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FABRICATOR 211i

INTRODUCTION

INTRODUCTION

2-2

Manual 0-5157

2.05 Transportation Methods

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH

live electrical parts. Disconnect input power

conductors from de-energized supply line

before moving the welding power source.

WARNING

FALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage.

Lift Power Source with handles built into the top of the

front and rear molded panels.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure Power Source

on a proper skid before transporting.

2.06 User Responsibility

This equipment will perform as per the information con-

tained herein when installed, operated, maintained and

repaired in accordance with the instructions provided.

This equipment must be checked periodically. Defective

equipment (including 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 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 any of its parts should not be altered

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 re-

pair by anyone other than appropriately qualified persons

approved by Thermal Arc.

2.07 Fabricator 211i Portable System

Package (Part No. W1004201)

• Fabricator 211i Power Source
• 12 ft. (3.6 m) Tweco WeldSkill 220 Amp MIG Gun
• Victor Argon Regulator / Flowmeter
• Drive Rolls:

.023"/.030" (0.6/0.8mm) "V" groove,
.023"/.035" (0.6/0.9mm)"V" groove (fitted with .035"

groove lined up) ,

.030"/.035" (0.8/0.9mm) "V" knurled for Flux Cored

Wire,

• Contact Tips (1 each)

.023"(0.6mm),.030"(0.8mm),
.035"(0.9mm) (fitted)

• Electrode Holder with 13 ft. (4m) lead
• Work Clamp with 10ft. (3.1m) lead
• Shielding Gas hose assembly
• 15A/20A Adapter Plug from 208/230V AC 50 Amps

to 115V Amps Circuits

• Thermal Arc Cap
• Electrodes
• Operating Manual
• DVD

Figure 2-1: Fabricator 211i System Packaged W1004201

Содержание 211i

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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