211i Service Manual Fabricator®

211i Service Manual Fabricator®

211i

Fabricator

®

Multi proceSS welding inverter

Art # A-11188

Service Manual

Issue Date: March 4, 2013 Manual No.: 0-5226 Revision: AB

Operating Features:

50

60

Hz

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call

+44 (0) 1257 261 755, or visit us on the web at www.Thermalarc.com

This Service Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety

Precautions. They will help you to avoid potential hazards that may exist when working with this product.

We have made every effort to provide you with accurate instructions, drawings, and photographs of the product(s) while writing this manual.

However errors do occur and we apologize if there are any contained in this manual.

Due to our constant effort to bring you the best products, we may make an improvement that does not get reflected in the manual. If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for Victor

Technologies International Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing,

Construction, Mining, Automotive, Aerospace, Engineering, Rural and

DIY/Hobbyist.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

!

WARNINGS

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 judgment, the Manufacturer assumes no liability for its use.

Service Manual Number 0-5226 for:

Thermal Arc Fabricator 211i Inverter Power Supply Part Number W1004206

Thermal Arc Fabricator 211i Inverter System Part Number W1004207

Published by:

Victor Technologies Europe

Europa Building

Chorley Industrial Park

Chorley, Lancaster,

England, PR6 7BX www.thermalarc.com

Copyright 2013 by

Victor Technologies International, 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: March 07, 2012

Revision Date: March 4, 2013

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

____________________________________

____________________________________

____________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 Principal Safety Standards .............................................................................. 1-5

1.03 Symbol Chart .................................................................................................. 1-6

1.04 Declaration Of Conformity .............................................................................. 1-7

1.05 Servicing Hazards ........................................................................................... 1-8

1.06 EMF Information ........................................................................................... 1-10

SECTION 2:

INTRODUCTION ..................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification ................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 User Responsibility ......................................................................................... 2-2

2.06 Transportation Methods .................................................................................. 2-2

2.07 Packaged Items .............................................................................................. 2-2

SECTION 3:

SAFETY AND INSTALLATION ....................................................................... 3-1

3.01 Duty Cycle ....................................................................................................... 3-1

3.02 Specifications ................................................................................................. 3-2

3.03 Environment ................................................................................................... 3-3

3.04 Location .......................................................................................................... 3-3

3.05 Ventilation ....................................................................................................... 3-3

3.06 Mains Supply Voltage Requirements .............................................................. 3-4

3.07 Electrical Input Connections ........................................................................... 3-5

3.08 Electromagnetic Compatibility ........................................................................ 3-6

3.09 Volt-Ampere Curves ........................................................................................ 3-8

SECTION 4: operation .............................................................................................. 4-1

4.01 Power Source Controls, Indicators and Features ............................................ 4-1

4.02 Attaching MIG Gun ........................................................................................ 4-7

4.03 Installing 15kg Spool (300mm diameter) ...................................................... 4-8

4.04 Installing 5kg Spool (200mm diameter) ......................................................... 4-8

4.05 Inserting Wire into the Wire Feed Mechanism ................................................ 4-9

4.06 Feed Roller Pressure Adjustment .................................................................. 4-10

4.07 Changing the Feed Roll ................................................................................. 4-10

4.08 Wire Reel Brake ............................................................................................ 4-11

4.09 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire ..................... 4-11

4.10 Setup for MIG (FCAW) Welding with Gasless MIG Wire ............................... 4-13

4.11 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire . 4-14

4.12 Setup for TIG (GTAW) Welding ..................................................................... 4-15

4.13 Setup for STICK (MMA) Welding ................................................................. 4-17

4.14 Leak Testing the System ............................................................................... 4-18

TABLE OF CONTENTS

SECTION 5:

TROUBLESHOOTING ................................................................................ 5-1

5.01 Basic Troubleshooting-Power Source Faults ................................................... 5-1

5.02 Routine Service and Calibration Requirements ............................................... 5-2

5.03 Check Unit before Applying Power .................................................................. 5-4

5.04 Test Equipment and Tools Needed for Troubleshooting and Servicing ............ 5-5

5.05 Visually Inspect ............................................................................................... 5-5

5.06 Preliminary DC Bus Measurement of the Main Inverter Board ........................ 5-6

5.07 Preliminary Check of the Main Inverter Board ................................................ 5-7

5.08 Check Main Input Rectifier .............................................................................. 5-8

5.09 DC Bus Voltage Measurement ........................................................................ 5-9

5.10 PCB Connectors ............................................................................................ 5-10

5.11 DIP Switch Settings, Control PCB ................................................................. 5-16

5.12 Calibration .................................................................................................... 5-17

5.13 Circuit Diagram ............................................................................................. 5-19

5.14 Main Circuit Description ............................................................................... 5-20

SECTION 6:

DISASSEMBLY PROCEDURE ....................................................................... 6-1

6.01 Safety Precautions for Disassembly ............................................................... 6-1

6.02 Control Board Removal ................................................................................... 6-2

6.03 Front Panel Assembly Removal ...................................................................... 6-3

6.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal ....................... 6-4

6.05 Back Panel Removal ....................................................................................... 6-5

6.06 Power Switch S1 and Power Cord Removal ................................................... 6-6

6.07 Base Panel Removal ....................................................................................... 6-7

SECTION 7:

ASSEMBLY PROCEDURES .......................................................................... 7-1

7.01 Installing Base Board ...................................................................................... 7-1

7.02 Installing Back Panel ....................................................................................... 7-2

7.03 Installing Front Panel ...................................................................................... 7-3

7.04 Installing Main Control Panel and Clear Cover Sheet ...................................... 7-4

7.05 Installing Case ................................................................................................ 7-6

SECTION 8:

KEY SPARE PARTS ................................................................................... 8-1

8.01 Power Source Spare Parts .............................................................................. 8-1

SECTION 9:

OPTIONAL ACCESSORIES .......................................................................... 9-1

9.01 Optional Accessories ...................................................................................... 9-1

THERMAL ARC - LIMITED WARRANTY TERMS

TERMS OF WARRANTY – JANUARY 2011

SAFETY INSTRUCTIONS FABRICATOR 211i

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

!

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN

AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE

INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

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 European Standard EN60974-1 entitled: Safety in welding and allied processes

Part 2: Electrical. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE,

AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

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 semi-automatic 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.

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.

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.

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.

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.

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.

Manual 0-5226 1-1 SAFETY INSTRUCTIONS AND WARNINGS

FABRICATOR 211i SAFETY INSTRUCTIONS

2. Wear approved safety glasses. Side shields recommended.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

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.

6. Never wear contact lenses while welding.

AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida

Guide for Shade Numbers

Process

Electrode Size in.

(mm)

Arc Current

(Amperes)

Minimum

Protective

Shade

Suggested*

Shade No.

(Comfort)

Shielded Metal Arc Welding

(SMAW)

Less than 3/32 (2.4)

3/32-5/32 (2.4-4.0)

5/32-1/4 (4.0-6.4)

More than 1/4 (6.4)

Less than 60

60-160

160-250

250-550

7

8

10

11

-

10

12

14

Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding

(FCAW)

Gas Tungsten arc Welding

(GTAW)

Air Carbon Arc Cutting (CAC-A)

Plasma Arc Welding (PAW)

 

 

(Light)

(Heavy)

 

Less than 60

60-160

160-250

250-550

Less than 50

50-150

150-500

Less than

500

500-1000

Less than 20

20-100

100-400

400-800

8

8

10

7

10

10

10

10

11

6

8

10

11

-

11

12

14

10

12

14

12

14

6 to 8

10

12

14

Plasma Arc Cutting (PAC)

 

Less than 20

20-40

40-60

60-80

80-300

300-400

400-800

8

9

10

6

8

4

5

9

12

14

6

8

4

5

* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.

SAFETY INSTRUCTIONS AND WARNINGS 1-2 Manual 0-5226

SAFETY INSTRUCTIONS FABRICATOR 211i

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.

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.

1. Keep your head out of the fumes. Do not breathe the fumes.

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.

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.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long, possibly unknown paths and causing electric shock and fire hazards.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

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.

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 vapours to form highly toxic and irritating gases.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal.

As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

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.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns.

Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

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 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.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

Manual 0-5226 1-3 SAFETY INSTRUCTIONS AND WARNINGS

FABRICATOR 211i SAFETY INSTRUCTIONS

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

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.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

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.

!

WARNING

Engines can be dangerous.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

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.

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 fuelling. 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 fuelling is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

WARNING

SPARKS can cause BATTERY GASES TO

EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

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.

WARNING

STEAM AND PRESSURIZED HOT

COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

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.

SAFETY INSTRUCTIONS AND WARNINGS 1-4 Manual 0-5226

SAFETY INSTRUCTIONS

NOTE

Considerations About Welding And The

Effects of Low Frequency Electric and

Magnetic Fields

The following is a quotation from the General 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 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 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.

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.

FABRICATOR 211i

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.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

Manual 0-5226 1-5 SAFETY INSTRUCTIONS AND WARNINGS

FABRICATOR 211i SAFETY INSTRUCTIONS

1.03 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

S

See Note

See Note

Art # A-10663

SAFETY INSTRUCTIONS AND WARNINGS 1-6 Manual 0-5226

SAFETY INSTRUCTIONS

1.04 Declaration Of Conformity

FABRICATOR 211i

Manufacturer:

Address:

Victor Technologies International, Inc.

16052 Swingley Ridge Road, Suite 300

St Louis, Mo63017

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage

Directive’ (European Council Directive 2006/95/EC) and to the National legislation for the enforcement of this

Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC

Directive” (European Council Directive 2004/108/EC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

• ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to welding equipment and associated accessories.

• For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

• 2002/95/EC RoHS directive

!

WARNING

This equipment does not comply with IEC 61000-3-12. If it is connected to a public low voltage system, it is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment may be connected.

Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

Steve Ward

Operations Director

Victor Technologies Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

Manual 0-5226 1-7 SAFETY INSTRUCTIONS AND WARNINGS

FABRICATOR 211i SAFETY INSTRUCTIONS

1.05 Servicing Hazards

• Use proper static-proof bags and boxes to store, move, or ship PC boards.

!

WARNING

WARNING

FIRE OR EXPLOSION hazard.

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.

Only qualified persons should test, maintain, and repair this unit.

Only qualified persons should test, maintain, and repair this unit.

• Do not place unit on, over, or near combustible surfaces.

• Do not service unit near flammables.

WARNING

FLYING METAL or DIRT can injure eyes.

• Wear safety glasses with side shields or face shield during servicing.

