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PORTAFEED® VS 212 Service Manual

1. qe 15 9 Art A 07257 Figure 4 7 Meter Switches 4 4 Manual No 0 4936B PORTAFEED VS 212 3 Using Table 4 1 as a reference carefully slide each white DIP switch up or down to change the meter to the desired function 4 Hold Function Off Wire Feed Speed Displayed Wire Feed Speed in IPM Currently Not In Use DOWN Function Hold Function On Output Current Displayed Wire Feed Speed in MPMiCurrently Not In Use Table 4 1 Lower Meter Switch Settings 4 08 Meter Hold Function The meter hold function is enabled when DIP switch num ber 1 is set to the On position as defined in the tabe above When this function is activated the meter s dis plays are retained for 5 seconds after the last welding operation has ended This provides the time needed for the operator to remove his welding shield and read the meters before the display goes blank 4 09 Operation Hours Display The total number of arc hours that the VS 212 has been operating can be displayed by pressing and holding the small black button located directly above the 4 DIP switches shown in Figure 4 7 The reading is displayed over both meters as follows Ones Hundreths Tenths Art A 07258 Figure 4 8 Displaying Operation Hours For example the above display would be read as 1 234 56 hours Manual No 0 4936B 4 10 Protec
2. ka na 4 1 2 01 Preweldihg PrOCEdUTE na 4 1 4 02 Weldiri cicoria 4 2 4 03 Welding In Mode vs CV Mode essent 4 2 4 04 Theory Of Operation ETT 4 2 4 05 Adjusting Burnback TIM i i4 ya Run ds 4 3 4 06 Wire Feed Sheed RANGES 4 3 4 07 Changing Meter FurlCt OTIS L 4 4 4 08 Mater Hold FUNGO 4 4 4 09 Operation Hours DISPO 4 5 4 10 Protection And Sale VICE 4 5 TABLE OF CONTENTS SECTION 5 MAINTENANCE silla dini 5 1 o 01 Gleaning Of THE mr 5 1 5 02 Cleaning Of The Feed Rolls uiui ciere ets 5 1 5 03 Gas Valve NOIMENAN R lie 5 2 SECTION 6 TROUBLESHOOTING lt lele 6 1 6 01 Troubleshooting Guide 6 1 6 02 Troubleshooting EN 6 1 6 03 Troubleshooting Set up 6 6 2 6 04 Input Voltage amp Power Supply Test ere 6 3 DOS AR AE 6 4 MOST alle 6 5 6 07 Input Voltage amp Power Supply Problems 6 6 5 09 Logic Function PODI 6 6 6 09 Wire Feed iii 6 8 SECTION 7 PARTS LIST eee c 6 1 7 01 Equipment Identification tirarla iaia 6 1 7 02 How To Use This Parts List sciare 6 1 7 03 External 6 2 104 Front MN a an dan aan Dale cou 6 3
3. Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev MN AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer _ _ Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ve travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE lunettes ou casque selon AWS ANSI 749 1 2005 Dimension d lectrode ou Nuance Epiasseur de m tal ou de Intensit
4. Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Operation Thickness or Welding Shade Soierng A 2 Gastungstenarewedim och ang TA Get or Cutting Electrode Size Metal Filter Operation Thickness or Welding Shade Oxygen Cutting Gas Welding Under 1 8 in 3 mm 4o tight 8 12 3 12 May 4 Over 1 2 in 12 mm Plasma Arc Welding Shielded Metal Arc Welding Stick Electrodes ESSA 77777777 Carbon Arc Gouging Under 20 Amp 6108 Light Under 5 32 in 4 mm 2010 100 10 Medium Under 5 32 to 4 to 6 4m 12 Medium 10010400 0ver Kun 64 mm 400 08008101 Gas Metal Arc Welding tight 6010160 Amp 300 to 400 Amp 16010 250 Amp 40010 800 Amp Plasma Arc Cutting Light Under60 Amp 7 Light __under 300 Amo 9 2 Tj Safety and Warnings 1 2 Manual No 0 4936B WARNING FLYING SPARKS AND HOT METAL can cause injury V Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If dama
5. 4 3 Operation PORTAFEED VS 212 The low setting provides greater knob sensitivity but over a narrower range The high setting provides less sensitivity but yields a wider range The ranges are as follows 50 400 ipm 1 27 10 16 mpm 50 800 ipm 1 27 20 32 mpm Low High Art A 07255 Low Range High Range Figure 4 5 Low and High Feed Speed Ranges 4 07 Changing Meter Functions NOTE The VS212 can be ordered with a meter W3512002 or without a meter W3512001 The following 3 sections apply to the meter version The Portafeed VS 212 has two digital meters on the front panel The top meter always displays the welding power supply s voltage output However the lower meter can be set to display either the wire feed speed orthe welding power supply s current output Furthermore when it is set to display the wire feed speed an additional setting can be made to display this parameter in either inches per minute ipm or in meters per minute mpm Refer to Figure 4 6 Operation Voltage Output Wire Feed Speed ipm or mpm or Current Output Art A 07256 Figure 4 6 Digital Meter Functions Changing The Lower Meter Functions 1 Open the VS 212 case door NOTE The power does not need to be turned off to change these settings 2 Locate the 4 white DIP switches on the side of the meter display s printed circuit board Refer to Figure 4 7 ff Hour Display Button
6. Workpiece With i Output Voltage Off Welding Gun Purging Of Gas Continuous Weld D Mode Fee 2 Step Trigger AR Operation Press to initiate wirefeed and welding release to stop 4 Step Trigger Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Inches Per Minute Line Connection Touch Start GTAW MPM Meters Per Minute Auxiliary Power Variable Inductance 115V 15 Receptacle Rating V Input Auxiliary Power HEBES AW RA GA T30 2 lt Introduction 2 Manual No 0 4936B 2 04 General The PORTAFEED VS 212 is a portable solid state controlled voltage sensing wire feeder that operates on arc voltage and can be used with most constant voltage CV and constant current CC DC type power sources The only connection required between the power source and the wire feeder is the welding cable The unique design of this wire feeder allows operation in a constant wire feed speed mode when used with CV power sources and in a voltage sensing wire feed speed mode wire feed speed varies with respect to arc voltage when used with CC power sources The PORTAFEED VS 2125 steel reinforced flame retardant case totally encloses the solid state control circuitry welding wire and wire drive system A hinged latched door allows quick and easy access to the contactor welding wire and feedhead assembly t
7. 4 June 2 2006 PORTAFEED VS 212 18 VOLTMETER J4 11 DISPLAY BOARD PCB3 29 RES 44 10 SWITCH TRIGGER 17 WFS J4 9 MODE SELECTOR SW3 15 WFS J4 8 J2 1 2r 20 WFS POT MAX J4 12 21 WFS WIPER 44 13 142 4 E SWITCH GUN 22 WFS POT MIN J4 14 1 19 MOTOR BOARD ENABLE 44 7 J2 2 INCH Sws 35 OVER VOLTAGE FAULT J4 5 e PURGE _ 12 3 24 SWITCH INCH PURGE J2 5 1 23 MOTOR WIRE FEED SWITCH HIGH LOW SW6 J4 1 PURGE TRIGGER LOW J4 6 7 44 4 41 3 CS1 J1 2 2 CURRENT 3 SENSE TRANSDUCER J1 1 J5 J5 DIGITAL Jes DISPLAY ka PCB3 June 2 2006 Art A 07595_AB VS 212 SCHEMATIC DIAGRAM LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada July 2007 LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice an
8. 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables Manual No 0 4936B 1 5 Safety and Warnings PORTAFEED VS 212 7 9 AVERTISSEMENT eo LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certains proc d s peut endommager E Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 749 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit
9. Gas flow stops Depress the gun trigger Gas flows Contactor closes Drive roll turns Release gun trigger Gas flow stops Contactor opens Drive roll stops Trouble Shooting 9 Set meter DIP switches on the Meter Display PCB as follows Switch Position 1 UP 2 UP 3 DOWN 4 N A Digital Display if so equipped BOTTOM METER will change from Inches Minute to Meters Minute This completes the Logic Function Test If the above are all correct then proceed to Section 6 06 If the above does not function as noted then note the symptom and proceed to Section 6 08 Logic Function Problems 6 4 Manual No 0 4936B 6 06 Wire Feed Test 1 Re assemble the case Install wire and appropriate Feed Rolls Input and Outlet Guides Re engage the Pressure Adjust Device on the Feed Head Assembly Set Power Supply Voltage Wire Feed Speed appropriate for welding Position the gun in a position ready to weld Depress trigger and observe the following Gas flows Contactor energizes Feed rolls turn Wire feeds Welding arc begins Digital Display if so equipped TOP METER reads voltage supplied from the power supply BOTTOM METER reads wire feed speed preview Release gun trigger Welding are stops Gas flow stops Contactor de energizes Feed roll stops turning Wire feed stops Set meter DIP switches on the Meter Display PCB as follows Switch Position 1 DOWN 2 DOWN 3 DOWN 4 N A Manual No 0 4936B
