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ESAB Fabricator 181i, Service Manual

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ESAB FABRICATOR 181i

ASSEMBLY PROCEDURES                                                                  8-6                                                                             Manual 0-5449

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.  Plug harness into NTCs connector.
7.  Plug harness into IGBT OT connector .
8.  Plug harness into GUN connector.
9.  Plug harness into QF/DY connector.
10. Plug harness into WVIN connector.
11  Plug harness into MB connector.
12. Plug harness into PWM connector.
13. Plug harness into IFB connector.
Verify harness connections with the system schematic to insure all connections are correct.
14. Install clear protective sheet.

 

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Summary of Contents for Fabricator 181i

Page 1: ...A 12919 3163339 R vision AA Issue Date September 18 2015 Manual No 0 5449 Service Manual ESAB Fabricator 181i 3 IN 1 Multi Process Welding Systems esab com 180...

Page 2: ...take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand...

Page 3: ...rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party fo...

Page 4: ...reof contained in this manual and accom panying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked period...

Page 5: ...1 4 01 Power Source Controls Indicators and Features 4 1 4 02 Attaching the Tweco Fusion 180A Gun 4 7 4 03 Torch Adapter Thumb Screw Replacement 4 8 4 04 Installing 4 100mm Diameter Spool 4 9 4 05 In...

Page 6: ...it Description 6 18 6 16 Circuit Diagram 6 20 SECTION 7 DISASSEMBLY PROCEDURE 7 1 7 01 Safety Precautions for Disassembly 7 1 7 02 Control Board Removal 7 1 7 03 Front Panel Assembly Removal 7 3 7 04...

Page 7: ...arted up no one is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from drafts 4 Personal safety equipment Always wear recommended personal safety equipment...

Page 8: ...lter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby...

Page 9: ...WARNING A procedure which if not properly fol lowed may cause injury to the operator or others in the operating area WARNING Gives information regarding possible electrical shock injury Warnings will...

Page 10: ...leads should not be used Parts that are broken missing plainly worn distorted or contaminated should be replaced immediately Should such repairs or replacements become necessary it is recommended tha...

Page 11: ...designed to operate at a 20 duty cycle 180 amperes at 23 volts This means that it has been designed and built to provide the rated amperage 180 A for 2 minutes i e arc welding time out of every 10 mi...

Page 12: ...requency 50 60Hz Welding Current Range MIG Mode 10 180A Wirefeed Speed Range 100 650 IPM MIG Welding Voltage Range 14 5 23V DC Nominal OCV 62V DC Effective Input Current I1eff for MIG GMAW FCAW for LI...

Page 13: ...or lying position with physical contact with conductive parts 2 In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or ac cidenta...

Page 14: ...0 60 Hz AC power supply The input voltage must match one of the electri cal input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about...

Page 15: ...as simple as earthing the welding circuit see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work complete with associate...

Page 16: ...ilizing devices should be adjusted and maintained according to the manufacturer s recommendation 3 Welding Cables The welding cables should be kept as short as possible and should be positioned close...

Page 17: ...INSTALLATION 3 08 Volt Ampere Curves Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other set tings fall between curves shown Art A 11...

Page 18: ...ESAB FABRICATOR 181i SAFETY AND INSTALLATION 3 8 Manual 0 5449 This Page Intentionally Blank...

Page 19: ...NTRODUCTION SECTION 4 OPERATION 4 01 Power Source Controls Indicators and Features 1 2 3 4 5 7 8 11 12 13 14 A 13038 6 9 10 15 16 Figure 4 1 Front Panel Figure 4 2 Rear Panel 18 19 20 21 Art A 10355 F...

Page 20: ...d the transfer mode of the welding arc ie dip versus spray transfer Where exact settings are required in the case of procedural work it is recommended that alternate measurement methods be utilized to...

Page 21: ...this heavy duty bayonet type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can...

