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211i Operating Manual FabricatOr®

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2. Manual 0 5225 1 7 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 SAFETY INSTRUCTIONS This Page Intentionally Blank SAFETY INSTRUCTIONS AND WARNINGS 1 8 Manual 0 5225 INTRODUCTION FABRICATOR 2111 SECTION 2 INTRODUCTION 2 01 How To Use This Manual To ensure safe operation read the entire manual includ ing the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular atten tion to the information provided under these headings These special annotations are easily recognized as follows WARNING A WARNING gives information regarding possible personal injury CAUTION A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concern ing certain operating procedures You will also notice icons from the safety section ap pearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that follows Some may have multiple hazards that apply and would look something like this 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is identified only
3. 3 Nozzle Angle This refers to the position of the welding gun in relation to the joint The transverse angle is usually one half the included angle between plates forming the joint The longitudinal angle is the angle between the centre line of the welding gun and a line perpendicular to the axis of the weld The longitudinal angle is generally called the Nozzle Angle and can be either trailing pulling or leading pushing Whether the operator is left handed or right handed has to be considered to realize the effects of each angle in relation to the direction of travel Transverse Angle Longitudinal Angle Axis of Weld Art 08998 Transverse and Longitudinal Nozzle Axes Figure 4 9 Direction of Gun Travel Leading or Pushing 90 Trailing or Pulling Angle Angle Forward Pointing Backward Pointing Nozzle Angle Right Handed Operator Art A 08999_AC Figure 4 10 Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work it is recommended that practice welds be made on a Sample metal of the same material as that of the finished piece BASIC WELDING GUIDE 4 4 Manual 0 5225 BASIC WELDING FABRICATOR 2111 The easiest welding procedure for the beginner to experiment with welding is the flat position The equipment is capable of flat vertical and overhead positions For practicing welding secure some pieces of 16 gauge 1 6mm or 18 ga
4. Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 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 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 211i 1 03 Symbol Chart Note that only some of these symbols will appear on your model Three Phase Static Dangerous Voltage Frequency Converter Transformer R ectifier Circuit Breaker Duty Cycle 0 AC Auxiliary Power Percentage ANDER I Shielded Metal Arc Welding SMAW Gas Metal Arc 9 Welding GMAW Hz Iz Hertz cycles sec Constant Voltage Direct Current DC E arth Auxiliary Power Variable Inductance 115 15A Receptacle Rating 6 Voltage Input Gas Tungsten Arc Welding GTAW Air Carbon Arc Cutting CAC A High Temperature Auxiliary Power SAFETY INSTRUCTIONS AND WARNINGS 1 6 SAFETY INSTRUCTIONS Wire Feed Function Wire Feed Towards
5. 9 Power indicator will not The mains supply voltage Ensure that the mains supply illuminate and welding arc has exceeded voltage limits voltage is within 230VAC 15 cannot be established of the power source 10 TIG electrode melts when torch is connected to Connect the TIG torch to the arc is struck the VE terminal VE terminal 11 Arc flutters during TIG Tungsten electrode is too select the correct size of tung welding large for the welding cur sten electrode Refer to Table rent 4 6 Table 5 1 Power Source Problems 5 02 Routine Service and Calibration Requirements WARNING There are extremely dangerous voltage and power levels present inside this Inverter Power Source Do not attempt to open or repair unless you are an accredited Thermal Arc Service Provider Discon nect the Welding Power Source from the Mains Supply Voltage before disassembling Routine Inspection Testing amp Maintenance The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc s original specifications A Testing Schedule 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of t
6. INSTALLATION SETUP FABRICATOR 2111 SECTION 3 INSTALLATION OPERATION AND SETUP 3 01 Environment This unit is designed for use in environments with increased hazard of electric shock as outlined in EN 60974 1 Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock Please refer to relevant local standards for further information prior to using in such areas A Examples of environments with increased hazard of electric shock are 1 In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sit ting or lying position with physical contact with conductive parts In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories B Environments with increased hazard of electric shock do not include places where electrically conduc tive parts in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines areas free from moisture and dust B Ambient temperature between 0 C 32 F to 40 C 104 F
7. in which case actual welding amperage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode NOTE The preview functionality provided on this power source is intended to act as a guide only Some dif ferences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transfer Where exact settings are required the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate 4 Amperage Control Wirespeed The amperage control knob adjusts the amount of welding current delivered by the power source In STICK and LIFT TIG GTAW modes the amperage control knob directly adjusts the power inverter to deliver the desired level of output current MIG GMAW FCAW mode the amperage knob adjusts the speed of the wire feed motor which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc The optimum wire speed required will dependent on the type of welding application The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications NOTE The previ
8. 10 minute duty cycle period the following example is used Suppose a Welding Power Source is designed to oper ate at a 20 duty cycle 210 amperes at 24 5 volts This means that it has been designed and built to provide the rated amperage 210A for 2 minutes i e arc welding time out of every 10 minute period 20 of 10 minutes is 2 minutes During the other 8 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool The thermal cut out will operate if the duty cycle is exceeded 100 90 FABRICATOR 2111 O lt E v STICK TIG E 50 40 gt 30 SAFE OPERATING REGION 2 M MIG TIG amp STICK 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 Welding Current AMPS Figure 2 2 Fabricator 211i Duty Cycle on 230VAC 100 90 lt FABRICATOR 211 80 S STICK a TIG 70 60 N 50 9 40 USE M 30 SAFE OPERATING REGION B 20 TIG amp STICK A 10 MIG 0 10 20 30 40 50 60 20 80 90 100 110 120 130 140 150 Welding Current AMPS Art A 10936 Figure 2 3 Fabricator 211i Duty Cycle on 110VAC Man
9. C In areas free from oil steam and corrosive gases D In areas not subjected to abnormal vibration or shock E In areas not exposed to direct sunlight or rain Manual 0 5225 3 1 F Place at a distance of 1 foot or more from walls or similar that could restrict natural air flow for cooling The enclosure design of this power source meets the requirements of 235 as outlined in EN 60529 Precautions must be taken against the power source toppling over The power source must be located on a suitable horizontal surface in the upright position when in use ul This equipment should be electrically con nected by a qualified electrician 3 03 Ventilation AS e WARNING Since the inhalation of welding fumes can be harmful ensure that the welding area is effectively ventilated 3 04 Mains Supply Voltage Requirements The Mains supply voltage should be within 15 of the rated Mains supply volt age low of a supply voltage may cause poor welding performance or wirefeeder malfunction Too high of a supply voltage will cause components to overheat and possibly fail A WARNING The Fabricator 211i must be electrically connected by a qualified electrical trades person Damage to the PCA Power Control Assembly could occur if 276 VAC or higher 15 applied to the Primary Power Cable INSTALLATION SETUP FABRICATOR 211i INSTALLATION SETUP 50 60 Hz Primary Supply Mi
10. Workpiece With 1 Output Voltage OFF Welding Gun T P urging Of Gas Continuous Weld Mode em g i Press to initiate wirefeed and welding release to stop 2 Step Trigger Operation 4 Step Trigger Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Inches Per Minute Meters Per Minute Ea Art A 10663 Manual 0 5225 SAFETY INSTRUCTIONS FABRICATOR 2111 1 04 Declaration Of Conformity Manufacturer Thermadyne Industries 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 National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 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 CENELEC EN50199 EMC Product Standard for
11. commonly referred to as stick out To decrease the burnback time or lengthen the amount of wire protruding from the MIG gun at the completing of welding turn the burnback control knob anti clockwise To increase the burnback time or shorten the amount of wire protruding from the MIG gun at the completing of welding turn the Burnback Control knob clockwise 20 MIG Gun SPOOL Gun Switch located in wirefeed compartment The Gun SPOOL Gun switch is used to switch welding mode between Gun functionality and SPOOL Gun functionality 21 Cooling Fan The Fabricator 2111 is fitted with a fan as needed feature Fan as needed automatically switches the cooling fan off when it is not required This has two main advantages 1 to minimize power consumption and 2 to minimise the amount of contaminants such as dust that are drawn into the power source Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required 3 07 Attaching MIG Gun Fit the MIG gun to the power source by pushing the MIG gun connector into the MIG gun adaptor and screwing the plastic nut clockwise to secure the MIG gun to the MIG gun adaptor MIG Gun Adaptor Art 10423 AB Figure 3 5 Attaching MIG Gun INSTALLATION SETUP 3 10 Manual 0 5225 INSTALLATION SETUP FABRICATOR 211i 3 08 Installing 15kg Spool 300mm diameter As delivered from the factory the unit is fitted with a Wi
12. flat horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 15 through 4 22 Art A 07687 Figure 4 11 Flat Position Down Hand Butt Weld BASIC WELDING GUIDE 4 10 Manual 0 5225 BASIC WELDING FABRICATOR 211i Figure 4 12 Flat Position Gravity Fillet Weld Art 07689 Art 07690 Figure 4 14 Horizontal Vertical HV Position TUE Art A 07691 Figure 4 15 Vertical Position Butt Weld Art 07692 Figure 4 16 Vertical Position Fillet Weld Art A 07693 Figure 4 17 Overhead Position Butt Weld Manual 0 5225 4 11 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING Art A 07694 Figure 4 18 Overhead Position Fillet Weld Joint Preparations In many cases it will be possible to weld steel sections without any special preparation For heavier sections and for repair work on castings etc it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints In general surfaces being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 19 Open Square Butt Single Vee oint Not than Joint Gap varies fr
13. 09 EE 2 4 2 10 Optional 2 5 SECTION 3 INSTALLATION OPERATION AND SETUP 3 1 3 01 Environment MONEE 3 1 3 02 3 1 S MER cH Rm 3 1 3 04 Mains Supply Voltage Requirements 3 1 3 05 Electromagnetic Compatibility 3 2 3 06 Power Source Controls Indicators and Features 3 4 SECTION 4 BASIC WELDING GUIDE 4 1 4 01 GMAW FCAW Basic Welding Technique 4 1 402 MIG GMAW FCAW Welding Troubleshooting 4 7 4 03 STICK MMA Basic Welding Technique 4 10 4 04 STICK MMA Welding Troubleshooting 4 20 4 05 TIG GTAW Basic Welding Technique 4 22 406 TIG GIAW Welding Problems 4 24 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 1 5 01 Power Source Problems 5 1 5 02 Routine Service and Calibration 5 2 5 03 Cleaning the Welding
14. Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60974 1 EN50192 EN50078 applicable to welding equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the 5 mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications WARNING 2002 95 EC RoHS directive This equipment does not comply with 61000 3 12 If it is connected to a public low voltage system it is the responsibility of the installer or user of the equipment to ensure by consultation With the distribution network operator if necessary that the equipment may be connected Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative oteve Ward Operations Director Thermadyne Europe Europa Building Chorley Industrial Park Chorley Lancashire England PR6 7
