Thermal Arc 181i FABRICATOR Service Manual
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Thermal Arc 181i FABRICATOR Service Manual

Multi process welding inverter
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See also: Service Manual , Operating Manual
181i
Service Manual
Fabricator
Multi proceSS welding
inverter
Revision: AB
Issue Date: April 06, 2012
Operating Features:
Art # A-10107
Manual No.: 0-5152

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Summary of Contents for Thermal Arc 181i FABRICATOR

  • Page 1 181i Fabricator Multi proceSS welding inverter Art # A-10107 Service Manual Revision: AB Issue Date: April 06, 2012 Manual No.: 0-5152 Operating Features:...
  • 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 Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
  • Page 3 Manufacturer assumes no liability for its use. Service Manual Number 0-5152 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. 16052 Swingley Ridge Road, Suite 300 St Louis, Mo63017 www.thermadyne.com...

  • 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 Principal Safety Standards ................1-4 1.03 Declaration of Conformity ................1-5 1.04 Symbol Chart ....................1-6 1.05 Servicing Hazards ................... 1-7 1.06 EMF Information .....................
  • Page 5 SECTION 9: REPLACEMENT PARTS ..............9-1 9.01 Tweco WeldSkill 180A MIG Torch ................ 9-1 9.02 Power Source ...................... 9-2 SECTION 10: OPTIONS AND ACCESSORIES ............10-1 10.01 Options and Accessories ................10-1 THERMAL ARC - LIMITED WARRANTY TERMS TERMS OF WARRANTY – JANUARY 2011...

  • Page 7: Section 1: 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.

  • Page 8: Safety Instructions And Warnings

    FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 3. If ventilation is poor, use an approved air-supplied respirator. WARNING 4. Read the Material Safety Data Sheets (MSDSs) and the manu- FLYING SPARKS AND HOT METAL can cause injury.
  • Page 9 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i Recommended Protective Filters for Electric Welding Approximate Range of Minimum Shade Number of Description of Process Welding Current in Amps Filter(s) Less than or equal to 100 100 to 200 Manual Metal Arc Welding - covered 200 to 300 electrodes (MMA) 300 to 400...

  • Page 10: Principal Safety Standards

    FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS WARNING ABOUT PACEMAKERS: MOVING PARTS can cause injury. The above procedures are among those also normally recommended for pacemaker wearers. Consult your Moving parts, such as fans, rotors, and belts can cut fingers and doctor for complete information.

  • Page 11: Declaration Of Conformity

    16052 Swingley Ridge Road, Suite 300 St Louis, Mo63017 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.

  • Page 12: 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 13: Servicing Hazards

    SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 181i 1.05 Servicing Hazards WARNING WARNING FLYING METAL or DIRT can injure eyes. The symbols shown below are used throughout this • Wear safety glasses with side shields or face shield during manual to call attention to and identify possible haz- servicing. ards. When you see the symbol, watch out, and follow • Be careful not to short metal tools, parts, or wires together the related instructions to avoid the hazard.

  • Page 14: Emf Information

    FABRICATOR 181i SAFETY INSTRUCTIONS AND WARNINGS 1.06 EMF Information Considerations About Welding And The Effects Of Low Frequency WARNING Electric And Magnetic Fields MOVING PARTS can cause injury, Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern • Keep away from moving parts such as fans.

  • Page 15: Section 2: Introduction

    2.04 Description Gives information regarding possible per- sonal injury. Warnings will be enclosed in a The Thermal Arc Fabricator 181i is a self contained sin- box such as this. gle phase multi process welding inverter that is capable of performing GMAW/FCAW (MIG), MMA (Stick) and GTAW (Lift TIG) welding processes.

  • Page 16: Packaged Items

    FABRICATOR 181i INTRODUCTION 2.06 Packaged Items Fabricator 181i Plant (Part No. W1003186) • Fabricator 181i Inverter Power Source • Tweco WeldSkill 180A MIG Torch • Feed rolls: 0.6/0.8mm V Groove (fitted) • Electrode Holder with 4m Lead • Work Clamp with 4m Lead • Shielding Gas Hose Assembly • Shoulder Strap • Operating Manual Introduction Manual 0-5152...

  • Page 17: Section 3: 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 that 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 18: Specifications

    FABRICATOR 181i SAFETY AND INSTALLATION 3.02 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 Number of Phases...

