ESAB fabricator 141i Service Manual
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ESAB fabricator 141i Service Manual

3-in-1 multi process welding systems
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ESAB Fabricator
141i
®
3-IN-1 Multi Process
Welding Systems
Service
Manual
3163339
Révision : AA Issue Date: September 17, 2015 Manual No.: 0-5448
esab.com

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  • Page 1: Service Manual

    ESAB Fabricator 141i ® 3-IN-1 Multi Process Welding Systems Service Manual 3163339 Révision : AA Issue Date: September 17, 2015 Manual No.: 0-5448 esab.com...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB 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 network.
  • Page 3 ESAB 2800 Airport Rd. Denton, TX 76208 www.esab.com Copyright 2015 by ESAB 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.
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equip- ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...

  • Page 5: Table Of Contents

    How To Use This Manual ..................... 2-1 2.05 Transportation Methods ....................2-2 2.06 User Responsibility ..................... 2-2 2.07 Fabricator 141i Portable System Package (Part No. W1003141) ........ 2-2 SECTION 3: SAFETY AND INSTALLATION .................. 3-1 3.01 Duty Cycle ........................3-1 3.02 Specifications ......................
  • Page 6 TABLE OF CONTENTS SECTION 6: TROUBLESHOOTING .................... 6-1 6.01 Pre-Power Up Checks....................6-1 6.02 Tools Needed for Troubleshooting and Servicing ............6-1 6.03 Troubleshooting ......................6-1 6.04 Case Removal ......................6-4 6.05 Clear protective Sheet Removal ................... 6-5 6.06 Visually Inspect ......................6-5 6.07 Preliminary DC Bus Measurement of the Main PCB1 ..........

  • Page 7: Section 1: Safety

    SECTION 1: SAFETY Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment.
  • Page 8 ESAB FABRICATOR 141i Arc welding and cutting can be injurious to yourself and others. WARNING Take precautions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data. ELECTRIC SHOCK - Can kill.

  • Page 9: Introduction

    2.04 Description CAUTION The ESAB Fabricator 141i is a self contained single phase multi A procedure which, if not properly fol- process welding system that is capable of performing MIG lowed, may cause damage to the equip- (GMAW/FCAW), STICK (SMAW) and LIFT TIG (GTAW) welding ment.

  • Page 10: Transportation Methods

    ESAB. Advice in this regard can be obtained by contacting an Accredited ESAB Distributor. This equipment or any of its parts should not be altered from standard specification without prior written approval of ESAB. 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 quali- fied persons approved by ESAB.

  • Page 11: Safety And Installation

    (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. Fabricator 141i Safe Operating TIG (GTAW) Region STICK (SMAW) / MIG (GMAW/ FCAW) Art # A-11276_AB Welding Current (amps) Figure 3-1: Fabricator 141i Duty Cycle Manual 0-5448 SAFETY AND INSTALLATION...

  • Page 12: Specifications

    ESAB FABRICATOR 141i 3.02 Specifications DESCRIPTION FABRICATOR 141i MULTI PROCESS 3 IN 1 WELDER Power Source Part No. W1003140 Power Source Dimensions H16.14” x W8.27” x D17.72” (410mm x 210mm x 450mm) Power Source Weight 32.2lb(14.6kg) Cooling Fan Cooled Welder Type...

  • Page 13: Environment

    Article 630, National Electrical Code) ESAB continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speci fications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

  • Page 14: Ventilation

    • Connected to the correct size power point and fuse as per the Specifications on page 3-2. WARNING The Fabricator 141i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 140 VAC or higher is applied to the Primary Power Cable.

  • Page 15: Electromagnetic Compatibility

    ESAB FABRICATOR 141i 50 / 60 Hz Single Phase Supply Supply Voltage 115V AC 28.4 Amps Input Current at Maximum Output 30 Amps Maximum Recommended Fuse* or Circuit Breaker Rating *Time Delay Fuse, UL class RK5. Refer to UL248 30 Amps Maximum Recommended Fuse^ or Circuit Breaker Rating ^Normal Operating , UL class K5.

  • Page 16: Victor Flowmeter/ Regulator

    ESAB FABRICATOR 141i access and service doors and covers should be closed NOTE! and properly fastened when the welding equipment The welding circuit may or may not be is in operation. The welding equipment should not be earthed for safety reasons. Changing the...
  • Page 17 ESAB FABRICATOR 141i WARNING WARNING Use the flowmeter/ regulator for the gas DO NOT attach or use the flowmeter/ regu- and pressure for which it is designed. lator if oil, grease, flamma ble substances NEVER alter a flowmeter/ regulator for use or damage is present! Have a qualified with any other gas.

