indicators and Features ............................................ 3-6
3.11 Attaching the ESAB Fusion 180A Gun ........................................................... 3-11
3.12 Torch Adapter Thumb Screw Replacement .................................................. 3-12
3.13 Installing 4" (100mm) Diameter Spool ......................................................... 3-13
3.14 Installing 8" (200mm) Diameter Spool .......................................................... 3-14
3.15 Inserting Wire into the Wire Feed Mechanism .............................................. 3-15
3.16 Feed Roller Pressure Adjustment .................................................................. 3-16
3.17 Changing the Feed Roll ................................................................................. 3-16
3.18 Wire Reel Brake ............................................................................................ 3-17
3.19 Gas Regulator Operation ............................................................................... 3-17
3.20 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 3-18
3.21 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire .................... 3-19
3.22 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 3-21
3.23 Setup for LIFT TIG (GTAW) Welding ............................................................. 3-22
3.24 Setup for STICK (SMAW) Welding .............................................................. 3-24
TABLE OF CONTENTS
SECTION 4:
BASIC WELDING GUIDE ............................................................................ 4-1
4.01 MIG (GMAW/FCAW) Basic Welding Technique ............................................... 4-1
4.02 MIG (GMAW/FCAW) Welding Troubleshooting ............................................... 4-5
4.03 Stick (SMAW) Basic Welding Technique ......................................................... 4-8
4.04 Effects of Stick Welding Various Materials ...................................................... 4-8
4.05 Stick (SMAW) Welding Troubleshooting ....................................................... 4-15
4.06 TIG (GTAW) Basic Welding Technique .......................................................... 4-17
4.07 TIG (GTAW) Welding Problems ..................................................................... 4-19
SECTION 5: Power Source PROBLEMS AND
ROUTINE SERVICE REQUIREMENTS .............................................................. 5-1
5.01 Power Source Problems ................................................................................. 5-1
5.02 Routine Service and Calibration Requirements ............................................... 5-2
5.03 Cleaning the Welding Power Source ............................................................... 5-4
5.04 Cleaning the Feed Rolls ................................................................................... 5-4
5.05 Volt-Ampere Curves ........................................................................................ 5-5
SECTION 6: KEY SPARE PARTS .......................................................................... 6-1
6.01 Tweco Fusion 180A MIG Gun Parts ................................................................ 6-1
6.02 Power Source ................................................................................................. 6-2
APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM .................................................... A-1
REVISION HISTORY ........................................................................................ A-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 0-5421 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
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 0-5421
Read and understand the instruction manual before
installing or operating.
!
ESAB FABRICATOR 211i
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specification or part numbers listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION,
DANGER, and NOTE may appear. Pay particular attention to
the information provided under these headings. These special
annotations are easily recognized as follows:
NOTE!
An operation, procedure, or background
information which requires additional emphasis or is helpful in efficient operation of
the system.
CAUTION
!
A procedure which, if not properly followed, may cause damage to the equipment.
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial number usually appear on a data tag
attached to the rear panel. Equipment which does not have
a data tag such as torch and cable assemblies are identified only by the specification or part number printed on
loosely attached card or the shipping container. Record these
numbers on the bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for
possible damage due to shipping. If there is any damage,
notify the carrier immediately to file a claim. Furnish complete
information concerning damage claims or shipping errors to
the location in your area listed in the inside back cover of this
manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.
2.04 Description
WARNING
!
!
Additional copies of this manual may be purchased by contacting ESAB at the address and phone number in your area listed
on back cover of this manual. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the ESAB web site
listed below
http://www.esab.eu
A procedure which, if not properly followed, may cause injury to the operator or
others in the operating area.
WARNING
Gives information regarding possible
electrical shock injury. Warnings will be
enclosed in a box such as this.
DANGER
Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
The ESAB Fabricator 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.
2.05 Transportation Methods
WARNING
Disconnect input power conductors from deenergized supply line before moving the welding
Power Source. Lift Power Source with handle on
top of case. Use handcart or similar device of
adequate capacity. If using a fork lift vehicle, secure the Power Source on a proper skid before
transporting.
