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ESAB fabricator 141i Operating Manual

3-in-1 multi process welding systems
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ESAB Fabricator
141i
®
3-IN-1 Multi Process
Welding Systems
Operating
Manual
3163339
Révision : AA Issue Date: September 10, 2015 Manual No.: 0-5420
esab.com

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  • Page 1 ESAB Fabricator 141i ® 3-IN-1 Multi Process Welding Systems Operating Manual 3163339 Révision : AA Issue Date: September 10, 2015 Manual No.: 0-5420 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

    Description ..................... 2-1 2.05 Transportation Methods ..................2-2 2.06 User Responsibility ....................2-2 2.07 Fabricator 141i Portable System Package (Part No. W1003141) ......2-2 2.08 Duty Cycle ......................2-3 2.09 Specifications ....................... 2-3 SECTION 3: INSTALLATION, OPERATION AND SETUP ..........3-1 3.01...
  • Page 6 SECTION 6: KEY SPARE PARTS ................6-1 6.01 Tweco Fusion 140A MIG Gun Parts ..............6-1 6.02 Power Source ....................6-2 6.03 Hardware List ....................6-4 APPENDIX ....................A-1 APPENDIX: FABRICATOR 141I CIRCUIT DIAGRAM ............ A-2 REVISION HISTORY ..................A-4 INTERNATIONAL CONTACT INFORMATION ..........REAR COVER...

  • 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 141i 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 141i is a self contained single phase multi A procedure which, if not properly fol- process welding system that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding lowed, may cause injury to the operator or processes.

  • Page 10: Transportation Methods

    ESAB. Advice in this regard can be obtained by contacting an Accredited ESAB Distributor. This equipment or any of its parts should not be altered from standard specification without prior written approval of ESAB. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately quali- fied persons approved by ESAB.

  • Page 11: Duty Cycle

    Art # A-11276_AB Welding Current (amps) Figure 2-1: Fabricator 141i Duty Cycle 2.09 Specifications DESCRIPTION FABRICATOR 141i MULTI PROCESS 3 IN 1 WELDER Power Source Part No. W1003140 Power Source Dimensions H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm) Power Source Weight 32.2lb(14.6kg)
  • Page 12 ESAB FABRICATOR 141i This Page Intentionally Blank INTRODUCTION Manual 0-5420...

  • Page 13: Section 3: Installation, Operation And Setup

    2-4. 3.02 Location WARNING Be sure to locate the welder according to the following guide- The Fabricator 141i must be electri- lines: cally connected by a qualified electri- A. In areas, free from moisture and dust. cal trades-person. Damage to the PCA (Power Control Assembly) could occur B.
  • Page 14 ESAB FABRICATOR 141i source whenever necessary to inspect or service the unit. Do not connect an input (WHITE or BLACK) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal. • Correctly installed, if necessary, by a qualified electrician.

  • Page 15: Electromagnetic Compatibility

    ESAB FABRICATOR 141i 3.05 Electromagnetic Compatibility 8. The compatibility of other equipment in the environ- ment: the user shall ensure that other equipment being used in the environment is compatible: this may WARNING require additional protection measures. Extra precautions for Electromagnetic...

  • Page 16: Victor Flowmeter/ Regulator

    ESAB FABRICATOR 141i conform with the requirements of UL 404, be made by direct connection to the workpiece, but in some countries where direct connection is not “Indicating Pressure Gauges for Compressed Gas permitted, the bonding should be achieved by suitable Service.”...

  • Page 17: Leak Testing The System

    ESAB FABRICATOR 141i b) If the low-pressure gauge drops, there is a leak WARNING in the down stream equipment, hose, hose fitting, DO NOT tamper with the relief valve or outlet fitting or low-pressure gauge. Check for remove it from the flowmeter/ regulator.