15. Source Positive Welding Terminal QV Electrode Holder Negative Welding ex Terminal Work Lead 4 el Art A 10433 Figure 3 17 Setup for Manual Arc Welding 3 20 Manual 0 5225 BASIC WELDING FABRICATOR 211i SECTION 4 BASIC WELDING GUIDE 4 01 MIG GMAW FCAW Basic Welding Technique Two different welding processes are covered in this section GMAW and FCAW with the intention of providing the very basic concepts in using the MIG mode of welding where a welding gun is hand held and the electrode welding wire is fed into a weld puddle and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture GAS METAL WELDING GMAW This process also known as welding CO welding Micro Wire Welding short arc welding dip transfer welding wire welding etc is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a solid continuous consumable electrode and the work Shielding is obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture The process is normally applied semi automatically however the process may be operated automatically and can be machine operated The process can be used to weld thin and fairly thick steels and some non ferrous metals in all positions Shielding Gas Nozzle Electrode PAN 116 Solidified lt IS We
16. Source then raise gas pressure and blow out impurities Gas regulator turned F Turn on off Torch valve is turned G Turn on off The electrode is too H Increase electrode diameter or reduce the Small for the welding welding current current Power source is set Set Power Source to LIFT TIG mode MIG welding BASIC WELDING GUIDE 4 24 Manual 0 5225 BASIC WELDING FABRICATOR 2111 Dirty weld pool A Electrode contaminated A Clean the electrode by grinding off the by contact with work contaminates piece or filler rod mate rial B Work piece surface has B Clean surface foreign material on it C Gas contaminated with Check gas lines for cuts and loose fitting or change gas cylinder 8 Poor weld finish Inadequate shielding Increase gas flow or check gas line for gas gas flow problems 9 Arc start is not smooth A Tungsten electrode A Select the right size electrode Refer to too large for the weld Table 4 6 ing current B The wrong electrode B Select the right electrode type Refer to is being used for the Table 4 8 welding job C Gas flow rate is too C Select the right rate for the welding job high Refer to Table 4 9 D Incorrect shielding gas D Select the right shielding gas is being used E Poor work clamp con E Improve connection to work piece nection to work piece 10 Arc flutters during TIG Tungsten electrode is select the right size electrode Refer to welding too
17. Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Connect the work lead to the positive welding terminal If in doubt consult the electrode wire manufacturer Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection D Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information A WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packaging material prior to use Do not block the air vents at the front or rear of the Weld ing Power Source MIG Gun Negative Welding Terminal MIG Polarity Lead Terminal 4 Work Lead Art A 10431 Figure 3 14 Setup for MIG Welding with Gasless MIG Wire INSTALLATION SETUP 3 16 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 3 16 Setup for SPOOL GUN MIG GMAW Welding with Gas Shielded MIG Wire A B select MIG mode with the process selection control refer to Section 3 06 13 for further information Connect th
18. applicable Thermal Arc power source specifications Table 5 3 Calibration Parameters Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified C Calibration Equipment All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question Only test equipment with valid calibration certificates NATA certified laboratories shall be utilized 5 03 Cleaning the Welding Power Source WARNING There are dangerous voltage and power levels present inside this product Do not attempt to open or repair unless you are a qualified electrical tradesperson Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling To clean the Welding Power Source open the enclosure and use a vacuum cleaner to remove any accumulated dirt metal filings slag and loose material Keep the shunt and lead screw surfaces clean as accumulated foreign material may reduce the welders output welding current PROBLEMS AND ROUTINE SERVICE 9 4 Manual 0 5225 PROBLEMS SERVICE FABRICATOR 211i 5 04 Cleaning the Feed Rolls Clean the grooves in the drive rolls frequently This can be done by using a small wire brush Also wipe off or clean the grooves on the upper feed roll After cleaning tighten the feed roll retaining knobs CAUTION Do NOT use compressed air to clean the Welding Power Sour
19. approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping 3 Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 5 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING Engines can be dangerous WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas If us
20. are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerospace Engineering Rural and DIY Hobbyist We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry AN WARNINGS head and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgment the Manufacturer assumes no liability for its use Operating Manual Number 0 5225 for Thermal Arc Fabricator 211i Inverter Power Supply Part Number W1004206 Thermal Arc Fabricator 211i Inverter System Part
21. be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transfer Where exact settings are required the case of procedural work it is recommended that alternate measurement methods be utilised to ensure output values are accurate When MIG GMAW FCAW Mode is Selected In this mode the control knob is used to adjust the output voltage of the unit The welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti clockwise The optimum voltage level required will dependent on the type of welding application The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications When STICK MMA Mode is Selected In this mode the multifunction control knob is used to adjust arc force Arc force control provides an adjust able amount of welding force or dig control This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit up in certain situations with particular electrodes In general increasing the arc force control toward 10 maximum arc force allows greater penetration control to be achieved Arc force is increased by turning the control knob clockwise or decre
22. between a single tungsten non consumable electrode and the work piece Shielding is obtained from a welding grade shielding gas or welding grade shielding gas mixture which is generally Argon based A filler metal may also be added manually in some circumstances depending on the welding application A 09658 AB Gas Cup Either Ceramic Work Piece High Impact or Can Be Any Commercial Water Cooled Metal N Metal Tungsten Electrode Non Consumable Welds Made With or Without Addition of Filler Metal adit T Shields Electrode and Weld Puddle Figure 4 38 TIG Welding Application Shot Tungsten Electrode Current Ranges 1 16 3 32 2 4mm 1 8 3 2mm 135 200 9 32 4 0mm 190 280 3 16 4 8mm 250 340 Table 4 6 Current Ranges for Various Tungsten Electrode Sizes Guide for Selecting Filler Wire Diameter Filler Wire Diameter DC Current Range Amps 1 16 1 6mm 20 90 3 32 2 4mm 65 115 1 8 3 2mm 100 165 3 16 4 8mm 200 350 Table 4 7 Filler Wire Selection Guide BASIC WELDING GUIDE 4 22 Manual 0 5225 FABRICATOR 2111 BASIC WELDING Tungsten Electrode Types Electrode Type Ground Finish Welding Application 0 Colour Code Excellent arc starting Long life High current carrying capacity DC welding of mild steel stainless steel and copper Thoriated 2 High quality AC weld Self cleaning Long ing of aluminium
23. by the specification or part number printed on the shipping container Record these numbers on the bottom of page for future reference Manual 0 5225 2 03 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as de scribed above along with a full description of the parts error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 04 Description The Thermal Arc Fabricator 211i is a self contained single phase multi process welding inverter that is ca of performing MIG GMAW FCAW STICK and LIFT GTAW welding processes The unit is equipped with an integrated wire feed unit digital volt age and amperage meters and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional The unit is also fully compliant to Standard EN 60974 1 The Thermal Arc Fabricator 211i provides excellent welding performance across a broad range of applica tions when used
24. hose from the rear of the power source to the regulator flowmeter outlet Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information pa Z WARNING Before connecting the work clamp to the work make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder an upright position by chaining it to a suitable sta tionary support to prevent falling or INSTALLATION SETUP 3 14 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packaging material prior to use Do not block the air vents at the front or rear of the Weld ing Power Source shielding Gas Hose Fitted with Quick Connect Q Positive Welding Terminal Spy MIG Pol MIG Gun Lo arity Lead Negative Welding Terminal Work Lead c a E Figure 3 13 Setup for MIG Welding with Gas Shielded MIG Wire 10430 AB Manual 0 5225 3 15 INSTALLATION SETUP FABRICATOR 2111 INSTALLATION SETUP 3 15 Setup for MIG FCAW Welding with Gasless MIG Wire A Select mode with the process selection control refer to Section 3 06 13 for further information B Connect the MIG polarity lead to the negative welding terminal If in doubt consult the electrode wire manu facturer
25. i Ires Singapore Fax 1 940 483 8178 Canada Customer Care Customer Care Customer Care Ph 61 3 0474 7508 Sales Office Ph 1 905 827 4515 Ph 39 0236546801 Ph 4603 6092 2988 Fax 61 3 0474 7488 Ph 65 6832 8066 Fax 1 800 588 1714 tollfree Fax 39 0236546840 Fax 4603 6092 1085 i Fax 65 6763 5812 2010 2011 2012 Thermadynelndustries Inc www thermadyne com
26. is damaged Gas passage contains impurities Gas regulator turned off Empty gas cylinder 5 1 Set power source to the cor rect mode of operation with the process selection switch Repair or replace torch trigger switch lead Leave the power source switched ON and allow it to cool Note that fault indicator must be extinguished prior to com mencement of welding Check for clogged kinked MIG gun conduit liner or worn con tact tip Replace faulty compo nents Have an Accredited Thermal Arc Service Provider investigate the fault Change the trigger mode selec tion switch from 4T latch mode to 2T normal mode Repair or replace torch trigger switch lead Connect the MIG gun polar ity lead to either the positive welding output terminal or the negative welding output terminal as required Clean work clamp area and en sure good electrical contact A Replace if necessary B Replace C Reduce brake tension on spool hub Clean or replace conduit liner A Replace or repair Disconnect gas hose from the rear of power source and blow out impurities Turn on regulator D Replace gas cylinder PROBLEMS AND ROUTINE SERVICE FABRICATOR 2111 PROBLEMS SERVICE 8 Gas flow continues after Gas valve has jammed open Have an accredited Thermal the trigger switch has been due to impurities in the gas Arc service provider repair or released mode or the gas line replace gas valve
27. life Maintains balled magnesium and their end High current car alloys rying capacity Zirconated 1 AC amp DC welding of Longer life More mild steel stainless stable arc Easier steel copper alumin starting Wider current ium magnesium and range Narrower more their alloys concentrated arc Ceriated 2 Table 4 8 NOTE The Fabricator 211i Inverter is not suited for AC TIG welding DC Current DC Current Filler Rod for Mild for Stainless Diameter if Steel Steel required Tungsten Electrode Diameter Base Metal Thickness Argon Gas Joint Type Flow Rate Litres min 0 040 1 0mm 0 045 1 2mm 1 16 1 6mm 1 8 3 2mm 3 16 4 8mm 1 4 6 4mm 35 45 20 30 40 50 25 35 45 55 30 45 50 60 35 50 60 70 40 60 70 90 50 70 90 100 65 85 90 115 90 110 115 135 100 125 140 165 125 150 160 175 170 200 135 160 160 180 0 040 1 0mm 0 040 1 0mm 1 16 1 6mm 1 16 1 6mm 3 32 2 4mm 1 8 3 2mm 1 16 1 6mm 1 16 1 6mm 1 16 1 6mm 3 32 2 4mm 1 8 3 2mm 5 32 4 0mm 5 7 Butt Corner Lap Fillet 5 7 Butt Corner Lap Fillet 7 Butt Corner Lap Fillet 7 Butt Corner Lap Fillet 10 Butt Corner Lap Fillet Butt Corner Lap Fillet Table 4 9 TIG Welding is generally regarded as a specialised process that requires operator competency While many of the principles outlined in the previous Arc Weldin
28. of the weld metal to fill the root of the weld A Welding current too low Electrode too large for joint Insufficient gap Non metallic par ticles are trapped in the weld metal Non metallic particles may A be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow Slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is pre venting full fusion Wrong electrode for posi tion in which welding is done 05866 Incorrect Sequence Insufficient Gap A groove has been A Welding current is too formed in the base high metal adjacent to HE B Welding arc is too long and has not been filled by the weld metal undercut Angle of the electrode is incorrect Joint preparation does not D allow correct electrode angle Electrode too large for joint Insufficient deposit time at F edge of weave Power source is set for GMAW FCAW welding BASIC WELDING GUIDE 4 20 Reduce the ARC FORCE control knob until weld ing current is reasonably constant while prohibit ing the electrode from sticking to the work piece when you dig the electrode into the workpiece Increase welding current Use smaller diameter electrode Allow wider gap If a bad undercut is present clean slag bout and cover with a run from a smaller gauge electrode Allow for adequa
