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PORTAFEED® VS 212 Operating Manual

1. R68 located on this PCB Remove the four screws and Internal Cover Figure 4 3 Accessing PCB for Burnback Manual No 0 4845 PORTAFEED VS 212 3 Locate component R68 Burnback on the motor con trol printed circuit board refer to Figure 4 3 The best procedure is to make only slight adjustments until the amount of burnback is acceptable Component R68 has a single turn 300 range of adjustment To increase burnback time adjust component R68 clockwise To decrease burnback time adjust component R68 counterclockwise 4 Replace the internal cover 5 Replace the wire spool hub refer to 3 03 Adjustment Of Spool Tension in Section 3 of this manual 4 06 Wire Feed Speed Ranges The range of the wire feed speed adjustment knob on the front panel can be set to either High or Low The High Low switch is located on the inside panel next to the CC CV switch Refer to figure 4 4 Art A 07254 cc High CV Low Figure 4 4 High Low Switch Location 4 3 OPERATION PORTAFEED VS 212 The low setting provides greater knob sensitivity but over narrower range The high setting provides less sensitivity but yields a wider range The ranges are as follows Low 50 400 ipm 1 27 10 16 mpm High 50 800 ipm 1 27 20 32 mpm Art A 0
2. 2 avec fil plein GMAW Brassage fort toutes conditions 3 ou 4 m taux non ferreux toutes conditions 11 au SE m taux ferreux toutes conditions Soudage l arc sous gaz avec mince moins de 1 po 25 mm lectrode tungst ne GTAW toutes conditions Soudage l hydrog ne 20 de1 46 po 25 4150 mm 0 25 4 150 mm 4 ou 5 toutes conditions 12 P de146 po 254150 m 4005 atomique AHW Ne June Soudage l arc avec as pais lus de 6 po 150 mm toutes condit 12 _pl s de6 po t80 mm 506 lectrode de carbone CAW N Soudageauxgaz _ aux gaz Soudage l arc Plasma PAW toutes dimensions moins de t 8 po Gin Gougeage Air Arc avec lectrode de carbone noe po 3 412 mm map e Soudage l arc avec lectrode enrobees moins de 5 32 po 4 mm Coupage l arc Plasma PAC SMAW S 4 464 mn mons de 300 amperes 9 E sis de 1 4 po 64 mm de 300 4 400 amper s plus de 400 ampers Manual No 0 4845 1 7 SAFETY INSTRUCTIONS PORTAFEED VS 212 7 soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiq
3. paasa akan an 6 1 6 02 HOW To Use PARIS L S Sakan da anne 6 1 6 09 External Replacement PATES Ana NAKATANIM 6 2 6 04 Internal Replacement Pars Lucca etie sacer cta bates duet deter ron 6 3 6 05 Wire Feeder Replacement Parts 6 4 APPENDIX 1 DRIVE ROLL KITS ne data coles 1 APPENDIX 2 OPTIONS AND ACCESSORIES A 2 APPENDIX 3 MIG GUN CARTRIDGE SYSTEM nus 3 APPENDIX 4 SYSTEM SCHEMATIC A 4 Statement of Warranty Warranty SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover SAFETY INSTRUCTIONS PORTAFEED VS 212 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS A 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 Safe practices h
4. Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tezle moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur N AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 Notez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d dter compl tement le bouchon 1 06 Principales Normes De Securite Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami
5. 2 3 Hold Function Off Wire Feed Speed Displayed Wire Feed Speed in IPM Currently Not In Use Hold Function On referto 4 07 Output Current Displayed Wire Feed Speed in MPM Currently Not In Use Table 4 1 Lower Meter Switch Settings 4 08 Meter Hold Function The meter hold function is enabled when DIP switch num ber 1 is set to the RIGHT position as defined in the tabe above When this function is activated the meter s dis plays are retained for 5 seconds after the last welding operation has ended This provides the time needed for the operator to remove his welding shield and read the meters before the display goes blank 4 09 Operation Hours Display The total number of arc hours that the VS 212 has been operating can be displayed by pressing and holding the small black button located directly above the 4 DIP switches shown in Figure 4 7 The reading is displayed over both meters as follows Ones Hundreths Tenths Art 07258 Figure 4 8 Displaying Operation Hours For example the above display would be read as 1 234 56 hours Manual No 0 4845 4 5 4 10 Protection And Safety Circuits The following protection and safety circuits come standard with this wire feeder and are designed to protect by disabling the wire feeder against unfavorable operation and or equipment damage 1 Undervoltage Protection the input voltage drops below the specified voltage range for an extended period
6. WELDING CABLES POWER SOURCE Art A 07194 Figure 3 1 System Hook up Outline Manual No 0 4845 3 1 INSTALLATION PORTAFEED VS 212 3 02 Installation Of Wire Spool NOTE The wire hub supplied with the unit is provided for mounting 44 pound 20 kg spool of wire Optional adapters are available allowing a 10 4 5 kg or 15 6 8 kg pound spool of wire or a 14 6 4 kg pound coil of wire to be used 1 Remove the wire spool hub nut by turning counterclockwise 2 Slide the spool of wire over the wire spool hub 3 Make sure that the alignment pin on the hub enters the hole in the backside of the wire spool Replace the wire spool hub nut and turn clockwise to a Snug position NOTE Install the welding wire spool so the wire feeds from the bottom of the spool into the input wire guide INSTALLATION Wire Spool Hub Nut I A Figure 3 2 Wire Spool Installation 3 2 Manual No 0 4845 3 03 Adjustment Of Spool Tension Adjust the wire spool tension so the wire will feed freely into the input wire guide However the spool of welding wire must not coast when wire feeding stops To adjust the wire spool tension tighten or loosen the hub tension bolt accordingly NOTE Excessive tightening of the hub tension bolt will result in a shorter mo
7. 375980 092 Guides 3 Narrow 30 V Manual No 0 4845 1 APPENDIX PORTAFEED VS 212 APPENDIX 2 OPTIONS AND ACCESSORIES Drive Roll Kit One kit 375980 092 is supplied standard with each wire NO RONKI 375980 XXX feeder see drive roll kit chart to select a different drive roll style Wire Spool Coil Adapters 10 Ib 4 5kg 8 spool 375585 001 15 Ib 6 8kg 8 spool 375864 001 14 lb 6 4kg coil 375942A KAT W4000001 Low profile large caster cart Cage __ 14003001 Protective tube steel rol cage MIG Gun Adaptor Integrated cartridge to accept other style MIG guns Tweco 4 4004001 Miller W4005001 Lincoln gasless W4006001 Lincoln W4006002 Euro style W4007001 APPENDIX A 2 Manual No 0 4845 PORTAFEED VS 212 APPENDIX 3 MIG GUN CARTRIDGE SYSTEM Removable Gun Cartridge System Patent Pending The MIG gun cartridge can easily be removed and replaced with a different cartridge that will fit other brands of MIG guns Miller Lincoln Euro Refer to Appendix 2 for specific models Art 07414 Manual No 0 4845 A 3 APPENDIX PORTAFEED VS 212 APPENDIX 4 SYSTEM SCHEMATIC TO FEEDHEAD CONTACTOR W1 J2 5 400 AMP BREAKER CIRCUIT 8 AMP 2 2 SW1 RB J1 1 142 3 POWER t SOURCE D x ER 2 1 1 2 3 BR1 SWITCH POWER VV 41 3
8. 08 B Check for shorted welding gun trigger leads while the gun switch on the welding gun is released 1 If shorted repair or replace the welding gun 6 Wire feeds but no gas flows A Check to see if the gas cylinder is empty or the valve closed 1 Make sure proper gas flow rate has been set B Check for a possible restriction in the gas line or gas valve 1 Check to see if the welding gun nozzle is plugged 7 Gas flows all the time or leaks A Make sure all connections are tight B Check for foreign material inside the gas valve 8 Wire feeds contactor closes but welding wire is not hot there is no arc A Make sure all connections have been made to both the power source and wire feeder B Make sure the cable between the contactor and feedhead is properly connected 1 If using a CV power source make sure the output contactor has been energized 2 Refer to section 4 01 Prewelding Procedure in this manual C Work lead not connected 9 Meters do not function A Check meters M1 and M2 and plug J2 on the motor control PC board for loose faulty or reversed connections Manual No 0 4845 PORTAFEED VS 212 SECTION 6 PARTS LIST 6 01 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include
