ESAB VS 212 TRANSMIG® Stealth CC/CV Semiautomatic Solid State Controlled Wire Feeder User manual
VS 212
TRANSMIG
®
STEALTH
CC/CV SEMIAUTOMATIC
SOLID STATE CONTROLLED
WIRE FEEDER
Art # A-07640
Operating Manual
Revision: AD
Operating Features:
Issue Date: February 25, 2010 Manual No.: 0-4949
VS
15-100
800
IPM
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Cigweld 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
+1300 654 674, or visit us on the web at www.cigweld.com.au.
This Operating Manual has been designed to instruct you on the correct use and operation of your Cigweld 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.
CIGWELD is the Market Leading Brand of Arc Welding Products for Thermadyne Industries Inc. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining,
Automotive, Engineering, Rural and DIY.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.
!
WARNINGS
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.
Cigweld Transmig VS 212 CC/CV Semiautomatic Solid State Controlled Wire Feeder
Instruction Manual Number 0-4949 for:
Part Number: W3512005 (no meters), W3512006 (with meters)
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711 www.cigweld.com.au
Copyright 2007, 2008, 2009 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:
Revision AD Date:
February 14, 2007
February 25, 2010
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Equipment Serial #:
___________________________________
___________________________________
___________________________________ i
TABLE OF CONTENTS
TABLE OF CONTENTS (continued)
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS .................................... 1-1
3.06 MIG Gun Compatibility And Installation and Removal .................................... 3-4
TABLE OF CONTENTS
OPTIONS AND ACCESSORIES ..................................................................... A-2
MIG GUN CARTRIDGE SYSTEM ................................................................... A-3
SYSTEM SCHEMATIC ............................................................................... A-4
Statement of Warranty
Warranty SCHEDULE
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover
TRANSMIG VS 212
SECTION 1:
ARC WELDING 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.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the Australian Standard AS1674.2-2003 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
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.
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 holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or covers.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground) circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts at once.
Manual No. 0-4949 1-1 SAFETY INSTRUCTIONS
TRANSMIG VS 212
13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
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.
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.
WARNING
1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
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.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
3. 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 and rays of the arc can react with vapors to form highly toxic and irritating gases.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A 8.2-73
Welding or Cutting operation
Electrode size Metal Thickness or Welding Current
Torch soldering
Torch brazing
Oxygen cutting
Light
Medium
Heavy
Light
All
All
Under 1 in., 25 mm
1 – 6 in., 25 – 150 mm
Over 6 in., 150 mm
Gas welding
Under 1/8 in., 3 mm
Medium
Heavy
1/8 – 1/2 in., 3 – 12 mm
Over 1/2 in., 12 mm
Shielded metal-arc welding (stick) electrodes
Under 5/32 in., 4 mm
Under 5/32 to ¼ in., 4 to 6.4mm
Over ¼ in., 6.4 mm
Filter shade no.
2
2 or 3
3 or 4
4 or 5
Welding or Cutting operation Electrode size Metal
Thickness or Welding
Current
Gas metal arc welding
Non Ferrous base metal
Ferrous base metal
All
All
Gas tungsten arc welding (TIG)
Atomic Hydrogen welding
All
All
5 or 6 Carbon Arc welding
Plasma arc Welding
All
All
4 or 5 Carbon Arc Gouging
5 or 6
6 or 8
10
12
14
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Under 300 Amp
300 to 400 Amp
Over 400 Amp
Filter shade no.
12
14
9
12
14
11
12
12
12
12
12
SAFETY INSTRUCTIONS 1-2 Manual No. 0-4949
TRANSMIG VS 212
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 airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.
WARNING
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.
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.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. 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.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. 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.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
Manual No. 0-4949 1-3 SAFETY INSTRUCTIONS
TRANSMIG VS 212
WARNING
WARNING
Engines can be dangerous.
MOVING PARTS can cause injury.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
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.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open flames.
3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes and skin.
WARNING
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
SAFETY INSTRUCTIONS 1-4 Manual No. 0-4949
WARNING
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and skin.
The coolant in the radiator can be very hot and under pressure.
TRANSMIG VS 212
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body as practical.
ABOUT PACEMAKERS:
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
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 &
Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and
Magnetic Fields
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S.
Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear sciencebased advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures.