Page 22: ...10 maximum arc force allows greater penetration control to be achieved Arc force is increased by turning the control knob clockwise or decreased by turning the knob counterclockwise When LIFT TIG Mode...

Page 23: ...modes At the completion of welding the digital voltage meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes The voltage meter will hold the value unti...

Page 24: ...e trigger will operate at all times on the remote control socket irrespective of the position of the local remote switch ie in both local and remote modes Should a remote device be connected and the l...

Page 25: ...n 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 thr...

Page 26: ...panel as you turn each screw out Set these aside for reassembly Leave screws sitting in the pockets of the panel Screws Securing Block Art A 11483 3 Open the wire compartment door and release the tens...

Page 27: ...G Wire Spool Brake Clockwise rotation of this nut with nylon insert tight ens the brake The brake is correctly adjusted when the spool stops within 3 8 10mm to 3 4 20mm measured at the outer edge of t...

Page 28: ...is released Wire should be slack without becoming dislodged from the spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical components and pos...

Page 29: ...into the MIG Gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 4 8 Remove the con tact tip from the MIG Gun With the MIG Gun lead reasonably...

Page 30: ...clockwise WARNING Before changing the feed roller ensure that the Electricity Supply to the Power Source is switched off CAUTION The use of excessive pressure may cause rapid wear of the feed rollers...

Page 31: ...or to approximate working pressure It is recommended that testing for leaks at the regulator connection points be carried out using a suitable leak detection solution or soapy water 3 Purge air or oth...

Page 32: ...as hose from the rear of the Power Source to the regulator flow gauge outlet F Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information G Switch the LOCAL...

Page 33: ...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 Refer t...

Page 34: ...81i INTRODUCTION 4 16 Manual 0 5449 A 09587_AD MIG Gun Polarity Lead Negative Welding Terminal Positive Welding Terminal MIG Gun 8 pin Plug Work Lead Figure 4 14 Setup for MIG FCAW Welding with Flux C...

Page 35: ...pe terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Connect the work lead to the positive welding terminal Welding curren...

Page 36: ...erminal F Switch the LOCAL REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources Amperage control or REMOTE for remote amperage using a Foot Control Art A 10364 Work lead MI...

Page 37: ...onet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection WARNING Before connecting the work clamp to the work and inserti...

Page 38: ...flow rate 3 Close the cylinder valve Watch to see if the high pressure or contents gauge drops if it does you have a leak in the con nection between the regulator and the cylinder 4 Once leak testing...

Page 39: ...sformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply Inverter Tec...

Page 40: ...ESAB FABRICATOR 181i THEORY OF OPERATION 5 2 Manual 0 5449 This Page Intentionally Blank...

Page 41: ...is switched to SPOOL GUN B Switch the MIG GUN SPOOL GUN switch to MIG GUN 4 Welding wire continues to feed when torch trigger is released A Trigger mode selection switch is in 4T latch mode A Change...

Page 42: ...onnect the TIG Torch to the VE terminal 11 Arc flutters during TIG welding Tungsten electrode is too large for the welding current Select the correct size of tungsten electrode Refer to Table 4 7 in t...

Page 43: ...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 rear mouldings d Remove the three bottom screws and the t...

Page 44: ...scorched parts or wires or evidence of arcing c Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Par...

Page 45: ...odes Positive meter lead to testpoint 7 Negative meter lead to testpoint 8 0 2 0 8 VDC Table 6 3 Output Diodes Multimeter set to measure Diode Voltage IGBT Testing Multimeter Lead Placement Diode Volt...

Page 46: ...50 IGBT 3 Positive meter lead to testpoint 19 Negative meter lead to testpoint 13 150 to 350 IGBT 4 Positive meter lead to testpoint 20 Negative meter lead to testpoint 15 150 to 350 Table 6 5 IGBT s...

Page 47: ...Switch Multimeter set to measure ohms 6 10 Check Main Input Rectifier Input Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC Positive meter lead to AC1 Negative meter lead to testpo...