  • Page 18: Volt-Ampere Curves

    Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. Fabricator 141i TIG (GTAW) MIG (GMAW/ FCAW) STICK (SMAW) 90 100 110 120 130 140 150 Welding Current (Amps) Art # A-11807 Figure 3-2: Fabricator 141i Volt-Ampere Curves SAFETY AND INSTALLATION Manual 0-5448...
  • Page 19 ESAB FABRICATOR 141i Notes Manual 0-5448 SAFETY AND INSTALLATION...
  • Page 20 ESAB FABRICATOR 141i This Page Intentionallly Blank SAFETY AND INSTALLATION 3-10 Manual 0-5448...

  • Page 21: Operation

    ESAB FABRICATOR 141i SECTION 4: OPERATION 4.01 Power Source Controls, Indicators and Features A-13037 Figure 4-1: Front Panel Figure 4-2: Rear Panel Art # A-10355 Figure 4-3: Wire Feed Compartment Control Manual 0-5448 OPERATION...
  • Page 22 4. MIG Gun Adapter (ESAB Style) The MIG Gun adapter is standard ESAB connection with an 8 pin gun trigger for the Fusion MIG Gun. Connect the MIG Gun by pushing the MIG Gun connector into the brass MIG Gun Adapter firmly and screw the locking screw in the MIG Gun Adapter within the Wire Feed Compartment to secure the Fusion MIG Gun in position.
  • Page 23 ESAB FABRICATOR 141i 6. MIG Gun Polarity Lead The polarity lead is used to connect the MIG Gun 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 aluminum electrode wire.
  • Page 24 ESAB FABRICATOR 141i Note that the Local/ Remote Switch (Control No. 18) located in the wirefeed compartment should be set to Remote for remote amperage/voltage controls to operate. 9. Multifunction Control - Voltage, Down Slope & Arc Force The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc Force (STICK Mode) depending on the welding mode selected.
  • Page 25 ESAB FABRICATOR 141i 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 MIG or TIG Trigger Switch and the output will remain active. To deactivate the Power Source, the trigger switch must...
  • Page 26 17. Intelligent Fan Control The Fabricator 141i is designed with an intelligent fan control. It automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimize the amount of contaminants such as dust that are drawn into the Power Source.

  • Page 27: Attaching The Fusion 140A Mig Gun

    ESAB FABRICATOR 141i 4.02 Attaching the Fusion 140A MIG Gun Fit the MIG Gun to the Power Source by pushing the MIG Gun connector into the MIG Gun Adapter and tightening the Locking Screw to secure the MIG Gun in the MIG Gun Adapter.

  • Page 28: Inserting Wire Into The Wire Feed Mechanism

    ESAB FABRICATOR 141i 4.03 Inserting Wire into the Wire Feed Mechanism Release the tension from the Pressure Roller Arm by turning the adjustable Wire Drive Tension Screw in a counterclockwise. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm.

  • Page 29: Installing 4" (100Mm) Diameter Spool

    ESAB FABRICATOR 141i 4.04 Installing 4" (100mm) Diameter Spool As delivered from the factory, the Power Source is fitted with a Wire Spool Hub which accepts a 8" (200mm) diameter spools. In order to fit a 4" (100mm) diameter spool assemble parts in the sequence shown below in Figure 4-8.

  • Page 30: Feed Roller Pressure Adjustment

    ESAB FABRICATOR 141i Alignment pin Alternate Alignment Pin Brass Flat Position Washer Wire Spool Hub Friction Washer 8” (200mm) Plastic Spacer diameter spool Spring Flat Washer Nut with Nylon Insert Spool Hub Nut Art # A-10358 Figure 4-9: 8" (200mm) Diameter Spool Installation 4.06 Feed Roller Pressure Adjustment...

  • Page 31: Changing The Feed Roll

    ESAB FABRICATOR 141i 4.07 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an counterclockwise 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 023"(0.6mm) -.030" (0.8mm) diameter hard wires. Select the roller required with the chosen wire size marking facing outward.

  • Page 32: Flowmeter/ Regulator Operation

    ESAB FABRICATOR 141i Wire Reel Brake Adjustment Nut Art # A-10361 Figure 4-12: Wire Reel Brake 4.09 Flowmeter/ Regulator Operation With the flowmeter/ regulator connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of flowmeter/ regulator and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal parts.

