Thermal Arc 211i Operating Manual Download Page 1

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Art # A-11239

211i

Operating Manual

Revision:

Issue Date:

May 4, 2012

Manual No.:

0-5157

Operating Features:

FabricatOr

3 in 1 Multi-prOcess

welding systeM

3163339

Summary of Contents for 211i

Page 1: ...Art A 11239 Art A 11239 211i Operating Manual Revision AA Issue Date May 4 2012 Manual No 0 5157 Operating Features Fabricator 3 in 1 Multi process welding system 3163339...

Page 2: ...d 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...

Page 3: ...madyne Industries Inc 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 USA www thermadyne com Copyright 2012 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or...

Page 4: ...s 2 2 2 06 User Responsibility 2 2 2 07 Fabricator 211i Portable System Package Part No W1004201 2 2 2 08 Duty Cycle 2 3 2 09 Specifications 2 4 2 10 Optional Accessories 2 6 2 11 Volt Ampere Curves 2...

Page 5: ...lding Technique 4 1 4 02 MIG GMAW FCAW Welding Troubleshooting 4 5 4 03 STICK SMAW Basic Welding Technique 4 8 4 04 Effects of Arc Welding Various Materials 4 8 4 04 STICK SMAW Welding Troubleshooting...

Page 6: ......

Page 7: ...wrap cables around your body 10 Ground the workpiece to a good electrical earth ground 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Re...

Page 8: ...1 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No C...

Page 9: ...within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks...

Page 10: ...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 u...

Page 11: ...ctical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 General Safety Information For Victor CS...

Page 12: ...instructions can result in fire explosion damage to equipment or injury to the operator E Compressed Gas Cylinders The Department of Transportation DOT approves the design and manufacture of cylinder...

Page 13: ...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...

Page 14: ...Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function...

Page 15: ...ngers relatifs au soudage l arc AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler gravement L lectrode et le circuit de soudage sont sous tension d s la mise...

Page 16: ...fi avec l accord de l American Welding Society AWS Miami Florida Guide de teinte des lentilles Proc d Taille de l lectrode en mm po Courant d arc amp res Gamme d intensit minimum Num ro de teinte reco...

Page 17: ...paisse un pantalon revers des bottines de s curit et un casque 2 Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s 3 Entourez l aire de soudage de rideaux ou de cloisons po...

Page 18: ...ents et les pi ces connexes doivent tre maintenus en bon tat 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf...

Page 19: ...r des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter m...

Page 20: ...ge D Protection Personnelle Les flammes de gaz produisent une radiation infrarouge qui peut avoir un effet n faste sur la peau et particu li rement sur les yeux Choisissez des lunettes ou un masque av...

Page 21: ...a vanne de la bouteille d logeant ainsi d ventu lIes pous si res ou salet s qui pour raient tre pr sentes dans la vanne Mise en Garde Ouvrez la vanne de bouteille l g rement Si vous l ouvrez trop en g...

Page 22: ...Prise Source Auxiliaire Art A 07639F_AC 115V 15A t t1 t2 X IPM MPM t Fusible D roulement du Fil Alimentation du Fil Vers la Pi ce de Fabrication Hors Tension Dur e de Pr D bit Dur e de Post D bit Dur...

Page 23: ...74 1 and IEC 60974 1 applicable to welding equipment and associated accessories 2002 95 EC RoHS directive Extensive product design verification is conducted at the manufacturing facility as part of th...

Page 24: ...FABRICATOR 211i SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS AND WARNINGS 1 18 Manual 0 5157 This page left blank intentionally...

Page 25: ...etail how to cor rectly 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 un...

Page 26: ...hat such repairs be carried out by ap propriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor This equipment or...

Page 27: ...e 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 allowed to cool The thermal cut out will operate...

Page 28: ...6A 23 3A 22 9A 24 5A 30 1A 29 4A Single Phase Generator Requirement 7 5 kVA 3 7 kVA MIG GMAW FCAW Welding Output 104 F 10 min 210A 20 24 5V 122A 60 20 1V 95A 100 18 8V 110A 45 19 5V 99A 60 19 0V 77A 1...