Manual 0-5421 2-1 INTRODUCTION
ESAB FABRICATOR 181i
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)
A-12920
INTRODUCTION 2-2 Manual 0-5421
ESAB FABRICATOR 211i
A-10352
Duty Cycle (percentage)
Safe
Operating
Region
0
20 40 60
80
100
120 140 160 180
30
50
70
90
40
60
20
10
80 100
0
Welding Current (amps)
STICK (SMAW)
TIG (GTAW)
MIG (GMAW/FCAW)
2.08 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output
without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the
following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 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.
Figure 2-1: Fabricator 181i Duty Cycle
2.09 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)
Manual 0-5421 2-3 INTRODUCTION
)
1eff
15.9 Amps
14.3 Amps
17.2 Amps
ESAB FABRICATOR 181i
Maximum Input Current (I
for MIG (GMAW/FCAW)
for LIFT TIG (GTAW)
for STICK (SMAW)
1max
)
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
Table 2-1: Fabricator 181i Specification
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)
ESAB continuously strives to produce the best product possible and therefore reserves the right to
change, improve or revise the speci fications or design of this or any product without prior notice. Such
updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment
may differ from the above specifications due to in part, but not exclusively, to any one or more of the
following; variations or changes in manufactured components, installation location and conditions and
local power grid supply conditions.
The thermal protection switch is rated at 80°C.
INTRODUCTION 2-4 Manual 0-5421
ESAB FABRICATOR 211i
2.10 Options and Accessories
DESCRIPTION PART NUMBER
ESAB 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
Stick Lead, 200A, 13ft, 50mm Dinse
F180TA-12-3035
SG160TA-12-3035
W4013802
W4015301
W4014700
600285
4100-1004
W4014800
7977036
7977660
7977731
7977264
7977732
704277
WS200E13
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 2-2: Fabricator 181i Options and Accessories List
WS200G10
0781-4169
P062900010
Manual 0-5421 2-5 INTRODUCTION
ESAB FABRICATOR 181i
This Page Intentionally Blank
INTRODUCTION 2-6 Manual 0-5421
SECTION 3:
ESAB FABRICATOR 181i
INSTALLATION, OPERATION
AND SETUP
3.01 Environment
This Power Source is designed for use in environments with
increased hazard of electric shock.
A. Examples of environments with increased hazard of
electric shock are:
1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the
work in a cramped (kneeling, sitting or lying) position
with physical contact with conductive parts.
2. In locations which are fully or partially limited by
conductive elements, and in which there is a high risk
of unavoidable or accidental contact by the operator.
3. In wet or damp hot locations where humidity or
perspiration considerable reduces the skin resistance
of the human body and the insulation properties of
accessories.
B. Environments with increased hazard of electric shock
do not include places where electrically conductive parts
in the near vicinity of the operator, which can cause
increased hazard, have been insulated.
3.02 Location
Be sure to locate the welder according to the following guidelines:
A. In areas, free from moisture and dust.
B. Ambient temperature between 32 to 104° F (0 to 40° C).
C. In areas, free from oil, steam and corrosive gases.
D. In areas, not subjected to abnormal vibration or shock.
E. In areas, not exposed to direct sunlight or rain.
F. Place at a distance of 12" (300mm) or more from walls
or similar that could restrict natural air flow for cooling.
G. The enclosure design of this Power Source meets the
requirements of IP23S as outlined in EN 60529. This provides adequate protection against solid objects (greater
than 1/2", 12mm), and direct protection from vertical
drops. Under no circumstances should the Power Source
be operated or connected in a micro environment that
will exceed the stated conditions. For further information
please refer to EN 60529.
H. Precautions must be taken against the power source
toppling over. The power source must be located on a
suitable horizontal surface in the upright position when
in use.
WARNING
This equipment should be electrically
connected by a qualified electrician.
3.03 Ventilation
!
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area
is effectively ventilated.
3.04 Electricity Supply Voltage
CAUTION
!
SHUT DOWN welding Power Source, disconnect input power
employing lockout/tagging procedures. Lock-out/tagging procedures consist of padlocking line disconnect switch in open
position, removing fuses from fuse box, or shutting OFF and
red-tagging circuit breaker or other disconnecting device.
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
2-4.
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.
Manual 0-5421 3-1 INSTALLATION, OPERATION AND SETUP
ESAB FABRICATOR 181i
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 qualied electrician.
• Correctly earthed (electrically) in accordance with local regulations.