29. short arc exhibits voltage polarity on the flux cored wires Refer to the electrode wire when the wirefeed front panel manufacturer for the correct polarity speed and voltage are adjusted cor rectly Table4 4 GMAW FCAW Welding Problems Manual 0 5225 4 9 BASIC WELDING GUIDE FABRICATOR 211i BASIC WELDING 4 03 STICK MMA Basic Welding Technique Size of Electrode The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available Small welding machines will only provide sufficient current amperage to run the smaller size electrodes For thin sections it is necessary to use smaller electrodes otherwise the arc may burn holes through the job A little practice will soon establish the most suitable electrode for a given application Storage of Electrodes Always store electrodes in a dry place and in their original containers Electrode Polarity Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity The WORK LEAD is connected negative polarity and is connected to the work piece If in doubt consult the electrode data sheet or your nearest Accredited Thermal Arc Distributor Effects of Arc Welding Various Materials A High tensile and alloy steels The two most prominent effects of welding these steels are the formation of a hardened zone in the weld area and if suitable precautions are not
30. to a minimum Maintain the MIG gun good A Ensure that the gas holes are not blocked and gas is exiting working order out of the MIG gun nozzle B Do not restrict gas flow by allowing spatter to build up inside the MIG gun nozzle C Check that the MIG gun O rings are not damaged Table 4 2 Solving Problems beyond the Welding Terminals Porosity Disengage the feed roll when testing for gas flow by ear Manual 0 5225 4 7 BASIC WELDING GUIDE FABRICATOR 211i BASIC WELDING Solving Problems Beyond the Welding Terminals Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points FAULT CAUSE 1 Feedroller driven by motor in the Wire spool brake is too tight cabinet slipped 2 Wire spool unwinded and tangled Wire spool brake is too loose 3 Worn or incorrect feed roller size A Usea feed roller matched to the size you are welding B Replace feed roller if worn 4 Wire rubbed against the mis aligned Mis alignment of inlet outlet guides guides and reduced wire feedability 5 Liner blocked with swarf Increased amounts of swarf are produced by the wire passing through the feed roller when excessive pres sure is applied to the pressure roller adjuster B Swarfcan also be produced the wire passing through an incorrect feed roller groove shape or size Swarfis fed into the conduit liner where it accumu lates thus reducing wire feedability 6 Incorrect or worn contact tip
31. will go OFF and the over temperature condition will automatically reset Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently Do not switch the unit off should a thermal overload condition be present Digital Amps Meter Left Digital Display MIG Mode This digital meter is used to display the pre set preview Wirefeed Speed in Meters Per Minute MPM in mode and actual welding amperage of the power source when welding At times of non welding the digital meter will display a pre set preview value of Wirefeed Speed This value can be adjusted by varying the Amperage Control Knob 4 STICK and LIFT TIG Modes The digital meter is used to display the pre set preview amperage in STICK LIFT modes and actual welding amperage of the power source when welding At times of non welding the amperage meter will display a pre set preview value in both STICK and LIFT TIG modes This value can be adjusted by varying the Amperage Control Knob 4 When welding this digital meter will display actual welding amperage in all modes At the completion of welding the digital meter will hold the last recorded amperage value for a period of approximately 10 seconds in all modes The amperage meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to preview mode 2 welding is recommenced
32. 12 Trigger Mode Control MIG and LIFT TIG Mode only The trigger mode control is used to switch the functionality of the of the torch trigger between 2T normal and 4T latch mode 2T Normal Mode In this mode the torch trigger must remain depressed for the welding output to be active Press and hold the torch trigger to activate the power source weld Release the torch trigger switch to cease welding 4T Latch Mode This mode of welding is mainly used for long welding runs to reduce operator fatigue In this mode the opera tor can press and release the torch trigger and the output will remain active To deactivate the power source the trigger switch must again be depressed and realised thus eliminating the need for the operator to hold the torch trigger Note that when operating in LIFT TlG GTAW mode the power source will remain activated until the selected downslope time has elapsed refer Item 10 13 Process Selection Control The process selection control is used to select the desired welding mode Three modes are available GMAW FCAW LIFT GTAW and STICK modes Refer to section 3 14 3 15 or 3 16 for MIG GMAW FCAW set up details section 3 17 for LIFT TIG GTAW set up details or section 3 18 for STICK MMA set up details Note that when the unit is powered off the mode selection control will automatically default to mode This is necessary so as to prevent inadvertent arcing should an electr
33. 67 Y Figure 4 20 Striking an Arc Arc Length The securing of an arc length necessary to produce a neat weld soon becomes almost automatic You will find that a long arc produces more heat A very long arc produces a crackling or spluttering noise and the weld metal comes across in large irregular blobs The weld bead is flattened and spatter increases A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the electrode tip being solidified in If this should happen give the electrode a quick twist back over the weld to detach it Contact or touch weld electrodes such as 27014 do not stick in this way and make welding much easier Rate of Travel After the arc is struck your next concern is to maintain it and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away At the same time the electrode has to move along the plate to form a bead The electrode is directed at the weld pool at about 20 from the vertical The rate of travel has to be adjusted so that a well formed bead is produced If the travel is too fast the bead will be narrow and strung out and may even be broken up into individual globules If the travel is too slow the weld metal piles up and the bead will be too large Manual 0 5225 4 13 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING Making Welded Joints Having a
34. 7 1 5VDC 2 TO U15 PING 1 PWM RETURN 1 15 2 IGBT Driver A 3 IGBT Driver B YELLOW WHITE 5 IGBT Driver A WHITE 6 Over Current Signal 1 OUTPUT 3 OUTPUT 1 15 2 15V REMOVE AMPS WIRESPEED POT WIPER 8 REMOVE VOLTAGE POT WIPER 7 TORCH SWITCH RIN OVDC 6 TORCH SWITCH RIN OVDC 5 SPOOL GUN 2VDC 4 TORCH SWITCH RIN OVDC 3 TORCH SWITCH 24V 2 SPOOL GUN OV 1 LOCAL REMOTE o 3 15VDC 4 GND 9 Amps Wirefeed Display boy Wirefeed Amps 2 PWM MOTOR DRIVER 5VDC PEAK 3 Current Feedback 5 TLOd OveroozM S 82 Ova AAA D fps AA LAAN AAN 3 9 E 8 10d lt INVH5VIGd LNOAVT MB ae 2GASL Yad V 2103 ZI H3dM 2103 1 NOLLRSHShd 55400 TIYIS t 5 119 Avadsia MIS QvOT TIAS I 9 lt lt lt lt Down Slope Arc Force NINININI YWYYYYY To 5 Display 4 W7005602 Process LIFT TIG Trigger Volts Display 2T Normal 4T Latch Volts Arc Co
35. A The contact tip transfers the weld current to the elec trode wire If the hole in the contact tip is too large then arcing may occur inside the contact tip resulting in the wire jamming in the contact tip B When using soft wire such as aluminium it may become jammed in the contact tip due to expansion of the wire when heated A contact tip designed for soft wires should be used Poor work lead contact to work piece If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc 6 Bentliner This will cause friction between the wire and the liner thus reducing wire feedability Table 4 3 Wire Feeding Problems BASIC WELDING GUIDE 4 8 Manual 0 5225 BASIC WELDING FABRICATOR 211i Basic MIG GMAW FCAW Welding Troubleshooting FAULT CAUSE REMEDY 1 Undercut A Welding arc voltage too Decrease voltage or increase the wire feed speed high B Incorrect MIG gun angle B Adjust angle C Excessive heat input C Increase the MIG gun travel speed and or decrease welding current by decreasing the voltage or decreasing the wire feed speed 2 Lack of penetration Welding current too low Increase welding current by increasing wire feed speed and increasing voltage B Joint preparation too B Increase joint angle or gap narrow or gap too tight C Shielding gas incorrect C Change to a gas which gives higher penetration 3 Lack of fu
36. IHERMAL FABRIGATOR MULTI PROCESS WELDING INVERTER IHERMAL ARC _ THERMAL ARC Art A 10934 Operating Manual Revision AB Issue Date February 29 2012 Manual No 0 5225 Operating Features INVERTER Ta 200 CC 110 C 211 2 20 2 5 IHERMAL WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 44 0 1257 261 755 or visit us on the web at www Thermalarc com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product We have made every effort to provide you with accurate instructions drawings and photographs of the product s while writing this manual However errors do occur and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you
37. LLATION SETUP 3 18 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 Positive Welding Terminal x2 TIG Remote Control 7 Figure 3 16 Setup for TIG Welding Work Le 7 Negative Welding Terminal Manual 0 5225 3 19 INSTALLATION SETUP FABRICATOR 2111 INSTALLATION SETUP 3 18 Setup for STICK MMA Welding A INSTALLATION SETUP Connect the Electrode Holder lead to the positive welding terminal If in doubt consult the electrode manu facturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Connect the work lead to the negative welding terminal If in doubt consult the electrode manufacturer Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Select STICK mode with the process selection control refer to Section 3 06 13 for further information F WARNING A i Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Welding Power
38. Number W1004207 Published by Thermadyne Europe Europa Building Chorley Industrial Park Chorley Lancaster England PR6 BX www thermalarc com Copyright 2011 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date December 23 2011 Revision AB Date February 29 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial 7 TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 Ae 1 1 1 02 Principal Safety iata Un iu 1 5 LOS Symbol IEEE 1 6 1 04 Declaration Of Conformity 1 7 SECTION 2 INTRODUCTION 2 1 2 01 HOW TOUSE undo nec uo 2 1 2 02 Equipment Identification 2 1 209 Receipt Of Equipment __ ode 2 1 ZA DOSED ON RET 2 1 2 2 206 Transportation eter es 2 2 206 Packaged Items cence 2 2 2 08 Duty a 3c nnns 2 3 2
39. Power Source 5 4 5 04 Cleaning the Feed 5 5 5 TABLE OF CONTENTS SECTION 6 KEY SPARE 6 1 6 01 Power Source 6 1 APPENDIX FABRICATOR 211i CIRCUIT DIAGRAM 1 THERMAL LIMITED WARRANTY TERMS TERMS OF WARRANTY JANUARY 2011 SAFETY INSTRUCTIONS FABRICATOR 2111 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and 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 oafe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extens
40. and gauntlets You won t be worrying then about being burnt or sparks setting alight to your clothes Place the work so that the direction of welding is across rather than to or from your body The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down If the lead is slung over your shoulder it allows greater freedom of movement and takes a lot of weight off your hand Be sure the insulation on your cable and electrode holder is not faulty otherwise you are risking an electric shock Striking the Arc Practice this on a piece of scrap plate before going on to more exacting work You may at first experience difficulty due to the tip of the electrode sticking to the work piece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 6mm to 3 2mm gap between the burning electrode end and the parent metal Draw the electrode slowly along as it melts down Another difficulty you may meet is the tendency after the arc is struck to withdraw the electrode so far that the arc is broken again A little practice will soon remedy both of these faults 20 A 07696 WO X7 29291 mm 14
