Thermal Arc Fabricator 181i Operating Manual
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Thermal Arc Fabricator 181i Operating Manual

3 in 1 multi-process welding systems
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See also: Service Manual
181i
Operating Manual
FabricatOr
3 in 1 Multi-PrOcess
Welding systeMs
Revision: AB
Operating Features:
3163339
Issue Date: April 24, 2012
SMAW
Art# A-10820
Manual No.: 0-5191

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Summary of Contents for Thermal Arc Fabricator 181i

  • Page 1 181i FabricatOr 3 in 1 Multi-PrOcess Welding systeMs Art# A-10820 Operating Manual Revision: AB Issue Date: April 24, 2012 Manual No.: 0-5191 Operating Features: SMAW 3163339...
  • 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 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: Thermadyne Industries, Inc. 16052 Swingley Ridge Road, Suite 300St.

  • Page 4: Table Of Contents

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

  • Page 7: Safety Instructions And Warnings

    Fabricator 181i 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 Fabricator 181i Fabricator 181i 15. Keep all panels and covers securely in place. 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,...
  • Page 9 Fabricator 181i 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 Fabricator 181i 7. Keep protective cap in place over valve except when 3. Have only qualified people remove guards or cylinder is in use or connected for use. covers for maintenance and troubleshooting as necessary. 8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA 4.

  • Page 11: General Safety Information For Victor Cs Regulator

    Fabricator 181i 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 Fabricator 181i 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

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

  • Page 14: Symbol Chart

    Fabricator 181i Fabricator 181i 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...

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

    Fabricator 181i 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 Fabricator 181i 9. N’enroulez pas de câbles électriques autour de votre corps. AVERTISSEMENT 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder. LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT 11.
  • Page 17 Fabricator 181i Fabricator 181i 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. AVERTISSEMENT 3. Entourez l’aire de soudage de rideaux ou de cloisons LE SOUDAGE PEUT CAUSER UN INCENDIE pour protéger les autres des coups d’arc ou de OU UNE EXPLOSION l’éblouissement;...
  • Page 18 Fabricator 181i Fabricator 181i 8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements AVERTISSEMENT connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous. LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLES- SURES.

  • Page 19: Informations Générales De Sécurité

    Fabricator 181i Fabricator 181i 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT AVERTISSEMENT CAUSER DES BLESSURES. LA VAPEUR ET LE LIQUIDE DE REFROID- Des pièces en mouvement, tels des ventila- ISSEMENT BRULANT SOUS PRESSION teurs, des rotors et des courroies peuvent PEUVENT BRULER LA PEAU ET LES YEUX.
  • Page 20 Fabricator 181i Fabricator 181i 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...

  • Page 21: Principales Normes De Securite

    Fabricator 181i Fabricator 181i 1.08 Principales Normes De Securite AVIS Ce document CGA p. t peut être obtenu en Safety in Welding and Cutting, norme ANSI Z49.1, écrivant à “Compressed Gas Association”, American Welding Society, 550 N.W. LeJeune Rd., 4221 Walney Roed, 5th Floor. Chantilly, VA Miami, FL 33128.

  • Page 22: Graphique De Symbole

    Fabricator 181i Fabricator 181i 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...

  • Page 23: Declaration Of Conformity

    Thermadyne 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 Elaine Slatter Senior Brand Manager Thermal Arc Country Manager/Director Thermadyne Industries, Inc Thermadyne Canada 16052 Swingley Ridge Road...

  • 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: Duty Cycle

    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/FCAW) Region STICK (SMAW) Welding Current (amps) A-10352 Figure 2-1: Fabricator 181i Duty Cycle Manual 0-51 INTRODUCTION...

  • Page 28: Specifications

    Fabricator 181i 2.09 Specifications DESCRIPTION FABRICATOR 181i MULTI PROCESS 3 IN 1 WELDER Power Source Part No. W1003180 Power Source Dimensions H16.14" x W8.27" x D17.72" (410mm x 210mm x 450mm) Power Source Mass 32.2lb(14.6kg) Cooling Fan Cooled Welder Type...

  • Page 29: Options And Accessories

    Source (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.

  • Page 31: Installation, Operation And Setup

    Fabricator 181i SECTION 3: INSTALLATION, OPERATION AND SETUP 3.01 Environment G. The enclosure design of this Power Source meets the requirements of IP23S as outlined in EN 60529. This This Power Source is designed for use in environments provides adequate protection against solid objects with increased hazard of electric shock.
  • Page 32 Fabricator 181i WARNING The Fabricator 211i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts.

  • Page 33: Electromagnetic Compatibility

    Fabricator 181i NOTE Welding arc outs may be experienced if an extension cord is used when STICK welding when operation the Power Source on 208 VAC due to the lack of DC voltage at the STICK electrode. Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors.