  • Page 18: Power Source Controls, Indicators And Features

    ESAB FABRICATOR 141i 3.10 Power Source Controls, Indicators and Features A-13037 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 0-5420...
  • Page 19 4. MIG Gun Adapter (ESAB Style) been established. It also displays preview amperage in both The MIG Gun adapter is standard ESAB connection with an the STICK and LIFT TIG modes only then actual amperage 8 pin gun trigger for the Fusion MIG Gun. Connect the MIG (weld current) once an arc has been established.
  • Page 20 ESAB FABRICATOR 141i 7. Negative Welding Output Terminal The negative welding terminal is used to connect the welding output of the Power Source to the appropriate welding accessory such as the MIG Gun (via the MIG Gun polarity lead), TIG Torch or work lead. Negative welding current flows to the Power Source via 25mm Dinse style connector.
  • Page 21 ESAB FABRICATOR 141i 2T (Normal Mode) When MIG Mode is Selected In this mode, the MIG or TIG Trigger Switch must remain In this mode the control knob is used to adjust the MIG depressed for the welding output to be active. Press and welding voltage of the Power Source.
  • Page 22 ESAB FABRICATOR 141i When triggered in MIG mode, fan will not turn on until Power NOTE! Supply reaches temperatures in which cooling is required. The preview functionality provided on When in Lift TIG mode, as soon as output is enabled, the...

  • Page 23: Attaching The Fusion 140A Mig Gun

    ESAB FABRICATOR 141i 3.11 Attaching the Fusion 140A MIG Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter.

  • Page 24: Installing 4" (100Mm) Diameter Spool

    ESAB FABRICATOR 141i WARNING Before connecting the work clamp to the work piece, make sure you have ceased feeding wire so prema- ture arcing will not occur. The electrode wire will be at welding voltage potential while it is being fed through the system.

  • Page 25: Installing 8" (200Mm) Diameter Spool

    ESAB FABRICATOR 141i Spring Plastic Spacer Friction Washer 4”（100mm） Brass Flat Diameter spool Washer Flat Washer Nut with Nylon Insert Art # A-10357 Figure 3-11: 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 26: Feed Roller Pressure Adjustment

    ESAB FABRICATOR 141i 3.15 Feed Roller Pressure Adjustment 3.17 Wire Reel Brake The pressure (top) roller applies pressure to the grooved The wire reel hub incorporates a friction brake which is feed roller via an adjustable pressure screw. These devices adjusted during manufacture for optimum breaking.

  • Page 27: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    ESAB FABRICATOR 141i Adjusting Flow Rate G. Switch the LOCAL/REMOTE switch inside the wire feed compartment With the flowmeter/ regulator ready for operation, adjust work- to LOCAL to use the Power Sources ing flow rate as follows: Wirespeed and Voltage controls.

  • Page 28: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    ESAB FABRICATOR 141i 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 29: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    ESAB FABRICATOR 141i 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 3.21 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire Set the Process Selection Control to MIG for Spool Gun welding.

  • Page 30: 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 31: Setup For Stick (Smaw) Welding

    ESAB FABRICATOR 141i Art # A-11576_AB Connect to shielding gas regulator/flow gauge. Secure the gas cylinder Positive Welding in an upright position by Terminal (+) chaining it to a stationary support to prevent falling or tipping. Negative welding terminal (-)

  • Page 32: Torch Adapter Thumb Screw Replacement

    ESAB FABRICATOR 141i Positive Welding Terminal (+) Negative Welding Electrode MIG Gun Terminal (-) Holder polarity lead not connected. Art # A-10365 Work Lead Figure 3-19: Setup for Stick Welding(SMAW) 3.24 Torch Adapter Thumb Screw Replacement WARNING All power to unit should be removed.
  • Page 33 ESAB FABRICATOR 141i Securing Block Screws Art # A-11483 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 4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed.
  • Page 34 ESAB FABRICATOR 141i Push Upward Thumb Screw Fully Exposed Art # A-11485_AB 5. Remove damaged thumb screw and replace with new one. Art # A-11486 6. To reassemble, reverse steps 1 through 4. INSTALLATION, OPERATION AND SETUP 3-22 Manual 0-5420...

