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181i Operating Manual FABRICATOR

1. 122 Negative Welding Terminal jj MIG Torch Polarity Lead 09587 AB Work Lead Figure 3 15 Setup for MIG Welding with Gasless MIG Wire INSTALLATION OPERATION AND SETUP 3 18 Manual 0 5151 Fabricator 181i 3 17 Setup for TIG GTAW Welding Select Lift TIG mode with the process selection control refer to Section 3 06 12 for further information Connect the TIG Torch to the negative 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 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 Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in Lift TIG Mode NOTE If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the 8 pin socket Refer to section 3 06 8 Remote Control Socket for further information Fit the welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 3 14 then connect the shielding gas hose from the
2. Type of gas not applicable to self shielding wires FCAW Gas flow rate not applicable to self shielding wires FCAW Primary Adjustable Variables These control the process after preselected variables have been found They control the penetration bead width bead height arc stability deposition rate and weld soundness They are Arc Voltage Welding current wire feed speed Travel speed Manual 0 5151 4 3 BASIC WELDING GUIDE Fabricator 181i Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation They are 1 Stick out distance between the end of the contact tube tip and the end of the electrode wire Maintain at about 10mm stick out 2 Wire Feed Speed Increase in wire feed speed increases weld current Decrease in wire feed speed decreases weld current Ga Nozzle Contact Tip Tube Electrode Wire Actual Stickout e E Arc Length Electrode Stick Out 4 09 Figure 4 8 Tip to Work Distance 3 Nozzle Angle This refers to the position of the welding gun in relation to the joint The transverse angle is usually one half the included angle between plates forming the joint The longitudinal angle is the angle between the centre line of the welding gun and a line perpendicular to the axis of the weld The longitudinal angle is generally called the Nozzle Angle and can be either trailing pullin
3. 60 70 40 60 1 6mm 70 90 50 70 1 8 80 100 65 85 1 16 3 32 3 2mm 90 115 90 110 1 6mm 2 4mm 3 16 115 135 100 125 3 32 1 8 4 8mm 140 165 125 150 2 4mm 3 2mm 1 6mm Butt Corner Lap Fillet Butt Corner Lap Fillet Butt Corner Lap Fillet 1 8 3 2mm Table 4 10 5 32 4 0mm 1 4 160 175 135 160 6 4mm 170 200 160 180 TIG Welding is generally regarded as a specialised process that requires operator competency While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual For further information please refer to www thermadyne com or contact Thermal Arc BASIC WELDING GUIDE Manual 0 5151 Fabricator 181i 4 07 TIG GTAW Welding Problems FAULT CAUSE REMEDY 1 Excessive beard build up Welding current is too Increase weld current and or faulty joint or poor penetration or poor low preparation fusion at edges of weld 2 Weld bead too wide and Welding current is too Decrease weld current flat or undercut at edges high of weld or excessive burn through 3 Weld bead too small or Travel speed too fast Reduce travel speed insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or Travel speed too slow Increase travel speed excessive bead build up or excessive penetration in butt joint 5 Uneven leg length in fillet Wrong placement of Re pos
4. Cutting CAC A f 4 Step Trigger Constant Current uH Operation Press and hold for preflow release onstant Voltage to start arc Press to stop arc and C Or Constant Potential hold for preflow Burnback Time l Disturbance In Fault Indication Ground System Touch Start GTAW 2 2 Manual 0 5151 2 06 Description The Thermal Arc Fabricator 181i is a self contained single phase multi process welding inverter that is capable of performing GMAW FCAW MIG MMA Stick and GTAW Lift TIG welding processes The unit is equipped with an integrated wire feed unit digital voltage and amperage meters and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional The unit is also fully compliant to European Standard EN 60974 1 The Fabricator 181i MIG provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source Please read these instructions thoroughly before using the unit 2 07 User Responsibility This equipment will perform as per the information contained herein when installed operated maintained and repaired in accordance with the instructions pro vided This equipment must be checked periodically Defective equipment inclu
5. Welding 3 21 TABLE CONTENTS SECTION 4 BASIC WELDING GUIDE 4 1 4 01 MIG GMAW FCAW Basic Welding Technique 4 1 4 00 MIG GMAW FCAW Welding Troubleshooting sss 4 7 4 03 Stick MMA Basic Welding Technique sss 4 10 4 04 Effects of Stick Welding Various MaterialS sss 4 10 4 05 Stick MMA Welding Troubleshooting 4 21 4 06 Ma GTAW Basic Welding Technique ood 4 23 4 07 TIGI GTAW Welding Problemgs o ton par tte e pecu 4 25 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Power Source Problems 2 02 rre et er e ee Eh eed pedis 5 1 5 02 Routine Service and Calibration 5 2 5 03 Cleaning the Welding Power Source pe 5 4 5 04 Cleaning the Feed Rolls im eet 5 5 SECTION 6 KEY SPARE PARTS eire occi qe ege vun Ea Sec Ev Tent ors erra Yon 6 1 6 01 Tweco WeldSkill 180A MIG Torch eese 6 1 6 02 POWEF SEENEN 6 2 APPENDIX FABRICATOR 181i CIRCUIT DIAGRAM eene A THERMAL ARC LIMITED WARRANTY TERMS TERMS WARRANTY JANUARY 2011 Fabricator 181i SECTION 1 WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL
6. amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields GENERAL INFORMATION The following is a quotation from the General Con clusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Govern ment Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coher ent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical e Nd ABOUT PACEMAKERS The
7. welds general purpose plate welding Mild Steel E7018 A low hydrogen all position electrode used when quality is an issue or for hard to weld metals It has the capability of producing more uniform weld metal which has better impact properties at low temperatures Suitable for joining all cast irons except white cast iron Stainless Steel E318L 16 High corrosion resistances Ideal for dairy work etc 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 Welding Position The electrodes dealt with in this publication can be used in most positions i e they are suitable for welding in flat horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 15 through 4 22 e Art A 07687 Figure 4 11 Flat Position Down Hand Butt Weld Art A 07689 Figure 4 13 Horizontal Position Butt Weld Manual 0 5151 4 11 BASIC WELDING GUIDE Fabricator 181i Art A 07690 Figure 4 14 Horizontal Vertical HV Position rmm Tes Y Art A 07691 Figure 4 15 Vertical Position Butt Weld Art A 07692 Figure 4 16 Vertical Position Fillet Weld Art A 07693 Figure 4 17 Ove
8. At first you may notice a tendency for undercut to form but keeping the arc length short the angle of the electrode at about 20 from vertical and the rate of travel not too fast will help eliminate this The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc To complete the joint in thin plate turn the job over clean the slag out of the back and deposit a similar weld 209309 0 Electrode Tack weld Tack weld Art A 07697 Art A 07698 Figure 4 22 Weld Build up Sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a wire brush It is important to do this to prevent slag being trapped by the second run Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 22 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a suitable joint for depositing the backing run If a backing bar is used it is not usually necessary to remove this since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld B Fillet Welds These are welds of approximately triangular cross section made by depositing met
9. MIG Torch Polarity Lead The polarity lead is used to connect the MIG torch to the appropriate positive or negative output terminal allowing polarity reversal for different welding applications In general the polarity lead should be connected in to the positive welding terminal when using steel stainless steel or aluminium electrode wire When using gasless wire the polarity lead is generally connected to the negative welding terminal If in doubt consult the manufacturer of the electrode wire for the correct polarity It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection AN Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 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 It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection i Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 8 Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control
10. Match regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas 3 Connect the regulator inlet connection to cylinder or pipeline and tighten it firmly but not excessively with a suitable spanner 4 Connect and tighten the outlet hose firmly and attach down stream equipment 5 To protect sensitive down stream equipment a separate safety device may be necessary if the regulator is not fitted with a pressure relief device 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 2 With valves on downstream equipment closed adjust regulator 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 Manual 0 5151 3 15 INSTALLATION OPERATION AND SETUP Fabricator 181i 3 Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator by individually opening then closing the equipment control valves Complete purging may take up to ten seconds or more depending upo
11. NO DESCRIPTION 521 37 Nozzle 10mm 521 50 Nozzle 13mm WS21 62 Nozzle 16mm WS11 23 WS11 35 11 40 WS11 45 551 WS80 140 WS90 WS90 LEV WS90 LEV S Trigger Lever Spring pkg 5 each 174X 2 Euro Kwit Nut 174EX 1 Euro Rear Connector 42 23 15 Conductor Assembly 0 6mm Solid Wire Dia 10 WS42 3035 15 Conductor Assembly 0 8 0 9mm Solid Wire Dia WS42N 3545 15 Teflon Conduit Assembly 0 8 1 2mm Al Wire Dia Table 6 1 Manual 0 5151 6 1 KEY SPARE PARTS Fabricator 1811 6 02 Power Source 6OLOL V uv Figure 6 2 KEY SPARE PARTS 6 2 Manual 0 5151 Fabricator 181i PART NUMBER W7004905 Wiredrive Assembl W7004906 Feed Roll Retaining Thumbscrew 62020 Feed Roll 0 6 0 8mm V groove fitted as standard Refer to options and accessories table for other feed rolls available W7004907 Fan Assembl W7003010 Input Rectifier W7004908 Gas Solenoid Valve Assembl W7004909 Dinse Socket 50mm 704461 Dinse Plug Male 50mm Control Socket 8 pin Note that 8 pin control plug part number is W7004923 Side and Top Panels not shown Table 6 2 Manual 0 5151 6 3 KEY SPARE PARTS Fabricator 181i This page is left blank intentionally KEY SPARE PARTS 6 4 Manual 0 5151 Fabricator 181i APPENDIX FABRICATOR 181i CIRCUIT DIAGRAM rurarmmrerg ot T v 1 rarer T wer F T mr T T sirorsr INO Nid SHOIDHNNOD SSHNHYHQ3INDOW 82d T scr si 1 3t
12. NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC 60974 13 Arc Welding Equipment Installation and use under preparation Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signalling and telephone cables above below and adjacent to the welding equipment 2 Radio and television transmitters and receivers 3 Computer and other control equipment 4 Safety critical equipment e g guarding of industrial equipment 5 The health of people around e g the use of pacemakers and hearing aids 6 Equipment used for calibration and measurement 7 The time of day that welding or other activities are to be carried out INSTALLATION OPERATION AND SETUP 3 2 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 The size of the surrounding area to be considered will depend on the st
13. TIG torch to the regulator flowmeter outlet Note that the TIG torch shielding gas hose is connected directly to the regulator flowmeter The power source is not fitted with a shielding gas solenoid to control the gas flow in TIG mode therefore the TIG torch will require a gas valve A WARNING Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping n EM e daa CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Manual 0 5151 3 19 INSTALLATION OPERATION AND SETUP Fabricator 181i A 09588_AD Positive welding terminal Connect to shielding gas regulator flowmeter MIG Torch polarity lead not connected Negative welding terminal Note This 8 pin connectionplug is for TIG torch trigger connection and remote TIG torch current Work lead TIG Torch control if applicable Figure 3 16 Setup for TIG Welding INSTALLATION OPERATION AND SETUP 3 20 Manual 0 5151 Fabricator 1811 3 18 Setup for Manual Arc Welding A Connect the Electrode Holder lea