  • Page 33: Setup For Mig (Gmaw) Welding With Gas Shielded Mig Wire

    ESAB FABRICATOR 141i 4.10 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire A. Select MIG mode with the process selection control. (Refer to Section 4.01 for further information) B. Connect the MIG Gun Polarity Lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.

  • Page 34: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    ESAB FABRICATOR 141i 4.11 Setup for MIG (FCAW) Welding with Flux Core (Gasless) Wire A. Select MIG mode with the process selection control (refer to Section 4.01.12 for further information). B. Connect the MIG Gun Polarity Lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.

  • Page 35: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    NOTE! A ESAB 17V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a ESAB Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.
  • Page 36 ESAB FABRICATOR 141i WARNING Secure the shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. CAUTION Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

  • Page 37: Setup For Stick (Smaw) Welding

    ESAB FABRICATOR 141i 4.14 Setup for STICK (SMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via Dinse style connectors. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

  • Page 38: Torch Adapter Thumb Screw Replacement

    ESAB FABRICATOR 141i 4.15 Torch Adapter Thumb Screw Replacement WARNING All power to unit should be removed. 1. Place unit on its back. A-12958 2. Remove 2 screws in bottom of the front panel. A securing block will become detached and fall free from the front panel as you turn each screw out.
  • Page 39 ESAB FABRICATOR 141i 3. Open the wire compartment door and release the tension knob so the pressure arm and tension knob hang downwardly. Tension Knob Pressure Arm Art # A-11484 4. Gently push the bottom of the front panel upward until the thumb screw is fully exposed.
  • Page 40 ESAB FABRICATOR 141i This Page Intentionally Blank OPERATION 4-20 Manual 0-5448...

  • Page 41: Theory Of Operation

    ESAB FABRICATOR 141i SECTION 5: THEORY OF OPERATION 5.01 Inverter Design What does the word inverter mean? The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC.
  • Page 42 ESAB FABRICATOR 141i Notes THEORY OF OPERATION Manual 0-5448...

  • Page 43: Troubleshooting

    ESAB FABRICATOR 141i SECTION 6: TROUBLESHOOTING 6.01 Pre-Power Up Checks It is best to perform the following Pre-Power Up test procedures in order to prevent blowing Primary Line Fuses or causing further dam- age to the power supply. Checking Unit Before Applying Power...

  • Page 44: Troubleshooting

    ESAB FABRICATOR 141i A. Unit is completely inactive: No lights come on; Displays 2. Broken wire in machine do not come on, Fan does not operate. Check and replace. 1. Primary Voltage Supply problem 3. Defective Control PCB2 a) Measure for 115VAC (+/- 15%) at Primary Sup- a) Replace Control PCB2.
  • Page 45 ESAB FABRICATOR 141i 1. Defective torch trigger F. No gas flow 1. Empty gas cylinder a) Check the torch trigger switch and replace it. 2. 8pin gun connector not connected a) Replace gas cylinder. 2. Flow meter/regulator turned off a) Connect 8 pin gun connector.

  • Page 46: Case Removal

    ESAB FABRICATOR 141i 6.04 Case Removal WARNING Read and follow safety information in Section 6.02 before proceeding. 1. Cover Remove Screws Lossen Screws Front & Rear Art # A-10456 a) Remove the two top screws from the front & rear mouldings.

  • Page 47: Clear Protective Sheet Removal

    ESAB FABRICATOR 141i 6.05 Clear protective Sheet Removal WARNING Read and follow safety information in Section 6.02 before proceeding. 1. Clear protective sheet Take out clear protective sheet. Art # A-12170 6.06 Visually Inspect Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, trans- formers, switches, or rectifier when a failure occurs.

  • Page 48: Preliminary Dc Bus Measurement Of The Main Pcb1

    ESAB FABRICATOR 141i 6.07 Preliminary DC Bus Measurement of the Main PCB1 WARNING Read and follow safety information in Section 6.02 before proceeding. Art # A-12171 DC Bus Testing Multimeter Lead Placement Voltage with SW1 OFF Negative meter lead to testpoint1...

  • Page 49: Check Main On / Off Switch

    ESAB FABRICATOR 141i IGBT Testing Multimeter Lead Placement Impedance Positive meter lead to testpoint 17 IGBT 1 150 to 350 Ω Negative meter lead to testpoint 9 Positive meter lead to testpoint 18 IGBT 2 150 to 350 Ω Negative meter lead to testpoint 11...

