Thermal Arc 181i Fabricator Service Manual
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Thermal Arc 181i Fabricator Service Manual

3 in 1 multi-process welding system
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181i

Service Manual

3163339
Fabricator
3 in 1 Multi-ProceSS
Welding SySteMS
Revision: AC
Issue Date: February 28, 2013
Operating Features:
SMAW
Art # A-10455
Manual No.: 0-5192

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

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Steve James
March 11, 2025

The wire feed speed indicator reads zero, the wire feeds out but at a constant speed. The speed dial has no effect on the speed

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1 comments:
Mr. Anderson
March 11, 2025

The wire feed speed indicator on a Thermal Arc 181i Fabricator could read zero while the wire feeds out at a constant speed due to a calibration issue. The manual mentions settings related to the calibration of wire feed speed. If SW0-1, SW0-3, or SW0-4 are incorrectly set, it may disable the calibration, causing the display to show incorrect values. Checking and adjusting these switch settings may resolve the issue.

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Summary of Contents for Thermal Arc 181i Fabricator

  • Page 1: Service Manual

    181i Fabricator 3 in 1 Multi-ProceSS Welding SySteMS Art # A-10455 Service Manual Revision: AC Issue Date: February 28, 2013 Manual No.: 0-5192 Operating Features: 3163339 SMAW...
  • Page 2 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 Victor Tech- nologies International, Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
  • Page 3 Thermal Arc Fabricator 181i Portable System Package Part Number W1003181 Thermal Arc Fabricator 181i Power Source Part Number W1003180 Thermal Arc Fabricator 181i Portable System Package with Cart Part Number W1003182 Published by: Victor Technologies International, Inc. 16052 Swingley Ridge Road, Suite 300St.

  • Page 4: Table Of Contents

    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...
  • Page 5 TABLE OF CONTENTS 4.13 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 4-20 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 ................
  • Page 6 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 SECTION 10: Options and Accessories ................10-1 10.01 Options and Accessories ................10-1 Thermal Arc - LIMITED WARRANTY TERMS ..............2...

  • Page 7: Safety Instructions And Warnings

    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.
  • Page 8 FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 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, WARNING flame-resistant material (wool and leather) and foot ARC RAYS can burn eyes and skin;...
  • Page 9 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i 6. Be aware that welding on a ceiling, floor, bulkhead, 1. Keep your head out of the fumes. Do not breathe or partition can cause fire on the hidden side. the fumes. 7. Do not weld on closed containers such as tanks or 2.
  • Page 10 FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 6. Turn face away from valve outlet when opening 2. Stop engine before installing or connecting unit. cylinder valve. 3. Have only qualified people remove guards or 7. Keep protective cap in place over valve except when covers for maintenance and troubleshooting as cylinder is in use or connected for use.

  • Page 11: General Safety Information For Victor Cs Regulator

    SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i NOTE 1.02 General Safety Information for Victor CS Regulator Considerations About Welding And The Effects of Low Frequency Electric and Mag- Fire Prevention netic Fields Welding and cutting operations use fire or combustion The following is a quotation from the General Conclu- as a basic tool.
  • Page 12 FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS Ventilation Compressed Gas Cylinders The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases WARNING used for welding or cutting operations. Ade quately ventilate welding, heating, and 1. Place the cylinder (Figure 1-1) where you will cutting work areas to prevent accumula- use it.

  • Page 13: Principal Safety Standards

    SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i 4. NEVER use compressed gas cylinders without 1.03 Principal Safety Standards a pressure reducing regulator attached to the cylinder valve. Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., 5.

  • Page 14: Symbol Chart

    FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 1.04 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 Transformer-Rectifier...

  • Page 15: Precautions De Securite En Soudage A L'arc

    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).
  • 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 AVERTISSEMENT à la terre de la pièce à souder. LE RAYONNEMENT DE L’ARC PEUT BRÛLER 11.
  • 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 AVERTISSEMENT pour protéger les autres des coups d’arc ou de LE SOUDAGE PEUT CAUSER UN INCENDIE l’éblouissement;...
  • Page 18 FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation. 8. Lisez et respectez les consignes relatives aux AVERTISSEMENT bouteilles de gaz comprimé et aux équipements LES ETINCELLES ET LES PROJECTIONS connexes, ainsi que la publication P-1 de la CGA, BRULANTES PEUVENT CAUSER DES BLES- identifiée dans la liste de documents ci-dessous.