14. a control valve When downstream equipment is not in use for extended periods of time shut off the gas at the cylinder valve and release the gas from the equipment 5 OPEN the cylinder valve SLOWLY Close after use INSTALLATION OPERATION AND SETUP 3 14 Manual 0 5151 Fabricator 1811 User Responsibilities This equipment will perform safely and reliable only when installed operated and maintained and repaired in accordance with the instructions provided Equipment must be checked periodically and repaired replaced or reset as necessary for continued safe and reliable performance Defective equipment should not be used Parts that are broken missing obviously worn distorted or contaminated should be replaced immediately The user of this equipment will generally have the sole responsibility for any malfunction which results from improper use faulty maintenance or by repair by anyone other than an accredited repairer A CAUTION Match regulator to cylinder NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas s Figure 3 13 Fit Regulator to Cylinder Installation 1 Remove cylinder valve plastic dust seal Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator Crack the valve open then close momentarily pointing the outlet away from people and sources of ignition Wipe with a clean lint free cloth 2
15. above procedures are among those also normally recommended for pace maker wearers Consult your doctor for complete information 1 4 Manual 0 5151 Fabricator 181i 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 S
16. by or furnished by 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 No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS 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 TERMS WARRANTY JANUARY 2011 In accordance with the warranty periods stated below Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual Thermadyne welding products are manufactured for use by commercial and industrial users and trained per sonnel with experience in the use and maintenance of electrical wel
17. devices to the welding power source To make connections align keyway insert plug and rotate threaded collar fully clockwise lt Trigger Switch Remote Volts in we GMAW Mode fica Remote Wirespeed in GMAW mode E Remote Amps in GTAW mode Figure 3 4 Remote Control Socket Manual 0 5151 3 5 INSTALLATION OPERATION AND SETUP Fabricator 181i Trigger Switch Input Trigger Switch Input Not connected ies 5k ohm maximum connection to 5k ohm remote control potentiometer 6 Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control Wirespeed GMAW MIG mode potentiometer Wiper arm connection to 5k ohm remote control Amps GTAW TIG mode potentiometer EN Wiper arm connection to 5k ohm remote control Volts GMAW MIG mode potentiometer 9 Table 3 1 Note that the remote local switch item 18 located in the wirefeed compartment should be set to remote for the amperage voltage controls to be operative Multifunction Control Voltage Down Slope amp Arc Force The multifunction control knob is used to adjust three main parameters depending on the welding mode selected When GMAW FCAW MIG Mode is Selected In this mode the control knob is used to adjust the output voltage of the unit The welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti clockwise The optimum voltage level requir
18. easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding cur rent from travelling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off 1 2 3 4 welding wire at contact tip when not in use 4h 2 gt WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin J 2 WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equip ment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical ci
19. every 12 months D General Maintenance Checks Welding equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure that 1 Hexible cord is of the multi core tough rubber or plastic sheathed type of adequate rating correctly connected and in good condition 2 Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit 3 The Welding System is clean internally especially from metal filing slag and loose material E Accessories Accessory equipment including output leads electrode holders torches wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition All unsafe accessories shall not be used F Repairs If any parts are damaged for any reason it is recommended that replacement be performed by an ac credited Thermal Arc Service Provider Manual 0 5151 5 3 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS Fabricator 1811 Power Source Calibration A Schedule Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels Calibration intervals shall be as outlined below 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months If equipment is to be used in a hazardous
20. location or environments with a high risk of electrocution as outlined in EN 60974 1 then the above tests should be carried out prior to entering this location B Calibration Requirements Where applicable the tests outlined in Table 6 3 below shall be conducted by an accredited Thermal Arc service agent Testing Requirements Output current to be checked to ensure it falls within applicable Thermal Arc power source specifications utput 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 Accuracy of digital meters to be checked to ensure it falls within applicable Thermal Arc power source specifi Table 5 3 Calibration Parameters Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified C Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question Only test equipment with valid calibration certificates NATA certified laboratories shall be utilized 5 03 Cleaning the Welding Power Source A 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 Disconne
21. processes EN 60974 1 IEC 60974 1 applicable to welding equipment and associated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process to ensure the product is safe and performs as specified Rigorous testing is in corporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications WARNING This equipment does not comply with IEC 61000 3 12 If it is connected to a public low voltage system it is the responsibility of the installer or user of the equipment to ensure by consultation With the distribution network operator if necessary that the equipment may be connected Thermadyne has been manufacturing and merchandising an extensive equipment range with superior per formance ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence Manufacturers responsible representative in Europe Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX GENERAL INFORMATION 1 6 Manual 0 5151 Fabricator 181i SECTION 2 INTRODUCTION 2 01 How to Use This Manual This Manual usually applies to the part numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the word WA
22. that the tip of the electrode just keeps ahead of the slag The electrode should point upwards at an angle of about 45 3 Overhead Welds Apart from the rather awkward position necessary overhead welding is not much more difficult that downhand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45 to the horizontal and tilted 10 in the line of travel Figure 4 28 The tip of the electrode may be touched lightly on the metal which helps to give a steady run A weave technique is not advisable for overhead fillet welds Use a 3 2mm E6013 Stick electrode at 100 amps and deposit the first run by simply drawing the electrode along at a steady rate You will notice that the weld deposit is rather convex due to the effect of gravity before the metal freezes Tilted 10 inline of travel Angie tacked to pipe Figure 4 28 Overhead Fillet Weld Manual 0 5151 4 17 BASIC WELDING GUIDE Fabricator 1811 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 The study of distorti
23. wee 2 3 SH Db OyGlgsu cesse io X eame A Heo Go ede qd T 2 4 2 10 Specifications cute ro e eb o er tee ein 2 5 241 Options ue 2 6 SECTION 3 INSTALLATION OPERATION AND SETUP eere esee 3 1 3 01 3 1 3 02 gt Sui MEN 3 1 3 95 NES a a a ME 3 1 3 04 Supply Voltage Heguirements pp 3 1 3 05 Electromagnetic Compatibility 2 2 Aere scene tae e Resa dicte decet 3 1 3 06 Fabricator 181i Power Source Controls Indicators and Features 3 3 3 07 X Attaching the Tweco WeldSkill 180 Torch 3 9 3 08 Installing 100mm Diameter Spool eere 3 10 3 09 Installing 200mm Diameter Spool eee 3 11 3 10 Inserting Wire into the Wire Feed 3 12 3 11 Feed Roller Pressure Adjustment eelere ia d 3 13 3 12 Changing the Feed Roll eese rnnt 3 13 SJ Wire CGB RKO E oce t i EE A eder OM E 3 14 3 14 Shielding Gas Regulator Operating 3 14 3 15 Setup for MIG GMAW Welding with Gas Shielded MIG Wire 3 17 3 16 Setup for MIG GMAW Welding with Gasless MIG Wire 3 18 3 17 Setup for TIG GTAW Welding E 3 19 3 18 Setup for Manual Arc MMA
24. welding machines at the same time or touch other people with the holder or electrode Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live when ever the output is on The input power cir 8 Donot use worn damaged undersized or poorly cuit and machine internal circuits are also spliced cables live when power is on In semiautomatic 9 Do not wrap cables around your body or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and body protection 3 Insulate yourself from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on acciden tally 5 Properly install and ground this equipment accord ing to its Owner s Manual and national state and local codes Manual 0 5151 12 Use only well maintained equipment Repair or replace damaged parts at once 13 In confined spaces or damp locations do not use a welde
25. will hold the last recorded voltage value for a period of approximately 10 seconds in all modes The voltage meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to preview mode 2 welding is recommenced in which case actual welding amperage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode 14 Thermal Overload Indicator This welding power source is protected by a self resetting thermostat The indicator will illuminate if the duty cycle of the power source has been exceeded Should the thermal overload indicator illuminate the output of the power source will be disabled Once the power source cools down this light will go OFF and the over temperature condition will automatically reset Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently Do not switch the unit off should a thermal overload condition be present Manual 0 5151 3 7 INSTALLATION OPERATION AND SETUP Fabricator 1811 15 Gas Inlet MIG mode only The Gas Inlet connection is used to supply the appropriate MIG welding gas to the unit Refer to section 3 15 or 3 16 for FCAW GMAW MIG set up details WARNING Only Inert Shielding Gases specifically designed for welding applications should be used 16 0n Off Switch This switc
26. 7V 113A Q 60 14 5V 88A 100 13 5V Table 2 1 Fabricator 181i Specification NOTE Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service Manual 0 5151 2 5 INTRODUCTION Fabricator 181i 2 11 Options and Accessories Table 2 2 Fabricator 181i Options and Accessories List INTRODUCTION 2 6 Manual 0 5151 Fabricator 181i SECTION 3 INSTALLATION OPERATION AND SETUP 3 01 Environment These units are designed for use in environments with increased hazard of electric shock A Examples of environments with increased hazard of electric shock are 1 In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts Inlocations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator In wet or damp hot locations where humidity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accessories Environments with increased hazard of electric shock do not include pla
