ESAB Fabricator 181i Operating Manual
  1. Manuals
  2. Brands
  3. ESAB Manuals
  4. Welding System
  5. Fabricator 181i
  6. Operating manual

ESAB Fabricator 181i Operating Manual

3-in-1 multi process welding systems
Hide thumbs Also See for Fabricator 181i:
Table of Contents

Advertisement

Quick Links

See also: Service Manual
ESAB Fabricator
181i
®
3-IN-1 Multi Process
Welding Systems
Operating
Manual
A-12919
180
3163339
Révision : AA Issue Date: September 9, 2015 Manual No.: 0-5421
esab.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Fabricator 181i and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ESAB Fabricator 181i

Summary of Contents for ESAB Fabricator 181i

  • Page 1 ESAB Fabricator 181i ® 3-IN-1 Multi Process Welding Systems Operating Manual A-12919 3163339 Révision : AA Issue Date: September 9, 2015 Manual No.: 0-5421 esab.com...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network.
  • Page 3 ESAB 2800 Airport Rd. Denton, TX 76208 www.esab.com Copyright 2015 by ESAB All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equip- ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...

  • Page 5: Table Of Contents

    2.04 Description ..................... 2-1 2.05 Transportation Methods .................. 2-1 2.06 User Responsibility ..................2-2 2.07 Fabricator 181i Portable System Package (Part No. W1003181) ....2-2 2.08 Duty Cycle ....................... 2-3 2.09 Specifications ....................2-3 2.10 Options and Accessories ................2-5 SECTION 3: INSTALLATION, OPERATION AND SETUP ............
  • Page 6 Cleaning the Feed Rolls ................... 5-4 5.05 Volt-Ampere Curves ..................5-5 SECTION 6: KEY SPARE PARTS ................6-1 6.01 Tweco Fusion 180A MIG Gun Parts ..............6-1 6.02 Power Source ....................6-2 APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM ............ A-1 INTERNATIONAL CONTACT INFORMATION ..........REAR COVER...

  • Page 7: Section 1: Safety

    SECTION 1: SAFETY Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment.
  • Page 8 ESAB FABRICATOR 181i Arc welding and cutting can be injurious to yourself and others. WARNING Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill.

  • Page 9: Section 2 System: Introduction

    2.04 Description ment. WARNING The ESAB Fabricator 181i is a self contained single phase multi process welding system that is capable of performing MIG A procedure which, if not properly fol- (GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding lowed, may cause injury to the operator or processes.

  • Page 10: User Responsibility

    ESAB. Advice in this regard can be obtained by contacting an Accredited ESAB Distributor. This equipment or any of its parts should not be altered from standard specification without prior written approval of ESAB. The...

  • Page 11: Duty Cycle

    Welding Current (amps) A-10352 Figure 2-1: Fabricator 181i Duty Cycle 2.09 Specifications DESCRIPTION FABRICATOR 181i MULTI PROCESS 3 IN 1 WELDER Power Source Part No. W1003180 Power Source Dimensions H16.14" x W8.27" x D17.72" (410mm x 210mm x 450mm) Power Source Mass 32.2lb(14.6kg)
  • Page 12 Power Source (Based on Article 630, National Electrical Code) ESAB continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speci fications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the correspond- ing changes, updates, improvements or replacement of such items.

  • Page 13: Options And Accessories

    PART NUMBER ESAB Fusion 180A MIG Gun, 12ft (3.6m) Length F180TA-12-3035 ESAB Spool Gun 160A,12ft (3.6M) Length, suits 4" (100mm) spools for aluminum welding SG160TA-12-3035 W4013802 TIG Torch, 17V, 12.5 ft, 8 pin and accessory kit with 1/16", 3/32", 1/8" thoriated tungstens;...
  • Page 14 ESAB FABRICATOR 181i This Page Intentionally Blank INTRODUCTION Manual 0-5421...

  • Page 15: Installation, Operation And Setup

    A. In areas, free from moisture and dust. WARNING B. Ambient temperature between 32 to 104° F (0 to 40° C). The Fabricator 181i must be electri- C. In areas, free from oil, steam and corrosive gases. cally connected by a qualified electri- cal trades-person.
  • Page 16 ESAB FABRICATOR 181i Electrical Input Requirements Operate the welding Power Source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the elec- trical 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.