41. anual Thermadyne welding products are manufactured for use by commercial and industrial users and trained per sonnel with experience in the use and maintenance of electrical welding and cutting equipment Thermadyne will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the warranty period The warranty period begins on the date of sale to the end user Thermal Arc Fabricator 211i Component Warranty Period MIG Gun Electrode Holder Lead amp Work Lead 3 Months Gun Consumables If warranty is being sought Please contact your Thermadyne product supplier for the warranty repair proce dure Thermadyne warranty will not apply to e Equipment that has been modified by any other party other than Thermadyne s own service personnel with prior written consent obtained from Thermadyne Service Department e Equipment that has been used beyond the specifications established in the operating manual e nstallation not in accordance with the installation operating manual Any product that has been subjected to abuse misuse negligence or accident Failure to clean and maintain including lack of lubrication maintenance and protection the machine as set forth in the operating installation or service manual Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation This manual also offers
42. arks 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 WARNING Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Manual 0 5225 1 3 9 FABRICATOR 2111 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Bealertthat welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Beaware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes 10 Remove stick electrode from holder or cut off 1 2 welding wire at contact tip when not in use gt FA WARNING FLYING SPARKS AND HOT METAL can cause Injury Chipping and grinding cause flying metal As welds cool they can throw off slag Wear
43. ased by turning the knob anti clockwise When LIFT TIG Mode is Selected In this mode the multifunction control knob is used to adjust down slope Down slope allows the user to select the ramp down time at the completion of the weld The main function of down slope is to allow the welding current to be gradually reduced over a pre set time frame such that the welding pool is given time to cool sufficiently Manual 0 5225 3 7 INSTALLATION SETUP FABRICATOR 2111 INSTALLATION SETUP Note that when in 21 normal mode refer item 12 the unit will enter down slope mode as soon as the trigger switch is released ie if the multifunction control knob is set to 5 the unit will ramp down from the present welding current to zero over 5 seconds If no down slope time is selected then the welding output will cease immediately If the unit is set to 4T latch mode to enter down slope mode the trigger must be held in for the selected time period ie press and release trigger to commence welding then press and hold trigger again to enter down slope mode Should the trigger be released during the down slope phase 4T only the output will cease immediately 11 Arc Control Inductance The arc control operates MIG GMAW FCAW mode only and is used to adjust the intensity of the welding arc Lower arc control settings make the arc softer with less weld spatter Higher arc control settings give a stronger driving arc which can increase weld penetration
44. basic troubleshooting operational and technical details including application usage You may also wish to visit our web site www thermadyne com select your product class and then select lit erature Here you will find documentation including Operator manuals e Service manuals e Product guides Alternatively please contact your Thermadyne distributor and speak with a technical representative NOTE Warranty repairs must be performed by either a Thermadyne Service Centre a Thermadyne distributor or an Authorised Service Agent approved by the Company Printed in China Customer Care UK 44 0 1257 261 755 Fax 44 0 1257 224 800 Customer Care Italy 39 02 36546801 Fax 39 02 36546480 www thermadyne com THERMADYNE A Global Cutting amp Welding Market Leader WORLD HEADQUARTERS 16052 Swingley Ridge Road Suite St Louis Missouri 63017 U S A THE AMERICAS EUROPE ASIA PACIFIC Denton TX USA Miami FL USA Chorley United Kingdom Cikarang Indonesia Melbourne Australia Shanghai China U S Customer Care Sales Office Latin America Customer Care Customer Care Australia Customer Care Sales Office Ph 1 800 426 1888 tollfree Ph 1 954 727 8371 Ph 44 1257 261755 6221 8990 6095 Ph 1300 654 674 tollfree Ph 486 21 64072626 Fax 1 800 535 0557 tollfree Fax 1 954 721 8376 Fax 44 1257 224800 Fax 6221 8990 6096 Ph 61 3 9474 7400 Fax 86 21 64483032 Oakville Ontario Canada Milan Italy Rawang Malaysia
45. being fused in the bayonet terminal 7 Polarity Lead The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal al lowing polarity reversal for different welding applications In general the polarity lead should be connected in to the positive welding terminal when using steel stainless steel or aluminium electrode wire When using gasless wire the polarity lead is generally connected to the negative welding terminal If in doubt consult the manufacturer of the electrode wire for the correct polarity It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 8 Negative Welding Output Terminal The negative welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG gun the MIG polarity lead TIG torch or work lead Negative welding current flows to the power source via this heavy duty bayonet type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 9 Remote Control Socket The 8 pin Remote Cont
46. ce Compressed air can force metal particles to lodge between live electrical parts and earthed metal parts within the Welding Power Source This may result in arcing between these parts and their eventual failure Manual 0 5225 0 0 PROBLEMS AND ROUTINE SERVICE FABRICATOR 2111 PROBLEMS SERVICE This Page Intentionally Blank PROBLEMS AND ROUTINE SERVICE 5 6 Manual 0 5225 REPLACEMENT PARTS FABRICATOR 2111 SECTION 6 KEY SPARE PARTS 6 01 Power Source Spare Parts Art 11234 Item Part Number W7005600 PCB Power W7005601 PCB Control W7005602 Display W7005607 Spool Gun 6 w7005603 Wiredrive Assembly o em Feed Roll 0 6 0 8mm V groove fitted as standard Refer to options and accessories table for other feed rolls available 9 wrooseoa fran W7004930 Shielding Gas Hose Assembly not shown Table 6 1 Key Spare Parts Manual 0 5225 6 1 KEY SPARE PARTS FABRICATOR 2111 REPLACEMENT PARTS This Page Intentionally Blank KEY SPARE PARTS 6 2 Manual 0 5225 CIRCUIT DIAGRAM FABRICATOR 2111 NND 100dS APPENDIX FABRICATOR 211i CIRCUIT DIAGRAM zer AOSC N8 5 TV L3ALL33HS UIN 2909 09 1 JINDY 23d UNYI UUU 7TOULNOO INMd IGBT Driver A 2 IGBT DriverB 3 IGBT DriverB 4 IGBT DriverA 5 Over Current Signal 6 GND
47. d off Secure the welding grade shielding gas cylinder in an upright position by chaining It to a suitable sta tionary support to prevent falling or CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal Remove any packing material prior to use Do not block the air vents at the front or rear of the Welding Power Source shielding Gas Hose Fitted with Quick Connect 9 legative Welding MIG polarity lead Terminal Positive Welding li Terminal Gun Mh Art 10576 Figure 3 15 Setup for Spool Gun Welding with Gas Shielded MIG Wire Manual 0 5225 9 17 INSTALLATION SETUP FABRICATOR 2111 INSTALLATION SETUP 3 17 Setup for TIG GTAW Welding A B select LIFT mode with the process selection control refer to Section 3 06 13 for further information Connect the TIG Torch to the negative welding terminal Welding current flows from the power source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Connect the work lead to the positive welding terminal Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Connect the TIG torch trigger sw
48. e MIG polarity lead to the positive welding terminal If in doubt consult the electrode wire manu facturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Fit the Euro Spool Gun to the power source using the front panel EURO adaptor refer also to section 3 07 Attaching MIG gun Connect the 8 pin Remote Control Plug to the 8 pin Remote Control Socket on the power source Connect work lead to the negative welding terminal If in doubt consult the electrode wire manufacturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Htthe welding grade shielding gas regulator flowmeter to the shielding gas cylinder then connect the shielding gas hose from the rear of the power source to the regulator flowmeter outlet Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information G Select MIG mode with the process selection control refer to section 3 06 13 for further information H Set the Spool Gun Switch located inside the wire drive compartment to SPOOL GUN AN gt WARNING Before connecting the work clamp to the work make sure the main power supply is switche
49. e machine which releases the pressure roller arm Figure 3 8 With the MIG welding wire feeding from the bottom of the spool Figure 3 9 pass the electrode wire through the inlet guide between the rollers through the outlet guide and into the gun Re secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly Figure 3 8 Remove the contact tip from the MIG gun With the MIG gun lead reasonably straight feed the wire through the MIG gun by depressing the trigger switch Fit the appropriate contact tip WARNING Before connecting the work clamp to the work make sure the mains power supply 15 switched off The electrode wire will be at welding voltage potential while it is being feed through the system Keep gun away from eyes and face Local Local Ti Wire Drive Tension Screw Pressure Roller Arm Art A 10426 Inlet Guide Outlet Guide Figure 3 8 Wire Drive Assembly Components MIG Welding Wire Art 10427 AB Figure 3 9 MIG Welding Wire Installation INSTALLATION SETUP 3 12 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 3 11 Feed Roller Pressure Adjustment The pressure top roller applies pressure to the grooved feed roller via an adjustable pressure screw These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage slipping occurs and inspection of the wire contact tip reveals no wear distortio
50. ed in a closed area vent engine exhaust outside and away from any building air intakes 4 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fuelling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuelling is spilled clean up before starting engine WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS 1 Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shi
51. eld when working on a battery Stop engine before disconnecting or connecting battery cables Do notallow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries p WARNING STEAM AND PRESSURIZED HOT can burn face eyes and skin The coolant in the radiator can be very hot under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing cap Allow pressure to escape before completely removing cap Manual 0 5225 SAFETY INSTRUCTIONS NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Con clusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Govern ment Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet al
52. ew functionality provided on this power source is intended to act as a guide only Some dif ferences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transfer Where exact settings are required the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate Manual 0 5225 3 5 INSTALLATION SETUP FABRICATOR 211i INSTALLATION SETUP 5 MIG Gun Adaptor Euro Style The gun adaptor is the connection point for the welding gun Connect the gun by pushing the gun connector into the brass gun adaptor firmly and screwing the plastic nut clockwise to secure in position To remove the MIG gun simply reverse these directions 6 Positive Welding Output Terminal The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the gun via the polarity lead electrode holder lead or work lead Positive welding current flows from the power source via this heavy duty bayonet type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug
53. g SAFETY INSTRUCTIONS Wear approved safety glasses Side shields recommended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Useapproved ear plugs or ear muffs if noise level 1 high Never wear contact lenses while welding AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers Lm Minimum Suggested Jb 2 Protective Shade No Shade Comfort Less than 3 32 2 4 Less than 60 T Shielded Metal Arc Welding 3 32 5 32 2 4 4 0 60 160 8 10 SMAW 5 32 1 4 4 0 6 4 160 250 10 12 More than 1 4 6 4 250 550 11 14 7 Less than 60 60 160 10 11 160 250 10 12 250 550 10 14 10 Gas Metal Arc Welding GMAW and Flux Cored Arc Welding FCAW Gas Tungsten arc Welding GTAW Air Carbon Arc Cutting CAC A Less than 20 20 100 100 400 400 800 Less than 20 20 40 40 60 Plasma Arc Cutting PAC 60 80 80 300 300 400 400 800 Plasma Arc Welding PAW As a rule of thumb start with a shade that is too dark to see the weld zone Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum In oxyfuel gas welding cutting or brazing where the torch and or the flux produces a high yellow light