9. An electronic controlled protection circuitry to protect against an undervoltage an overvoltage a voltage Spike a shorted or locked motor a shorted contactor coil and a shorted gas valve 10 electronic controlled dynamic brake 11 An electronic controlled current limit to motor 12 electronic controlled start circuit for improved arc starting 13 A low voltage gun trigger circuit for operator safety 14 A drive roll kit 15 In addition to these standard features model numbers W3512002 and W35120L2 also include a digital display for wire feed speed amps and arc voltage with arc time and memory hold 16 Trigger Hold Switch The PORTAFEED VS 212 has been designed to comply with IEC 60974 1 CE CSA NRTL C and NEMA EW 3 standards 2 2 Manual No 0 4845 PORTAFEED VS 212 2 05 Product Specifications Portafeed VS212 Specifications Input Voltage Range 15 100 VDC Maximum Input Current 10 Amps dependent on arc voltage Wire Sizes 12 304 8 mm 44 Lbs 20 kg 425A at 60 Duty Cycle Welding Gun Inlet Size Std 5 8 16mm Nominal Tweco Style 74 Maximum Shielding Gas 100 psi 6 9 bar Inlet Pressure Degree of Protection IP23C Weight Less wire 44 bs 20 kg Approvals IEC 60974 5 CE CSA NRTL C pending NEMA EW3 Table 2 1 Specifications 15 3 in 289mm Figure 2 1 Dimensional Information Manual No 0 4845 2 3 INTRODUCTION PORTAFE
10. Black On off 870359PKD 2 6 2 WA Art A 07606 PARTS LIST 6 2 Manual No 0 4845 6 04 Interna PORTAFEED VS 212 Replacement Parts Qty Description Part Number 1 N 1 2 1 1 1 zm Case Internal Parts Storage 870865PKD Circuit Breaker PB 10A 7978049PKD Rocker Switch Single Pole Black On Off 870359PKD SC Thumb 1 4 UNC Narrow Head 7950348PKD Clamp Gun Tube 171362PKD Wire Spool Hub Assembly 871616PKD LM FE HUA Le Art A 07607 Manual 0 4845 6 3 PARTS LIST PORTAFEED VS 212 6 05 Wire Feeder Replacement Parts Hem Qty a A E D N 9 5 and lt CO Description Tension Rod Subassembly Pressure Arm Machined Two Roll see note 2 Idler Gear Assembly M4x10 Pan Head Screw M6x1 Pan Head 30 MM long Gear Retainer Drive Gear Assembly M8 X 16 Hex Head Cap Screw M6x1 Socket Head Cap Screw 35MM Long Clamp Gun Tube see note 2 Feedplate 2 Roll Machined see note 2 Insulator Motor see note 2 Dowel Pin 6x50 Pressure Arm hinge see note 2 1 This part may be purchased at a local hardware store 2 This part is shown for reference purposes only It is not available i
11. FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Com pressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Associa tion canadienne de normalisation Standards Sales 276 Rexdale Bou levard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 518 National Fire Pro tection Association Batterymarch Park Quincy MA 02269 1 9 SAFETY INSTRUCTIONS PORTAFEED VS 212 1 07 Graphique de Symbole Seulement certains de ces symboles appara tront sur votre mod le d Sous Tension Hors Tension Tension dangereuse Augmentez Diminuer 9 Source AC Auxiliaire Fusible Intensit de Courant Hertz cycles sec Hz Courant Continue DC D Terre de Protection DD Connexion de la Ligne Source Auxiliaire 115V 15A Classement de Prise Source Auxiliaire SAFETY INSTRUCTIONS Tri Phase Statique PACD BE Fr quence Convertisseur Transformateur Redresseur Distant Facteur de Marche Et Pourcentage Panneau Local Soudage Arc Electrique Avec Electrode Enrob
12. RECTIFIER BRIDGE Hi TO WORK J1 2 6 l J3 1 J1 9 J1 8 7 gt SWITCH CC CV swat 1 10 11 12 7 J1 10 03 3 4 V CAP 12 J3 4 wea tt PCB1 MOTOR CONTROL PCB 376395C REGULATOR 12V J1 CONTACTOR BOARD ENABLE J1 QMdl00 89700ZL 49d CL J1 9 9 9 5011 GAS VALVE 12 VDC 11 14 Art 07595_ APPENDIX 4 0 4845 DISPLAY BOARD PORTAFEED VS 212 18 VOLTMETER J4 11 PCB3 MERE 4 10 SWITCH TRIGGER 17 WFS J4 9 MODE SELECTOR SW3 15 WFS J4 8 J2 1 o 20 WFS J4 12 MW SWA 21 WFS POT WIPER 4 13 gt J2 4 REZA SWITCH GUN 22 WFS POT MIN J4 14 1 19 MOTOR BOARD ENABLE J4 7 J2 2 INCH oe o 35 OVER VOLTAGE FAULT J4 5 R PURGE J2 3 24 SWITCH INCH PURGE J2 5 23 MOTOR WIRE FEED us SWITCH HIGH LOW N SW6 J4 1 PURGE TRIGGER LOW J4 6 J4 4 CS1 CURRENT SENSE TRANSDUCER DIGITAL DISPLAY 11 07595_ Manual 0 4845 VS 212 SCHEMATIC DIAGRAM A 5 APPENDIX Statement of Warranty as of March 15 2009 LIMITED WARRANTY THERMADYNE warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applica
13. and rays of the arc can react with vapors to form highly toxic and irritating gases 7 Do not 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 Torch soldering Cd Torch brazing ing amp wA Under 1 25mm Gas welding 1 8 to 1 2 in 3 12 mm SAFETY INSTRUCTIONS in or or 3 Shielded metal arc 9820 1 4in 12 Plasma are cutting _ Pp light Over 1 4 in 6 4 mm Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 Welding or cutting Electrode Size Welding or cutting Electrode Size Filter 2 ___ Non ferrous base meta 3 Oxygen Cutting Ferrous base metal Under 1 in 25 mm Gas tungsten arc welding Atomic hydrogen welding Carbon arc welding Plasma arc welding 1 to 6 in 25 150 mm TIG i i Carbon arc air gouging 300 to 400 Amp Over 400 Amp SAFETY INSTRUCTIONS Nolo WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accid
14. hanging or moving of the 3 INPUT POWER CABLE Provides an inlet and secure feeder over the work area fixture for the power cable from the welding power 2 GAS VALVE INLET This is where the shielding gas paaa hose if used is connected to the wire feeder 4 WELDING GUN HOLDER This is an insulated holder used to hold the welding gun when not welding INTRODUCTION 2 6 Manual No 0 4845 2 09 Internal Controls And Connections Art A 07138 PORTAFEED VS 212 OR 1 STORAGE BOX 2 HIGH LOW RANGE SWITCH 13 INPUT CIRCUIT cc High 14 HUB TENSION x BREAKER 3 WIRE SPEED AMP METER BOLT 2 O D SELECTION DIP SWITCHES L o Qe 12 CC CV MODE ibis SWITCH 4 CARTRIDGE GUN LEADS 5 UPPER RETAINING 11 PRESSURE ADJUST DEVICE R 10 INPUT WIRE GUIDE Te P 6 GUN CLAMP KNOB ORY _ ___ j zi 8 INPUT GUIDE LOCKSCREW 7 OUTPUT GUIDE LOCKSCREW 8 LOWER RETAINING KNOB Figure 2 4 Internal Controls and Connections STORAGE BOX On the job storage for drive rolls tips nozzels etc To remove lift up to release velcro and slide it up and over the side retainers HIGH LOW RANGE SWITCH Gives a finer dial control over the wi
15. regulations of the EMC Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment e ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting 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 manufact
16. shall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the Purchaser Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty supersedes all previous THERMADYNE warrantiesWarranty SCHEDULE Warranty SCHEDULE as of March 15 2009 The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the purchaser THERMADYNE reserves the right to request documented evidence of date of purchase ENGINE DRIVEN WELDERS Paris Labor S Ua Maf Power Sos asin yeas 3 yeas Original Main Power Stators and Inductors 5 years 3 years All Other Origin