  • Page 17: Electromagnetic Compatibility

    ESAB FABRICATOR 181i 8. The immunity of other equipment in the environment: 3.05 Electromagnetic Compatibility the user shall ensure that other equipment being used in the environment is compatible: this may require WARNING additional protection measures. Extra precautions for Electromagnetic...

  • Page 18: Victor Regulator

    ESAB FABRICATOR 181i in some countries where direct connection is not b) Low pressure gauges must be UL recognized for permitted, the bonding should be achieved by suitable the class of regulator they are being used on ac- capacitance, selected according to national regula- cording to UL252A.

  • Page 19: Leak Testing The System

    ESAB FABRICATOR 181i 3.07 Leak Testing the System WARNING DO NOT tamper with the relief valve or Leak test the system before putting into operation. remove it from the regulator. 1. Be sure that there is a valve in the downstream equip- ment to turn OFF the gas flow.

  • Page 20: Power Source Controls, Indicators And Features

    ESAB FABRICATOR 181i 3.10 Power Source Controls, Indicators and Features A-13038 Figure 3-4: Front Panel Figure 3-5: Rear Panel Art # A-10355 Figure 3-6: Wire Feed Compartment Control INSTALLATION, OPERATION AND SETUP Manual 0-5421...
  • Page 21 2. Digital Wirespeed/Amperage Meter (Left Digital Dis- 4. MIG Gun Adaptor (ESAB Style) play) The MIG Gun adaptor is the connection point for the ESAB This digital meter displays preview Wirespeed in MIG mode Fusion MIG Gun. Connect the MIG Gun by pushing the MIG...
  • Page 22 8. Remote Control and Spool Gun Socket The 8 pin socket is used to connect the ESAB Fusion MIG Gun, remote control device or spool gun plug to the welding Power Source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.
  • Page 23 ESAB FABRICATOR 181i When MIG Mode is Selected 2T (Normal Mode) In this mode the control knob is used to adjust the MIG In this mode, the MIG or TIG Trigger Switch must remain welding voltage of the Power Source. The welding voltage depressed for the welding output to be active.
  • Page 24 The 10A fuse is used to protect the spool gun motor. 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)

  • Page 25: Attaching The Esab Fusion 180A Gun

    3.11 Attaching the ESAB Fusion 180A Gun Fit the ESAB 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.

  • Page 26: Torch Adapter Thumb Screw Replacement

    ESAB FABRICATOR 181i 3.12 Torch Adapter Thumb Screw Replacement 1. Place unit on its back. A-12958 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.

  • Page 27: Installing 4" (100Mm) Diameter Spool

    ESAB FABRICATOR 181i 4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed. Push Upward Thumb Screw Fully Exposed Art # A-11485_AB 5. Remove damaged thumb screw and replace with new one. Art # A-11486 6.

  • Page 28: Installing 8" (200Mm) Diameter Spool

    ESAB FABRICATOR 181i Spring Plastic Spacer Friction Washer 4”（100mm） Brass Flat Diameter spool Washer Flat Washer Nut with Nylon Insert Art # A-10357 Figure 3-9: 4" (100mm)Diameter Spool Installation 3.14 Installing 8" (200mm) Diameter Spool As delivered from the factory, the Power Source is set for a 8" (200mm) diameter spool.

  • Page 29: Inserting Wire Into The Wire Feed Mechanism

    ESAB FABRICATOR 181i 3.15 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 3-11).

  • Page 30: Feed Roller Pressure Adjustment

    ESAB FABRICATOR 181i 3.16 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.

  • Page 31: Wire Reel Brake

    ESAB FABRICATOR 181i 3.18 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"...

  • Page 32: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    C. Fit the MIG Gun to the Power Source. (Refer to section 3.07 Attaching the ESAB Fusion 180A MIG 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.

  • Page 33: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    ESAB FABRICATOR 181i Art # A-10362 Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. Positive Welding Shielding Gas Hose Fitted Terminal (+) with 5/8"-18 UNF connection MIG Gun...
  • Page 34 ESAB FABRICATOR 181i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead. A-09587_AD Work Lead Figure 3-17: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire INSTALLATION, OPERATION AND SETUP 3-20...