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
1.02 PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, 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 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 in welding and allied processes Part 2:
Electrical, AS1674.2-2003 from SAI Global Limited, www.saiglobal.com
Manual No. 0-4949 1-5 SAFETY INSTRUCTIONS
TRANSMIG VS 212
1.03 DECLARATION OF CONFORMITY
Manufacturer:
Address:
CIGWELD
71 Gower St, Preston
Victoria 3072
Australia
Description of equipment: Welding Equipment (GMAW, MMAW, GTAW, and CAG). Including, but not limited to
CIGWELD TRANSMIG 500SP, 400SP, 320SP, VS212 Stealth and associated accessories.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive
73/23/EU, as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the
Directive.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and regulations.
• EN60974-1 applicable to welding equipment and associated accessories.
• AS60974.1 applicable to welding equipment and associated accessories.
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
CIGWELD has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.
SAFETY INSTRUCTIONS 1-6 Manual No. 0-4949
TRANSMIG VS 212
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:
!
WARNING
A WARNING gives information regarding possible personal injury.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
A NOTE offers helpful information concerning certain operating procedures.
Additional copies of this manual may be purchased by contacting Cigweld 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 copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Cigweld web site listed below and clicking on the Literature Library link: http://www.cigweld.com.au
2.02 Equipment Identification
The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the rear panel. In some cases, the nameplate may be attached to the control panel. Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.
2.03 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 uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to uncrate the unit.
Manual No. 0-4949 2-1 INTRODUCTION
TRANSMIG VS 212
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
115V 15A
Receptacle Rating-
Auxiliary Power
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
Single Phase
Three Phase
Three Phase Static
Frequency Converter-
Transformer-Rectifier
Remote
X
%
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
V
Voltage Input
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
t1 t
Spot Time
Preflow Time
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
Art # A-04130
INTRODUCTION 2-2 Manual No. 0-4949
TRANSMIG VS 212
2.05 General
The TRANSMIG 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 TRANSMIG VS 212’s steel-reinforced, flameretardant 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.
TRANSMIG VS 212 comes with:
• Robust injection molded case
• Changeable MIG gun cartridge system
• Heavy duty contactor
• Internal parts storage
• Power cable and drive rolls
• Gas valve solenoid
The TRANSMIG VS 212, includes the following features:
1. An on/off rocker switch
2. A wire feed speed control knob
3. A welding gun holder
4. A carrying handle
5. A contactor
6. A gas valve
7. A CC/CV mode switch
8. An input circuit breaker for complete system protection
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. An electronic controlled dynamic brake
11. An electronic controlled current limit to motor
12. An 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, the
Transmig VS212 also includes a digital display for wire feed speed/amps and arc voltage, with arc time and memory hold.
16. Trigger Hold Switch
The TRANSMIG VS 212 has been designed to comply with IEC 60974-1 (CE), CSA NRTL/C, and NEMA EW
3 standards.
Manual No. 0-4949 2-3 INTRODUCTION
TRANSMIG VS 212
2.06 Product Specifications
Transmig VS212 Specifications
Input Voltage Range 15-100vdc
Maximum Input Current 10 amps
Wire Speed Range
(dependent on arc voltage)
50-800 IPM
(1.27 - 22.86 MPM)
Wire Sizes
0.024 - 5/64''
(0.6 - 2.0 mm)
Max Wire Spool
Capacity
Drive Rolls
12'' (304.8 mm) up to 44 Lbs. (20 kg)
2 (Both Gear Driven)
Welding Current (I)
425A @ 60% duty cycle
330A @ 100% duty
Welding Gun Inlet Size
(Std) Tweco Style #4
Maximum Shielding
Gas Inlet Pressure
5/8'' (16mm) Nominal
100 psi (6.9 bar)
Degree of Protection IP21C
Weight (Less wire)
40 lbs (18 kg)
Approvals
IEC 60974-5
NEMA EW3
Table 2-1 Specifications
Art # A-07130
15.3 in.
289mm
INTRODUCTION
21.3 in.
541mm
Figure 2-1: Dimensional Information
9.4 in.
239mm
2-4 Manual No. 0-4949
TRANSMIG VS 212
2.07 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
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, nozzles, etc.
Machined feed head & tension arms
Insures wire alignment tolerances of ±0.05mm.
Inch switch & 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.
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 1.2ft (360mm) power cable, Dinse connector and .035/.045in (0.9/1.2mm) drive rolls for hard/tubular wire. Geared top & bottom drive rolls. Excellent traction on the wire.
Quick change drive rolls
Change the drive rolls without tools.