27. ATOR VDR OFF INDICATOR fldei seio Power Indicator TANVd LNOUW Fault Indicator adoj kar Process unt maen 12 A YOLVOIGNI NOLS NOLVOKINL OA YOLVOIGNI DLL LAT E sown quaqod yonuog ary rei lt Cer lt JAV3DVIG LNOAVT na 118 3 Current Sensor Signal n2 sv E neg ien i z ERT d GEEEGEKEKER Big RA ESERE SER EEE SEZ ET BWV WW gee FEELERS PEEREEEEES vv zy Z RO 7 nn xiu ue gt gt 56 miis pc 9 323 14 amp Amps Setpoint 123 13 Inductance pot terminal 1 323 12 Volts Setpoint 123 11 Inductance pot terminal 2 123 10 Remote Local switch c isv DC 1238 MODE Pushbutton 23 7 amp Chip Slect 223 6 Stick Mode 123 5 Serial display eprom 123 4 21 47 pushbutton 123 3 Serial display data CLK 123 2 Serial display data LOAD 123 1 Serial display data amp eprom D IN vad vi H TORCH SWITCH Y v 4 Liuwe lt lt lt sare lt 5 lt cu 4 cs lt Remote Control Socket Manual 0 5151 A 1 APPENDIX THERMAL ARC LIMITED WARRANTY TERMS LIMITED WARRANTY Thermal Arc G Inc A Thermadyne Company hereafter Ther
28. AW and FCAW with the intention of providing the very basic concepts in using the MIG mode of welding where a welding gun is hand held and the electrode welding wire is fed into a weld puddle and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture GAS METAL ARC WELDING GMAW This process also known as MIG welding CO welding Micro Wire Welding short arc welding dip transfer welding wire welding etc is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous consumable electrode and the work Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture The process is normally applied semi automatically however the process may be operated automatically and can be machine operated The process can be used to weld thin and fairly thick steels and some non ferrous metals in all positions Shielding Gas Nozzle Molten Weld Metal Electrode Solidified Weld Metal GMAW Process um 8 Figure 4 1 FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous flux filled electrode wire and the work Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding may or may not be obtained from an extern
29. 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 Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Safe practices are outlined in the European Standard EN60974 1 entitled Safety in welding and allied processes Part 2 Electrical This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Arc Welding Hazards 6 Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or DE out of service EN 7 Use fully insulated electrode holders Never dip E holder in water to cool it or lay it down on the ELECTRIC SHOCK can kill ground or the work surface Do not touch holders connected to two
30. Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 www thermadyne com Shanghai China Sales Office Ph 486 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 Printed in China
31. GUIDE Fabricator 181i Art A 07709 Art A 07710 Block Sequence The spaces between the welds are filled in when the welds are cool Figure 4 34 Welding Sequence Art A 07711 Figure 4 37 Staggered Intermittent Welding BASIC WELDING GUIDE 4 20 Manual 0 5151 4 05 Stick Welding Troubleshooting FAUT cause REMEDY Reduce the ARC FORCE control knob until weld ing current is reasonably constant while prohibit ing the electrode from sticking to the work piece when you dig the electrode into the workpiece 1 Welding current varying A gap is left by failure of the weld metal to fill the root of the weld Non metallic par ticles are trapped in the weld metal ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length Welding current too low A B Electrode too large for joint Insufficient gap Non metallic particles A be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is pre venting full fusion Wrong electrode for posi tion in which welding is done Art 05866 AC Incorrect Sequence Insufficient Gap A groove has been A formed in the base metal adjacent to B the toe of a weld and has not been filled by the weld C metal un
32. IHERMAL 181i FABRICATOR MULTI PROCESS WELDING INVERTER THERMAL ALR Operating Manual Revision AB Issue Date April 27 2011 Manual No 0 5151 Operating Features C S joc THERMAL A RC WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service net work To locate your nearest distributor or service agency call 44 0 1257 261 755 or visit us on the web at www Thermalarc com This Operating Manual has been designed to instruct you on the cor rect use and operation of your Thermal Arc product Your satisfac tion with this product and its safe operation is our ultimate concern Therefore please 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 We have made every effort to provide you with accurate instructions drawings and photographs of the product s we used when writing this manual However errors do occur and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual wit
33. Lever PART No FEEDROLL DESCRIPTION Trigger Lever Spring pkg 5 each 174X 2 Euro Kwik Nut 62020 0 6 0 8 mm HARD WIRE 62022 0 9 1 2 mm HARD WIRE 7 8 9 174EX 1 42 23 15 10 Euro Rear Connector ConduitAssembly 0 6 mm Solid Wire Dia 62179 0 8 0 9 mm SOFT WIRE WS42 3035 15 WS42N 3545 15 Note This set up information is intended to act as a guide only Please refer to operating manual for further information 62024 1 0 1 2 mm SOFT WIRE 62028 0 8 0 9 mm CORED WIRE 831557_AA A 09941 Conduit Assembly 0 8 0 9 mm Solid Wire Dia Teflon Conduit Assembly 0 8 1 2 mm Al Wire Dia Table 4 1 Thermal Arc MIG Wire Selection Chart BASIC WELDING GUIDE Manual 0 5151 Fabricator 1811 4 02 MIG GMAW FCAW Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding GMAW problems is to start at the wire spool then work through to the MIG torch There are two main areas where problems occur with GMAW Porosity and 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 Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal Contaminants range from no gas around the welding arc to dirt on the work pi
34. OURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 2 Manual 0 5151 Fabricator 181i Minimum Insulation Components to be Tested Resistance M Input circuit including any connected control circuits to welding circuit including any connected control circuits All circuits to exposed conductive parts Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage exceeding extra low voltage Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage not exceeding extra low voltage Separate welding circuit to separate welding circuit Table 5 2 Minimum Insulation Resistance Requirements Thermal Arc Inverter Power Sources C Earthing The resistance shall not exceed 10 between any metal of a power source where such metal is required to be earthed and 1 The earth terminal of a fixed power source or 2 he earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring the integrity of fixed wiring supplying Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below 1 For outlets wiring and associated accessories supplying transportable equipment at least once every 3 months and 2 For outlets wiring and associated accessories supplying fixed equipment at least once
35. RNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING Gives information regarding possible per sonal injury Warnings will be enclosed in box such as this A CAUTION Refers to possible equipment damage Cautions will be shown in bold type NOTE Offers helpful information concerning certain operating procedures Notes will be shown in italics You will also notice icons from the safety section ap pearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that follows Some may have multiple hazards that apply and would look something like this AA 2 Manual 0 5151 2 1 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate attached to the machine is identified only by the specification or part number printed on the shipping container Record these numbers for future reference 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immedi ately to file a claim Furnis
36. afety in welding and allied processes Part 1 Fire Precautions EN 60974 1 from SAI Global Limited www saiglobal com Safety in welding and allied processes Part 2 Electrical EN 60974 1 from SAI Global Limited www saiglobal com Filters for eye protectors Filters for protection against radiation generated in welding and allied operations AS NZS 1338 1 1992 from SAI Global Limited www saiglobal com Manual 0 5151 1 5 GENERAL INFORMATION Fabricator 181i 1 03 Declaration of Conformity Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA Description of equipment Welding Equipment GMAW FCAW GTAW 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 The equipment conforms to all applicable aspects and regulations of the Low Voltage Directive Directive 73 23 EU as recently changed in Directive 93 68 EU and to the National legislation for the enforcement of the Directive National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are e IEC 60974 10 applicable to Industrial Equipment generic emissions and regulations EN 60974 1 Safety in welding and allied
37. al in the corner of two faces meeting at right angles Refer to Figure 4 14 A piece of angle iron is a suitable specimen with which to begin or two lengths of strip steel may be tacked together at right angles Using a 3 2mm E7014 Stick electrode at 100 amps position angle iron with one leg horizontal and the other vertical This is known as a horizontal vertical HV fillet Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure 4 23 Do not attempt to build up much larger than 6 4mm width with a 3 2mm electrode otherwise the weld metal tends to sag towards the base and undercut forms on the vertical leg Multi runs can be made as shown in Figure 4 24 Weaving in HV fillet welds is undesirable Manual 0 5151 4 15 BASIC WELDING GUIDE Fabricator 181i 45 from vertical 11 60 70 from line of weld Figure 4 23 Electrode Position for HV Fillet Weld 07700 Figure 4 24 Multi runs Fillet Weld C Vertical Welds 1 Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position Use a 3 2 E7014 Stick electrode and set the current at 100 amps Make yourself comfortable on a seat in front of the job and strike the arc in the c
38. ally supplied gas or gas mixture The process is normally applied semi automatically however the process may be applied automatically or by machine It is commonly used to weld large diameter electrodes in the flat and horizontal position and small electrode diameters in all positions The process is used to a lesser degree for welding stainless steel and for overlay work Shielding Gas Optional Nozzle Optional Molten Metal Flux Cored Molten Electrode Slag Slag Solidified Weld Metal FCAW Process 4 08992_A8 Figure 4 2 Manual 0 5151 4 1 BASIC WELDING GUIDE Fabricator 1811 Position of MIG Torch The angle of MIG torch to the weld has an effect on the width of the weld 2 ro Vertical Drag Pull Art 07185_ Figure 4 3 The welding gun should be held at an angle to the weld joint see Secondary Adjustment Variables below Hold the gun so that the welding seam is viewed at all times Always wear the welding helmet with proper filter lenses and use the proper safety equipment A CAUTION Do not pull the welding gun back when the arc is established This will create excessive wire extension stick out and make a very poor weld The electrode wire is not energized until the gun trigger switch is depressed The wire may therefore be placed on the seam or joint prior to lowering the helmet Longitudinal ON Z Direction of Travel Art A 08993 Butt a
39. ate C Wrong electrode angle D Travel speed of electrode is too high E Scale or dirt on joint surface Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Lack of inter run fusion Art A 05867 AC Lack of side fusion scale dirt small electrode amperage too low Lack of root fusion 6 Gas pockets or voids in weld metal porosity High levels of sulphur in steel Electrodes are damp C Welding current is too high A Small electrodes used A B Welding current is too low B Use larger electrodes and preheat the plate Increase welding current Adjust angle so the welding arc is directed more into the base metal Reduce travel speed of electrode Clean surface before welding Figure 2 Example of Lack of Fusion Use an electrode that is designed for high sul phur steels B Dry electrodes before use Surface impurities such as D oil grease paint etc Welding in a windy envi ronment Electrode damaged ie flux F coating incomplete 7 Crack occurring in A weld metal soon after solidification B commences Rigidity of joint Insufficient throat thick ness Weld current is too high trapped in Not cleaned 22 undercut or incorrect electrode Slag trapped in root Reduce welding current Clean joint before welding Shield the weld area from the wind Discard damaged electrodes and only use elec trodes with a compl