  • Page 50: Check Main Input Rectifier

    ESAB FABRICATOR 141i 6.09 Check Main Input Rectifier Input Rectifier Testing Multimeter Lead Placement Diode Voltage Positive meter lead to AC1 AC1 to DC+ 0.2 – 0.8 VDC Negative meter lead to testpoint DC+ Positive meter lead to AC2 AC2 to DC+ 0.2 –...

  • Page 51: Pcb Connectors

    ESAB FABRICATOR 141i DC Bus Testing Multimeter Lead Placement Voltage with Supply Voltage ON Negative meter lead to testpoint1 Buck CAPACITOR 161 VDC +/-10% Positive meter lead to testpoint2 Table 6-8 DC BUS, Multimeter set to measure DC volts Note: These DC voltages are at nominal mains supply voltage of 115VAC.
  • Page 52 ESAB FABRICATOR 141i MD Header Pin Pin Function Signal Motor positive 0-24V between Pin 1 and Pin 2, depending on wire speed Motor negative Table 6-11 MD Header Pin Function (Connects to MT header on Spool Gun PCB6) NTCS Header Pin...
  • Page 53 ESAB FABRICATOR 141i Control PCB2 Vmin WVIN QF/DY IGBT OT Imin Imax NTCS FUNs SOURCE DRIVE Art # A-12173 GUN Header Pin Pin Function Signal +23V~25VDC (0V when +24V Trigger positive Trigger closed) Trigger Common Table 6-16 GUN Header Pin Function (Connects to GUN1 header on Remote Interface PCB4)
  • Page 54 ESAB FABRICATOR 141i DRIVE Header Pin Pin Function Signal +15V +15 VDC IGBT1 ,4 PWM Driver Signal 5VDC Vpk IGBT2 ,5 PWM Driver Signal 5VDC Vpk IGBT2 ,5 PWM Driver Signal 5VDC Vpk IGBT1 ,4 PWM Driver Signal 5VDC Vpk...
  • Page 55 ESAB FABRICATOR 141i MB Header Pin Pin Function Signal Serial display date& EPROM (D-IN) 5VDC digital Serial display data(LOAD) 5VDC digital Serial display data (CLK) 5VDC digital 2T/4T push button 0VDC Serial display EPROM (D-OUT) 5VDC digital Not used Chip select...
  • Page 56 ESAB FABRICATOR 141i J1 Header Pin Pin Function Signal Serial display date& EPROM (D-IN) 5VDC digital Serial display data(LOAD) 5VDC digital Serial display data (CLK) 5VDC digital 2T/4T push button 0VDC Serial display EPROM (D-OUT) 5VDC digital Not used Chip select...
  • Page 57 ESAB FABRICATOR 141i R-G Header Pin Pin Function Signal 0-24V between Spool Gun motor negative pin 1 and 4 +23V-25VDC, +24V trigger positive 0V@ trigger closed Trigger switch RTN 0-24V between Spool Gun motor positive pin 1 and 4 -12VDC Pot Max...
  • Page 58 ESAB FABRICATOR 141i J11 Header Pin Pin Function Signal Serial display date& EPROM (D-IN) 5VDC digital Serial display data(LOAD) 5VDC digital Serial display data (CLK) 5VDC digital 2T/4T push button 0VDC Serial display EPROM (D-OUT) 5VDC digital MIG/ LIFT TIG/ STICK Selection Button...
  • Page 59 ESAB FABRICATOR 141i 6. Spool Gun PCB6 Art # A-12177 FUSE Header Pin Pin Function Signal 10A Fuse connector Closed Table 6-37 FUSE Header Pin Function (Connects to 10A Motor Fuse) PP Header Pin Pin Function Signal Closed when Remote...

  • Page 60: Dip Switch Settings, Control Pcb2

    DRIVE Art # A-12173 Art # A-12221 SW0 position Function Set to OFF for Fabricator 141i Set to OFF for Fabricator 141i Set to OFF for Fabricator 141i Set to OFF for Fabricator 141i Table 6-41 SW0 Dip Switch functions...