54. g section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual For further information please refer to www thermadyne com or contact Thermal Arc Manual 0 5225 4 23 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING 4 06 TIG GTAW Welding Problems FAULT CAUSE REMEDY Excessive bead build up or Welding current is too Increase weld current and or faulty joint poor penetration or poor low preparation fusion at edges of weld 2 Weld bead too wide and Welding current is too Decrease weld current flat or undercut at edges high of weld or excessive burn through 3 Weld bead too small or Travel speed too fast Reduce travel speed insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or Travel speed too slow Increase travel speed excessive bead build up or excessive penetration in butt joint 5 Uneven leg length in fillet Wrong placement of Re position filler rod joint filler rod 6 Electrode melts or oxidises Torch lead connected A Connect torch lead to negative welding when an arc is struck to positive welding terminal terminal B No gas flowing to weld B Check the gas lines for kinks or breaks ing region and gas cylinder contents Torch is clogged with C Clean torch dust or dirt Gas hose is cut D Replace gas hose Gas passage contains Disconnect gas hose from the rear of impurities Power
55. he periodic tests and a system of tagging including the date of the most recent inspection Atransportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated NOTE Please refer to local guidelines for further information B Insulation Resistance Minimum insulation resistance for in service Thermal Arc Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5 2 below Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met PROBLEMS AND ROUTINE SERVICE 0 2 Manual 0 5225 PROBLEMS SERVICE FABRICATOR 2111 Minimum Insulation Components to be Tested Resistance Input circuit including any connected control circuits to welding circuit including any connected control circuits All circuits to exposed conductive parts Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage exceeding extra low voltage Welding circuit including any connected control circuits to any auxiliary circuit which operates at a voltage not exceeding extra low voltage separate welding circuit to separate welding circuit Table 5 2 Minimum Insulation Resistance Requirements Thermal Arc Inverter Power Sources C Earth
56. ible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equip ment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the welding circuit see NOTE below In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work complete with associated input filters In all cases electromagnetic disturbances shall be reduced to the point where they are no longer Troublesome NOTE The welding circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment INSTALLATION SETUP 3 2 Manual 0 5225 INSTALLATION SETUP B Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account Other supply cables control cables signalling and telephone cables above below and adjacent to the welding equipment Radio and television transmitters and receivers Computer and other control e
57. ing The resistance shall not exceed 10 between any metal of a power source where such metal is required to be earthed and 1 The earth terminal of a fixed power source or 2 The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring the integrity of fixed wiring supplying Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below 1 For outlets wiring and associated accessories supplying transportable equipment at least once every 3 months and 2 For outlets wiring and associated accessories supplying fixed equipment at least once every 12 months D General Maintenance Checks Welding equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure that 1 Flexible cord is of the multi core tough rubber or plastic sheathed type of adequate rating correctly connected and in good condition 2 Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short Circuit 3 The Welding System is clean internally especially from metal filing slag and loose material E Accessories Accessory equipment including output leads electrode holders torches wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable conditio
58. ing no further than 10 20mm after release of the trigger The electrode wire should be slack without becoming dislodged from wire spool CAUTION Overtension of brake will cause rapid wear of mechanical WIREFEED parts overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip NS opool Hub Tension pa Thumb Screw 10429 Figure 3 12 Wire Reel Brake 3 14 Setup for MIG GMAW Welding with Gas Shielded MIG Wire A B select MIG mode with the process selection control refer to Section 3 06 13 for further information Connect the MIG polarity lead to the positive welding terminal If in doubt consult the electrode wire manu facturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Fit the MIG gun to the power source Refer to section 3 07 Attaching MIG gun Connect work lead to the negative welding terminal If in doubt consult the electrode wire manufacturer Welding current flows from the Power Source via heavy duty bayonet type terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection Fitthe welding grade shielding gas regulator flowmeter to the shielding gas cylinder then connect the shielding gas
59. ire brush It is important to do this to prevent slag being trapped by the second run Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 22 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root and to prepare a Suitable joint for depositing the backing run If a backing bar is used it is not usually necessary to remove this since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld B Fillet Welds These are welds of approximately triangular cross section made by depositing metal in the corner of two faces meeting at right angles Refer to Figure 4 14 A piece of angle iron is a suitable specimen with which to begin or two lengths of strip steel may be tacked together at right angles Using a 3 2mm E7014 electrode at 100 amps position angle iron with one leg horizontal and the other vertical This is known as a horizontal vertical HV fillet Strike the arc and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45 from the vertical Some electrodes require to be sloped about 20 away from the perpendicular position to prevent slag from running ahead of the weld Refer to Figure 4 23 Do not attempt to build up m
60. it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum SAFETY INSTRUCTIONS AND WARNINGS 1 2 Manual 0 5225 SAFETY INSTRUCTIONS WARNING FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets 5055 and the manufacturer s instruction for metals consumables coatings and cleaners Work a confined space only if it is well ventilated or while wearing an air supplied respirator shielding gases used for welding can displace air causing injury or death Be sure the breathing air Is safe Donot weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases Donot weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded WELDING can cause fire or explosion Sp
61. itch via the 8 pin socket located on the front of the power source as shown below The TIG torch will require a trigger switch to operate in LIFT Mode NOTE If the torch has a remote TIG torch current control fitted then it will require to be connected to the 8 pin socket Refer to section 3 06 9 Remote Control Socket for further information Fit the welding grade shielding gas regulator flowmeter to the shielding gas cylinder refer to Section 3 14 then connect the shielding gas hose from the TIG torch to the regulator flowmeter outlet Note that the TIG torch shielding gas hose is connected directly to the regulator flowmeter The power source is not fitted with a shielding gas solenoid to control the gas flow in LIFT mode therefore the TIG torch will require a gas valve WARNING Before connecting the work clamp to the work and inserting the electrode TIG Torch make sure the mains power supply is switched off Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping A CAUTION Remove any packaging material prior to use Do not block the air vents at the front or rear of the Weld ing Power Source Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal INSTA
62. ive training in welding and cutting practices should not attempt to weld oafe practices are outlined in the European Standard EN60974 1 entitled Safety in welding and allied processes Part 2 Electrical This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Arc Welding Hazards 6 Turn OFF all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service 7 Use fully insulated electrode holders Never dip WARNING holder in water to cool it or lay it down on the ground or the work surface Do not touch holders ELECTRIC SHOCK can kill connected to two welding machines at the same Touching live electrical parts can cause time or touch other people with the holder or fatal shocks or severe burns The electrode electrode and work circuit 15 electrically live when 8 Do not use worn damaged undersized or poorly ever the output is on The input power cir spliced cables cuit and machine internal circuits are also live when power is on In semi automatic 9 Do not wrap cables around your body or automatic wire welding the wire wire 10 Ground the workpiece to a good electrical earth reel drive roll housing and all metal parts ground touching the welding wire are electrically uu live Incorrectly i
63. l contraction stresses distortion or the weld may crack in any case there will remain locked up stresses in the job Figures 4 29 and 4 30 illustrate how distortion is created Art 07705 AB Weld Upsetting m Expansion with compression m Hot Cool Figure 4 30 Parent Metal Contraction Overcoming Distortion Effects There are several methods of minimizing distortion effects A Peening This is done by hammering the weld while it is still hot The weld metal is flattened slightly and because of this the tensile stresses are reduced a little The effect of peening is relatively shallow and is not advisable on the last layer Manual 0 5225 4 17 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING B Distribution of Stresses Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out See Figures 4 30 through 4 33 for various weld sequences Choice of a suitable weld sequence is probably the most effective method of overcoming distortion although an unsuitable sequence may exaggerate it Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in
64. large for the weld Table 4 6 ing current Table 4 10 TIG GTAW Welding Problems Manual 0 5225 4 25 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING This Page Intentionally Blank BASIC WELDING GUIDE 4 26 Manual 0 5225 PROBLEMS SERVICE FABRICATOR 2111 SECTION 5 POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS 5 01 Power Source Problems FAULT CAUSE REMEDY Mains supply voltage is ON A Power source is not in the power indicator is illumi nated however unit will not commence welding when the torch trigger switch is depressed Fault Indicator is illumi nated and unit will not commence welding when the torch trigger switch is depressed Unit will not feed wire in MIG mode Welding wire continues to feed when torch trigger is released Welding arc cannot be established in MIG mode Inconsistent wire feed No gas flow in MIG mode Manual 0 5225 correct mode of operation Faulty torch trigger Duty cycle of power source has been exceeded Electrode wire stuck in conduit liner or contact tip burn back jam Internal fault in power source Trigger mode selection switch is in 4T latch mode Torch trigger leads shorted MIG gun polarity lead is not connected into a welding output terminal Poor or no work lead contact Worn or dirty contact tip Worn feed roll C Excessive brake tension on wire reel hub Worn kinked or dirty con duit liner Gas hose
65. late The applied techniques and end results in the GMAW process are controlled by these variables Preselected Variables Preselected variables depend upon the type of material being welded the thickness of the material the welding position the deposition rate and the mechanical properties These variables are of electrode wire Size of electrode wire e Type of gas not applicable to self shielding wires FCAW e Gas flow rate not applicable to self shielding wires FCAW Primary Adjustable Variables These control the process after preselected variables have been found They control the penetration bead width bead height arc stability deposition rate and weld soundness They are e Arc Voltage e Welding current wire feed speed e Travel speed Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation They are Manual 0 5225 4 3 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING 1 Stick out distance between the end of the contact tube tip and the end of the electrode wire Maintain at about 10mm stick out 2 Wire Feed Speed Increase in wire feed speed increases weld current Decrease in wire feed speed decreases weld current Gas Nozzl as Ur Contact Tip Tube Electrode Wire Actual Stick out Tip to Work Distance Average Arc Length Electrode Stick Out Art A 08997 AD Figure 4 8
