Page 1
180
3163339
FABRICATOR® 181i
3-IN-1 Multi Process
Welding Systems
Service
Manual
Revision: AF Issue Date: November 19, 2014 Manual No.: 0-5192
Tweco.com
Page 2
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Tweco product. We are proud to have you as our customer and
will strive to provide you with the best service and support in the industry. This product is backed by
our extensive warranty and world-wide service network.
We know you take pride in your work and we feel privileged to provide you with this high performance
product that will help you get the job done.
For more than 75 years Tweco has provided quality products you can trust, when your reputation is on
the line.
YOU ARE IN GOOD COMPANY!
Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish
ourselves from our competition through market-leading innovation and truly dependable products that
will stand the test of time.
We strive to enhance your productivity, efficiency and welding performance enabling you to excel in
your craft. We design products with the welder in mind delivering- advanced features, durability, ease
of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time to
read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Tweco product, please contact our friendly
and knowledgeable Customer Service Team at:
1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.Tweco.com
Page 3
!
WARNINGS
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 judgment,
the Manufacturer assumes no liability for its use.
Service Manual Number 0-5192 for:
Tweco Fabricator 181i Portable System Package Part Number: W1003181
Tweco Fabricator 181i Power Source Part Number: W1003180
Tweco Fabricator 181i Portable System Package with Cart Part Number: W1003182
Published by:
Victor Technologies International, Inc.
16052 Swingley Ridge Road,
Suite 300St. Louis, MO 63017
USA
www.victortechnologies.com
Copyright © 2011, 2012, 2013, 2014 by
Victor Technologies International, Inc.
® 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.
Publication Date: August 02, 2012
Revision Date: November 19, 2014
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
Page 4
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 General Safety Information for Victor CS Regulator .......................................... 1-5
1.03 Principal Safety Standards .............................................................................. 1-7
1.04 Symbol Chart .................................................................................................. 1-8
1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-9
1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-9
1.07 Informations Générales de Sécurité .............................................................. 1-14
1.08 Principales Normes De Securite ................................................................... 1-16
1.09 Graphique de Symbole .................................................................................. 1-17
SECTION 2:
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
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 ........................................................................ 3-6
3.08 Volt-Ampere Curves ........................................................................................ 3-8
SECTION 4:
OPERATION .......................................................................................... 4-1
4.01 Power Source Controls, Indicators and Features ............................................ 4-1
4.02 Attaching the Tweco Fusion 180A Gun ............................................................ 4-8
4.03 Torch Adapter Thumb Screw Replacement .................................................... 4-9
4.04 Installing 4" (100mm) Diameter Spool ......................................................... 4-11
4.05 Installing 8" (200mm) Diameter Spool .......................................................... 4-12
4.06 Inserting Wire into the Wire Feed Mechanism .............................................. 4-13
4.07 Feed Roller Pressure Adjustment .................................................................. 4-14
4.08 Changing the Feed Roll ................................................................................. 4-14
4.09 Wire Reel Brake ............................................................................................ 4-15
4.10 Gas Regulator Operation ............................................................................... 4-16
4.11 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 4-16
4.12 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire .................... 4-18
4.13 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 4-20
Page 5
TABLE OF CONTENTS
4.14 Setup for LIFT TIG (GTAW) Welding ............................................................. 4-21
4.15 Setup for STICK (SMAW) Welding .............................................................. 4-23
4.16 Leak Testing the System ............................................................................... 4-24
SECTION 5:
THEORY OF OPERATION ............................................................................ 5-1
5.01 Inverter Design ..................................................................................................... 5-1
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 ........................ 6-5
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 ................................................................................... 7-2
7.03 Front Panel Assembly Removal ...................................................................... 7-4
7.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal ....................... 7-6
7.05 Back Panel Removal ....................................................................................... 7-7
7.06 Power Switch S1 and Power Cord Removal ................................................... 7-8
7.07 Base Panel Removal and Main PCB Disassembly ........................................... 7-9
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 ................................................................................................ 8-8
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
Page 6
SECTION 10:
Options and Accessories ..........................................................................10-1
10.01 Options and Accessories .............................................................................. 10-1
LIMITED WARRANTY TERMS ........................................................ INSIDE REAR COVER
INTERNATIONAL CONTACT INFORMATION ................................................. REAR COVER
Page 7
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
!
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE
INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training
in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
This publication and other guides to what you should learn before operating this equipment are listed at the
end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and
machine internal circuits are also live when
power is on. In semi-automatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before
installing or servicing this equipment. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or
out of service.
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the ground
or the work surface. Do not touch holders connected
to two welding machines at the same time or touch
other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
Manual 0-5192 1-1 SAFETY INSTRUCTIONS AND WARNINGS
Page 8
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
14. Wear a safety harness to prevent falling if working
above floor level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE
can damage hearing. Arc rays from the
welding process produce intense heat and
strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can
damage hearing.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
Process
Shielded Metal Arc Welding
(SMAW)
Electrode Size in.
(mm)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
1. Wear a welding helmet fitted with a proper shade
of filter (see ANSI Z49.1 listed in Safety Standards)
to protect your face and eyes when welding or
watching.
2. Wear approved safety glasses. Side shields
recommended.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level
is high.
Arc Current
(Amperes)
Less than 60
60-160
160-250
250-550
Minimum
Protective
Shade
7
8
10
11
Suggested*
Shade No.
(Comfort)
10
12
14
Gas Metal Arc Welding (GMAW)
and Flux Cored Arc Welding
(FCAW)
Gas Tungsten arc Welding
(GTAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Plasma Arc Cutting (PAC)
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter
shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas
welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable
to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.
(Light)
(Heavy)
Less than 60
60-160
160-250
250-550
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
7
10
10
10
8
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
11
12
14
10
12
14
12
14
6 to 8
10
12
14
4
5
6
8
9
12
14
SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5192
Page 9
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
3. Remove all flammables within 35 ft (10.7 m) of the
welding arc. If this is not possible, tightly cover them
WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
1. Keep your head out of the fumes. Do not breathe
the fumes.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing
injury or death. Be sure the breathing air is safe.
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or
drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding current
from traveling long, possibly unknown paths and
causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
WARNING
6. Do not weld in locations near degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapors to form highly toxic and
irritating gases.
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well
ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding
arc. The flying sparks and hot metal, weld
spatter, hot workpiece, and hot equipment
can cause fires and burns. Accidental contact
of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike flammable
material.
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to treat
them carefully.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
Manual 0-5192 1-3 SAFETY INSTRUCTIONS AND WARNINGS
Page 10
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
!
4. Never allow a welding electrode to touch any
cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific
application; maintain them and associated parts in
good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
WARNING
Engines can be dangerous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated
areas.
2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any
sparks or open flames.
3. Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working
on a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5192
WARNING
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot
and under pressure.
Page 11
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
!
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely
removing cap.
!
WARNING
WARNING: This product contains chemicals,
including lead, known to the State of
California to cause birth defects and other
reproductive harm.
handling.
Considerations About Welding And The
Effects of Low Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology
Assessment, Biological Effects of Power Frequency
Electric & Magnetic Fields - Background Paper, OTABP-E-63 (Washington, DC: U.S. Government Printing
Office, May 1989): “...there is now a very large volume
of scientific findings based on experiments at the cellular level and from studies with animals and people
which clearly establish that low frequency magnetic
fields interact with, and produce changes in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the
evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite
conclusions about questions of possible risk or to offer
clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.
1. Keep cables close together by twisting or taping
them.
Wash hands after
NOTE
ABOUT PACEMAKERS:
The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.
1.02 General Safety Information for
Victor CS Regulator
A. Fire Prevention
Welding and cutting operations use fire or combustion
as a basic tool. The process is very useful when properly
controlled. However, it can be extremely destructive
if not performed cor rectly in the proper environment.
