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211i Service Manual Fabricator®

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1. 3 1 3 01 Bye 3 1 92 Rm 3 2 Ilem 3 3 3 04 TT 3 3 3 3 3 06 Mains Supply Voltage Requirements 3 4 3 07 Electrical Input Connections usse soupe des Gute cuta eben te benc 3 5 3 08 Electromagnetic Compatibility ue 3 6 902 ee 3 6 SECTION 4 Jc mee gt 4 1 4 01 Power Source Controls Indicators and 4 1 AO cte eM eem 4 7 4 03 Installing 15kg Spool 300mm diameter 55 nmi ees 4 0 4 04 Installing 5kg Spool 200mm diameter 4 8 4 05 Inserting Wire into the Wire Feed Mechanism 4 9 4 06 Feed Roller Pressure Adjustment eene 4 10 4 07 Changing the E EE 4 10 4 08 NEP 4 11 4 09 Setup for MIG GMAW Welding with Gas Shielded MIG Wire 4 11 4 10 Setup for MIG FCAW Welding with Gasless MIG Wire 4 13 4 11 setup for SPOOL GUN MIG GMAW Welding with Gas Shielded MIG Wire 4 14 412 5 for GTAW Welding 4 15 413 Setup for STICK Welding 4 17 4 14 Leak Testin
2. LIL ILI 38 5 Cite pet 069 weed fr oa fed es Pss ves ves es 99 DC Bus Testing Multimeter Lead Placement Voltage with Supply Voltage ON Positive meter lead to testpoint 1 ane Upper capacitor bank Negative meter lead to testpoint 2 190 VDC 10 O Art A 10750 Positive meter lead to testpoint 2 PT Negative meter lead to testpoint 3 Positive meter lead to testpoint 1 T Overall capacitor bank EE EE 385 VDC 10 Table 5 11 DC BUS Multimeter set to measure DC volts Note These DC voltages are at nominal mains supply voltage of 240VAC 110VAC Manual 0 5226 979 TROUBLESHOOTING FABRICATOR 2111 5 10 PCB Connectors 1 Inverter PCB RX ACOUT1 ACOUT2 o x9 pcs TROUBLESHOOTING DY2 DY1 IN QF FJ PWM MD e D ef VE DENN di esu lee s IGBT 1 pwm drive signal 15V p p square wave IGBT 2 pwm drive signal 15V p p square wave IGBT 2 pwm drive signal 15V p p square wave IGBT 1 pwm drive signal 15V p p square wave Rectified secondary of current transformer TR8 15 VDC pk Table 5 12 IN Header pin function connects to DRIVE header on control PCB PWM Header Pin Signal ODC Motor pwm drive signal 5 VDC pk Table 5 13
3. os Cube edle _ __ Kg bea Kei een Eis Art A 10752 C S O T e Input Rectifier Multimeter Lead Placement Diode Voltage Positive meter lead to 16 Negative meter lead to testpoint 18 Positive meter lead to 17 Negative meter lead to testpoint 18 Positive meter lead to testpoint 19 Negative meter lead to testpoint 16 Positive meter lead to testpoint 19 Negative meter lead testpoint 17 Table 5 10 Input Rectifier Multimeter set to measure Diode Voltage Measurements may be made directly onto the main input rectifier AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position TROUBLESHOOTING 5 8 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 5 09 DC Bus Voltage Measurement Apply voltage to the Power Source h 7 There are extremely dangerous voltage and power levels present inside these Power Sources Do not attempt to diagnose or repair unless you have had training in power electronics measurement and trouble shooting techniques Once power is applied to the Power Source there are extremely hazardous voltage and power levels present Do not touch any live parts STUODA pel E i e mid LT H CR 2 5 i i6 aa rana ANN LL
4. Signal 24VDC 24 VDC 202 4 E Fan control signal OV Fan ON Table 5 38 FUNs Header pin function not used DRIVE Header Pin Pinfunction Sigal 10 2 IGBT1pwmdrivesignal 15V square wave 15VDCpk 3 IGBT2pwmdrivesignal 15V square wave 15VDCpk 4 IGBT2pwmdrivesignal 15V square wave 15VDCpk 25 IGBT1pwmdrivesignal 15V square wave 15VDCpk 26 Rectified secondary of current transformer TR8 15 Mp Ua owe Table 5 39 DRIVE Header pin function connects to IN header on inverter PCB WvVINHeaderPin Sigal Table 5 40 WVIN Header pin function IFBHeaderPin Signal 3 Cmretsenorsna Table 5 41 IFB Header pin function Connects to welding output current sensor SOURCE Header Pin Signal Table 5 42 SOURCE Header pin function connects to DY2 header on control PCB CRHeaderPin Pinfunction Signal _ 2 Wiper 10k Burnback potentiometer 0 5VDO 8 Table 5 43 CR Header pin function connects to 10k Burnback potentiometer OTi Header Pin Sigal ____1 ___ Diode thermostat Diode thermostat _ Table 5 44 OT1 Header pin function connects to igbt thermostat OT2HeaderPin Pinfuncion 1 Signal obt thermostat OVDC when thermostat closed M
5. face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING Engines can be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes 4 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fuelling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuelling is spilled clean up before starting engine WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS 1 Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers fo
6. MMAW Stick 0 A 2 40 80 120 160 200 240 jndjno NO I O O O O O jndjno 8 e Welding Current amps _ GTAW Lift Tig 40 80 120 160 200 240 Welding Current amps _ GMAW Mig 40 80 120 160 200 240 Welding Current amps Art A 10435 Figure 3 3 Fabricator 211i Volt Ampere Curves 3 8 Manual 0 5226 OPERATION FABRICATOR 2111 SECTION 4 OPERATION 4 01 Power Source Controls Indicators and Features 1 Art A 10937 Figure 4 1 Fabricator Front and Control Panel Figure 4 2 Fabricator Front Connections Power Indicator The power indicator is illuminated 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 2 Thermal Overload Indicator Fault Indicator 3 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 swit
7. Art A 10760 14 13 12 11 Art A 10769 15 Manual 0 5226 1 5 ASSEMBLY PROCEDURES FABRICATOR 2111 ASSEMBLY PROCEDURES 7 05 Installing Case 1 Install Ground Screw which connects the ground wire to the cover 2 Install case Install Screws Tighten screws 1 Art A 10770 Install Screws MULTI PROCESS WELDING SYSTEM IHERMAL Are Ses eu ds Tii Art A 11193 Tighten Screws Front amp Rear ASSEMBLY PROCEDURES 7 6 Manual 0 5226 KEY SPARE PARTS FABRICATOR 2111 SECTION 8 KEY SPARE PARTS 8 01 Power Source Spare Parts Art A 11234 Part Number MEME 1 W7005600 PCB Power woso 73 wose 6 W7005603 Wiredrive Assembly o Feed Roll 0 6 0 8mm V groove titted as standard Refer to options and accessories table for other feed rolls available 9 Loge Table 8 1 Key Spare Parts Manual 0 5226 0 1 KEY SPARE PARTS FABRICATOR 2111 KEY SPARE PARTS Notes KEY SPARE PARTS 0 2 Manual 0 5226 OPTIONAL ACCESSORIES FABRICAOTR 211i SECTION 9 OPTIONAL ACCESSORIES 9 01 Optional Accessories ZbV TIG Torch 4 M PROPERE Part No 310 090 001 n Tweco TWE2 3 m 250A MIG Gun Part No 161 550 307 fr Tweco WeldSkill 220A MIG Gun 3 m Part No WS220XE 10 3035 Professional 4 Wheel Cart Dual Cylinder Part No W4015002
8. Professional 4 Wheel Cart Single Cylinder Part No W4015001 a Cart Single Cylinder Part No W4014700 HOU GAGE Part No 4015104 Foot Part No 10 4016 amp Pendant Control 10 4014 Tweco WeldSkill Helmet Part No WHF41001 Feed Roll 0 6 0 8mm V groove hard fitted Part No 62020 Feed Roll 0 9 1 2mm V groove hard Part No 62022 Feed Roll 0 8 0 9mm U groove soft Part No 62179 Feed Roll 1 0 1 2mm U groove soft Part No 62024 Feed Roll 0 8 0 9mm V knurled flux cored Part No 62028 Manual 0 5226 9 1 OPTIONS ACCESSORIES THERMAL LIMITED WARRANTY TERMS LIMITED WARRANTY Thermal Arc Inc Victor Technologies Company hereafter Thermal Arc warrants to customers of its authorized distributors hereafter Purchaser that its products will be free of defects in work manship 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 specifica tions instructions recommendations and recognized standard
9. ve Remote Volts in Sc MIG GMAW FCAW Remote Wirespeed MIG GMAW FCAW mode Art 10421_ Remote Amps in LIFT TIG GTAW mode Figure 4 3 Remote Control Socket spool Gun Motor Negative Trigger Switch Input Trigger Switch Input spool Gun Motor Positive ok ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control Wirespeed MIG GMAW FCAW mode potentiometer Wiper arm connection to 5k ohm remote control Amps LIFT GTAW mode potentiometer Wiper arm connection to 5k ohm remote control Volts MIG GMAW FCAW mode potentiometer Table 4 1 Note that the local remote switch item 18 located in the wirefeed compartment should be set to remote for the amperage voltage controls to be operative Manual 0 5226 4 3 OPERATION FABRICATOR 2111 10 Multifunction Control Voltage Down Slope amp Arc Force The multifunction control knob is used to adjust Voltage MIG Mode Down slope Mode and Arc Force STICK Mode depending on the welding mode selected NOTE The preview functionality provided on this power source is intended to act as a guide only Some dif ferences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques a
10. Gas Tungsten Arc Hertz cycles sec Welding GTAW Air Carbon Arc Keier Cutting CAC A Constant Voltage Or Constant Potential Direct Current DC High Temperature 1 Earth E NEN Auxiliary Power Variable Inductance Receptacle Rating Auxiliary Power Wire Feed Function Wire Feed Towards lo Workpiece With 1 Output Voltage OFF e Welding Gun Purging Of Gas Continuous Weld Ka Mode Spot Weld Mode Preflow Time Postflow Time 2 Step Trigger _ 4 Operation Press to initiate wirefeed and welding release to stop 4 Step Trigger tt Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Inches Per Minute Lg Meters Per Minute Ea Art A 10663 SAFETY INSTRUCTIONS AND WARNINGS 1 6 Manual 0 5226 SAFETY INSTRUCTIONS FABRICATOR 2111 1 04 Declaration Of Conformity Manufacturer Victor Technologies International Inc Address 16052 Swingley Ridge Road Suite 300 ot Louis Mo63017 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 2006 95 EC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 2004 108 EC and to