• Be careful not to short metal tools, parts, or wires together during testing and servicing.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.

• Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.

• Do not leave live unit unattended.

• If this procedure requires and energized unit, have only personnel familiar with and following standard safety practices do the job.

• When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free.

• Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

• Turn Off inverters, disconnect input power, and discharge input capacitors according to instructions in Troubleshooting Section before touching any parts.

WARNING

STATIC (ESD) can damage PC boards.

• Put on grounded wrist strap BEFORE handling boards or parts.

WARNING

HOT PARTS can cause sever burns.

• Do not touch hot parts bare handed.

• Allow cooling period before working on equipment.

• To handle not parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

WARNING

EXPLODING PARTS can cause injury.

• Failed parts can explode or cause other parts to explode when power is applied to inverters.

• Always wear a face shield and long sleeves when servicing inverters.

WARNING

SHOCK HAZARD from testing.

• Turn Off welding power source and wire feeder or stop engine before making or changing meter lead connections.

• Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.

• Read instructions for test equipment.

SAFETY INSTRUCTIONS AND WARNINGS 1-8 Manual 0-5226

SAFETY INSTRUCTIONS

WARNING

FALLING UNIT can cause injury.

• Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

• Use equipment of adequate capacity to lift and support unit.

• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

WARNING

MOVING PARTS can cause injury,

• Keep away from moving parts such as fans.

• Keep away from pinch points such as drive rolls.

• Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary.

• Keep hands, hair, loose clothing, and tools away from moving parts.

• Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

FABRICATOR 211i

• Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units.

• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

• If notified by the FCC about interference, stop using the equipment at once.

• Have the installation regularly checked and maintained.

• Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

!

WARNING

READ INSTRUCTIONS.

• Use Testing Booklet (Part No. 150 853) when servicing this unit.

• Consult the Owner’s Manual for welding safety precautions.

• Use only genuine replacement parts from the manufacturer.

WARNING

MAGNETIC FIELDS can affect Implanted

Medical Devices.

• Wearers of Pacemakers and other Implanted

Medical Devices should keep away from servicing areas until consulting their doctor and the device manufacturer.

WARNING

OVERUSE can cause OVERHEATING.

• Allow cooling period; follow rated duty cycle.

• Reduce current or reduce duty cycle before starting to weld again.

• Do not block or filter airflow to unit.

WARNING

H.F. RADIATION can cause interference.

• High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

Manual 0-5226 1-9 SAFETY INSTRUCTIONS AND WARNINGS

FABRICATOR 211i SAFETY INSTRUCTIONS

1.06 EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.

SAFETY INSTRUCTIONS AND WARNINGS 1-10 Manual 0-5226

INTRODUCTION FABRICATOR 211i

2.01 How To Use This Manual

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

SECTION 2:

INTRODUCTION

A WARNING gives information regarding possible personal injury.

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.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

You will also notice icons from the safety section appearing throughout the manual. These are to advise you of specific types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:

2.04 Description

The Thermal Arc Fabricator 211i is a self contained single phase multi process welding inverter that is capable of performing MIG (GMAW/FCAW), STICK (MMA) and LIFT TIG (GTAW) welding processes. The unit is equipped with an integrated wire feed unit, digital voltage and amperage meters, and a host of other features in order to fully satisfy the broad operating needs of the modern welding professional. The unit is also fully compliant to Standard EN 60974.1.

The Thermal Arc Fabricator 211i provides excellent welding performance across a broad range of applications when used with the correct welding consumables and procedures. The following instructions detail how to correctly and safely set up the machine and give guidelines on gaining the best efficiency and quality from the Power Source. Please read these instructions thoroughly before using the unit.

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel.

Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

Manual 0-5226 2-1 INTRODUCTION

FABRICATOR 211i INTRODUCTION

2.05 User Responsibility 2.07 Packaged Items

Fabricator 211i Power Source (Part No. W1004206)

This equipment will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided.

This equipment must be checked periodically. Defective equipment (including welding leads) should not be used.

Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Thermal Arc.

Advice in this regard can be obtained by contacting an

Accredited Thermal Arc Distributor.

This equipment or any of its parts should not be altered from standard specification without prior written approval of Thermal Arc. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Thermal Arc.

• Fabricator 211i Inverter Power Source

• Shielding Gas hose assembly

• Operating Manual

Fabricator 211i System Part No. (W1004207)

• Fabricator 211i Inverter Power Source

• Feedrolls 0.6/0.8mm "V" groove (fitted),

0.9/1.2mm "V" groove,

1.0/1.2mm "U" groove,

0.8/0.9mm "V" knurled,

• MIG gun 3m long

• Electrode Holder with 4m lead

• Work Clamp with 4m lead

• Shielding Gas hose assembly

• Operating Manual

2.06 Transportation Methods

This unit is equipped with a handle for carrying purposes.

!

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input power conductors from de-energized supply line before moving the welding power source.

!

WARNING

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handles built into the top of the front and rear moulded panels.

Use handcart or similar device of adequate capacity.

If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

Figure 2-1: Fabricator 211i System Packaged W1004207

INTRODUCTION 2-2 Manual 0-5226

SAFETY/INSTALLATION

SECTION 3:

SAFETY AND INSTALLATION

3.01 Duty Cycle

FABRICATOR 211i

The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding current output without exceeding the temperature limits of the insulation of the component parts. To explain the

10 minute duty cycle period the following example is used. Suppose a Welding Power Source is designed to operate at a 20% duty cycle, 210 amperes at 24.5 volts. This means that it has been designed and built to provide the rated amperage (210A) for 2 minutes, i.e. arc welding time, out of every 10 minute period (20% of 10 minutes is

2 minutes). During the other 8 minutes of the 10 minute period the Welding Power Source must idle and allowed to cool. The thermal cut out will operate if the duty cycle is exceeded.

100

90

80

70

60

50

40

30

20

10

0

0

SAFE OPERATING REGION

(MIG, TIG & STICK)

FABRICATOR 211i

STICK / TIG

MIG

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Welding Current (AMPS)

Art # A-10935

Figure 3-1: Fabricator 211i Duty Cycle on 230VAC

100

90

80

70

60

50

40

30

20

10

0

STICK

SAFE OPERATING REGION

(MIG, TIG & STICK)

FABRICATOR 211i

MIG

TIG

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Welding Current (AMPS)

Art # A-10936

Figure 3-2: Fabricator 211i Duty Cycle on 110VAC

Manual 0-5226 3-1 SAFETY/INSTALLATION

FABRICATOR 211i

3.02 Specifications

SAFETY/INSTALLATION

Wirefeed Speed Range

Effective Input Current (I1eff)

Maximum Input Current (I1max)

Single Phase Generator Requirement

MIG (GMAW/FCAW) Welding Output, 40ºC, 10 min

Description

Power Source Plant Part No.

Power Source Dimensions

Power Source Mass

Cooling

Welder Type

Applicable Standard

Number of Phases

Nominal Supply Voltage

Nominal Supply Frequency

Welding Current Range (MIG Mode)

STICK (MMA) Welding Output, 40ºC, 10 min.

TIG (GTAW) Welding Output, 40ºC, 10 min.

Open circuit voltage

Protection Class

Fabricator 211i Multi Process Welding Inverter

W1004206

H435mm x W266mm x D617mm

26kg

Fan Cooled

Multi Process Inverter Power Source

EN 60974-1

Single Phase

230V±15%

50/60Hz

10-210A

2.5 - 18 MPM

15 Amps

30 Amps

7 k VA

210A @ 20%, 24.5V

130A @ 60%, 20.5V

101A @ 100%, 19.1V

200A @ 25%, 28.0V

130A @ 60%, 25.2V

101A @ 100%, 24.0V

200A @ 25%, 18V

130A @ 60%, 15.2V

101A @ 100%, 14.0V

110V±15%

50/60Hz

10-140A

2.5 - 18 MPM

19.6 Amps

39 Amps

4.5 k VA

140A @ 20%, 21V

99A @ 60%, 19V

77A @ 100%, 17.9V

125A @ 25%, 25.0V

80A @ 60%, 23.2V

60A @ 100%, 22.4V

150A @ 35%, 16V

115A @ 60%, 14.6V

90A @ 100%, 13.6V

79V

IP23S

Table 3-1: Fabricator 211i Specifications

Note 1: The Effective Input Current should be used for the determination of cable size & supply requirements.

Note 2: Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.

Note 3: Generator Requirements at the Maximum Output Duty Cycle.

NOTE

Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock . Please refer to relevant local standards for further information prior to using in such areas.

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

SAFETY/INSTALLATION 3-2 Manual 0-5226

SAFETY/INSTALLATION

3.03 Environment

FABRICATOR 211i

This unit is designed for use in environments with increased hazard of electric shock as outlined in EN 60974.1.

Additional safety precautions may be required when using unit in an environment with increased hazard of electric shock. Please refer to relevant local standards for further information prior to using in such areas.

A. Examples of environments with increased hazard of electric shock are:

1. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts.

2. In locations which are fully or partially limited by conductive elements, and in which there is a high risk of unavoidable or accidental contact by the operator.

3. In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories.

B. Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator, which can cause increased hazard, have been insulated.

3.04 Location

Be sure to locate the welder according to the following guidelines:

A. In areas, free from moisture and dust.

B. Ambient temperature between 0°C (32°F) to 40°C (104°F).

C. In areas, free from oil, steam and corrosive gases.

D. In areas, not subjected to abnormal vibration or shock.

E. In areas, not exposed to direct sunlight or rain.

F. Place at a distance of 1 foot or more from walls or similar that could restrict natural air flow for cooling.

G. The enclosure design of this power source meets the requirements of IP23S as outlined in EN 60529.

H. Precautions must be taken against the power source toppling over. The power source must be located on a suitable horizontal surface in the upright position when in use.

WARNING

This equipment should be electrically connected by a qualified electrician.

3.05 Ventilation

!

WARNING

Since the inhalation of welding fumes can be harmful, ensure that the welding area is effectively ventilated.

Manual 0-5226 3-3 SAFETY/INSTALLATION

FABRICATOR 211i

3.06 Mains Supply Voltage Requirements

SAFETY/INSTALLATION

The Mains supply voltage should be within ± 15% of the rated Mains supply voltage.

Too low of a supply voltage may cause poor welding performance or wirefeeder malfunction. Too high of a supply voltage will cause components to overheat and possibly fail.