  • Page 19: Informations Générales De Sécurité

    SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES. LA VAPEUR ET LE LIQUIDE DE REFROID- ISSEMENT BRULANT SOUS PRESSION Des pièces en mouvement, tels des ventila- PEUVENT BRULER LA PEAU ET LES YEUX.
  • Page 20 FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS manches et poches boutonnés. Il ne faut pas remonter vos manches ou les pantalons à revers. AVERTISSEMENT Quand vous travaillez dans un environnement non N’effectuez d’opérations de soudage dédié au soudage ou découpage, portez toujours une JAMAIS sur un récipient qui a contenu des liquides protection des yeux appropriées ou un masque facial.

  • Page 21: Principales Normes De Securite

    SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i AVIS 1.08 Principales Normes De Securite Ce document CGA p. t peut être obtenu en écrivant à “Compressed Gas Association”, Safety in Welding and Cutting, norme ANSI Z49.1, 4221 Walney Roed, 5th Floor. Chantilly, VA American Welding Society, 550 N.W.

  • Page 22: Graphique De Symbole

    FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage Torch de...

  • Page 23: Declaration Of Conformity

    Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Tom Wermert Senior Brand Manager Thermal Arc Victor Technologies International, Inc. 16052 Swingley Ridge Road Chesterfield, Missouri 63017 USA...
  • Page 24 Notes...

  • Page 25: Introduction

    WARNING 2.04 Description Gives information regarding possible per- The Thermal Arc Fabricator 181i is a self contained sonal injury. Warnings will be enclosed in a single phase multi process welding system that is box such as this.

  • Page 26: User Responsibility

    This equipment or any of its parts should not be altered from standard specification without prior written approval of Thermal Arc. 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 Thermal Arc.

  • Page 27: Safety And Installation

    SAFETY AND INSTALLATION FABRICATOR 181i 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.

  • Page 28: Specifications

    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...

  • Page 29: Environment

    (Based on Article 630, National Electrical Code) Thermal Arc 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.

  • Page 30: Ventilation

    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.
  • Page 31 SAFETY AND INSTALLATION FABRICATOR 181i • Correctly earthed (electrically) in accordance with local regulations. • Connected to the correct size power point, fuse and primary supply lead based on Table 3-2. Refer to Table 3-2. 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.

  • Page 32: Electromagnetic Compatibility

    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.
  • 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.

  • Page 34: Volt-Ampere Curves

    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. Art # A-11296 Figure 3-2: Fabricator 181i Volt-Ampere Curves Safety and Installation Manual 0-5192...

  • Page 35: Operation

    OPERATION FABRICATOR 181i SECTION 4: OPERATION 4.01 Power Source Controls, Indicators and Features POWER FAULT LIFT TIG STICK SOFT HARD DOWNSLOPE (S) WIRESPEED ARC FORCE (%) INDUCTANCE Art # A-10353 Art # A-10354 Figure 4-1: Front Panel Figure 4-2: Rear Panel Art # A-10355 Figure 4-3: Wire Feed Compartment Control...
  • 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.
  • 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).
  • Page 38 FABRICATOR 181i OPERATION Socket Pin Function Spool gun motor (0V) 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.
  • 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).
  • 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.
  • 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.

  • Page 42: Attaching The Tweco Fusion 180A Gun

    FABRICATOR 181i OPERATION 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.

  • Page 43: Torch Adapter Thumb Screw Replacement

    OPERATION FABRICATOR 181i 4.03 Torch Adapter Thumb Screw Replacement 1. Place unit on its back. Art # A-11482 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 44 FABRICATOR 181i OPERATION 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 5. Remove damaged thumb screw and replace with new one. Art # A-11486 6.

  • Page 45: Installing 4" (100Mm) Diameter Spool

    OPERATION FABRICATOR 181i 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.

  • Page 46: Installing 8" (200Mm) Diameter Spool

    FABRICATOR 181i OPERATION 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.

  • Page 47: Inserting Wire Into The Wire Feed Mechanism

    OPERATION FABRICATOR 181i 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).

  • Page 48: Feed Roller Pressure Adjustment

    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.

  • Page 49: Wire Reel Brake

    OPERATION FABRICATOR 181i 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.

  • Page 50: Gas Regulator Operation

    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.
  • Page 51 OPERATION FABRICATOR 181i 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. WARNING Before connecting the work clamp to the work make sure the Electricity Supply is switched off.

  • Page 52: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    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.
  • Page 53 OPERATION FABRICATOR 181i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead. A-09587_AD Work Lead Figure 4-14: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire Manual 0-51 4-19 Operation...

  • Page 54: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    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.

  • Page 55: Setup For Lift Tig (Gtaw) Welding

    NOTE A Thermal Arc 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 Thermal Arc 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 56 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Thermal Arc Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as...

  • Page 57: Setup For Stick (Smaw) Welding

    OPERATION FABRICATOR 181i 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.

  • Page 58: Leak Testing The System

    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.

  • Page 59: Theory Of Operation

    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.
  • Page 60 Notes...