11. 3 DISASSEMBLY PROCEDURE 6 4 Manual 0 5226 DISASSEMBLY PROCEDURE FABRICATOR 2111 6 05 Back Panel Removal A Read and follow safety information in Section 5 03 before proceeding with disassembly 1 Remove the screws on the back 2 Remove Rear Panel screws 3 Remove The Ground Wire 4 Wire from Main PCB1 Disconnect the two wires from switch 5 Remove The Screw and Disconnect the pipe from gas inlet 1 IHERMAL ARC 9 IHERMAL MULTI PROCESS WELDING SYSTEM E m Art 11191 Manual 0 5226 6 5 DISASSEMBLY PROCEDURE FABRICATOR 2111 DISASSEMBLY PROCEDURE 6 06 Power Switch S1 and Power Cord Removal AN Read and follow safety information in Section 5 03 before proceeding with disassembly 1 Gas inlet Remove gas inlet from rear panel Remove The Ground Wire Remove the screws which control the supply cord Remove the two screws and push SW1 out from the rear panel Remove the two supply wires from the switch Remove the supply wires which connect to main PCB Aa N Input Power Cord ground wire filter Cut the tie wrap and remove the Ferrite core from the ground wire 8 Remove The Screw and Disconnect the pipe from gas inlet 9 Disconnect harness from main PCB1 10 Remove Fan 4 c 9 2 4 E at es w Ly e 4 des Art 10764 DISASSEMBLY PROCEDURE 6 6 Manual 0
12. Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 055 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 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 EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer 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 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 VICTOR TECHNOLOGIES INNOVATION SHAPE THE WORLD U S Customer Care 800 426 1888 rax 800 535 0557 Canada Customer Care 905 827 4515 rax 800 588 1714 International Customer Care 940 381 1212 rax 940 483 8178 2012 Victor Technologies International Inc victortechnologies com Printed in China
13. 5226 DISASSEMBLY PROCEDURE FABRICATOR 2111 6 07 Base Panel Removal Read and follow safety information in Section 5 03 before proceeding with disassembly 1 Remove Wire Feeder Screws 2 Remove inductor assembly Screws 9 4 Remove Central Panel Screws Remove Main PCB assembly Screws Art A 10765 Manual 0 5226 6 7 DISASSEMBLY PROCEDURE FABRICATOR 2111 DISASSEMBLY PROCEDURE Notes DISASSEMBLY PROCEDURE 6 8 Manual 0 5226 ASSEMBLY PROCEDURE FABRICATOR 211i SECTION 7 ASSEMBLY PROCEDURES 1 01 Installing Base Board 1 Main Power PCB assembly Install main PCB assembly screws Install inductor assembly Screws Install Wire Feeder Screws N Install Central Panel Screws Art 10766 Manual 0 5226 1 1 ASSEMBLY PROCEDURES FABRICATOR 2111 ASSEMBLY PROCEDURES 1 02 Installing Back Panel 1 Install gas inlet Install the power supply cord and the screws Install fan Reconnect the pipe to gas inlet and the screw Reconnect the supply wires Reconnect the supply wires which connect to main PCB Install the two screws Reinstall magnetic core onto Ground Wire Reconnect Ground Wire to the terminal 10 Reconnect Rear Panel screws 11 Reconnect the harness to FAN connector Art A 10767 ASSEMBLY PROCEDURES 1 2 Manual 0 5226 ASSEMBLY PROCEDURE FABRICATOR 211i 1 03 Installing Front Panel 1 Reinstall output Dinse on front panel wit
14. 9 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 B Insulation Resistance Minimum insulation resistance for in service Thermal Arc Inverter Power Sources shall be measured at a volt age of 500V between the parts referred to in Table 5 3 below 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 Minimum Insulation Components to be Tested Resistance 0 Input circuit including any connected control circuits to welding circuit including any connected control circuits circuits to exposed conductive parts 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 3 Minimum Insulation Resistance Requirements Thermal Arc Inverter Power Sources Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage exceeding extra low voltage 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 earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wirin
15. FUNs connector Disconnect IGBT OT2 harness from IGBT OT2 connector Disconnect IGBT OT1 harness from IGBT OT1 connector Disconnect GUN harness from GUN connector O d eS Disconnect QF DY harness from QF DY connector 10 Disconnect WVIN harness from WVIN connector 11 Disconnect MB harness from MB connector 12 Disconnect JC harness from JC connector 13 Disconnect PWM harness from PWM connector 14 Disconnect IFB harness from IFB connector Art A 10760 14 13 12 11 DISASSEMBLY PROCEDURE 6 2 Manual 0 5226 DISASSEMBLY PROCEDURE FABRICATOR 211i 6 03 Front Panel Assembly Removal Read and follow safety information in Section 5 03 before proceeding with disassembly 1 Screws on front panel 2 Positive output terminal bolts Unscrew output terminal bolts 3 Negative output terminal bolts Unscrew Negative output terminal bolts THERMAL 2 xe eot SYSTEM DESS Ww ING THERMAL A n m Art 11189 Manual 0 5226 6 3 DISASSEMBLY PROCEDURE FABRICATOR 2111 DISASSEMBLY PROCEDURE 6 04 Front Panel Operator Interface Circuit Board PCB3 Removal AN Read and follow safety information in Section 5 03 before proceeding with disassembly 1 Remove Control Panel screw 4 2 Front Panel PCB 3 Disconnect the harnesses from the connectors Arc MULTI PROCESS WELDING SYSTEM Wu Apr m Art A 1190
16. 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 otandard 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 Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard 487 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 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 SAFETY INSTRUCTIONS 1 03 Symbol Chart Note that only some of these symbols will appear on your model Three Phase Static Frequency Converter Transformer Rectifier e Panel Local A Shielded Metal Lado Arc Welding SMAW Voltaae Gas Metal Arc Welding GMAW
17. PWM Header pin function connects to PWM header on control PCB MD Header Pin Motor positive 24 VDC Motor negative 0 VDC Table 5 14 MD Header pin function connects to MT IN header on motor PCB TROUBLESHOOTING 5 10 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 Signal 24V Header Pin Pinfunction 02 Table 5 16 DY1 Header pin function QF FJ Header Pin 24V VRD positive Solenoid negative 24 solenoid positive 0 RXHeaderPin Pintunction 0 2 JCHeaderPin _ OK signal 5V PFC OK Table 5 19 JC Header pin function connects to PFC header on control PCB FJ Header Pin Pin function Sigal Table 5 20 FJ Header pin function connects to FAN CON3 Header Pin 24VDC 3 Fan control signal Fan ON Table 5 21 CONS Header pin function connects to FUNs on control PCB Manual 0 5226 9 11 TROUBLESHOOTING FABRICATOR 211i TROUBLESHOOTING 2 Motor PCB FUSE Signal Motor positive from Inverter PCB Motor negative from Inverter PCB Motor negative Table 5 22 MT IN Header pin function Connects to MD header on Inverter PCB amp to Motor SGM Header Pin Signal opool Gun Motor negative 0 VDC Spool Gun Motor positive 24 VDC Table 5 23 SG M Header pin function connects to SGM header on display PCB PPHeaderPin Signal Gun Switch NENNEN Gun S
18. Tungsten arc Welding GTAW e Air Carbon Arc Cutting CAC A Less than 20 20 100 100 400 400 800 Less than 20 20 40 40 60 Plasma Arc Cutting PAC 60 80 80 300 300 400 400 800 Plasma Arc Welding PAW As a rule of thumb start with a shade that is too dark to see the weld zone Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum In oxyfuel gas welding cutting or brazing where the torch and or the flux produces a high yellow light it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum SAFETY INSTRUCTIONS AND WARNINGS 1 2 Manual 0 5226 SAFETY INSTRUCTIONS Se 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 breathe 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 instruction for metals consumables coatings and cleaners Work in a confined space only if it is well ventilated 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 locatio
19. consultation with the distribution network operator if necessary that the equipment may be connected Victor Technologies has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative oteve Ward Operations Director Victor Technologies Europe Europa Building Industrial Park Chorley Lancashire England PR6 7 Manual 0 5226 17 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 1 05 Servicing Hazards WARNING The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should test main tain and repair this unit Only qualified persons should test main fain and repair this unit A WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from receptacle or stop engine before servicing unless the procedure specifi cally requires an energized unit Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground Do not leave live unit unattended If this procedure requires a
20. is filtered by an inductor before connecting to the welding output terminals A thermal overload device thermistor is fixed to the rectifier heatsink When an over temperature occurs the control circuit inhibits the trigger gas solenoid wire drive system and the welding output The thermal overload indicator LED on the front panel is illuminated The current transformer provides a signal to the control circuit to indicate both transformer primary current and also detect transformer saturation The Hall effect current sensor is powered from regulated amp 15VDC supplies and provides a voltage signal proportional to the output DC welding current to allow the control circuit to regulate welding current TROUBLESHOOTING 5 20 Manual 0 5226 DISASSEMBLY PROCEDURE FABRICATOR 211i SECTION 6 DISASSEMBLY PROCEDURE 6 01 Safety Precautions for Disassembly Read and follow safety information in Section 5 03 before proceeding Unplug unit before beginning Disassembly procedure Manual 0 5226 6 1 DISASSEMBLY PROCEDURE FABRICATOR 2111 DISASSEMBLY PROCEDURE 6 02 Control Board Removal AN Read and follow safety information in Section 5 03 before proceeding with disassembly Remove case before remove control board 1 MA Screw Remove 4 screws from Control panel Disconnect DRIVE harness from DRIVE connector Disconnect SOURCE harness from SOURCE connector Disconnect CR harness from CR connector Disconnect FUNs harness from
