Thermal arc dc cc/cv welding generator, stick, mig, auxiliary power (33 pages)
Summary of Contents for Thermal Arc FABRICATOR 181i
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181i FABRICATOR MULTI PROCESS WELDING INVERTER Art# A-09939_AC Operating Manual Revision: AB Issue Date: April 27, 2011 Manual No.: 0-5151 Operating Features:...
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YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
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Manufacturer assumes no liability for its use. Operating Manual Number 0-5151 for: Thermal Arc Fabricator 181i Inverter Plant Part Number W1003186 Thermal Arc Fabricator 181i Inverter Power Source (unpacked) Part Number W1003185 Published by: Thermadyne Industries, Inc. 82 Benning Street...
Fabricator 181i SECTION 1: ARC WELDING 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.
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Fabricator 181i 2. Wear approved safety glasses. Side shields recom- mended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the ARC RAYS can burn eyes and skin; NOISE arc.
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Fabricator 181i 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from FUMES AND GASES can be hazardous to welding can easily go through small cracks and your health.
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Fabricator 181i 5. Use only correct shielding gas cylinders, regulators, The following is a quotation from the General Con- hoses, and fittings designed for the specific clusions Section of the U.S. Congress, Office of application; maintain them and associated parts Technology Assessment, Biological Effects of Power in good condition.
Fabricator 181i 1.02 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.
Description of equipment: Welding Equipment (GMAW, FCAW, GTAW, MMA) including, but not limited to Thermal Arc Fabricator 181i Multi Process Welding Inverter and associated accessories. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
Fabricator 181i SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.02 Equipment Identification This Manual usually applies to the part numbers listed The unit’s identification number (specification or part on page i. To ensure safe operation, read the entire...
Fabricator 181i 2.05 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage...
Fabricator 181i 2.06 Description 2.08 Packaged Items The Thermal Arc Fabricator 181i is a self contained Fabricator 181i Plant (Part No. W1003186) single phase multi process welding inverter that is • Fabricator 181i Inverter Power Source capable of performing GMAW/FCAW (MIG), MMA • Tweco WeldSkill 180A MIG Torch...
(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. Safe TIG (GTAW) Operating MIG (GMAW) Region Stick (MMA) Welding Current (amps) A-09985 Figure 2-1: Fabricator 181i Duty Cycle INTRODUCTION Manual 0-5151...
Fabricator 181i 2.10 Specifications FABRICATOR 181i MULTI PROCESS WELDING DESCRIPTION INVERTER Power Source (unpacked) Part No. W1003185 Power Source Dimensions H410mm x W210mm x D450mm Power Source Mass 14.6kg Cooling Fan Cooled Welder Type Multi Process Inverter Power Source European Standard EN 60974.1...
Feed Roll 0.9/1.2mm V groove (hard) 62022 Feed Roll 0.8/0.9mm U groove (soft) 62179 Feed Roll 1.0/1.2mm U groove (soft) 62024 Feed Roll 0.8/0.9mm V knurled (flux cored) 62028 Table 2-2: Fabricator 181i Options and Accessories List INTRODUCTION Manual 0-5151...
Fabricator 181i SECTION 3: INSTALLATION, OPERATION AND SETUP H. Precautions must be taken against the power 3.01 Environment source toppling over. The power source must be located on a suitable horizontal surface in the These units are designed for use in environments with upright position when in use.
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Fabricator 181i A. Installation and Use - Users Responsibility 8. The immunity of other equipment in the environment: the user shall ensure that other The user is responsible for installing and using the equipment being used in the environment welding equipment according to the manufacturer’s is compatible: this may require additional instructions.
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications. 3.06 Fabricator 181i Power Source Controls, Indicators and Features POWER FAULT...
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Fabricator 181i A-09593 Figure 3-3: Wire Feed Compartment Control 1. Power Indicator The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/OFF switch located on the rear panel is in the ON position.