40. ces where electrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines C In areas free from moisture and dust Ambient temperature between 0 C to 40 C In areas free from oil steam and corrosive gases In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a distance of 300mm or more from walls or similar that could restrict natural air flow for cooling The enclosure design of this power source meets the requirements of IP23S as outlined in EN 60529 This provides adequate protection against solid objects greater than 12mm and direct protection from vertical drops Under no circumstances should the unit be operated or connected in a micro environment that will exceed the stated conditions For further information please refer to EN 60529 Manual 0 5151 3 1 Precautions must be taken against the power source toppling over The power source must be located on a suitable horizontal surface in the upright position when in use 3 03 Ventilation Since the inhalation of welding fumes can be harmful ensure that the welding area is effectively ventilated 3 04 Mains Supply Voltage Requirements The Mains supply voltage should be within 1596 of the rated mains supply voltage Too low a v
41. cking to the work piece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 6mm to 3 2mm gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults 20 Art A 07696 re Ke BS X2 J emm 1 16 s A ZI Figure 4 20 Striking an Arc Arc Length The securing of an arc length necessary to produce a neat weld soon becomes almost automatic You will find that a long arc produces more heat A very long arc produces a crackling or spluttering noise and the weld metal comes across in large irregular blobs The weld bead is flattened and spatter increases A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in If this should happen give the electrode a quick twist back over the weld to detach it Contact or touch weld electrodes such as E7014 Stick electrodes do not stick in this way and make welding m
42. ct the Welding Power Source from the Mains Supply Voltage before disassembling n Sees To clean the Welding Power Source open the enclosure and use a vacuum cleaner to remove any accumulated dirt metal filings slag and loose material Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 4 Manual 0 5151 Fabricator 1811 5 04 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently This can be done by using a small wire brush Also wipe off or clean the grooves on the upper feed roll After cleaning tighten the feed roll retaining knobs A CAUTION Do not use compressed air to clean the Welding Power Source Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source This may result in arcing between this parts and their eventual failure Manual 0 5151 5 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS Fabricator 181i This page is left blank intentionally POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 6 Manual 0 5151 Fabricator 181i SECTION 6 SPARE PARTS 6 01 Tweco WeldSkill 180A MIG Torch Torch Part No WS180XE 10 3035 Torch Parts Art A 09954 Figure 6 1 TORCH PARTS ITEM PART
43. ctrical connection C Fit the MIG Torch to the power source Refer to section 3 07 Attaching the Tweco WeldSkill 180 MIG Torch D Connect the work lead to the negative welding terminal If in doubt consult the electrode wire 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 E Fitthe welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 3 14 then connect the shielding gas hose from the rear of the power source to the regulator flowmeter outlet F Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information A WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping AA TION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source A 09586_AC Positive Welding Terminal with Quick Connect Negative Welding Terminal MIG Torch Polarity Lead Work Lead F
44. d thus eliminating the need for the operator to hold the torch trigger Note that when operating in GTAW TIG mode the power source will remain activated until the selected downslope time has elapsed refer Item 10 12 Process Selection Control The process selection control is used to select the desired welding mode Three modes are available GMAW FCAW MIG GTAW Lift TIG and MMA Stick modes Refer to section 3 15 or 3 16 for FCAW GMAW MIG set up details section 3 17 for GTAW TIG set up details or section 3 18 for MMA stick set up details Note that when the unit is powered off the mode selection control will automatically default to MIG mode This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up 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 This value can be adjusted by varying the multifunction control knob item 10 Note that in MMA stick and GTAW TIG modes the voltage meter will not preview welding voltage and will display zero When welding the voltage meter will display actual welding current in all modes At the completion of welding the digital voltage meter
45. d 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 B Connect the work lead to the negative 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 ires WARNING Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off A CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source A KN ss Positive Welding Terminal A Y See 27 MIG Torch 20 e polarity lead d not connected Negative Welding Electrode Terminal Holder Work Lead A 09589 AB Figure 3 17 Setup for Manual Arc Welding Manual 0 5151 3 21 INSTALLATION OPERATION AND SETUP Fabricator 181i INSTALLATION OPERATION AND SETUP 3 22 Manual 0 5151 Fabricator 181i SECTION 4 BASIC WELDING GUIDE 4 01 MIG GMAW FCAW Basic Welding Technique Two different welding processes are covered in this section GM
46. de for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range Amps 1 16 1 6mm 20 90 3 32 2 4mm 65 115 1 8 3 2mm 100 165 3 16 4 8mm 200 350 Table 4 8 Filler Wire Selection Guide Manual 0 5151 4 23 BASIC WELDING GUIDE Fabricator 181i Tungsten Electrode Types Electrode Type Ground Finish Welding Application Colour Code DC welding of mild steel stainless steel and copper Thoriated 296 High quality AC weld ing of aluminium magnesium and their alloys Zirconated 196 AC amp DC welding of mild steel stainless steel copper alumin ium magnesium and Ceriated 296 Excellent arc starting Long life High current carrying capacity Self cleaning Long life Maintains balled end High current car rying capacity Longer life More Stable arc Easier Starting Wider current range Narrower more their alloys concentrated arc Table 4 9 NOTE The Fabricator 181i Inverter is not suited for AC TIG welding DC Current for Mild for Stainless Electrode Diameter if Steel Steel Diameter required 0 040 35 45 20 30 0 040 1 16 5 7 Butt Corner 1 0mm 40 50 25 35 1 0mm 1 6mm Lap Fillet 0 045 45 55 30 45 0 040 1 16 5 7 Butt Corner 1 2mm 50 60 35 50 1 0mm 1 6mm Lap Fillet 1 16 1 16 7 Butt Corner 1 6mm Lap Fillet Base Metal DC Current Filler Rod Thickness Tungsten Argon Gas Flow Rate Litres min Joint Type 1 16
47. dercut Manual 0 5151 Fabricator 181i Increase welding current Use smaller diameter electrode Allow wider gap If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode Allow for adequate penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from comers Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult Figure 1 Example of insufficient gap or incorrect sequence Welding current is too high Welding arc is too long Angle of the electrode is incorrect Joint preparation does not D allow correct electrode angle Electrode too large for joint Insufficient deposit time at F edge of weave Power source is set for MIG GMAW welding A Reduce welding current Reduce the length of the welding arc Electrode should not be inclined less than 45 to the vertical face Allow more room in joint for manipulation of the electrode Use smaller gauge electrode Pause for a moment at edge of weave to allow weld metal buildup Set power source to STICK MMA mode BASIC WELDING GUIDE Fabricator 181i 5 Portions of the weld run do not fuse to the surface of the metal or edge of the joint heavy cold pl
48. ding and cutting equipment 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 MIG Torch Electrode Holder Lead amp Work Lead 3 Months MIG Torch Consumables If warranty is being sought Please contact your Thermadyne product supplier for the warranty repair proce dure Thermadyne warranty will not apply to Equipment that has been modified by any other party other than Thermadyne s own service personnel or with prior written consent obtained from Thermadyne Service Department Equipment that has been used beyond the specifications established in the operating manual Installation not in accordance with the installation operating manual Any product that has been subjected to abuse misuse negligence or accident Failure to clean and maintain including lack of lubrication maintenance and protection the machine as set forth in the operating installation or service manual Within this operating manual are details regarding the maintenance necessary to ensure trouble free opera tion This manual also offers basic troubleshooting operational and technical details including application usage You may also wish to visit our web site www thermadyne com select your product class and the
49. ding welding 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 that such re pairs be carried out by appropriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor This equipment or any of its parts should not be al tered 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 Manual 0 5151 2 3 Fabricator 181i 2 08 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 Fabricator 181i 2 09 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 du
50. ece surface Porosity can be reduced by checking the following points Shielding gas cylinder contents Ensure that the shielding gas cylinder is not empty and the and flow meter flow meter is correctly adjusted to 15 litres per minute 2 Gas leaks Check for gas leaks between the regulator cylinder connec tion and in the gas hose to the Power Source 3Internal gas hose in the Power Ensure the hose from the solenoid valve to the torch adaptor Source has not fractured and that it is connected to the torch adaptor 4Welding in a windy environment Shield the weld area from the wind or increase the gas flow 5 Welding dirty oily painted Clean contaminates off the work piece oxidised or greasy plate 6Distance between the MIG torch Keep the distance between the MIG torch nozzle and the work nozzle and the work piece piece to a minimum Refer to section 2 03 7 Maintain the MIG torch in good AEnsure that the gas holes are not blocked and gas is exiting working order out of the torch nozzle BDo not restrict gas flow by allowing spatter to build up inside the torch nozzle CCheck that the MIG torch O rings are not damaged Table 4 2 Solving Problems beyond the Welding Terminals Porosity WARNING Disengage the feed roll when testing for gas flow by ear Manual 0 5151 4 7 BASIC WELDING GUIDE Fabricator 1811 Solving Problems Beyond the Welding Terminals Inconsistent Wire Feed Wire feeding problems can be reduced by ch
51. ecking the following points 1Feed roller driven by motor in the Wire Spool brake is too tight cabinet slipped 2Wire spool unwinded and tangled Wire spool brake is too loose 3Worn or incorrect feed roller size AUse a feed roller matched to the size you are welding BReplace feed roller if worn 4Wire rubbed against the mis aligned Mis alignment of inlet outlet guides guides and reduced wire feedability D mer blocked with swarf Alncreased amounts of swarf are produced by the wire passing through the feed roller when excessive pres sure is applied to the pressure roller adjuster BSwarf can also be produced by the wire passing through an incorrect feed roller groove shape or size CSwarf is fed into the conduit liner where it accumu lates thus reducing wire feedability 6Incorrect or worn contact tip AThe contact tip transfers the weld current to the elec trode wire If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the wire jamming in the contact tip BWhen using soft wire such as aluminium it may become jammed in the contact tip due to expansion of the wire when heated A contact tip designed for soft wires should be used TPoor work lead contact to work piece If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc 8Bent liner This will cause friction between the wire and the lin