1. The work area must have a fireproof floor.
2. Work benches or tables used during welding or
cutting operations must have fireproof tops.
3. Use heat resistant shields or other approved material to protect nearby walls or unprotected flooring
from sparks and hot metal.
4. Keep an approved fire extinguisher of the proper
size and type in the work area. Inspect it regularly to ensure that it is in proper working order.
Know how to use the fire extin guisher.
5. Move combustible materials away from the work
site. If you can not move them, protect them
with fireproof covers.
WARNING
NEVER perform welding, heating, or cutting operations on a container that has held
toxic, combustible or flammable liq uids, or
vapors. NEVER perform welding, heating,
or cutting operations in an area containing
combustible vapors, flam mable liquids, or
explosive dust.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cable around the body.
4. Keep welding Power Source and cables as far
away from body as practical.
Manual 0-5192 1-5 SAFETY INSTRUCTIONS AND WARNINGS
Page 12
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
!
!
!
!
B. Housekeeping
WARNING
NEVER allow oxygen to contact grease, oil, or
other flam mable substances. Although oxygen by itself will not burn, these substances
become highly explosive. They can ignite
and burn violently in the presence of oxygen.
Keep ALL apparatus clean and free of grease, oil and
other flammable substances.
C. Ventilation
WARNING
Ade quately ventilate welding, heating, and
cutting work areas to prevent accumulation of explosive or toxic concen trations
of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes.
Use respiratory protection equipment in
these circumstances. When welding/brazing,
read and understand the Material Safety Data
Sheet for the welding/brazing alloy.
D. Personal Protection
Gas flames produce infrared radiation which may have
a harm ful effect on the skin and especially on the eyes.
Select goggles or a mask with tempered lenses, shaded
4 or darker, to protect your eyes from injury and provide
good visibility of the work.
Always wear protective gloves and flame-resistant clothing
to protect skin and clothing from sparks and slag. Keep
collars, sleeves, and pockets buttoned. DO NOT roll up
sleeves or cuff pants.
When working in a non-welding or cutting environment,
always wear suitable eye protection or face shield.
E. Compressed Gas Cylinders
The Department of Transportation (DOT) approves the
design and manufacture of cylinders that contain gases
used for welding or cutting operations.
1. Place the cylinder (Figure 1-1) where you will
use it. Keep the cylinder in a vertical position.
Secure it to a cart, wall, work bench, post, etc.
Art # A-12127
Figure 1-1: Gas Cylinders
WARNING
Cylinders are highly pressurized. Handle
with care. Serious accidents can result from
improper handling or mis use of compressed
gas cylinders DO NOT drop the cylinder,
knock it over, or expose it to excessive heat,
flames or sparks. DO NOT strike it against
other cylinders. Contact your gas supplier
or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.
NOTE
CGA P-1 publication is available by writing
the Compressed Gas Association, 4221
Walney Road, 5th Floor, Chantilly,VA 201512923
2. Place the valve protection cap on the cylinder
whenever mov ing it, placing it in storage, or not
using it. Never drag or roll cylinders in any way.
Use a suitable hand truck to move cylin ders.
WARNING
Practice the following safety and operation
precautions EVERY TIME you use pressure
regulation equipment. Deviation from the
following safety and operation instructions
can result in fire, explosion, damage to
equipment, or injury to the operator.
SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5192
3. Store empty cylinders away from full cylinders.
Mark them “EMPTY” and close the cylinder
valve.
Page 13
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
!
4. NEVER use compressed gas cylinders without
a pressure reducing regulator attached to the
cylinder valve.
5. Inspect the cylinder valve for oil, grease, and
damaged parts.
WARNING
DO NOT use the cylinder if you find oil,
grease or damaged parts. Inform your gas
supplier of this condition immediately.
6. Momentarily open and close (called “cracking”)
the cylinder valve to dislodge any dust or dirt that
may be present in the valve.
CAUTION
Open the cylinder valve slightly. If you open
the valve too much, the cylinder could tip
over. When cracking the cylinder valve, DO
NOT stand directly in front of the cylinder
valve. Always perform cracking in a well
ventilated area. If an acetylene cylinder
sprays a mist when cracked, let it stand for
15 minutes. Then, try to crack the cylinder
valve again. If this problem persists, contact
your gas supplier.
1.03 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Manual 0-5192 1-7 SAFETY INSTRUCTIONS AND WARNINGS
Page 14
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Art # A-04130_AB
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Meters Per Minute
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
S
See Note
See Note
S
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
Cannot be disposed with household garbage.
1.04 Symbol Chart
Note that only some of these symbols will appear on your model.
SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5192
Page 15
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
!
1.05 Precautions De Securite En Soudage A L’arc
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA
MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ
LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR
CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité
et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques
doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi
un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent
les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les
pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser
cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION,
D’ENTRETIEN ET D’ESSAI.
1.06 Dangers relatifs au soudage à
l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou
brûler gravement. L’électrode et le circuit
de soudage sont sous tension dès la mise
en circuit. Le circuit d’alimentation et les
circuits internes de l’équipement sont aussi
sous tension dès la mise en marche. En
soudage automatique ou semi-automatique
avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement
et toutes les pièces métalliques en contact
avec le fil de soudage sont sous tension.
Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et
non troués.
3 Isolez-vous de la pièce à souder et de la mise à la
terre au moyen de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement
ou arrêtez le moteur avant de l’installer ou d’en faire
l’entretien. Bloquez le commutateur en circuit ouvert
ou enlevez les fusibles de l’alimentation afin d’éviter
une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à
la terre selon le manuel d’utilisation et les codes
nationaux, provinciaux et locaux applicables.
6. Arrêtez tout équipement après usage. Coupez
l’alimentation de l’équipement s’il est hors d’usage
ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne
jamais plonger les porte-électrodes dans l’eau pour
les refroidir. Ne jamais les laisser traîner par terre ou
sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
Manual 0-5192 1-9 SAFETY INSTRUCTIONS AND WARNINGS
Page 16
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
9. N’enroulez pas de câbles électriques autour de votre
corps.
10. N’utilisez qu’une bonne prise de masse pour la mise
à la terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec
le circuit de soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez
ou remplacez aussitôt les pièces endommagées.
LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
AVERTISSEMENT
brûler les yeux et la peau. Le bruit causé par
13. Dans des espaces confinés ou mouillés, n’utilisez
pas de source de courant alternatif, à moins qu’il
soit muni d’un réducteur de tension. Utilisez plutôt
une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en
hauteur.
15. Fermez solidement tous les panneaux et les capots.
AWS F2.2 : 2001 (R2010), Modifié avec l’accord de l’American Welding Society (AWS), Miami, Florida
Guide de teinte des lentilles
Procédé
Taille de l’électrode
enmm (po)
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire
de nuance appropriée (consultez la norme ANSI Z49
indiquée ci-après) pour vous protéger le visage et
les yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
Courant
d’arc
(ampères)
Gamme
d’intensité
minimum
Numéro de teinte
recommandée*
(Confort)
Soudage à l’arc avec
électrode enrobée (procédé
SMAW)
Soudage à l’arc sous gaz
avec fil plein (procédé
GMAW) et soudage avec fil
fourré (procédé FCAW)
Soudage à l’électrode
réfractaire (procédé GTAW)
Coupage à l’arc avec
électrode de carbone et jet
d’air (procédé AAC)
Soudage à l’arc au plasma
(procédé PAW)
Coupage plasma (procédé
PAC)
* En règle générale, commencer avec une teinte plus foncée pour voir la zone de soudage. Réduire ensuite
progressivement vers la teinte qui permet de voir la zone de soudage sans dépasser le minimum. Lors
dusoudage, du coupage ou du brasage au gaz oxygéné, la torche ou le fondant produit une puissante
lumière jaune; il est préférable d’utiliser un filtre qui absorbe cette lumière jaune ou le sodium du spectre
de la lumière visible.