  • Page 34: Victor Regulator

    Fabricator 181i 8. The immunity of other equipment in the by touching the metallic components and the environment: the user shall ensure that other electrode at the same time. The operator should equipment being used in the environment be insulated from all such bonded metallic is compatible: this may require additional components.
  • Page 35 Fabricator 181i NOTE Regulators purchased with open 1/8”, 1/4”, WARNING 3/8”, or 1/2” NPT ports must be assembled DO NOT attach or use the regulator if oil, to their intended system. grease, flamma ble substances or damage is 1. Note the maximum inlet pressure stamped present! Have a qualified repair technician on the regulator.

  • Page 36: Leak Testing The System

    Fabricator 181i b) If the low-pressure gauge drops, there is a leak in the down stream equipment, hose, hose fitting, outlet fitting or low-pressure gauge. Check for leaks using an approved leak detector solution. c) If the high-pressure gauge drops and the low-pressure gauge increases at the same time, there is a leak in the regulator seat.

  • Page 37: Power Source Controls, Indicators And Features

    Fabricator 181i 3.10 Power Source Controls, Indicators and Features LIFT TIG STICK SOFT HARD DOWNSLOPE (S) WIRESPEED ARC FORCE (%) INDUCTANCE Art # A-10353_AB Art # A-10354 Figure 3-4: Front Panel Figure 3-5: Rear Panel Art # A-10355 Figure 3-6: Wire Feed Compartment Control...
  • Page 38 Fabricator 181i 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 39 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 Gun (via the MIG Gun polarity lead), electrode holder lead or work lead.
  • Page 40 Fabricator 181i Negative Trigger Switch Spool Gun Motor Positive Remote Volts in MIG (GMAW/FCAW) Remote Wirespeed in MIG (GMAW/FCAW) mode Remote Amps in LIFT TIG (GTAW) mode Art # A-10421_AC Figure 3-7: Remote Control Socket Socket Pin Function Spool gun motor (0V)
  • Page 41 Fabricator 181i When 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 42 Fabricator 181i 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 43 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 44: Attaching The Tweco Weldskill 180 Gun

    Fabricator 181i 3.11 Attaching the Tweco WeldSkill 180 Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adaptor and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter.

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

    Fabricator 181i 3.12 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 3-9.

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

    Fabricator 181i 3.13 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 3-10.

  • Page 47: Inserting Wire Into The Wire Feed Mechanism

    Fabricator 181i 3.14 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in an counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 3-11).

  • Page 48: Feed Roller Pressure Adjustment

    Fabricator 181i 3.15 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

    Fabricator 181i 3.17 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 3.18 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 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 3.20 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 3.10.12 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 Fabricator 181i Positive Welding Terminal (+) MIG Gun Negative Welding Terminal (-) 8 pin Plug MIG Gun Polarity Lead. A-09587_AD Work Lead Figure 3-17: Setup for MIG (FCAW) Welding with Flux Cored (Gasless) Wire Manual 0-51 3-23 INSTALLATION, OPERATION AND SETUP...

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

    Fabricator 181i 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. For setup and operation of the spool gun, please refer to the spool gun operations manual.

  • 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

    Fabricator 181i 3.23 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 Fabricator 181i INSTALLATION, OPERATION AND SETUP 3-28 Manual 0-5191...

  • Page 59: Basic Welding Guide

    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 MIG 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.
  • Page 60 Fabricator 181i Position of MIG Gun The angle of MIG Gun to the weld has an effect on the width of the weld. Push Vertical 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 MIG Gun so that the welding seam is viewed at all times.
  • Page 61 Fabricator 181i 10° to 20° Longitudinal Angle 10° Longitudinal Angle 30° to 60° 30° to 60° Transverse Transverse Angle Angle Direction of Travel Vertical Fillet Welds Art # A-08995 Figure 4-6 Direction of Travel 30° to 60° Transverse Angle 5° to 15°...
  • Page 62 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 3/8"...
  • Page 63 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.
  • Page 64 Fabricator 181i Thermal Arc MIG, Lift TIG, Stick Wire Selection Chart Art # A-10366_AB Table 4-1: MIG, Lift TIG, Stick Welding Set up Chart BASIC WELDING GUIDE Manual 0-5191...

  • Page 65: Mig (Gmaw/Fcaw) Welding Troubleshooting

    Fabricator 181i 4.02 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG Gun. There are two main areas where problems occur with MIG, Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals - Porosity When there is a gas problem the result is usually porosity within the weld metal.
  • Page 66 Fabricator 181i Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the Wire spool brake is too tight. cabinet slipped.
  • Page 67 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 a crisp The MIG Gun has been con-...