  • Page 35: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    ESAB FABRICATOR 181i 3.22 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.

  • Page 36: Setup For Lift Tig (Gtaw) Welding

    NOTE! A ESAB 17V TIG torch with an 8 pin plug must be used to turn the weld current ON/OFF via the TIG torch trigger switch to TIG weld OR a ESAB Foot Control with an 8 pin plug must be used to turn the weld current ON/OFF as well as providing remote control of the weld current.
  • Page 37 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a ESAB Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as...

  • Page 38: Setup For Stick (Smaw) Welding

    ESAB FABRICATOR 181i 3.24 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.

  • Page 39: Basic Welding Guide

    ESAB FABRICATOR 181i SECTION 4: Shielding Gas Nozzle (Optional) BASIC WELDING GUIDE (Optional) Molten Metal Flux Cored Molten Electrode 4.01 MIG (GMAW/FCAW) Basic Welding Slag Slag Technique Solidified Two different welding processes are covered in this section Base Metal Weld Metal...
  • Page 40 ESAB FABRICATOR 181i Preselected Variables Preselected variables depend upon the type of material being 5° to 15° welded, the thickness of the material, the welding position, the Longitudinal Angle deposition rate and the mechanical properties. These variables 30° to 60°...
  • Page 41 ESAB FABRICATOR 181i Transverse When changing to a different electrode wire diameter, different Angle control settings are required. A thinner electrode wire needs more Wirespeed to achieve the same current level. A satisfactory weld cannot be obtained if the Wirespeed and...
  • Page 42 ESAB FABRICATOR 181i ESAB MIG, Lift TIG, Stick Wire Selection Chart A-12921 Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart BASIC WELDING GUIDE Manual 0-5421...

  • Page 43: Mig (Gmaw/Fcaw) Welding Troubleshooting

    ESAB FABRICATOR 181i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG Gun. There are two main areas where problems occur with MIG, Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
  • Page 44 ESAB FABRICATOR 181i WARNING Disengage the feed roll when testing for gas flow by ear. Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE Feed roller driven by motor in the Wire spool brake is too tight.
  • Page 45 9 Poor weld result from setup Contact tip has arc marks in the Replace the contact tip with only a Genuine ESAB chart parameters bore causing excessive drag on Velocity contact tip. the wire...

  • Page 46: Stick (Smaw) Basic Welding Technique

    ESAB FABRICATOR 181i 4.03 Stick (SMAW) Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide sufficient current (amperage) to run the smaller size electrodes.
  • Page 47 ESAB FABRICATOR 181i Art # A-07694 Art # A-07688 Figure 4-12: Flat Position, Gravity Fillet Weld Figure 4-18: Overhead Position, Fillet Weld Art # A-07689 Figure 4-13: Horizontal Position, Butt Weld Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position Art A-07691...

  • Page 48: Lap Joint

    ESAB FABRICATOR 181i Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 49 ESAB FABRICATOR 181i Striking the Arc A. Butt Welds Practice this on a piece of scrap plate before going on to more Set up two plates with their edges parallel, as shown in exacting work. You may at first experience difficulty due to the Figure 4-21, allowing 1/16"(1.6mm) to 3/32"(2.4mm)
  • Page 50 ESAB FABRICATOR 181i These are welds of approximately triangular cross-section motion is necessary to cover the first run and obtain made by depositing metal in the corner of two faces meeting good fusion at the edges. At the completion of each at right angles.
  • Page 51 ESAB FABRICATOR 181i B. Expansion and Contraction of Parent Metal in the Apart from the rather awkward position necessary, Fusion Zone: overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead While welding is proceeding, a relatively small volume of the...
  • Page 52 ESAB FABRICATOR 181i Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion. C. Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and tack welds Art # A-07710_AB Block Sequence.

  • Page 53: Stick (Smaw) Welding Troubleshooting

    ESAB FABRICATOR 181i 4.05 Stick (SMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob Reduce the ARC FORCE control knob until welding varying is set at a value that causes current is reasonably constant while prohibiting the...
  • Page 54 ESAB FABRICATOR 181i FAULT CAUSE REMEDY 4 A groove has been A Welding current is too high. A Reduce welding current. formed in the base metal adjacent to B Welding arc is too long. B Reduce the length of the welding arc.