Moins de 2,4 (3/32)
3/32-5/32 (2,4-4,0)
5/32-1/4 (4,0-6,4)
Plus de 1/4 (6,4)
(Clair)
(Sombre)
Moins de 60
60-160
160-250
250-550
Moins de 60
60-160
160-250
250-550
Moins de 50
50-150
150-500
Moins de
500 500-
1000
Moins de 20
20-100
100-400
400-800
Moins de 20
20-40
40-60
60-80
80-300
300-400
400-800
7
8
10
11
7
10
10
10
8
8
10
10
11
6
8
10
11
4
5
6
8
8
9
10
10
12
14
11
12
14
10
12
14
12
14
6 à 8
10
12
14
4
5
6
8
9
12
14
SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5192
Page 17
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
2. Portez des lunettes de sécurité approuvées. Des
écrans latéraux sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons
pour protéger les autres des coups d’arc ou de
l’éblouissement; avertissez les observateurs de ne
pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.
LE SOUDAGE PEUT CAUSER UN INCENDIE
OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal
chaud, les projections de soudure et
l’équipement surchauffé peuvent causer
un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode
avec un objet métallique peut provoquer des
étincelles, un échauffement ou un incendie.
AVERTISSEMENT
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des
fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est
bien ventilée ou que les fumées et les vapeurs sont
aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes
du fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer
l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
2. Ne soudez pas dans un endroit où des particules
volantes ou des projections peuvent atteindre des
matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon
de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes
par de petites ouvertures ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur
à portée de la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut
enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir
ou un baril.
8. Connectez le câble de soudage le plus près possible
de la zone de soudage pour empêcher le courant de
suivre un long parcours inconnu, et prévenir ainsi
les risques d’électrocution et d’incendie.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir avec des vapeurs
et former des gaz hautement toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au
plomb ou au cadmium que si les zones à souder ont
été grattées à fond, que si l’espace est bien ventilé;
si nécessaire portez un respirateur à adduction d’air.
Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au
moment du soudage.
Manual 0-5192 1-11 SAFETY INSTRUCTIONS AND WARNINGS
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil
au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels
des gants en cuir, une chemise épaisse, un pantalon
revers, des bottines de sécurité et un casque.
Page 18
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
8. Lisez et respectez les consignes relatives aux
bouteilles de gaz comprimé et aux équipements
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES BLESSURES.
connexes, ainsi que la publication P-1 de la CGA,
identifiée dans la liste de documents ci-dessous.
Le piquage et le meulage produisent des
particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats
de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont
recommandés.
2. Portez des vêtements appropriés pour protéger
la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles
endommagées peuvent exploser. Comme
les bouteilles font normalement partie du
procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les
sources de chaleur intense, les chocs et les arcs de
soudage.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS
PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.
2. Si vous utilisez ces équipements dans un endroit
confiné, les fumées d’échappement doivent être
envoyées à l’extérieur, loin des prises d’air du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.
2. Enchainez verticalement les bouteilles à un support
ou à un cadre fixe pour les empêcher de tomber ou
d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou
de tout soudage.
4. Empêchez tout contact entre une bouteille et une
électrode de soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des
détendeurs, des boyauxs et des raccords conçus
pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus
en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet
de la bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en
utilisation ou lorsque raccordé pour utilisation.
SAFETY INSTRUCTIONS AND WARNINGS 1-12 Manual 0-5192
2. Ne faites pas le plein en fumant ou proche d’une
source d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de
faire le plein de carburant ou d’en vérifier le niveau
au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.
Page 19
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT
CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent
couper doigts et mains, ou accrocher des
vêtements amples.
1. Assurez-vous que les portes, les panneaux, les
capots et les protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez
le moteur.
3. Seules des personnes qualifiées doivent démonter
des protecteurs ou des capots pour faire l’entretien
ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant
l’entretien, débranchez le câble d’accumulateur à la
borne négative.
5. N’approchez pas les mains ou les cheveux de pièces
en mouvement; elles peuvent aussi accrocher des
vêtements amples et des outils.
6. Réinstallez les capots ou les protecteurs et fermez
les portes après des travaux d’entretien et avant de
faire démarrer le moteur.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION
PEUVENT BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur
peut être brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.
2. Mettez des gants et posez un torchon sur le bouchon
pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.
!
AVERTISSEMENT
AVERTISSEMENT : Ce produit contient des
produits chimiques, notamment du plomb,
reconnu par l’État de la Californie pour
causer des malformations congénitales et
d’autres dommages touchant le système
reproductif.
Se laver les mains après ma-
nipulation.
REMARQUE
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE
D’UN ACCUMU-LATEUR PEUT BRULER LA
PEAU ET LES YEUX.
Les accumulateurs contiennent de
l’électrolyte acide et dégagent des vapeurs
explosives.
1. Portez toujours un écran facial en travaillant sur un
accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler
sur un accumulateur.
4. N’utilisez pas une source de courant de soudage
pour charger un accumulateur ou survolter momentanément un véhicule.
Facteurs relatifs au soudage et aux effets
des champs magnétiques et électriques de
basse fréquence
Voici une citation tirée du chapitre des conclusions
générales du document de base de l’Office of Technology
Assessment (bureau des évaluations technologiques)
del’U.S. Congress, « Biological Effects of Power
Frequency Electric & Magnetic Fields », OTA-BP-E-63
(Washington, DC : U.S. Government Printing Office,
mai 1989) : « ... il existe de nos jours, un nombre
très élevé de travaux scientifiques qui rapportent les
résultats d’expériences menées au niveau cellulaire et
d’études auprès d’homme et d’animaux qui établissent
nettement le rapport entre les champs magnétiques
de basse fréquence et les systèmes biologiques, soit
par des interactions ou des modifications. Quoique
la plupart de ces travaux soient de très bonne
qualité, les résultats sont complexes. Àla lumière
des connaissances scientifiques actuelles, il nous est
encore impossible d’interpréter les évidences en un seul
cadre de référence cohérent. La situation est toutefois
Manual 0-5192 1-13 SAFETY INSTRUCTIONS AND WARNINGS
Page 20
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
!
!
!
très contrariante. En effet, il nous est aussi impossible
de tirer des conclusions définitives quant aux risques
éventuels ou de proposer des stratégies fondées sur
des faits scientifiques visant à atténuer ou éviter des
risques potentiels ».
Pour atténuer les champs magnétiques sur les lieux
detravail, respectez les procédures qui suivent :
1. Maintenez les câbles l’un près de l’autre en les
entrelaçant ou les reliant ensemble au ruban.
2. Acheminez les câbles à un côté du soudeur, le
plus loin possible.
3. N’enroulez pas de câble autour du corps.
N’effectuez JAMAIS d’opérations de soudage
sur un récipient qui a contenu des liquides
ou vapeurs toxiques, combustibles ou inflammables. N’effectuez JAMAIS d’opérations
de soudage dans une zone contenant des
vapeurs combustibles, des liquides inflammables ou des poussières explosives.
B. Entretien des Locaux
AVERTISSEMENT
4. Maintenez le bloc d’alimentation du poste
desoudage et les câbles aussi loin que possible
du corps.
STIMULATEURS CARDIAQUES :
Les procédures décrites ci-dessus sont
habituellement celles recommandées pour
les porteurs de stimulateurs cardiaques.
Pour de plus amples renseignements,
consulter unmédecin.
Ne laissez jamais l’oxygène en contact avec
la graisse, l’huile ou d’autres substances inflammables. Bien que l’oxygène elle même ne
brûle pas, ces substances peuvent devenir
extrême ment explosives. Elles peuvent prendre feu et brûler violem ment en présence
d’oxygène.