21. maximum required delivery flow rate 3 Close the cylinder valve Watch to see if the high pressure or contents gauge drops if it does you have leak in the connection between the regulator and the cylinder 4 Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed AN WARNING leak has been detected anywhere in the system discontinue use have the system repaired DO NOT use leaking equipment Do not attempt to repair a leaking system while the system is under pressure OPERATION 4 18 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 SECTION 5 TROUBLESHOOTING 5 01 Basic Troubleshooting Power Source Faults The following table is a guide for analysing problems and making repairs to the Power Source PesibleCauie 0 There is no weld The main Power a is set to OFF main Power Switch to ON C output and all front Line fuse is blown Replace Line fuse panel displays are off The main Power Switch is faulty Replace main Power Switch D Loose connection to EMC board Tighten connections E Faulty Power Inverter board Replace Power Inverter board F Faulty Control board Replace Control board Faulty Display board Replace Display board or flickering on amp off regulation may cause a supply voltage in excess of 2 4VAC Connect Power Source to a supply voltage lt 274 There is no weld Unit has over
22. national state and local codes Manual 0 5226 1 1 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 WARNING ARC RAYS can burn eyes and skin NOISE 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 Wear a welding helmet fitted with a proper shade of filter see ANSI Z49 1 listed in Safety Standards to protect your face and eyes when welding or watching SAFETY INSTRUCTIONS Wear approved safety glasses Side shields recommended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Useapproved ear plugs or ear muffs if noise level 1 high Never wear contact lenses while welding AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Lm Minimum Suggested Jb 2 Protective Shade No Shade Comfort Less than 3 32 2 4 Less than 60 Shielded Metal Arc Welding 3 32 5 32 2 4 4 0 60 160 8 10 SMAW 5 32 1 4 4 0 6 4 160 250 10 12 More than 1 4 6 4 250 550 11 14 1 Less than 60 60 160 10 11 160 250 10 12 250 550 10 14 10 Gas Metal Arc Welding GMAW and Flux Cored Arc Welding FCAW Gas
23. wiring has become Check amp Repair loose C Trigger wires or torch switch faulty D Faulty Power Inverter board The wirefeed motor Faulty Power Inverter board Replace Power Inverter board operates at maximum Faulty Display board Replace Display board when the torch trigger switch is depressed Replace Power Inverter board speed and cannot be adjusted Table 5 1 Power Source Faults Manual 0 5226 SM TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING The following table is a guide for analysing problems and making repairs to the Power Source o oo Possible Cause Wirefeed motor operates Internal wiring fault Check solenoid wiring header is when the torch trigger plugged securely into Control switch is depressed but the board Check solenoid wiring is gas valve does not operate not damaged Faulty Solenoid Replace Solenoid Impurity in gas system causing Clean out gas system solenoid to stay open or closed Disassemble solenoid amp clean out impurities Faulty Power Inverter board Replace Power Inverter board Faulty Control board Replace Control board A welding arc can be Work Lead cable too small Use correct weld cable size established but the weld is Loose welding connections Tighten welding connections erratic or inconsistent Loose earth clamp Tighten earth clamp Incorrect weld polarity selected Correct weld polarity Refer to weld consumable manufacturers recommended polarity No shielding g
24. with all appliance local electrical codes Input Power Each unit incorporates an INRUSH circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit pro vides pre charging for the input capacitors A relay in the Main Power PCB1 will turn on after the input capacitors have charged to operating voltage after approximately 5 seconds Manual 0 5226 3 5 SAFETY INSTALLATION FABRICATOR 2111 SAFETY INSTALLATION 3 08 Electromagnetic Compatibility A WARNING pm SSS SS 7 Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source 15 used in a domestic situation A 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 equip ment 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 NOTE The welding circuit may or may not be ea
25. 1 5VDC OUTPUT CONTROL SIGNAL 55 YELLOW 2 TO 015 PING 2 2 S 5 8 5 s 9 RED o 1 PWM RETURN 2 5 3 gt 2 PWM MOTOR DRIVER 5VDC 2 o e D 8 d 2 9 FIT 5 24VDC 1 4 24VDC z 5 et lt GND 2 2 GND 5 24VDC 3 3 24VDC a LM 79 2 9 o 5 n N 15 1 AME IGBT Driver 2 WHITE 2 IGBT Driver WHITE Ww IGBT Driver 3 3 IGBT Driver IGBT Driver B 4 K 4 IGBT Driver B IGBT Driver A 5 5 IGBT Driver A Over Current Signal 6 6 Over Current Signal WHITE GND 7 K 7 GND Q N Nl 3 2 BEACK 1 OUTPUT 8 d 9 BER K 3 OUTPUT 9 a m 55628 gt lt 5 2 G gt 5 gt d ER E 1 15 9 9 5 gt 5 YELLOW x m E 835359 3922 2 3 Current Feedback 5 21 8 95 S 22925 52 a 4 GND Zh Nd 28 2 2 52485 8 4 MB On ho HM ch GUN l AYYY YYYY Y YY Y YY Ye 2 o c c c 5 AA AKRAKRAKAAKRKA pu Q gt Display PCB4 Power Fault A MIG Process gt LOCAL O LIFT TIG REMOTE lt STICK REMOVE AMPS WIRESPEED WIPER 8 REMOVE VOLTAGE POT WIPER 7 TORCH SWITCH RIN 0VDC 6 TORCH SWITCH RIN 0VDC 5 SPOOL GUN 2VDC 4 TORCH SWITCH RIN 0VDC 3 TORCH SWITCH 24V 2 SPOO
26. 2 INTRODUCTION 2 01 How To Use This Manual To ensure safe operation read the entire manual includ ing the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular atten tion to the information provided under these headings These special annotations are easily recognized as follows WARNING A WARNING gives information regarding possible personal injury CAUTION A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concern ing certain operating procedures 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 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 control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page for future reference Manual 0 5226 2 03 Receipt Of Equipment When you receive the equipment check it agai
27. ETY OR PERFORMANCE OF ANY THERMAL 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 OF WARRANTY JANUARY 2011 In accordance with the warranty periods stated below Victor Technologies 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 Victor Technologies welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment Victor Technologies 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 211i Component Warranty Period MIG Gun Electrode Holder Lead amp Work Lead 3 Months MIG Gun Consumables If warranty is being sought Please contact your Victor Technologies product supplier for the w
28. IHERMAL MULTI PROCESS WELDING INVERTER Art 11188 Revision AB Issue Date March 4 2013 Manual No 0 5226 Operating Features INVERTER m 200 CC 110 nda IHERMAL 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 network 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 while 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 man
29. ING 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 sta tionary support to prevent falling or tipping Manual 0 5226 4 11 OPERATION FABRICATOR 2111 OPERATION CAUTION 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 Weld ing Power Source shielding Gas Hose Fitted with Quick Connect Q Positive Welding Terminal Negative Welding Terminal A MIG Gun Work Lead Ei RN Art A 10430_AB Figure 4 13 Setup for MIG Welding with Gas Shielded MIG Wire OPERATION 4 12 Manual 0 5226 OPERATION FABRICATOR 2111 4 10 Setup for MIG FCAW Welding with Gasless MIG Wire A Select MIG mode with the process selection control refer to Section 4 01 13 for further information B Connect the MIG polarity lead to the negative welding terminal If in doubt consult the electrode wire manu facturer 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 elect
30. L GUN 0V 1 3 15 Trigger Amps Wirefeed Display Volts Display 2T Normal Ki 4T Latch Volts Wirefeed Amps Down Slope Arc Arc Control o 1 joods 9joUJ8H 8 5 lt 5 Art 11233 Manual 0 5226 919 TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING 5 14 Main Circuit Description 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 The mains supply voltage is connected via a double pole switch to the input rectifier Q1 through an EMC filter Overvolt age protection is provided by varistor The rectifier output charges the main capacitor bank C16 C17 C18 C19 C22 and C23 to high voltage Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds The primary igbt transistors T1 T2 T4 and T5 switch the transformer primary at high frequency and varying duty cycle The transformer return wire is taken from the junction of the capacitors C20 and C21 the voltage at this point is approximately half the DC bus voltage secondary output voltage from the transformer is rectified by the output diodes 113 114 T15 T16 T17 118 119 and 120 to DC This DC is controlled by the PWM of the primary side igbt transistors and
31. R 2111 C 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 its 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 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 Welding Cables The welding cables should be kept as short as possible and should be positioned close together but never coiled and running at or close to the floor level 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 c
32. ad 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 OPERATION 4 2 Manual 0 5226 FABRICATOR 2111 CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 8 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 gun the MIG 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 A CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 9 Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source To make connections align keyway insert plug and rotate threaded collar fully clockwise Negative Positive
33. al 6 4 Pre RE 6 5 6 06 Power Switch 51 and Power Cord 6 6 6 07 Base Panel 6 SECTION 7 ASSEMBLY PROCEDURES 7 1 7 01 installing Base Bodi 7 1 1 02 7 2 1 03 Installing Front Panel nnne 7 3 7 44 Installing Main Control Panel and Clear Cover Sheet 7 4 7 05 Installing Case 7 6 SECTION 8 KEY SPARE PAB IS tue eua rra eom ri na S rr te aa 8 1 9 01 Power Source Spare Parts teo 8 1 SECTION 9 OPTIONAL ACCESSORIES 9 1 9 01 Optional E 9 1 THERMAL LIMITED WARRANTY TERMS TERMS OF WARRANTY JANUARY 2011 SAFETY INSTRUCTIONS FABRICATOR 2111 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and wel