  • Page 55: Tig (Gtaw) Basic Welding Technique

    ESAB FABRICATOR 181i FAULT CAUSE REMEDY Slag trapped in undercut Not cleaned, or incorrect electrode Slag trapped in root Art # A-05868_AC Figure 3: Example of Slag Inclusion 8 The Stick The Stick electrode being Use E6013 or E7018 Stick electrodes for steel or...
  • Page 56 Wider current Grey copper, aluminum, range, Narrower more magnesium and their concentrated arc. alloys Table 4-9 NOTE! The Fabricator 181i is not suited for AC TIG welding. Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type Thickness...

  • Page 57: Tig (Gtaw) Welding Problems

    Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.thermalarc.com or contact ESAB. 4.07 TIG (GTAW) Welding Problems...
  • Page 58 ESAB FABRICATOR 181i FAULT CAUSE REMEDY 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates. piece or filler rod material. B Work piece surface has B Clean surface. foreign material on it.

  • Page 59: Section 5: Power Source Problems And Routine Service Requirements

    ESAB FABRICATOR 181i SECTION 5: Power Source PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY Electricity Supply is A Power Source is not in the Set the Power Source to the ON, power indicator is correct mode of operation.

  • Page 60: Routine Service And Calibration Requirements

    B. Insulation Resistance Minimum insulation resistance for in-service ESAB Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 6-1below. Power Sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.
  • Page 61 2. The earth terminal of the associated plug of a transportable Power Source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying ESAB welding Power Sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.

  • Page 62: Cleaning The Welding Power Source

    Output current (A) to be checked to ensure it falls within applicable ESAB Power Source specifications Output Voltage (V) to be checked to ensure it falls within applicable ESAB Power Source specifications Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required ESAB Power Source / wire feeder specifications...

  • Page 63: Volt-Ampere Curves

    ESAB FABRICATOR 181i 5.05 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. Art # A-11296 Figure 5-1: Fabricator 181i Volt-Ampere Curves Manual 0-5421 TROUBLESHOOTING AND SERVICE...
  • Page 64 ESAB FABRICATOR 181i This Page Intentionally Blank TROUBLESHOOTING AND SERVICE Manual 0-5421...

  • Page 65: Section 6: Key Spare Parts

    ESAB Rear Connector 350-174H ESAB Control Wire 35K-350-1 ESAB Control Wire & Plug WS-354-TA-LC Table 6-1: Tweco Fusion 180A MIG Gun Parts ** Patent Pending Figure 6-1 * Refer to ESAB Catalog No. 64-2103 for additional options. Manual 0-5421 KEY SPARE PARTS...

  • Page 66: Power Source

    ESAB FABRICATOR 181i 6.02 Power Source Figure 6-2 KEY SPARE PARTS Manual 0-5421...
  • Page 67 ESAB FABRICATOR 181i FABRICATOR 181i POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7004962 PCB,Power,181i W7004963 PCB,Control,181i W7003033 Solenoid,Valve,24VDC W7004970 PCB,Display,181i W7004969 PCB,Remote Interface,181i W7004905 Wiredrive Assy,w/ Motor,181i W7004906 Feedroll retaining thumb screw 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed W7004947 Fan,24VDC,4.75"x4.75"x1",181i...
  • Page 68 ESAB FABRICATOR 181i This Page Intentionally Blank KEY SPARE PARTS Manual 0-5421...

  • Page 69: Appendix: Fabricator 181I Circuit Diagram

    ESAB FABRICATOR 181i APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM 3 +24VDC1 1 +12VDC 2 RETURN Manual 0-5421 APPENDIX...

  • Page 70: Revision History

    ESAB FABRICATOR 181i REVISION HISTORY Date Rev Description 09/09/2015 Manual release APPENDIX Manual 0-5421...
  • Page 72 ESAB Asia/Pacific Pte Ltd ESAB Nederland B.V. Singapore Amersfoort Tel: +65 6861 43 22 Tel: +31 33 422 35 55 Fax: +65 6861 31 95 Fax: +31 33 422 35 44 www.esab.eu ©2015 ESAB Welding and Cutting Products Printed in China...

Table of Contents