Gardez TOUS les appareils propres et exempts de graisse,
huile ou autres substances inflammables.
C. Aération
AVERTISSEMENT
1.07 Informations Générales de
Sécurité
A. Prévention D’incendie
Les opérations de soudage utilisent le feu ou la combustion
comme outil de base. Ce processus est très utile quand il
est cor rectement contrôlé.
1. La zone doit comporter un sol ignifugé.
2. Les établis ou tables utilisés pendant les opérations de soudage doivent avoir un revêtement
ignifuge.
3. Utilisez des écrans résistants à la chaleur ou en
matériau approuvé pour protéger les cloisons
proches ou le sol vul nérable des étincelles et du
métal chaud.
4. Gardez un extincteur approuvé du bon type et de
la bonne taille dans la zone de travail. Inspectez-le
régulièrement pour vous assurer qu’il est en état de
fonctionner. Apprenez à vous en servir.
5. Enlevez tous les matériaux combustibles de la
zone de travail. Si vous ne pouvez pas les enlever,
protégez-les avec une cou vre ignifuge.
SAFETY INSTRUCTIONS AND WARNINGS 1-14 Manual 0-5192
Ventilez les zones de soudage, chauffage et
découpage de façon adéquate pour éviter
l’accumulation de gaz explosifs ou toxiques.
Certaines combinaisons de métaux, revêtements et gaz génèrent des fumées toxiques:
Utilisez un équipement de protection respiratoire dans ces circonstances. Si vous
soudez ou brasez, lisez et assimilez la fiche
technique de sécurité de matériau relative à
l’alliage de soudage/brasage.
D. Protection Personnelle
Les flammes de gaz produisent une radiation infrarouge
qui peut avoir un effet néfaste sur la peau, et particulièrement sur les yeux. Choisissez des lunettes ou un
masque avec des verres trempés assombris au niveau 4
ou plus sombre, pour protéger vos yeux des dommages
et garder une bonne visibilité sur le travail.
Portez en permanence des gants de protection et des
vête ments ignifuges pour la protection de la peau et des
vêtements contre les étincelles et le laitier. Gardez col,
manches et poches boutonnés. Il ne faut pas remonter
vos manches ou les pantalons à revers.
AVERTISSEMENT
Page 21
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
!
!
!
Quand vous travaillez dans un environnement non
dédié au soudage ou découpage, portez toujours une
protection des yeux appropriées ou un masque facial.
AVERTISSEMENT
Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à
chaque fois que vous utilisez cet appareil
de régulation de pression. Si vous déviez de
ces procédures, cela peut entraîner incendie,
explosion, dégâts matériels et/ou blessures
corporelles pour l’opérateur.
E. Bouteilles de Gaz Comprimé
Le Département des Transports américain (DOT) approuve la conception et la fabrication des bouteilles
qui contiennent les gaz utilisés pour les opérations de
soudage ou de découpage.
1. Placez la bouteille (Le schéma 1) là où elle sera
utilisée. Gardez-la en position verticale. Fixez-la sur
un chariot une cloison, un établi, etc.
AVIS
Ce document CGA p. t peut être obtenu en
écrivant à “Compressed Gas Association”,
4221 Walney Roed, 5th Floor. Chantilly, VA
20151.2923, USA.
2. Placez le bouchon de protection de vanne sur
la bouteille à chaque fois que vous la déplacez
ou ne l’utilisez pas. Ne faites jamais glisser ou
rouler d’aucune manière les bouteilles. Utilisez
un diable approprié pour les déplacer.
3. Entreposez les bouteilles vides à l’écart des
bouteilles pleines. Marquez-les “VIDE” et refermez leur vanne.
4. N’utilisez JAMAIS des bouteilles de gaz comprimé
sans un régulateur de pression en série sur la
vanne de bouteille.
5. Inspectez la vanne de bouteille pour y détecter
de l’huile ou de la graisse, ou dès pièces
endommagées.
Art # A-12127
Le schéma 1-1: Cylindres de gaz
AVERTISSEMENT
Les bouteilles sont sous haute pression. Manipulez-les avec précautions. Des accidents sérieux
peuvent résulter d’une mauvaise manutention
ou d’un mauvais emploi des bouteilles de gaz
comprimé. NE faites PAS tomber la bouteille,
ne la cognez pas, ne l’exposez pas à une chaleur
excessive, aux flammes ou étincelles. NE la cognez
PAS contre d’autres bouteilles. Contactez votre
fournisseur de gaz ou reportez vous à la publication
CGA P-1 “Manipulation sécurisée des gaz comprimés en conteneur” pour plus d’informations sur
l’utilisation et la manutention des bouteilles.
AVERTISSEMENT
N’UTILISEZ PAS la bouteille si vous trouvez
de l’huile, de la graisse ou des pièces endommagées. Informez immédiate ment votre
fournisseur de’ gaz de cet état.
6. Ouvrez et fermez momentanément la vanne de
la bouteille, délogeant ainsi d’éventu lIes poussières ou saletés. qui pour raient être présentes
dans la vanne.
Mise en Garde
Ouvrez la vanne de bouteille légèrement.
Si vous l’ouvrez trop en grand, la bouteille
pourrait se renverser. Quand vous ouvrez/
fermez rapidement la vanne de bouteille, ne
vous tenez pas directement devant. Opérez
toujours cette opération dans une zone bien
ventilée. Si une bouteille d’acétylène crache
un brouillard, laissez reposer pendant 15
minutes. Essayez de nouveau la vanne. Si le
problème persiste, con tactez votre fournisseur de gaz.
Manual 0-5192 1-15 SAFETY INSTRUCTIONS AND WARNINGS
Page 22
FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS
1.08 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Of-
fice, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous
Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards
Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National
Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
SAFETY INSTRUCTIONS AND WARNINGS 1-16 Manual 0-5192
Page 23
SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i
1.09 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
SousTension
Hors Tension
Tension dangereuse
Augmentez/Diminuer
Disjoncteur
Source AC Auxiliaire
Fusible
Intensité de Courant
Tension
Hertz (cycles/sec)
Fréquence
Négatif
Positif
Courant Continue (DC)
X
%
Mono Phasé
Trois Phasé
Tri-Phase Statique
Fréquence Convertisseur
Transformateur-Redresseur
Distant
Facteur de Marche
Pourcentage
Panneau/Local
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Decoupe Arc Carbone
(CAC-A)
Courant Constant
Tension Constante
Ou Potentiel Constant
Haute Température
Déroulement du Fil
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Torch de Soudage
Purge Du Gaz
Mode Continu de
Soudure
Soudure Par Point
Duréc du Pulse
t
t1
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
Durée de Pré-Dèbit
Durée de Post-Dèbit
t2
Détente à 2-Temps
Détente à 4-Temps
Probléme de Terre
t
Terre de Protection
Ligne
Connexion de la Ligne
Source Auxiliaire
115V 15A
Note: Pour les environnements avec des risques de choc électrique, le fournisseur d'énergie portant la marque conforme
à EN50192 lorsqu'utilisé en conjonction avec des lampes de poche avec des conseils exposés, si équipés avec des guide à
l'hauteur de buse correctement installé.
Ne pas déposer avec les déchets ménagers.
Classement de PriseSource Auxiliaire
Manual 0-5192 1-17 SAFETY INSTRUCTIONS AND WARNINGS
Force d'Arc
Amorçage de L’arc au
Contact (GTAW)
Inductance Variable
Tension
V
IPM
MPM
S
Pouces Par Minute
Mètres Par Minute
Voir Note
Voir Note
Art # A-07639_AB
S
Page 24
This Page Intentionally Blank
Page 25
INTRODUCTION FABRICATOR 181i
!
SECTION 2:
INTRODUCTION
2.01 How to Use This Manual
This Manual usually applies to the 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 word WARNING,
CAUTION and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as follows:
!