  • Page 61: Calibration

    ESAB FABRICATOR 141i 6.13 Calibration Calibration Vmin Imax Imin Art # A-12224 Set SW0-1 to ON, SW0-2 to ON, SW0-3 to ON, SW0-4 to OFF to allow calibration of output volts & amps, and calibration of wire feed speed. Output Current Calibration Select STICK mode on the front panel.
  • Page 62 ESAB FABRICATOR 141i W05 MAX SPEED W0 2 MIN SPEED U0 2 pin 6 E U0 1 pin 1 F U0 1 pin 2 G U0 1 pin 3 0V for wiredrive circuit (R017) Art # A-12178 Select MIG mode on the front panel.
  • Page 63 ESAB FABRICATOR 141i TEST POINT “A” 5V/div TEST POINT “B” 5V/div TEST POINT “C” 5V/div TEST POINT “D” 5V/div TEST POINT “E” and “F” 5V/div TEST POINT “G” 5V/div Art # A-11231 Manual 0-5448 6-21 TROUBLESHOOTING...

  • Page 64: Main Circuit Description

    ESAB FABRICATOR 141i 6.14 Main Circuit Description WARNING Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage. TROUBLESHOOTING 6-22 Manual 0-5448...
  • Page 65 ESAB FABRICATOR 141i The mains supply voltage is connected via a double pole switch to the input rectifier BR1 &BR2. Overvoltage protection is provided by varistor CY1. The rectifier output charges the main capacitor bank (C16, C18, C18-1) to high voltage. Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

  • Page 66: Circuit Diagram

    ESAB FABRICATOR 141i 6.15 Circuit Diagram TROUBLESHOOTING 6-24 Manual 0-5448...

  • Page 67: Disassembly Procedure

    ESAB FABRICATOR 141i SECTION 7: DISASSEMBLY PROCEDURE 7.01 Safety Precautions for Disassembly WARNING Read and follow safety information in Section 6.02 before proceeding. WARNING STATIC (ESD) can damage PC boards. Unplug unit before beginning Disassembly procedure. 7.02 Control PCB2 Removal WARNING Read and follow safety information in Section 6.02 before proceeding with disassembly.
  • Page 68 ESAB FABRICATOR 141i Art # A-12180 WVIN QF/DY IGBT OT FUNs SOURCE DRIVE NTCS A-10018 DISASSEMBLY PROCEDURE Manual 0-5448...

  • Page 69: Display Pcb3 Removal

    ESAB FABRICATOR 141i 7.03 Display PCB3 Removal WARNING Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove Control Panel screws. 2. Disconnect the harness from the connectors. 3 Remove Display PCB3. 4. Remove Remote Interface PCB4.
  • Page 70 ESAB FABRICATOR 141i Art # A-12181 DISASSEMBLY PROCEDURE Manual 0-5448...

  • Page 71: Front Panel Assembly Removal

    ESAB FABRICATOR 141i 7.04 Front Panel Assembly Removal CAUTION Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove the five screws on front panel. 2 Unscrew Negative output terminal bolts. 3. Unscrew torch cable terminal bolts.

  • Page 72: Rear Panel Removal

    ESAB FABRICATOR 141i 7.05 Rear Panel Removal CAUTION Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove the rear panel screws. 2. Disconnect the gas tube. 3. Disconnect Input Cord ground wire. 4. Disconnect the four wires from the switch.

  • Page 73: On/ Off Switch Sw1 And Power Cord Removal

    ESAB FABRICATOR 141i 7.06 ON/ OFF Switch SW1 and Power Cord Removal CAUTION Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Gas inlet. Remove gas inlet from rear panel. 2. SW1 locking tabs Squeeze the locking tabs and push SW1 out from the rear panel.

  • Page 74: Base Panel Removal And Main Pcb1 Disassembly

    ESAB FABRICATOR 141i 7.07 Base Panel Removal and Main PCB1 Disassembly CAUTION Read and follow safety information in Section 6.02 before proceeding with disassembly. 1. Remove Wire Feeder Screws. 2. Remove Inductor Screws. 3. Remove Central Panel Screws. 4. Remove Main PCB1 assembly Screws.

  • Page 75: Assembly Procedures

    ESAB FABRICATOR 141i SECTION 8: ASSEMBLY PROCEDURES 8.01 Installing Base panel 1. Main PCB1 assembly. 2. Heatsink on Main PCB1 assembly. 3. Install the feet of Main PCB1 assembly. 4. Install Rectifiers (torque 15 kgfcm). 5. Install Inductor. 6. Install Main PCB1 assembly screws.

  • Page 76: Installing Rear Panel

    ESAB FABRICATOR 141i 8.02 Installing Rear panel 1. Install gas inlet. 2. Install ON/OFF switch 3. Install wire cord and 2 screws. 4. Reconnect Input Wire on the ON/OFF switch. 5. Install fan. 6. Install plastic inserts into rear panel feet and install panel screws.