10. Roll Cage W4003001 Protective tube steel roll cage MIG Gun Adaptor Cartridge Integrated cartridge to accept other style MIG guns Wire feeder comes with Tweco 4 cartridge installed Tweco 4 W4004001 Miller W4005001 Lincoln gasless W4006001 Lincoln W4006002 Euro style W4007001 A 2 June 2 2006 PORTAFEED VS 212 APPENDIX 3 MIG GUN CARTRIDGE SYSTEM Removable Gun Cartridge System Patent Pending The MIG gun cartridge can easily be removed and replaced with a different cartridge that will fit other brands of MIG guns Miller Lincoln Euro Refer to Appendix 2 for specific models Art A 07414 June 2 2006 3 PORTAFEED VS 212 APPENDIX 4 SYSTEM SCHEMATIC FEEDHEAD CONTACTOR Wi 1255 400 BREAKER CIRCUIT 8 AMP _ 42 2 SW1 J1 1 J2 3 TO POWER 1 SOURCE va dps 4 r 12 1 1 2 3 BR1 SWITCH POWER 57 1 3 RECTIFIER BRIDGE 1 4 TO WORK 5 1 5 J1 2 43 J1 9 J1 8 SWITCH CC CV 7 sw2 J1 10 J1 12 1 8 J1 10 J3 3 v CAP J1 12 J3 4 V_CAP T 11 11 1 MOTOR CONTROL PCB n 376395C REGULATOR J1 CONTACTOR BOARD ENABLE J1 COMA L00 99700Z1 god OCA caod J1 9A 14 wr GAS VALVE 12 VDC lt gt 11 Art A 07595
11. of the weld run GUN SWITCH RECEPTACLE The gun switch receptacle accepts the welding gun control wires The gun switch receptacle is where a gun switch closure is inputted to the wire feeder Manual No 0 4936B 8 VOLTAGE SENSING RECEPTACLE This receptacle serves as the voltage sensing point for the wire feeder and must be connected to the work piece through the voltage sensing lead for proper operation Ifthe voltage PORTAFEED VS 212 9 WELDING GUN CABLE CONNECTION The welding gun cable is connected to the wire feeder at this point Connections must be tight otherwise arcing or overheating could result sensing lead from the wire feeder and the weld cable from the power source are not connected to the work piece the wire feeder will not work 10 REMOVABLE MIG GUN CARTRIDGE Patent Pending The whole cartridge is interchangeable to accept competitive types of MIG gun connections No external adapters required See Appendix 2 and 3 for installation information and to select the adapter for other MIG Gun styles ie Miller Lincoln or Euro 2 08 Rear Panel Controls And Connections 4 MIG Gun Holder Art A 07137 1 Lifting Eye 2 Gas Valve Inlet 3 Input Power Cable Figure 2 3 Rear Panel Connections 1 LIFTING EYE Allows for hanging or moving of the feeder over the work area 2 GAS VALVE INLET This is where the shi
12. 7 05 Wire Feeder Replacement Pans 6 4 7 06 Internal Electrical Hardware Dci 6 5 7 07 internal Electrical Hardware liscia 6 6 7 08 Solenoid 4898 cito 6 7 Spool RUD 6 8 7 10 MIG Gun Adapter Cartridges nia 6 9 APPENDIX 1 DRIVE ROLL KITS ana lepri 1 APPENDIX 2 OPTIONS AND ACCESSORIES A 2 APPENDIX 3 MIG GUN CARTRIDGE SYSTEM A 3 APPENDIX 4 SYSTEM SCHEMATIC 2 2 1 A 4 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover PORTAFEED VS 212 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 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 welding 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 Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training bef
13. PORTAFEED VS 212 4 Position the gun in a position ready to weld Depress trigger and observe the following Gas flows Contactor energizes Feed rolls turn Wire feeds Welding arc begins Digital Display if so equipped TOP METER reads voltage supplied from the power supply BOTTOM METER reads welding amperage 5 Release gun trigger Welding are stops Gas flow stops Contactor de energizes Feed roll stops turning Wire feed stops Digital Display if so equipped TOP METER holds welding voltage for 5 seconds after arc stops BOTTOM METER holds welding amperage for 5 seconds after arc stops After 5 seconds Digital Display if so equipped TOP METER displays power supply voltage BOTTOM METER displays wire feed speed preview This completes the Wire Feed Test If the above does not function as noted then note the symptom and proceed to Section 6 09 Wire Feed Problems 6 5 Trouble Shooting PORTAFEED VS 212 6 07 Input Voltage amp Power Supply Problems 1 is present but V2 V3 amp V4 are low or zero display is off 1 SWI is in OFF position Turn SW1 ON position 2 Defective SW1 a Measure voltage across the switch between wires 1 amp 2 If voltage is present replace SWI 3 CBI is tripped Reset CB1 4 BRI is defective a Check continuity and replace if open or shorted B V1 amp V2 are present but V3 amp V4 are low or zero display is on 1 PCBI is defective a Rep
14. PORTAFEED VS 212 7 03 External Hardware Item Qty Ref Des 1 Description Part Number Handle Assembly VS 212 WF Hinge Bar VS212 0 25 Dia WF Clip Hinge Bar Retention WF Door Assembly VS 212 WF Lifting Eye VS 212 WF Case Storage INT WF i l2 A po lk Parts List 7 2 870972PKD 870839WBLKPKD 870956PKD 870953PKD 870974PKD 870865PKD GIA Art A 08482 Manual No 0 4936B PORTAFEED VS 212 7 04 Front Panel Qty Ref Des Part Number Description 414 M 9 amp 3 o l5 N N wn gt 5 s Oo 5 5 lt cso er ere dc sE O O CD CD c 825 Nn rM 4 lt V xy ae ZA 7 v SLI M a 7 IZ Art A 08483 Parts List 7 3 Manual No 0 4936B PORTAFEED VS 212 7 05 Wire Feeder Replacement Parts Item Qty Ref Des 1 1 2 1 3 1 4 2 5 3 6 1 1 8 2 9 1 10 1 11 1 12 1 13 1 1 Description Rod Tension Subassembly WF Pressure Arm 2R M C WF Gear Idler Assembly WF Screw M4x10 Pan Head WF Screw M6x1 30 MM long WF Retainer Drive Gear 2R Plate Gear Drive Roll 2
15. c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril E PORTAFEED VS 212 4h AVERTISSEMENT 2 LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre 8 Connectez le c ble de soudag
16. de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement 7 la pi ce souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux NS 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres
17. feed electrically hot welding wire If this hot welding wire touches the work piece a welding arc will be established Depress the inch switch if equipped or gun switch and adjust the wire feed speed to the desired value by means of the wire feed speed control The wire feed speed control can be adjusted during setup or while welding If the gun switch is depressed the wire feeder Will feed electrically hot welding wire If this hot welding wire touches the work piece a welding arc will be established Operation PORTAFEED VS 212 4 02 Welding Procedure A WARNING In semiautomatic or automatic wire welding the welding wire wire reel if used input guide feed rolls output guide feedhead and welding gun metal parts are all ELECTRICALLY HOT Refer to Functional Timing Diagram below 1 start the weld position the welding gun above the work piece and depress the gun switch trigger The solid state control then enables the gas valve wire feed motor and power source 2 To end the weld release the gun switch trigger while pulling the welding gun away from the work piece The solid state control then disables the gas valve wire feed motor and power source NOTE After the weld is completed it is recommended to pull the welding gun away from the work while releasing the gun switch This allows the welding arc to partially extinguish at the work piece which reduces the arcing at the contacto
18. 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 Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX Manual No 0 4936B 1 9 Safety and Warnings PORTAFEED VS 212 Safety and Warnings 1 10 Manual No 0 4936B PORTAFEED VS 212 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Service Manual applies to just specification or part numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING A WARNING gives information regarding possible personal injury A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermadyne at the address and phone number in your area listed in the inside ba
19. outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Safety and Warnings 1 8 Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur N AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression N 6tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon 1 05 Principales Normes De Securite Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OS
20. tip C Meter does not hold weld readings for 5 seconds after weld is stopped 1 Defective PCB3 a Replace PCB3 D Bottom meter will not display weld 1 Defective CS1 a Replace CSI 2 Defective PCB3 a Replace PCB3 Trouble Shooting 6 8 Manual No 0 4936B SECTION 7 PARTS LIST 7 01 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly numbers 1 02 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts Most parts of the equipment are listed except commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List PART NUMBERS W3512001 without digital meters W3512002 with digital meters Manual No 0 4936B 7 1 PORTAFEED VS 212 Parts List
21. without running wire Gun trigger hold 2T AT Allows standard or latched gun trigger Manual No 0 4936B PORTAFEED VS 212 Heavy duty removable voltage sensing lead Allows storage of lead with less lead breakage MIG gun holder A place to hold your MIG gun while not welding Lifting eye Allows for hanging or moving of the feeder over the Work area Gas valve solenoid Controls on off flow of shielding gases Wire speed high low range Gives a finer dial control of larger diameter flux cored wires Ready to weld Supplied with 2ft 7m power cable Tweco connectors and 045in 1 2mm drive rolls for hard tubular wire Geared top amp bottom feed rolls Excellent traction on the wire Quick change drive rolls Change the feed rolls without tools 2 5 Introduction PORTAFEED VS 212 2 07 Front Panel Controls And Connections 4 Arc Voltage Meter 3 Wire Feed Speed Amp Meter 2 Wire Feed Speed Control 1 On Off Power Switch 9 Welding Gun Cable Connection EI Art A 07136_AB 2 8 Inch Purge Switch 6 2T 4T Trigger Mode Selector Switch 7 Gun Switch Receptacle 8 Voltage Sensing Receptacle 25mm Dinse 10 Removable MIG Gun Cartridge Tweco style shown Figure 2 2 Front Panel Controls and Connections POWER ON OFF SWITCH This switch controls input power only to the wire feeder and not to the power source WIRE FEED SPEED CONTROL This knob controls the wire feed speed