WARNING
Gives information regarding possible personal injury. Warnings will be enclosed in a
box such as this.
CAUTION
Refers to possible equipment damage. Cautions will be shown in bold type.
NOTE
Offers helpful information concerning certain operating procedures. Notes will be
shown in italics
You will also notice icons from the safety section appearing throughout the manual. These are to advise you
of specific types of hazards or cautions related to the
portion of information that follows. Some may have
multiple hazards that apply and would look something
like this:
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.
2.04 Description
The Tweco 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.
2.02 Equipment Identification
The Power Source's identification number (specification or part number), model, and serial number usually
appear on a nameplate attached to the machine. Equipment which does not have a nameplate attached to the
machine is identified only by the specification or part
number printed on the shipping container. Record these
numbers for future reference.
Manual 0-5192 2-1 Introduction
2.05 Transportation Methods
ductors from de-energized supply line before moving
the welding Power Source.
Lift Power Source with handle on top of case. Use
handcart or similar device of adequate capacity. If using
a fork lift vehicle, secure the Power Source on a proper
skid before transporting.
Disconnect input power con-
Page 26
FABRICATOR 181i INTRODUCTION
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 Tweco. Advice in
this regard can be obtained by contacting an Accredited Tweco Distributor.
This equipment or any of its parts should not be altered from standard specification without prior written approval
of Tweco. 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 Tweco.
2.07 Fabricator 181i Portable System Package (Part No. W1003181)
Introduction 2-2 Manual 0-5192
A-12166
Page 27
SAFETY AND INSTALLATION FABRICATOR 181i
Duty Cycle (percentage)
100
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
0
20 40 60
80 100
120 140 160 180
Welding Current (amps)
A-10352
Figure 3-1: Fabricator 181i Duty Cycle
Manual 0-5192
3-1
Safety and Installation
Page 28
FABRICATOR 181i SAFETY AND INSTALLATION
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
Table 3-1: Fabricator 181i Specification
Safety and Installation
3-2
Manual 0-5192
Page 29
SAFETY AND INSTALLATION 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.
Manual 0-5192
3-3
Safety and Installation
Page 30
FABRICATOR 181i SAFETY AND INSTALLATION
!
WARNING
This equipment should be electrically connected by a qualified electrician.
3.05 Ventilation
WARNING
Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.
3.06 Electricity Supply Voltage
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:
• Correctlyinstalled,ifnecessary,byaqualiedelectrician.
• Correctlyearthed(electrically)inaccordancewithlocalregulations.
• ConnectedtothecorrectsizepowerpointandfuseaspertheSpecicationsonpage3-2.
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.
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.
• Correctlyinstalled,ifnecessary,byaqualiedelectrician.
Safety and Installation
3-4
Manual 0-5192
Page 31
SAFETY AND INSTALLATION FABRICATOR 181i
• Correctlyearthed(electrically)inaccordancewithlocalregulations.
• Connectedtothecorrectsizepowerpoint,fuseandprimarysupplyleadbasedonTable3-2.RefertoTable3-2.
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
50 Amps
Table 3-2: Electrical Service Guide
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)
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%
Table 3-3: Primary Circuit Sizes to Achieve Maximum Current
Manual 0-5192
3-5
Safety and Installation
Page 32
FABRICATOR 181i SAFETY AND INSTALLATION
3.07 Electromagnetic Compatibility
WARNING
Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is
used in a domestic situation.
A. Installation and Use - Users Responsibility
The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.
If 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).
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.
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 interference 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.
Safety and Installation
3-6
Manual 0-5192
Page 33
SAFETY AND INSTALLATION FABRICATOR 181i
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 interference. Screening the entire welding installation may be considered for special applications.
Manual 0-5192
3-7
Safety and Installation
Page 34
FABRICATOR 181i SAFETY AND INSTALLATION
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.
Figure 3-2: Fabricator 181i Volt-Ampere Curves
Safety and Installation
Art # A-11296
3-8
Manual 0-5192
Page 35
OPERATION FABRICATOR 181i
MIG
STICK
4T
2T
POWER
SOFT
WIRESPEED
HARD
FAULT
DOWNSLOPE(S)
10 10
22
99
11
ARCFORCE(%)
INDUCTANCE
2
6
8
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Art #
A-12167
MIG
LIFT TIG
STICK
4T
2T
WIRESPEED INDUCTANCE
-
HARD+ SOFT
DOWNSLOPE (S)
ARC FORCE (%)
A
V
10 10
22
44
77
99
11
33
66
88
2
4
6
8
Art #
A-10354
16
17
15
18
SECTION 4:
OPERATION
4.01 Power Source Controls, Indicators and Features
Figure 4-1: Front Panel Figure 4-2: Rear Panel
19
Art #
20
21
A-10355
Figure 4-3: Wire Feed Compartment Control
Manual 0-5192 4-1 Operation
Page 36
FABRICATOR 181i OPERATION
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.
Operation 4-2 Manual 0-5192
Page 37
OPERATION FABRICATOR 181i
CAUTION
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
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
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the bayonet terminal.
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
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.
2
1
5
4
8
7
Art # A-10421_AC
1
2
3
4
3
6
5
6
7
8
Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Trigger Switch
WV
Remote Volts in
MIG (GMAW/FCAW)
Negative
Spool Gun Motor
Positive
Figure 4-4: Remote Control Socket
Manual 0-5192 4-3 Operation
Page 38
FABRICATOR 181i OPERATION
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 4-1
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.
Operation 4-4 Manual 0-5192
Page 39
OPERATION FABRICATOR 181i
Note that when in 2T normal mode (Control No. 11), the Power Source will enter down slope mode as soon
as the trigger switch is released (ie if the multifunction control knob is set to 5, the Power Source will ramp
down from the present welding current to zero over 5 seconds). If no down slope time is set then the welding
output will cease immediately. If the Power Source is set to 4T latch mode, to enter down slope mode the
trigger must be held in for the selected time period (ie press and release trigger to commence welding, then
press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope
phase (4T only), the output will cease immediately.
10. Arc Control (Inductance)
The arc control operates in MIG mode only and is used to adjust the intensity of the welding arc. Lower arc
control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc
which can increase weld penetration. Soft means maximum inductance while Hard means minimum inductance.
11. Trigger Mode Control (MIG and LIFT TIG Mode only)
The trigger mode control is used to switch the functionality of the of the MIG or TIG Trigger Switch between
2T (normal) and 4T (latch mode)
2T (Normal Mode)
In this mode, the MIG or TIG Trigger Switch must remain depressed for the welding output to be active. Press
and hold the MIG or TIG Trigger Switch to activate the Power Source (weld). Release the MIG or TIG Trigger
Switch to cease welding.
4T (Latch Mode)
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator
can press and release the MIG or TIG Trigger Switch and the output will remain active. To deactivate the Power
Source, the trigger switch must again be depressed and released, thus eliminating the need for the operator
to hold the MIG or TIG Trigger Switch
Note that when operating in LIFT TIG mode, the Power Source will remain activated until the selected Downslope
time has elapsed (refer Control No. 9).
12. Process Selection Control
The process selection control is used to select the desired welding mode. Three modes are available, MIG,
LIFT TIG and STICK modes. Refer to section 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.
Manual 0-5192 4-5 Operation
Page 40
FABRICATOR 181i OPERATION
!
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.
16. On / Off Switch
This switch is used to turn the Power Source on/off.
When the front digital displays are lit, the machine is connected to the Mains supply voltage and the
internal electrical components are at Mains voltage potential.
Operation 4-6 Manual 0-5192
WARNING
Page 41
OPERATION FABRICATOR 181i
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).
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.
Manual 0-5192 4-7 Operation
Page 42
FABRICATOR 181i OPERATION
Art #
A-10356_AB
MIG Gun Adaptor
MIG Gun Connector
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.