  • Page 19: Location

    WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician. 3.05 Ventilation Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

  • Page 20: Electrical Input Connections

    FABRICATOR 181i SAFETY AND INSTALLATION 3.08 Electromagnetic Compatibility 3.07 Electrical Input Connections WARNING WARNING ELECTRIC SHOCK can kill; SIGNIFICANT Extra precautions for Electromagnetic DC VOLTAGE is present after removal of Compatibility may be required when this input power. Welding Power Source is used in a domestic situation.
  • Page 21 SAFETY AND INSTALLATION FABRICATOR 181i 6. Equipment used for calibration and measurement. 7. The time of day that welding or other activities are to be carried out. 8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

  • Page 22: Volt-Ampere Curves

    FABRICATOR 181i SAFETY AND INSTALLATION 3.09 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. 230VAC Input Mig Max Stick Max Lift Tig Max AMPS A-10111 Figure 3-2: Fabricator 181i Volt-Ampere Curves Safety and Installation Manual 0-5152...

  • Page 23: Section 4: Operation

    OPERATION FABRICATOR 181i SECTION 4: OPERATION 4.01 Fabricator 181i Power Source Controls, Indicators and Features POWER FAULT LIFT TIG STICK SOFT HARD DOWNSLOPE (S) WIRESPEED ARC FORCE (%) INDUCTANCE A-09938 A-09940 Figure 4-1: Front Panel Figure 4-2: Rear Panel A-09593 Figure 4-3: Wire Feed Compartment Control 1.
  • Page 24 FABRICATOR 181i OPERATION 2. Digital Amps Meter The digital amperage meter is used to display both the pre-set current (Stick and TIG modes only) and actual output current (all modes) of the power source. At times of non-welding, the amperage meter will display a pre-set (preview) value in both MMA (Stick) and GTAW (TIG) modes.
  • Page 25 OPERATION FABRICATOR 181i 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 torch (via the MIG torch polarity lead), TIG torch or work lead. Negative welding current flows to the power source via this heavy duty bayonet type terminal.
  • Page 26 FABRICATOR 181i OPERATION When MMA (Stick) Mode is Selected In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes.
  • Page 27 OPERATION FABRICATOR 181i 13. Digital Voltage Meter The digital voltage meter is used to display the both the pre-set 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 pre-set (preview) value in GMAW/FCAW (MIG) modes.

  • Page 28: Attaching The Tweco Weldskill 180 Torch (Euro)

    FABRICATOR 181i OPERATION 18. Burnback Control (located in wirefeed compartment) The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG torch after the completion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG torch at the completing of welding), turn the burnback control knob anti clockwise.

  • Page 29: Installing 100Mm Diameter Spool

    OPERATION FABRICATOR 181i 4.03 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 4-6. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake.

  • Page 30: Installing 200Mm Diameter Spool

    FABRICATOR 181i OPERATION 4.04 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 4-7. Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake. Clockwise rotation of this nut with nylon insert tightens the brake.

  • Page 31: Inserting Wire Into The Wire Feed Mechanism

    OPERATION FABRICATOR 181i 4.05 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 4-8).

  • Page 32: Feed Roller Pressure Adjustment

    FABRICATOR 181i OPERATION 4.06 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 33: Wire Reel Brake

    OPERATION FABRICATOR 181i 4.08 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 34: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    FABRICATOR 181i OPERATION 4.09 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire A. Select MIG mode with the process selection control. (refer to Section 4.01.12 for further information) B. Connect the MIG torch polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.

  • Page 35: Setup For Mig (Gmaw) Welding With Gasless Mig Wire

    OPERATION FABRICATOR 181i 4.10 Setup for MIG (GMAW) Welding with Gasless MIG Wire A. Select MIG mode with the process selection control (refer to Section 4.01.12 for further information). B. Connect the MIG Torch polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.
  • Page 36 FABRICATOR 181i OPERATION C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. D.

  • Page 37: Setup For Manual Arc (Mma) Welding

    OPERATION FABRICATOR 181i 4.12 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.

  • Page 38: Leak Testing The System

    FABRICATOR 181i OPERATION 4.13 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 39: Section 5: 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 40 FABRICATOR 181i THEORY OF OPERATION Notes Theory of Operation Manual 0-5152...

  • Page 41: Section 6: 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 Possible Cause Remedy There is no weld The main Power Switch is set to OFF Set main Power Switch to ON output and all front Line fuse is blown...