  • Page 77: Installing Front Panel

    ESAB FABRICATOR 141i 8.03 Installing Front Panel 1. Reinstall output terminals on front panel with 27mm wrench. 2. Place Display PCB3 and Remote Interface PCB4 assembly into front panel and install screws. A-12934 3. Reconnect torch polarity cable to the torch connector.

  • Page 78: Installing Control Pcb2 And Clear Protective Sheet

    ESAB FABRICATOR 141i Art # A-12183 8.04 Installing Control PCB2 and Clear Protective Sheet 1. Install 4 screws. 2 Plug harness into DRIVE connector. 3. Plug harness into SOURCE connector. 4. Plug harness into CR connector. 5. Plug harness into FUNs connector 6.
  • Page 79 ESAB FABRICATOR 141i Art # A-12184 Manual 0-5448 ASSEMBLY PROCEDURES...

  • Page 80: Installing Case

    ESAB FABRICATOR 141i 8.05 Installing Case 1. Install Case. 2. Install Ground Screw, which connects the ground wire to the cover. 3. Install Screws. Tighten screws. Install Screws Tighten Screws Front & Rear Art # A-12092 ASSEMBLY PROCEDURES Manual 0-5448...
  • Page 81 ESAB FABRICATOR 141i Notes Manual 0-5448 ASSEMBLY PROCEDURES...
  • Page 82 ESAB FABRICATOR 141i Notes ASSEMBLY PROCEDURES Manual 0-5448...

  • Page 83: Section 9: Key Spare Parts

    5B Tweco Control Wire 35K-350-1 2000-2352 5C Tweco Control Wire WS-354-TA-LC 2060-2141 & Plug Table 9-1: Tweco Fusion 140A MIG Gun Parts ** Patent Pending Figure 9-1 * Refer to ESAB Catalog No. 64-2103 for additional options. Manual 0-5448 KEY SPARE PARTS...

  • Page 84: Power Source

    ESAB FABRICATOR 141i 9.02 Power Source Figure 9-2 KEY SPARE PARTS Manual 0-5448...
  • Page 85 ESAB FABRICATOR 141i FABRICATOR 141i POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7006216 PCB,Power,141i W7006227 PCB,Control,141i W7003033 Solenoid,Valve,24VDC W7006226 PCB, Remote Interface Integrated with Display, 141i W7006209 Wiredrive Assy,w/ Motor,141i W7004906 Feedroll retaining thumb screw 7977036 Feed Roll .024(0.6mm)-.030"(0.8mm) V groove Installed W7004947 Fan,24VDC,4.75"x4.75"x1",141i...

  • Page 86: Hardware List

    48 ± 1 kgfcm Wirefeeder Plate Screw Skt Set M4 × 0.7 15 ± 1 kgfcm ESAB No. 4 Torch Adaptor Screw Hexagon M6 × 1.0-10 ST ZP 48 ± 1 kgfcm ESAB No. 4 Torch Adaptor Nut Hexagon M10 × 1. 5 ST ZP ≥...
  • Page 87 ESAB FABRICATOR 141i SCREW ITEM 4, OFF USED TO SECURE MOULDING TO INTERNAL PANEL SCREW ITEM 5, OFF USED TO SECURE MOULDING TO BASE PANEL SCREW ITEM 5, 2 OFF USED TO SECURE REAR MOULDING TO BASE PANEL SCREW ITEM 4, 2 OFF USED...
  • Page 88 ESAB FABRICATOR 141i Notes KEY SPARE PARTS Manual 0-5448...

  • Page 89: Options And Accessories

    DESCRIPTION PART NUMBER Fusion 140A MIG Gun, 10ft (3.0m) Length F140TA-10-3035 1017-1321 ESAB Spool Gun 160A,12ft (3.6M) Length, suits 4" (100mm) spools for alumini- um welding SG160TA-12-3035 1027-1390 W4013802 TIG Torch, 17V, 12.5 ft, 8 pin and accessory kit with 1/16", 3/32", 1/8" thori- ated tungstens;...

  • Page 90: Revision History

    ESAB FABRICATOR 141i REVISION HISTORY Date Rev Description 09/17/2015 Manual release ACCESSORIES 10-2 Manual 0-5448...
  • Page 92 ESAB Nederland B.V. ESAB Asia/Pacific Pte Ltd Amersfoort Singapore Tel: +31 33 422 35 55 Tel: +65 6861 43 22 Fax: +31 33 422 35 44 Fax: +65 6861 31 95 www.esab.eu ©2015 ESAB Welding and Cutting Products Printed in China...

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