Operation 4-8 Manual 0-5192
Figure 4-5: Attaching MIG Gun
Page 43
OPERATION FABRICATOR 181i
Art # A-11482_AB
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.
Screws
Art # A-11483
Securing Block
3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang
downwardly.
Tension Knob
Pressure Arm
Art # A-11484
Manual 0-5192 4-9 Operation
Page 44
FABRICATOR 181i OPERATION
4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed.
Thumb Screw
Fully Exposed
Art # A-11485_AB
5. Remove damaged thumb screw and replace with new one.
Push Upward
6. To reassemble, reverse steps 1 through 4.
Operation 4-10 Manual 0-5192
Art # A-11486
Page 45
OPERATION FABRICATOR 181i
Art #
A-10357
Friction Washer
4”（100mm）
Diameter spool
Nut with
Nylon Insert
Spring
Plastic Spacer
Brass Flat
Washer
Flat Washer
4.04 Installing 4" (100mm) Diameter Spool
As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter
spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 4-6.
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.
Figure 4-6: 4" (100mm) Diameter Spool Installation
Manual 0-5192 4-11 Operation
Page 46
FABRICATOR 181i OPERATION
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
Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical
components and possibly an increased incidence of electrode wire Burnback into contact tip.
Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 8" (200mm)
diameter spool.
NOTE
This alignment pin can be removed by unscrewing in an counterclockwise direction and locating
in the appropriate position.
Operation 4-12 Manual 0-5192
Figure 4-7: 8" (200mm) Diameter Spool Installation
Page 47
OPERATION 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.
Manual 0-5192 4-13 Operation
Figure 4-8: Wire Drive Assembly Components
MIG Welding Wire
Figure 4-9: MIG Welding Wire - Installation
Art #
A-10360
Page 48
FABRICATOR 181i OPERATION
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
The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.
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.
GROOVE “B”GROOVE “A”
GROOVE “B” SIZE
GROOVE “A” SIZE
A-09583
Figure 4-10: Dual Groove Feed Roller
Art #
A-09584_AC
Retaining Screw
Operation 4-14 Manual 0-5192
Feed Roll
Feed Roll
Figure 4-11: Changing the Feed Roll
Page 49
OPERATION 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
Manual 0-5192 4-15 Operation
Page 50
FABRICATOR 181i OPERATION
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.
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 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.
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.
Operation 4-16 Manual 0-5192
Page 51
OPERATION FABRICATOR 181i
Art #
A-10362
Shielding Gas Hose Fitted
with 5/8"-18 UNF
connection
Primary Cord
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.
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.
!
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.
WARNING
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
Figure 4-13: Setup for MIG Welding with Gas Shielded MIG Wire
Manual 0-5192 4-17 Operation
Page 52
FABRICATOR 181i OPERATION
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 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.
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.
Operation 4-18 Manual 0-5192
Page 53
OPERATION 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
Manual 0-5192 4-19 Operation
Page 54
FABRICATOR 181i OPERATION
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.
Art #
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.
A-10363
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.
Operation 4-20 Manual 0-5192
Page 55
OPERATION FABRICATOR 181i
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 Tweco 17V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch
trigger switch to TIG weld OR a Tweco Foot Control with an 8 pin plug must be used to turn the 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.
!
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.
Remove any packaging material prior to use. Do not block the air vents at the front or rear of the
Welding Power Source.
Loose welding terminal connections can cause overheating and result in the male plug being fused in
the terminal.
F. Switch the LOCAL/REMOTE switch inside the
wire feed compartment to LOCAL to use the
Power Sources Amperage control or REMOTE
for remote amperage using a Foot Control.
WARNING
CAUTION
Manual 0-5192 4-21 Operation
Page 56
FABRICATOR 181i OPERATION
A-10364
(+)
Art #
Connect to shielding gas
regulator/ow gauge.
Positive welding
terminal
.
Secure the gas cylinder
in an upright position by
chaining it to a stationary
support to prevent falling
or tipping.
MIG Gun
polarity lead
not connected.
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
turn the weld current on/o as well as
providing remote control of the weld current.
Figure 4-15: Setup for TIG Welding
Negative welding
terminal (- ).
Operation 4-22 Manual 0-5192
Page 57
OPERATION 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 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.
WARNING
Before connecting the work clamp to the work and inserting the electrode in the electrode 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.
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.
Manual 0-5192 4-23 Operation
Figure 4-16: Setup for Manual Arc Welding.
Page 58
FABRICATOR 181i OPERATION
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.
Operation 4-24 Manual 0-5192
Page 59
THEORY OF OPERATION 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
- -le -Smooth - - - le -Smooth
gh oltage gh o ltage gh voltage gh o ltage o oltage o oltage o oltage
o merage o merage o merage o merage gh merage gh merage gh merage
Art # A-09846
Manual 0-5192 5-1
Theory of Operation
Page 60
This Page Intentionally Blank
Page 61
TROUBLESHOOTING FABRICATOR 181i
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 cor-
rect mode of operation.
B Faulty torch trigger. B Repair or replace torch trigger
A Set the Power Source to the correct
mode of operation with the process
selection switch.
switch/lead.
2 Fault Indicator is illuminat-
ed 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.
B Poor or no work lead contact. B Clean work clamp area and ensure
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.
good electrical contact.
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 0-5192 6-1
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 impuri-
ties.
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.
Troubleshooting
Page 62
FABRICATOR 181i TROUBLESHOOTING
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
Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.
Have an accredited Tweco 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.
Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before
removing case.
!
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 0-5192
Page 63
TROUBLESHOOTING FABRICATOR 181i
1
2
6.04 Case Removal
!
Read and follow safety information in Section 6.02 before proceeding.
1. Cover
Remove Screws
Lossen Screws
Front & Rear
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 0-5192 6-3
Art # A-10457_AB
Troubleshooting
Page 64
FABRICATOR 181i TROUBLESHOOTING
6.05 Clear Cover Sheet Removal
!
Read and follow safety information in Section 6.02 before proceeding.
1. Clear protective sheet
Take out clear protective sheet.
1
Art # A-10458
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.
Troubleshooting
6-4 Manual 0-5192
Page 65
TROUBLESHOOTING 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
6.07 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
6.08 Preliminary Check of the Main Inverter Board
!
Read and follow safety information in Section 6.02 before proceeding.
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
0 VDC
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
Manual 0-5192 6-5
Positive meter lead to testpoint 5
Negative meter lead to testpoint 6
Positive meter lead to testpoint 7
Negative meter lead to testpoint 8
0.2 – 0.8 VDC
0.2 – 0.8 VDC
Troubleshooting
Page 66
FABRICATOR 181i TROUBLESHOOTING
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 Diode Voltage
IGBT 1
IGBT 2
IGBT 3
IGBT 4
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
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)
0.2 – 0.8 VDC
0.2 – 0.8 VDC
0.2 – 0.8 VDC
0.2 – 0.8 VDC
150 to 350 Ω
150 to 350 Ω
150 to 350 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 0-5192
Positive meter lead to testpoint 21
Negative meter lead to testpoint 22
0 to 100 Ω
Page 67
TROUBLESHOOTING FABRICATOR 181i
6.09 Check Main On / Off Switch
24
23
2526
Art # A-10459
Power Switch Testing Multimeter Lead Placement Impedance
Switch ON
Switch ON
Switch OFF
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-
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
0 to 1 Ω
> 1k Ω
> 1k Ω
0.2 – 0.8 VDC
0.2 – 0.8 VDC
0.2 – 0.8 VDC
0.2 – 0.8 VDC
Table 6-8 IGBT’s, Multimeter set to measure Diode Voltage
Measurements may be made directly onto the main input rectifier. AC1 and AC2 may be measured from the pins on
the mains supply plug with the main power switch set to the ON position.
Manual 0-5192 6-7
Troubleshooting
Page 68
FABRICATOR 181i TROUBLESHOOTING
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.