Page 29: ...roduce the best product possible and therefore reserves the right to change improve or revise the specifications or design of this or any product without prior notice Such updates or changes do not en...

Page 30: ...8 0 9 mm U groove Part No 7977731 Drive Roll 040 3 64 1 0 1 2 mm U groove Part No 7977264 Drive Roll 030 035 0 8 0 9 mm V knurled Part No 7977732 Drive Roll 045 1 2 mm V knurled Part No 704277 Stick L...

Page 31: ...NTRODUCTION 2 11 Volt Ampere Curves Voltage Amperage Curves shows maximum voltage and amperage output capabilities of welding power source Curves of other settings fall between curves shown Art A 1129...

Page 32: ...FABRICATOR 211i INTRODUCTION INTRODUCTION 2 8 Manual 0 5157...

Page 33: ...rosive gases D In areas not subjected to abnormal vibration or shock E In areas not exposed to direct sunlight or rain F Place at a distance of 12 305mm or more from walls or similar that could restri...

Page 34: ...ower supply input cable plug to 115 V input power Art A 11275 Figure 3 1 115 VAC Adapter Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power supply The...

Page 35: ...fer to UL248 50 Amps 50 Amps 30 Amps 30 Amps Maximum Recommended Fuse or Circuit Breaker Rating Normal Operating UL class K5 Refer to UL248 Minimum Recommended Cord Size 12 AWG 12 AWG Maximum Recommen...

Page 36: ...etic problems in the surrounding area The following shall be taken into account 1 Other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment 2...

Page 37: ...safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Ca...

Page 38: ...Indicating Pres sure Gauges for Compressed Gas Service b Low pressure gauges must be UL recognized for the class of regulator they are being used on according to UL252A WARNING Do not use a regulator...

Page 39: ...d the regulator For your safety NEVER STAND IN FRONT OF OR BEHIND A REGULA TOR WHEN OPENING THE CYLINDER VALVE 9 Slowly and carefully open the cylinder valve Figure 3 5 until the maximum pressure show...

Page 40: ...res service or repair take it to a qualified repair technician 5 Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed WARNING If a leak...

Page 41: ...Art A 11241 MIG LIFT TIG STICK 4T 2T WIRESPEED DOWNSLOPE S ARC FORCE INDUCTANCE SOFT HARD 2 4 6 8 POWER FAULT A 0 1 2 4 7 9 1 3 6 8 V 0 1 2 4 7 9 1 3 6 8 IG L 3 4 5 6 7 8 9 11 10 12 13 2 1 14 16 15 2...

Page 42: ...t times of non welding the amperage meter will display a pre set preview value in both STICK and LIFT TIG modes This value can be adjusted by varying the Amperage Control Knob 4 When welding this digi...

Page 43: ...crew in the MIG Gun Adapter within the Wire Feed Compartment to secure the Tweco MIG Gun in position Failure to properly lock the Tweco MIG Gun into the MIG Gun Adapter will result in the Tweco MIG Gu...

Page 44: ...Wirespeed in MIG GMAW FCAW mode Remote Amps in LIFT TIG GTAW mode Remote Volts in MIG GMAW FCAW 1 2 3 4 5 6 7 8 W V 3 4 5 6 7 8 1 2 Negative Spool Gun Motor Positive Art A 10421_AC Figure 3 9 Remote...

Page 45: ...n 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 i...

Page 46: ...in all modes At the completion of welding the digital meter will hold the last recorded voltage value for a period of approxi mately 10 seconds in all modes The voltage meter will hold the value until...

Page 47: ...rrespective of the remote control device setting As an example if the output current on the power source front panel is set to 50 and the remote control device is set to 100 the maximum achievable out...

Page 48: ...tic nut clockwise to secure the MIG gun to the MIG gun adapter Connect the 8 pin plug by aligning he keyway then inserting the 8 pin plug into the 8 pin socket and rotate threaded collar fully clockwi...