52. ed will dependent on the type of welding application The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications 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 In general increasing the arc force control toward 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 anti clockwise When TIG Mode is Selected In this mode the multifunction control knob is used to adjust down slope Down slope allows the user to select the ramp down time at the completion of the weld The main function of down slope is to allow the welding current to be gradually reduced over a pre set time frame such that the welding pool is given time to cool sufficiently Note that when in 2T normal mode refer item 12 the unit will enter down slope mode as soon as the trigger switch is released ie if the multifunction control knob is set to 5 the unit will ramp down from the present welding current to zero over 5 seconds If no down s
53. een 30 aaISINHNOdINODJNOMH AMAIA Art A 10151 7 09 0 DVAOYZ IndNI T8Od NIVIN ESCH BEN m gt NA A g S 424V ena amp gt 223 gt lt 92224 gt NA S Vv TIG GAS is gt NA Ki w a D E 3 KR OHL Am x lq par gt cor gt gt u 5 oo p 3 s gt white MD Motor Positive 24V 2 d Motor Negative 0V gt 112 2 eS Box black s dc QUE omy H gt 1 24 VDR Positive H gt J142 s k JI24 V Solenoid Negatiove a3 gt 113 34 24V Solenoid Positive gt gt d lt 4 ov NTCS lt white lt RE 0 6 i SOURCE gt lt white oy n2 gt gt white lt lt gt a 3 M iie 5 E DRIVE nag wv 5 gt gt white 4 white 4 2 white Tite lt wi J1 6 Rectified secondary of current transformer t IGBT 1 pwm driver signal IGBT 2 pwm driver signal 11 3 IGBT 2 pwm driver signal 0 06 o PWM 4 H 116 14 gt ues S 115 1 Positive Q NA 1152 5 black 115 3 amp Negative white yellow gray VDR ON INDIC
54. elding can be carried out in the downhand position Make sure that the work clamp is making good electrical contact with the work either directly or through the work table For light gauge material always clamp the work lead directly to the job otherwise a poor circuit will probably result 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 Relax and you will find that the job becomes much easier You can add much to your peace of mind by wearing a leather apron and gauntlets You won t be worrying then about being burnt or sparks setting alight to your clothes Manual 0 5151 4 13 BASIC WELDING GUIDE Fabricator 181i Place the work so that the direction of welding is across rather than to or from your body The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down If the lead is slung over your shoulder it allows greater freedom of movement and takes a lot of weight off your hand Be sure the insulation on your cable and electrode holder is not faulty otherwise you are risking an electric shock Striking the Arc Practice this on a piece of scrap plate before going on to more exacting work You may at first experience difficulty due to the tip of the electrode sti
55. en exceeded Electrode wire stuck in conduit liner or contact tip burn back jam Internal fault in power source Trigger mode selection switch is in 4T latch mode Torch trigger leads shorted MIG torch polarity lead is not connected into a weld ing output terminal Poor or no work lead contact A Worn or dirty contact tip Worn feed roll C Excessive brake tension on wire reel hub Worn kinked or dirty con duit liner A Gas hose is damaged Gas passage contains impurities C Gas regulator turned off Empty gas cylinder A Setthe power source to the cor rect mode of operation with the process selection switch Repair or replace torch trigger switch lead Leave the power source switched ON and allow it to cool Note that fault indicator must be extinguished prior to com mencement of welding Check for clogged kinked MIG torch conduit liner or worn contact tip Replace faulty com ponents Have an Accredited Thermal Arc Service Provider investigate the fault Change the trigger mode selec tion switch from 4T latch mode to 2T normal mode Repair or replace torch trigger switch lead Connect the MIG torch polar ity lead to either the positive welding output terminal or the negative welding output terminal as required Clean work clamp area and en sure good electrical contact A Replace if necessary Replace C Reduce brake tension on spool hub Clean o
56. ence which will distribute the stresses suitably so that they tend to cancel each other out See Figures 4 30 through 4 33 for various weld sequences Choice of a suitable weld sequence is probably the most effective method of overcoming distortion although an unsuitable sequence may exaggerate it Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure 4 31 E Preheating Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure 4 32 shows a simple application By removing the heating source from b and c as soon as welding is completed the sections b and c will contract at a similar rate thus reducing distortion t 1 L Preheat Dotted lines Show effect if no preheat is Used Figure 4 32 Reduction of Distortion by Preheating Manual 0 5151 4 19 BASIC WELDING
57. ent Tungsten Electrode Size B The wrong electrode Select the right electrode type Refer to is being used for the Table 4 9 Tungsten Electrode Types welding job C Gas flow rate is too C Select the right rate for the welding job high Refer to Table 4 10 D Incorrect shielding gas D Select the right shielding gas is being used E Poor work clamp con E Improve connection to work piece nection to work piece 10 Arc flutters during TIG Tungsten electrode is Select the right size electrode Refer to welding too large for the weld Table 4 7 Current Ranges for Various ing current Electrode Size Table 4 11 GTAW TIG Welding Problems BASIC WELDING GUIDE 4 26 Manual 0 5151 SECTION 5 Fabricator 181i POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 01 Power Source Problems FAULT REMEDY Mains supply voltage is ON A Power source is not in the power indicator is illumi nated however unit will not commence welding when the torch trigger switch is depressed Fault Indicator is illumi nated and unit will not commence welding when the torch trigger switch is depressed Unit will not feed wire in MIG mode Welding wire continues to feed when torch trigger is released Welding arc cannot be established in MIG mode Inconsistent wire feed No gas flow in MIG mode Manual 0 5151 correct mode of operation Faulty torch trigger Duty cycle of power source has be
58. er thus reducing wire feedability Table 4 3 Wire Feeding Problems BASIC WELDING GUIDE 4 8 Manual 0 5151 Fabricator 1811 Basic GMAW MIG Welding Troubleshooting FAUT cause REMEDY 1 Undercut A Welding arc voltage too A Decrease voltage or increase the wire feed speed high B Incorrect torch angle B Adjust angle C Excessive heat input C Increase the torch travel speed and or decrease welding current by decreasing the voltage or decreasing the wire feed speed 2 Lack of penetration A Welding current too low Increase welding current by increasing wire feed speed and increasing voltage B Joint preparation too B Increase joint angle or gap narrow or gap too tight C Shielding gas incorrect C Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase voltage 4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control B Voltage too low B Increase the voltage or decrease wirespeed 5 Irregular weld shape A Incorrect voltage and A Adjust voltage and current by adjusting the voltage current settings Con control and the wirespeed control vex voltage too low Concave voltage too high Wire is wandering B Replace contact tip Incorrect shielding gas C Check shielding gas Insufficient or excessive D Adjust the wirespeed control or the voltage heat input control 6 Weld cracking Weld beads too small A Decrease travel speed We
59. ete flux coating Redesign to relieve weld joint of severe stresses or use crack resistance electrodes Travel slightly slower to allow greater build up in throat Decrease welding current Figure 3 Example of Slag Inclusion Table 4 6 Welding Problems MMA Stick BASIC WELDING GUIDE Manual 0 5151 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 Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based A filler metal may also be added manually in some circumstances depending on the welding application 09658 AB Gas Cup Either Ceramic Work Piece High impact or Can Be Any Commercial Water Cooled Metal Bw Metal Tungsten Electrode Non Consumable Welds Made With or Without Addition of Filler Metal Inert Gas Shields Electrode and Weld Puddle Figure 4 38 TIG Welding Application Shot Tungsten Electrode Current Ranges Electrode Diameter DC Current Amps 0 040 1 0mm 30 60 1 16 1 6mm 60 115 3 32 2 4mm 100 165 1 8 3 2mm 135 200 5 32 4 0mm 190 280 3 16 4 8mm 250 340 Table 4 7 Current Ranges for Various Tungsten Electrode Sizes Gui
60. g or leading pushing Whether the operator is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel Transverse Angle Ca Longitudinal ngle Transverse and Longitudinal Nozzle Axes Art A 08998 Figure 4 9 Direction of Gun Travel uw Leading 4 Pushing troling x Forward 1 Pointing Backward Pointing Nozzle Angle Right Handed Operator 1 08999 AB Figure 4 10 BASIC WELDING GUIDE 4 4 Manual 0 5151 Fabricator 1811 Establishing the Arc 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 The easiest welding procedure for the beginner to experiment with MIG welding is the flat position The equipment is capable of flat vertical and overhead positions For practicing MIG welding secure some pieces of 16 or 18 gauge 0 06 1 5mm or 0 08 2 0mm mild steel plate 6 x 6 150 x 150mm Use 0 030 0 8mm flux cored gasless wire or a solid wire with shielding gas Setting of the Power Source Power source and Wirefeeder setting requires some practice by the operator as the welding plant has two control settings that have to balance These are the Wirespeed control refer to section 3 06 3 and the welding Voltage Control refer to section 3 06 9 The welding curre
61. h complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identifica tion numbers as described above along with a full description of the parts in error 2 04 Transportation Methods Disconnect input power conductors from de energized supply line before moving the welding power source Lift unit with handle on top of case Use handcart or similar device of adequate capacity If using a fork lift vehicle secure the unit on a proper skid before transporting INTRODUCTION Fabricator 181i 2 05 Symbol Chart Note that only some of these Symbols will appear on your model Ir Je Dangerous Voltage Circuit Breaker AC Auxiliary Power Hertz cycles sec Ed Direct Current DC Ground gt i Auxiliary Power 1 15V 15A Receptacle Rating Auxiliary INTRODUCTION 3 N Three Phase Workpiece With Output Voltage Off Wire Feed Function Wire Feed Towards Three Phase Static Frequency Converter Welding Gun Transformer Rectifier Continuous Weld Duty Cycle Mode Panel Local Spot Time Shielded Metal 7 e Welding SMAW ti Preflow Time Gas Metal Arc Welding GMAW fie Postflow Time Gas Tungsten Arc 2 Step Trigger Welding GTAW G __ Operation Press initiate wirefeed and Air Carbon Arc welding release to stop
62. h is used to turn the unit on off 17 Local Remote Switch located in wirefeed compartment The remote local switch is used only when a remote control device such as a TIG torch with remote current control is fitted to the unit via the remote control socket item 9 When the local remote switch is in the remote position the unit will detect a remote device and work accordingly When in the local mode the unit will not detect the remote device and will operate from the power source controls only Note that the 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 remote local switch set to remote the maximum setting of the power source will be determined by the respective front panel control irrespective of the remote control device setting As an example if the output current on the power source front panel is set to 5096 and the remote control device is set to 100 the maximum achievable output from the unit will be 50 Should 10096 output be required the respective front panel control must be set to 10095 in which case the remote device will then be able to control between 0 100 output 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