Manual No. 0-4949 2-5 INTRODUCTION
TRANSMIG VS 212
2.08 Front Panel Controls And Connections
Art # A-07136_AB
(4) Arc Voltage Meter
(3) Wire Feed Speed/Amp Meter
(2) Wire Feed Speed Control
(1) On/Off Power Switch
(5) Inch/Purge Switch
(9) Welding Gun Cable Connection
(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
1. POWER ON/OFF SWITCH: This switch controls input power only to the wire feeder and not to the power source.
2. WIRE FEED SPEED CONTROL: This knob controls the wire feed speed. The wire feed speed control can be adjusted during setup or actual welding.
3. 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.
4. ARC VOLTAGE METER: The arc voltage meter displays the actual voltage output of the power source.
5. INCH/PURGE SWITCH: Depressing the INCH portion of the switch will feed wire at a speed set by the WFS control. The wire will not be electrically hot when using the INCH switch. Depressing the
PURGE portion of the switch will allow shielding gas to flow out of the welding gun without feeding wire.
INTRODUCTION 2-6
6. TRIGGER HOLD SWITCH: This switch selects either 2 Step or 4 Step gun switch mode.
7. 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.
8. VOLTAGE SENSING RECEPTACLE: This receptacle serves as the voltage sensing point for the wire feeder and must be connected to the work piece through the voltage sensing lead for proper operation. 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.
9. WELDING GUN CABLE CONNECTION: The welding gun cable is connected to the wire feeder at this point. Connections must be tight; otherwise, arcing or overheating could result.
10.REMOVABLE MIG GUN CARTRIDGE (Patent
Pending): The whole cartridge is interchangeable to accept competitive types of MIG gun connections. No external adapters required. See
Appendix 2 and 3 for installation information and to select the adapter for other MIG Gun styles, ie.
Miller
®
, Lincoln
®
or Euro.
Manual No. 0-4949
2.09 Rear Panel Controls And Connections
(4) MIG Gun Holder
Art # A-07137
TRANSMIG VS 212
(1) Lifting Eye
(2) Gas Valve Inlet
(3) Input Power
Cable
Figure 2-3: Rear Panel Connections
1. LIFTING EYE: Allows for hanging or moving of the feeder over the work area.
2. GAS VALVE INLET: This is where the shielding gas hose (if used) is connected to the wire feeder.
3. INPUT POWER CABLE: Provides an inlet and secure fixture for the power cable from the welding power source.
4. WELDING GUN HOLDER: This is an insulated holder used to hold the welding gun when not welding.
Manual No. 0-4949 2-7 INTRODUCTION
TRANSMIG VS 212
2.10 Internal Controls And Connections
Art # A-07138
(14) HUB TENSION
BOLT
(13) INPUT CIRCUIT
BREAKER
(12) CC/CV MODE
SWITCH
CC
High
CV
Low
(11) PRESSURE ADJUST DEVICE
(10) INPUT WIRE GUIDE
(1) STORAGE BOX
(2) HIGH/LOW RANGE SWITCH
(3) WIRE SPEED/AMP METER
SELECTION DIP SWITCHES
(4) CARTRIDGE GUN LEADS
(5) UPPER RETAINING KNOB
(6) GUN CLAMP KNOB
(9) INPUT GUIDE LOCKSCREW (7) OUTPUT GUIDE LOCKSCREW
(8) LOWER RETAINING KNOB
Figure 2-4: Internal Controls and Connections.
1. STORAGE BOX: On the job storage for drive rolls, tips, nozzles, etc. To remove, lift up to release velcro and slide it up and over the side retainers.
2. HIGH/LOW RANGE SWITCH: Gives a finer dial control over the wire speed, which is especially useful with larger diameter flux-cored wires.
3. WIRE SPEED/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.
4. CARTRIDGE GUN LEADS: These two spade terminals provide the MIG gun switch connection.
5. UPPER RETAINING KNOB: This knob is used to secure the bearing feed roll. Remove this knob to change the bearing feed roll.
6. GUN CLAMP KNOB: Tighten this knob to secure the welding gun to the wire feeder.
7. OUTPUT GUIDE LOCKSCREW: Tighten this screw to secure the output wire guide.
8. LOWER RETAINING KNOB: This knob is used to secure the drive feed roll. Remove this knob to change the drive feed roll.
9. 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 to adjust the amount of force the bearing feed roll exerts on the welding wire.
INTRODUCTION 2-8 Manual No. 0-4949
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 constant 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.