17. without tools 2 4 Manual No 0 4845 2 07 Front Panel Controls And Connections 4 Arc Voltage Meter 3 Wire Feed Speed Amp Meter E _ 2 Wire Feed Speed Control 1 On Off Power Switch 9 Welding Gun Cable Connection PORTAFEED VS 212 Art 07136 6 2T 4T Trigger Mode Selector Switch 7 Gun Switch Receptacle 8 Voltage Sensing Receptacle 25mm Dinse 10 Removable MIG Gun Cartridge Tweco style shown Figure 2 2 Front Panel Controls and Connections POWER ON OFF SWITCH This switch controls input power only to the wire feeder and not to the power source WIRE FEED SPEED CONTROL This knob controls the wire feed speed The wire feed speed control can be adjusted during setup or actual welding WIRE FEED SPEED AMP METER The wire feed speed meter displays the actual wire feed speed output of the wire feeder This meter can be changed to display the actual amperage output of the power source by adjusting the DIP switches located on the edge of the display board inside the unit Refer to Section 4 07 for details ARC VOLTAGE METER The arc voltage meter displays the actual voltage output of the power source INCH PURGE SWITCH Depressing the INCH portion of the switch will feed wire at a speed set by the WFS control The wire will not be electrically hot when using the INCH switch Depressing the PURGE portion of the switch will allow shielding gas to flow out of the welding gun witho
18. 03 Troubleshooting Guide 1 Scope The troubleshooting guide is intended to be used by qualified service technicians The troubleshooting guide contains information which can be used to diagnose and correct unsatisfactory Operation or failure of the various components of the wire feeder Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem 2 Safety To ensure safe operation and service read this entire manual before attempting to service or repair this machine The service technician may be asked to check voltage levels while the machine is turned ON to assure safety use care and follow all instructions accordingly 5 04 Troubleshooting Hints Examine connections for proper assembly and contact before replacing an electrical component or printed circuit board Wire lugs should be in tight contact with the lead s conductor and should be crimped to the lead s insulation The mating surfaces of the connection should be clean and free of oxidation Do not pull on wires to disassemble connections Firmly grasp each lug or connector when disconnecting Pulling on wires for disassembly can damage the integrity of the connection and cause future malfunctions Manual No 0 4845 PORTAFEED VS 212 Prior to disassembly or servicing of the machine note the wiring and connections in the machine Reassembling should place the wires in the same location and routing as received
19. 135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Bolsena 7 20098 5 Giuliano Milan Italy Tel 39 02 36546801 Fax 39 02 36546840 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters THERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE d gt St Louis MO 63017 Telephone 636 728 3000 FAX 636 728 3010 Email sales thermalarc com www thermalarc com
20. 7255 Low Range High Range Figure 4 5 Low and High Feed Speed Ranges 4 07 Changing Meter Functions The Portafeed VS 212 has two digital meters on the front panel The top meter always displays the welding power supply s voltage output However the lower meter can be set to display either the wire feed speed or the welding power supply s current output Furthermore when it is set to display the wire feed speed an additional setting can be made to display this parameter in either inches per minute ipm or in meters per minute mpm Refer to Figure 4 6 Voltage Output Wire Feed Speed ipm or mpm or Current Output Art 07256 Figure 4 6 Digital Meter Functions OPERATION Changing The Lower Meter Functions 1 Open the VS 212 case door NOTE The power does not need to be turned off to change these settings 2 Locate the 4 white DIP switches on the side of the meter display s printed circuit board The LEFT RIGHT diagram in Figure 4 7 indicates the factory default positions of the lower meter DIP switches Hour Display Button High CV Low ps o Art A 07257 Figure 4 7 Meter DIP Switches 4 4 Manual No 0 4845 PORTAFEED VS 212 3 Using Table 4 1 as a reference carefully slide each white DIP switch left or right to change the meter to the desired function LEFT Position RIGHT Position
21. ED VS 212 2 06 Features Benefits Robust injection molded case Long lasting and unbreakable Changeable MIG gun cartridge system Patent Pending No external MIG gun adapters needed for other style guns with the integrated cartridge system Digital display models W3512002 and W35120L2 Monitor wire speed amps volts arc time and meter hold Makes parameter set up easy Heavy duty contactor Longer life on higher amperage applications Internal parts storage On the job storage for drive rolls tips nozzels etc Machined feed head amp tension arms Insures wire alignment tolerances of 002 Inch switch amp purge switch Cold inching of wire at set wire feed speed and purging of gas without running wire Gun trigger hold 2T 4T Allows standard or latched gun trigger INTRODUCTION Heavy duty removable voltage sensing lead Allows storage of lead with less lead breakage MIG gun holder A place to hold your MIG gun while not welding Lifting eye Allows for hanging or moving of the feeder over the work area Gas valve solenoid Controls on off flow of shielding gases Wire speed high low range Gives a finer dial control of larger diameter flux cored wires Ready to weld Supplied with 2ft 7m power cable Tweco connectors and 045in 1 2mm drive rolls for hard tubular wire Geared top amp bottom drive rolls Excellent traction on the wire Quick change drive rolls Change the drive rolls
22. Equipment Serial TABLE 5 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 1 01 cc EGENT UE 1 1 1 02 Principal Safety Standards aasa na AA AASA 1 4 penes RE HL AA AAO AAP 1 5 1 04 Precautions De Securite En Soudage 1 6 1 05 Dangers relatifs au soudage 1 6 1 06 Principales Normes aasa haaa 1 9 1 07 Graphique d aa cue asit rante eb Gar edad AA 1 10 1 08 Declaration Of Conformity 1 11 SECTION 2 INTRODUCTION ser 2 1 2 01 How To Use This Manual j s i i in niy ni 2 1 2 02 Equipment Identification say sawa manyay d y n la la 2 1 2 03 Receipt Of EGUIDITIB L 6 a 2 1 PRA ECT AM cae EE AA 2 2 2 09 Prod t Specifications Rd been 2 3 2 06 Features BE nn am armani 2 4 2 07 Front Panel Controls And GODfPeellofiS un menus 2 5 2 08 Rear Panel Controls And 5 2 6 2 09 Internal Controls And Connections L eee 2 7 2 10 Power Source Compatibility essen 2 8 SECTION 3 INSTALLATION fmc CE 3 1 SU e up H lek k n 3 1 3 02 Installation Of Wir
23. IHERMAL VS 21 PORTAFEED CC CV SEMIAUTOMATIC SOLID STATE CONTROLLED WIRE FEEDER IHERMAL ARC 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 1 800 752 7621 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 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
24. MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard 787 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 Manual No 0 4845 SAFETY INSTRUCTIONS PORTAFEED VS 212 1 03 Symbol Chart Note that only some of these symbols will appear on your model Three Phase Static Dangerous Voltage FCO Frequency Converter Transformer Rectifier Duty Cycle Shielded Metal mperage Arc Welding SMAW Voltage Gas Metal Arc 9 Welding GMAW Gas Tungsten Arc Z Hertz cycles sec Welding GTAW F Air Carbon Arc eq Cutting CAC A ET Constant Voltage Direct Current DC High Temperature Protective Earth Xe Wire Feed Function Wire Feed Towards Workpiece With i Output Voltage Off Welding Purging Of Gas Continuous Weld 8 2 Step Trigger tt Operation Press to initiate wirefeed and welding release t
25. SMAW Soudage L arc Avec Fil Electrodes Fusible GMAW Soudage L arc Avec Electrode Non Fusible GTAW Decoupe Arc Carbone CAC A T Courant Constant Tension Constante Ou Potentiel Constant Haute Temp rature Force d Arc L arc au Contact GTAW a Inductance Variable SAFETY INSTRUCTIONS D roulement du Fil Alimentation du Fil Vers la Pi ce de Fabrication Hors Tension Torch de Soudage Purge Du Gaz Mode Continu de Soudure Soudure Par Point Dur c du Pulse Dur e de Pr D bit Dur e de Post D bit D tente 2 Temps HUA Appuyez pour deruarer Palimentation du fils et la soudure le relacher pour arreter Detente a 4 Temps DUH pn Maintenez appuyez pour pre debit relailez pour initier l arc Appuyez pour arr ter l arc et mainteuir pour pr d bit Probl me de Terre Pouces Par Minute M tres Par Minute Manual No 0 4845 SAFETY INSTRUCTIONS PORTAFEED VS 212 1 08 Declaration Of Conformity Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and