• Connected to the correct size power point, fuse and primary supply lead based on Table 3-1.
WARNING
An electrical shock or fire hazard is probable if the following electrical service guide recommendations
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
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
50 Amps
50 Amps
Table 3-1: Electrical Service Guide
NOTE!
Welding arc outs may be experienced if an extension cord is used when STICK welding when operation
the Power Source on 208 VAC due to the lack of DC voltage at the STICK electrode..
Input Power
Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned ON, the inrush circuit provides pre-charging
for the input capacitors. A relay in the Power Control Assembly (PCA) will turn ON after the input capacitors have charged to operating voltage (after approximately 5 seconds)
NOTE!
Damage to the PCA could occur if 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 3-2: Primary Circuit Sizes to Achieve Maximum Current
Minimum Primary
Current Circuit Size
(Vin/Amps)
MIG (GMAW/
FCAW)
Current & Duty Cycle
STICK (SMAW)
208-230V/40A 180A @ 20% 175A @ 20%
208-230V/25A
LIFT TIG
(GTAW)
175A @
25%
INSTALLATION, OPERATION AND SETUP 3-2 Manual 0-5421
ESAB FABRICATOR 181i
3.05 Electromagnetic Compatibility
WARNING
!
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the weld-
ing equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then
it shall be the responsibility of the user of the welding
equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial
action may be as simple as earthing the welding circuit,
see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding
Power Source and the work, complete with associated
input filters. In all cases, electromagnetic disturbances
shall be reduced to the point where they are no longer
troublesome.
B. Assessment of Area
Before installing welding equipment, the user shall make
an assessment of potential electromagnetic problems in
the surrounding area. The following shall be taken into
account
1. Other supply cables, control cables, signaling and
2. Radio and television transmitters and receivers.
3. Computer and other control equipment.
4. Safety critical equipment, e.g. guarding of industrial
5. The health of people around, e.g. the use of pacemak-
6. Equipment used for calibration and measurement.
7. The time of day that welding or other activities are to
Manual 0-5421 3-3 INSTALLATION, OPERATION AND SETUP
Extra precautions for Electromagnetic
Compatibility may be required when
this Welding Power Source is used in a
domestic situation.
NOTE!
The welding circuit may or may not be
earthed for safety reasons. Changing the
earthing arrangements should only be
authorized by a person who is competent to assess whether the changes will
increase the risk of injury, e.g. by allowing parallel welding current return paths
which may damage the earth circuits of
other equipment. Further guidance is given
in EN 60974-13 Arc Welding Equipment Installation and use (under preparation).
telephone cables; above, below and adjacent to the
welding equipment.
equipment.
ers and hearing aids.
be carried out.
8. The 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.
The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
C. Methods of Reducing Electromagnetic Emissions
1. Electricity Supply
Welding equipment should be connected to the Elec-
tricity Supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of
the Electricity Supply. Consideration should be given
to shielding the supply cable of permanently installed
welding equipment in metallic conduit or equivalent.
Shielding should be electrically continuous throughout
it’s length. The shielding should be connected to the
Welding Power Source so that good electrical contact
is maintained between the conduit and the Welding
Power Source enclosure.
2. Maintenance of Welding Equipment
The welding equipment should be routinely main-
tained according to the manufacturer’s recommendations. All access and service doors and covers should
be closed and properly fastened when the welding
equipment is in operation. The welding equipment
should not be modified in any way except for those
changes and adjustments covered in the manufacturer’s instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted
and maintained according to the manufacturer’s
recommendations.
3. Welding Cables
The welding cables should be kept as short as pos-
sible and should be positioned close together, running
at or close to the floor level.
4. Equipotential Bonding
Bonding of all metallic components in the welding
installation and adjacent to it should be considered.
However. Metallic components bonded to the work
piece will increase the risk that the operator could
receive a shock by touching the metallic components
and the electrode at the same time. The operator
should be insulated from all such bonded metallic
components.
5. Earthing of the Workpiece
Where the workpiece is not bonded to earth for
electrical safety, nor connected to earth because of
it’s size and position, e.g. ship’s hull or building steelwork, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances.
Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to users, or
damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should
be made by direct connection to the workpiece, but
ESAB FABRICATOR 181i
A-09414_AC
A-09845_AB
in some countries where direct connection is not
permitted, the bonding should be achieved by suitable
capacitance, selected according to national regulations.