Page 49: ...Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool NOTE The Hub tension h...

Page 50: ...spool alignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool NOTE The Hub tension has been pre adjusted a...

Page 51: ...ise Make sure to align the spool alignment pin on the hub with the mating hole in the wire spool 3 Replace the Wire Spool Hub Retaining Clip in the set of holes closest to the spool NOTE The Hub tensi...

Page 52: ...guide and into the MIG gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 3 14 Remove the contact tip from the MIG gun With the MIG gun lead...

Page 53: ...ing the pressure screw clockwise WARNING Before changing the feed roller ensure that the Electricity Supply to the power source is switched off CAUTION The use of excessive pressure may cause rapid we...

Page 54: ...sitive welding terminal If in doubt consult the electrode wire manufac turer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plu...

Page 55: ...up for MIG Welding with Gas Shielded MIG Wire 3 20 Setup For MIG FCAW Welding With Flux Core Gasless Wire A Select MIG mode with the process selection control refer to Section 3 10 13 for further info...

Page 56: ...ore connecting the work clamp to the work make sure the Electricity Supply is switched off CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in t...

Page 57: ...l of the Power Source 1 Make sure the welding power source is turned OFF before connecting the welding gun 2 Open side panel and loosen thumb screw 3 Insert the back end of the Spool gun into the gun...

Page 58: ...elding 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 electric...

Page 59: ...g 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...

Page 60: ...s essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Select STICK mode with the process selection control refer to Section 3 10 13 for furt...

Page 61: ...welded by heating them with an arc between a continu ous flux filled electrode wire and the work Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding ma...

Page 62: ...on rate and the mechanical proper ties These variables are Type of electrode wire Size of electrode wire Type of gas not applicable for FCAW self shielding wires Gas flow rate not applicable for FCAW...

Page 63: ...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...

Page 64: ...10 10 10 10 Mild Steel Wirespeed Display 123 152 174 226 Voltage Display 13 16 5 17 5 19 Inductance Display 8 10 10 10 ER70S 6 035 0 9 mm 100 C0 2 123 152 174 213 278 290 13 16 5 17 5 20 5 22 8 23 5 8...

Page 65: ...sted to 31 75 CFH 2 Shielding gas cylinder contents and flow gauge Ensure that the shielding gas cylinder is not empty and the flow meter is correctly adjusted to workshop welding 28 35 CFH or outdoor...

Page 66: ...pres sure is applied to the pressure roller adjuster B Swarf can also be produced by the wire passing through an incorrect feed roller groove shape or size C Swarf is fed into the conduit liner where...

Page 67: ...e control and the wirespeed control B Wire is wandering B Replace contact tip C Incorrect shielding gas C Check shielding gas D Insufficient or excessive heat input D Adjust the wirespeed control or t...

Page 68: ...Thermal Arc Distributor 4 04 Effects of Arc Welding Various Materials A High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the...

Page 69: ...at horizontal vertical and overhead positions Numer ous 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 throu...

Page 70: ...ot less than 70 Double Vee Butt Joint 1 16 1 6mm Lap Joint Tee Joints Fillet both sides of the joint Edge Joint Fillet Joint Corner Weld Plug Weld Plug Weld Not less than 70 Single Vee Butt Joint Not...

Page 71: ...hese faults Art A 10673 20 1 16 1 6 mm 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...

Page 72: ...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 t...

Page 73: ...eld Art A 07703 Figure 4 27 Examples of Vertical Fillet Welds 2 Vertical Down The E7014 electrode makes welding in this position particularly easy Use a 1 8 3 2 mm electrode at 100 amps The tip of the...

Page 74: ...inued 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...

Page 75: ...ed to reduce distortion Figure 4 32 shows a simple applica tion 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 re...

Page 76: ...Non metallic particles may be trapped in undercut from previous run A If a bad undercut is present clean slag out and cover with a run from a smaller gauge electrode B Joint preparation too restricte...