34. anual 0 5226 919 TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING 0 VDC Table 5 45 OT2 Header pin function connects to NTCS header on inverter PCB MBHeaderPin Pinfuntion 0 serial display data amp eprom D IN Volts setpoint Inductance pot terminal 1 Amps setpoint 5VDC UV Table 5 46 MB Header pin function connects to J12 header on display PCB 5 11 DIP Switch Settings Control PCB 1 DIP Switch SWO control PCB ew CJI 029 short sh or t gt C97 S UL AT 8 ib e LLI R12 8 R75 d __ LJ d a o 013 2 N W2 Art A 10757 SWO No SWO Position Set to OFF for Fabricator 2111 Set to ON for Fabricator 2111 Table 5 47 SWO Dip Switch Position TROUBLESHOOTING 5 16 Manual 0 5226 TROUBLESHOOTING 5 12 Calibration 1 Calibration yum l 18 Lu B 1 a n aUL FT MUN W2 FABRICATOR 211i Art A 10757_AB Set SWO position 1 to ON while the power source is turned off to allow calibration of output volts amp amps 2 Output Current Calibration Select STICK mode on the front panel Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0 2V of the measured value Connect a load to the output terminals The
35. apid wear of mechanical WIREFEED parts overheating of electrical componentry and possibly an Increased incidence of electrode wire Burnback into contact tip Ny opool Hub Tension Thumb Screw Art A 10429 Figure 4 12 Wire Reel Brake 4 09 Setup for MIG GMAW Welding with Gas Shielded MIG Wire A B select MIG mode with the process selection control refer to Section 4 01 13 for further information Connect the MIG polarity lead to the positive welding terminal If in doubt consult the electrode wire manu facturer 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 Fit the MIG gun to the power source Refer to section 4 02 Attaching MIG gun 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 Fitthe welding grade shielding gas regulator flowmeter to the shielding gas cylinder then connect the shielding gas hose from the rear of the power source to the regulator flowmeter outlet Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information WARN
36. arcing of PCB transformers switches or rectifier when a failure occurs Carefully inspect all components within these units Look in particular for the following a Loose or broken wires or connectors b Burned or scorched parts or wires or evidence of arcing Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list of components used in the Power Source Locate the faulty component s then replace where necessary Manual 0 5226 a TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING 5 06 Preliminary DC Bus Measurement of the Main Inverter Board WARNING Check DC bus voltage has discharged to less than 5VDC before servicing Ensure the mains supply plug is disconnected from receptacle MMM LL IL JL JL LI 8 ef vs _ Art A 10750 DC Bus Testing Multimeter Lead Placement Voltage with Supply Voltage OFF capacitor bank Positive meter lead to testpoint 1 ii Negative meter lead to testpoint 2 Positive meter lead to testpoint 2 Negative meter lead to testpoint 3 Table 5 5 DC BUS Multimeter set to measure DC volts Lower capacitor bank 0 VDC TROUBLESHOOTING 9 6 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 5 07 Preliminary Check of the Main Inverter Board and follow safety information in Section 5 03 before pro
37. arranty repair procedure Victor Technologies warranty will not apply to e Equipment that has been modified by any other party other than Victor Technologies s own service person nel or with prior written consent obtained from Victor Technologies Service Department Equipment that has been used beyond the specifications established in the operating manual e 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 Victor Technologies com select your product class and then select literature Here you will find documentation including e Operator manuals e Service manuals e Product guides Alternatively please contact your Victor Technologies distributor and speak with a technical representative NOTE Warranty repairs must be performed by either a Victor Technologies Service Centre a Victor Technologies distributor or an Authorised Service Agent approved by the Company THE AMERICAS Denton TX USA U S
38. as Connect shielding gas Wind blows shielding gas away Shield welding area from draughts Incorrect TIG tungsten electrode Use correct tungsten type Poorly prepared or worn TIG Regrind tungsten to correct tungsten shape Table 5 2 Power Source Faults 5 02 Routine Service and Calibration Requirements 1 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 Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling Routine Inspection Testing amp Maintenance The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc s original specifications 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 includ ing the date of the most recent inspection A transportable 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 TROUBLESHOOTING
39. ave been insulated 3 04 Location Be sure to locate the welder according to the following guidelines In areas free from moisture and dust Ambient temperature between 0 C 32 F 40 C 104 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 1 foot 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 235 as outlined in EN 60529 mmo UD gt 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 A Wi WARNING This equipment should be electrically connected by a qualified electrician WARNING Since the inhalation of welding fumes can be harmful ensure that the welding area is effectively ventilated 3 05 Ventilation Manual 0 5226 3 3 SAFETY INSTALLATION FABRICATOR 2111 SAFETY INSTALLATION 3 06 Mains Supply Voltage Requirements The Mains supply voltage should be within 15 of the rated Mains supply voltage Too low of a supply voltage may cause poor welding performance or wirefeeder malfunction Too high of a supply voltage will cause components to overheat and possibly fail WARNING The Fabricator 211i must be electrically conne
40. ceeding 8 US TUODA A mmg ICE ERN Ate Hi 7 rn nnn C ll m E nnn cci oft Spe TIE m Art A 10751 Multimeter Lead Placement Table 5 6 IGBT s Multimeter set to measure Diode Voltage Teer Testing Multimeter Lead Placement Ohms _ IGBT V8 amp 6 1 Positive meter lead to testpoint 4 gt 1500 IGBT T1 amp T2 Positive meter lead to testpoint 5 gt 150 IGBT T4 amp T5 Positive meter lead to testpoint 7 gt 1500 1 Table 5 7 IGBT s Multimeter set to measure ohms Inrush Resistor Multimeter Lead Placement m Resistor Positive meter lead to testpoint 8 Negative meter lead to testpoint 9 Table 5 8 Inrush Multimeter set to measure ohms 0 Manual 0 5226 9 7 TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING Positive meter lead to testpoint 10 Negative meter lead to testpoint 11 DIODE T18 T19 T20 21 0 2 0 8 VDC Negative meter lead to testpoint 13 0 2 0 8 VDC Negative meter lead to testpoint 15 Table 5 9 Diodes Multimeter set to measure Diode Voltage 5 08 Check Main Input Rectifier e 9099 el ese UE Gd in e TEC nnn MMA LI eo mE eec
41. ch the unit off should a thermal overload condition be present Digital Amps Meter Left Digital Display Mode This digital meter is used to display the pre set preview Wirefeed Speed in Meters Per Minute MPM in MIG mode and actual welding amperage of the power source when welding At times of non welding the digital meter will display a pre set preview value of Wirefeed Speed This value can be adjusted by varying the Amperage Control Knob 4 STICK and LIFT TIG Modes The digital meter is used to display the pre set preview amperage in STICK LIFT modes and actual welding amperage of the power source when welding At 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 Manual 0 5226 4 1 OPERATION FABRICATOR 2111 OPERATION When welding this digital meter will display actual welding amperage in all modes At the completion of welding the digital 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 pr
42. cted by a qualified electrical trades person Damage to the PCA Power Control Assembly could occur if 276 VAC or higher is applied to the Primary Power Cable 50 60 Hz Primary Supply Minimum Minimum Current amp Duty Cycle Single Phase Lead Size Primary Current Plug Size TIG STICK Circuit Size Vin lin 230V 15A 20 210 25 200A 25 200A 110V 32A 20 140A 35 150 25 125 Table 3 2 Input Power Source Leads for Fabricator 2111 yl WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lock out tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting OFF and red tagging circuit breaker or other disconnecting device Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power source The Welding Power Source must be Correctly installed if necessary by a qualified electrician Correctly earthed electrically in accordance with local regulations Connected to the correct size power point fuse and primary supply lead based on Table 3 2 WARNING Any electrical work must be carried out by a qualified Electrical Tradesperson SAFETY INSTALLATION 3 4 Manual 0 5226 SAFETY INSTALLATION FABRICATOR 211i 3 07 E
43. ctrode and Work circuit 15 electrically live when 8 Do use worn damaged undersized or poorly ever the output is on The input power cir spliced cables cuit and machine internal circuits are also live when power is on In semi automatic 9 Do not wrap cables around your body or automatic wire welding the wire wire 10 Ground the workpiece to a good electrical earth reel drive roll housing and all metal parts ground touching the welding wire are electrically uu live Incorrectly installed or improperly 11 Do not touch electrode while in contact with the grounded equipment is a hazard work ground circuit 1 Do not touch live electrical parts 12 Use only well maintained equipment Repair or replace damaged parts at once 2 Wear dry hole free insulating gloves and body protection 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with 3 Insulate yourself from work and ground using dry a voltage reducer Use equipment with DC output insulating mats or covers 14 Wear safety harness to prevent falling if working 4 Disconnect input power or stop engine before above floor level installing or servicing this equipment Lock input power disconnect switch open or remove line 19 Keep all panels and covers securely in place fuses so power cannot be turned on accidentally 9 Properly install and ground this equipment according to its Owner s Manual and