66. ld Metal d au Metal GMAW Process 891 Figure 4 1 Molten Weld Metal FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuses together the parts to be welded by heating them with an arc between a continuous flux filled electrode wire and the work Shielding is obtained through decomposition of the flux within the tubular wire Additional shielding may or may not be obtained from an externally supplied gas or gas mixture The process is normally applied semi automatically however the process may be applied automatically or by machine It is commonly used to weld large diameter electrodes in the flat and horizontal position and small electrode diameters in all positions The process is used to a lesser degree for welding stainless steel and for overlay work Shielding Gas Optional Nozzle Optional Molten Metal Flux Cored Molten Electrode Solidified 4 IS Weld Metal cry Base Metal FCAW Process Art A 08992 AB Figure 4 2 Manual 0 5225 4 1 BASIC WELDING GUIDE FABRICATOR 211i BASIC WELDING Position of MIG Gun The angle of MIG gun to the weld has an effect on the width of the weld gt Push Vertical Drag Pull gt 1 Art 07185 AB Figure 4 3 The welding gun should be held at an angle to the weld joint see Secondary Adjustment Variables below Hold the gun so that the welding seam is viewed at all times Always wear the welding helmet with proper fil
67. low us to interpret the evidence in a single coherent frame work Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cable around the body Keep welding Power Source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information Manual 0 5225 1 5 FABRICATOR 2111 1 02 Principal Safety Standards safety in Welding and Cutting ANSI Standard 749 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society otandard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269
68. n unsafe accessories shall not be used F Repairs If any parts are damaged for any reason it is recommended that replacement be performed by an ac credited Thermal Arc Service Provider Manual 0 5225 5 3 PROBLEMS AND ROUTINE SERVICE FABRICATOR 2111 PROBLEMS SERVICE Power Source Calibration A Schedule Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels Calibration intervals shall be as outlined below 1 For transportable equipment at least once every 3 months and 2 For fixed equipment at least once every 12 months If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974 1 then the above tests should be carried out prior to entering this location B Calibration Requirements Where applicable the tests outlined in Table 6 3 below shall be conducted by an accredited Thermal Arc service agent Testing Requirements Output current A to be checked to ensure it falls within applicable Thermal Arc power source specifications Output Voltage V to be checked to ensure it falls within applicable Thermal Arc power source specifications Motor Speed RPM of wire drive motors to be checked to ensure it falls within required Thermal Arc power source wire feeder specifications Accuracy of digital meters to be checked to ensure it falls within
69. n or burn back jam the conduit liner should be checked for kinks and clogging by metal flakes and swarf If it is not the cause of slipping the feed roll pressure can be increased by rotating the pressure screw clockwise WARNING Before changing the feed roller ensure that the mains supply to the power source is switched off CAUTION The use of excessive pressure may cause rapid wear of the feed rollers shafts and bearing 3 12 Changing the Feed Roll To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction Once the feed roll is removed then to replace feed roll simply reverse these directions dual groove feed roller is supplied as standard can accommodate 0 6 0 8mm diameter hard wires Select the roller required with the chosen wire size marking facing outward GROOVE J SROOVE GROOVE B SIZE GROOVE A SIZE A 09583 Figure 3 10 Dual Groove Feed Roller Feed Roll Retaining Screw A 10428 Figure 3 11 Changing the Feed Roll Manual 0 5225 3 13 INSTALLATION SETUP FABRICATOR 2111 INSTALLATION SETUP 3 13 Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking If itis considered necessary adjustment can be made by turning the Thumb Screw inside the open end of the hub clockwise to tighten the brake Correct adjustment will result in the wire reel circumference continu
70. ngs all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and Service INTRODUCTION 2 4 Manual 0 5225 INTRODUCTION 2 10 Optional Accessories 26V TIG Torch 4 m Tweco TWE2 3 m 250A MIG Gun Tweco WeldSkill 220A MIG Gun m Professional 4 Wheel Cart Dual Cylinder Professional 4 Wheel Cart Single Cylinder Cart Single Cylinder c Foot Pendant Control Tweco WeldSkill Helmet Feed Roll 0 6 0 8mm V groove hard fitted Feed Roll 0 9 1 2mm V groove hard Feed Roll 0 8 0 9mm U groove soft Feed Roll 1 0 1 2mm U groove soft Feed Roll 0 8 0 9mm V knurled flux cored Manual 0 5225 2 5 FABRICATOR 2111 310 090 001 161 550 307 Part No WS220XE 10 3035 Part No W4015002 Part No W4015001 Part No W4014700 Part No W4015104 Part No 10 4016 Part No 10 4014 Part No WHF41001 Part No 62020 Part No 62022 Part No 62179 Part No 62024 Part No 62028 INTRODUCTION FABRICATOR 2111 INTRODUCTION This Page Intentionally Blank INTRODUCTION 2 6 Manual 0 5225
71. nimum Minimum Single Phase Lead Size Primary Current Plug Size TIG STICK Circuit Size Vin lin 230V 15A 20 210 25 200A 25 200A 110V 32A 20 140A 35 150 25 125 Table 3 1 Input Power Source Leads for Fabricator 2111 l WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power 00 NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lock out tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting OFF and red tagging circuit breaker or other disconnecting device Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power source The Welding Power Source must be Correctly installed if necessary by a qualified electrician Correctly earthed electrically in accordance with local regulations Connected to the correct size power point fuse and primary supply lead based on Table 3 1 A WARNING Any electrical work must be carried out by a qualified Electrical Tradesperson 3 05 Electromagnetic Compatibility Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source 15 used in a domestic situation A Installation and Use Users Responsibility The user is respons
72. nstalled or improperly 11 Do not touch electrode while in contact with the grounded equipment is a hazard work ground circuit 1 Do not touch live electrical parts 12 Use only well maintained equipment Repair or replace damaged parts at once 2 Wear dry hole free insulating gloves and body protection 13 In confined spaces or damp locations do not use a welder with AC output unless it is equipped with 3 Insulate yourself from work and ground using dry a voltage reducer Use equipment with DC output insulating mats or covers 14 Wear a safety harness to prevent falling if working 4 Disconnect input power or stop engine before above floor level installing or servicing this equipment Lock input power disconnect switch open or remove line 19 Keep all panels and covers securely in place fuses so power cannot be turned on accidentally 9 Properly install and ground this equipment according to its Owner s Manual and national state and local codes Manual 0 5225 171 SAFETY INSTRUCTIONS AND WARNINGS FABRICATOR 2111 WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Wear a welding helmet fitted with a proper shade of filter see ANSI Z49 1 listed in Safety Standards to protect your face and eyes when welding or watchin
73. ntrol Art A 11233 Manual 0 5225 APPENDIX THERMAL ARC LIMITED WARRANTY TERMS LIMITED WARRANTY Thermal Arc Inc Thermadyne Company hereafter Thermal Arc warrants to cus tomers of its authorized distributors hereafter Purchaser that its products will be free of defects in workman ship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY 1 EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respec
74. oblems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding GMAW problems is to start at the wire spool then work through to the MIG gun There are two main areas where problems occur with GMAW Porosity and Inconsistent wire feed Solving Problems Beyond the Welding Terminals Porosity When there is a gas problem the result is usually porosity within the weld metal Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal Contaminants range from no gas around the welding arc to dirt on the work piece surface Porosity can be reduced by checking the following points FAULT CAUSE 1 Shielding gas cylinder contents Ensure that the shielding gas cylinder is not empty and the and flow meter flow meter is correctly adjusted to 15 litres per minute 2 Gas leaks Check for gas leaks between the regulator cylinder connec tion and in the gas hose to the Power Source 3 Internal gas hose in the Power Ensure the hose from the solenoid valve to the Euro adaptor Source has not fractured and that it is connected to the Euro adaptor 4 Welding in a windy environment shield the weld area from the wind or increase the gas flow 5 Welding dirty oily painted Clean contaminates off the work piece oxidised or greasy plate 6 Distance between the MIG gun Keep the distance between the MIG gun nozzle and the work nozzle and the work piece piece
75. ode holder be connected to the unit and mistakenly be in contact with the work piece during power up 14 Digital Voltage Meter Right Digital Display MIG Mode This digital meter is used to display the pre set preview Voltage mode and actual welding voltage of the power source when welding At times of non welding the digital meter will display a pre set preview value of Voltage This value can be adjusted by varying the Multifunction Control Knob 10 STICK and LIFT TIG Modes This digital meter is used to display the Welding Output Terminal Voltage in STICK LIFT TlG modes during non welding or welding This value cannot be adjusted by varying the Multifunction Control Knob 10 When welding this digital meter will display actual welding voltage in all modes At the completion of welding the digital meter will hold the last recorded voltage value for a period of approxi mately 10 seconds in all modes The voltage meter will hold the value until 1 any of the front panel controls are adjusted in which case the unit will revert to preview mode 2 welding is recommenced in which case actual welding amperage will be displayed or 3 a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode INSTALLATION SETUP 3 8 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 NOTE The preview functionality provided on this power source is intended to act as a guide only S
76. om 1 6mm 1 16 to 4 8mm 3 16 P depending on plate thickness 1 6mm 1 16 ES PM Single Vee oint 7757 Double Vee Butt oint Not less than 70 1 6mm 1 16 max Lap oint 1 6mm 1 16 uM Teej 5 Fillet oint Fillet both sides of the joint Comer Wed Edge oint Plug Weld Art A 07695 Figure 4 19 Typical Joint Designs for Arc Welding Arc Welding Technique A Word to Beginners For those who have not yet done any welding the simplest way to commence is to run beads on a piece of scrap plate Use mild steel plate about 6 0mm thick and a 3 2mm electrode Clean any paint loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position Make sure that the work clamp is making good electrical contact with the work either directly or through the work table For light gauge material always clamp the work lead directly to the job otherwise a poor circuit will probably result BASIC WELDING GUIDE 4 12 Manual 0 5225 BASIC WELDING FABRICATOR 2111 The Welder Place yourself in a comfortable position before beginning to weld Get a seat of suitable height and do as much work as possible sitting down Don t hold your body tense A taut attitude of mind and a tensed body will soon make you feel tired Relax and you will find that the job becomes much easier You can add much to your peace of mind by wearing a leather apron
77. ome dif ferences may be observed between preview values and actual welding values due to factors including the mode of welding differences in consumables gas mixtures individual welding techniques and the transfer mode of the welding arc dip versus spray transfer Where exact settings are required the case of procedural work it is recommended that alternate measurement methods be utilized to ensure output values are accurate 15 Gas Inlet MIG mode only The Gas Inlet connection is used to supply the appropriate MIG welding gas to the unit Refer to section 3 15 set up details AN WARNING Only Inert Shielding Gases specifically designed for welding applications should be used 16 0n Off Switch This Single Phase circuit breaker performs a dual function It is used to turn the unit on off and it will also trip in the event of a fault WARNING LLL uL When the front digital displays are lit the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential 17 Wiredrive Motor Circuit Breaker The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload NOTE a circuit breaker trips a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button 18 Local Remote S
78. ould be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions Welding Cables The welding cables should be kept as short as possible and should be positioned close together but never coiled and running at or close to the floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing grounding of the Work Piece Where the work piece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earth ing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to the work