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 0-5192
161 VDC +/-10%
161 VDC +/-10%
322 VDC +/-10%
Page 69
TROUBLESHOOTING FABRICATOR 181i
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
6.12 PCB Connectors
1 Inverter PCB
IN Header Pin Pin function Signal
15 VDC
15 VDC pk
15 VDC pk
15 VDC pk
15 VDC pk
15 VDC pk
0 VDC
1 +15V
2
3
4
5
6
7
IGBT 1 pwm drive signal, 15V p-p square wave
IGBT 2 pwm drive signal, 15V p-p square wave
IGBT 2 pwm drive signal, 15V p-p square wave
IGBT 1 pwm drive signal, 15V p-p square wave
Rectified secondary of current transformer TR8
0V
Table 6-10 IN Header pin function (connects to DRIVE header on control PCB)
PWM Header Pin Pin function Signal
5 VDC pk
1 0VDC
2
Motor pwm drive signal
Table 6-11 PWM Header pin function (connects to PWM header on control PCB)
MD Header Pin Pin function Signal
1 Motor positive
2
Motor negative
Table 6-12 MD Header pin function (connects to motor)
0 VDC
24 VDC
0 VDC
Manual 0-5192 6-9
Troubleshooting
Page 70
FABRICATOR 181i TROUBLESHOOTING
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
2
3
0V
-24V
Table 6-14 DY2 Header pin function (connects to SOURCE header on control PCB)
DY1 Header Pin Pin function signal
1 +24V (solenoid positive)
2
3
4
5
+24V (solenoid positive)
Solenoid negative
0V
No connection
Table 6-15 DY1 Header pin function
QF/FJ Header Pin Pin function signal
1 +24V (VRD positive, South Pacific Version Only)
2
3
4
Solenoid negative
+24V (solenoid positive)
0V
Table 6-16 QF/FJ Header pin function (Connects to QF/DY header on control PCB)
24 VDC
0 VDC
-24 VDC
24 VDC
0V
n/c
24 VDC
0 VDC
24 VDC
0 VDC
24 VDC
0 VDC
GAS Header Pin Pin function signal
1 +24V (solenoid positive)
2
Solenoid negative
24 VDC
0 VDC
Table 6-17 GAS Header pin function (connects to Solenoid)
2 Control PCB
Troubleshooting
6-10 Manual 0-5192
Page 71
TROUBLESHOOTING FABRICATOR 181i
GUN Header Pin Pin function Signal
1 +24V trigger positive (0V when trigger closed)
2
0VDC
Table 6-18 GUN Header pin function (connects to GUN header on display PCB)
PWM Header Pin Pin function Signal
1 0VDC
2
Motor pwm drive signal
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)
2
3
4
Solenoid negative
+24V (solenoid positive)
0V
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)
2
0V (Fan negative) when fan is on
Table 6-21 FUNs Header pin function (not used)
24 VDC
0 VDC
0 VDC
5 VDC pk
24 VDC
0 VDC
24 VDC
0 VDC
24 VDC
0 VDC
DRIVE Header Pin Pin function Signal
1 +15V
2
3
4
5
6
7
IGBT 1 pwm drive signal, 15V p-p square wave
IGBT 2 pwm drive signal, 15V p-p square wave
IGBT 2 pwm drive signal, 15V p-p square wave
IGBT 1 pwm drive signal, 15V p-p square wave
Rectified secondary of current transformer TR8
0V
15 VDC
15 VDC pk
15 VDC pk
15 VDC pk
15 VDC pk
15 VDC pk
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
2
3
No connection
Negative welding terminal
positive VDC
n/c
0 VDC
Table 6-23 WVIN Header pin function
IFB Header Pin Pin function Signal
1 +15V
2
3
Current sensor signal
-15V
4 0V
15 VDC
-15 VDC
0 VDC
Table 6-24 IFB Header pin function (Connects to welding output current sensor)
SOURCE Header Pin Pin function Signal
1 +24V
2
3
Table 6-25 SOURCE Header pin function (connects to DY2 header on control PCB)
Manual 0-5192 6-11
0V
-24V
24 VDC
0 VDC
-24 VDC
Troubleshooting
Page 72
FABRICATOR 181i TROUBLESHOOTING
J12
Volts/Downslope / Arcforce
GUN1
GUN
R-G
J11
REMOTE
Amps
Inductance
JC
J1
A-09992
CR Header Pin Pin function Signal
1 +5V
2
3
Wiper 10k Burnback potentiometer
0V
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)
2
0V
Table 6-27 IGBT OT Header pin function (connects to igbt thermostat)
NTCS Header Pin Pin function Signal
1 +24V
2
0V
Table 6-28 NTCS Header pin function (connects to NTCS header on inverter PCB)
MB Header Pin Pin function Signal
1 Serial display data & eprom (D-IN)
2
3
4
5
6
2T/4T pushbutton (0V when button pushed)
Serial display data (LOAD)
Serial display data (CLK)
Serial display eprom (D-OUT)
Stick mode (used for remote / local)
7 Chip select
8
9
10
11
MODE pushbutton (0V when button pushed)
15VDC
Remote / Local switch
Inductance pot terminal 2
12 Volts setpoint
13
Inductance pot terminal 1
14 Amps setpoint
15
16
5VDC
0V
5 VDC
0 – 5 VDC
0 VDC
VDC
0 VDC
24 VDC
0 VDC
5 VDC digital
5 VDC digital
5 VDC digital
0VDC
5 VDC digital
5 VDC digital
0VDC
15 VDC
0 – 5 VDC
0 – 5 VDC
5 VDC
0 VDC
Table 6-29 MB Header pin function (connects to J12 header on display PCB)
3 Display PCB
Troubleshooting
6-12 Manual 0-5192
Page 73
TROUBLESHOOTING FABRICATOR 181i
GUN Header Pin Pin function Signal
1 +24V trigger positive (0V when trigger closed)
2
0VDC
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)
2
0VDC
Table 6-31 GUN Header pin function (connects to front panel torch trigger terminals)
REMOTE Header Pin Pin function Signal
1
2
Remote switch
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)
2
3
4
5
6
2T/4T pushbutton (0V when button pushed)
Serial display data (LOAD)
Serial display data (CLK)
Serial display eprom (D-OUT)
Stick mode (used for remote / local)
7 Chip select
8
9
10
11
MODE pushbutton (0V when button pushed)
15VDC
Remote / Local switch
Inductance pot terminal 2
12 Volts setpoint
13
Inductance pot terminal 1
14 Amps setpoint
15
16
5VDC
0V
24 VDC
0 VDC
24 VDC
0 VDC
5 VDC digital
5 VDC digital
5 VDC digital
0VDC
5 VDC digital
5 VDC digital
0VDC
15 VDC
0 – 5 VDC
0 – 5 VDC
5 VDC
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)
3
4
5 -12VDC
6
7
8
Table 6-34 R-G Header pin function (connects to front panel 8 pin remote socket)
Manual 0-5192 6-13
No connection Fabricator 181i
Spool gun motor negative for Fabricator 141i & 181i)
0VDC
No connection Fabricator 181i
Spool gun motor positive for Fabricator 141i & 181i)
+12VDC
Remote amps
Remote volts
24 VDC
0 VDC
-12 VDC
+12 VDC
-12 to +12 VDC
-12 to +12 VDC
Troubleshooting
Page 74
FABRICATOR 181i TROUBLESHOOTING
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)
2
3
4
5
6
2T/4T pushbutton (0V when button pushed)
Serial display data (LOAD)
Serial display data (CLK)
Serial display eprom (D-OUT)
Stick mode (used for remote / local)
7 Chip select
8
9
10
11
MODE pushbutton (0V when button pushed)
15VDC
Remote / Local switch
Inductance pot terminal 2
12 Volts setpoint
13
Inductance pot terminal 1
14 Amps setpoint
15
16
5VDC
0V
Table 6-35 J1 Header pin function (connects to MB header on control PCB)
5 VDC digital
5 VDC digital
5 VDC digital
0VDC
5 VDC digital
5 VDC digital
0VDC
15 VDC
0 – 5 VDC
0 – 5 VDC
5 VDC
0 VDC
6.13 DIP Switch Settings, Control PCB
1 DIP Switch SW0, control PCB
Troubleshooting
6-14 Manual 0-5192
A-12583
Page 75
TROUBLESHOOTING FABRICATOR 181i
SW0 position Normal Calibration
1 OFF Set to ON for Fabricator 181i
2
3
4
Table 6-36 SW0 Dip Switch functions
6.14 Calibration
1 Calibration
Imin
Imax
OFF Set to ON for Fabricator 181i
OFF Set to ON for Fabricator 181i
OFF OFF
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
SW0
WVF
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.