TRANSMIG VS 212
2.11 Power Source Compatibility
Since the TRANSMIG 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 TRANSMIG 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 TRANSMIG
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 TRANSMIG 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 of the
TRANSMIG 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 CIGWELD Power Sources
Transarc 250Si, 300Si
Transtig 200Pi, 250Pi, 300Pi
Transmig 500i, 500P, 6045
Engine Driven Welders:
MPM 5/190, MPM 8/255, MPM 8/270
MPM 12/400, MPM 20/500
2.12 Options and Accessories
Refer to the Appendix section of this manual for the list of available options and accessories for this product.
Manual No. 0-4949 2-9 INTRODUCTION
TRANSMIG VS 212
NOTES
INTRODUCTION 2-10 Manual No. 0-4949
TRANSMIG VS 212
SECTION 3:
INSTALLATION
3.01 Connections
CAUTION
Make sure all connections are tight; otherwise, arcing or overheating could result.
1. Using the supplied adapter, connect a weld cable from the power source to the power cable connection on the rear of the VS 212.
2. Connect a weld cable from the power source to the work connection.
3. Connect the voltage sensing lead from the wire feeder to the work connection.
!
WARNING
ELECTRIC SHOCK CAN KILL! DO NOT touch the metal portions of the voltage sensing lead when the power source output is on.
4. Make the proper gas line connection from the gas supply to the wire feeder gas valve (if gas will be used).
5. Attach the welding gun to the wire feeder.
6. Connect the welding gun control leads to the wire feeder gun switch terminals located on the front of the wire feeder.
GAS SUPPLY
GAS LINE
REAR VIEW
VOLTAGE SENSING
WIRE FEEDER
WELDING GUN
WORK TABLE
-
+
WELDING CABLE FRONT VIEW GUN SWITCH LEADS
VOLTAGE
SENSING LEAD
WELDING CABLES
POWER SOURCE
Art # A-07194
Figure 3-1: System Hook-up Outline
Manual No. 0-4949 3-1 INSTALLATION
TRANSMIG VS 212
3.02 Installation Of Wire Spool
NOTE
The wire spool hub supplied with the unit is provided for mounting up to a 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.
4. Replace the wire spool hub nut and turn clockwise to a snug position.
NOTE
Install the welding wire spool so the wire feeds from the bottom of the spool into the input wire guide.
Art # A-07195
Wire Spool
Hub Nut
Step
1
Alignment Pin
Wire Spool
Hub
Step
2
+
3
INSTALLATION
Wire
Spool
Step
4
3-2
Figure 3-2: Wire Spool Installation
Manual No. 0-4949
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 motor life.
Art # A-07196
TRANSMIG VS 212
3.04 Input And Output Wire Guide
Installation
1. Install the input wire guide (the longer one) by loosening the input guide lockscrew and inserting the guide into the hole in the feedhead assembly.
The recessed end of the guide should be towards the wire spool. Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew.
2. Install the output wire guide (with the conical end towards the feed rolls) in the same manner as the input guide. The conical end of the guide should be as close to the feed rolls as practical. Tighten the output guide lockscrew.
NOTE
Before tightening the input and output guide lockscrews, install the drive feed roll to help in the alignment of the wire guides.
Art # A-07197
Hub Tension Bolt
Figure 3-3: Hub Tension Bolt
Input Wire
Guide
Input Guide
Lockscrew
Output Wire
Guide (inside)
Manual No. 0-4949 3-3
Output Guide Lockscrew
Figure 3-4: Wire Guide Installation
INSTALLATION
TRANSMIG 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 wire size or range stamped on the side of the roll.
On rolls with different size grooves, the outer (visible when installed) stamped wire size indicates the groove in use.
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.
3.06 MIG Gun Compatibility And
Installation and Removal
The Transmig VS 212 wire feeder is designed to be used with most MIG welding guns. It comes configured from the factory to work with all Tweco guns. Refer to the Section 2.11 Available Options for the ordering information of other MIG gun adapter cartridges.
1. To install the welding gun, loosen the gun clamp knob and insert the welding gun cable end into the feedhead until it stops.
2. Tighten the gun clamp knob and connect the welding gun control wires to the gun switch receptacle.
3. To remove, loosen the gun clamp knob and pull the gun cable end out.
NOTE
Before inserting the welding gun into the feedhead, make sure the gun clamp does not extend into the feedhead; otherwise, the welding gun cannot be properly inserted.
Art # A-07198
Welding Gun Cable
!
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.
Gun Clamp Knob
Figure 3-5: Installing Welding Gun
INSTALLATION 3-4 Manual No. 0-4949
3.07 Threading Wire Into Feedhead
Refer to Figure 3-6.