WARNING

The Fabricator 211i must be electrically connected by a qualified electrical trades-person. Damage to the

PCA (Power Control Assembly) could occur if 276 VAC or higher is applied to the Primary Power Cable

50/60 Hz

Single Phase

Yes

Yes

Primary Supply

Lead Size

Minimum

Primary Current

Circuit Size

(Vin/Iin)

Minimum

Plug Size

MIG

Current & Duty Cycle

TIG STICK

2.5mm² 230V/15A 15A 20%@210A 25%@200A 25%@200A

2.5mm² 110V/32A 20A 20%@140A 35%@150A 25%@125A

Table 3-2: Input Power Source Leads for Fabricator 211i

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT

TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting OFF and red-tagging circuit breaker or other disconnecting device.

Electrical Input Requirements

Operate the welding power source from a single-phase 50/60 Hz, AC power source. The Welding Power Source must be:

• Correctly installed, if necessary, by a qualified electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point, fuse and primary supply lead based on Table 3-2.

WARNING

Any electrical work must be carried out by a qualified Electrical Tradesperson.

SAFETY/INSTALLATION 3-4 Manual 0-5226

SAFETY/INSTALLATION

3.07 Electrical Input Connections

FABRICATOR 211i

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lock-out/ tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

• Electrical Input Requirements

Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required. The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

Do not connect an input (WHITE or BLACK) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.

1. Connection end of ground (GREEN or GREEN/YELLOW) conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

2. Connect ends of active (BROWN) and Neutral (BLUE) input conductors to a suitable power supply system that complies with all appliance local electrical codes.

Input Power

Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors. A relay in the Main Power PCB1 will turn on after the input capacitors have charged to operating voltage (after approximately 5 seconds).

Manual 0-5226 3-5 SAFETY/INSTALLATION

FABRICATOR 211i

3.08 Electromagnetic Compatibility

SAFETY/INSTALLATION

!

WARNING

Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the welding circuit, see NOTE below. In other cases it could involve constructing an electromagnetic screen enclosing the Welding Power Source and the work, complete with associated input filters.

In all cases, electromagnetic disturbances shall be reduced to the point where they are no longer Troublesome.

NOTE

The welding circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, e.g. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

B. Assessment of Area

Before installing welding equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account.

1. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the welding equipment.

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial equipment.

5. The health of people around, e.g. the use of pace-makers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to be carried out.

8. The immunity of other equipment in the environment: the user shall ensure that other equipment being used in the environment is compatible: this may require additional protection measures.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

SAFETY/INSTALLATION 3-6 Manual 0-5226

SAFETY/INSTALLATION

C. Methods of Reducing Electromagnetic Emissions

FABRICATOR 211i

1. Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.

If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.

Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the Welding Power Source so that good electrical contact is maintained between the conduit and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions.

3. Welding Cables

The welding cables should be kept as short as possible and should be positioned close together but never coiled and running at or close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching the metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

5. Earthing/grounding of the Work Piece

Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening the entire welding installation may be considered for special applications.

Manual 0-5226 3-7 SAFETY/INSTALLATION

FABRICATOR 211i

3.09 Volt-Ampere Curves

SAFETY/INSTALLATION

Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source.

Curves of other settings fall between curves shown.

SAFETY/INSTALLATION

Art # A-10435_AB

Figure 3-3: Fabricator 211i Volt-Ampere Curves

3-8 Manual 0-5226

OPERATION

SECTION 4:

OPERATION

4.01 Power Source Controls, Indicators and Features

1

2 14

3

4

POWER FAULT

4

A

6

2

3

1

WIRESPEED 1 0

7

8

9

4

V

6

3

2

1

DOWNSLOPE (S)

ARC FORCE (%)

1 0

7

9

8

2

4 6

SOFT HARD

INDUCTANCE

L

STICK

2T

4T

8

13

12

11

16

15

10

FABRICATOR 211i

5

21

6

7

9 8

Art # A-10937

Figure 4-1: Fabricator Front and Control Panel Figure 4-2: Fabricator Front Connections

1. Power Indicator

The power indicator is illuminated when the correct mains power is applied to the power source and when the

ON/OFF switch located on the rear panel is in the ON position.

2. Thermal Overload Indicator (Fault Indicator)

This welding power source is protected by a self resetting thermostat. The indicator will illuminate if the duty cycle of the power source has been exceeded. Should the thermal overload indicator illuminate the output of the power source will be disabled. Once the power source cools down this light will go OFF and the over temperature condition will automatically reset. Note that the mains power switch should remain in the on position such that the fan continues to operate thus allowing the unit to cool sufficiently. Do not switch the unit off should a thermal overload condition be present.

3. Digital Amps Meter (Left Digital Display)

MIG Mode

This digital meter is used to display the pre-set (preview) Wirefeed Speed in Meters Per Minute (MPM) in

MIG mode and actual welding amperage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Wirefeed Speed. This value can be adjusted by varying the Amperage Control Knob (4).

STICK and LIFT TIG Modes

The digital meter is used to display the pre-set (preview) amperage in STICK / LIFT TIG modes and actual welding amperage of the power source when welding. At times of non-welding, the amperage meter will display a pre-set (preview) value in both STICK and LIFT TIG modes. This value can be adjusted by varying the Amperage Control Knob (4).

Manual 0-5226 4-1 OPERATION

FABRICATOR 211i

When welding, this digital meter will display actual welding amperage in all modes.

OPERATION

At the completion of welding, the digital meter will hold the last recorded amperage value for a period of approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.

4. Amperage Control (Wirespeed)

The amperage control knob adjusts the amount of welding current delivered by the power source. In STICK

(MMA) and LIFT TIG (GTAW) modes, the amperage control knob directly adjusts the power inverter to deliver the desired level of output current. In MIG (GMAW/FCAW) mode, the amperage knob adjusts the speed of the wire feed motor (which in turn adjusts the output current by varying the amount of MIG wire delivered to the welding arc). The optimum wire speed required will dependent on the type of welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.

5. MIG Gun Adaptor (Euro Style)

The MIG gun adaptor is the connection point for the MIG welding gun. Connect the gun by pushing the gun connector into the brass gun adaptor firmly and screwing the plastic nut clockwise to secure in position. To remove the MIG gun simply reverse these directions.

6. Positive Welding Output Terminal

The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG gun (via the MIG polarity lead), electrode holder lead or work lead. Positive welding current flows from the power source via this heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

7. MIG Polarity Lead

The polarity lead is used to connect the MIG gun to the appropriate positive or negative output terminal (allowing polarity reversal for different welding applications). In general, the polarity lead should be connected in to the positive welding terminal (+) when using steel, stainless steel or aluminium electrode wire. When using gasless wire, the polarity lead is generally connected to the negative welding terminal (-). If in doubt, consult the manufacturer of the electrode wire for the correct polarity. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

OPERATION 4-2 Manual 0-5226

OPERATION FABRICATOR 211i

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

8. Negative Welding Output Terminal

The negative welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as the MIG gun (via the MIG polarity lead), TIG torch or work lead. Negative welding current flows to the power source via this heavy duty bayonet type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal.

9. Remote Control Socket

The 8 pin Remote Control Socket is used to connect remote control devices to the welding power source. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

5

8

2

4

7

1

Art # A-10421_AC

3

6

7

8

5

6

1

2

3

4

W

Trigger Switch

V

Negative

Spool Gun Motor

Positive

Remote Volts in

MIG (GMAW/FCAW)

Remote Wirespeed in MIG (GMAW/FCAW) mode

Remote Amps in LIFT TIG (GTAW) mode

Figure 4-3: Remote Control Socket

Socket Pin

1

2

5

6

3

4

7

Function

Spool Gun Motor Negative

Trigger Switch Input

Trigger Switch Input

Spool Gun Motor Positive

5k ohm (maximum) connection to 5k ohm remote control potentiometer.

Zero ohm (minimum) connection to 5k ohm remote control potentiometer.

Wiper arm connection to 5k ohm remote control Wirespeed MIG (GMAW/FCAW) mode potentiometer. Wiper arm connection to 5k ohm remote control Amps LIFT TIG (GTAW) mode potentiometer.

8

Wiper arm connection to 5k ohm remote control Volts MIG (GMAW/FCAW) mode potentiometer.

Table 4-1

Note that the local/ remote switch (item 18) located in the wirefeed compartment should be set to remote for the amperage/voltage controls to be operative.

Manual 0-5226 4-3 OPERATION

FABRICATOR 211i

10. Multifunction Control - Voltage, Down Slope & Arc Force

OPERATION

The multifunction control knob is used to adjust Voltage (MIG Mode), Down slope (LIFT TIG Mode) and Arc

Force (STICK Mode) depending on the welding mode selected.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilised to ensure output values are accurate.

When MIG (GMAW/FCAW) Mode is Selected

In this mode the control knob is used to adjust the output voltage of the unit. The welding voltage is increased by turning the knob clockwise or decreased by turning the knob anti-clockwise. The optimum voltage level required will dependent on the type of welding application. The setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications.

When STICK (MMA) Mode is Selected

In this mode the multifunction control knob is used to adjust arc force. Arc force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes.

In general increasing the arc force control toward ‘10’ (maximum arc force) allows greater penetration control to be achieved. Arc force is increased by turning the control knob clockwise or decreased by turning the knob anti-clockwise

When LIFT TIG Mode is Selected

In this mode the multifunction control knob is used to adjust down slope. Down slope allows the user to select the ramp down time at the completion of the weld. The main function of down slope is to allow the welding current to be gradually reduced over a pre-set time frame such that the welding pool is given time to cool sufficiently.

Note that when in 2T normal mode (refer item 12), the unit will enter down slope mode as soon as the trigger switch is released (ie if the multifunction control knob is set to 5, the unit will ramp down from the present welding current to zero over 5 seconds). If no down slope time is selected then the welding output will cease immediately. If the unit is set to 4T latch mode, to enter down slope mode the trigger must be held in for the selected time period (ie press and release trigger to commence welding, then press and hold trigger again to enter down slope mode). Should the trigger be released during the down slope phase (4T only), the output will cease immediately.

11. Arc Control (Inductance)

The arc control operates in MIG (GMAW/FCAW) mode only and is used to adjust the intensity of the welding arc. Lower arc control settings make the arc softer with less weld spatter. Higher arc control settings give a stronger driving arc which can increase weld penetration.

12. Trigger Mode Control (MIG and LIFT TIG Mode only)

The trigger mode control is used to switch the functionality of the torch trigger between 2T (normal) and 4T

(latch mode)

2T Normal Mode

In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.

OPERATION 4-4 Manual 0-5226

OPERATION

4T Latch Mode

FABRICATOR 211i

This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the operator can press and release the torch trigger and the output will remain active. To deactivate the power source, the trigger switch must again be depressed and realised, thus eliminating the need for the operator to hold the torch trigger.