26. al The PORTAFEED VS 212 is a portable solid state controlled voltage sensing wire feeder that operates on arc voltage and can be used with most constant voltage CV and constant current CC DC type power sources The only connection required between the power source and the wire feeder is the welding cable The unique design of this wire feeder allows operation in a constant wire feed speed mode when used with CV power sources and in a voltage sensing wire feed speed mode wire feed speed varies with respect to arc voltage when used with CC power sources The PORTAFEED VS 212 s steel reinforced flame retardant case totally encloses the solid state control circuitry welding wire and wire drive system A hinged latched door allows quick and easy access to the contactor welding wire and feedhead assembly that features quick change gear driven drive rolls PORTAFEED VS 212 comes with Robust injection molded case Changeable MIG gun cartridge system Digital display models W3512002 and W35120L2 Heavy duty contactor Internal parts storage Power cable and drive rolls Gas valve solenoid INTRODUCTION The PORTAFEED VS 212 includes the following features An on off rocker switch A wire feed speed control knob A welding gun holder A carrying handle A contactor A gas valve A CC CV mode switch An input circuit breaker for complete system protection
27. al Circuits and Components Including but not Limited to Relays Switches Contactors Solenoids Fans Power Switch Semi Conductors 1 1 year Engines and Associated Components are NOT Warranted by Thermal Arc See the Engine Although Most are Warranted by the Engine Manufacturer SEE THE ENGINE Manufacturers Warranty MANUFACTURERS WARRANTY FOR DETAILS for Details GMAW FCAW MIG WELDING EQUIPMENT Parts Labor Fahricator amp 140 180 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P 320SP 400SP 500SP Excel Arc 6045 Wire Feeders Ultrafeed Porta feed Original Main Power Transformer and Inductor 5 years 3 years Original Main Power Rectifiers Control P C Boards Power Switch Semi Conductors 3 years 3 years All Other Original Circuits and Components Including but not Limited to Relays Switches Contactors Solenoids Fans Electric Motors 1 year 1 year GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT Paris Labor 16075 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards Power Switch Semi Conductors 3 years 3 years Other Original Circuits and Components Including but not Limited to Relays Switches Contactors Solenoids Fans Electric Motors 1 year 1 year PLASMA WELDING EQUIPMENT Paris Labor Ultima 150 Original Main Power Magn
28. any dash numbers following the Specification or Assembly numbers 6 02 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List PART NUMBERS W3512001 with Tweco MIG cartridge and without digital meters W3512002 with Tweco MIG cartridge and with digital meters W35120L2 with Lincoln gas less MIG cartridge and with digital meters Manual No 0 4845 6 1 PARTS LIST PORTAFEED VS 212 6 03 External Replacement Parts Qty Description Part Number 1 1 Control Knob 8 0696PKD 2 2 Rocker Switch Single Pole Black 8 0359PKD 3 1 Rocker Switch Single Pole Momentary Black 8 0863PKD 4 2 Door Latch Assembly VS 212 871621PKD 5 1 Assembly Handle VS 212 870972PKD 6 1 Assembly Door VS 212 870953PKD 7 1 Lifting Eye VS 212 870974PKD 8 1 Power Input Pigtail Assembly VS 212 871032PKD 9 1 Rocker Switch Single Pole
29. ave developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Safe practices are outlined in the American National Standard 249 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE 1 01 Arc Welding Hazards 7 Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same Xa time or touch other people with the holder or electrode 8 Do not use worn damaged undersized or poorly spliced cables WARNING 9 Do not wrap cables around your body 10 Ground the workpiece to a good electrical earth ground ELECTRIC SHOCK can kill 11 Do not touch electrode while in contact with the work ground circuit Touching live electrical parts can cause fatal shocks 12 Use only well maintained equipment Repair or replace damaged severe burns The electrode and work circuit is electri
30. ble 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 fuel is spilled clean up before starting engine we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine 5 WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear face shield when working on a battery 2 Stop engine before disconnecting or connecting battery cables ENGINE EXHAUST GASES can kill 3 Do not allow tools to cause sparks when working on battery Engines produce harmful exhaust gases 4 Do not use welder to charge batteries or jump start vehicles 1 Use equipment outside in open well ventilated areas 5 Observe correct polarity and on batteries Ma
31. ble to the THERMADYNE products as stated below THERMADYNE shall upon written notification thereof and substantiation that the product has been stored installed Operated and maintained in accordance with THERMADYNE s specifications instructions recommendations and recognized standard industry practice and not been subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at THERMADYNE s sole option of any components or parts of the product determined by THERMADYNE to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY THERMADYNE shall not under any circumstances be liable for special indirect or consequential damages such as but not limited to damage or loss of purchased or replacement goods business interruption or loss of profit or claims of customers of distributor hereinafter the Purchaser for service interruption The rem edies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by THERMADYNE whether arising out of contract negligence strict tort or under any warranty or otherwise
32. cally parts at once live whenever the output is on The input power circuit and machine internal circuits are also live when power 13 In confined spaces or damp locations do not use a welder with is on In semi automatic or automatic wire welding the AC output unless it is equipped with a voltage reducer Use wire wire reel drive roll housing and all metal parts equipment with DC output touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts 15 Keep all panels and covers securely in place 14 Wear a safety harness to prevent falling if working above floor level N um Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers WARNING 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch ARC RAYS can burn eyes and skin NOISE can damage open or remove line fuses so power cannot be turned on hearing Arc rays from the welding process produce accidentally intense heat and strong ultraviolet rays that can burn 5 Properly install and ground this equipment according to its Owner s eyes and skin Noise from some processes can damage hearing Manual and national state and local codes 6 off all equipment when not in use Disconnect power to Wear a welding helme
33. ctrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous f AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs Manual No 0 4845 SAFETY INSTRUCTIONS PORTAFEED VS 212 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent 4 N1 AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein 2 Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Sic est possib