  • Page 35: Section 4: Basic Welding Guide

    ESAB FABRICATOR 141i SECTION 4: BASIC WELDING Shielding Gas Nozzle (Optional) (Optional) GUIDE Molten Metal Flux Cored Molten Electrode Slag 4.01 MIG (GMAW/FCAW) Basic Welding Slag Technique Solidified Base Metal Two different welding processes are covered in this section Weld Metal...
  • Page 36 ESAB FABRICATOR 141i 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 37 ESAB FABRICATOR 141i When changing to a different electrode wire diameter, different Transverse 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 Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece.
  • Page 38 ESAB FABRICATOR 141i ESAB MIG, Lift TIG, Stick Wire Selection Chart A-12918 Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart BASIC WELDING GUIDE Manual 0-5420...

  • Page 39: Mig (Gmaw/Fcaw) Welding Troubleshooting

    ESAB FABRICATOR 141i 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 40 ESAB FABRICATOR 141i 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 or drive roll tension not cabinet slipped tight enough.
  • Page 41 ESAB FABRICATOR 141i Basic MIG Welding Troubleshooting FAULT CAUSE REMEDY 1 Undercut A Welding arc voltage too high. A Decrease voltage or increase the wire feed speed. B Incorrect MIG Gun angle B Adjust angle. C Excessive heat input C Increase the MIG Gun travel speed and/or decrease welding current by decreasing the voltage or decreasing the wire feed speed.
  • Page 42 C Low primary voltage C Contact supply authority. D Fault in power source D Have an Accredited ESAB Service Provider to test then replace the faulty component. 8 Arc does not have a The MIG Gun has been Connect the MIG Gun to the positive (+)

  • Page 43: Stick (Smaw) Basic Welding Technique

    Some of the common types of welds are shown in the work piece. If in doubt consult the electrode data sheet or Figures 4-11 through 4-18. your nearest Accredited ESAB Distributor. 4.04 Effects of Stick Welding Various Materials High Tensile and Alloy Steels...
  • Page 44 ESAB FABRICATOR 141i Art A-07691 Figure 4-15: Vertical Position, Butt Weld Art # A-07692 Figure 4-16: Vertical Position, Fillet Weld Art# A-07693 Figure 4-17: Overhead Position, Butt Weld Art # A-07694 Figure 4-18: Overhead Position, Fillet Weld 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...

  • Page 45: Lap Joint

    ESAB FABRICATOR 141i Single Vee Butt Joint Open Square Butt Not less than 70° Joint 1/16" (1.6mm) max Gap varies from 1/16" (1.6mm) to 3/16" (4.8mm) depending on plate thickness 1.6mm (1/16”) Not less than Single Vee Butt Joint Double Vee Butt Joint Not less than 45°...
  • Page 46 ESAB FABRICATOR 141i Do not weave the electrode, but maintain a steady rate of Art # A-10368 travel along the joint sufficient to produce a well-formed bead. At first you may notice a tendency for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º...
  • Page 47 ESAB FABRICATOR 141i 45º from the vertical. Some electrodes require to be sloped Art # A-07701 about 20º away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 4-23. Do not attempt to build up much larger than 1/4"(6.4mm) width with a 1/8"(3.2mm) electrode, otherwise the weld...
  • Page 48 ESAB FABRICATOR 141i overhead position as shown in the sketch. The elec- the weld", but when it attempts to expand "across the weld" trode is held at 45º to the horizontal and tilted 10º in or "along the weld", it meets considerable resistance, and the line of travel (Figure 4-28).
  • Page 49 ESAB FABRICATOR 141i D. Presetting It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the components to be welded,...

  • Page 50: Stick (Smaw) Welding Troubleshooting

    ESAB FABRICATOR 141i 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 51 ESAB FABRICATOR 141i 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 52: Tig (Gtaw) Basic Welding Technique

    ESAB FABRICATOR 141i FAULT CAUSE REMEDY 7 Crack occurring in A Rigidity of joint. A Redesign to relieve weld joint of severe stresses or weld metal soon use crack resistance electrodes. after solidification B Insufficient throat thickness. B Travel slightly slower to allow greater build up in commences throat.
  • Page 53 Easier stainless steel, Ceriated 2% starting, Wider current Grey copper, aluminum, range, Narrower more magnesium and their concentrated arc. alloys Table 4-8 NOTE! The Fabricator 141i is not suited for AC TIG welding. Manual 0-5420 4-19 BASIC WELDING GUIDE...