44. d 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 OPERATION 4 4 Manual 0 5226 OPERATION FABRICATOR 2111 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the opera tor 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 realised thus eliminating the need for the operator to hold the torch trigger Note that when operating in LIFT TIG GTAW mode the power source will remain activated until the selected downslope time has elapsed refer Item 10 13 Process Selection Control The process selection control is used to select the desired welding mode Three modes are available MIG GMAW FCAW LIFT TIG GTAW and STICK MMA modes Refer to section 4 10 4 11 for MIG GMAW FCAW set up details section 4 12 for LIFT GTAW set up details or section 4 13 for STICK set up details Note that when the unit is powered off the mode selection control will automatically default to 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 14 Digital Voltage Meter Right Digital Display Mode This digital meter is used to dis
45. ding gas regulator flowmeter to the shielding gas cylinder then connect the shielding gas hose from the 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 LIFT TIG mode therefore the TIG torch will require a gas valve Z WARNING Before connecting the work clamp to the work and inserting the electrode in the Torch make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder 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 Weld ing Power Source Loose welding terminal connections can cause overheating and result in the male plug being fused the terminal Manual 0 5226 4 15 OPERATION FABRICATOR 2111 Positive Welding Terminal e Work ef o 1 as Negative Welding Terminal Ze TIG Remote Control 7 Torch 10482 Figure 4 16 Setup for TIG Welding OPERATION 4 16 OPERATION Manual 0 5226 FABRICATOR 2111 4 13 Setup for STICK Welding A Connect Electrode Holder lead to the positive welding terminal If in doubt consult the el
46. ding 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 oafe 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 oafe 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 out of service 7 Use fully insulated electrode holders Never dip WARNING holder in water to cool it or lay it down on the ground the work surface Do touch holders ELECTRIC SHOCK can kill connected to two welding machines at the same Touching live electrical parts can cause time or touch other people with the holder or fatal shocks or severe burns The electrode ele
47. e gt gt WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handles built into the top of the front and rear moulded panels Use handcart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting INTRODUCTION 2 INTRODUCTION 2 07 Packaged Items Fabricator 211i Power Source Part No W1004206 Fabricator 211i Inverter Power Source Shielding Gas hose assembly Operating Manual Fabricator 211i System Part No W1004207 Fabricator 211i Inverter Power Source Feedrolls 0 6 0 8mm V groove fitted 0 9 1 2mm V groove 1 0 1 2mm U groove 0 8 0 9mm V knurled MIG gun 3m long e Electrode Holder with 4m lead e Work Clamp with 4m lead Shielding Gas hose assembly Operating Manual Figure 2 1 Fabricator 2111 System Packaged W1004207 Manual 0 5226 SAFETY INSTALLATION FABRICATOR 211i SECTION 3 SAFETY AND INSTALLATION 3 01 Duty 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 duty cycle period the following example is used Suppose a Welding Power Source is designed to oper ate at a 20 duty cycle 210 amperes at 24 5 volts This means that it has been de
48. ectrode manu facturer 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 C Select STICK mode with the process selection control refer to Section 4 01 13 for further information A 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 CAUTION 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 4 Electrode Holder Negative Welding A SS Terminal Work Lead Art A 10433 Figure 4 17 Setup for Manual Arc Welding Manual 0 5226 4 17 OPERATION FABRICATOR 2111 OPERATION 4 14 Leak Testing the System Leak test the system before putting into operation 1 that there is a valve in the downstream equipment to turn off the gas flow 2 With the cylinder valve open adjust the regulator to deliver the
49. er Where exact settings are required the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate 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 4 10 set up details AN WARNING Only Inert Shielding Gases specifically designed for welding applications should be used Manual 0 5226 4 5 OPERATION FABRICATOR 2111 OPERATION 16 0n Off Switch This Single Phase circuit breaker performs a dual function It is used to turn the unit on off and it will also trip in the event of a fault WARNING When the front digital displays are lit the machine is connected to the Mains supply voltage the internal electrical components are at Mains voltage potential o eis Art A 10938 Figure 4 4 Wire Feed Compartment Control 17 Wiredrive Motor Circuit Breaker The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload NOTE circuit breaker trips a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button 18 Local Remote Switch located in wirefeed compartment The local remote switch is used only when a remote control device such as torch with rem
50. ese instructions thoroughly before using the unit INTRODUCTION FABRICATOR 2111 2 05 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 ap proval of Thermal Arc The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modifica tion from standard specification faulty maintenance damage or improper repair by anyone other than ap propriately qualified persons approved by Thermal Arc 2 06 Transportation Methods This unit is equipped with a handle for carrying pur poses Du 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 sourc
51. eview mode NOTE The preview functionality provided on this power source is intended to act as a guide only Some dif ferences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transfer Where exact settings are required In the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate 4 Amperage Control Wirespeed The amperage control knob adjusts the amount of welding current delivered by the power source In STICK and LIFT GTAW modes the amperage control knob directly adjusts the power inverter to deliver the desired level of output current In MIG GMAW FCAW mode 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 NOTE The preview functionality provided on this power source is intended to act as a guide only Some dif ferences may be observed between preview values and actual welding values due to fac
52. front panel WIRESPEED AMPS potentiometer to maximum AMPS display should read 218 Adjust W05 trimpot until motor volts are 24 V 0 2V or motor feedroll shaft speed is 191rpm Recheck settings Turn Mains power off amp allow power supplies to discharge oet SWO position 1 to OFF while the power source is turned off to resume normal power source operation TROUBLESHOOTING 5 18 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 5 13 Circuit Diagram T 5 79 N gg Se 2 5 lt gt Q aa PU D 2 S a 009500 J9Mog UIEN JopaojoutM qas ber eer aas 209500 NND 100446 ser 10045 NNO S Xd 82d BLACK 24CDC 1 N A 2 WHITE WHITE 1104 076700 MOTI3A aas vr L yyy Nr WY SOd 2 92 sr 0 84 WARY d e lt 5 c 8 5 9 gt E Q pcs D 5 637 lt 9 5 ki 9 n 24 3 E Q A lt lt L7 lt 8 c c 548 als INPUT 230V 115V lt
53. g the integrity of 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 accessories supplying transportable equipment at least once every 3 months and 2 Foroutlets wiring and associated accessories supplying fixed equipment at least once every 12 months D General Maintenance Checks Welding equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure that 1 Flexible 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 accredited Thermal Arc Service Provider Manual 0 5226 9 9 TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING Power Source Calibration A Schedule Output testing of all Thermal A
54. g the System 4 18 TABLE OF CONTENTS SECTION 5 TROUBLESHOOTING 5 1 5 01 Basic Troubleshooting Power Source 5 1 502 Routine Service and Calibration 5 2 5 03 Check Unit before Applying ower 5 4 5 04 Test Equipment and Tools Needed for Troubleshooting and Servicing 5 5 US ASA HUE 5 5 5 06 Preliminary DC Bus Measurement of the Main Inverter 5 6 5 07 Preliminary Check of the Main Inverter Board 5 7 5 08 Check Input Rechter 5 8 509 DC Bus Voltage Measurement 20 1 4 5 9 5 10 5 11 DIP Switch Settings Control EE 5 16 SAPE RE 5 17 5 13 Circuit Diagram 5 19 514 Circuit Description 02 042 0 1 1441 5 20 SECTION 6 DISASSEMBLY PROCEDURE 6 1 6 01 safety Precautions for Disassembly me 6 1 6 02 Control Board Removal nnne 6 2 6 08 Front Panel Assembly 6 3 6 04 Front Panel Operator Interface Circuit Board PCB3 Remov