  • Page 42: Checking Unit Before Applying Power

    FABRICATOR 181i TROUBLESHOOTING The following table is a guide for analysing problems and making repairs to the Power Source Fault Possible Cause Remedy 8 Wirefeed motor operates Internal wiring fault Check solenoid wiring header is plugged securely into Control when the torch trigger board.

  • Page 43: Case Removal

    TROUBLESHOOTING FABRICATOR 181i 6.04 Case Removal Read and follow safety information in Section 6.02 before proceeding. 1. Cover Remove Screws Loosen Screws Front & Rear A-09987 a) Remove the two top screws from the front & rear mouldings. b) Remove the centre screws from the front & rear mouldings. c) Loosen slightly the two bottom screws from the front &...

  • Page 44: 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. A-09962 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 45: Preliminary Check Of The Main Inverter Board

    TROUBLESHOOTING FABRICATOR 181i 6.08 Preliminary check of the main inverter board Read and follow safety information in Section 6.02 before proceeding. A-09988 Output Diode Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 5 Left Output Diodes 0.2 – 0.8 VDC Negative meter lead to testpoint 6 Positive meter lead to testpoint 7 Right Output Diodes...
  • Page 46 FABRICATOR 181i TROUBLESHOOTING IGBT Testing Multimeter Lead Placement Impedance IGBT 1 Positive meter lead to testpoint 17 150 to 350 Ω Negative meter lead to testpoint 9 Positive meter lead to testpoint 18 IGBT 2 150 to 350 Ω Negative meter lead to testpoint 11 Positive meter lead to testpoint 19 IGBT 3 150 to 350 Ω...

  • Page 47: Check Main On / Off Switch

    TROUBLESHOOTING FABRICATOR 181i 6.09 Check main On / Off Switch A-09989 Power Switch Testing Multimeter Lead Placement Impedance Switch ON Positive meter lead to testpoint 23 0 to 1 Ω Negative meter lead to testpoint 24 Switch ON Positive meter lead to testpoint 25 0 to 1 Ω...

  • Page 48: 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 trou- bleshooting techniques.

  • Page 49: 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 R103 R101 R102 R100 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 50 FABRICATOR 181i TROUBLESHOOTING DY2 Header Pin Pin function signal +24V 24 VDC 0 VDC -24V -24 VDC Table 6-15 DY2 Header pin function (connects to SOURCE header on control PCB) DY1 Header Pin Pin function signal +24V (solenoid positive) 24 VDC No connection +24V (solenoid positive) 24 VDC...

  • Page 51: Troubleshooting

    TROUBLESHOOTING FABRICATOR 181i PWM Header Pin Pin function Signal 0VDC 0 VDC Motor pwm drive signal 5 VDC pk Table 6-20 PWM Header pin function (connects to PWM header on inverter PCB) QF/DY Header Pin Pin function Signal +24V (VRD positive, South Pacific Version Only) 24 VDC Solenoid negative 0 VDC...
  • Page 52 FABRICATOR 181i TROUBLESHOOTING IGBT OT Header Pin Pin function signal Igbt thermostat (0VDC when thermostat closed) 0 VDC Table 6-28 IGBT OT Header pin function (connects to igbt thermostat) NTCS Header Pin Pin function Signal +24V 24 VDC 0 VDC Table 6-29 NTCS Header pin function (connects to NTCS header on inverter PCB) MB Header Pin Pin function...
  • Page 53 TROUBLESHOOTING FABRICATOR 181i REMOTE Header Pin Pin function Signal Remote switch Remote switch Table 6-33 REMOTE Header pin function (connects to remote switch) J1 & J11 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)

  • Page 54: 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 55: 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 6-37 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 calibration of wire feed speed.
  • Page 56 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 57 TROUBLESHOOTING FABRICATOR 181i Wire Speed Testpoint Waveforms TEST POINT “A” 5V/div TEST POINT “B” 5V/div TEST POINT “C” 5V/div TEST POINT “D” 5V/div TEST POINT “E” and “F” 5V/div TEST POINT “G” 5V/div A-09996 Manual 0-5152 6-17 Troubleshooting...

  • Page 58: 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 0-5152...
  • Page 59 TROUBLESHOOTING FABRICATOR 181i The mains supply voltage is connected via a double pole switch to the input rectifier Q1 through an EMC filter. Overvoltage protection is provided by varistor CY1. The rectifier output charges the main capacitor bank (C16, C17, C18, C19, C22 and C23) to high voltage. Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

  • Page 60: Circuit Diagram

    FABRICATOR 181i TROUBLESHOOTING 6.16 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 QF/FJ VDR Positive J14-1 J13-1...

