181i Fabricator - Gases, Welding, Industrial, MRO Safety Multi proceSS welding inverter. ... 5.01...

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Transcript of 181i Fabricator - Gases, Welding, Industrial, MRO Safety Multi proceSS welding inverter. ... 5.01...

  • Art # A-10107

    181i

    Service ManualRevision: AB Issue Date: April 06, 2012 Manual No.: 0-5152Operating Features:

    FabricatorMulti proceSS weldinginverter

  • 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 Service Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction 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 If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.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 prod-ucts to achieve a safer working environment within the welding industry.

  • ! WARNINGSRead and understand this entire Manual and your employers safety practices before installing, operating, or servicing the equipment.

    While the information contained in this Manual represents the Manufacturers best judgement, the Manufacturer assumes no liability for its use.

    Service Manual Number 0-5152 for:Thermal Arc Fabricator 181i Inverter Plant Part Number W1003186Thermal Arc Fabricator 181i Inverter Power Source (unpacked) Part Number W1003185

    Published by:Thermadyne Industries, Inc.16052 Swingley Ridge Road, Suite 300St Louis, Mo63017USA

    www.thermadyne.com

    Copyright 2011 byThermadyne Industries, Inc.

    All rights reserved.

    Reproduction of this work, in whole or in part, without written permission of the pub-lisher 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: April 27, 2011Revision AB Date: April 06, 2012

    Record the following information for Warranty purposes:

    Where Purchased: ____________________________________

    Purchase Date: ____________________________________

    Equipment Serial #: ____________________________________

  • TABLE OF CONTENTS

    SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............................................... 1-1

    1.01 Arc Welding Hazards ....................................................................................... 1-11.02 Principal Safety Standards .............................................................................. 1-41.03 Declaration of Conformity ............................................................................... 1-51.04 Symbol Chart .................................................................................................. 1-61.05 Servicing Hazards ........................................................................................... 1-71.06 EMF Information ............................................................................................. 1-8

    SECTION 2: INTRODUCTION .............................................................................. 2-1

    2.01 How to Use This Manual ................................................................................. 2-12.02 Equipment Identification ................................................................................. 2-12.03 Receipt of Equipment ...................................................................................... 2-12.04 Description ..................................................................................................... 2-1 2.05 Transportation Methods .................................................................................. 2-12.06 Packaged Items .............................................................................................. 2-2

    SECTION 3: SAFETY AND INSTALLATION ............................................................... 3-1

    3.01 Duty Cycle ....................................................................................................... 3-13.02 Specifications ................................................................................................. 3-23.03 Environment ................................................................................................... 3-23.04 Location .......................................................................................................... 3-33.05 Ventilation ....................................................................................................... 3-33.06 Mains Supply Voltage Requirements .............................................................. 3-33.07 Electrical Input Connections ........................................................................... 3-33.08 Electromagnetic Compatibility ........................................................................ 3-43.09 Volt-Ampere Curves ........................................................................................ 3-6

    SECTION 4: OPERATION ................................................................................... 4-1

    4.01 Fabricator 181i Power Source Controls, Indicators and Features ................... 4-14.02 Attaching the Tweco WeldSkill 180 Torch (Euro) ............................................ 4-64.03 Installing 100mm Diameter Spool ................................................................. 4-64.04 Installing 200mm Diameter Spool .................................................................. 4-74.05 Inserting Wire into the Wire Feed Mechanism ................................................ 4-84.06 Feed Roller Pressure Adjustment .................................................................... 4-94.07 Changing the Feed Roll ................................................................................. 4-104.08 Wire Reel Brake ............................................................................................ 4-104.09 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 4-114.10 Setup for MIG (GMAW) Welding with Gasless MIG Wire .............................. 4-124.11 Setup for TIG (GTAW) Welding ..................................................................... 4-134.12 Setup for Manual Arc (MMA) Welding ........................................................ 4-144.13 Leak Testing the System ............................................................................... 4-15

    SECTION 5: THEORY OF OPERATION .................................................................... 5-1

    5.01 Inverter Design ..................................................................................................... 5-1

  • TABLE OF CONTENTS

    SECTION 6: TROUBLESHOOTING ........................................................................ 6-1

    6.01 Basic Troubleshooting-Power Source Faults ................................................... 6-16.02 Checking Unit Before Applying Power ............................................................ 6-26.03 Tools Needed for Troubleshooting and Servicing ............................................ 6-26.04 Case Removal ................................................................................................. 6-36.05 Clear Cover Sheet Removal ............................................................................. 6-46.06 Visually Inspect ............................................................................................... 6-46.07 Preliminary DC Bus measurement of the main inverter board ........................ 6-46.08 Preliminary check of the main inverter board ................................................. 6-56.09 Check main On / Off Switch ............................................................................ 6-76.10 Check main input rectifier ............................................................................... 6-76.11 DC Bus voltage measurement ......................................................................... 6-86.12 PCB Connectors .............................................................................................. 6-96.13 DIP switch settings, Control PCB .................................................................. 6-146.14 Calibration .........................