!
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.
CAUTION
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.
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.
TRANSMIG VS 212
2. Pass the wire through the output wire guide and into the welding gun assembly.
3. 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 clockwise for increased force or counterclockwise for decreased force.
NOTE
If the force applied to the wire is too great, the welding wire will bird nest in the feedhead and not feed properly.
4. 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.
Wire Feed Speed Control
Figure 3-7: Wire Feed Speed Control
Art # A-07253
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. 0-4949 3-5 INSTALLATION
TRANSMIG VS 212
NOTES
INSTALLATION 3-6 Manual No. 0-4949
TRANSMIG VS 212
SECTION 4:
OPERATION
4.01 Prewelding Procedure
Follow all installation instructions for the welding power source, the welding gun, and the VS 212 CC/
CV wire feeder before attempting to weld.
1. Make sure all necessary connections have been made (refer to Connections in the Installation chapter of this manual).
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).
5. Depress the inch switch (if equipped) or gun switch and adjust the wire feed speed to the desired value by means of the wire feed speed control. The wire feed speed control can be adjusted during setup or while welding.
!
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.
CC
High
CV
Low
Art # A-07254
6. Adjust the 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.
7. If using a CV power source, the output contactor on the power source will have to be energized. In most cases, this will require a jumper to be added to the power source or a switch on the power source to be turned on. Read the power source owner’s manual for proper connections or settings required.
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.
!
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.
Gun Switch
Gas Valve
Wire Feed
Power Source
Art # A-05126
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Figure 4-2: Functional Timing Diagram
Manual No. 0-4949 4-1 OPERATION
TRANSMIG VS 212
4.02 Welding Procedure
!
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.
2. To end the weld, release the gun switch trigger while pulling the welding gun away from the work piece. The solid state control then disables the gas valve, wire feed motor, and power source.
NOTE
After the weld is completed, it is recommended to pull the welding gun away from the work while releasing the gun switch. This allows the welding arc to partially extinguish at the work piece which reduces the arcing at the contactor contacts. Using this procedure will lengthen the life of the contactor contacts especially when welding at high amperage.
3. At the end of the work day or when welding has been completed, it is recommended that the gas be SHUT OFF at the cylinder, and the wire feeder and power source be turned OFF.
4.03 Welding In CC Mode vs. CV
Mode
1. Welding in CC Mode: When welding with a constant current (CC) power source, changes in wire feed speed will affect welding voltage.
To adjust the amount of welding current from the
CC power source, a control knob on the power source or an optional control knob on the wire feeder will have to be adjusted.
The solid state control of a “slow run-in” circuit automatically reduces the initial wire feed speed when operating with a CC power source. This initial reduction in wire feed speed will compensate for the high open circuit voltage associated with CC power sources and improve arc starting performance.
B. Welding in CV Mode: When welding with a constant voltage (CV) power source, changes in wire feed speed will affect welding current.
Changes in wire feed speed can be obtained by adjusting the wire feed speed control knob.
To adjust the amount of welding voltage from the
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 the Appendix 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 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.
OPERATION 4-2 Manual No. 0-4949
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 remaining 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.
WARNING
ELECTRIC SHOCK CAN KILL. Make certain the power source and wire feeder are both turned OFF before beginning the procedure.
TRANSMIG VS 212
3. Locate component R68 (Burnback) on the motor control 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 (360°) 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.
1. Using a nut driver or socket, remove the wire spool hub .
2. Remove the internalcover (refer to Figure 4-3).
Art # A-07254
Artr # A-09406
CC
High
CV
Low
R68 located on this PCB
Remove the four screws and Internal Cover
Figure 4-3: Accessing PCB for Burn Back
Manual No. 0-4949 4-3
Figure 4-4: High/Low Switch Location
OPERATION
TRANSMIG VS 212
The low setting provides greater knob sensitivity, but over a narrower range. The high setting provides less sensitivity but yields a wider range.
The ranges are as follows:
Low 50 - 400 ipm (1.27 - 10.16 mpm)
High 50 - 800 ipm (1.27 - 20.32 mpm)
Voltage Output
Wire Feed Speed
(ipm or mpm) or
Current Output
Art # A-07255
50 400
Low Range
50 800
High Range
Figure 4-5: Low and High Feed Speed Ranges
4.07 Changing Meter Functions
The Transmig 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.
Art # A-07256
Figure 4-6: Digital Meter Functions
Changing The Lower Meter Functions:
1. Open the VS 212 case door.
NOTE
The power does not need to be turned off to change these settings.