  • Page 54: 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.victortechnologies.com or contact ESAB. 4.07 TIG (GTAW) Welding Problems...
  • Page 55 ESAB FABRICATOR 141i FAULT CAUSE REMEDY 6 Electrode melts or oxidizes A TIG Torch lead A Connect TIG Torch lead to negative welding when an arc is struck. connected to positive terminal. welding terminal. B No gas flowing to B Turn TIG Torch gas valve ON. Check the gas welding region.
  • Page 56 ESAB FABRICATOR 141i FAULT CAUSE REMEDY 9 Arc start is not smooth. A Tungsten electrode A Select the right size electrode. Refer to Table is too large for the 4-7 Current Ranges for Various Tungsten welding current. Electrode Size. B The wrong electrode B Select the right electrode type.

  • Page 57: Power Source Problems And Routine Service Requirements

    ESAB FABRICATOR 141i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems FAULT CAUSE REMEDY Primary Power Supply A Power Source is not in the Set the Power Source to the is ON, power indicator is correct mode of operation.

  • Page 58: Routine Service

    There are extremely dangerous voltage and power levels present inside this Power Source. Do not attempt to open or repair unless you are an accredited ESAB Service Provider. Disconnect the Welding Power Source from the Electricity Supply Voltage before disassembling.

  • Page 59: Cleaning The Welding Power Source

    All unsafe accessories shall not be used. D. Repairs If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited ESAB Service Provider. 5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product.

  • Page 60: 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. Fabricator 141i TIG (GTAW) MIG (GMAW/ FCAW) STICK (SMAW) 90 100 110 120 130 140 150 Welding Current (Amps) Art # A-11807 Figure 5-1: Fabricator 141i Volt-Ampere Curves TROUBLESHOOTING AND SERVICE Manual 0-5420...

  • Page 61: Section 6: Key Spare Parts

    5B ESAB Control Wire 35K-350-1 2000-2352 5C ESAB Control Wire & WS-354-TA-LC 2060-2141 Plug Table 6-1: Tweco Fusion 140A MIG Gun Parts ** Patent Pending Figure 6-1 * Refer to ESAB Catalog No. 64-2103 for additional options. Manual 0-5420 KEY SPARE PARTS...

  • Page 62: Power Source

    ESAB FABRICATOR 141i 6.02 Power Source Figure 6-2 KEY SPARE PARTS Manual 0-5420...
  • Page 63 ESAB FABRICATOR 141i FABRICATOR 141i POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006216 PCB,Power,141i W7006227 PCB,Control,141i W7003033 Solenoid,Valve,24VDC W7006226 PCB, Remote Interface Integrated with Display, 141i W7006209 Wiredrive Assy,w/ Motor,141i 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",141i...

  • Page 64: Hardware List

    Screw Hexagon HD 9/32 × 16 ×19 Wirefeeder Plate Screw Skt Set M4 × 0.7 ESAB No. 4 Torch Adaptor Screw Hexagon M6 × 1.0-10 ST ZP ESAB No. 4 Torch Adaptor Nut Hexagon M10 × 1. 5 ST ZP ESAB No.
  • Page 65 ESAB FABRICATOR 141i SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL SCREW ITEM 4, 2 OFF USED...
  • Page 66 ESAB FABRICATOR 141i This Page Intentionally Blank KEY SPARE PARTS Manual 0-5420...

  • Page 67: Appendix

    ESAB FABRICATOR 141i APPENDIX This Page Intentionally Blank. Manual 0-5420 APPENDIX...

  • Page 68: Appendix: Fabricator 141I Circuit Diagram

    ESAB FABRICATOR 141i APPENDIX: FABRICATOR 141i CIRCUIT DIAGRAM CONNECTOR LAY WVIN QF/DY NTCS FUNS 1 2 3 PPENDIX Manual 0-5420...
  • Page 69 ESAB FABRICATOR 141i YOUT DIAGRAM DRIVE SOURCE Art # A-11792 _AC Manual 0-5420 APPENDIX...

  • Page 70: Revision History

    ESAB FABRICATOR 141i Revision History Date Rev Description 09/10/2015 Manual release PPENDIX Manual 0-5420...
  • 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...

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