79. piece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations screening and Shielding selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening the entire welding installation may be considered for special applications INSTALLATION SETUP FABRICATOR 21 1i INSTALLATION SETUP 3 06 Power Source Controls Indicators and Features Q 3 E I THERMAL POWER ee 1 6 6 9 8 Art 10937 Figure 3 1 Fabricator Front and Control Panel Figure 3 2 Fabricator Front Connections oz Art A 10938 Figure 3 3 Wire Feed Compartment Control 1 Power Indicator The power indicator is illuminated when the correct mains power is applied to the power source and when the ON OFF switch located on the rear panel is in the ON position INSTALLATION SETUP 3 4 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 2 Thermal Overload Indicator Fault Indicator 3 This welding power source is protected by a self resetting thermostat The indicator will illuminate if the duty cycle of the power source has been exceeded Should the thermal overload indicator illuminate the output of the power source will be disabled Once the power source cools down this light
80. pped with a handle for carrying pur poses Du 0 WARNING ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source gt gt WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage Lift unit with handles built into the top of the front and rear moulded panels Use handcart or similar device of adequate capacity If using a fork lift vehicle place and secure unit on a proper skid before transporting INTRODUCTION 2 INTRODUCTION 2 07 Packaged Items Fabricator 211i Power Source Part No W1004206 Fabricator 211i Inverter Power Source Shielding Gas hose assembly Operating Manual Fabricator 211i System Part No W1004207 Fabricator 211i Inverter Power Source Feedrolls 0 6 0 8mm groove fitted 0 9 1 2mm V groove 1 0 1 2mm 0 groove 0 8 0 9mm V knurled MIG gun 3m long e Electrode Holder with 4m lead e Work Clamp with 4m lead Shielding Gas hose assembly e Operating Manual Figure 2 1 Fabricator 211i System Packaged W1004207 Manual 0 5225 INTRODUCTION FABRICATOR 2111 2 08 Duty Cycle The rated duty cycle of a Welding Power Source is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts To explain the
81. quipment oafety critical equipment e g guarding of industrial equipment The health of people around e g the use of pace makers and hearing aids Equipment used for calibration and measurement The time of day that welding or other activities are to be carried out The immunity of other equipment in the environment the user shall ensure that other equipment being used in the environment is compatible this may require additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises C Methods of Reducing Electromagnetic Emissions 1 Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the Welding Power source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure Manual 0 5225 3 3 2 FABRICATOR 2111 Maintenance of Welding Equipment The welding equipment sh
82. re Spool Hub which accepts Spool of 300mm diameter Remove the locking pin from the spool hub Install the wire spool over the spool hub locating the hole in the spool with the alignment pin on the spool hub Insert the locking pin back into the spool hub Retaining Clip Use inner holes on 300mm Pin Wire Spool Spoo Hub N Flat Washer N Hub Nut DEI 9 9 Flat Washer Keyed Washer id i SmallHole Spring Art A 10939 Figure 3 6 300mm 15kg Spool Installation 3 09 Installing 5kg Spool 200mm diameter Remove the locking pin from the spool hub Install the 5kg Spool over the spool hub locating the hole in the 5kg Spool with the alignment pin on the Spool Hub Insert the locking pin back into the spool hub in the rear position as shown ensuring the wire spool is firmly secured in position Fibre Washer Retaining Clip 200mm Use inner holes on Wire Spool Spool Hub Flat Washer Wire Spool Large Hole Hub Nut PT Flat Washer Keyed Washer SmallHole Spring Spool Hub A 10940 Figure 3 7 200mm 5kg Spool Installation Manual 0 5225 3 11 INSTALLATION SETUP FABRICATOR 211i INSTALLATION SETUP 3 10 Inserting Wire into the Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti clockwise direction Then to release the pressure roller arm push the tension screw toward the front of th
83. restraint is very great as for example in a heavy section of plate the weld metal may crack Even in cases where the weld metal does not crack there will still remain stresses in the structure If the joint material is relatively weak for example a butt joint in 2 0mm sheet the contracting weld metal may cause the sheet to become distorted B Expansion and Contraction of Parent Metal in the Fusion Zone While welding is proceeding a relatively small volume of the adjacent plate material is heated to a very high temperature and attempts to expand in all directions It is able to do this freely at right angles to the surface of the plate i e through the weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfil the desire for continued expansion it has to deform plastically that is the metal adjacent to the weld is at a high temperature and hence rather soft and by expanding pushes against the cooler harder metal further away and tends to bulge or is upset When the weld area begins to cool the upset metal attempts to contract as much as it expanded but because it has been upset it does not resume its former shape and the contraction of the new shape exerts a strong pull on adjacent metal Several things can then happen The metal in the weld area is stretched plastic deformation the job may be pulled out of shape by the powerfu
84. rol Socket is used to connect remote control devices to the welding power source To make connections align keyway insert plug and rotate threaded collar fully clockwise Remote Volts in MIG GMAW FCAW Remote Wirespeed GMAW FCAW mode Art A 10421 Remote Amps in LIFT TIG GTAW mode Figure 3 4 Remote Control Socket INSTALLATION SETUP 3 6 Manual 0 5225 INSTALLATION SETUP FABRICATOR 2111 spool Gun Motor Negative Trigger Switch Input Trigger Switch Input spool Gun Motor Positive ok ohm maximum connection to 5k ohm remote control potentiometer Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control Wirespeed GMAW FCAW mode potentiometer Wiper arm connection to 5k ohm remote control Amps LIFT GTAW mode potentiometer Wiper arm connection to 5k ohm remote control Volts MIG GMAW FCAW mode potentiometer Table 3 2 Note that the remote local switch item 18 located in the wirefeed compartment should be set to remote for the amperage voltage controls to be operative 10 Multifunction Control Voltage Down Slope amp Arc Force The multifunction control knob is used to adjust Voltage Mode Down slope LIFT Mode and Arc Force STICK Mode depending on the welding mode selected NOTE The preview functionality provided on this power source is intended to act as a guide only Some dif ferences may
85. sion Voltage too low Increase voltage 4 Excessive spatter A Voltage too high A Decrease voltage or increase the wirespeed control B Voltage too low B Increase the voltage or decrease wirespeed 5 Irregular weld shape A Incorrect voltage and A Adjust voltage and current by adjusting the voltage current settings Con control and the wirespeed control vex voltage too low Concave voltage too high Wire is wandering B Replace contact tip Incorrect shielding gas C Check shielding gas Insufficient or excessive D Adjust the wirespeed control or the voltage heat input control 6 Weld cracking Weld beads too small A Decrease travel speed Weld penetration narrow Reduce current and voltage and increase MIG gun and deep travel speed or select a lower penetration shielding gas Excessive weld stresses C Increase weld metal strength or revise design Excessive voltage D Decrease voltage Cooling rate too fast E Slow the cooling rate by preheating part to be welded or cool slowly Cold weld puddle Loose welding cable A Check all welding cable connections connection B Low primary voltage B Contact supply authority C Faultin power source Have an Accredited Thermal Arc Service Provider to test then replace the faulty component 9 Arc does not have The gun has been Connect the MIG Polarity Cable to the positive a crisp sound that connected to the wrong welding terminal for solid wires and gas shielded
86. small electrode amperage too low Lack of root fusion Pigure 2 Example of Lack of Fusion Gas pockets or High levels of sulphur in Use an electrode that is designed for high sul voids in weld Steel phur steels metal porosity Electrodes are damp B Dry electrodes before use C Welding current is too C Reduce welding current high Surface impurities such as D Clean joint before welding oil grease paint etc Welding in a windy envi shield the weld area from the wind ronment Electrode damaged ie flux F Discard damaged electrodes and only use elec coating incomplete trodes with a complete flux coating Crack occurring in A Rigidity of joint Redesign to relieve weld joint of severe stresses weld metal soon or use crack resistance electrodes after solidification Insufficient throat thick Travel slightly slower to allow greater build up in commences ness throat Weld current is too high Decrease welding current Slag EN trapped in IN undercut Not cleaned A or incorrect electrode Sl g trapped in root Art 05808 Figure 3 Example of Slag Inclusion Table 4 5 Welding Problems STICK MMA Manual 0 5225 4 21 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING 4 05 TIG GTAW Basic Welding Technique Gas Tungsten Arc Welding GTAW or Tungsten Inert Gas as it is commonly referred to is a welding process in which fusion is produced by an electric arc that is established
87. some cases to tell from past experience or to find by trial and error or less frequently to calculate how much distortion will take place in a given welded structure By correct pre setting of the components to be welded constructional stresses can be made to pull the parts into correct alignment A simple example is shown in Figure 4 31 E Preheating ouitable preheating of parts of the structure other than the area to be welded can be sometimes used to reduce distortion Figure 4 32 shows a simple application By removing the heating source from b and c as soon as welding is completed the sections b and c will contract at a similar rate thus reducing distortion Preheat Preheat Dotted lines show effect if no preheat is used Figure 4 32 Reduction of Distortion by Preheating Art 07709 Figure 4 33 Examples of Distortion BASIC WELDING GUIDE 4 18 Manual 0 5225 BASIC WELDING FABRICATOR 2111 Block Sequence The spaces between the weld filled in when the welds are Figure 4 34 Welding Sequence Art 07711 Figure 4 35 Step back Sequence Figure 4 37 Staggered Intermittent Welding Manual 0 5225 4 19 BASIC WELDING GUIDE FABRICATOR 2111 4 04 STICK MMA Welding Troubleshooting FAULT CAUSE REMEDY BASIC WELDING ARC FORCE control knob is set at a value that causes the welding current to vary excessively with the arc length 1 Welding current varying A gap is left by failure
88. speed can be seen in the shape of the weld deposit and heard by a smooth regular arc sound Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup information Electrode Wire Size Selection The choice of Electrode wire size and shielding gas used depends on the following e Thickness of the metal to be welded of joint Capacity of the wire feed unit and Power Source he amount of penetration required e he deposition rate required e he bead profile desired e he position of welding Cost of the wire Manual 0 5225 4 5 BASIC WELDING GUIDE BASIC WELDING Thermal Arc MIG Lift TIG Stick Wire Selection Chart FABRICATOR 2111 uv 0 9188 9215 9215 Jayn 10 BuneJedo 0 19491 esea d Aju epin e se 199 0 papuajul si dn jas siu 9 0019 90049 anm 60 80 82009 emwyosuuziOL 95059 ennisog 10199195 Yos 60 80 6219 2 1 6 0 8009 8090 02029 Aelod 94 5 s 001 59 Kejdsig 5 ennisog 0 TIT 651 06 SZ 06 66 Aejdsig Jojnquisiq 2Jy Jeuuau paipa129e 159199 10 19948 ejep eu
89. t to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor TERMS OF WARRANTY JANUARY 2011 In accordance with the warranty periods stated below Thermadyne guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating m
90. taken the occurrence in this zone of under bead cracks may result Hardened zone and under bead cracks in the weld area may be reduced by using the correct electrodes preheating using higher current settings using larger electrodes sizes short runs for larger electrode deposits or tempering in a furnace B Austenitic manganese steels The effect on manganese steel of slow cooling from high temperatures is to embrittle it For this reason it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or skip welding to distribute the heat C Cast iron Most types of cast iron except white iron are weldable White iron because of its extreme brittleness generally cracks when attempts are made to weld it Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron D Copper and alloys The most important factor is the high rate of heat conductivity of copper making preheating of heavy sections necessary to give proper fusion of weld and base metal Arc Welding Practice The techniques used for arc welding are almost identical regardless of what types of metals are being joined Naturally enough different types of electrodes would be used for different metals as described in the preceding section Welding Position The electrodes dealt with in this publication can be used in most positions i e they are suitable for welding in