2. Locate the 4 white DIP switches on the side of the meter display's printed circuit board. The LEFT/
RIGHT diagram in Figure 4-7 indicates the factory default positions of the lower meter DIP switches.
CC
High
CV
Low
Hour Display Button
4
3
2
1
Art # A-08353
Figure 4-7: Meter DIP Switches
LEFT
RIGHT
3. Using Table 4-1 as a reference, carefully slide each white DIP switch left or right to change the lower meter to the desired function.
DIP Switch # 1 2 3 4
LEFT Position
Hold Function "Off" Wire Feed Speed Displayed Wire Feed Speed in IPM Currently Not In Use
RIGHT Position
Hold Function "On"
(refer to 4.07)
Output Current Displayed Wire Feed Speed in MPM Currently Not In Use
Table 4-1: Lower Meter Switch Settings
OPERATION 4-4 Manual No. 0-4949
4.08 Meter Hold Function
The meter hold function is enabled when DIP switch number 1 is set to the "RIGHT" position as defined in the table above. When this function is activated, the meter's displays 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
Tho us an
Hun ds dr
Te ed ns s
1 2 3
4.5 6
Art # A-07258
Hundreths
Tenths
Figure 4-8: Displaying Operation Hours
For example, the above display would be read as:
1,234.56 hours
TRANSMIG VS 212
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: If the input voltage drops below the specified voltage range for an extended period of time, an electronic circuit will activate, and the wire feeder will not operate. The undervoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range.
2. Overvoltage Protection: If the input voltage rises above the specified voltage range for an extended period of time, an electronic circuit will activate, and the wire feeder will not operate. The overvoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range.
3. Input Current Protection: If the input current rises above the specified maximum input current for an extended period of time, the input circuit breaker will trip, and the wire feeder will not operate. The input circuit breaker will have to be manually reset if it were to trip.
4. 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.
CAUTION
Note
The elapsed arc hours function is not available in the 4T mode.
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 Section 5.03
Troubleshooting Guide in this manual).
Manual No. 0-4949 4-5 OPERATION
TRANSMIG VS 212
5. Contactor And Gas Valve Overcurrent Protection:
If the contactor or gas valve becomes shorted, an electronic circuit will activate, and both the contactor and gas valve will not operate. If this circuit activates, a light on the 12 V driver printed circuit board labeled [Fault 1] will turn on. The contactor and gas valve overcurrent protection circuit will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds.
CAUTION
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 5.03
Troubleshooting Guide in this manual).
OPERATION 4-6 Manual No. 0-4949
TRANSMIG VS 212
SECTION 5:
SERVICE
5.05 Common Symptoms
5.01 Cleaning Of The Unit
About every 6 months, remove the interior panel cover to expose the printed circuit boards and other components. Using a vacuum cleaner or clean, dry, compressed air of not more than 25 psi (172 kPa, 1.72
bar) pressure, vacuum or blow out the interior of the wire feeder. While the interior panel cover is removed, check all electrical components for loose connections and correct if necessary.
5.02 Cleaning Of The Feed Rolls
!
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.
About every 3 months, clean the grooves on the feed rolls using a small wire brush. If the feed roll has a smooth surface, wipe off the feed roll with a clean, dry cloth. After cleaning the feed rolls, tighten the upper and lower feed roll retaining knobs accordingly.
!
WARNING
5.03 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!
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.
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.
Prior to disassembly or servicing of the machine, note the wiring and connections in the machine.
Reassembling should place the wires in the same location and routing as received from the factory. Keep wires and leads away from hot parts and sharp objects.
Manual No. 0-4949 5-1
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.
D. Check for a damaged power switch.
E. Check for a damaged or tripped circuit breaker.
SERVICE
TRANSMIG VS 212
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 tight.
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.
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.
SERVICE 5-2
5. Wire feed motor continues to run after gun switch has been released.
A. Check Trigger Hold switch (see section
2.08).
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.