34. e 3 2 3 03 Adjustment Of Spool 510 3 3 3 04 Input And Output Wire Guide Installation 3 3 3 05 Selection And Installation Of Feed Rolls 3 4 3 06 MIG Gun Compatibility And Installation and Removal 3 4 3 07 Threading Wire Into inn dn canin esnaya n 3 5 TABLE 5 SECTION 4 OP RATIONS AA none cc d e 4 1 4 01 Prewelding Procedure educa 4 1 4 02 Welding Procedure er rici n 4 2 4 03 Welding In CC Mode vs CAMION nn 4 2 4 04 o SEDED CH NR 4 2 4 05 Adjusting Burnback FII amahan a japan ste no Seite 4 3 4 06 Wire Feed Speed Ranges uu keke kereke keke kek ek 4 3 4 07 Changing Meter FUNCHONS esse 4 4 4 08 Meter Hold Function 4 4 4 09 Operation Hours Display sus 4 5 4 10 Protection And Safety Circuits 4 5 SECTION 5 SERVICE a EU 5 1 SOL Gleaning Ot NE ee E TE 5 1 5 02 Cleaning Of The Feed ROIS ne 5 1 5 03 Troubleshooting ess uno an 5 1 9 04 Ina MINS mens nanas 5 1 503 COMMON une 5 1 SECTION 6 Ligier AA 6 1 6 01 Equipment TOEIC 6 saeua near n
35. ental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Light Under 300 Amp 9 Manual No 0 4845 SAFETY INSTRUCTIONS 4h gt WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin A i WARNING CYLINDERS can explode if damaged Shieldin
36. er to Connections the Installation chapter of this manual 2 Turn ON the power source and the wire feeder 3 Set the CC CV mode switch on the wire feeder to the proper position refer to paragraph 12 CC CV Mode Switch on page 2 9 and figure 4 1 1 Art 07254 CC High Oe Figure 4 1 CC CV Switch Location 4 If shielding gas will be used depress the purge switch if equipped or gun switch and adjust the flow of gas A If the gun switch is depressed the wire feeder Will feed electrically hot welding wire If this hot welding wire touches the work piece a welding arc will be established Manual No 0 4845 9 Depress the inch switch if equipped or gun switch 4 1 and adjust the wire feed speed to the desired value by means of the wire feed speed control The wire feed speed control can be adjusted during setup or while welding A WARNING If the gun switch is depressed the wire feeder Will feed electrically hot welding wire If this hot welding wire touches the work piece a welding arc will be established Adjustthe voltage control on a CV machine or current control on a CC machine to the desired value The voltage or current control can be adjusted during setup or while welding If using a CV power source the output contactor on the power source will have to be ener
37. etics 5 years 3 years All Other Original Circuits and Components Including but not Limited to Relays MEM Switches Contactors Solenoids Fans Electric Motors Coolant Recirculators 1 year 1 year SMAW Stick WELDING EQUIPMENT Parts Labor Original Main Power Magnetics 1 year 1 year Original Main Power Rectifiers Control P C Boards 1 year 1 year All Other Original Circuits and Components Including but not Limited to Relays Switches Contactors Solenoids Fans Power Switch Semi Conductors 1 year 1 year Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards 3 years 3 years All Other Original Circuits and Components Including but not Limited to Relays Switches Contactors Solenoids Fans Power Switch Semi Conductors 1 year 1 year GENERAL ARC EQUIPMENT Parts Labor IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171
38. 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 A WARNINGS Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Portafeed VS 212 CC CV Semiautomatic Solid State Controlled Wire Feeder Instruction Manual Number 0 4845 for Part Numbers W3512001 W3512002 and W35120L2 Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2007 2008 2009 2010 2011 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date January 19 2006 Revision AH Date March 3 2011 Record the following information for Warranty purposes Where Purchased Purchase Date
39. f the PORTAFEED VS 212 and allows the welding wire to remain electrically cold until the gun switch trigger is depressed This contactor is rated for 425 amps of welding current at a 60 duty cycle If the weld current or duty cycle rating is exceeded the contactor will be damaged or its life shortened Compatible Thermal Arc Power Sources ArcMaster 4005 300MST 400MST 400MSTP abstar 4030 PowerMaster Series Excel Arc Series Scout Raider 10000 engine driven Manual No 0 4845 PORTAFEED VS 212 SECTION 3 INSTALLATION 3 01 Connections WARNING CAUTION ELECTRIC SHOCK CAN KILL DO NOT touch Make sure all connections are tight otherwise 2 i a a yagi sing lead arcing or overheating could result 1 Using the supplied adapter connect a weld cable from 4 Make the proper gas line connection from the gas the power source to the power cable connection on supply to the wire feeder gas valve if gas will be used the rear of the VS 212 5 Attach the welding gun to the wire feeder 2 Connect a weld cable from the power source to the work connection 6 Connect the welding gun control leads to the wire feeder gun switch terminals located on the front of 3 Connect voltage sensing lead from the wire feeder the wire feeder to the work connection GAS SUPPLY REAR VIEW VOLTAGE SENSING va WIRE FEEDER WELDING GUN WORK TABLE VOLTAGE SENSING LEAD
40. from the factory Keep wires and leads away from hot parts and sharp objects 5 05 Common Symptoms A WARNING ELECTRIC SHOCK can kill Follow all safety precautions Do not touch live electrical parts Turn OFF input power before servicing the machine unless otherwise noted Only qualified technicians are to service the machine A WARNING This machine contains static sensitive devices Use static proof bags to store electronic components Use grounded wrist strap Use qualified personnel when testing or handling device NOTE Refer to the Connection Diagram and the Schematic Diagram in the Appendix chapter of this manual for graphical assistance in disassembling and troubleshooting the wire feeder Use only genuine replacement parts 1 Unit is completely inoperative nothing functions A Make sure all connections have been made to both the power source and wire feeder B Make sure both the power source and wire feeder are turned ON C Check 18 ga wire connection on rear bus bar of the contactor for loose or faulty connections 5 1 SERVICE PORTAFEED VS 212 D Check for a damaged power switch E Check for a damaged or tripped circuit breaker 2 Wire feed motor operates but wire does not feed or feeds erratically A Incorrect voltage current and or wire feed speed settings 1 Make sure all connections to the wire feeder are tight 2 Make sure feed rolls are tig
41. g gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards A WARNING Engines can be dangerous 9 f WARNING 2 PORTAFEED VS 212 If used a closed area vent engine exhaust outside and away from any building air intakes TA 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possi
42. gized In most cases this will require a jumper to be added to the power source or a switch on the power source to be turned on Read the power source owner s manual for proper connections or settings required Art A 05126 1 ON 1 1 Gas Valve _____ OFF e i ON Wire Feed Lt OFF Figure 4 2 Functional Timing Diagram OPERATION PORTAFEED VS 212 4 02 Welding Procedure A WARNING In semiautomatic or automatic wire welding the welding wire wire reel if used input guide feed rolls output guide feedhead and welding gun metal parts are all ELECTRICALLY HOT Refer to Functional Timing Diagram on the previous page 1 To start the weld position the welding gun above the work piece and depress the gun switch trigger The solid state control then enables the gas valve wire feed motor and power source To end the weld release the gun switch trigger while pulling the welding gun away from the work piece The solid state control then disables the gas valve wire feed motor and power source NOTE After the weld is completed it is recommended to pull the welding gun away from the work while releasing the gun switch This allows the welding arc to partially extinguish at the work piece which reduces the arcing at the contactor contacts Using this procedure will lengthen the life of the contactor contacts especially when welding at high amperage At the end of the work day or when welding ha