Note that when operating in LIFT TIG (GTAW) mode, the power source will remain activated until the selected downslope time has elapsed (refer Item 10).

13. Process Selection Control

The process selection control is used to select the desired welding mode. Three modes are available, MIG

(GMAW/FCAW), LIFT TIG (GTAW) and STICK (MMA) modes. Refer to section 4.10 or 4.11 for MIG (GMAW/

FCAW) set up details, section 4.12 for LIFT TIG (GTAW) set-up details or section 4.13 for STICK (MMA) setup details.

Note that when the unit is powered off the mode selection control will automatically default to MIG mode.

This is necessary so as to prevent inadvertent arcing should an electrode holder be connected to the unit and mistakenly be in contact with the work piece during power up.

14. Digital Voltage Meter (Right Digital Display)

MIG Mode

This digital meter is used to display the pre-set (preview) Voltage in MIG mode and actual welding voltage of the power source when welding. At times of non-welding, the digital meter will display a pre-set (preview) value of Voltage. This value can be adjusted by varying the Multifunction Control Knob (10).

STICK and LIFT TIG Modes

This digital meter is used to display the Welding Output Terminal Voltage in STICK / LIFT TIG modes during non-welding or welding. This value cannot be adjusted by varying the Multifunction Control Knob (10).

When welding, this digital meter will display actual welding voltage in all modes.

At the completion of welding, the digital meter will hold the last recorded voltage value for a period of approximately 10 seconds in all modes. The voltage meter will hold the value until; (1) any of the front panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced, in which case actual welding amperage will be displayed, or (3) a period of 10 seconds elapses following the completion of welding in which case the unit will return to preview mode.

NOTE

The preview functionality provided on this power source is intended to act as a guide only. Some differences may be observed between preview values and actual welding values due to factors including the mode of welding, differences in consumables/gas mixtures, individual welding techniques and the transfer mode of the welding arc (ie dip versus spray transfer). Where exact settings are required (in the case of procedural work), it is recommended that alternate measurement methods be utilized to ensure output values are accurate.

15. Gas Inlet (MIG mode only)

The Gas Inlet connection is used to supply the appropriate MIG welding gas to the unit. Refer to section 4.10 set up details.

!

WARNING

Only Inert Shielding Gases specifically designed for welding applications should be used.

Manual 0-5226 4-5 OPERATION

FABRICATOR 211i

16. On / Off Switch

This Single Phase circuit breaker performs a dual function.

It is used to turn the unit on/off and it will also trip in the event of a fault.

OPERATION

WARNING

When the front digital displays are lit, the machine is connected to the Mains supply voltage and the internal electrical components are at Mains voltage potential.

17

Art # A-10938

Figure 4-4: Wire Feed Compartment Control

17. Wiredrive Motor Circuit Breaker

The 4A Circuit Breaker protects the unit from electrical faults and will operate in the event of a motor overload.

NOTE

If a circuit breaker trips, a short cooling period must be allowed before an attempt is made to reset the unit by pressing the circuit breaker reset button

.

18. Local / Remote Switch (located in wirefeed compartment)

The local/ remote switch is used only when a remote control device (such as a TIG torch with remote current control) is fitted to the unit via the remote control socket (item 9). When the local/ remote switch is in the remote position, the unit will detect a remote device and work accordingly. When in the local mode, the unit will not detect the remote device and will operate from the power source controls only. Note that the trigger will operate at all times on the remote control socket irrespective of the position of the local/ remote switch

(ie in both local and remote modes).

Should a remote device be connected and the local/ remote switch set to remote, the maximum setting of the power source will be determined by the respective front panel control, irrespective of the remote control device setting. As an example, if the output current on the power source front panel is set to 50% and the remote control device is set to 100%, the maximum achievable output from the unit will be 50%. Should 100% output be required, the respective front panel control must be set to 100%, in which case the remote device will then be able to control between 0-100% output.

OPERATION 4-6 Manual 0-5226

OPERATION

19. Burnback Control (located in wirefeed compartment)

FABRICATOR 211i

The burnback control is used to adjust the amount of MIG wire that protrudes from the MIG gun after the completion of MIG welding (commonly referred to as stick out). To decrease the burnback time (or lengthen the amount of wire protruding from the MIG gun at the completing of welding), turn the burnback control knob anti clockwise. To increase the burnback time (or shorten the amount of wire protruding from the MIG gun at the completing of welding), turn the Burnback Control knob clockwise.

20. MIG Gun/ SPOOL Gun Switch (located in wirefeed compartment)

The MIG Gun / SPOOL Gun switch is used to switch welding mode between MIG Gun functionality and SPOOL

Gun functionality.

21. Cooling Fan

The Fabricator 211i is fitted with a fan as needed feature. Fan as needed automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source.

Note that the fan will only operate when required for cooling purposes and will automatically switch off when not required.

4.02 Attaching MIG Gun

Fit the MIG gun to the power source by pushing the MIG gun connector into the MIG gun adaptor and screwing the plastic nut clockwise to secure the MIG gun to the MIG gun adaptor.

MIG Gun Adaptor

MIG Gun Connector

Art # A-10423_AB

Figure 4-5: Attaching MIG Gun

Manual 0-5226 4-7 OPERATION

FABRICATOR 211i

4.03 Installing 15kg Spool (300mm diameter)

OPERATION

As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 300mm diameter.

Remove the locking pin from the spool hub. Install the wire spool over the spool hub, locating the hole in the spool, with the alignment pin on the spool hub.Insert the locking pin back into the spool hub.

Wire Spool

Hub Nut

300mm

Wire Spool

Flat Washer

Large Hole

Retaining Clip

Use inner holes on

Spool Hub

Pin

Fibre Washer

Flat Washer

Small Hole

Spring

Keyed Washer

Spool Hub

Art # A-10939

Figure 4-6: 300mm 15kg Spool Installation

4.04 Installing 5kg Spool (200mm diameter)

Remove the locking pin from the spool hub.

Install the 5kg Spool over the spool hub, locating the hole in the 5kg Spool, with the alignment pin on the Spool Hub.

Insert the locking pin back into the spool hub, in the “rear” position, as shown, ensuring the wire spool is firmly secured in position.

Wire Spool

Hub Nut

200mm

Wire Spool

Retaining Clip

Use inner holes on

Spool Hub

Flat Washer

Large Hole

Pin

Fibre Washer

Flat Washer

Small Hole

Spring

Keyed Washer

Spool Hub

Figure 4-7: 200mm 5kg Spool Installation

Art # A-10940

OPERATION 4-8 Manual 0-5226

OPERATION

4.05 Inserting Wire into the Wire Feed Mechanism

FABRICATOR 211i

Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti-clockwise direction. Then to release the pressure roller arm push the tension screw toward the front of the machine which releases the pressure roller arm (Figure 4-8). With the MIG welding wire feeding from the bottom of the spool

(Figure 4-9) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into the MIG gun. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly

(Figure 4-8). Remove the contact tip from the MIG gun. With the MIG gun lead reasonably straight, feed the wire through the MIG gun by depressing the trigger switch. Fit the appropriate contact tip.

WARNING

Before connecting the work clamp to the work make sure the mains power supply is switched off.

The electrode wire will be at welding voltage potential while it is being feed through the system.

Keep MIG gun away from eyes and face.

Wire Drive Tension Screw

Pressure Roller Arm

Art # A-10426

Inlet Guide

Outlet Guide

Figure 4-8: Wire Drive Assembly Components

MIG Welding Wire

Manual 0-5226

Art # A-10427_AB

Figure 4-9: MIG Welding Wire - Installation

4-9 OPERATION

FABRICATOR 211i

4.06 Feed Roller Pressure Adjustment

OPERATION

The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf. If it is not the cause of slipping, the feed roll pressure can be increased by rotating the pressure screw clockwise.

WARNING

Before changing the feed roller ensure that the mains supply to the power source is switched off.

CAUTION

The use of excessive pressure may cause rapid wear of the feed rollers, shafts and bearing.

4.07 Changing the Feed Roll

To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction. Once the feed roll is removed then to replace feed roll simply reverse these directions.

A dual groove feed roller is supplied as standard. It can accommodate 0.6/0.8mm diameter hard wires. Select the roller required with the chosen wire size marking facing outward.

GROOVE “A” GROOVE “B”

GROOVE “B” SIZE GROOVE “A” SIZE

A-09583

Figure 4-10: Dual Groove Feed Roller

Feed Roll Retaining Screw

Art # A-10428

Figure 4-11: Changing the Feed Roll

OPERATION 4-10 Manual 0-5226

OPERATION

4.08 Wire Reel Brake

FABRICATOR 211i

The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking.

If it is considered necessary, adjustment can be made by turning the Thumb Screw inside the open end of the hub clockwise to tighten the brake. Correct adjustment will result in the wire reel circumference continuing no further than 10-20mm after release of the trigger. The electrode wire should be slack without becoming dislodged from wire spool.

CAUTION

Overtension of brake will cause rapid wear of mechanical WIREFEED parts, overheating of electrical componentry and possibly an increased incidence of electrode wire Burnback into contact tip.

Spool Hub Tension

Thumb Screw

Art # A-10429

Figure 4-12: Wire Reel Brake

4.09 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire

A. Select MIG mode with the process selection control. (refer to Section 4.01.13 for further information)

B. Connect the MIG polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Fit the MIG gun to the power source. (Refer to section 4.02 Attaching MIG gun).

D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.

Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder, then connect the shielding gas hose from the rear of the power source to the regulator/flowmeter outlet.

F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

!

WARNING

Before connecting the work clamp to the work make sure the mains power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

Manual 0-5226 4-11 OPERATION

FABRICATOR 211i OPERATION

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

Shielding Gas Hose Fitted with Quick Connect

Positive Welding

Terminal (+)

MIG Polarity Lead

MIG Gun

Negative Welding

Terminal (-)

Work Lead

Art # A-10430_AB

Figure 4-13: Setup for MIG Welding with Gas Shielded MIG Wire

OPERATION 4-12 Manual 0-5226

OPERATION

4.10 Setup for MIG (FCAW) Welding with Gasless MIG Wire

FABRICATOR 211i

A. Select MIG mode with the process selection control (refer to Section 4.01.13 for further information).

B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer. Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer.

Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

D. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

WARNING

Before connecting the work clamp to the work make sure the mains power supply is switched off.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

Manual 0-5226

MIG Gun

Positive Welding

Terminal (+)

Work Lead

Negative Welding

Terminal (-)

MIG Polarity Lead

Art # A-10431_AB

Figure 4-14: Setup for MIG Welding with Gasless MIG Wire

4-13 OPERATION

FABRICATOR 211i OPERATION

4.11 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire

A. Select MIG mode with the process selection control (refer to Section 4.01.13 for further information).

B. Connect the MIG polarity lead to the positive welding terminal (+). If in doubt, consult the electrode wire manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Fit the Euro Spool Gun to the power source using the front panel EURO adaptor (refer also to section 4.02

Attaching MIG gun). Connect the 8 pin Remote Control Plug to the 8 pin Remote Control Socket on the power source.

D. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode wire manufacturer.

Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder, then connect the shielding gas hose from the rear of the power source to the regulator/flowmeter outlet.

F. Refer to the Weld Guide located on the inside of the wirefeed compartment door for further information.

G. Select MIG mode with the process selection control (refer to section 4.01.13 for further information).

H. Set the Spool Gun Switch located inside the wire drive compartment, to SPOOL GUN.

!

WARNING

Before connecting the work clamp to the work make sure the main power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support to prevent falling or tipping.

CAUTION

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal. Remove any packing material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

Shielding Gas Hose Fitted with Quick Connect

OPERATION

Spool Gun Switch

MIG polarity lead

Spool Gun

Negative Welding

Terminal (-)

Positive Welding

Terminal (+)

Work Lead

Art # A-10576

Figure 4-15: Setup for Spool Gun Welding with Gas Shielded MIG Wire

4-14 Manual 0-5226

OPERATION

4.12 Setup for TIG (GTAW) Welding

FABRICATOR 211i

A. Select LIFT TIG mode with the process selection control (refer to Section 4.01.13 for further information).

B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Connect the work lead to the positive welding terminal (+). Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below. The TIG torch will require a trigger switch to operate in LIFT TIG Mode.

NOTE

If the TIG torch has a remote TIG torch current control fitted then it will require to be connected to the

8 pin socket. (Refer to section 4.01.9 Remote Control Socket for further information).

E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder then connect the shielding gas hose from the TIG torch to the regulator/flowmeter outlet. Note that the TIG torch shielding gas hose is connected directly to the regulator/flowmeter. The power source is not fitted with a shielding gas solenoid to control the gas flow in LIFT TIG mode therefore the TIG torch will require a gas valve.

!

WARNING

Before connecting the work clamp to the work and inserting the electrode in the TIG Torch make sure the mains power supply is switched off.

Secure the welding grade shielding gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the Welding Power Source.

Loose welding terminal connections can cause overheating and result in the male plug being fused in the terminal.

Manual 0-5226 4-15 OPERATION

FABRICATOR 211i OPERATION

Positive Welding

Terminal (+)

Work Lead

Negative Welding

Terminal (-)

TIG Remote Control

TIG Torch

Art # A-10432_AB

Figure 4-16: Setup for TIG Welding

OPERATION 4-16 Manual 0-5226

OPERATION

4.13 Setup for STICK (MMA) Welding

FABRICATOR 211i

A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer. Welding current flows from the Power Source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

B. Connect the work lead to the negative welding terminal (-). If in doubt, consult the electrode manufacturer.

Welding current flows from the power source via heavy duty bayonet type terminals. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection.

C. Select STICK mode with the process selection control (refer to Section 4.01.13 for further information).

WARNING

Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the mains power supply is switched off.

CAUTION

Remove any packaging material prior to use. Do not block the air vents at the front or rear of the

Welding Power Source.

Manual 0-5226

Positive Welding

Terminal (+)

Electrode Holder

Negative Welding

Terminal (-)

Work Lead

Art # A-10433

Figure 4-17: Setup for Manual Arc Welding

4-17 OPERATION

FABRICATOR 211i

4.14 Leak Testing the System

Leak test the system before putting into operation.

OPERATION

1. Be sure that there is a valve in the downstream equipment to turn off the gas flow.

2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery flow rate.

3. Close the cylinder valve. Watch to see if the high pressure or contents gauge drops, if it does you have a leak in the connection between the regulator and the cylinder.

4. Once leak testing has been performed and there are no leaks in the system, slowly open the cylinder valve and proceed.

!

WARNING

If a leak has been detected anywhere in the system, dis continue use and have the system repaired.

DO NOT use leaking equipment. Do not attempt to repair a leaking system while the system is under pressure..

OPERATION 4-18 Manual 0-5226

TROUBLESHOOTING

SECTION 5:

TROUBLESHOOTING

5.01 Basic Troubleshooting-Power Source Faults

FABRICATOR 211i

The following table is a guide for analysing problems and making repairs to the Power Source.

Fault

1 There is no weld output and all front panel displays are off

2

3

There is no weld output and all front panel displays are off or flickering on & off

There is no weld output and the yellow over temperature light is on

E

F

G

A

B

C

D

A The internal protection circuit to shut the unit down if the mains supply voltage is too high has operated

A

B

C

Possible Cause

The main Power Switch is set to OFF

Line fuse is blown

The main Power Switch is faulty

Loose connection to EMC board

Faulty Power Inverter board

Faulty Control board

Faulty Display board

Unit has overheated

Airflow inlet or outlet ducts are blocked

Fan does not operate

A Faulty Display board

E

F

G

A

B

C

D

Remedy

Set main Power Switch to ON

Replace Line fuse

Replace main Power Switch

Tighten connections

Replace Power Inverter board

Replace Control board

Replace Display board

C

A

B

A Check to see if mains supply voltage is <274VAC. A generator with poor voltage regulation may cause a supply voltage in excess of 274VAC.

Connect Power Source to a supply voltage <274VAC.

Allow unit to cool with fan running until over temperature light extinguishes

Remove blockages from airflow ducts

Replace fan. Check fan wiring header is plugged securely into Control board. Check fan wiring is not damaged

A Replace Display board 4 Mode switch does not change welding mode

5 The wirefeed motor and the weld output do not operate when the torch trigger switch is depressed

6

7

The wirefeed motor does not operate when the torch trigger switch is depressed

The wirefeed motor operates at maximum speed and cannot be adjusted.

A

B

C

D

E

F

G

H

A

B

C

D

A

B

Internal wiring fault

Over temperature light is on

Power Source set to REMOTE

Trigger wires shorted to weld voltage inside torch

Trigger wires or torch switch faulty

Faulty Power Inverter board

Faulty Control board

Faulty Display board

Power Source set to TIG or STICK mode

Wirefeeder motor wiring has become loose

Trigger wires or torch switch faulty

Faulty Power Inverter board

Faulty Power Inverter board

Faulty Display board

E

A

B

C

D

F

G

H

A

B

C

D

A

B

Check continuity of internal wiring from Torch adaptor through to boards

Allow unit to cool

Set switch to LOCAL

Repair trigger wires in torch

Check & Repair

Replace Power Inverter board

Replace Control board

Replace Display board

Set power Source to MIG mode

Check motor wiring

Check & Repair

Replace Power Inverter board

Replace Power Inverter board

Replace Display board

Table 5-1 Power Source Faults

Manual 0-5226 5-1 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

The following table is a guide for analysing problems and making repairs to the Power Source

Fault

8 Wirefeed motor operates when the torch trigger switch is depressed but the gas valve does not operate.

9 A welding arc can be established but the weld is erratic or inconsistent

E

F

A

B

C

D

G

H

B

C

A

D

E

Possible Cause

Internal wiring fault

Faulty Solenoid

Impurity in gas system causing solenoid to stay open or closed

Faulty Power Inverter board

Faulty Control board

Work Lead cable too small

Loose welding connections

Loose earth clamp

Incorrect weld polarity selected

No shielding gas

Wind blows shielding gas away

Incorrect TIG tungsten electrode

Poorly prepared or worn TIG tungsten

Table 5-2 Power Source Faults

E

F

A

B

C

D

G

H

B

C

A

D

E

Remedy

Check solenoid wiring header is plugged securely into Control board. Check solenoid wiring is not damaged

Replace Solenoid

Clean out gas system.

Disassemble solenoid & clean out impurities

Replace Power Inverter board

Replace Control board

Use correct weld cable size

Tighten welding connections

Tighten earth clamp

Correct weld polarity. Refer to weld consumable manufacturers recommended polarity

Connect shielding gas

Shield welding area from draughts

Use correct tungsten type

Regrind tungsten to correct shape

5.02 Routine Service and Calibration Requirements

WARNING

There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited Thermal Arc Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.

Routine Inspection, Testing & Maintenance

The inspection and testing of the power source and associated accessories shall be carried out by a licensed electrician. This includes an insulation resistance test and an earthing test to ensure the integrity of the unit is compliant with Thermal Arc's original specifications.

A. Testing Schedule

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests and a system of tagging, including the date of the most recent inspection.

A transportable power source is deemed to be any equipment that is not permanently connected and fixed in the position in which it is operated.

NOTE

Please refer to local guidelines for further information.

TROUBLESHOOTING 5-2 Manual 0-5226

TROUBLESHOOTING

B. Insulation Resistance

FABRICATOR 211i

Minimum insulation resistance for in-service Thermal Arc Inverter Power Sources shall be measured at a voltage of 500V between the parts referred to in Table 5-3 below. Power sources that do not meet the insulation resistance requirements set out below shall be withdrawn from service and not returned until repairs have been performed such that the requirements outlined below are met.

Components to be Tested

Minimum Insulation

Resistance (MΩ)

Input circuit (including any connected control circuits) to welding circuit

(including any connected control circuits)

All circuits to exposed conductive parts

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage exceeding extra low voltage

5

2.5

10

Welding circuit (including any connected control circuits) to any auxiliary circuit which operates at a voltage not exceeding extra low voltage

1

Separate welding circuit to separate welding circuit

1

Table 5-3: Minimum Insulation Resistance Requirements: Thermal Arc Inverter Power Sources

C. Earthing

The resistance shall not exceed 1Ω between any metal of a power source where such metal is required to be earthed, and -

1. The earth terminal of a fixed power source; or

2. The earth terminal of the associated plug of a transportable power source

Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Thermal Arc welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below -

1. For outlets/wiring and associated accessories supplying transportable equipment - at least once every

3 months; and

2. For outlets/wiring and associated accessories supplying fixed equipment - at least once every 12 months.

D. General Maintenance Checks

Welding equipment should be regularly checked by an accredited Thermal Arc Service Provider to ensure that:

1. Flexible cord is of the multi-core tough rubber or plastic sheathed type of adequate rating, correctly connected and in good condition.