22. 1 Scope The troubleshooting guide is intended to be used by qualified service technicians The troubleshooting guide contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the wire feeder Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem 2 Safety To ensure safe operation and service read this entire manual before attempting to service or repair this machine The service technician may be asked to check voltage levels while the machine is turned ON to assure safety use care and follow all instructions accordingly Manual No 0 4936B 6 02 Troubleshooting Hints Examine connections for proper assembly and contact before replacing an electrical component or printed circuit board Wire 1105 should be in tight contact with the lead s conductor and should be crimped to the lead s insulation The mating surfaces of the connection should be clean and free of oxidation Before replacing a suspect printed circuit board disconnect all wire plugs from the printed circuit board Then firmly reconnect all wire plugs to the printed circuit board and retest the machine to see if the problem persists Faulty connections or wiring problems are often the cause of an equipment malfunction Do not pull on wires to disassemble connections Firmly grasp each lug or connector when disconnecting Pulling on wires
23. A P WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure lr_ T y __ 12 7 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 This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government 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 and 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 fr
24. CB1 between J1 1 to J1 2 This voltage should measure approximately 1 5 VDC less than V1 3 Measure and note the voltage V3 on PCB1 between 42 5 to J2 2 This voltage should measure approximately 1 5 VDC less than V1 4 Measure and note the voltage V4 on PCB2 between J1 2 to J1 4 This voltage should measure approximately 7 VDC less than 5 Measure and note the voltage V5 on PCB2 between J1 1 to J1 4 This voltage should measure approximately 7 VDC less than V4 This completes the Primary Power Test If the above all correct then proceed to Section 6 05 If the above does not function as noted then note the symptom and proceed to Section 6 07 Input Voltage amp Supply Problems Manual No 0 4936B 6 3 PORTAFEED VS 212 Trouble Shooting PORTAFEED VS 212 6 05 Logic Function Test 1 Push and hold the INCH PURGE SWITCH SW5 to the INCH position Drive roll turns Turn the WIRE FEED SPEED CONTROL from minimum to maximum Digital Display if so equipped BOTTOM METER will vary from minimum to maximum speed reading Drive roll speed will vary from slow to fast Set the HIGH LOW RANGE SWITCH 5 6 10 LOW position Digital Display if so equipped BOTTOM METER will drop to approximately 1 2 of the HIGH position reading Drive roll speed drops approximately 1 2 speed Release SW5 Drive roll stops turning Depress SW5 to PURGE position Gas flows Release SW5
25. CV power source a control knob on the power source will have to be adjusted 4 04 Theory Of Operation Refer to the System Schematic Diagram in the Appendix 4 chapter of this manual Input power is supplied through the on off switch 51 and input circuit breaker CB1 to the bridge rectifier CR1 CR1 ensures that the proper polarity input voltage is fed into the PC boards independent of the welding polarity When the gun switch on the welding gun is pulled a short is provided on the gun switch receptacle J4 causing the wire feed motor M to turn feeding wire the gas valve SOL1 to open allowing gas flow and the contactor K1 to close making the welding wire electrically hot When the gun switch on the welding gun is released the short on the gun switch receptacle is removed causing the wire feed motor to stop feeding wire the gas valve to close stopping gas flow and the contactor to open making the welding wire electrically cold 4 2 Manual No 0 4936B 4 05 Adjusting Burnback Time Burnback time is set at the factory but the motor control printed circuit board contains a component that permits adjustment of burnback time Burnback time relates to the amount of welding wire re maining at the end of the welding gun after the welding process ends Increasing burnback time results in less wire remaining at the end of the welding gun the end of the weld Decreasing burnback time results in more wire remaining at th
26. HA 29 CFR 1910 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 norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Association canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B National Fire Protection Association Batterymarch Park Quincy MA 02269 Manual No 0 4936B PORTAFEED VS 212 1 06 Declaration Of Conformity Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the Natio
27. IHERMAL ARC 15 212 PORTAFEED CC CV SEMIAUTOMATIC SOLID STATE CONTROLLED WIRE FEEDER b L n un IHERMAL RC WARNINGS Read 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 judgement the manufacturer assumes no liability for its use Portafeed VS 212 CC CV Semiautomatic Solid State Controlled Wire Feeder Service Manual Number 0 4936 for Part Numbers W3512001 and W3512002 Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2007 2008 2009 2010 2011 by Thermadyne Industries Inc rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date June 2 2006 Revision AH Date March 3 2011 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 LOANO Ha
28. Installation PORTAFEED VS 212 NOTES Installation 3 6 Manual No 0 4936B PORTAFEED VS 212 SECTION 4 OPERATION 4 01 Prewelding Procedure Follow all installation instructions for the welding power source the welding gun and the VS 212 CC CV wire feeder before attempting to weld 1 Make sure all necessary connections have been made refer to Connections in the Installation chapter of this manual Turn ON the power source and the wire feeder Adjustthe voltage control on a CV machine or current control on a CC machine to the desired value The voltage or current control can be adjusted during setup or while welding The output contactor on the power source will have to be energized In most cases this will require a jumper to be added to the power source or a switch on the power source to be turned on Read the power source owners manual for proper connections or settings required Set the CC CV mode switch on the wire feeder to the proper position refer to paragraph 12 CC CV Mode Switch on page 2 9 and figure 4 1 Tex Art A 07254 CC High 9 OR One Figure 4 1 CC CV Switch Location Manual No 0 4936B 6 If shielding gas will be used depress the purge switch 4 1 or gun switch and adjust the flow of gas Z N If the gun switch is depressed the wire feeder will
29. MENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ve faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst me arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des
30. PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years Original Main Power Rectifiers Control P C Boards 3 years other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer See the Engine Manufactures Warranty for Details MIG WELDING EQUIPMENT WARRANTY PERIOD Fabricator 131 181 140 180 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P 320SP 400SP 500SP Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year MULTI PROCESS INVERTER WELDING EQUIPMENT 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards power switch semi conductors other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors PLASMA WELDING EQUIPMENT Ultima 150 Original Main Power Magnet
31. R Plate Screw M8 X 16 Hex Head WF Screw M6x1 35MM Long WF Clamp MIG gun 2R Plate Feedplate 2 Roll WF Insulator Motor 2R Plate Pin 6x50mm 2R amp 4R Plate 1 This part may be purchased at a local hardware store Parts List 7 4 Art A 08484 Part Number 870933PKD 870679PKD 871001PKD See note 1 See note 1 870733PKD 870560PKD See note 1 See note 1 171362 870558PKD 870695PKD 870509PKD Manual No 0 4936B 7 06 Internal Electrical Hardware 1 Item Qty Ref Des 1 1 CRI 2 1 1 3 1 PCB2 4 1 K1 5 1 CSI Internal Cover Artr A 08485 Manual No 0 4936B Description Rectifier Bridge 35A 800V PCB Motor Control WF PCB 12V Driver WF Contactor 425A WF Transducer Current WF PORTAFEED VS 212 Part Number 409554 002 3 6395CPKD 170046B 001PKD 870710PKD 870858PKD Collapsed view with internal cover removed 7 5 Parts List PORTAFEED VS 212 7 07 internal Electrical Hardware 2 Qty Ref Des Description 1 1 Motor Wire Drive 3 2A 20VDC 1 Feed Plate Assy 2 Roll 2 SW2 SW6 Switch Rocker SP WF 1 CB1 Circuit Breaker 8A WF gt Parts List 7 6 Part Number 8 0891PKD 8 0924PKD 8 0359 203627 008 Art A 07625 Manual No 0 4936B PORTAFEED VS 212 7 08 Solenoid Assembly Qty Ref Des Description Part Number 1 1 5011