Page 77: ...eave to allow weld metal buildup G Power source is set for MIG GMAW welding G Set power source to STICK SMAW mode 5 Portions of the weld run do not fuse to the surface of the metal or edge of the join...

Page 78: ...g on the welding application Welds Made With or Without Addition of Filler Metal Work Piece Can Be Any Commercial Metal Gas Cup Either Ceramic High lmpact or Water Cooled Metal Inert Gas Shields Elect...

Page 79: ...ss DC Current for Mild Steel DC Current for Stainless Steel Tungsten Electrode Diameter Filler Rod Diameter if required Argon Gas Flow Rate CFH Joint Type 0 040 1 0mm 35 45 40 50 20 30 25 35 0 040 1 0...

Page 80: ...vel speed 5 Uneven leg length in fillet joint Wrong placement of filler rod Re position filler rod 6 Electrode melts or oxidizes when an arc is struck A TIG Torch lead connect ed to positive welding t...

Page 81: ...is being used for the welding job B Select the right electrode type Refer to Thermal Arc Electrode Selection Chart C Gas flow rate is too high C Select the right rate for the welding job Refer to Tabl...

Page 82: ...FABRICATOR 211i BASIC WELDING BASIC WELDING 4 22 Manual 0 5157...

Page 83: ...t liner or contact tip burn back jam A Check for clogged kinked MIG gun conduit liner or worn con tact tip Replace faulty compo nents B Internal fault in power source B Have an Accredited Thermal Arc...

Page 84: ...ge 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 Disconnect the Welding Power Source from the El...

Page 85: ...f fixed wiring sup plying 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 accessorie...

Page 86: ...alls within applicable Thermal Arc power source specifications Output Voltage V to be checked to ensure it falls within applicable Thermal Arc power source specifications Motor Speed RPM of wire drive...

Page 87: ...rial Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current Warning Disconnect input power before maintaining Each Use Visual check...

Page 88: ...brush Also wipe off or clean the grooves on the upper feed roll After cleaning tighten the feed roll retaining knobs CAUTION Do NOT use compressed air to clean the Welding Power Source Compressed air...

Page 89: ...Skill 220 MIG Gun TWECO WELDSKILL 220A MIG GUN PARTS ITEM PART NO DESCRIPTION 1 1210 1112 Nozzle 1 2 12 7 mm Flush 2 1110 1102 Contact Tip 035 0 9mm 3 1510 1140 Gas Diffuser 4 2042 2053 Microswitch 5...

Page 90: ...ATOR 211i REPLACEMENT PARTS REPLACEMENT PARTS 6 2 Manual 0 5157 6 02 Power Source Spare Parts Art A 11250 1 2 3 6 7 9 8 10 11 12 14 13 15 16 18 19 4 5 20 22 23 24 25 26 17 30 31 29 32 33 34 36 35 Figu...

Page 91: ...s 15 W7005623 Switch CB Main On Off 16 W7004911 CT Output 17 W7005617 Spool Hub Assembly 18 W7005608 Washer Friction Spool Hub 19 W7005609 Spool Hub 20 W7004966 Adapter Tweco 4 141i 211i 21 W7005619 G...

Page 92: ...FABRICATOR 211i REPLACEMENT PARTS REPLACEMENT PARTS 6 4 Manual 0 5157...

Page 93: ...FC 2 MB 1 POT1 1 CR JC QF DY GND 24VDC 3 POT MAX 5VDC 2 WIPER 1 POT MIN RED BLK YEL 1 24VDC 1 1 OUTPUT 3 OUTPUT 8 Pin Remote Control Spool Gun 1 SPOOL GUN 0V 1 TORCH SWITCH 24V 2 TORCH SWITCH RIN 0VDC...

Page 94: ...mages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set...

Page 95: ...or FirePower Welders 5 Years Parts No Labor Victor Professional Thermadyne limited warranty shall not apply to Consumable Parts for MIG TIG Plasma welding Plasma cutting and Oxy fuel torches O rings f...

Page 96: ...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...

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