55. h 27mm wrench Reconnect positive output terminal bolts and tighten with 17mm wrench Note reconnect wires pay attention to the wire colour Reconnect negative output terminal bolts and tighten with 17mm wrench note reconnect wires and attention to the wire colour 2 Place front panel PCB assembly into front panel and install screws 3 Reconnect Front Panel screws IHERMAL ARC MULTI PROCESS WELDING SYSTEM THERMAL ARC Tr m Art 11192 Manual 0 5226 7 3 ASSEMBLY PROCEDURES FABRICATOR 2111 ASSEMBLY PROCEDURES 1 04 Installing Main Control Panel and Clear Cover Sheet Refer to diagram on page 7 5 Install 4 screws Plug harness into DRIVE connector Plug harness into SOURCE connector Plug harness into CR connector Plug harness into FUNs connector Plug harness into m IGBT OT2 connector Plug harness into IGBT OT1 connector Plug harness into GUN connector N O A Plug harness into QF DY connector 10 Plug harness into WVIN connector 11 Plug harness into MB connector 12 Plug harness into JC connector 13 Plug harness into PWM connector 14 Plug harness into IFB connector Verify harness connections with the system schematic to insure all connections are correct 15 Install clear protective sheet ASSEMBLY PROCEDURES 7 4 Manual 0 5226 ASSEMBLY PROCEDURE FABRICATOR 2111 6 dE 2002 SH ilis za
56. h the alignment pin on the spool hub Insert the locking pin back into the spool hub Retaining Clip Fibre Washer Use inner holes on 300mm Wire Spool Spool Hub N in Flat Washer Wire Spool Large Hole Hub Nut N 20 Flat Washer Keyed Washer 5200 um Small Hole Spring Art A 10939 Figure 4 6 300mm 15kg Spool Installation 4 04 Installing 5kg Spool 200mm diameter Remove the locking pin from the spool hub Install the 5kg Spool over the spool hub locating the hole in the 5kg Spool with the alignment pin on the Spool Hub Insert the locking pin back into the spool hub in the rear position as shown ensuring the wire spool is firmly Secured in position Fibre Washer Retaining Clip 200mm Use inner holes on Wire Spool Spool Hub Flat Washer Wire Spool Large Hole Hub Nut SC 29 m E NV Flat Washer Keyed Washer Small Spring Art A 10940 Figure 4 7 200mm 5kg Spool Installation OPERATION 4 8 Manual 0 5226 OPERATION FABRICATOR 211i 4 05 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 4 8 With the MIG welding wire feeding from the bottom of the spool Figure 4 9 pass the electrode wire through
57. heated A Allow unit to cool with fan output and the yellow running until over temperature B C There is no weld The internal protection circuit to shut Check to see if mains supply output and all front the unit down if the mains supply voltage is 2 4VAC A panel displays are off voltage is too high has operated generator with poor voltage over temperature light light extinguishes is on Remove blockages from airflow ducts Replace fan Check fan wiring header is plugged securely into Control board Check fan wiring is not damaged 4 Mode switch does not Faulty Display board Replace Display board change welding mode The wirefeed motor A Internal wiring fault A Check continuity of internal and the weld output wiring from Torch adaptor do not operate when through to boards the torch trigger Over temperature light is on Allow unit to cool switch is depressed Power Source set to REMOTE C Set switch to LOCAL D Trigger wires shorted to weld voltage ir tri Ires inside torch E Trigger wires or torch switch faulty F Faulty Power Inverter board G Faulty Control board Faulty Display board The wirefeed motor Power Source set to TIG or STICK does not operate mode B Airflow inlet or outlet ducts are blocked Fan does not operate E Check Repair F Replace Power Inverter board Replace Control board Replace Display board Set power Source to MIG mode Check motor wiring Wirefeeder motor
58. hnologies Europe Europa Building Chorley Industrial Park Lancaster England PR6 BX www thermalarc com Copyright 2013 by Victor Technologies International Inc 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 March 07 2012 Revision Date March 4 2013 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial 7 TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 E 1 1 1402 Principal Safety STAG AGS E 1 5 IEEE uo 1 6 1 7 105 1 8 LOG 1 10 SECTION 2 2 1 2 01 HOW T0 Use This Manual E 2 1 2092 EELER ENEE 2 1 Receipt USO ETE 2 1 2 1 2 05 User Responsibility RR RR 2 2 2 06 Transportation 1 5 2 2 2 2 SECTION 3 SAFETY AND
59. 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 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 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 SAF
60. ion connects to MB header on control PCB Manual 0 5226 2 13 TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING R GHeaderPin 0 2 Spool gun motor negative 24 VDC 24V trigger positive OV when trigger closed 0VDC Spool gun motor 8 1 Remotevits 20 2 00 Sigal Motor negative 0 VDC Motor positive 24 VDC _ Sign OVDC 15 VDC Table 5 33 15V Header pin function connects to 15V header on motor PCB 4 Control PCB DRIVE Imax Imin SOURCE CR de R75 Q T5 d m a e 013 2 N W2 42 C44 Vmin PWM B Art A 10756 SWO 24 trigger positive 0 when trigger closed OVDC Table 5 34 GUN Header pin function connects to GUN header on display PCB PWM Header Pin Signal OVDC Motor pwm drive signal Table 5 35 PWM Header pin function connects to PWM header on inverter PCB PFC Header Pin Signal _____ OK signal 1 PFC OK Table 5 36 PFC Header pin function connects to JC header on inverter PCB TROUBLESHOOTING 9 14 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 QF DYHeaderPin Pin function _ Sign 2 Solenoidnegative 22 424 solenoid positive 24700 __ MEM oM Table 5 37 QF FJ Header pin function Connects to QF FJ header on inverter PCB FUNs Header Pin
61. lectric 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 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 coherent frame work 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 Arrange cables to one side and away from the operator Do not coil or drape cable around the body Keep welding Power Source and cables as far away from body as practical 9 5 ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information Manual 0 5226 FABRICATOR 2111 1 02 Principal Safety Standards safety in Welding and Cutting ANSI Standard 749 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 safety and
62. lectrical Input Connections WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lock out tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device e Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power supply The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit Do not connect an input WHITE or BLACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal 1 Connection end of ground GREEN or GREEN YELLOW conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of active BROWN and Neutral BLUE input conductors to a suitable power supply system that complies
63. load should be of a resistance to give 25V at 250A oet front panel AMPS potentiometer to minimum Adjust Imin trimpot until output amps is 10A 0 2A oet front panel AMPS potentiometer to maximum Adjust Imax trimpot until output amps is 200A 1A Recheck settings oet front panel AMPS potentiometer to maximum Adjust A potentiometer so Amps display reads within 0 5A of the measured value 3 Output Voltage Calibration select MIG mode on the front panel Remove the load from the output terminals oet front panel VOLTS potentiometer to minimum Adjust Vmin trimpot until output volts is 14 0V 0 2V oet front panel VOLTS potentiometer to maximum Adjust W2 trimpot until output volts is 26V 0 2V Recheck settings Manual 0 5226 9 17 TROUBLESHOOTING FABRICATOR 2111 TROUBLESHOOTING 4 Wire Speed Calibration NOTE these adjustments are on the wiring side of the main inverter module circuit board wo2 WO05 raa wd MMM cm LJLIL IL IL 111 eo nb LIL ILI LI e 9 LIJLILILILILILILIL IL o o 0 Art A 10758 select MIG mode on the front panel Remove the load from the output terminals set MIG output voltage to maximum set front panel WIRESPEED AMPS potentiometer to minimum AMPS display should read 30 Adjust 02 trimpot until motor volts are 4 2V 0 2V or motor feedroll shaft speed is 2 rpm oet
64. nd energized unit have only personnel familiar with and following standard safety practices do the job When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free Disconnect input power conductors from de energized supply line BEFORE moving a welding power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverters disconnect input power and discharge input capacitors according to instruc tions in Troubleshooting Section before touching any parts 79 lt gt WARNING STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS Use proper static proof bags and boxes to store move or ship PC boards WARNING FIRE EXPLOSION hazard Do not place unit on over or near combustible surfaces Do not service unit near flammables ah WARNING FLYING METAL or DIRT can injure eyes Wear safety glasses with side shields or face Shield during servicing Be careful not to short metal tools parts or wires together during testing and servicing WARNING HOT PARTS can cause sever burns Do not touch hot parts bare handed Allow cooling period before working on equip ment To handle not parts use proper tools and or wear heavy insulated welding gloves and cloth WARNING EXPLODING PARTS can cause inju
65. nd the transfer mode of the welding arc dip versus spray transfer Where exact settings are required the case of procedural work it 15 recommended that alternate measurement methods be utilised to ensure output values are accurate When MIG GMAW FCAW 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 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 When STICK MMA Mode is Selected In this mode the multifunction control knob is used to adjust arc force Arc force control provides an adjust able 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 LIFT TIG Mode is Selected In this mode the multifunction control knob is used to adjust down slope Down slope allows the u
66. ns 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 WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire WARNING Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Manual 0 5226 9 FABRICATOR 2111 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Bealertthat welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Beaware 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 w