32. Solenoid Valve 12VDC WF 870945PKD Art A 08476 Manual No 0 4936B 7 7 Parts List PORTAFEED VS 212 7 09 Spool Hub Assembly Qty Ref Des Description N OO 4 9 gt i ion lb cL lE NS adi 1 Hub Spool Wire Assembly WF Hub Wire Spool Nut Wire Spool Hub Plunger Spring Nut Hub Washer 1 1 64 Flat Nylon Hub Spacer Spool Hub Washer 3 4 Flat Keyed Hub Shaft Wire Spool WF Washer 1 2 Flat 1 38 OD WF Spring Spool Hub Nut Hex 5 13 WF 1 This part may be purchased at a local hardware store Parts List 7 8 Part Number 870939PKD 405376 405377 170459 001 405448 374552 001 374551 374546 See Note 1 400562 027 See Note 1 Manual No 0 4936B PORTAFEED VS 212 7 10 MIG Gun Adapter Cartridges Item Qty Description Part Number 1 1 Cartridge Assy Miller WF W4005001 2 1 Cartridge Assy Linc Gas WF W4006002 3 1 Cartridge Assy Linc WF W4006001 4 1 Cartridge Assy EURO WF W4007001 5 1 Knob Torch Locking 10 6187 Art A 08486 Manual No 0 4936B 7 9 Parts List PORTAFEED VS 212 NOTES Parts List 7 10 Manual No 0 4936B PORTAFEED VS 212 APPENDIX 1 DRIVE ROLL KITS FEED ROLL KITS 375980 Series 2 ROLL FEED ROLL STYLES ARA DOUBLE uU Style 1 Style 2 Style 3 Style 4 Style 5 Style 6 Double Smooth Doubl
33. The wire feed speed control can be adjusted during setup or actual welding WIRE FEED SPEED AMP METER The wire feed speed meter displays the actual wire feed speed output of the wire feeder This meter can be changed to display the actual amperage output of the power source by adjusting the DIP switches located on the edge of the display board inside the unit Refer to Section 4 07 for details AVAILABLE IN MODEL W3512002 ONLY ARC VOLTAGE METER The arc voltage meter displays the actual voltage output of the power source INCH PURGE SWITCH Depressing the INCH portion of the switch will feed wire at a speed set by the WFS control The wire will not be electrically hot when using the INCH switch Depressing the PURGE portion of the switch will allow shielding gas to flow out of the welding gun without feeding wire Introduction 6 2T AT TRIGGER MODE SELECTOR SWITCH This switch selects either 2 Step or 4 Step gun switch mode 2T Continuous Welding This mode of welding is used to weld two or more components together with a continuous weld When the MIG gun trigger switch is depressed welding commences When the MIG gun trigger switch is released welding ceases 4T Latch This mode of welding is mainly used for long weld runs as the operator need only press the trigger to activate the weld then press the trigger again to stop This replaces the need for the operator to depress and hold the trigger for the complete length
34. Z49 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended Manual No 0 4936B 1 1 Safety and Warnings PORTAFEED VS 212 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc 4 Wear protective clothing made from durable flame resistant material wool and leather and foot protection 5 Use approved ear plugs or ear muffs if noise level is high 9 t2 WARNING n 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 1 Keep your head out of the fumes Do not breath the fumes 2 If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases 3 lf ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 5 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 6 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases 7 Do not weld on
35. afeed VS212 Specifications Input Voltage Range 15 100 VDC Maximum Input Current 10 Amps Wire Speed Range 50 800 IPM 1 27 20 32 MPM dependent on arc voltage Wire Sizes 0 024 5 64 0 6 2 0 mm Max Wire Spool Capacity 12 304 8 mm 44 Lbs 20 kg Drive Rolls 2 Both Gear Driven Welding Current 1 425A at 60 Duty Cycle Welding Gun Inlet Size Std 5 8 16mm Nominal Tweco Style 4 Maximum Shielding Gas 100 psi 6 9 bar Inlet Pressure Degree of Protection 23 Weight Less wire 44 Ibs 20 kg Approvals IEC 60974 5 CE CSA NRTL C pending NEMA EW3 Table 2 1 Specifications 153 in 289mm Figure 2 1 Dimensional Information Introduction 2 4 Manual No 0 4936B 2 06 Features Benefits Robust injection molded case Long lasting and unbreakable Changeable MIG gun cartridge system Patent Pending No external MIG gun adapters needed for other style guns with the integrated cartridge system Digital display Model W3512002 Monitor wire speed amps volts arc time and meter hold Makes parameter set up easy Heavy duty contactor Longer life on higher amperage applications Internal parts storage On the job storage for drive rolls tips nozzels etc Machined feed head amp tension arms Insures wire alignment tolerances of 002 Inch switch amp purge switch Cold inching of wire at set wire feed speed and purging of gas
36. amework 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 Pi Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information Safety and Warnings 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard 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 fro
37. as supply to the wire feeder gas valve if gas will be used Attach the welding gun to the wire feeder Connect the welding gun control leads to the wire feeder gun switch terminals located on the front of the wire feeder VOLTAGE SENSING WELDING GUN WORK TABLE VOLTAGE SENSING LEAD Art A 07194 Figure 3 1 System Hook up Outline Manual No 0 4936B Installation PORTAFEED VS 212 3 02 Installation Of Wire Spool NOTE The wire spool hub supplied with the unit is provided for mounting a 44 pound 20 kg spool of wire Optional adapters are available y allowing a 10 4 5 kg or 15 6 8 kg pound ZA wra spool of wire or a 14 6 4 kg pound coil of wire to be used 1 Remove the wire spool hub nut by turning counterclockwise 2 Slide the spool of wire over the wire spool hub 3 Make sure that the alignment pin on the hub enters the hole in the backside of the wire spool 4 Replace the wire spool hub nut and turn clockwise to a snug position NOTE Install the welding wire spool so the wire feeds from the bottom of the spool into the input wire guide Figure 3 2 Wire Spool Installation Installation 3 2 Manual No 0 4936B 3 03 Adjustment Of Spool Tension Adjust the wire spool tension so the wire will feed freely into the input wire guide However the
38. ck cover of this manual Include the Owner s Manual number and equipment identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature link http www thermalarc com Manual No 0 4936B 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 rear panel In some cases the nameplate may be attached to the control panel Equipment which does not have a name plate 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 i for future reference 2 1 Introduction PORTAFEED VS 212 2 03 Symbol Chart Note that only some of these symbols will appear on your model dle Three Phase Static Dangerous Voltage FCO Frequency Converter Transformer Rectifier A O O Circuit Breaker Duty Cycle XA AC Auxiliary Power Percentage O A Shielded Metal Arc Welding SMAW Voltage Gas Metal Arc 9 Welding GMAW Gas Tungsten Arc Z Hertz cycles sec Welding GTAW Fr Cutting Positive Constant Voltage Or Constant Potential Direct Current DC High Temperature Protective Earth Dee Wire Feed Function Wire Feed Towards
39. 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 10 WARNING 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 and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire _ _r _ e e Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 of the welding arc If this is not possible tightly cover them with approved covers Be alert that 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 Be aware 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 work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards
40. ct to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in Thermal Arc s sole judgment impaired the safety or performance of any Thermal Arc product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized 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 Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated July 1 2007 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada July 2007 ENGINE DRIVEN WELDERS WARRANTY
41. d not subject to misuse repair neglect alteration or damage correct such defects by suitable repair replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective This warranty is exclusive and in lieu of warranty of merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including 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 tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty and Thermal Arc shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respe