  • Page 61: Troubleshooting

    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, A Power Source is not in the cor- A Set the Power Source to the correct power indicator is illumi- rect mode of operation.

  • Page 62: Checking Unit Before Applying Power

    FABRICATOR 181i TROUBLESHOOTING 8 Gas flow continues after Gas valve has jammed open Have an accredited Thermal Arc the torch trigger switch has due to impurities in the gas or service provider repair or replace been released (MIG mode). the gas line.

  • Page 63: Case Removal

    TROUBLESHOOTING FABRICATOR 181i 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 &...

  • Page 64: Clear Cover Sheet Removal

    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. 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.

  • Page 65: Preliminary Dc Bus Measurement Of The Main Inverter Board

    TROUBLESHOOTING FABRICATOR 181i 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 Positive meter lead to testpoint 1 Upper capacitor bank 0 VDC Negative meter lead to testpoint 2...
  • Page 66 FABRICATOR 181i TROUBLESHOOTING IGBT Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 9 IGBT 1 0.2 – 0.8 VDC Negative meter lead to testpoint 10 Positive meter lead to testpoint 11 IGBT 2 0.2 – 0.8 VDC Negative meter lead to testpoint 12 Positive meter lead to testpoint 13 IGBT 3...

  • Page 67: Check Main On / Off Switch

    TROUBLESHOOTING FABRICATOR 181i 6.09 Check Main On / Off Switch Art # A-10459 Power Switch Testing Multimeter Lead Placement Impedance Positive meter lead to testpoint 23 Switch ON 0 to 1 Ω Negative meter lead to testpoint 24 Positive meter lead to testpoint 25 Switch ON 0 to 1 Ω...

  • Page 68: Dc Bus Voltage Measurement

    FABRICATOR 181i TROUBLESHOOTING 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 troubleshoot- ing techniques.

  • Page 69: Pcb Connectors

    TROUBLESHOOTING FABRICATOR 181i 6.12 PCB Connectors Inverter PCB QF/FJ NTCS CIN2 CIN1 OUT+ OUT- T19-1 T18-1 T17-1 T16-1 T15-1 T14-1 T13-1 T20-1 COUT1 COUT2 R102 R100 R103 R101 C101 C100 A-09990 IN Header Pin Pin function Signal +15V 15 VDC IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk IGBT 2 pwm drive signal, 15V p-p square wave...
  • Page 70 FABRICATOR 181i TROUBLESHOOTING NTCS Header Pin Pin function Signal +24V 24 VDC 0 VDC Table 6-13 NTCS Header pin function (connects to NTCS header on control PCB) DY2 Header Pin Pin function signal +24V 24 VDC 0 VDC -24V -24 VDC Table 6-14 DY2 Header pin function (connects to SOURCE header on control PCB) DY1 Header Pin Pin function...
  • Page 71 TROUBLESHOOTING FABRICATOR 181i GUN Header Pin Pin function Signal +24V trigger positive (0V when trigger closed) 24 VDC 0VDC 0 VDC Table 6-18 GUN Header pin function (connects to GUN header on display PCB) PWM Header Pin Pin function Signal 0VDC 0 VDC Motor pwm drive signal...
  • Page 72 FABRICATOR 181i TROUBLESHOOTING CR Header Pin Pin function Signal 5 VDC Wiper 10k Burnback potentiometer 0 – 5 VDC 0 VDC Table 6-26 CR Header pin function (connects to 10k Burnback potentiometer) IGBT OT Header Pin Pin function signal Igbt thermostat (0VDC when thermostat closed) 0 VDC Table 6-27 IGBT OT Header pin function (connects to igbt thermostat) NTCS Header Pin...
  • Page 73 TROUBLESHOOTING FABRICATOR 181i GUN Header Pin Pin function Signal +24V trigger positive (0V when trigger closed) 24 VDC 0VDC 0 VDC Table 6-30 GUN Header pin function (connects to GUN header on control PCB) GUN1 Header Pin Pin function Signal +24V trigger positive (0V when trigger closed) 24 VDC 0VDC...

  • Page 74: Dip Switch Settings, Control Pcb

    FABRICATOR 181i TROUBLESHOOTING J1 Header Pin Pin function Signal Serial display data & eprom (D-IN) 5 VDC digital Serial display data (LOAD) 5 VDC digital Serial display data (CLK) 5 VDC digital 2T/4T pushbutton (0V when button pushed) 0VDC Serial display eprom (D-OUT) 5 VDC digital Stick mode (used for remote / local) Chip select...

  • Page 75: Calibration

    TROUBLESHOOTING FABRICATOR 181i SW0 position Function Set to OFF for Fabricator 181i Set to ON for Fabricator 181i Set to OFF for Fabricator 181i Table 6-36 SW0 Dip Switch functions 6.14 Calibration Calibration Imin Imax 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 calibra- tion of wire feed speed.
  • Page 76 FABRICATOR 181i TROUBLESHOOTING 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 Wire Speed Calibration...
  • Page 77 TROUBLESHOOTING FABRICATOR 181i 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.