Manual No. 0-4949
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 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:
W3512006
TRANSMIG VS 212
TRANSMIG VS 212
6.03 External Replacement Parts
Item # Qty
7
8
5
6
9
3
4
1
2
1
1
1
1
1
1
2
1
2
Control Knob
Rocker Switch, Single Pole, Black
Rocker Switch, Single Pole,Momentary, Black
Door Latch Assembly, VS 212
Assembly, Handle, VS 212
Assembly, Door, VS 212
Lifting Eye, VS 212
Power Input Pigtail Assembly, VS 212
Rocker Switch, Single Pole, Black. On/off
870696PKD
870359PKD
870863PKD
871621PKD
870972PKD
870953PKD
870974PKD
871316PKD
870359PKD
7
8
Art# A-07606
4
5
6
1
9
3
2
6.04 Internal Replacement Parts
Item # Qty
3
4
1
2
5
6
2
1
1
1
1
1
Case, Internal Parts Storage
Circuit Breaker PB 10A
Rocker Switch, Single Pole, Black On/Off
SC Thumb 1/4" UNC Narrow Head
Clamp, Gun Tube
Wire Spool Hub Assembly
TRANSMIG VS 212
870865PKD
7978049PKD
870359PKD
7950348PKD
171362PKD
871616PKD
1
2
3
4
5
6
Art #A-07607_AB
TRANSMIG VS 212
6.05 Wire Feeder Replacement Parts
Item # Qty
7
8
5
6
3
4
1
2
9
10
11
12
13
1
2
3
1
1
2
1
1
1
1
1
1
1
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)
870933PKD
870679PKD
871001PKD
See note 1
See note 1
870733PKD
870560PKD
See note 1
See note 1
171362PKD
870558PKD
870695-001PKD
870509PKD
2
1
13
3
4
6
5
7
8
NOTES:
1. This part may be purchased at a local hardware store.
9
10
11
Art # A-07608
12
TRANSMIG VS 212
APPENDIX 1:
DRIVE ROLL KITS
DRIVE ROLL KITS (#375980-Series) 2 ROLL
Top
Bottom
Style 1 Style 2
Flat
Double
Smooth "V"
Flat Knurled
Double
Smooth "V"
Style 3
Double Smooth
"V"
Double Smooth
"V"
Style 4
Double
Style 5
Knurled "V" Double Cog
Double
Knurled "V" Double Cog
Style 6
Double "U"
Double "U"
Wire Type
Wire Size
.024" / 0.6mm
.030", .035" / 0.8, 0.9mm
Hard
375980-031
375980-001
.030", .035", .045" / 0.8, 0.9, 1.2mm
375980-028*
.035" / 0.9mm
375980-040*
.035", .045" 3/64" / 0.9, 1.2, 1.2mm
.045" / 1.2mm
3/64 / 1.2mm
-
375980-002*
-
Hard
-
-
-
-
-
-
-
Soft/Hard/Tubular Hard/Tubular
-
375980-010
-
-
375980-030
-
375980-011
.052" / 1.3mm
.052", 1/16" / 1.3, 1.6mm
1/16" / 1.6mm
5/64" / 2.0mm
375980-090*
-
375980-005*
375980-006*
-
-
-
-
375980-012
-
-
-
Notes: 1) One Kit is supplied standard w ith each w ire feeder.
2) Drive Roll Kits include: Drive Rolls; Input, Output , #375980-028 Guides
-
-
-
-
Tubular
-
-
-
-
-
375980-092 375980-022
-
-
375980-017 375980-023
-
375980-018
-
-
3) Narrow 30° "V"
Soft (Aluminum)
-
-
375980-034
-
-
-
-
375980-032
-
-
375980-033
Manual No. 0-4949 A-1 APPENDIX
TRANSMIG VS 212
APPENDIX 2:
OPTIONS AND ACCESSORIES
Drive Roll Kits 375980-XXX
One kit (#375980-092) is supplied standard with each wire feeder, see drive roll kit chart to select a different drive roll style
Wire Spool / Coil Adapters
10 lb (4.5kg), 8” spool
15 lb (6.8kg), 8” spool
14 lb (6.4kg) coil,
Wire Feeder Cart
375585-001
375864-001
375942A
W4000001
Roll Cage
MIG Gun Adaptor
W4003001
Tweco® #4 W4004001
Miller® W4005001
Lincoln® (gasless) W4006001
Lincoln® W4006002
Euro-style W4007001
Low profile, large caster cart
Protective tube steel roll cage
Integrated cartridge to accept other style MIG guns.
APPENDIX A-2 Manual No. 0-4949
TRANSMIG VS 212
APPENDIX 3:
MIG GUN CARTRIDGE SYSTEM
Removable Gun Cartridge System (Patent Pending)
The MIG gun cartridge can easily be removed and replaced with a different cartridge that will fit other brands of MIG guns (Miller®, Lincoln®, Euro). Refer to Appendix 2 for specific models.