63. h the product you received then check for a newer version of the manual on our website or contact our customer support for assistance 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 We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry WARNINGS REESEN Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Operating Manual Number 0 5151 for Thermal Arc Fabricator 181i Inverter Plant Part Number W1003186 Thermal Arc Fabricator 181i Inverter Power Source unpacked Part Number W1003185 Published by Thermadyne Indu
64. igure 3 14 Setup for MIG Welding with Gas Shielded MIG Wire Manual 0 5151 3 17 INSTALLATION OPERATION AND SETUP Fabricator 1811 3 16 Setup for MIG GMAW Welding with Gasless MIG Wire A Select MIG mode with the process selection control refer to Section 3 06 12 for further information B Connect the MIG Torch polarity lead to the negative welding terminal If in doubt consult the electrode wire manufacturer 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 C Connect the work lead to the positive welding terminal If in doubt consult the electrode wire 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 us Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information A WARNING Before connecting the work clamp to the work make sure the mains power supply is switched Off Az Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power Source Positive Welding Terminal
65. ired level of output current In GMAW FCAW modes MIG the amperage knob adjusts the speed of the wire feed motor which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc The optimum wire speed required will dependent on the type of welding application The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications MIG Torch Adaptor Euro Style The MIG torch adaptor is the connection point for the MIG welding torch Connect the torch by pushing the torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to secure in position To remove the MIG Torch simply reverse these directions INSTALLATION OPERATION AND SETUP 3 4 Manual 0 5151 Fabricator 1811 5 Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG torch via the MIG torch polarity lead electrode holder lead or work lead Positive welding current flows from the power source via 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 A E CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 6
66. ition filler rod joint filler rod 6 Electrode melts or oxidises A Torch lead connected A Connect torch lead to negative welding when an arc is struck to positive welding terminal terminal No gas flowing to weld B Check the gas lines for kinks or breaks ing region and gas cylinder contents Torch is clogged with C Clean torch dust or dirt Gas hose is cut D Replace gas hose Gas passage contains E Disconnect gas hose from the rear of impurities Power Source then raise gas pressure and blow out impurities Gas regulator turned F Turn on off Torch valve is turned G Turn on off The electrode is too H Increase electrode diameter or reduce the small for the welding welding current current Power source is set for Set Power Source to Lift TIG mode MIG welding Manual 0 5151 4 25 BASIC WELDING GUIDE Fabricator 181i 7 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates piece or filler rod mate rial B Work piece surface has B Clean surface foreign material on it C Gas contaminated with C Check gas lines for cuts and loose fitting air or change gas cylinder 8 Poor weld finish Inadequate shielding Increase gas flow or check gas line for gas gas flow problems 9 Arc start is not smooth A Tungsten electrode is A Select the right size electrode Refer to too large for the weld Table 4 7 Current Ranges for Various ing curr
67. ld penetration narrow B Reduce current and voltage and increase MIG torch and deep travel speed or select a lower penetration shielding gas Excessive weld stresses C Increase weld metal strength or revise design Excessive voltage D Decrease voltage Cooling rate too fast E Slow the cooling rate by preheating part to be welded or cool slowly 7 Cold weld puddle Loose welding cable A Check all welding cable connections connection B Low primary voltage B Contact supply authority C Fault in power source C Have an Accredited Thermal Arc Service Provider to test then replace the faulty component 8 Arc does not have The MIG torch has been Connect the MIG torch to the positive welding a crisp sound that connected to the wrong terminal for solid wires and gas shielded flux cored short arc exhibits voltage polarity on the wires Refer to the electrode wire manufacturer for when the wirefeed front panel the correct polarity speed and voltage are adjusted cor rectly Table4 4 GMAW MIG Welding Problems Manual 0 5151 4 9 BASIC WELDING GUIDE Fabricator 1811 4 03 Stick Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available Small welding machines will only provide sufficient current amperage to run the smaller size electrodes For thin sections it is necessary to use smaller electrode
68. less Steel Gas Tungsten Arc Welding GTAW TIG Flux cored Arc Welding FCAW with or without shielding gas Less than or equal to 100 100 to 200 200 to 300 300 to 400 Greater than 400 Less than or equal to 150 150 to 250 250 to 300 300 to 400 Greater than 400 Less than or equal to 250 250 to 350 Less than or equal to 100 100 to 200 200 to 250 250 to 350 Greater than 350 Less than or equal to 300 300 to 400 400 to 500 Greater than 500 14 Air Arc Gouging Less than or equal to 400 Plasma Arc Cutting 50 to 100 100 to 400 400 to 800 12 10 12 14 Plasma Arc Spraying 15 8 Plasma Arc Welding Less than or equal to 20 20 to 100 100 to 400 400 to 800 14 Submerged Arc Welding 2 5 Resistance Welding Safety Spectacles or eye shield Refer to standard AS NZS 1338 1 1992 for comprehensive information regarding the above table GENERAL INFORMATION Manual 0 5151 os WARNING FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s i
69. lope time is selected then the welding output will cease immediately If the unit is set to 4T latch mode to enter down slope mode the trigger must be held in for the selected time period ie press and release trigger to commence welding then press and hold trigger again to enter down slope mode Should the trigger be released during the down slope phase 4T only the output will cease immediately INSTALLATION OPERATION AND SETUP 3 6 Manual 0 5151 Fabricator 1811 10 Arc Control Inductance The arc control operates in GMAW MIG mode only and is used to adjust the intensity of the welding arc Lower arc control settings make the arc softer with less weld spatter Higher arc control settings give a stronger driving arc which can increase weld penetration 11 Trigger Mode Control MIG and TIG Mode only The trigger mode control is used to switch the functionality of the of the torch trigger between 2T normal and 4T latch mode 2T Normal Mode In this mode the torch trigger must remain depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torch trigger switch to cease welding 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the operator can press and release the torch trigger and the output will remain active To deactivate the power source the trigger switch must again be depressed and realise
70. mal Arc warrants to cus tomers of its authorized distributors hereafter Purchaser that its products will be free of defects in workman ship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered
71. minated when the correct mains power is applied to the power source and when the ON OFF switch located on the rear panel is in the ON position 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 This value can be adjusted by varying the amperage potentiometer item 4 Note that in GMAW FCAW MIG mode the amperage meter will not preview welding current and will display Zero When welding the amperage meter will display actual welding current in all modes At the completion of welding the amperage meter will hold the last recorded amperage value for a period of approximately 10 seconds in all modes The amperage meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to preview mode 2 welding is recommenced in which case actual welding amperage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode 3 Amperage Control Wirespeed 4 The amperage control knob adjusts the amount of welding current delivered by the power source In MMA stick and GTAW TIG modes the amperage control knob directly adjusts the power inverter to deliver the des
72. mp Horizontal Welds Figure 4 4 5 to 15 tudinal Angle 30 to 60 Transverse Angle Art A 08994 Horizontal Fillet Weld Figure 4 5 BASIC WELDING GUIDE 4 2 Manual 0 5151 Fabricator 181i 10 to 20 Longitudinal Angle Li 3 te de 30 to 60 inge Transverse Angie Direction of Travel Vertical Fillet Welds Art A 08995 Figure 4 6 Direction of Travel c 30 to ec o 5 eg Ze Longitudinal 7 GY Ak p Overhead Weld Figure 4 7 Art A 08996 Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20 0mm This distance may vary depending on the type of joint that is being welded Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run MIG Welding GMAW Variables Most of the welding done by all processes is on carbon steel The items below describe the welding variables in short arc welding of 24gauge 0 024 0 6mm to 4 6 4mm mild sheet or plate The applied techniques and end results in the GMAW process are controlled by these variables Preselected Variables Preselected variables depend upon the type of material being welded the thickness of the material the welding position the deposition rate and the mechanical properties These variables are of electrode wire e Size of electrode wire
73. n select lit erature Here you will find documentation including Operator manuals Service manuals Product guides Alternatively please contact your Thermadyne distributor and speak with a technical representative NOTE Warranty repairs must be performed by either a Thermadyne Service Centre a Thermadyne distributor or an Authorised Service Agent approved by the Company 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 amp Welding Market Leader WORLD HEADQUARTERS 16052 Swingley Ridge Road Suite 300 St Louis Missouri 63017 U S A 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 Form No 0 5151AB 27 Apr 2011 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 Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 2011 Thermadyne Industries Inc Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 4603 6092 1085 Melbourne Australia Australia Customer
74. n the length and size of the hose being purged Adjusting Flow Rate With the regulator ready for operation adjust working flow rate as follows 1 Adjust the gas flow rate as recommended by the regulator manufacturer NOTE It may be necessary to re check the shielding gas regulator flow rate following the first weld sequence due to back pressure present within shielding gas hose assembly Shutdown Close cylinder valve whenever the regulator is not in use To shut down for extended periods more than 30 minutes 1 Close cylinder or upstream valve tightly 2 Open downstream equipment valves to drain the lines Bleed gas into a well ventilated area and away from any ignition source 3 After gas is drained completely disengage adjusting screw and close downstream equipment valves 4 Before transporting cylinders that are not secured on a cart designed for such purposes remove regulators INSTALLATION OPERATION AND SETUP 3 16 Manual 0 5151 Fabricator 1811 3 15 Setup for MIG GMAW Welding with Gas Shielded MIG Wire A Select MIG mode with the process selection control refer to Section 3 06 12 for further information B Connect the MIG torch polarity lead to the positive welding terminal If in doubt consult the electrode wire manufacturer 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 ele