6. Screening and Shielding
Selective screening and shielding of other cables
and equipment in the surrounding area may alleviate problems of interference. Screening the entire
welding installation may be considered for special
applications.
3.06 Victor Regulator
Pressure regulator (Figure 3-1) attached to the cylinder valve
reduce high cylinder pressures to suitable low working pressures for welding, cutting, and other applications.
Figure 3-1: Victor CS Regulator
WARNING
!
Use the regulator for the gas and pressure for which it is designed. NEVER alter
a regulator for use with any other gas.
b) Low pressure gauges must be UL recognized for
the class of regulator they are being used on according to UL252A.
WARNING
!
DO NOT use a regulator that delivers
pressure exceeding the pressure rating
of the downstream equipment unless
pro visions are made to prevent overpressurization (i.e. system relief valve).
Make sure the pressure rating of the
down stream equipment is compatible
with the maximum delivery pressure of
the regulator.
5. Be sure that the regulator has the correct pressure
rating and gas service for the cylinder used.
6. Carefully inspect the regulator for damaged threads,
dirt, dust, grease, oil, or other flammable substances.
Remove dust and dirt with a clean cloth. Be sure the
inlet swivel filter is clean and in place. Attach the
regulator (Figure 3-2) to the cylinder valve. Tighten
securely with a wrench.
WARNING
!
DO NOT attach or use the regulator if oil,
grease, flamma ble substances or damage is present! Have a qualified repair
technician clean the regulator or repair
any damage.
NOTE!
Regulators purchased with open 1/8”,
1/4”, 3/8”, or 1/2” NPT ports must be assembled to their intended system.
1. Note the maximum inlet pressure stamped on the
regulator. DO NOT attach the regulator to a system
that has a higher pressure than the maximum rated
pressure stamped on the regulator.
2. The regulator body will be stamped “IN” or “HP” at
the inlet port. Attach the inlet port to the system supply pressure connection.
3. Wrap pipe threads with Teflon tape 1 1/2 to 2 turns
to effect a seal. If other sealants are used, they must
be compatible with the gas that will be used in the
system.
4. If gauges are to be attached to the regulator and the
regu lator is stamped and listed by a third party (i.e.
“UL” or “ETL”). The following requirements must be
met:
a) Inlet gauges over 1000 PSIG (6.87 mPa) shall
conform with the requirements of UL 404,
“Indicating Pressure Gauges for Compressed Gas
Service.”
INSTALLATION, OPERATION AND SETUP 3-4 Manual 0-5421
Figure 3-2: Regulator to Cylinder Valve
7. Before opening the cylinder valve, turn the regulator
adjusting screw counterclockwise until there is no
pressure on the adjusting spring and the screw turns
freely.
8. Relief Valve (where provided): The relief valve is
designed to protect the low pressure side of the
regulator from high pres sures. Relief valves are not
intended to protect down stream equipment from high
pressures.
ESAB FABRICATOR 181i
Art # A-09828
WARNING
!
!
9. Slowly and carefully open the cylinder valve (Figure
DO NOT tamper with the relief valve or
remove it from the regulator.
WARNING
Stand to the side of the cylinder opposite
the regulator when opening the cylinder
valve. Keep the cylinder valve between
you and the regulator. For your safety,
NEVER STAND IN FRONT OF OR BEHIND A
REGULATOR WHEN OPENING THE CYLINDER VALVE!
3-3) until the maximum pressure shows on the high
pressure gauge.
Figure 3-3: Open Cylinder Valve
10. On all cylinders, except acetylene, open the valve
completely to seal the valve packing. On gaugeless
regulators, the indicator will register the cylinder
contents open.
11. On acetylene cylinders, open the valve 3/4 of a turn
and no more than 1-1/2.
WARNING
!
!
12. Attach the desired downstream equipment.
Acetylene delivery pressure must not exceed 15 PSIG (103 kPa) or 30 PSIG (207
kPa). Acetylene can dissociate (decompose with explosive violence) above these
pressure limits. .
CAUTION
Keep the cylinder valve wrench, if one is
required, on the cylinder valve to turn OFF
the cylinder quickly, if necessary..
3.07 Leak Testing the System
Leak test the system before putting into operation.