  • Page 68: Stick (Smaw) Basic Welding Technique

    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...
  • Page 69 Fabricator 181i Arc Welding Practice The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally enough, different types of electrodes would be used for different metals as described in the preceding section.
  • Page 70 Fabricator 181i 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 BASIC WELDING GUIDE 4-12 Manual 0-5191...
  • Page 71 Fabricator 181i Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints.
  • Page 72 Fabricator 181i The Welder Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired.
  • Page 73 Fabricator 181i A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1/16"(1.6mm) to 3/32"(2.4mm) gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment.
  • Page 74 Fabricator 181i 45° from vertical 60° - 70° from line of weld Art # A-07699_AB Figure 4-23: Electrode Position for HV Fillet Weld Art # A-07700_AB 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 1/8"(3.2mm) E7014 Stick electrode and set the current at 100 amps.
  • Page 75 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 1/8"(3.2mm) electrode at 100 amps.
  • Page 76 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.
  • Page 77 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.
  • Page 78 Fabricator 181i Art # A-07709 Figure 4-33: Examples of Distortion Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 4-34: Welding Sequence Art # A-07711_AB Figure 4-35: Step back Sequence...

  • Page 79: Stick (Smaw) Welding Troubleshooting

    Fabricator 181i 4.05 Stick (SMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current ARC FORCE control knob is Reduce the ARC FORCE control knob until welding varying set at a value that causes the current is reasonably constant while prohibiting the...
  • Page 80 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.

  • Page 81: Tig (Gtaw) Basic Welding Technique

    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.
  • Page 82 Wider current Grey num, magnesium and range, Narrower more their alloys concentrated arc. Table 4-9 NOTE The Fabricator 181i is not suited for AC TIG welding. Base Metal DC Current DC Current Tungsten Filler Rod Argon Gas Joint Type...

  • Page 83: Tig (Gtaw) Welding Problems

    Fabricator 181i 4.07 TIG (GTAW) Welding Problems FAULT CAUSE REMEDY 1 Excessive bead build up or Welding current is too Increase weld current and/or faulty joint poor penetration or poor preparation. fusion at edges of weld. 2 Weld bead too wide and Welding current is too Decrease weld current.
  • Page 84 Fabricator 181i 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the con- by contact with work taminates. piece or filler rod mate- rial. B Work piece surface has B Clean surface. foreign material on it.

  • Page 85: Power Source Problems And Routine Service Requirements

    Fabricator 181i SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5.01 Power Source Problems 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 86: Routine Service And Calibration Requirements

    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 insulation resistance test and an earthing test to ensure the integrity of the Power Source is compliant with Thermal Arc's original specifications.
  • Page 87 Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring sup- plying Thermal Arc welding Power Sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
  • Page 88 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...

  • Page 89: Cleaning The Welding Power Source

    Fabricator 181i 5.03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source from the Electricity Supply Voltage before disassembling.

  • Page 90: Volt-Ampere Curves

    Fabricator 181i 5.05 Volt-Ampere Curves Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. Art # A-11296 Figure 5-1: Fabricator 181i Volt-Ampere Curves TROUBLE SHOOTING AND SERVICE Manual 0-5191...
  • Page 91 Fabricator 181i Manual 0-5191 TROUBLE SHOOTING AND SERVICE...
  • Page 92 Fabricator 181i This page is left blank intentionally. TROUBLE SHOOTING AND SERVICE Manual 0-5191...

  • Page 93: Key Spare Parts

    Fabricator 181i SECTION 6: KEY SPARE PARTS 6.01 Tweco WeldSkill 180A MIG Gun MIG Gun Part No: WS180TA-12-3035 Art # A-10370 Figure 6-1 TWECO WELDSKILL 180A MIG GUN PARTS ITEM PART NO. DESCRIPTION 1210-1112 Nozzle 1110-1101 Contact Tip 1510-1101 Gas Diffuser...

  • Page 94: Power Source

    Fabricator 181i 6.02 Power Source Figure 6-2 KEY SPARE PARTS Manual 0-5191...
  • Page 95 Fabricator 181i FABRICATOR 181i POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7004962 PCB,Power,181i W7004963 PCB,Control,181i W7003033 Solenoid,Valve,24VDC W7004970 PCB,Display,181i W7004969 PCB,Remote Interface,181i W7004905 Wiredrive Assy,w/ Motor,181i W7004906 Feedroll retaining thumb screw 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed W7004947 Fan,24VDC,4.75"x4.75"x1",181i...
  • Page 96 Fabricator 181i This page is left blank intentionally. KEY SPARE PARTS Manual 0-5191...

  • Page 97: Appendix: Fabricator 181I Circuit Diagram

    Fabricator 181i APPENDIX: FABRICATOR 181i CIRCUIT DIAGRAM Manual 0-5191...
  • Page 98 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 99: Warranty Schedule

    * 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) 1 Years Parts and Labor Unless specified 95S, Water recirculators All Plasma Welding consols (i.e WC-1 Controller, WT Timer,...
  • Page 100 Printed in: China U.S. Customer Care: 800-426-1888 / 800-535-0557 Canada Customer Care: 905-827-4515 / 800-588-1714 • International Customer Care: 940-381-1212 / 940-483-8178 www.thermalarc.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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