67. nsions Power Source Mass Cooling Welder Type Applicable Standard Number of Phases Nominal Supply Voltage Nominal Supply Frequency Welding Current Range MIG Mode Wirefeed Speed Range Effective Input Current Maximum Input Current max single Phase Generator Requirement MIG GMAW FCAW Welding Output 40 C 10 210A 20 24 5V 140A 20 21V min 130A 60 20 5V 99A 60 19V 101A 100 19 1V 77A 100 17 9V STICK MMA Welding Output 40 C 10 min 200A 25 28 0V 125A 25 25 0V 130A 60 25 2V 80A 60 23 2V 101A 100 24 0V 60A 100 22 4V TIG GTAW Welding Output 40 C 10 min 200A 25 18V 150A 35 16V 130A 60 15 2V 115A 60 14 6V 101A 100 14 0V 90A 100 13 6V Open circuit voltage Protection Class IP23S Table 3 1 Fabricator 211i Specifications Note 1 The Effective Input Current should be used for the determination of cable size amp supply requirements Note 2 Motor start fuses or thermal circuit breakers are recommended for this application Check local re quirements for your situation in this regard Note 3 Generator Requirements at the Maximum Output Duty Cycle NOTE Additional safety precautions may be required when using unit in an environment with increased haz ard of electric shock Please refer to relevant local standards for further information prior to using in such areas Due to variations that can occur in manufactured products claimed perf
68. nst 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 immediately to file a claim Furnish 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 identification numbers as de scribed above along with a full description of the parts error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 04 Description The Thermal Arc Fabricator 211i is a self contained single phase multi process welding inverter that is ca pable of performing MIG GMAW FCAW STICK and LIFT GTAW welding processes The unit is equipped with an integrated wire feed unit digital volt age and amperage meters and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional unit is also fully compliant to Standard EN 60974 1 The Thermal Arc Fabricator 211i provides excellent welding performance across a broad range of applica tions 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 th
69. nt panel EURO adaptor refer also to section 4 02 Attaching MIG gun Connect the 8 pin Remote Control Plug to the 8 pin Remote Control Socket on the power source 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 Fitthe welding grade shielding gas regulator flowmeter to the shielding gas cylinder then connect the shielding gas hose from the rear of the power source to the regulator flowmeter outlet Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information Select MIG mode with the process selection control refer to section 4 01 13 for further information Set the Spool Gun Switch located inside the wire drive compartment to SPOOL GUN AN gt WARNING Before connecting the work clamp to the work make sure the main power supply is switched off Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable sta tionary support to prevent falling or tipping A CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packing material prior to use Do not block the air vents at the front or rea
70. ork cable to the work as close to the welding area as practical to prevent welding current 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 welding wire at contact tip when not in use gt d 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 Noe Z 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 equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition
71. ormance 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 SAFETY INSTALLATION 3 2 Manual 0 5226 SAFETY INSTALLATION FABRICATOR 2111 3 03 Environment This unit is designed for use in environments with increased hazard of electric shock as outlined in EN 60974 1 Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock Please refer to relevant local standards for further information prior to using in such areas A Examples of environments with increased hazard of electric shock are 1 Inlocations 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 2 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 3 In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories B Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator which can cause increased hazard h
72. ote 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 local remote 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 100 output be required the respective front panel control must be set to 100 in which case the remote device will then be able to control between 0 100 output OPERATION 4 6 Manual 0 5226 OPERATION FABRICATOR 211i 19 Burnback Control located in wirefeed compartment The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG gun after the completion of MIG welding commonly referred to as stick out To decrease the burnback time or lengthen the amount of wire protruding from the MIG gun at the completing of welding tu
73. ould 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 Earthing grounding of the Work Piece Where the work piece is not bonded to earth for electrical 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 emis sions in some but not all instances Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work piece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations ecreening 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 Manual 0 5226 3 7 SAFETY INSTALLATION FABRICATOR 2111 SAFETY INSTALLATION 3 09 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 SAFETY INSTALLATION 70 o O O jndjno N OO e O
74. play the pre set preview Voltage mode and actual welding voltage of the power source when welding At times of non welding the digital meter will display a pre set preview value of Voltage This value can be adjusted by varying the Multifunction Control Knob 10 STICK and LIFT Modes This digital meter is used to display the Welding Output Terminal Voltage in STICK LIFT modes during non welding or welding This value cannot be adjusted by varying the Multifunction Control Knob 10 When welding this digital meter will display actual welding voltage 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 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 NOTE The preview functionality provided on this power source is intended to act as a guide only Some dif ferences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transf
75. r of the Welding Power Source Shielding Gas Hose Fitted with Quick Connect legative Welding E polarity lead Terminal Positive Welding 6 N Ee Terminal opool Gun di Art A 10576 Figure 4 15 Setup for Spool Gun Welding with Gas Shielded MIG Wire OPERATION 4 14 Manual 0 5226 FABRICATOR 2111 4 12 Setup for TIG GTAW Welding A B select LIFT mode with the process selection control refer to Section 4 01 13 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 Mode NOTE If the torch has a remote torch current control fitted then it will require to be connected to the 8 pin socket Refer to section 4 01 9 Remote Control Socket for further information Fitthe welding grade shiel
76. r maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do notallow tools to cause sparks when working on a battery Do use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries ra p WARNING STEAM AND PRESSURIZED HOT can burn face eyes and skin The coolant in the radiator can be very hot under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing cap Allow pressure to escape before completely removing cap Manual 0 5226 SAFETY INSTRUCTIONS NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields 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 E
77. rc 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 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 5 4 below shall be conducted by an accredited Thermal Arc service agent Testing Requirements Output current A to be checked to ensure it falls 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 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 specifications Table 5 4 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 conduc
78. rn the burnback control knob anti clockwise To increase the burnback time or shorten the amount of wire protruding from the MIG gun at the completing of welding turn the Burnback Control knob clockwise 20 MIG Gun SPOOL Gun Switch located in wirefeed compartment MIG Gun SPOOL Gun switch is used to switch welding mode between MIG Gun functionality and SPOOL Gun functionality 21 Cooling Fan The Fabricator 2111 is fitted with a fan as needed feature Fan as needed 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 4 02 Attaching MIG Gun Fit the MIG gun to the power source by pushing the MIG gun connector into the MIG gun adaptor and screwing the plastic nut clockwise to secure the MIG gun to the MIG gun adaptor Gun Adaptor Art A 10423 AB Figure 4 5 Attaching MIG Gun Manual 0 5226 4 7 OPERATION FABRICATOR 2111 4 03 Installing 15kg Spool 300mm diameter As delivered from the factory the unit is fitted with a Wire Spool Hub which accepts a Spool of 300mm diameter Remove the locking pin from the spool hub Install the wire spool over the spool hub locating the hole in the spool wit
79. rode 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 D 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 CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused the terminal Remove any packaging material prior to use Do not block the air vents at the front or rear of the Weld ing Power Source MIG Gun Negative Welding Terminal MIG Polarity Lead Terminal 4 Work Lead Art A 10431 AB Manual 0 5226 4 13 OPERATION FABRICATOR 211i OPERATION 4 11 Setup for SPOOL GUN MIG GMAW Welding with Gas Shielded MIG Wire A select MIG mode with the process selection control refer to Section 4 01 13 for further information Connect the MIG polarity lead to the positive welding terminal If in doubt consult the electrode wire manu facturer 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 Fit the Euro Spool Gun to the power source using the fro