1. Be sure that there is a valve in the downstream equipment to turn OFF the gas flow.
2. With the cylinder valve open, adjust the regulator to
deliver the maximum required delivery pressure.
3. Close the cylinder valve.
4. Turn the adjusting screw/knob counterclockwise one
turn.
a) If the high-pressure gauge reading drops, there is
a leak in the cylinder valve, inlet fitting, or highpressure gauge.
b) If the low-pressure gauge drops, there is a leak
in the down stream equipment, hose, hose fitting,
outlet fitting or low-pressure gauge. Check for
leaks using an approved leak detector solution.
c) If the high-pressure gauge drops and the low-
pressure gauge increases at the same time, there
is a leak in the regulator seat.
d) If the regulator requires service or repair, take it to
a qualified repair technician.
5. Once leak testing has been performed and there are
no leaks in the system, slowly open the cylinder valve
and proceed.
WARNING
!
If a leak has been detected anywhere in
the system, dis continue use and have
the system repaired. DO NOT use leaking equipment. Do not attempt to repair a
leaking system while the system is under
pressure.
.
3.08 When You Finish Using the Regulator
1. Close the cylinder valve.
2. Open the valve on the downstream equipment. This
drains all pressure from the system.
3. Close the valve on the downstream equipment.
4. Turn the adjusting screw counterclockwise to release
the ten sion on the adjusting spring.
5. Check the gauges after a few minutes for verification
that the cylinder valve is closed completely.
3.09 Storage of the Regulator
When the regulator is not in use and has been removed from
the cylinder, it should be stored in an area where it will be protected from dust, oil, and grease. The inlet and outlet should be
capped to protect against internal contamination and prevent
insects from nesting.
Manual 0-5421 3-5 INSTALLATION, OPERATION AND SETUP
ESAB FABRICATOR 181i
3
3A
4
5
6
7
9
8
10
11
12
13
14
2
1
16
15
21
A-12956
18
3.10 Power Source Controls, Indicators and Features
Figure 3-4: Front Panel Figure 3-5: Rear Panel
19
20
21
Art #
A-10355
Figure 3-6: Wire Feed Compartment Control
INSTALLATION, OPERATION AND SETUP 3-6 Manual 0-5421
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.
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 (ESAB Style)
The MIG Gun adaptor is the connection point for the ESAB
Fusion MIG 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 ESAB Fusion MIG Gun
in position. Failure to properly lock the MIG Gun into the MIG
Gun Adapter will result in the 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.
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 recom-
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.
mended 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.
Manual 0-5421 3-7 INSTALLATION, OPERATION AND SETUP
!
CAUTION
Loose welding terminal connections can
cause overheating and result in the male
plug being fused in the bayonet terminal.
ESAB FABRICATOR 181i
Trigger Switch
Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Remote Volts in
MIG (GMAW/FCAW)
1
2
3
4
5
6
7
8
WV
3
4
5
6
7
8
1
2
Negative
Spool Gun Motor
Positive
Art # A-10421_AC
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.
CAUTION
!
8. Remote Control and Spool Gun Socket
The 8 pin socket is used to connect the ESAB Fusion MIG Gun, remote control device or spool gun plug to the welding Power
Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.
Figure 3-7: Remote Control Socket
Socket Pin
Function
1 Spool gun motor (0V)
2
3
4
5
6
Trigger Switch Input
Trigger Switch Input
Spool gun motor (+24V DC)
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
Wiper arm connection to 5k ohm potentiometer for the remote control of the Wirespeed in MIG mode.
7
Wiper arm connection to 5k ohm potentiometer for the remote control of the Amperage (Weld Current) in LIFT
TIG mode.
8
Wiper arm connection to 5k ohm remote control Volts MIG mode potentiometer.
Table 3-3
Note that the Local/ Remote Switch (Control No. 18) located in the wirefeed compartment should be set to Remote for remote
amperage/voltage controls to operate.
9. Multifunction Control - Voltage, Down Slope & Arc Force
The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc Force (STICK Mode)
depending on the welding mode selected.
NOTE!
The preview functionality provided on this power source is intended to act as a guide only. Some differences may
be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie
dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended
that alternate measurement methods be utilized to ensure output values are accurate..
INSTALLATION, OPERATION AND SETUP 3-8 Manual 0-5421
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