43. ht B Check for too little or too much pressure on the feed rolls 1 Refer to spring tension knob in section 2 09 Internal Controls and Connections in this manual 2 Check for correct feed roll size for welding wire being used 3 Check to see if wire spool tension is too great 4 Refer to hub tension bolt in section 2 09 Internal Controls and Connections in this manual C Check for restriction in welding gun and or contact tip D Check for correct gun liner and contact tip sizes for welding wire being used 3 Wire wraps around the feed rolls A Check for too much pressure on the feed rolls 1 Refer to spring tension knob in section 2 09 Internal Controls And Connections in this manual B Check alignment of input and output guides C Check for correct gun liner and contact tip sizes for welding wire being used D Worn or damaged contact tip 4 Wire does not feed with gun switch depressed A Check power supply input to the VS 212 and cable connection B Check for continuity of the welding gun trigger leads with the trigger depressed 1 If no continuity repair or replace the welding gun SERVICE C Check for a locked or shorted motor D An electronic protection circuit may have activated 1 Reset by placing power switch in the off position for at least 60 seconds 5 Wire feed motor continues to run after gun switch has been released A Check Trigger Hold switch see section 2
44. ircuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables SAFETY INSTRUCTIONS 1 6 Manual No 0 4845 SAFETY INSTRUCTIONS PORTAFEED VS 212 9 7 a AVERTISSEMENT QP AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE POUR LA SANTE de soudage produit une chaleur et des rayons Le soudage d gage des vapeurs et des fum es ultraviolets intenses susceptibles de br ler les yeux et dangereuses respirer la peau Le bruit caus par certains proc d s peut SN __ endommager louie 1 Eloignez la t te des fum es pour viter de les respirer _________________________________________________________ 1 Portez une casque soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que 3 Sila ventilation est inadequate portez un respirateur a adduction vous observez l ex cution d une soudure d air approuv 2 l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc 2 Portez des lunettes de s curit approuv es Des crans
45. ire size or range stamped on the side of the roll On rolls with different size grooves the outer visible when installed stamped wire size indicates the groove in use Bearing feed rolls are installed by unscrewing the upper retaining knob and removing the idler gear The bearing feed roll retaining knob is then removed from the idler gear and the bearing feed roll is placed over the lobes on the idler gear The bearing feed roll retaining knob is replaced and this assembly is returned and secured with the upper retaining knob Drive feed rolls are installed by removing the lower retaining knob placing the drive feed roll over the lobes on the drive gear and securing with the lower retaining knob NOTE Installation of all styles of feed rolls for this feeder is identical A WARNING The welding wire is electrically Hot if wire is fed by depressing gun switch Electrode contact to work piece will cause an arc with gun switch depressed INSTALLATION 3 06 MIG Gun Compatibility And Installation and Removal The Portafeed VS 212 wire feeder is designed to be used with most MIG welding guns Model numbers W3512001 and W3512002 come configured from the factory to work with all Tweco guns Model number W35120L2 comes configured from the factory to work with Lincoln gas less guns Refer to the Section 2 11 Available Options for the ordering information of other MIG gun adapter cartridges 1 install the weldi
46. ise for increased force or counterclockwise for decreased force NOTE If the force applied to the wire is too great the welding wire will bird nest in the feedhead and not feed properly Turn the welding machine and wire feeder ON and set the wire feed speed control to midrange refer to Figure 3 7 Remove contact tube from welding gun Refer to Gun Manual Press the gun switch or INCH switch until wire feeds out past the gun nozzle Place contact tube over the wire and screw into place and tighten Cut wire off at about 1 4 inch 6 mm from the nozzle 1 Place end of the welding wire into the input wire guide Feed it through the guide and over the drive roll groove closest to the feedhead casting De Art A 07253 7 EXER Pressure Adjustment Device Pressure Arm Welding Wire Input Wire Guide Output Wire Guide Figure 3 6 Wire Threaded Through Guides and Locked In Position Manual No 0 4845 INSTALLATION PORTAFEED VS 212 NOTES INSTALLATION 3 6 Manual No 0 4845 PORTAFEED VS 212 SECTION 4 OPERATION 4 01 Prewelding Procedure Follow all installation instructions for the welding power source the welding gun and the VS 212 CC CV wire feeder before attempting to weld 1 Make sure all necessary connections have been made ref
47. lat raux Lisez les fiches signal tiques et les consignes du fabricant rela sont recommand s tives aux m taux aux produits consummables aux rev tements 3 Entourez l aire de soudage de rideaux ou de cloisons pour prot ger et aux produits nettoyants les autres des coups d arc ou de l blouissement avertissez les 5 Netravaillez dans un espace confin que s il est bien ventil sinon observateurs de ne pas regarder l arc portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Op ration de coupage Op ration de coupage 22 ou soudage filtre oculaire ou soudage Intensit de courant Intensit de courant Brassage tendre Soudage l arc sous gaz toutes conditions au chalumeau
48. le laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Nefaites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples XE EDED DD DEDEN 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils 6 R installez les capots ou les protecteurs et fermez les portes des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Manual No 0 4845
49. les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 4h AVERTISSEMENT gt LES ETINCELLES LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une le
50. ndividually PARTS LIST 6 4 Art A 07608 Part Number 870933PKD 870679PKD 871001PKD See note 1 See note 1 870733PKD 870560PKD See note 1 See note 1 171362PKD 870558PKD 870695 001PKD 870509PKD Manual No 0 4845 PORTAFEED VS 212 APPENDIX 1 DRIVE ROLL KITS DRIVE ROLL KITS 375980 Series 2 ROLL FEED ROLL STYLES STYLE STYLE 4 STY TYLE HARD wike HARD amp TUBULAR WIRE WIRE TUBULAR WIRE FLAT KNURLED DOUBLE COG DOUBLE DOUBLE uU Style 1 Style 2 Style 3 Style 4 Style 5 Style 6 Double Smooth Double Flat Flat Knurled Knurled Double Double U Double Double Double Smooth Double Smooth V Smooth V Knurled Double Double U Wire Type Soft Hard Tubular Hard Tubular Soft Aluminum 0307 055 08 09mm 375980 003 37598010 090 095 0457 08 09 12mm 375980 028 seem pp soom 1769600 ana ms 045 aer 1am 999 Lus 12mm 769 0 002 3769800 376960 092 37980 92 woe 59095 iam 375080000 sees osm ite 1 7 smemos fesses 5 64 20mm 57550 TT Ters TT Notes 1 One Kit is supplied standard with each wire feeder 2 Drive Roll Kits include Drive Rolls Input Output