42. de courant filtre oculaire toutes conditions Op ration de coupage ou soudage Brassage tendre au chalumea Brassage fort 9 toutes conditions 30u4 mince au chalumeau mum sur 1 _ Oxycoupage iti 2 mons de po 25 m n plus de 6 po 150 mm Soudage aux gaz moins de 1 8 po 3 mm 4005 mince moyn 401881 3412 Sous plus de 12 po 2 mm Soudage 4 l arc avec lectrode enrobees SMAW plus de 1 4 po 54 m n Soudage l arc sous gaz avec fil plein GMAW Op ration de coupage ou soudage pais Soudage 4 l hydrog ne atomique AHW Soudage l arc avec lectrode de carbone CAW Dimension d lectrode ou Nuance Epiasseur de m tal ou de Intensit de courant filtre oculaire Soudage 4 l arc sous gaz avec lectrode de tungst ne GTAW amp rages inf rieurs 50 A 150 500 toutes conditions toutes conditions ougeage Air Arc avec lectrode de carbone oudage l arc Plasma PAW pais Coupage l arc Plasma PAC amp rages inf rieurs 60 A amp rages inf rieurs 300 A 60 160 moyen amp rages inf rieurs 20 A moins de 5 32 4 mm 20 100 5182 1 4 po 4 464 mm 100 400 1 1 1 1 Coa nasna 4 EE eni 10 12 14 12 12 WWE 0 2 4 300 400 2 4 16022503 100 8003 Safety and Warnings 1 6 Manual No 0 4936B Ne soudez des t les galvanis
43. e Flat Flat Knurled Knurled V Double Double U Double Double Double Smooth Double Smooth V Smooth V Knurled V Double Double U Wire Type Soft Hard Tubular Hard Tubular Soft Aluminum 030 035 0 8 0 9mm 375980 001 375980 003 375980 010 030 035 045 0 8 0 9 1 2mm 375980 028 375980 029 2035 0 9mm 87084040 375980032 1035 045 3 64 0 9 1 2 12mm 837598000 L045 12mm 7 1375980 002 375980 004 1 375980 092 375980022 e4 12mm 3798001 375980083 082 13 7 375980 090 8759002 L062 1 16 1 8 1 6mm 375980 017 375980 0223 1 16 1 6mm 03759800057 875980094 edi Notes 1 One Kit is supplied standard with each wire feeder 2 Feed Roll Kits include Feed Rolls Input Output 375980 092 Guides 3 Narrow 30 V June 2 2006 A 1 PORTAFEED VS 212 APPENDIX 2 OPTIONS AND ACCESSORIES Product Part No Description One kit 375980 092 is supplied standard with each wire feeder see Feed Roll Kit chart to select a different Feed roll style Wire Spool Coil Adapters 10 Ib 4 5kg 8 spool 375585 001 15 Ib 6 8kg 8 spool 375864 001 14 Ib 6 4kg coil Lincoln amp 375942 Wire Feeder Cart W4000001 Low profile large caster cart
44. e end of the welding gun after the welding process ends dese gage oro _ e xx ELECTRIC SHOCK CAN KILL Make certain the power source and wire feeder are both turned OFF before beginning the procedure 1 Using a nut driver or socket remove the wire spool hub 2 Remove the internal cover refer to Figure 4 3 R68 located on this PCB Remove the four screws and Internal Cover Figure 4 3 Accessing PCB for Burnback Manual No 0 4936B PORTAFEED VS 212 3 Locate component R68 Burnback on the motor con trol printed circuit board refer to Figure 4 3 The best procedure is to make only slight adjustments until the amount of burnback is acceptable Component R68 has a single turn 300 range of adjustment To increase burnback time adjust component R68 clockwise To decrease burnback time adjust component R68 counterclockwise 4 Replace the internal cover 5 Replace the wire spool hub refer to 3 03 Adjustment Of Spool Tension in Section 3 of this manual 4 06 Wire Feed Speed Ranges The range of the wire feed speed adjustment knob on the front panel can be set to either High or Low The High Low switch is located on the inside panel next to the CC CV switch Refer to figure 4 4 Art A 07254 Oe Figure 4 4 High Low Switch Location
45. e le plus pr s possible de la zone maintenus en bon tat de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture 9 Ne d gelez pas les tuyaux avec un source de courant XW 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou 10 Otez l lectrode du porte lectrode ou coupez le fil au tube con lorsque raccord pour utilisation tact lorsqu inutilis apr s le soudage 8 Lisez et respectez les consignes relatives aux bouteilles de gaz Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous f AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs Manual No 0 4936B 1 7 Safety and Warnings PORTAFEED VS 212 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent 4 AVERTISSE
46. elding gas hose if used is connected to the wire feeder 3 INPUT POWER CABLE Power cable and TWECO connectors male and female supplied Provides an inlet and secure fixture for the power cable from the welding power source 4 WELDING GUN HOLDER This is an insulated holder used to hold the welding gun when not welding Manual No 0 4936B 2 7 Introduction PORTAFEED VS 212 2 09 Internal Controls And Connections Art A 07138 L 13 INPUT CIRCUIT BREAKER 1 STORAGE BOX 2 HIGH LOW RANGE SWITCH 14 HUB TENSION BOLT 9 2 12 CC CV MODE SWITCH NM j e 3 WIRE SPEED AMP METER SELECTION DIP SWITCHES Low a 4 CARTRIDGE GUN LEADS 9 INPUT GUIDE LOCKSCREW 5 UPPER RETAINING KNOB 11 PRESSURE ADJUST DEVICE o o 10 INPUT WIRE GUIDE 6 GUN CLAMP KNOB e o 7 OUTPUT GUIDE LOCKSCREW 8 LOWER RETAINING KNOB Figure 2 4 Internal Controls and Connections STORAGE BOX On the job storage for drive rolls tips nozzels etc To remove lift up to release velcro and slide it up and over the side retainers HIGH LOW RANGE SWITCH Gives a
47. er is depressed If voltage does not drop replace PCB3 Manual No 0 4936B 6 7 PORTAFEED VS 212 When gun trigger is depressed gas flows feed rolls turn but W1 does not close 1 Defective W1 a Measure for 12 VDC between wires 9A to 14 on W1 coil when gun trigger is closed If voltage is correct replace W1 2 Defective PCB3 a Measure for 12 VDC on PCB3 between J4 3 to J4 4 If voltage is 12 VDC replace PCB3 When gun trigger is depressed gas flows W1 closes but feed roll does not turn 1 Defective PCB3 a Measure at PCB2 between J2 1 to J3 1 Voltage is 12 VDC and drops to less than 1 VDC when gun trigger is depressed If voltage does not drop replace PCB3 When DIP switch 43 on PCB3 is set in the down position meter still displays speed in IPM 1 Defective PCB3 a Replace Trouble Shooting PORTAFEED VS 212 6 09 Wire Feed Problem A Wire does not feed when gun is depressed 1 Wire hub tension is too tight a See Section 3 03 2 Pressure Adjustment Device is too tight a See Section 3 07 step 3 3 Worn or incorrect feed rolls or guides a Relpace worn or incorrect feed rolls or guides 4 Wire on spool is tangled or is not feeding off spool a Replace wire spool B Wire bird nests inside feeder 1 Defective gun conduit a Replace gun conduit 2 Excessive tension on Pressure Adjustment Device a See Section Section 3 07 step 3 3 Damaged contact tip a Replace contact
48. es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur ad duction Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie H M ayy Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre
49. finer dial control over the wire speed which is especially useful with larger diameter flux cored wires WIRE SPEED AMP METER SELECTION DIP SWITCHES Set these switches to change the lower meter display from wire speed to amperage output ofthe power source Refer to Section 2 08 item 3 and section 4 06 for DIP switch setting information GUN LEADS These two spade terminals provide the MIG gun switch connection UPPER RETAINING KNOB This knob is used to secure the bearing feed roll Remove this knob to change the bearing feed roll Introduction 6 GUN CLAMP KNOB Tighten this knob to secure the welding gun to the wire feeder OUTPUT GUIDE LOCKSCREW Tighten this screw to secure the output wire guide LOWER RETAINING KNOB This knob is used to secure the drive feed roll Remove this knob to change the drive feed roll INPUT GUIDE LOCKSCREW Tighten this screw to secure the input wire guide 10 INPUT WIRE GUIDE This guide is required to direct the welding wire from the wire spool to the feed roll 11 PRESSURE ADJUSTMENT DEVICE Use the pressure adjustment device to adjust the amount of force the bearing feed roll exerts on the welding wire Manual No 0 4936B 12 CC CV MODE SWITCH The CC position provides a voltage sensing wire feed speed mode of operation for use with constant current CC power sources The CV position provides a constant wire feed speed mode of operation for use with constan
50. for disassembly can damage the integrity of the connection and cause future malfunctions Prior to disassembly or servicing of the machine note the wiring and connections in the machine Reassembling should place the wires in the same location and routing as received from the factory Keep wires and leads away from hot parts and sharp objects Most of the printed circuit boards in the machine contain static sensitive devices Use a grounding strap or other suitable grounding means before attempting to service or make measurements on printed circuit boards All signals referenced in the following troubleshooting guide can be measured with a digital multimeter DMM 6 1 Trouble Shooting PORTAFEED VS 212 6 03 Troubleshooting Set up A WARNING ELECTRIC SHOCK can kill Follow all safety precautions Do not touch live electrical parts Turn OFF input power before servicing the machine unless otherwise noted Only qualified technicians are to service the machine A WARNING This machine contains static sensitive devices Use static proof bags to store electronic components Use grounded wrist strap Use qualified personnel when testing or handling device NOTE Refer to the Connection Diagram and the Schematic Diagram in the Appendix chapter of this manual for graphical assistance in disassembling and troubleshooting the wire feeder The acceptable tolerance in most cases on resistance and vo