80. rthed for safety reasons Changing the earthing arrangements should only be authorized 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 B 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 Radio and television transmitters and receivers Computer and other control equipment oafety critical equipment e g guarding of industrial equipment The health of people around e g the use of pace makers and hearing aids Equipment used for calibration and measurement The time of day that welding or other activities are to be carried out use x 20 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 structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises SAFETY INSTALLATION 3 6 Manual 0 5226 SAFETY INSTALLATION FABRICATO
81. ry Failed parts can explode or cause other parts to explode when power 1 applied to inverters Always wear a face shield and long sleeves when Servicing inverters WARNING SHOCK HAZARD from testing Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections Use at least one meter lead that has a self retaining spring clip such as an alligator clip Read instructions for test equipment Manual 0 5226 SAFETY INSTRUCTIONS WARNING FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit we WARNING MOVING PARTS can cause injury Keep away from moving parts such as fans Keep away from pinch points such as drive rolls Have only qualified persons remove doors panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power S WARNING MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away from servic ing areas until consulting their doctor and the device manufac
82. se electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them or using a cable cover Arrange cables to one side and away from the operator Do not coil or drape cables around your body Keep welding power source and cables as far away from operator as practical qe Connect work clamp workpiece as close to the weld as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before perform ing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recommended SAFETY INSTRUCTIONS AND WARNINGS 1 10 Manual 0 5226 INTRODUCTION FABRICATOR 2111 SECTION
83. ser 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 slope 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 11 Arc Control Inductance The arc control operates MIG GMAW FCAW 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 12 Trigger Mode Control MIG and LIFT TIG Mode only The trigger mode control is used to switch the functionality of the torch trigger between 2T normal and 4T latch mode 2T Normal Mode In this mode the torch trigger must remain depresse
84. signed and built to provide the rated amperage 210A 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 allowed to cool The thermal cut out will operate if the duty cycle is exceeded 100 90 Lu FABRICATOR 2111 op lt 70 T TIG 50 E o 40 gt 30 SAFE OPERATING REGION l MIG TIG amp STICK 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 Welding Current AMPS Figure 3 1 Fabricator 211i Duty Cycle 220VAC 100 90 FABRICATOR 211i H 80 N TIG STICK 70 60 s N S o 50 T lt 40 SR M O 30 gt OPERATING REGION gt TIG amp STICK 4 5 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Welding Current AMPS Art A 10936 Figure 3 2 Fabricator 211i Duty Cycle on 110VAC Manual 0 5226 3 1 SAFETY INSTALLATION FABRICATOR 2111 SAFETY INSTALLATION 3 02 Specifications Description Power Source Plant Part No Power Source Dime
85. the National legislation for the enforcement of this Directive serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CENELEC EN50199 EMC Product Standard for Arc Welding Equipment e ISO IEC 60974 1 BS 638 PT10 60 974 1 50192 EN50078 applicable to welding equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the 5 mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications WARNING e 2002 95 EC RoHS directive 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
86. the inlet guide between the rollers through the outlet guide and into the MIG gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 4 8 Remove the contact tip from the MIG gun With the MIG gun lead reasonably straight feed the wire through the MIG gun by depressing the trigger switch Fit the appropriate contact tip 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 feed through the system Keep MIG gun away from eyes and face Burnback Wire Drive Tension Screw Pressure Roller Arm Art A 10426 Inlet Guide Outlet Guide Figure 4 8 Wire Drive Assembly Components MIG Welding Wire Art 10427 Figure 4 9 MIG Welding Wire Installation Manual 0 5226 4 9 OPERATION FABRICATOR 2111 OPERATION 4 06 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 11 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 press
87. ting the measurement in question Only test equipment with valid calibration certificates NATA certi fied laboratories shall be utilized 5 03 Check Unit before Applying Power If the problem cannot be solved by the basic external troubleshooting guide the Power Source cover will have to be removed to allow the technician to analyse failures with a few common tools 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 Checking Unit Before Applying Power Turn SW1 to OFF position and disconnect unit from primary line voltage before working on unit oignificant DC voltage can remain on capacitors after unit is Off Wait until all front panel LED s are off before removing case TROUBLESHOOTING 9 4 Manual 0 5226 TROUBLESHOOTING FABRICATOR 2111 AN Check DC bus voltage according to Section 5 06 after removing case A Before troubleshooting or applying power to unit complete the following checks to avoid causing further damage 5 04 Test Equipment and Tools Needed for Troubleshooting and Servicing Art A 09849 e Digital Multimeter DC clip on ammeter e Screwdriver and spanner e CRO 20 Mhz bandwidth amp isolating transformer 5 05 Visually Inspect Visually inspect the inside of the Power Source The levels of current present in these units can cause burning or
88. tors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transfer Where exact settings are required in the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate 5 MIG Gun Adaptor Euro Style The MIG gun adaptor is the connection point for the MIG welding gun Connect the gun by pushing the gun connector into the brass gun adaptor firmly and screwing the plastic nut clockwise to secure in position To remove the MIG gun simply reverse these directions 6 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 gun via the MIG polarity lead electrode holder lead or work lead Posi tive 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 CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 7 MIG Polarity Lead The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal al lowing polarity reversal for different welding applications In general the polarity le
89. turer NC WARNING OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit V WARNING H F RADIATION can cause interference High frequency can interfere with radio navigation safety services computers and communications equipment Manual 0 5226 FABRICATOR 2111 Have only qualified persons familiar with elec tronic equipment install test and service H F producing units The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference AN WARNING READ INSTRUCTIONS Use Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for welding safety precautions Use only genuine replacement parts from the manufacturer SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 SAFETY INSTRUCTIONS 1 06 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cau
90. ual 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 Victor Technologies International 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 head 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 judgment the Manufacturer assumes no liability for its use Service Manual Number 0 5226 for Thermal Arc Fabricator 211i Inverter Power Supply Part Number 1004206 Thermal Arc Fabricator 211i Inverter System Part Number W1004207 Published by Victor Tec
91. ure screw clockwise WARNING EE Before changing the feed roller ensure that the mains supply to the power source 15 switched off HEX a ee CAUTION use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 4 07 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 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 J GROOVE B GROOVE B SIZE e GROOVE A SIZE A 09583 Figure 4 10 Dual Groove Feed Roller _ Feed Roll Retaining Screw Art A 10428 Figure 4 11 Changing the Feed Roll OPERATION 4 10 Manual 0 5226 FABRICATOR 2111 4 08 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking If itis considered necessary adjustment can be made by turning the Thumb Screw 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 CAUTION Overtension of brake will cause r
92. witch Table 5 24 PP Header pin function connects to Spool Gun Switch 15V Header Pin Sigal OVDC 15VDC Table 5 25 15V Header pin function connects to 15V header on display PCB FUSEHeaderPin Sigal Circuit Breaker Table 5 26 FUSE Header pin function connects to Motor Circuit Breaker TROUBLESHOOTING 5 12 Manual 0 5226 TROUBLESHOOTING FABRICATOR 211i 3 Display PCB R2 201 GI E D 2 E Us ati 83 E E 2 d C23 e m 938 3 s n e 8 G 5 E L4 c 2 6 a n smr e Le Us is iol o m 3 D 9 S o 20 E a 04 e e 5 119 120 24 trigger positive when trigger closed OVDC GUN1 Header Pin ____ ___ OVDC Table 5 28 GUN Header pin function connects to front panel torch trigger terminals REMOTE Header Pin Pin function Signal 24 trigger positive OV when trigger closed Remote switch 2 Remote switch 2 Table 5 29 REMOTE Header pin function connects to remote switch Ji2HeaderPin 1 Sigal ____2 Serial display data LOAD 5VDCdigtal _ 8 Serial display data CLK 5VDCdigtal Serial display eprom D OUT otick mode used for remote local select MODE pushbutton when button pushed Table 5 30 J12 Header pin funct

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