91. te penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from comers Clean joint before welding Use electrodes designed for position in which welding is done otherwise proper control of slag is difficult Figure 1 Example of insufficient gap or incorrect sequence Reduce welding current Reduce the length of the welding arc Electrode should not be inclined less than 45 to the vertical face Allow more room in joint for manipulation of the electrode Use smaller gauge electrode Pause for a moment at edge of weave to allow weld metal buildup oet power source to STICK MMA mode Manual 0 5225 BASIC WELDING FABRICATOR 2111 9 Portions of the omall electrodes used Use larger electrodes and preheat the plate weld run do not heavy cold plate fuse to the surface of the metal or Welding current is too low B Increase welding current edge of the joint Wrong electrode angle Adjust angle so the welding arc is directed more into the base metal Travel speed of electrode Reduce travel speed of electrode 15 too high ocale or dirt on joint Clean surface before welding surface Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Art 05867 AC Lack of inter run fusion Lack of side fusion scale dirt
92. ter lenses and use the proper safety equipment CAUTION Do not pull the welding gun back when the arc is established This will create excessive Wire extension stick out and make a very poor weld The electrode wire is not energized until the gun trigger switch is depressed The wire may therefore be placed on the seam or joint prior to lowering the helmet Direction of 90 Travel Transverse Angle Art A 08993 Figure 4 4 5 to 15 Longitudinal Angle 30 to 60 Transverse Angle Direction of Travel Art A 08994 Figure 4 5 BASIC WELDING GUIDE 4 2 Manual 0 5225 BASIC WELDING FABRICATOR 2111 10 to 20 Longitudinal Angle 30 to 60 Transverse Angle Direction of Travel Vertical Fillet Welds 211 08995 Figure 4 6 Direction of Travel 5 to 15 Longitudinal Angle 08996 Figure 4 7 Distance from the MIG Gun Nozzle to the Work Piece The electrode wire stick out from the MIG gun nozzle should be between 10mm to 20 0mm This distance may vary depending on the type of joint that is being welded Travel Speed The speed at which the molten pool travels influences the width of the weld and penetration of the welding run MIG Welding GMAW Variables Most of the welding done by all processes is on carbon steel The items below describe the welding variables in short arc welding of 24gauge 0 024 0 6mm to 6 4mm mild sheet or p
93. the edge of weave and of weaving too rapidly Art A 07701 4 o Figure 4 25 Single Run Vertical Fillet Weld Manual 0 5225 4 15 BASIC WELDING GUIDE FABRICATOR 2111 BASIC WELDING Weaving motion for second and subsequent runs Pauseatedge of weave Figure 4 26 Multi Run Vertical Fillet Weld CORRECT INCORRECT Pause at edge of Note weld contour weave allows weld when insufficient metal to build up pause at edge and eliminates of weave undercut Art A 07703 Figure 4 27 Examples of Vertical Fillet Welds 2 Vertical Down The E7014 electrode makes welding in this position particularly easy Use a 3 2mm electrode at 100 amps The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag The electrode should point upwards at an angle of about 45 3 Overhead Welds Apart from the rather awkward position necessary overhead welding is not much more difficult that downhand welding Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch The electrode is held at 45 to the horizontal and tilted 10 in the line of travel Figure 4 28 The tip of
94. the electrode may be touched lightly on the metal which helps to give a steady run A weave technique is not advisable for overhead fillet welds Use 3 2mm E6013 electrode at 100 amps and deposit the first run by simply drawing the electrode along at a steady rate You will notice that the weld deposit is rather convex due to the effect of gravity before the metal freezes Tilted 10 line of travel to pipe Figure 4 28 Overhead Fillet Weld BASIC WELDING GUIDE 4 16 Manual 0 5225 BASIC WELDING FABRICATOR 2111 Distortion Distortion in some degree is present in all forms of welding In many cases it is so small that it is barely perceptible but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur The study of distortion is so complex that only a brief outline can be attempted hear The Cause of Distortion Distortion is caused by A Contraction of Weld Metal Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature This means that a cube of molten metal would contract approximately 2 2 per cent in each of its three dimensions In a welded joint the metal becomes attached to the side of the joint and cannot contract freely Therefore cooling causes the weld metal to flow plastically that is the weld itself has to stretch if it is to overcome the effect of shrinking volume and still be attached to the edge of the joint If the
95. ttained some skill in the handling of an electrode you will be ready to go on to make up welded joints A Butt Welds oet up two plates with their edges parallel as shown in Figure 4 21 allowing 1 6mm to 2 4mm gap between them and tack weld at both ends This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment Plates thicker than 6 0mm should have their mating edges bevelled to form a 70 to 90 included angle This allows full penetration of the weld metal to the root Using a 3 2mm E 014 electrode at 100 amps deposit a run of weld metal on the bottom of the joint Do not weave the electrode but maintain a steady rate of travel along the joint sufficient to produce a well formed bead At first you may notice a tendency for undercut to form but keeping the arc length short the angle of the electrode at about 20 from vertical and the rate of travel not too fast will help eliminate this The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc To complete the joint in thin plate turn the job over clean the slag out of the back and deposit a similar weld 20 30 Electrode Tack Weld 7 Tack Weld Art A 7507 AR Figure 4 21 Butt Weld Art A 07698 Figure 4 22 Weld Build up Sequence Heavy plate will require several runs to complete the joint After completing the first run chip the slag out and clean the weld with a w
96. ual 0 5225 2 3 INTRODUCTION FABRICATOR 211i INTRODUCTION 2 09 Specifications Nominal Supply Frequency Welding Current Range MIG Mode Wirefeed Speed Range Effective Input Current Maximum Input Current 11 max single Phase Generator Requirement MIG GMAW FCAW Welding Output 40 C 10 210A 20 24 5V 140A 20 21 0V min 130A 60 20 5V 99A 60 19 0V 101A 100 19 1V 77A 100 17 9V STICK MMA Welding Output 40 C 10 min 200A 25 28 0V 125A 25 25 0V 130A 60 25 2V 80A 60 23 2V 101A 100 24 0V 60A 100 22 4V TIG GTAW Welding Output 40 C 10 min 200A 25 18 0V 150A 35 16 0V 130A 60 15 2V 115A 60 14 6V 101A 100 14 0V 90A 100 13 6V Open circuit voltage Protection Class IP23S Table 2 1 Fabricator 211i Specifications Note 1 The Effective Input Current should be used for the determination of cable size amp supply requirements Note 2 Motor start fuses or thermal circuit breakers are recommended for this application Check local re quirements for your situation in this regard Note 3 Generator Requirements at the Maximum Output Duty Cycle NOTE Additional safety precautions may be required when using unit in an environment with increased haz ard of electric shock Please refer to relevant local standards for further information prior to using in such areas Due to variations that can occur in manufactured products claimed performance voltages rati
97. uch larger than 6 4mm width with a 3 2mm electrode otherwise the weld metal tends to sag towards the base and undercut forms on the vertical leg Multi runs can be made as shown in Figure 4 24 Weaving in HV fillet welds is undesirable BASIC WELDING GUIDE 4 14 Manual 0 5225 BASIC WELDING FABRICATOR 2111 45 from vertical 60 70 from line of weld Art 07699 Figure 4 23 Electrode Position for HV Fillet Weld Art 07700 Figure 4 24 Multi runs in HV Fillet Weld C Vertical Welds 1 Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position Use a 3 2mm 27014 electrode and set the current at 100 amps Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet The electrode needs to be about 10 from the horizontal to enable a good bead to be deposited Refer Figure 4 25 Use a short arc and do not attempt to weave on the first run When the first run has been completed de slag the weld deposit and begin the second run at the bottom This time a slight weaving motion is necessary to cover the first run and obtain good fusion at the edges At the completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 4 26 illustrates multi run technique and Figure 4 27 shows the effects of pausing at
98. uge 1 2mm mild steel plate 150 x 150mm Use 0 8mm flux cored gasless wire or a solid wire with shielding gas Setting of the Power Source Power source setting requires some practice by the operator as the welding plant has two control settings that have to balance These are the Wirespeed control refer to section 3 06 4 and the welding Voltage Control refer to section 3 06 10 The welding current is determined by the Wirespeed control the current will increase with increased Wirespeed resulting in a shorter arc Less wire speed will reduce the current and lengthen the arc Increasing the welding voltage hardly alters the current level but lengthens the arc By decreasing the voltage a shorter arc is obtained with a little change in current level When changing to a different electrode wire diameter different control settings are required A thinner electrode wire needs more Wirespeed to achieve the same current level A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the electrode wire diameter and the dimensions of the work piece If the Wirespeed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool and does not melt Welding in these conditions normally produces a poor weld due to lack of fusion If however the welding voltage is too high large drops will form on the end of the wire causing spatter The correct setting of voltage and Wire
99. witch located in wirefeed compartment The remote local switch is used only when a remote control device such as TIG torch with remote current control is fitted to the unit via the remote control socket item 9 When the local remote switch is in the remote position the unit will detect a remote device and work accordingly When in the local mode the unit will not detect the remote device and will operate from the power source controls only Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local remote switch ie in both local and remote modes should a remote device be connected and the remote local switch set to remote the maximum setting of the power source will be determined by the respective front panel control irrespective of the remote control device setting As an example if the output current on the power source front panel is set to 50 and the remote control device is set to 100 the maximum achievable output from the unit will be 50 Should 100 output be required the respective front panel control must be set to 10096 in which case the remote device will then be able to control between 0 100 output Manual 0 5225 3 9 INSTALLATION SETUP FABRICATOR 2111 INSTALLATION SETUP 19 Burnback Control located in wirefeed compartment The burnback control is used to adjust the amount of wire that protrudes from the gun after the completion of MIG welding
100. with the correct welding consumables and procedures The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source Please read these instructions thoroughly before using the unit INTRODUCTION FABRICATOR 2111 2 05 User Responsibility This equipment will perform as per the information con tained herein when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Defective equipment including welding leads should not be used Parts that are broken missing plainly worn distorted or contaminated should be replaced immediately Should such repairs or replacements become necessary it is recommended that such repairs be carried out by ap propriately qualified persons approved by Thermal Arc Advice in this regard can be obtained by contacting an Accredited Thermal Arc Distributor This equipment or any of its parts should not be altered from standard specification without prior written ap proval of Thermal Arc The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modifica tion from standard specification faulty maintenance damage or improper repair by anyone other than ap propriately qualified persons approved by Thermal Arc 2 06 Transportation Methods This unit is equi

211i Operating Manual FabricatOr®

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211i Operating Manual FabricatOr&reg;

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211i Operating Manual FabricatOr®