51. ng gun loosen the gun clamp knob and insert the welding gun cable end into the feedhead until it stops 2 Tighten the gun clamp knob and connect the welding gun control wires to the gun switch receptacle 3 To remove loosen the gun clamp knob and pull the gun cable end out NOTE Before inserting the welding gun into the feedhead make sure the gun clamp does not extend into the feedhead otherwise the welding gun cannot be properly inserted Welding Gun Cable Art A 07198 9 amp V IK VER Gun Clamp Knob Figure 3 5 Installing Welding Gun 3 4 Manual No 0 4845 3 07 Threading Wire Into Feedhead Refer to Figure 3 6 A WARNING ELECTRIC SHOCK CAN KILL Make certain the power source and wire feeder are turned OFF Do not turn the power ON until told to do so in these instructions UTION Use care when handling the spooled wire as the wire tends to unravel when loosened from the spool Grasp the end of the wire firmly and don t let it get away from you Make sure that the end of the wire is straight and free of burrs PORTAFEED VS 212 2 Pass the wire through the output wire guide and into the welding gun assembly Lock in position with the spring tension knob To adjust the amount of force the bearing feed roll exerts on the welding wire turn the spring tension knob clockw
52. ntactor And Gas Valve Overcurrent Protection the contactor or gas valve becomes shorted an electronic circuit will activate and both the contactor and gas valve will not operate If this circuit activates alight on the 12 V driver printed circuit board labeled Fault 1 will turn on The contactor and gas valve overcurrent protection circuit will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds If this protection circuit activates the contactor or gas valve is most likely shorted and one or both will have to be replaced refer to section 5 06 Troubleshooting Guide in this manual OPERATION 4 6 Manual No 0 4845 SECTION 5 SERVICE 5 01 Cleaning Of The Unit About every 6 months remove the interior panel cover to expose the printed circuit boards and other components Using a vacuum cleaner or clean dry compressed air of not more than 25 psi 172 1 72 bar pressure vacuum or blow out the interior of the wire feeder While the interior panel cover is removed check all electrical components for loose connections and correct if necessary 5 02 Cleaning Of The Feed Rolls About every months clean the grooves on the feed rolls using a small wire brush If the feed roll has a smooth surface wipe off the feed roll with a clean dry cloth After cleaning the feed rolls tighten the upper and lower feed roll retaining knobs accordingly 5
53. nual No 0 4845 1 3 SAFETY INSTRUCTIONS PORTAFEED VS 212 A p WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure Bu 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 A WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Ef fects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding doe
54. o stop f 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 Art A 04130 SAFETY INSTRUCTIONS Line Connection Touch Start GTAW Auxiliary Power Variable Inductance 115V 15 Receptacle Rating t NI Auxiliary Power Voltage Inpu 5 Manual No 0 4845 1 PORTAFEED VS 212 SAFETY INSTRUCTIONS 1 04 Precautions De Securite En Soudage A L arc MISE GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entra nement intensif en soudage et cou
55. of time an electronic circuit will activate and the wire feeder will not operate The undervoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range Overvoltage Protection If the input voltage rises above the specified voltage range for an extended period of time an electronic circuit will activate and the wire feeder will not operate The overvoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range Input Current Protection If the input current rises above the specified maximum input current for an extended period of time the input circuit breaker will trip and the wire feeder will not operate The input circuit breaker will have to be manually reset if it were to trip OPERATION PORTAFEED VS 212 4 Motor Overcurrent Protection If the drive motor becomes locked or shorted an electronic circuit will activate and the motor will not operate If this circuit activates a light on the motor control printed circuit board labeled Fault 2 will turn on The motor overcurrent protection circuit will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds If this protection circuit activates and the drive motor is not locked the drive motor is most likely shorted and will have to be replaced refer to Troubleshooting Guide section of this manual 5 Co
56. page ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 249 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 05 Dangers relatifs au soudage l arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez al pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique
57. peut tuer ou br ler gravement bia la pi ce souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en c
58. pies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com Manual No 0 4845 2 1 PORTAFEED VS 212 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on nameplate attached to the rear panel In some cases the nameplate may be attached to the control panel Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page i for future reference 2 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 described above along with a full description of the parts in 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 INTRODUCTION PORTAFEED VS 212 2 04 Gener
59. proper polarity input voltage is fed into the PC boards independent of the welding polarity When the gun switch on the welding gun is pulled a short is provided on the gun switch receptacle J4 causing the wire feed motor B1 to turn feeding wire the gas valve L1 to open allowing gas flow and the contactor K1 to close making the welding wire electrically hot When the gun switch on the welding gun is released the short on the gun switch receptacle is removed causing the wire feed motor to stop feeding wire the gas valve to close stopping gas flow and the contactor to open making the welding wire electrically cold Manual No 0 4845 4 05 Adjusting Burnback Time Burnback time is set at the factory but the motor control printed circuit board contains a component that permits adjustment of burnback time Burnback time relates to the amount of welding wire re maining at the end of the welding gun after the welding process ends Increasing burnback time results in less wire remaining at the end of the welding gun at the end of the weld Decreasing burnback time results in more wire remaining at the end of the welding gun after the welding process ends gt WARNING ELECTRIC SHOCK CAN KILL Make certain the power source and wire feeder are both turned OFF before beginning the procedure 1 Using a nut driver or socket remove the wire spool 2 Remove the internal cover refer to Figure 4 3
60. re speed which is especially useful with larger diameter flux cored wires WIRESPEED AMP METER SELECTION DIP SWITCHES Set these switches to change the lower meter display from wire speed to amperage output of the power source Refer to Section 2 08 item 3 and section 4 07 for DIP switch setting information CARTRIDGE GUN LEADS These two spade terminals provide the MIG gun switch connection UPPER RETAINING KNOB This knob is used to secure the bearing feed roll Remove this knob to change the bearing feed roll Manual No 0 4845 6 GUN CLAMP KNOB Tighten this knob to secure the 9 welding gun to the wire feeder OUTPUT GUIDE LOCKSCREW Tighten this screw to secure the output wire guide LOWER RETAINING KNOB This knob is used to secure the drive feed roll Remove this knob to change the drive feed roll INPUT GUIDE LOCKSCREW Tighten this screw to secure the input wire guide 10 INPUT WIRE GUIDE This guide is required to direct the welding wire from the wire spool to the drive feed roll 11 SPRING TENSION KNOB Use the spring tension knob 2 7 to adjust the amount of force the bearing feed roll exerts on the welding wire INTRODUCTION PORTAFEED VS 212 12 CC CV MODE SWITCH The CC position provides a voltage sensing wire feed speed mode of operation for use with constant current CC power sources The CV position provides a constant wire feed speed mode of operation for use with constan