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Fabricator 181i 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 torch (via the MIG torch polarity lead), electrode holder lead or work lead.
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Fabricator 181i Socket Pin Function Not connected Trigger Switch Input Trigger Switch Input Not connected 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 remote control Wirespeed GMAW (MIG) mode potentiometer.
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Fabricator 181i 10. Arc Control (Inductance) The arc control operates in GMAW (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.
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Burnback Control knob clockwise. 19. Fan on Demand The Fabricator 181i is fitted with a fan on demand feature. Fan on demand automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source.
Fabricator 181i 3.07 Attaching the Tweco WeldSkill 180 Torch (Euro) Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor.
Fabricator 181i 3.08 Installing 100mm Diameter Spool As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a 200mm diameter spools. In order to fit a 100mm diameter spool assemble parts in the sequence shown below in Figure 3-6.
Fabricator 181i 3.09 Installing 200mm Diameter Spool As delivered from the factory, the unit is set for a 200mm diameter spool. In order to re-fit a 200mm spool assemble parts in the sequence shown below in Figure 3-7. 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.
Fabricator 181i 3.10 Inserting Wire into the Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti- clockwise direction. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 3-8).
Fabricator 181i 3.11 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.
Fabricator 181i 3.13 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.
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Fabricator 181i User Responsibilities This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and reliable performance. Defective equipment should not be used.
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Fabricator 181i 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.
Fabricator 181i 3.15 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire A. Select MIG mode with the process selection control. (refer to Section 3.06.12 for further information) B. Connect the MIG torch polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.
Fabricator 181i 3.16 Setup for MIG (GMAW) Welding with Gasless MIG Wire A. Select MIG mode with the process selection control (refer to Section 3.06.12 for further information). B. Connect the MIG Torch polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
Fabricator 181i 3.17 Setup for TIG (GTAW) Welding A. Select Lift TIG mode with the process selection control (refer to Section 3.06.12 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.
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Fabricator 181i A-09588_AD Positive welding terminal (+). Connect to shielding gas regulator/flowmeter MIG Torch Negative welding polarity lead terminal (-). not connected. Note: This 8 pin connection plug is for TIG torch trigger connection and remote TIG torch current Work lead TIG Torch control if applicable.
Fabricator 181i 3.18 Setup for Manual Arc (MMA) 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.
Fabricator 181i SECTION 4: BASIC WELDING GUIDE 4.01 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the MIG mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
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Fabricator 181i Position of MIG Torch The angle of MIG torch to the weld has an effect on the width of the weld. Vertical Push Drag/Pull Art # A-07185_AB Figure 4-3 The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times.
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Fabricator 181i Vertical Fillet Welds Art # A-08995 Figure 4-6 Art # A-08996 Overhead Weld Figure 4-7 Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded.
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Fabricator 181i Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are: 1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 10mm stick-out 2.
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Fabricator 181i Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece.
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 torch. There are two main areas where problems occur with GMAW, Porosity and...
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Fabricator 181i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1Feed roller driven by motor in the Wire spool brake is too tight. cabinet slipped.
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B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited Thermal Arc Service Provider to test then replace the faulty component. 8 Arc does not have The MIG torch has been Connect the MIG torch to the positive (+) welding...
Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited Thermal Arc Distributor. 4.04 Effects of Stick Welding Various Materials...
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Fabricator 181i Metal Being Joined Electrode Comments Mild Steel E6011 This electrode is used for all-position welding or for welding on rusty, dirty, less-than-new metal. It has a deep, penetrating arc and is often the first choice for repair or maintenance work.
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Fabricator 181i Art # A-07690 Figure 4-14: Horizontal-Vertical (HV) Position 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...
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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.
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Fabricator 181i Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down.
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Fabricator 181i Do not weave the electrode, but maintain a steady rate of 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 from vertical, and the rate of travel not too fast, will help eliminate this.