51. ged 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 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn 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 Engines can be dangerous 9 f WARNING 2 PORTAFEED VS 212 If used in a closed area vent engine exhaust outside and away from any building air intakes 2 7 7 WARNING ENGINE FUEL can cause fire explosion Engine fuel is highly flammable 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 fueling If possible check and add fuel to cold engine before beginning job Do n
52. hat features quick change gear driven drive rolls PORTAFEED VS 212 comes with e Robustinjection molded case e Changeable MIG gun cartridge system Digital display model W3512002 only Heavy duty contactor e Internal parts storage Power cable and drive rolls e Gas valve solenoid Manual No 0 4936B PORTAFEED VS 212 The PORTAFEED VS 212 includes the following features An on off rocker switch A wire feed speed control knob A welding gun holder Acarrying handle 1 2 3 4 5 Acontactor 6 A gas valve 7 mode switch 8 Aninputcircuit breaker for complete system protection 9 Electronic controlled protection circuitry to protect against an undervoltage an overvoltage a voltage spike a shorted or locked motor a shorted contactor coil and a shorted gas valve 10 An electronic controlled dynamic brake 11 An electronic controlled current limit to motor 12 electronic controlled start circuit for improved arc starting 13 A low voltage gun trigger circuit for operator safety 14 A feed roll kit 15 addition to these standard features specification number W3512002 also includes a digital display for wire feed speed amps and arc voltage with arc time and memory hold 16 Trigger Hold Switch The PORTAFEED VS 212 has been designed to comply with IEC 60974 1 CE CSA NRTL C and NEMA EW 3 standards 2 3 Introduction PORTAFEED VS 212 2 05 Product Specifications Port
53. ics Original Main Power Rectifiers Control P C Boards power switch semi conductors Welding Console Weld Controller Weld Timer other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year SMAW Stick WELDING EQUIPMENT LABOR Dragster 85 Original Main Power Magnetics 1 year Original Main Power Rectifiers Control P C Boards 1 year other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year 160S 300S 400S Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards 3 years other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 days 180 days Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakvil
54. ire guide and into the welding gun assembly Lock in position with the pressure adjustment device To adjust the amount of force the idler feed roll exerts on the welding wire turn the pressure adjustment device clockwise for increased force or counterclockwise for decreased force NOTE If the force applied to the wire is too great the welding wire will bird nest in the feedhead and not feed properly Turn the welding machine and wire feeder ON and set the wire feed speed control to midrange refer to Figure 3 7 Remove contact tube from welding gun Refer to Gun Manual Press the gun switch or INCH switch until wire feeds out past the gun nozzle Place contact tip over the wire and screw into place and tighten Cut wire off at about 1 4 inch 6 mm from the nozzle 1 Place end of the welding wire into the input wire guide Feed it through the guide and over the drive roll groove closest to the feedhead casting Wire Feed Speed Control Figure 3 7 Wire Feed Speed Control Art A 07253 AU DIN pi Pressure Adjustment Device Pressure Arm x ORM Da Ca Welding Wire Input Wire Guide Output Wire Guide Figure 3 6 Wire Threaded Through Guides and Locked In Position Manual No 0 4936B 3 5
55. lace PCB1 C V1 V2 amp V3 are present but V4 is low or zero display is on 1 PCBI is defective a Replace PCB1 D V1 V4 are present but Digital Display is not on 1 Digital Display is defective a Replace Digital Display V1 V4 are present but V5 is not present 1 PCB2 is defective a Replace PCB2 Trouble Shooting 6 08 Logic Function Problem A Drive roll does not turn when SW5 is pushed to 6 6 INCH position 1 Defective SW5 a Check continuity between J2 2 to J2 5 on PCB3 while SW5 is in INCH position b Replace SW5 if continuity is not found 2 Defective PCB3 a Measure at PCB2 between J2 2 to J3 1 Voltage is 12 VDC and drops to less than 1 VDC when in INCH position If voltage does not drop replace PCB3 b Check for 0 to 10K ohms variation at PCB3 between J4 12 to J4 13 Then check for fixed 10K ohms between J4 14 to J4 12 Replace PCB 3 if not correct 3 Defective PCB2 a Measure for DC voltage between wires 23 and 24 to M1 If voltage is zero replace PCB2 4 Defective M1 a Measure for DC voltage between wires 23 and 24 to If voltage is present replace M1 CB1 trips when SW5 is put into INCH position 1 Defective M1 a Replace M1 Drive roll speed will not vary or is intermittent as WIRE FEED SPEED CONTROL is adjusted from min to max while SW5 is in INCH position 1 Defective PCB3 a Check for 0 to 10K ohms variation at PCB3 between J4 12 to J4 13 Re
56. le Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jin Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 5 Giuliano Milan Italy Tel 39 02 98 30320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters IHERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE 96 5 St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com
57. ltage measurements made with the DMM is 10 Use only genuine replacement parts Trouble Shooting Set up the VS 212 as follows 1 8 9 Connect Positive Power Supply Cable to the Input Power Cable pigtail connector on the back side of the unit Connect the Voltage Sensing Lead to the work piece which is connected to the PS output connection CV Power Supply output must be 15 100 VDC Connect Gas Hose to Gas Inlet on the rear panel Connect MIG Gun Set WIRE FEED SPEED CONTROL to position 4 NOTE The upper and lower speed limits will vary dependant upon the power supply output voltage Set ON OFF SWITCH to OFF position Set TRIGGER MODE SELECTOR SWITCH to 2T position Set CC CV MODE SWITCH to CV position Set HIGH LOW RANGE SWITCH to HIGH position 10 Open the PRESSURE ADJUST DEVICE so wire will not feed when drive roll turns 11 Set meter DIP switches on the Meter Display PCB as 6 2 follows Switch Position 1 UP 2 3 4 N A Manual No 0 4936B 6 04 Input Voltage amp Power Supply Test Turn ON OFF switch to ON and observe check the following Digital Display comes on if so equipped TOP METER reads voltage supplied from the power supply BOTTOM METER reads minimum speed 1 Measure and note the Input Supply Voltage V1 which is supplied by the Power Supply between the Input Power Cable and the Voltage Sensing Lead 2 Measure and note the voltage V2 on P
58. m 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 Z87 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 Manual No 0 4936B PORTAFEED VS 212 1 03 Precautions De Securite En Soudage A A MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION QU LES INSTRUCTIONS AVANT D INSTALLER UTILISER QU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratique
59. move the core assembly and core spring 7 All parts should now be inspected for foreign material and cleaned with a lint free cloth Do not nick or scratch any internal parts of the gas valve 8 Reassemble the gas valve in reverse order of disassembly paying careful attention to Figure 5 2 NOTE Tighten 2 bracket screws evenly to insure proper body gasket compression Torque bracket screws to 20 inch pounds 2 26 Nm Maintenance 9 Assemble the gas valve to the wire feeder NOTE It may be necessary to apply pipe compound sparingly to the gas adapter male threads only Do not apply compound to female threads of gas valve or first two threads of male fittings Also make sure the inlet port marked IN side of the gas valve is connected to the main gas supply otherwise the gas valve will leak After maintenance operate the gas valve a few times to be sure of proper operation If the gas valve continues to show signs of improper operation replace the gas valve assembly Art A 04202 Coil Plugnut Core Tube Sub Assembly Core Assembly Core Spring Valve Body Bracket Screws 2 Figure 5 2 Gas Valve Assembly 5 2 Manual No 0 4936B PORTAFEED VS 212 SECTION 6 TROUBLESHOOTING 6 01 Troubleshooting Guide NOTE Refer to the Connection Diagram and the Schematic Diagram in the Appendix chapter of this manual for graphical assistance in disassembling and troubleshooting the wire feeder