61. s been completed it is recommended that the gas be SHUT OFF at the cylinder and the wire feeder and power source be turned OFF OPERATION 4 2 4 03 Welding In CC Mode vs CV Mode 1 Welding in CC Mode When welding with a constant current CC power source changes in wire feed speed will affect welding voltage To adjust the amount of welding current from the CC power source a control knob on the power source or an optional control knob on the wire feeder will have to be adjusted The solid state control of a slow run in circuit automatically reduces the initial wire feed speed when operating with a CC power source This initial reduction in wire feed speed will compensate for the high open circuit voltage associated with CC power sources and improve arc starting performance Welding in CV Mode When welding with a constant voltage CV power source changes in wire feed speed will affect welding current Changes in wire feed speed can be obtained by adjusting the wire feed speed control knob To adjust the amount of welding voltage from the CV power source a control knob on the power source or an optional control knob on the wire feeder will have to be adjusted 4 04 Theory Of Operation Refer to the Connection and Schematic Diagram in theAppendix chapter of this manual Input power is supplied through the on off switch S1 and input circuit breaker CB1 to the bridge rectifier CR1 CR1 ensures that the
62. s not yet allow us to interpret the evidence in a single coherent framework 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 100 qms Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 1 02 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy
63. t fitted with a proper shade of filter see equipment if it will be left unattended or out of service ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended Manual No 0 4845 1 1 SAFETY INSTRUCTIONS PORTAFEED VS 212 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc 4 Wear protective clothing made from durable flame resistant material wool and leather and foot protection 5 Use approved ear plugs or ear muffs if noise level is high 9 19 WARNING n FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health 1 Keep your head out of the fumes Do not breath the fumes 2 lfinside ventilate the area and or use exhaust at the arc to remove welding fumes and gases 3 If ventilation is poor use an approved air supplied respirator 4 Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 5 Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe 6 Do not weld in locations near degreasing cleaning or spraying operations The heat
64. t voltage CV power Sources NOTE This switch does not select a CC or CV mode of operation The mode of operation is set by the type of power source being used 13 INPUT CIRCUIT BREAKER This circuit breaker provides complete system protection for the wire feeder in the case of a fault or overload condition 14 HUB TENSION BOLT The hub tension bolt is used to adjust the wire spool tension which acts as a mechanical brake to assist in the stopping of the welding wire at the completion of a weld INTRODUCTION 2 8 2 10 Power Source Compatibility Since the PORTAFEED VS 212 operates on arc voltage it will work with most constant current CC or constant voltage CV DC type power sources When connected to a PORTAFEED VS 212 the maximum allowed open circuit voltage OCV of the power source is 100 VDC Open circuit voltages exceeding 100 VDC will damage or shorten the life of the unit NOTE Because of the high open circuit voltage associated with most CC power sources it is recommended to place the PORTAFEED VS 212 power switch in the OFF position when not welding This procedure will prolong the life of electrical components connected to the power input lines When using the PORTAFEED VS 212 there must be at least 15 VDC between the output terminals of the power source during standby and while welding Otherwise the unit will not have enough input voltage to operate properly A contactor is a standard component o
65. tor life Figure 3 3 Hub Tension Bolt Manual No 0 4845 PORTAFEED VS 212 3 04 Input And Output Wire Guide Installation 1 Install the input wire guide the longer one by loosening the input guide lockscrew and inserting the guide into the hole in the feedhead assembly The recessed end of the guide should be towards the wire spool Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew 2 Install the output wire guide with the conical end towards the feed rolls in the same manner as the input guide The conical end of the guide should be as close to the feed rolls as practical Tighten the output guide lockscrew NOTE Before tightening the input and output guide lockscrews install the drive feed roll to help in the alignment of the wire guides Art 07197 Input Wire Guide gt ED E Input Guide Lockscrew CA Output Wire Guide inside Output Guide Lockscrew Figure 3 4 Wire Guide Installation 3 3 INSTALLATION PORTAFEED VS 212 3 05 Selection And Installation Of Feed Rolls Refer to feed roll kit chart in the Appendix chapter for the proper selection and ordering of feed roll kits Kit includes a bearing roll a drive roll an input wire guide and an output wire guide for a specific wire type and size NOTE All grooved feed rolls have their w
66. ues au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE O UNE EXPLOSION produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie C Sc Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas
67. ured product meets or exceeds all design specifications Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX Manual No 0 4845 1 11 SAFETY INSTRUCTIONS PORTAFEED VS 212 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 1 12 Manual No 0 4845 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Owner s Manual applies to just specification or part numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING gives information regarding possible personal injury CAUTION refers to possible equipment damage WARNING CAUTION NOTE A NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual Include the Owner s Manual number and equipment identification numbers Electronic co
68. ut feeding wire Manual No 0 4845 6 TRIGGER HOLD SWITCH This switch selects either 2 Step or 4 Step gun switch mode GUN SWITCH RECEPTACLE The gun switch receptacle accepts the welding gun control wires The gun switch receptacle is where a gun switch closure is inputted to the wire feeder VOLTAGE SENSING RECEPTACLE This receptacle serves as the voltage sensing point for the wire feeder and must be connected to the work piece through the voltage sensing lead for proper operation If the voltage sensing lead from the wire feeder and the weld cable from the power source are not connected to the work piece the wire feeder will not work WELDING GUN CABLE CONNECTION The welding gun cable is connected to the wire feeder at this point Connections must be tight otherwise arcing or overheating could result 10 REMOVABLE MIG GUN CARTRIDGE Patent Pending 2 5 The whole cartridge is interchangeable to accept competitive types of MIG gun connections No external adapters required See Appendix 2 and 3 for installation information and to select the adapter for other MIG Gun styles ie Miller Lincoln or Euro INTRODUCTION PORTAFEED VS 212 2 08 Rear Panel Controls And Connections 4 MIG Gun Holder Art A 07137 1 Lifting Eye 2 Gas Valve Inlet 3 Input Power Cable Figure 2 3 Rear Panel Connections 1 LIFTING EYE Allows for

PORTAFEED® VS 212 Operating Manual

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PORTAFEED&reg; VS 212 Operating Manual

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PORTAFEED® VS 212 Operating Manual