Manual 0-5192 6-15
Troubleshooting
Page 76
FABRICATOR 181i TROUBLESHOOTING
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
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
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 cali-
bration of wire feed speed and return to normal operation.
Troubleshooting
6-16 Manual 0-5192
Page 77
TROUBLESHOOTING FABRICATOR 181i
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.
TEST POINT “A” 5V/div TEST POINT “B” 5V/div
TEST POINT “C” 5V/div TEST POINT “D” 5V/div
TEST POINT “E” and “F” 5V/div TEST POINT “G” 5V/div
Manual 0-5192 6-17
Art # A-11231
Troubleshooting
Page 78
FABRICATOR 181i TROUBLESHOOTING
6.15 Main Circuit Description
!
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.
COUT1
OUT+
WVOUT
C100
J1
PTC
DC+
DC-
Q1
AC
R102
T14-1
T13-1
R100
AC
T20-1
T1
WVOUT -1
1
T15-1
TRANSFORMER
PRI-A
T2
R104
1
T16-1
T17-1
TR8
T19-1
T4
R106
C102
R107
T18-1
OUT -
C101
R103
R101
COUT2
A-09997
1
Troubleshooting
CY1
TR1
CIN1 CIN2
AC
6-18 Manual 0-5192
R200-1
CU3CU4 R200
AC1
R32
R24
C20
R39- 1
C19
C18
C23
DC+
R39
R33
R25
PRI-A
R28
C21
T5
R36
R38
R29
C16 C17
C24
R37
R38- 1
DC-
Page 79
TROUBLESHOOTING 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 0-5192 6-19
Troubleshooting
Page 80
FABRICATOR 181i TROUBLESHOOTING
6.16 Circuit Diagram
2
4
J
J
J24J
J
J
JJ
J
J
J
J
Art # A-11230
Troubleshooting
6-20 Manual 0-5192
Page 81
DISASSEMBLY PROCEDURE FABRICATOR 181i
SECTION 7:
DISASSEMBLY PROCEDURE
7.01 Safety Precautions for Disassembly
!
Read and follow safety information in Section 6.02 before proceeding.
Unplug unit before beginning Disassembly procedure.
Manual 0-5192 7-1
Disassembly Procedure
Page 82
FABRICATOR 181i DISASSEMBLY PROCEDURE
32
11
7.02 Control Board Removal
!
Read and follow safety information in Section 6.02 before proceeding with disassembly.
Remove case (refer to 6.04) before remove control board.
1. M4 Screw. Remove 4 screws from Control panel.
2 Disconnect DRIVE harness from DRIVE connector.
3. Disconnect SOURCE harness from SOURCE connector.
4. Disconnect CR harness from CR connector.
5. Disconnect FUNs harness from FUNs connector.
6. Disconnect NTCS harness from NTCS connector.
7. Disconnect IGBT OT harness from IGBT OT connector.
8. Disconnect GUN harness from GUN connector.
9. Disconnect QF/DY harness from QF/DY connector.
10. Disconnect WVIN harness from WVIN connector.
11 Disconnect MB harness from MB connector.
12. Disconnect PWM harness from PWM connector.
13. Disconnect IFB harness from IFB connector.
Ensure to unplug all harness from the main control PCB.
10
9
8
7
12
13
1
6
Disassembly Procedure
7-2 Manual 0-5192
5
Art # A-10460
4
Page 83
DISASSEMBLY PROCEDURE FABRICATOR 181i
WVIN
QF/DY
GUN
IGBT OT
NTCS
FUNs
CR
PWMMB
SOURCE
IFB
DRIVE
A-10018
Manual 0-5192 7-3
Disassembly Procedure
Page 84
FABRICATOR 181i DISASSEMBLY PROCEDURE
7.03 Front Panel Assembly Removal
!
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.
1
Art # A-10461_AB
3
2
4
Disassembly Procedure
7-4 Manual 0-5192
Page 85
DISASSEMBLY PROCEDURE FABRICATOR 181i
Manual 0-5192 7-5
A-09965_AB
Disassembly Procedure
Page 86
FABRICATOR 181i DISASSEMBLY PROCEDURE
7.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal
!
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.
1
Art # A-10462_AB
3
2
Art # A-10463
Disassembly Procedure
7-6 Manual 0-5192
Page 87
DISASSEMBLY PROCEDURE 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
Art # A-10464_AB
Manual 0-5192 7-7
5
Disassembly Procedure
Page 88
FABRICATOR 181i DISASSEMBLY PROCEDURE
7.06 Power Switch S1 and Power Cord Removal
!
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.
1
5
3
Art # A-10467_AB
4
2
6
Disassembly Procedure
7-8 Manual 0-5192
A_10006
Page 89
DISASSEMBLY PROCEDURE FABRICATOR 181i
3
4
7.07 Base Panel Removal and Main PCB Disassembly
!
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
5
A-10007
8
Art # A-10465
6
Manual 0-5192 7-9
7
Disassembly Procedure
Page 90
This Page Intentionally Blank
Page 91
ASSEMBLY PROCEDURE FABRICATOR 181i
5
SECTION 8:
ASSEMBLY PROCEDURES
8.01 Installing Base Board
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.
4
1
3
7
2
8
Manual 0-5192 8-1 Assem
6
Art # A-11269
bly Procedures
Page 92
FABRICATOR 181i ASSEMBLY PROCEDURES
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
Art # A-10116_AB
6
Assembly Procedures
8-2 Manual 0-5192
Page 93
ASSEMBLY PROCEDURE FABRICATOR 181i
7
8
Manual 0-5192 8-3 Assem
9
A-10114
bly Procedures
Page 94
FABRICATOR 181i ASSEMBLY PROCEDURES
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.
1
2
1
Art # A-11270_AB
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 0-5192
Page 95
ASSEMBLY PROCEDURE FABRICATOR 181i
Manual 0-5192 8-5 Assem
A-09965_AB
bly Procedures
Page 96
FABRICATOR 181i ASSEMBLY PROCEDURES
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 0-5192
Page 97
ASSEMBLY PROCEDURE FABRICATOR 181i
32
11
12
13
10
9
8
7
6
5
1
4
14
Art # A-11271
Manual 0-5192 8-7 Assem
bly Procedures
Page 98
FABRICATOR 181i ASSEMBLY PROCEDURES
8.05 Installing Case
1. Install Case.
2. Install Ground Screw, which connects the ground wire to the cover.
3. Install Screws. Tighten screws.
1
Install Screws
Tighten Screws
Front & Rear
2
Art # A-10468_AB
Assembly Procedures
8-8 Manual 0-5192
Page 99
KEY SPARE PARTS 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 0-5192 9-1 Key Spare Parts
TWECO WELDSKILL 180A MIG GUN PARTS
Page 100
FABRICATOR 181i KEY SPARE PARTS
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 0-5192
** Patent Pending
* Refer to Tweco Catalog No. 64-2103 for additional
options.
Loading...