  • Page 61: Section 7: 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 0-5152 Disassembly Procedure...

  • Page 62: 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. Refer to graphics on page 7-3. 1. M4 Screw. Remove 4 screws from Control panel. 2 Disconnect DRIVE harness from DRIVE connector.
  • Page 63 DISASSEMBLY PROCEDURE FABRICATOR 181i A-09963 WVIN QF/DY IGBT OT SOURCE NTCS FUNs DRIVE A-10018 Manual 0-5152 Disassembly Procedure...

  • Page 64: 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 65: Disassembly Procedure

    DISASSEMBLY PROCEDURE FABRICATOR 181i A-09965 Manual 0-5152 Disassembly Procedure...

  • Page 66: 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 screw (4). 2. Front Panel PCB. 3. Remote control PCB. A-10115 A-10000 A-10001 Disassembly Procedure...

  • Page 67: 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. ON/OFF switch. Ground wire screw. Disconnect Input cord ground wire from Main Power PCB1 using a 1/4" wench. 2. Terminal from supply cable. Disconnect two terminals from switch. 3.

  • Page 68: 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 69: Base Panel Removal

    DISASSEMBLY PROCEDURE FABRICATOR 181i 7.07 Base Panel Removal 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. A-10007 Manual 0-5152 Disassembly Procedure...
  • Page 70 FABRICATOR 181i DISASSEMBLY PROCEDURE Notes Disassembly Procedure 7-10 Manual 0-5152...

  • Page 71: Section 8: Assembly Procedures

    ASSEMBLY PROCEDURE FABRICATOR 181i SECTION 8: ASSEMBLY PROCEDURES 8.01 Installing Base Board 1. Main Power PCB assembly 2. Install main PCB assembly screws 3. Install central Panel Screws. 4. Install wire feeder. A-10009 A-10008 Manual 0-5152 Assembly Procedures...

  • Page 72: 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 73 ASSEMBLY PROCEDURE FABRICATOR 181i A-10011 A-10114 Manual 0-5152 Assembly Procedures...

  • Page 74: 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-10117 A-10000 A-10013 3. Reconnect torch polarity cable to the torch connector. 4.
  • Page 75 ASSEMBLY PROCEDURE FABRICATOR 181i A-09965 Manual 0-5152 Assembly Procedures...

  • Page 76: Installing Main Control Panel And Clear Cover Sheet

    FABRICATOR 181i ASSEMBLY PROCEDURES 8.04 Installing Main Control Panel and Clear Cover Sheet Refer to diagram on page 8-4. 1. Install 4 screws. 2 Plug harness into DRIVE connector. 3. Plug harness into SOURCE connector. 4. Plug harness into CR connector. 5.
  • Page 77 ASSEMBLY PROCEDURE FABRICATOR 181i A-10016 Manual 0-5152 Assembly Procedures...

  • Page 78: 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 A-10017 A-10112 Assembly Procedures Manual 0-5152...

  • Page 79: Tweco Weldskill 180A Mig Torch

    REPLACEMENT PARTS FABRICATOR 181i SECTION 9: REPLACEMENT PARTS 9.01 Tweco WeldSkill 180A MIG Torch Torch Part No: WS180XE-10-3035 Torch Parts Art # A-09954 Figure 9-1 TORCH PARTS ITEM PART NO. DESCRIPTION WS21-37 Nozzle 10mm WS21-50F Nozzle 13mm WS21-62 Nozzle 16mm WS11-23 Contact Tip 0.6mm WS11-35...

  • Page 80: Power Source

    FABRICATOR 181i REPLACEMENT PARTS 9.02 Power Source Figure 9-2 Replacement Parts Manual 0-5152...

  • Page 81: Replacement Parts

    REPLACEMENT PARTS 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) 62020 (Refer to options and accessories table for other feed rolls available).
  • Page 82 FABRICATOR 181i REPLACEMENT PARTS Notes Replacement Parts Manual 0-5152...

  • Page 83: Section 10: 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 Torch with 3M lead WS180XE-10-3035 TIG Torch 17V with 4m lead 310.050.002 Feed Roll 0.6/0.8mm V groove (hard), (fitted) 62020 Feed Roll 0.9/1.2mm V groove (hard) 62022...

  • Page 84: Thermal Arc - Limited Warranty Terms

    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.
  • Page 85 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...
  • Page 86 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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