60. nal 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 89 336 EEC and to 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 CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment e UL Underwriters Laboratory rating 94 0 flammability testing for all printed circuit boards used e CENELEC EN50199 EMC Product Standard for Arc Welding Equipment e ISO IEC 60974 1 BS 638 PT10 60 974 1 50192 EN50078 applicable to plasma cutting equipment and associated accessories e For environments with increased hazard of electrical shock Power Supplies bearing the S 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
61. ndard component of the PORTAFEED VS 212 and allows the welding wire to remain electrically cold until the gun switch trigger is depressed This contactor is rated for 425 amps of welding current at a 60 duty cycle If the weld current or duty cycle rating is exceeded the contactor will be damaged or its life shortened Compatible Thermal Arc Power Sources rcMaster 4005 300MST 400 5 400MSTP abstar 4030 owerMaster Series Excel Arc Series Scout Raider 10000 engine driven 2 11 Options and Accessories Refer to the Appendix 2 section of this manual for the list of available options and accessories for this product 2 9 Introduction PORTAFEED VS 212 NOTES Introduction 2 10 Manual No 0 4936B PORTAFEED VS 212 SECTION 3 INSTALLATION 3 01 Connections UTION Make sure all connections are tight otherwise arcing or overheating could result 1 Using the supplied adapter connect a weld cable from the power source to the power cable connection on the rear of the VS 212 2 Connect a weld cable from the power source to the work connection 3 Connectthe voltage sensing lead from the wire feeder to the work connection POWER SOURCE GAS SUPPLY REAR VIEW va WIRE FEEDER WELDING CABLES A WARNING ELECTRIC SHOCK CAN KILL DO NOT touch the metal portions of the voltage sensing lead when the power source output is on Make the proper gas line connection from the g
62. ore 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 Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING 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 Welding Hazards 7 Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode 8 Do not use worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks or 12 Use only well maintained equipment Repair or replace damaged severe burns The electrode and work circuit is electrically parts at once live whenever the output is on The input power circuit and machine internal circuits are also live when p
63. ose connections and correct if necessary Manual No 0 4936B 5 02 Cleaning Of The Feed Rolls About every 3 months clean the grooves on the feed rolls using a small wire brush If the feed roll has a smooth surface wipe off the feed roll with a clean dry cloth After cleaning the feed rolls tighten the upper and lower feed roll retaining knobs accordingly 5 1 Maintenance PORTAFEED VS 212 5 03 Gas Valve Maintenance Foreign material inside the valve body is the major cause of gas valve failure or improper operation Foreign material usually enters the valve body when disconnected gas lines are allowed to come in contact with the floor or ground before being connected or reconnected to the gas valve In general sluggish operation and or gas leakage are signs the gas valve needs to be cleaned internally To clean the gas valve internally follow these steps NOTE Before disassembly of the gas valve take note of the orientation of inlet marked IN and outlet ports with respect to electrical connections The reassembled gas valve should have the same orientation 1 Remove input power from the wire feeder and depressurize the gas valve 2 Remove the gas valve from the wire feeder 3 Remove the 2 bracket screws and bracket from the yoke of the gas valve 4 Slip the yoke containing coil off the plugnut core tube sub assembly 5 Removethe plugnut core tube sub assembly with the body gasket attached 6 Re
64. ot overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine 5 WARNING SPARKS can cause BATTERY GASES TO 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 2 Stop engine before disconnecting or connecting battery cables ENGINE EXHAUST GASES can kill 3 Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases 4 Do not use welder to charge batteries or jump start vehicles 1 Use equipment outside in open well ventilated areas 5 Observe correct polarity and on batteries Manual No 0 4936B 1 3 Safety and Warnings PORTAFEED VS 212
65. ower 13 In confined spaces or damp locations do not use a welder with is on In semiautomatic or automatic wire welding the AC output unless it is equipped with a voltage reducer Use wire wire reel drive roll housing and all metal parts equipment with DC output touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard 14 Wear a safety harness to prevent falling if working above floor level t _ m_ 5 1 Do not touch live electrical parts 15 Keep all panels and covers securely in place 2 Wear dry hole free insulating gloves and body protection Ab 3 Insulate yourself from work and ground using dry insulating mats or covers WARNING 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch ARC RAYS can burn eyes and skin NOISE can damage open or remove line fuses so power cannot be turned on hearing Arc rays from the welding process produce accidentally intense heat and strong ultraviolet rays that can burn 5 Properly install and ground this equipment according to its Owner s ew n skin Noise from some processes can damage Manual and national state and local codes 6 Turn off all equipment when not in use Disconnect power to 1 Wear a welding helmet fitted with a proper shade of filter see equipment if it will be left unattended or out of service ANSI
66. place PCB 3 if not correct 2 Defective M1 a Check DC voltages between wires 23 to 24 to transition smoothly from low to high as WIRE FEED SPEED CONTROL is adjusted min to max If voltage is correct replace M1 3 Defective PCB1 a If voltage between wires 23 to 24 is intermittent or does not vary smoothly replace PCBI Manual No 0 4936B D When SW6 is switched to LOW position the drive roll does not slow to 1 2 speed 1 Defective SW6 a Check continuity and replace if defective 2 Defective PCB3 a Replace PCB3 Gas does not flow when SW5 is put into PURGE position 1 Gas supply to gas inlet is not turned on a Turn on gas supply 2 Defective SW5 a Check continuity on between J2 3 to J2 5 with SW5 in PURGE position Replace SW5 if continuity is not found 3 Defective SOL1 a Measure 12 VDC at PCB2 between J1 1 to J1 3 Replace SOL1 is voltage is present 4 Defective PCB3 a Measure voltage from PCB1 J2 1 to PCB2 J1 6 Voltage is 12 VDC and drops to zero when SWb is put into PURGE position If voltage does not drop replace PCB3 5 Defective PCB2 a Measure for 12 VDC on PCB2 between J1 4 to J1 1 Nothing happens when gun trigger is depressed 1 Defective gun trigger or open wire in MIG gun leads a Check continuity and replace if open 2 Defective PCB3 a Measure at PCB2 between J2 2 to J3 1 Voltage is 12 VDC and drops to less than 1 VDC when gun trigg
67. r contacts Using this procedure will lengthen the life of the contactor contacts especially when welding at high amperage 3 Atthe end of the work day or when welding has been completed it is recommended that the gas be SHUT OFF at the cylinder and the wire feeder and power source be turned OFF Art A 05126 I T 1l I ON I I Gun Switch 1 I I I on Gas Valve 1 i OFF I I I N I I I Wire Feed 1 Power Source 1 Figure 4 2 Functional Timing Diagram Operation 4 03 Welding In CC Mode vs CV Mode 1 Welding in CC Mode When welding with a constant current CC power source changes in wire feed speed will affect welding voltage To adjust the amount of welding current from the CC power source a control knob on the power source or an optional control knob on the wire feeder will have to be adjusted The solid state control of a slow run in circuit automatically reduces the initial wire feed speed when operating with a CC power source This initial reduction in wire feed speed will compensate for the high open circuit voltage associated with CC power sources and improve arc starting performance B Welding in CV Mode When welding with a constant voltage CV power source changes in wire feed speed will affect welding current Changes in wire feed speed can be obtained by adjusting the wire feed speed control knob To adjust the amount of welding voltage from the