2. Welding terminals are in suitable condition and are shrouded to prevent inadvertent contact or short circuit.

3. The Welding System is clean internally, especially from metal filing, slag, and loose material.

E. Accessories

Accessory equipment, including output leads, electrode holders, torches, wire feeders and the like shall be inspected at least monthly by a competent person to ensure that the equipment is in a safe and serviceable condition. All unsafe accessories shall not be used.

F. Repairs

If any parts are damaged for any reason, it is recommended that replacement be performed by an accredited

Thermal Arc Service Provider.

Manual 0-5226 5-3 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

Power Source Calibration

A. Schedule

Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below -

1. For transportable equipment, at least once every 3 months; and

2. For fixed equipment, at least once every 12 months.

If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlined in EN 60974-1, then the above tests should be carried out prior to entering this location.

B. Calibration Requirements

Where applicable, the tests outlined in Table 5-4 below shall be conducted by an accredited Thermal Arc service agent.

Testing Requirements

Output current (A) to be checked to ensure it falls within applicable Thermal Arc power source specifications

Output Voltage (V) to be checked to ensure it falls within applicable Thermal Arc power source specifications

Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Thermal Arc power source / wire feeder specifications

Accuracy of digital meters to be checked to ensure it falls within applicable Thermal Arc power source specifications

Table 5-4: Calibration Parameters

Periodic calibration of other parameters such as timing functions are not required unless a specific fault has been identified.

C. Calibration Equipment

All equipment used for Power Source calibration shall be in proper working condition and be suitable for conducting the measurement in question. Only test equipment with valid calibration certificates (NATA certified laboratories) shall be utilized.

5.03 Check Unit before Applying Power

If the problem cannot be solved by the basic (external) troubleshooting guide, the Power Source cover will have to be removed to allow the technician to analyse failures with a few common tools.

WARNING

Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage.

Checking Unit Before Applying Power

!

!

Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.

!

Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing case.

TROUBLESHOOTING 5-4 Manual 0-5226

TROUBLESHOOTING FABRICATOR 211i

!

Check DC bus voltage according to Section 5.06 after removing case.

!

Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.

5.04 Test Equipment and Tools Needed for Troubleshooting and Servicing

Art # A-09849

• Digital Multimeter

• DC clip-on ammeter

• Screwdriver and spanner

• CRO (20 Mhz bandwidth) & isolating transformer

5.05 Visually Inspect

Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components within these units.

Look in particular for the following: a) Loose or broken wires or connectors.

b) Burned or scorched parts or wires or evidence of arcing.

c) Any accumulation of metal dust or filings that may have caused shorting or arcing.

If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components used in the Power Source.

Locate the faulty component(s) then replace where necessary.

Manual 0-5226 5-5 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

5.06 Preliminary DC Bus Measurement of the Main Inverter Board

WARNING

Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug is disconnected from receptacle

Art # A-10750

DC Bus Testing Multimeter Lead Placement

Upper capacitor bank

Lower capacitor bank

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

Positive meter lead to testpoint 2

Negative meter lead to testpoint 3

Table 5-5 DC BUS, Multimeter set to measure DC volts

Voltage with Supply

Voltage OFF

0 VDC

0 VDC

TROUBLESHOOTING 5-6 Manual 0-5226

TROUBLESHOOTING

5.07 Preliminary Check of the Main Inverter Board

!

Read and follow safety information in Section 5.03 before proceeding.

FABRICATOR 211i

Art # A-10751

IGBT Testing

IGBT V8 & V8-1

IGBT T1 & T2

IGBT T4 & T5

Multimeter Lead Placement

Positive meter lead to testpoint 3

Negative meter lead to testpoint 4

Positive meter lead to testpoint 6

Negative meter lead to testpoint 5

Positive meter lead to testpoint 3

Negative meter lead to testpoint 7

IGBT T1 & T2

IGBT T4 & T5

Table 5-6 IGBT’s, Multimeter set to measure Diode Voltage

IGBT Testing

IGBT V8 & V8-1

Multimeter Lead Placement

Positive meter lead to testpoint 4

Negative meter lead to testpoint 3

Positive meter lead to testpoint 5

Negative meter lead to testpoint 6

Positive meter lead to testpoint 7

Negative meter lead to testpoint 3

Diode Voltage

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

Ohms

>150 Ω

>150 Ω

>150 Ω

Table 5-7 IGBT’s, Multimeter set to measure ohms (Ω)

Inrush Resistor

Resistor

Multimeter Lead Placement

Positive meter lead to testpoint 8

Negative meter lead to testpoint 9

Table 5-8 Inrush PTC, Multimeter set to measure ohms (Ω)

Ohms

3 Ω

Manual 0-5226 5-7 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

DIODE Testing

DIODE V7 & V7-1

Multimeter Lead Placement

Positive meter lead to testpoint 10

Negative meter lead to testpoint 11

Diode Voltage

0.2 – 0.8 VDC

DIODE T18, T19, T20, T21

DIODE T14, T15, T16, T17

Positive meter lead to testpoint 12

Negative meter lead to testpoint 13

Positive meter lead to testpoint 14

Negative meter lead to testpoint 15

Table 5-9 Diodes, Multimeter set to measure Diode Voltage

0.2 – 0.8 VDC

0.2 – 0.8 VDC

5.08 Check Main Input Rectifier

Art # A-10752

Input Rectifier Testing

AC1 to DC+

AC2 to DC+

AC1 to DC-

AC2 to DC-

Multimeter Lead Placement

Positive meter lead to 16

Negative meter lead to testpoint 18

Positive meter lead to 17

Negative meter lead to testpoint 18

Positive meter lead to testpoint 19

Negative meter lead to testpoint 16

Positive meter lead to testpoint 19

Negative meter lead to testpoint 17

Diode Voltage

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

0.2 – 0.8 VDC

Table 5-10 Input Rectifier, Multimeter set to measure Diode Voltage

Measurements may be made directly onto the main input rectifier. AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position.

TROUBLESHOOTING 5-8 Manual 0-5226

TROUBLESHOOTING

5.09 DC Bus Voltage Measurement

Apply voltage to the Power Source.

FABRICATOR 211i

There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present.

Do not touch any live parts.

Art # A-10750

DC Bus Testing

Upper capacitor bank

Lower capacitor bank

Overall capacitor bank

Multimeter Lead Placement Voltage with Supply Voltage ON

Positive meter lead to testpoint 1

Negative meter lead to testpoint 2

Positive meter lead to testpoint 2

Negative meter lead to testpoint 3

Positive meter lead to testpoint 1

Negative meter lead to testpoint 3

Table 5-11 DC BUS, Multimeter set to measure DC volts

190 VDC +/-10%

190 VDC +/-10%

385 VDC +/-10%

Note: These DC voltages are at nominal mains supply voltage of 240VAC/110VAC.

Manual 0-5226 5-9 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

5.10 PCB Connectors

1 Inverter PCB

Art # A-10753

IN Header Pin

1

2

3

4

5

6

7

Pin function

+15V

IGBT 1 pwm drive signal, 15V p-p square wave

IGBT 2 pwm drive signal, 15V p-p square wave

IGBT 2 pwm drive signal, 15V p-p square wave

IGBT 1 pwm drive signal, 15V p-p square wave

Rectified secondary of current transformer TR8

0V

Table 5-12 IN Header pin function (connects to DRIVE header on control PCB)

Signal

15 VDC

15 VDC pk

15 VDC pk

15 VDC pk

15 VDC pk

15 VDC pk

0 VDC

PWM Header Pin

1

2

Pin function

0VDC

Motor pwm drive signal

Table 5-13 PWM Header pin function (connects to PWM header on control PCB)

Signal

0 VDC

5 VDC pk

MD Header Pin

1

2

Pin function

Motor positive

Motor negative

Table 5-14 MD Header pin function (connects to MT-IN header on motor PCB)

Signal

24 VDC

0 VDC

TROUBLESHOOTING 5-10 Manual 0-5226

TROUBLESHOOTING FABRICATOR 211i

DY2 Header Pin

1

2

Pin function

+24V

0V

Signal

24 VDC

0 VDC

3

-24V

-24 VDC

Table 5-15 DY2 Header pin function (connects to SOURCE header on control PCB)

DY1 Header Pin

1

2

3

4

5

Pin function

+24V (solenoid positive)

0V

No connection

+24V (solenoid positive)

Solenoid negative

Table 5-16 DY1 Header pin function

Signal

24 VDC

0V n/c

24 VDC

0 VDC

QF/FJ Header Pin

1

2

3

4

Pin function

+24V (VRD positive)

Solenoid negative

+24V (solenoid positive)

0V

Signal

24 VDC

0 VDC

24 VDC

0 VDC

Table 5-17 QF/FJ Header pin function (Connects to QF/DY header on control PCB)

RX Header Pin

1

2

Pin function

Inrush Resistor

Inrush Resistor

Table 5-18 RX Header pin function (connects to Inrush Resistor)

Signal

JC Header Pin

1

Pin function

+5V

2 PFC OK signal, 5V = PFC OK

Table 5-19 JC Header pin function (connects to PFC header on control PCB)

Signal

+5 VDC

FJ Header Pin

1

2

Pin function

Fan positive

Fan negative

Table 5-20 FJ Header pin function (connects to FAN)

Signal

+24 VDC

0 VDC

CON3 Header Pin

1

2

3

Pin function

24VDC

Fan control signal, 0V = Fan ON

Table 5-21 CON3 Header pin function (connects to FUNs on control PCB)

Signal

+24 VDC

0VDC

Manual 0-5226 5-11 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

2 Motor PCB

Art # A-10754

MT-IN Header Pin

1

2

3

4

Pin function

Motor positive from Inverter PCB

Motor negative from Inverter PCB

Motor negative

Motor positive

Signal

24 VDC

0 VDC

0 VDC

24 VDC

Table 5-22 MT-IN Header pin function (Connects to MD header on Inverter PCB & to Motor)

SGM Header Pin

1

2

Pin function

Spool Gun Motor negative

Spool Gun Motor positive

Table 5-23 SG-M Header pin function (connects to SGM header on display PCB)

Signal

0 VDC

24 VDC

PP Header Pin

1

2

Pin function

Spool Gun Switch

Spool Gun Switch

Table 5-24 PP Header pin function (connects to Spool Gun Switch)

Signal

15V Header Pin

1

2

Pin function

0VDC

15VDC

Table 5-25 15V Header pin function (connects to 15V header on display PCB)

Signal

0 VDC

15 VDC

Signal FUSE Header Pin

1

2

Pin function

Circuit Breaker

Circuit Breaker

Table 5-26 FUSE Header pin function (connects to Motor Circuit Breaker)