  • Page 78: Main Circuit Description

    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. Troubleshooting 6-18 Manual 0-5192...
  • 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 cur- rent limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

  • Page 80: Circuit Diagram

    FABRICATOR 181i TROUBLESHOOTING 6.16 Circuit Diagram Troubleshooting 6-20 Manual 0-5192...

  • Page 81: Disassembly Procedure

    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 Disassembly Procedure...

  • Page 82: Control Board Removal

    FABRICATOR 181i DISASSEMBLY PROCEDURE 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.
  • Page 83 DISASSEMBLY PROCEDURE FABRICATOR 181i WVIN QF/DY IGBT OT SOURCE NTCS FUNs DRIVE A-10018 Manual 0-5192 Disassembly Procedure...

  • Page 84: Front Panel Assembly Removal

    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.
  • Page 85 DISASSEMBLY PROCEDURE FABRICATOR 181i A-09965 Manual 0-5192 Disassembly Procedure...

  • Page 86: Front Panel (Operator Interface) Circuit Board Pcb3 Removal

    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. A-10000 Art # A-10462 Art # A-10463 Disassembly Procedure Manual 0-5192...

  • Page 87: Back Panel Removal

    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.

  • Page 88: Power Switch S1 And Power Cord Removal

    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.

  • Page 89: Base Panel Removal And Main Pcb Disassembly

    DISASSEMBLY PROCEDURE FABRICATOR 181i 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.
  • Page 90 Notes...

  • Page 91: Assembly Procedures

    ASSEMBLY PROCEDURE FABRICATOR 181i 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.

  • Page 92: Installing Back Panel

    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.
  • Page 93 ASSEMBLY PROCEDURE FABRICATOR 181i A-10011 A-10114 Manual 0-5192 Assembly Procedures...

  • Page 94: Installing Front Panel

    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. A-10000 Art # A-11270 3. Reconnect torch polarity cable to the torch connector. 4.
  • Page 95 ASSEMBLY PROCEDURE FABRICATOR 181i Art # A-09965 Manual 0-5192 Assembly Procedures...

  • Page 96: Installing Main Control Panel And Clear Cover Sheet

    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.
  • Page 97 ASSEMBLY PROCEDURE FABRICATOR 181i Art # A-11271 Manual 0-5192 Assembly Procedures...

  • Page 98: Installing Case

    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. Install Screws Tighten Screws Front & Rear Art # A-10468 Assembly Procedures Manual 0-5192...

  • Page 99: Key Spare Parts

    KAY SPARE PARTS FABRICATOR 181i SECTION 9: KEY SPARE PARTS 9.01 Tweco WeldSkill 180A MIG Gun (Used until February 2013) MIG Gun Part No: WS180TA-12-3035 Art # A-10370_AB TWECO WELDSKILL 180A MIG GUN PARTS ITEM PART NO. DESCRIPTION 1210-1112 Nozzle 1110-1101 Contact Tip 1510-1101...

  • Page 100: Tweco Fusion 180A Mig Gun Parts

    Handle / Trigger Repair Kit Conduit Assembly* WS42-3035-15 Tweco Rear Connector 350-174H Tweco Control Wire & Plug 35K-350-1 Thermal Arc Control Wire WS-354-TA-LC ** Patent Pending * Refer to Tweco Catalog No. 64-2103 for additional options. Key Spare Parts Manual 0-5192...

  • Page 101: Power Source

    KAY SPARE PARTS FABRICATOR 181i 9.03 Power Source Manual 0-5192 Key Spare Parts...
  • Page 102 FABRICATOR 181i KAY SPARE PARTS 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 W7003010...

  • Page 103: Options And Accessories

    OPTIONS AND ACCESSORIES FABRICATOR 181i SECTION 10: OpTIONS aNd aCCESSOrIES 10.01 Options and accessories dESCrIpTION parT NUMBEr Tweco WeldSkill 180A MIG Gun, 12ft (3.6m) Length WS180TA-12-3035 Tweco Fusion 180A MIG Gun, 12ft (3.6m) Length F180TA-12-3035 Tweco 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"...

  • Page 104: Thermal Arc - Limited Warranty Terms

    Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

  • Page 105: Warranty Schedule

    WARRANTY SCHEDULE 5 Years Parts* / 3 Years Labor ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster Portafeed, Ultrafeed, Ultima 150, WC 100B * 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards. * 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Victor Regulator for Fabricator 181i (No labor)
  • Page 106 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph: 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph: 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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