Art # A-07414
Manual No. 0-4949 A-3 APPENDIX
A
TRANSMIG VS 212
APPENDIX 4:
SYSTEM SCHEMATIC
4 5
D
J2-5
J2-2
J2-3
J2-1
4
J1-1
C
INPUT FROM
POWER SUPPLY 1 2
10A
3
+ +
5
6
J1-2
++
V.BUS
V.CAP
J3-3
10
J4-2
++
J1-12
24
J4-1
PCB2
12VDC DRIVER
170046B-001PKD
12VDC
REGULATION
J4-3
J1-11
23
/ENABLE
J4-6
J3-4
12
J4-4
/ENABLE
J3-1
B
7
8
J1-9
/CC MODE
J1-10
J1-8
PCB1
MOTOR CONTROL
376395C
J1-3
J1-4
J1-5
Art # A-08424_AB
5 4
APPENDIX A-4 Manual No. 0-4949
TRANSMIG VS 212
3 2 1
18
17
16
15
VOLTMETER (+)
VOLTMETER (-)
WFS METER (+)
WFS METER (-)
J7-11
J7-10
J7-9
J7-8
9
9A
14
11 11A
13
(ACTIVE LOW DURING
PURGE & START)
19
35
/4T MODE
J6-1
J6-2
/INCH
SELECTOR SW
/PURGE
J6-3
J6-5
25
J7-4
J7-3
J7-6
CONTACTOR
CONTROL
PCB3
PANEL PCB
870949APKD
(W/METER
871014PKD)
J6-4
+5VDC
J5-3
J5-2
J5-1
32
33
34
CS1 CURRENT
SENSE
TRANSDUCER
(MOUNTED ON
W1 BUSS BAR)
FEEDHEAD
25
26
2
1
J7-7
J7-5
/OVER-VOLTAGE
FAULT
+5VDC
1
2
3
4
5
6
1
2
3
4
5
6
DIGITAL DISPLAY
GUN SWITCH
(/START / STOP)
D
C
B
3
20
21
22
WFS POT MAX J7-12
WFS POT WIPER J7-13
WFS POT MIN J7-14
10K
/HIGH
J7-2
J7-1
34
30
Art # A-08424_AB
Rev Revisions
<RevCode>
By
Last Modified: Tuesday, March 04, 2008
09:09:46
Date
2
Information Proprietary to
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -
TITLE:
PCB No:
Assy No:
References
Scale Supersedes
Tuesday, February 26, 2008
Drawn: Date:
Chk:
Size
App: Sheet
1 of
DWG No:
1
A
STEALTH/HEFTY PRO
1
Manual No. 0-4949 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 applicable 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 remedies 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, 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
Scout®, Raider®, Explorer™
Original Main Power Stators and Inductors
Original Main Power Rectifiers, Control P.C. Boards
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors
Engines and Associated Components are NOT Warranted by Thermal Arc®,
Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE
MANUFACTURERS’ WARRANTY FOR DETAILS.
GMAW/FCAW (MIG) WELDING EQUIPMENT
Fabricator® 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
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Electric Motors
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Electric Motors
PLASMA WELDING EQUIPMENT
Ultima® 150
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors
Welding Console, Weld Controller, Weld Timer
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators
SMAW (Stick) WELDING EQUIPMENT
Dragster™ 85; 95S
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors
Parts / Labor
5 years / 3 years
3 years / 3 years
1 year / 1 year
See the Engine
Manufacturers’ Warranty for Details
Parts / Labor
5 years / 3 years
3 years / 3 years
1 year / 1 year
Parts / Labor
5 years / 3 years
3 years / 3 years
1 year / 1 year
Parts / Labor
5 years / 3 years
3 years / 3 years
3 years / 3 years
1 year / 1 year
Parts / Labor
1 year / 1 year
1 year / 1 year
1 year / 1 year
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors
GENERAL ARC EQUIPMENT
FirePower® MIG Welders
Water Recirculators
Plasma Welding Torches
Gas Regulators (Supplied with Power Sources)
MIG and TIG Torches (Supplied with Power Sources)
Replacement Repair Parts
MIG, TIG and Plasma Welding Torch Consumable Items
5 years / 3 years
3 years / 3 years
1 year / 1 year
Parts / Labor
5-2-1 years / NA
1 year / 1 year
180 days / 180 days
180 days / NA
90 days / NA
90 days / NA
NA / NA
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: [email protected]
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: 86-21-69171135
Fax: 86-21-69171139
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 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 S. 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
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX: (636) 728-3010
Email: [email protected]
www.thermalarc.com
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