Page 48: ...tage and power levels present Do not touch any live parts 4 3 1 2 5 6 7 8 10 9 12 11 14 13 16 15 17 18 19 20 21 22 A 09988 DC Bus Testing Multimeter Lead Placement Voltage with Supply Voltage OFF Uppe...

Page 49: ...p p square wave 15 VDC pk 3 IGBT 2 pwm drive signal 15V p p square wave 15 VDC pk 4 IGBT 2 pwm drive signal 15V p p square wave 15 VDC pk 5 IGBT 1 pwm drive signal 15V p p square wave 15 VDC pk 6 Rect...

Page 50: ...3 No connection n c 4 24V solenoid positive 24 VDC 5 Solenoid negative 0 VDC Table 6 15 DY1 Header pin function QF FJ Header Pin Pin function signal 1 24V VRD positive South Pacific Version Only 24 V...

Page 51: ...Fan positive 24 VDC 2 0V Fan negative when fan is on 0 VDC Table 6 21 FUNs Header pin function not used DRIVE Header Pin Pin function Signal 1 15V 15 VDC 2 IGBT 1 pwm drive signal 15V p p square wave...

Page 52: ...VDC 2 0V 0 VDC Table 6 28 NTCS Header pin function connects to NTCS header on inverter PCB MB Header Pin Pin function Signal 1 Serial display data eprom D IN 5 VDC digital 2 Serial display data LOAD 5...

Page 53: ...ata CLK 5 VDC digital 4 2T 4T pushbutton 0V when button pushed 0VDC 5 Serial display eprom D OUT 5 VDC digital 6 Stick mode used for remote local 7 Chip select 5 VDC digital 8 MODE pushbutton 0V when...

Page 54: ...e used for remote local 7 Chip select 5 VDC digital 8 MODE pushbutton 0V when button pushed 0VDC 9 15VDC 15 VDC 10 Remote Local switch 11 Inductance pot terminal 2 12 Volts setpoint 0 5 VDC 13 Inducta...

Page 55: ...y reads within 0 2V of the measured value Connect a load to the output terminals The load should be of a resistance to give 25V at 250A Set front panel AMPS potentiometer to minimum Adjust Imin trimpo...

Page 56: ...l motor volts is 4 2V 0 2V Set front panel WIRESPEED AMPS potentiometer to maximum AMPS display should read 218 Adjust W05 trimpot until motor volts is 24 7V 0 2V Recheck settings Set SW0 1 to OFF SW0...

Page 57: ...ESAB FABRICATOR 181i Manual 0 5449 6 17 TROUBLESHOOTING 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 Art A 11231...

Page 58: ...to discharge after disconnection from mains supply voltage AC 1 AC 3 2 4 Q1 TR1 C19 C16 C17 R25 R24 R32 R33 T18 1 T16 1 T14 1 T17 1 T15 1 T13 1 R102 R100 R101 R103 C100 COUT1 COUT2 C18 TRANSFORMER R3...

Page 59: ...oltage from the transformer is rectified by the output diodes T13 T14 T15 T16 T17 T18 T19 and T20 to DC This DC is controlled by the PWM of the primary side igbt transistors and is filtered by an indu...

Page 60: ...MB SOURCE GUN QF DY OT FUNS CR NTCS ON 4 1 2 3 Art A 11230_AC 1 SPOOL GUN 0V 2 TORCH SWITCH 24VDC 3 TORCH SWITCH RIN 0VDC 4 SPOOL GUN 24VDC 5 6 REMOTE CONTROL IN 15VDC 7 REMOTE AMPS WIRESPEED POT WIPE...

Page 61: ...nel 2 Disconnect DRIVE harness from DRIVE connector 3 Disconnect SOURCE harness from SOURCE connector 4 Disconnect CR harness from CR connector 5 Disconnect FUNs harness from FUNs connector 6 Disconne...