68. ries for the ordering information of other MIG gun adapter cartridges Refer to Section 7 10 for exploded view illustrations of the available MIG gun adapter cartridges Refer to Appendix 3 for more information on the MIG Gun Cartridge System 1 install the welding gun loosen the gun clamp knob and insert the welding gun cable end into the feedhead until it stops 2 Tighten the gun clamp knob and connect the welding gun control wires to the gun switch receptacle 3 To remove loosen the gun clamp knob and pull the gun cable end out NOTE Before inserting the welding gun into the feedhead make sure the gun clamp does not extend into the feedhead otherwise the welding gun cannot be properly inserted Welding Gun Cable ORO Installation 3 4 Gun Clamp Knob Figure 3 5 Installing Welding Gun Manual No 0 4936B 3 07 Threading Wire Into Feedhead Refer to Figure 3 6 A WARNING ELECTRIC SHOCK CAN KILL Make certain the power source and wire feeder are turned OFF Do not turn the power ON until told to do so in these instructions UTION Use care when handling the spooled wire as the wire tends to unravel when loosened from the spool Grasp the end ofthe wire firmly and don t let it get away from you Make sure that the end of the wire is straight and free of burrs PORTAFEED VS 212 2 Pass the wire through the output w
69. s doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 04 Dangers relatifs au soudage l arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de cables lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 pas
70. spool of welding wire must not coast when wire feeding stops To adjust the wire spool tension tighten or loosen the hub tension bolt accordingly NOTE Excessive tightening of the hub tension bolt will result in a shorter motor life Figure 3 3 Hub Tension Bolt Manual No 0 4936B PORTAFEED VS 212 3 04 Input And Output Wire Guide Installation 1 Install the input wire guide the longer one by loosening the input guide lockscrew and inserting the guide into the hole in the feedhead assembly The recessed end of the guide should be towards the wire spool Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew 2 Install the output wire guide with the conical end towards the feed rolls in the same manner as the input guide The conical end of the guide should be as close to the feed rolls as practical Tighten the output guide lockscrew NOTE Before tightening the input and output guide lockscrews install the drive feed roll to help in the alignment of the wire guides Art A 07197 Input Wire Guide o hi CD o e Input Guide Lockscrew gt Output Wire Guide inside Output Guide Lockscrew Figure 3 4 Wire Guide Installation 3 3 Installation PORTAFEED VS 212 3 05 Selection And Installation Of Feed Rolls Refer to feed roll kit chart in the Appendi
71. t voltage CV power sources NOTE This switch does not select a CC or CV mode of operation The mode of operation is set by the type of power source being used 13 INPUT CIRCUIT BREAKER This circuit breaker provides complete system protection for the wire feeder in the case of a fault or overload condition 14 HUB TENSION BOLT The hub tension bolt is used to adjust the wire spool tension which acts as a mechanical brake to assist in the stopping of the welding wire at the completion of a weld Manual No 0 4936B PORTAFEED VS 212 2 10 Power Source Compatibility Since the PORTAFEED VS 212 operates on arc voltage it will work with most constant current CC or constant voltage CV DC type power sources When connected to a PORTAFEED VS 212 the maximum allowed open circuit voltage OCV of the power source is 100 VDC Open circuit voltages exceeding 100 VDC will damage or shorten the life of the unit NOTE Because of the high open circuit voltage associated with most CC power sources it 15 recommended to place the PORTAFEED VS 212 power switch in the OFF position when not welding This procedure will prolong the life of electrical components connected to the power input lines When using the PORTAFEED VS 212 there must be at least 15 VDC between the output terminals of the power source during standby and while welding Otherwise the unit will not have enough input voltage to operate properly A contactor is a sta
72. tion And Safety Circuits The following protection and safety circuits come standard with this wire feeder and are designed to protect by disabling the wire feeder against unfavorable operation and or equipment damage 1 Undervoltage Protection If the input voltage drops below the specified voltage range for an extended period of time an electronic circuit will activate and the wire feeder will not operate The undervoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range 2 Overvoltage Protection If the input voltage rises above the specified voltage range for an extended period of time an electronic circuit will activate and the wire feeder will not operate The overvoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range 3 Input Current Protection If the input current rises above the specified maximum input current for an extended period of time the input circuit breaker will trip and the wire feeder will not operate The input circuit breaker will have to be manually reset if it were to trip 4 5 Operation PORTAFEED VS 212 4 Motor Overcurrent Protection If the drive motor becomes locked or shorted an electronic circuit will activate and the motor will not operate If this circuit activates a light on the motor control printed circuit board labeled Fault 2 will turn on The motor overcurrent protection circuit
73. will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds If this protection circuit activates and the drive motor is not locked the drive motor is most likely shorted and will have to be replaced refer to Troubleshooting Guide section of this manual 5 Contactor And Gas Valve Overcurrent Protection If the contactor or gas valve becomes shorted an electronic circuit will activate and both the contactor and gas valve will not operate If this circuit activates a light on the 12 V driver printed circuit board labeled Fault 1 will turn on The contactor and gas valve overcurrent protection circuit will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds If this protection circuit activates the contactor or gas valve is most likely shorted and one or both will have to be replaced refer to section 5 06 Troubleshooting Guide in this manual Operation 4 6 Manual No 0 4936B PORTAFEED VS 212 SECTION 5 MAINTENANCE 5 01 Cleaning Of The Unit About every 6 months remove the interior panel cover to expose the printed circuit boards and other components Using a vacuum cleaner or clean dry compressed air of not more than 25 psi 172 kPa 1 72 bar pressure vacuum or blow out the interior of the wire feeder While the interior panel cover is removed check all electrical components for lo
74. x chapter for the proper selection and ordering of feed roll kits Kit includes an idler roll a drive roll an input wire guide and an output wire guide for a specific wire type and size NOTE All grooved feed rolls have their wire size or range stamped on the side of the roll On rolls With different size grooves the outer visible when installed stamped wire size indicates the groove in use Idler feed rolls are installed by unscrewing the upper retaining knob and removing the idler gear The idler feed roll retaining knob is then removed from the idler gear and the idler feed roll is placed over the lobes on the idler gear The idler feed roll retaining knob is replaced and this assembly is returned and secured with the upper retaining knob Drive feed rolls are installed by removing the lower retaining knob placing the drive feed roll over the lobes on the drive gear and securing with the lower retaining knob NOTE Installation of all styles of feed rolls for this feeder is identical Art A 07198 WARNING The welding wire is electrically Hot if wire is fed by depressing gun switch Electrode contact to work piece will cause an arc with gun switch depressed 3 06 MIG Gun Compatibility And Installation and Removal The Portafeed VS 212 wire feeder is designed to be used with most MIG welding guns It comes configured from the factory to work with all Tweco guns Refer to the Appendix 2 Options and Accesso
75. zar dS iaia 1 1 1 02 Principal Safety Standards aaa 1 4 1 03 Precautions De Securite En Soudage 1 5 1 04 Dangers relatifs au soudage l Alta 1 5 1 05 Principales Normes De Securite 1 8 1 06 Declaration Of WIR 1 9 SECTION 2 DMIN H N erer rl lr mm 2 1 2 01 How To Use This Manual rire 2 1 2 02 Eguipment Identificati Msn a 2 1 ZE Cee RR I 2 2 RICO FR IRE 2 3 2 05 PIOOUCE Specifications claire 2 4 2 FEES nanc Qu d a a oa sn er nic 2 5 2 07 Front Panel Controls And GOnnections acli 2 6 2 08 Rear Panel Controls And Gonrectiolis rient 2 7 2 09 Internal Controls And Connections ie 2 8 2 10 P wer Source Compatibility loan 2 9 2 11 Options and Accessories 02422 2 9 SECTION 3 INSTALLATION e lt lt c 3 1 2 0 5 nee tete 3 1 9 02 Installati n Of Wire SO 3 2 3 05 Adjustment OF Spool TENSIONI 3 3 3 04 Input And Output Wire Guide Installation 3 3 3 05 Selection And Installation Of Feed Rolls entes 3 4 3 06 MIG Gun Compatibility And Installation and Removal 3 4 207 Threading Wire Into FOUN GAG an 3 5 SECTION 4 OPERATION nan

PORTAFEED® VS 212 Service Manual

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PORTAFEED&reg; VS 212 Service Manual

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PORTAFEED® VS 212 Service Manual