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Fabricator 181i Art # A-07699 Figure 4-23: Electrode Position for HV Fillet Weld Art # A-07700 Figure 4-24: Multi-runs in HV Fillet Weld C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm E7014 Stick electrode and set the current at 100 amps.
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Fabricator 181i Art # A-07702 Figure 4-26: Multi Run Vertical Fillet Weld Art # A-07703 Figure 4-27: Examples of Vertical Fillet Welds 2. Vertical Down The E7014 Stick electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps.
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Fabricator 181i Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.
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Fabricator 181i Overcoming Distortion Effects There are several methods of minimizing distortion effects. A. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.
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Fabricator 181i Art # A-07709 Figure 4-33: Examples of Distortion Art # A-07710 Figure 4-34: Welding Sequence Art # A-07711 Figure 4-35: Step back Sequence Art # A-07712 Figure 4-36: Chain Intermittent Welding Art # A-07713_AB Figure 4-37: Staggered Intermittent Welding...
Fabricator 181i 4.05 Stick (MMA) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob Reduce the ARC FORCE control knob until weld- varying is set at a value that ing current is reasonably constant while prohibit- causes the welding current...
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Fabricator 181i 5 Portions of the A Small electrodes used on A Use larger electrodes and preheat the plate. weld run do not heavy cold plate. fuse to the surface B Welding current is too low. B Increase welding current.
Fabricator 181i 4.06 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non- consumable) electrode and the work piece.
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Wider current Grey ium, magnesium and range, Narrower more their alloys concentrated arc. Table 4-9 NOTE The Fabricator 181i Inverter is not suited for AC TIG welding. Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type...
Fabricator 181i 4.07 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive beard build up Welding current is too Increase weld current and/or faulty joint or poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
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Fabricator 181i 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates. piece or filler rod mate- rial. B Work piece surface has B Clean surface. foreign material on it.
(burn-back jam). contact tip. Replace faulty com- ponents. B Internal fault in power B Have an Accredited Thermal Arc source Service Provider investigate the fault. 4 Welding wire continues to A Trigger mode selection...
The inspection and testing of the power source and associated accessories shall be carried out in accordance with Section 5 of EN 60974-1: Safety in Welding and Allied Processes-Part 2 Electrical. This includes an in- sulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc's original specifications.
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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 Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
Output Voltage (V) to be checked to ensure it falls within applicable Thermal Arc power source specifications Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Thermal Arc power source / wire feeder specifications...
Fabricator 181i 5.04 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs.
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Fabricator 181i This page is left blank intentionally. POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS Manual 0-5151...
Fabricator 181i 6.02 Power Source Figure 6-2 KEY SPARE PARTS Manual 0-5151...
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Fabricator 181i FABRICATOR 181i POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7004900 PCB Power W7004901 PCB Control W7004902 PCB EMC Filter W7004903 PCB Front Panel (Display) W7004904 PCB Front Panel (Piggy-Back) W7004905 Wiredrive Assembly W7004906 Feed Roll Retaining Thumbscrew Feed Roll 0.6/0.8mm V groove (fitted as standard)
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Fabricator 181i This page is left blank intentionally. KEY SPARE PARTS Manual 0-5151...
Fabricator 181i APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM AC IN AC IN AC OUT AC OUT DC IN DC IN TIG GAS J21-1 J21-2 +24V J22-1 blue J22-2 blue J22-3 J22-4 J22-5 Motor Positive +24V J12-1 Motor Negative J12-2 black QF/DY...
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.
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Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the warranty period. The warranty period begins on the date of sale to the end user. Thermal Arc Fabricator 181i Component Warranty Period...
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Customer Care UK: +44 (0)1257 261 755 / Fax: +44 (0)1257 224 800 Customer Care Italy +39 02 36546801 / Fax: +39 02 36546480 www.thermadyne.com A Global Cutting & Welding Market Leader ™ W O R L D H E A D Q U A R T E R S : 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 •...
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