75. nd testing of the power source and associated accessories shall be carried out in accordance with Section 5 of EN 60974 1 Safety in Welding and Allied Processes Part 2 Electrical This includes an in sulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc s original specifications If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974 1 then the above tests should be carried out prior to entering this location A Testing Schedule 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging including the date of the most recent inspection Atransportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated NOTE Please refer to local guidelines for further information B Insulation Resistance Minimum insulation resistance for in service Thermal Arc Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 6 1below Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met POWER S
76. nstruction for metals consumables coatings and cleaners Work in a confined space only if it is well venti lated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Donot weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases Donot weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded QS WELDING can cause fire or explosion WARNING Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld Spatter hot workpiece and hot equipment can cause fires and burns Accidental con tact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flam mable material Manual 0 5151 9 Fabricator 181i Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can
77. nt is determined by the Wirespeed control the current will increase with increased Wirespeed resulting in a shorter arc Less wire speed will reduce the current and lengthen the arc Increasing the welding voltage hardly alters the current level but lengthens the arc By decreasing the voltage a shorter arc is obtained with a little change in current level When changing to a different electrode wire diameter different control settings are required A thinner electrode wire needs more Wirespeed to achieve the same current level satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece If the Wirespeed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool and does not melt Welding in these conditions normally produces a poor weld due to lack of fusion If however the welding voltage is too high large drops will form on the end of the wire causing spatter The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information Electrode Wire Size Selection The choice of Electrode wire size and shielding gas used depends on the following e Thickness of the metal to be welded ype of joint Capacity of the wire feed unit and Po
78. oltage may cause poor welding performance Too high a supply voltage will cause components to overheat and possibly fail The Welding Power Source must be e Correctly installed if necessary by a qualified electrician e Correctly earthed electrically in accordance with local regulations Connected to the correct size power point and fuse as per the Specifications on page 2 5 A WARNING Any electrical work must be carried out by a qualified Electrical Tradesperson 3 05 Electromagnetic Compatibility N WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation INSTALLATION OPERATION AND SETUP Fabricator 1811 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 In some cases this remedial action may be 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 associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer troublesome
79. on is so complex that only a brief outline can be attempted hear The Cause of Distortion Distortion is caused by A Contraction of Weld Metal Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature This means that a cube of molten metal would contract approximately 2 2 per cent in each of its three dimensions In a welded joint the metal becomes attached to the side of the joint and cannot contract freely Therefore cooling causes the weld metal to flow plastically that is the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint If the restraint is very great as for example in a heavy section of plate the weld metal may crack Even in cases where the weld metal does not crack there will still remain stresses Locked up in the structure If the joint material is relatively weak for example a butt joint in 2 0mm sheet the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfil the desi
80. orner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be deposited Refer Figure 4 25 Use a short arc and do not attempt to weave on the first run When the first run has been completed de slag the weld deposit and begin the second run at the bottom This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges At the completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 4 26 illustrates multi run technique and Figure 4 27 shows the effects of pausing at the edge of weave and of weaving too rapidly Art A 07701 Figure 4 25 Single Run Vertical Fillet Weld BASIC WELDING GUIDE 4 16 Manual 0 5151 Fabricator 181i weaving motion for second and subsequent runs Pause at edge of weave Figure 4 26 Multi Run Vertical Fillet Weld CORRECT INCORRECT LN EN Pause at edge of Note weld contour weave allows weld when insufficient metal to build up pause at edge and eliminates of weave undercut Art 07703 Figure 4 27 Examples of Vertical Fillet Welds 2 Vertical Down The E7014 Stick electrode makes welding in this position particularly easy Use a 3 2mm electrode at 100 amps The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so
81. ositioned close together running at or close to the floor level Manual 0 5151 Fabricator 1811 4 Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However Metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components 5 Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of it s size and position e g ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations 6 Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications 3 06 Fabricator 181i Po
82. ower source is switched off AA TION The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 3 12 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction Once the feed roll is removed then to replace feed roll simply reverse these directions A dual groove feed roller is supplied as standard It can accommodate 0 6 0 8mm diameter hard wires Select the roller required with the chosen wire size marking facing outward GROOVE A GROOVE B GROOVE B SIZE E 4 Ps GROOVE A SIZE A 09583 Figure 3 10 Dual Groove Feed Roller A 09584 AB Feed Roll Retaining Screw Feed Roll Figure 3 11 Changing the Feed Roll Manual 0 5151 3 13 INSTALLATION OPERATION AND SETUP Fabricator 1811 3 13 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum breaking If it is considered necessary adjustment can be made by turning the large nut inside the open end of the hub clockwise to tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 10 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool Az Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical componentry and possibly an increased incidence of elect
83. r replace conduit liner A Replace or repair Disconnect gas hose from the rear of power source or wirefeeder and blow out impuri ties Turn on regulator Replace gas cylinder 5 1 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS Fabricator 181i 8 Gas flow continues after the torch trigger Switch has been released MIG mode Gas valve has jammed open due to impurities in the gas or the gas line 9 Power indicator will not illuminate and welding arc cannot be established 10 TIG electrode melts when arc is struck 11 Arc flutters during TIG welding The mains supply voltage has exceeded voltage limits of the power source TIG torch is connected to the VE terminal Tungsten electrode is too large for the welding cur rent Have an accredited Thermal Arc service provider repair or replace gas valve Ensure that the mains supply voltage is within 230VAC 15 Connect the TIG torch to the VE terminal Select the correct size of tung sten electrode Refer to Table 4 T Table 5 1 5 02 Routine Service and Calibration Requirements A WARNING There are extremely dangerous voltage and power levels present inside this Inverter Power Source Do not attempt to open or repair unless you are an accredited Thermal Arc Service Provider Discon nect the Welding Power Source from the Mains Supply Voltage before disassembling Routine Inspection Testing amp Maintenance The inspection a
84. r with AC output unless it is equipped with a voltage reducer Use equipment with DC output 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place GENERAL INFORMATION Fabricator 181i 4h sf Ze ee can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Use a Welding Helmet or Welding Faceshield fitted with a proper shade of filter see ANSI Z49 1 and 2 Wear approved safety glasses Side shields recom mended 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the ARC RAYS can burn eyes and skin NOISE arc 4 Wear protective clothing made from durable is high EN 60974 1 listed in Safety Standards to protect your face and eyes when welding or watching flame resistant material wool and leather and foot protection 5 Use approved ear plugs or ear muffs if noise level 6 Never wear contact lenses while welding Recommended Protective Filters for Electric Welding Deserintion of Process Approximate Range of Minimum Shade Number of p Welding Current in Amps Filter s Manual Metal Arc Welding covered electrodes MMA Gas Metal Arc Welding GWAW MIG other than Aluminium and Stainless Steel Gas Metal Arc Welding GMAW MIG Aluminium and Stain
85. racks when attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Copper and Alloys The most important factor is the high rate of heat conductivity of copper making pre heating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work These include some low hydrogen types for high tensile steel cellulose types for welding large diameter pipes etc The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered are all easy to use BASIC WELDING GUIDE 4 10 Manual 0 5151 Fabricator 181i Mild Steel E6011 This electrode is used for all position welding or for welding on rusty dirty less than new metal It has a deep penetrating arc and is often the first choice for repair or maintenance work Mild Steel E6013 This all position electrode is used for welding clean new sheet metal Its soft arc has minimal spatter moderate penetration and an easy to clean slag Mild Steel E7014 All positional ease to use electrode for use on thicker steel than E6013 Especially suitable sheet metal lap joints and fillet
86. rcuits Never allow a welding electrode to touch any cylinder GENERAL INFORMATION Fabricator 181i 5 Useonly correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition 6 Turn face away from valve outlet when opening cylinder valve 7 Keep protective cap in place over valve except when cylinder is in use or connected for use 8 Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from bat tery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine 9 WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health
87. re for continued expansion it has to deform plastically that is the metal adjacent to the weld is at a high temperature and hence rather soft and by expanding pushes against the cooler harder metal further away and tends to bulge or is upset When the weld area begins to cool the upset metal attempts to contract as much as it expanded but because it has been upset it does not resume its former shape and the contraction of the new shape exerts a strong pull on adjacent metal Several things can then happen The metal in the weld area is stretched plastic deformation the job may be pulled out of shape by the powerful contraction stresses distortion or the weld may crack in any case there will remain locked up stresses in the job Figures 4 29 and 4 30 illustrate how distortion is created Art A 07705_AB Weld Upsetting Vu Expansion with compression Contraction with tension Figure 4 30 Parent Metal Contraction BASIC WELDING GUIDE 4 18 Manual 0 5151 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 B Distribution of Stresses Distortion may be reduced by selecting a welding sequ