Page 62: ...ESAB FABRICATOR 181i DISASSEMBLY PROCEDURES 7 2 Manual 0 5449 6 7 5 4 3 2 Art A 10460 1 11 12 13 8 9 10 IFB PWM MB GUN QF DY WVIN IGBT OT NTCS FUNs CR SOURCE DRIVE A 10018...

Page 63: ...on 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 Posi...

Page 64: ...ESAB FABRICATOR 181i DISASSEMBLY PROCEDURES 7 4 Manual 0 5449 A 09965_AB...

Page 65: ...URES 7 04 Front Panel Operator Interface Circuit Board PCB3 Removal WARNING Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove Control Panel screws 2 Front...

Page 66: ...ad 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 w...

Page 67: ...s Squeeze the locking tabs and push SW1 out from the rear panel 3 Strain relief screws Remove the two screws from the strain relief 4 Remove Fan 5 Input Power Cord ground wire filter Cut the tie wrap...

Page 68: ...ow 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 Remove Control PCB 5 Remove Recti...

Page 69: ...CB 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 Install main PCB assembly screws 7 Install Central...

Page 70: ...witch 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 Reconnect power ON OFF switch to terminals on Main Power PC...

Page 71: ...ESAB FABRICATOR 181i Manual 0 5449 8 3 ASSEMBLY PROCEDURES 8 7 A 10011 9 A 10114...

Page 72: ...2936 3 Reconnect torch polarity cable to the torch connector 4 Reconnect positive output terminal bolts and tighten with 17mm wrench Note reconnect wires pay attention to the wire color 5 Reconnect ne...

Page 73: ...ESAB FABRICATOR 181i Manual 0 5449 8 5 ASSEMBLY PROCEDURES A 09965_AB...

Page 74: ...s connector 6 Plug harness into NTCs connector 7 Plug harness into IGBT OT connector 8 Plug harness into GUN connector 9 Plug harness into QF DY connector 10 Plug harness into WVIN connector 11 Plug h...

Page 75: ...0 5449 8 7 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 Fro...

Page 76: ...ESAB FABRICATOR 181i ASSEMBLY PROCEDURES 8 8 Manual 0 5449 This Page Intentionally Blank...

Page 77: ...180TA 12 3035 Art A 10370_AB 9 8 7 6 5 4 3 2 1 TWECO WELDSKILL 180A MIG GUN PARTS ITEM PART NO DESCRIPTION 1 1210 1112 Nozzle 2 1110 1101 Contact Tip 3 1510 1101 Gas Diffuser 4 2042 2053 Microswitch 5...

Page 78: ...50F VNS 62 VNS 62F VNS 37 VNS 37F VNS 75FAS 2 Velocity Contact Tip VTS 23 VTS 30 VTS 35 VTS 40 VTS 45 VTS 364 VTSA 364 VTS 52 VTS 116 VTSA 116 VTS 564 3 Handle Trigger Repair Kit F80 4 Conduit Assembl...

Page 79: ...ESAB FABRICATOR 181i Manual 0 5449 9 3 KEY SPARE PARTS Art A 10363 31 9 03 Power Source Art A 11243_AC...

Page 80: ...5552 Panel Front 19 W7005555 Panel Rear 20 W7004922 Handle 181i 21 W7005554 Side and Top Panels not shown 22 W7004966 Adapter ESAB 4 181i 23 W7004925 Guide Inlet 023 045 181i 24 W7004967 Guide Outlet...

Page 81: ...ing Helmet Skull Fire USA Only 4100 1004 Drive Roll 023 035 0 6 0 9mm V groove for steel stainless steel W4014800 Drive Roll 023 030 0 6 0 8mm V groove for steel stainless steel wires Fitted 7977036 D...

Page 82: ...REVISION HISTORY Date Rev Description 09 18 2015 AA Manual release...

Page 83: ......

Page 84: ...50 92 22 ESAB international AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 UKRAINE ESAB Ukraine LLC Kiev Tel 38 044 501 23 24 F...

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