88. rhead Position Butt Weld Art A 07694 Figure 4 18 Overhead Position Fillet Weld BASIC WELDING GUIDE Manual 0 5151 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 In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 19 Open Square Butt Single Vee Butt Joint See Joint varies from 1 6mm 1 16 to 4 8mm 3 16 le depending plate thickness 1 6mm 1 16 P Single Vee Butt Joint mm Double Vee Butt Joint DEn i 1 6mm 1 16 max Lap Joint 16mm 1 16 ud E Tee Joints Fillet Joint Fillet both sides of the joint Corner Weld Edge Joint Plug Weld Plug Weld Art A 07695 AE Figure 4 19 Typical Joint Designs for Arc Welding Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commence is to run beads on a piece of scrap plate Use mild steel plate about 6 0mm thick and a 3 2mm electrode Clean any paint loose scale or grease off the plate and set it firmly on the work bench so that w
89. rode wire Burnback into contact tip Wire Reel Brake Adjustment Nut A 09585 Figure 3 12 Wire Reel Brake 3 14 Shielding Gas Regulator Operating Instructions AN WARNING This equipment is designed for use with welding grade Inert shielding gases only Shielding Gas Regulator Safety This regulator is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it If the equipment is improperly used hazardous conditions are created that may cause accidents It is the users responsibility to prevent such conditions Before handing or using the equipment understand and comply at all times with the safe practices prescribed in this instruction SPECIFIC PROCEDURES for the use of regulators are listed below 1 NEVER subject the regulator to inlet pressure greater than its rated inlet pressure 2 NEVER pressurize a regulator that has loose or damaged parts or is in a questionable condition NEVER loosen a connection or attempt to remove any part of a regulator until the gas pressure has been relieved Under pressure gas can dangerously propel a loose part 3 DO NOT remove the regulator from a cylinder without first closing the cylinder valve and releasing gas in the regulator high and low pressure chambers 4 DO NOT use the regulator as
90. ructure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Electromagnetic Emissions 1 Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout it s length The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure 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 The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilising devices should be adjusted and maintained according to the manufacturer s recommendations 3 Welding Cables The welding cables should be kept as short as possible and should be p
91. s otherwise the arc may burn holes through the job A little practice will soon establish the most suitable electrode for a given application Storage of Electrodes Always store electrodes in a dry place and in their original containers Electrode Polarity 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 High Tensile and Alloy Steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area and if suitable precautions are not taken the occurrence in this zone of under bead cracks Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace Manganese Steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat Cast Iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally c
92. spool Az Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip Ensure that the alignment pin on the wire spool hub aligns with the hole allocated in 200mm diameter spool NOTE This alignment pin can be removed by unscrewing in an anticlockwise direction and locating in the appropriate position a Alignment pin d j Alternate Alignment Pin Position Brass Flat Washer Wire Spool Hub Friction 200mm Washer diameter spool Plastic Spacer Flat Washer Nut with Spool Hub Nut Nylon Insert 09523 AB Figure 3 7 200mm Diameter Spool Installation Manual 0 5151 3 11 INSTALLATION OPERATION AND SETUP Fabricator 1811 3 10 Inserting Wire into the Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension Screw in an anti clockwise direction Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm Figure 3 8 With the MIG welding wire feeding from the bottom of the spool Figure 3 9 pass the electrode wire through the inlet guide between the rollers through the outlet guide and into the MIG torch Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 3 8 Remove the contact
93. stries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermadyne com Copyright 2011 by Thermadyne Industries Inc All 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 for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date February 24 2011 Revision AB Date April 27 2011 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Arc Welding EK E EE 1 1 RIDE Gluten lt E 1 5 1 03 Declaration of Conformity oec e etd en C pb to p obama s 1 6 SEGTION Z INTRODUCTION E oe te a cpu oue Een ae cut or 2 1 2 01 How to Use This Manual eege EE 2 1 2 02 Equipment Identification s ore EE her en etae NS oe 2 1 2 03 RECEIPT OF EQUIP NIG cote ei tout dto iie eto pacta at qua dm toc RR 2 1 2 04 Transportation MethOdS EEN 2 1 2 2 2 007 DGS dee E 2 3 24077 DUserResponsibIlty sicot eive Eed 2 3 2 06 Packaged te MS uui aa co errand taints Miata Mase aah
94. tip from the MIG torch With the MIG Torch lead reasonably straight feed the wire through the torch by depressing the trigger switch Fit the appropriate contact tip A Es WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off The electrode wire will be at welding voltage potential while it is being fed through the system Keep MIG Torch away from eyes and face Wire Drive Tension Screw Pressure Roller Arm A 09581 Beem Inlet Guide Figure 3 8 Wire Drive Assembly Components TA MIG Welding Wire A 09582_AB Figure 3 9 MIG Welding Wire Installation INSTALLATION OPERATION AND SETUP 3 12 Manual 0 5151 Fabricator 1811 3 11 Feed Roller Pressure Adjustment The pressure top roller applies pressure to the grooved feed roller via an adjustable pressure screw These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage If slipping occurs and inspection of the wire contact tip reveals no wear distortion or burn back jam the conduit liner should be checked for kinks and clogging by metal flakes and swarf If it is not the cause of slipping the feed roll pressure can be increased by rotating the pressure screw clockwise A WARNING Before changing the feed roller ensure that the mains supply to the p
95. 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 To increase the burnback time or shorten the amount of wire protruding from the torch at the completing of welding turn the Burnback Control knob clockwise 19 Fan on Demand The Fabricator 181i is fitted with a fan on demand feature Fan on demand automatically switches the cooling fan off when it is not required This has two main advantages 1 to minimize power consumption and 2 to minimise the amount of contaminants such as dust that are drawn into the power source Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required INSTALLATION OPERATION AND SETUP 3 8 Manual 0 5151 Fabricator 181i 3 07 Attaching the Tweco WeldSkill 180 Torch Euro Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor A 09521 AB Figure 3 5 Attaching MIG Torch Manual 0 5151 3 9 INSTALLATION OPERATION AND SETUP Fabricator 1811 3 08 Installing 100mm Diameter 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 belo
96. ty cycle period the following example is used Suppose a Welding Power Source is 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 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power Source must idle and be allowed to cool 100 90 80 70 60 50 40 30 Duty Cycle percentage 20 10 0 INTRODUCTION Safe Operating _ MIG GMAW Region Sti 20 40 60 80 140 Welding Current amps Figure 2 1 Fabricator 181i Duty Cycle 2 4 Manual 0 5151 2 10 Specifications DESCRIPTION Power Source unpacked Part No Power Source Dimensions Power Source Mass Cooling Fabricator 181i FABRICATOR 181i MULTI PROCESS WELDING INVERTER W1003185 H410mm x W210mm x D450mm 14 6kg Fan Cooled Effective Input Current l 16 6 Amps Maximum Input Current 1 37 Amps Single Phase Generator Requirement 9 KVA MIG GMAW Welding Output 40 10 min STICK Welding Output 40 10 min TIG GTAW Welding Output 40 10 min Protection Class 180A 20 23V 113A Q 60 19 7V 88A Q 100 18 4V 175A 20 27V 101A 60 24V 78A Q 100 23 1V 175A 25 1
97. uch easier Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away At the same time the electrode has to move along the plate to form a bead The electrode is directed at the weld pool at about 20 from the vertical The rate of travel has to be adjusted so that a well formed bead is produced If the travel is too fast the bead will be narrow and strung out and may even be broken up into individual globules If the travel is too slow the weld metal piles up and the bead will be too large Making Welded Joints Having attained some skill in the handling of an electrode you will be ready to go on to make up welded joints A Butt Welds Set up two plates with their edges parallel as shown in Figure 4 21 allowing 1 6mm to 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 Plates thicker than 6 0mm should have their mating edges bevelled to form a 70 to 90 included angle This allows full penetration of the weld metal to the root Using a 3 2mm E7014 Stick electrode at 100 amps deposit a run of weld metal on the bottom of the joint BASIC WELDING GUIDE 4 14 Manual 0 5151 Fabricator 181i Do not weave the electrode but maintain a steady rate of travel along the joint sufficient to produce a well formed bead
98. w in Figure 3 6 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 The brake is correctly adjusted when the spool stops within 10 to 20mm measured at the outer edge of the spool after MIG Torch trigger is released Wire should be slack without becoming dislodged from the spool Az UTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip Spring Nut with Nylon Insert MS A 09522 AB Figure 3 6 100mm Diameter Spool Installation INSTALLATION OPERATION AND SETUP Plastic Spacer Friction Washer 100mm Brass Flat Diameter spool Washer N Flat Washer N 1 3 10 Manual 0 5151 Fabricator 181i 3 09 Installing 200mm Diameter Spool As delivered from the factory the unit is set for a 200mm diameter spool In order to re fit a 200mm spool assemble parts in the sequence shown below in Figure 3 7 Adjustment of the nut with nylon insert will control the MIG Wire Spool Brake Clockwise rotation of this nut with nylon insert tightens the brake The Brake is correctly adjusted when the spool stops within 10 to 20mm measured at the outer edge of the spool after MIG Torch trigger is released Wire should be slack without becoming dislodged from the
99. wer Source he amount of penetration required The deposition rate required he bead profile desired The position of welding Cost of the wire Manual 0 5151 4 5 BASIC WELDING GUIDE Fabricator 181i Thermal Arc MIG Wire Selection Chart THERMAL AIRC Sonesson MULTI PROCESS WELDING INVERTER Mig Set Up Guide Welding Wire LW1 6 0 8 mm Shield Gas 3 0 mm 93 5 CO 2 O2 gt 3 0 mm 86 Ar 12 CO 2 O2 Voltage Knob Polarity Selection Torch Positive Material Thickness Wirespeed Knob E 3 E e o E E o zi e Welding Wire AL5356 1 0 mm Shield Gas Pure Argon Polarity Selection Torch Positive Material Thickness Voltage Knob Wirespeed Knob Not Recommended WS21 37 WS21 50F PART Welding Wire 71 11 0 8 mm Shielding Gas Not Required Polarity Selection Depending on wire Material manufacturer s guidelines Thickness Voltage Knob Wirespeed Knob Not Recommended Tig Preferred TORCH PARTS DESCRIPTION Nozzle 13 mm WS21 62 Nozzle 16 mm WS11 23 511 35 Contact 0 6 0 8 11 40 Contact 1 0 WS11 45 Contact Tip 1 2 mm Size visible when fitting feedroll is size groove in use WS90 LEV S 3 4 WS80 140 Handle with Screws 5 WS90 Microswitch with Lead Wires 6 WS90 LEV Trigger
100. wer Source Controls Indicators and Features EEN BE IL E y Yi 6 J Aog938 d I U A 09940 U L Figure 3 1 Front Panel Figure 3 2 Rear Panel Manual 0 5151 3 3 INSTALLATION OPERATION AND SETUP Fabricator 181i 1 2 A 09593 J 4 TIE L z Y Em a V E Ges 0 Figure 3 3 Wire Feed Compartment Control Power Indicator The power indicator is illu

181i Operating Manual FABRICATOR

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