TROUBLESHOOTING 5-12 Manual 0-5226

TROUBLESHOOTING

3 Display PCB

FABRICATOR 211i

Art # A-10755

GUN Header Pin

1

2

Pin function

+24V trigger positive (0V when trigger closed)

0VDC

Table 5-27 GUN Header pin function (connects to GUN header on control PCB)

Signal

24 VDC

0 VDC

GUN1 Header Pin

1

2

Pin function

+24V trigger positive (0V when trigger closed)

0VDC

Signal

24 VDC

0 VDC

Table 5-28 GUN Header pin function (connects to front panel torch trigger terminals)

REMOTE Header Pin

1

2

Pin function

Remote switch

Remote switch

Table 5-29 REMOTE Header pin function (connects to remote switch)

Signal

J12 Header Pin

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Pin function

Serial display data & eprom (D-IN)

Serial display data (LOAD)

Serial display data (CLK)

2T/4T pushbutton (0V when button pushed)

Serial display eprom (D-OUT)

Stick mode (used for remote / local)

Chip select

MODE pushbutton (0V when button pushed)

15VDC

Remote / Local switch

Inductance pot terminal 2

Volts setpoint

Inductance pot terminal 1

Amps setpoint

5VDC

0V

Table 5-30 J12 Header pin function (connects to MB header on control PCB)

Signal

5 VDC digital

5 VDC digital

5 VDC digital

0VDC

5 VDC digital

5 VDC digital

0VDC

15 VDC

0 – 5 VDC

0 – 5 VDC

5 VDC

0 VDC

Manual 0-5226 5-13 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

4

R-G Header Pin Pin function Signal

1

Spool gun motor negative 24 VDC

2

3

4

5

6

7

8

+24V trigger positive (0V when trigger closed)

0VDC

Spool gun motor

-12VDC

+12VDC

Remote amps

Remote volts

24 VDC

0 VDC

0 VDC

-12 VDC

+12 VDC

-12 to +12 VDC

-12 to +12 VDC

Table 5-31 R-G Header pin function (connects to front panel 8 pin remote socket)

SGM Header Pin

1

2

Pin function

Motor negative

Motor positive

Table 5-32 SGM Header pin function (connects to SGM header on motor PCB)

Signal

0 VDC

24 VDC

15V Header Pin

1

2

Pin function

0VDC

15VDC

Table 5-33 15V Header pin function (connects to 15V header on motor PCB

Signal

0VDC

15 VDC

Control PCB

Art # A-10756

GUN Header Pin

1

2

Pin function

+24V trigger positive (0V when trigger closed)

0VDC

Table 5-34 GUN Header pin function (connects to GUN header on display PCB)

Signal

24 VDC

0 VDC

PWM Header Pin

1

2

Pin function

0VDC

Motor pwm drive signal

Signal

0 VDC

5 VDC pk

Table 5-35 PWM Header pin function (connects to PWM header on inverter PCB)

PFC Header Pin

1

2

Pin function

5V

PFC OK signal, 1= PFC OK

Table 5-36 PFC Header pin function (connects to JC header on inverter PCB)

Signal

+5 VDC

TROUBLESHOOTING 5-14 Manual 0-5226

TROUBLESHOOTING FABRICATOR 211i

QF/DY Header Pin

1

2

3

Pin function

+24V (VRD positive)

Solenoid negative

+24V (solenoid positive)

Signal

24 VDC

0 VDC

24 VDC

4 0V 0 VDC

Table 5-37 QF/FJ Header pin function (Connects to QF/FJ header on inverter PCB)

FUNs Header Pin

1

2

3

Pin function

24VDC

Fan control signal, 0V = Fan ON

Table 5-38 FUNs Header pin function (not used)

Signal

+24 VDC

DRIVE Header Pin

1

2

3

4

5

6

7

Pin function

+15V

IGBT 1 pwm drive signal, 15V p-p square wave

IGBT 2 pwm drive signal, 15V p-p square wave

IGBT 2 pwm drive signal, 15V p-p square wave

IGBT 1 pwm drive signal, 15V p-p square wave

Rectified secondary of current transformer TR8

0V

Signal

15 VDC

15 VDC pk

15 VDC pk

15 VDC pk

15 VDC pk

15 VDC pk

0 VDC

Table 5-39 DRIVE Header pin function (connects to IN header on inverter PCB)

WVIN Header Pin

1

2

3

Pin function

Positive welding terminal

No connection

Negative welding terminal

Table 5-40 WVIN Header pin function

Signal

positive VDC n/c

0 VDC

IFB Header Pin

1

2

3

4

Pin function

+15V

-15V

Current sensor signal

0V

Signal

15 VDC

-15 VDC

Table 5-41 IFB Header pin function (Connects to welding output current sensor)

0 VDC

SOURCE Header Pin

1

2

3

Pin function

+24V

0V

-24V

Signal

24 VDC

0 VDC

-24 VDC

Table 5-42 SOURCE Header pin function (connects to DY2 header on control PCB)

CR Header Pin

1

2

3

Pin function

+5V

Wiper 10k Burnback potentiometer

0V

Table 5-43 CR Header pin function (connects to 10k Burnback potentiometer)

Signal

5 VDC

0 – 5 VDC

0 VDC

OT1 Header Pin

1

2

Pin function

Diode thermostat

Diode thermostat

Table 5-44 OT1 Header pin function (connects to igbt thermostat)

Signal

OT2 Header Pin

1

Pin function

Igbt thermostat (0VDC when thermostat closed)

Signal

Manual 0-5226 5-15 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

2 0V

Table 5-45 OT2 Header pin function (connects to NTCS header on inverter PCB)

0 VDC

MB Header Pin

1

11

12

13

14

15

8

9

10

4

5

6

7

2

3

16

Pin function

Serial display data & eprom (D-IN)

Serial display data (LOAD)

Serial display data (CLK)

2T/4T pushbutton (0V when button pushed)

Serial display eprom (D-OUT)

Stick mode (used for remote / local)

Chip select

MODE pushbutton (0V when button pushed)

15VDC

Remote / Local switch

Inductance pot terminal 2

Volts setpoint

Inductance pot terminal 1

Amps setpoint

5VDC

0V

Signal

5 VDC digital

5 VDC digital

5 VDC digital

0VDC

5 VDC digital

5 VDC digital

0VDC

15 VDC

Table 5-46 MB Header pin function (connects to J12 header on display PCB)

0 – 5 VDC

0 – 5 VDC

5 VDC

0 VDC

5.11 DIP Switch Settings, Control PCB

1 DIP Switch SW0, control PCB

Art # A-10757_AB

SW0 No.

1

2

SW0 Position

Set to OFF for Fabricator 211i

Set to ON for Fabricator 211i

Table 5-47 SW0 Dip Switch Position

TROUBLESHOOTING 5-16 Manual 0-5226

TROUBLESHOOTING

5.12 Calibration

1 Calibration

FABRICATOR 211i

Art # A-10757_AB

Set SW0 position 1 to ON while the power source is turned off, to allow calibration of output volts & amps.

2 Output Current Calibration

Select STICK mode on the front panel.

Measure no load output welding voltage and adjust WVF potentiometer so Volts display reads within 0.2V of the measured value.

Connect a load to the output terminals. The load should be of a resistance to give 25V at 250A.

Set front panel AMPS potentiometer to minimum.

Adjust Imin trimpot until output amps is 10A +/- 0.2A

Set front panel AMPS potentiometer to maximum.

Adjust Imax trimpot until output amps is 200A +/- 1A

Recheck settings

Set front panel AMPS potentiometer to maximum.

Adjust A potentiometer so Amps display reads within 0.5A of the measured value.

3 Output Voltage Calibration

Select MIG mode on the front panel.

Remove the load from the output terminals.

Set front panel VOLTS potentiometer to minimum.

Adjust Vmin trimpot until output volts is 14.0V +/- 0.2V

Set front panel VOLTS potentiometer to maximum.

Adjust W2 trimpot until output volts is 26V +/- 0.2V

Recheck settings

Manual 0-5226 5-17 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

4 Wire Speed Calibration

NOTE: these adjustments are on the wiring side of the main inverter module circuit board.

Art # A-10758

Select MIG mode on the front panel.

Remove the load from the output terminals.

Set MIG output voltage to maximum.

Set front panel WIRESPEED (AMPS) potentiometer to minimum. AMPS display should read “30”

Adjust W02 trimpot until motor volts are 4.2V +/- 0.2V or motor feedroll shaft speed is 27rpm

Set front panel WIRESPEED (AMPS) potentiometer to maximum. AMPS display should read “218”

Adjust W05 trimpot until motor volts are 24.7V +/- 0.2V or motor feedroll shaft speed is 191rpm

Recheck settings

Turn Mains power off & allow power supplies to discharge

Set SW0 position 1 to OFF while the power source is turned off, to resume normal power source operation.

TROUBLESHOOTING 5-18 Manual 0-5226

TROUBLESHOOTING

5.13 Circuit Diagram

FABRICATOR 211i

BLACK

1 +24VDC

+

--

BLACK

RED

+24CDC 1

N/A 2

+24VDC

INPUT 230V/115V

OUTPUT CONTROL SIGNAL

+24VDC 1

GND 2

-24VDC 3

+15V 1

IGBT Driver A 2

IGBT Driver B 3

IGBT Driver B 4

IGBT Driver A 5

Over Current Signal 6

GND 7

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

RED

YELLOW

RED

BLACK

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

WHITE

1 +5VDC

2 TO U15 PIN6

1 PWM RETURN

2 PWM (MOTOR DRIVER 5VDC PEAK)

1 +24VDC

2 GND

3 -24VDC

1 +15V

2 IGBT Driver A

3 IGBT Driver B

4 IGBT Driver B

5 IGBT Driver A

6 Over Current Signal

7 GND

PFC

WVIN

QF / DY

GUN

BLACK

RED

GRAY

YELLOW

WHITE

RED

1 - OUTPUT

3 + OUTPUT

1 +15V

2 -15V

3 Current Feedback

4 GND

GUN

MB

LOCAL

REMOTE

(REMOVE AMPS/WIRESPEED) POT WIPER 8

(REMOVE VOLTAGE) POT WIPER 7

TORCH SWITCH RIN (0VDC) 6

TORCH SWITCH RIN (0VDC) 5

SPOOL GUN (+2VDC) 4

TORCH SWITCH RIN (0VDC) 3

TORCH SWITCH (+24V) 2

SPOOL GUN (0V) 1

1

1

1 +15VDC

1

1 +15VDC

3 -15VDC

Amps / Wirefeed Display

Power

Volts Display

Fault

Display PCB4

W7005602

Process

MIG

LIFT TIG

STICK

Trigger

2T Normal

4T Latch

Wirefeed / Amps

Volts

Down Slope / Arc Force(%) Arc Control

Art # A-11233

Manual 0-5226 5-19 TROUBLESHOOTING

FABRICATOR 211i TROUBLESHOOTING

5.14 Main Circuit Description

!

Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage.

The mains supply voltage is connected via a double pole switch to the input rectifier Q1 through an EMC filter. Overvoltage protection is provided by varistor CY1.

The rectifier output charges the main capacitor bank (C16, C17, C18, C19, C22 and C23) to high voltage. Inrush current limiting is provided by a PTC which is then bypassed by relay J1 after a few seconds.

The primary igbt transistors (T1, T2, T4, and T5) switch the transformer primary at high frequency and varying duty cycle. The transformer return wire is taken from the junction of the capacitors C20 and C21 (the voltage at this point is approximately half the DC bus voltage).

Secondary output voltage from the transformer is rectified by the output diodes (T13, T14, T15, T16, T17, T18, T19, and

T20) to DC. This DC is controlled by the PWM of the primary side igbt transistors, and is filtered by an inductor before connecting to the welding output terminals.

A thermal overload device (thermistor) is fixed to the rectifier heatsink. When an over temperature occurs, the control circuit inhibits the trigger, gas solenoid, wire drive system and the welding output. The thermal overload indicator LED on the front panel is illuminated.

The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current, and also detect transformer saturation. The Hall effect current sensor is powered from regulated + & - 15VDC supplies and provides a voltage signal proportional to the output DC welding current to allow the control circuit to regulate welding current.

TROUBLESHOOTING 5-20 Manual 0-5226

DISASSEMBLY PROCEDURE

SECTION 6:

DISASSEMBLY PROCEDURE

6.01 Safety Precautions for Disassembly

!

!

Read and follow safety information in Section 5.03 before proceeding.

Unplug unit before beginning Disassembly procedure.

FABRICATOR 211i

Manual 0-5226 6-1 DISASSEMBLY PROCEDURE

FABRICATOR 211i

6.02 Control Board Removal

DISASSEMBLY PROCEDURE

!

Read and follow safety information in Section 5.03 before proceeding with disassembly

Remove case before remove control board.

1. M4 Screw. Remove 4 screws from Control panel.

2. Disconnect DRIVE harness from DRIVE connector.

3. Disconnect SOURCE harness from SOURCE connector.

4. Disconnect CR harness from CR connector.

5. Disconnect FUNs harness from FUNs connector.

6. Disconnect IGBT OT2 harness from IGBT OT2 connector.

7. Disconnect IGBT OT1 harness from IGBT OT1 connector.

8. Disconnect GUN harness from GUN connector.

9. Disconnect QF/DY harness from QF/DY connector.

10. Disconnect WVIN harness from WVIN connector.

11. Disconnect MB harness from MB connector.

12. Disconnect JC harness from JC connector.

13. Disconnect PWM harness from PWM connector.

14. Disconnect IFB harness from IFB connector.

2

3

4 5 6

7

1

8

9

10

Art # A-10760

14

13 12 11

DISASSEMBLY PROCEDURE 6-2 Manual 0-5226

DISASSEMBLY PROCEDURE

6.03 Front Panel Assembly Removal

FABRICATOR 211i

!

Read and follow safety information in Section 5.03 before proceeding with disassembly

1. Screws on front panel.

2. Positive output terminal bolts. Unscrew output terminal bolts.

3. Negative output terminal bolts. Unscrew Negative output terminal bolts.

1

2

3

Art # A-11189

Manual 0-5226 6-3 DISASSEMBLY PROCEDURE

FABRICATOR 211i DISASSEMBLY PROCEDURE

6.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal

!

Read and follow safety information in Section 5.03 before proceeding with disassembly

1. Remove Control Panel screw (4).

2. Front Panel PCB.

3. Disconnect the harnesses from the connectors

1

2

3

Art # A-11190

DISASSEMBLY PROCEDURE 6-4 Manual 0-5226

DISASSEMBLY PROCEDURE

6.05 Back Panel Removal

FABRICATOR 211i

!

Read and follow safety information in Section 5.03 before proceeding with disassembly

1. Remove the screws on the back .

2. Remove Rear Panel screws .

3. Remove The Ground Wire.

4. Wire from Main PCB1.

Disconnect the two wires from switch.

5. Remove The Screw and Disconnect the pipe from gas inlet.

1

2

3

5

Manual 0-5226 6-5

4

Art # A-11191

DISASSEMBLY PROCEDURE

FABRICATOR 211i DISASSEMBLY PROCEDURE

6.06 Power Switch S1 and Power Cord Removal

!

Read and follow safety information in Section 5.03 before proceeding with disassembly

1. Gas inlet. Remove gas inlet from rear panel.

2. Remove The Ground Wire.

3. Remove the screws which control the supply cord.

4. Remove the two screws and push SW1 out from the rear panel.

5. Remove the two supply wires from the switch.

6. Remove the supply wires which connect to main PCB.

7. Input Power Cord ground wire filter.

Cut the tie-wrap and remove the Ferrite core from the ground wire.

8. Remove The Screw and Disconnect the pipe from gas inlet.

9. Disconnect harness from main PCB1.

10. Remove Fan.

3

5

4

1

7

2

6

8

2

10

Art # A-10764

9

DISASSEMBLY PROCEDURE 6-6 Manual 0-5226

DISASSEMBLY PROCEDURE

6.07 Base Panel Removal

FABRICATOR 211i

!

Read and follow safety information in Section 5.03 before proceeding with disassembly

1. Remove Wire Feeder Screws.

2. Remove inductor assembly Screws.

3. Remove Main PCB assembly Screws.

4. Remove Central Panel Screws.

2

3

1 4

Art # A-10765

Manual 0-5226 6-7 DISASSEMBLY PROCEDURE

FABRICATOR 211i

Notes

DISASSEMBLY PROCEDURE

DISASSEMBLY PROCEDURE 6-8 Manual 0-5226

ASSEMBLY PROCEDURE

SECTION 7:

ASSEMBLY PROCEDURES

7.01 Installing Base Board

1. Main Power PCB assembly.

2. Install main PCB assembly screws

3. Install inductor assembly Screws.

4. Install Wire Feeder Screws.

5. Install Central Panel Screws.

FABRICATOR 211i

3 2

1

4

Manual 0-5226 7-1

5

Art # A-10766

ASSEMBLY PROCEDURES

FABRICATOR 211i

7.02 Installing Back Panel

ASSEMBLY PROCEDURES

1. Install gas inlet.

2. Install the power supply cord and the screws.

3. Install fan.

4. Reconnect the pipe to gas inlet and the screw.

5. Reconnect the supply wires.

6. Reconnect the supply wires which connect to main PCB.

7. Install the two screws

8. Reinstall magnetic core onto Ground Wire.

9. Reconnect Ground Wire to the terminal.

10. Reconnect Rear Panel screws.

11. Reconnect the harness to FAN connector.

2

5

2

7

1

7

9

4

6

2

1

3

11

Art # A-10767

ASSEMBLY PROCEDURES 7-2 Manual 0-5226

ASSEMBLY PROCEDURE

7.03 Installing Front Panel

FABRICATOR 211i

1. Reinstall output Dinse on front panel with 27mm wrench.

Reconnect positive output terminal bolts and tighten with 17mm wrench. ( Note: reconnect wires, pay attention to the wire colour.)

Reconnect negative output terminal bolts and tighten with 17mm wrench. (note: reconnect wires and pay attention to the wire colour.)

2. Place front panel PCB assembly into front panel and install screws.

3. Reconnect Front Panel screws.

1

Manual 0-5226 7-3

2

3

Art # A-11192

ASSEMBLY PROCEDURES

FABRICATOR 211i ASSEMBLY PROCEDURES

7.04 Installing Main Control Panel and Clear Cover Sheet

Refer to diagram on page 7-5.

1. Install 4 screws.

2. Plug harness into DRIVE connector.

3. Plug harness into SOURCE connector.

4. Plug harness into CR connector.

5. Plug harness into FUNs connector.

6. Plug harness into m IGBT OT2 connector.

7. Plug harness into IGBT OT1 connector.

8. Plug harness into GUN connector.

9. Plug harness into QF/DY connector.

10. Plug harness into WVIN connector.

11. Plug harness into MB connector.

12. Plug harness into JC connector.

13. Plug harness into PWM connector.

14. Plug harness into IFB connector.

Verify harness connections with the system schematic to insure all connections are correct.

15. Install clear protective sheet.

ASSEMBLY PROCEDURES 7-4 Manual 0-5226

ASSEMBLY PROCEDURE

2

1

14

3

4 5

FABRICATOR 211i

6

7

8

9

10

Art # A-10760

13 12 11

15

Manual 0-5226 7-5

Art # A-10769

ASSEMBLY PROCEDURES

FABRICATOR 211i ASSEMBLY PROCEDURES

7.05 Installing Case

1. Install Ground Screw, which connects the ground wire to the cover.

2. Install case. Install Screws. Tighten screws.

1

Install Screws

Art # A-10770

2

Art # A-11193

Tighten Screws Front&Rear

ASSEMBLY PROCEDURES 7-6 Manual 0-5226

KEY SPARE PARTS

SECTION 8:

KEY SPARE PARTS

8.01 Power Source Spare Parts

3 4 5

20

19

11

FABRICATOR 211i

16 12 9

10

2

21

7

8

6

14

15

17

1

13

Art # A-11234

Item Part Number

1 W7005600 PCB Power

2 W7005601 PCB Control

3 W7005602 PCB Display

Description

4 W7005607 PCB Spool Gun

5

6

7

8

W7004902 PCB EMC Filter

W7005603 Wiredrive Assembly

W7004906 Feed Roll Retaining Thumbscrew

62020

Feed Roll 0.6/0.8mm V groove (fitted as standard)

(Refer to options and accessories table for other feed rolls available).

W7005604 Fan 9

10 W7003010 Input Rectifier (2 required)

11 W7003033 Gas Solenoid Valve Assembly

12 W7005605 Gas Inlet Fitting

13 W7004909 Dinse Socket 50mm²

14 W7004955 Dinse Plug Male 50mm²

15 W7003243 Control Socket 8 pin (Note that 8 pin control plug part number is UOA706900).

16 W7005606 Supply Circuit Breaker / Mains Supply Switch

17 W7004911 CT, Output

18 W7004930 Shielding Gas Hose Assembly (not shown)

19 W7005608 Friction Washer for Spool Hub

20 W7005609 Spool Hub

21 W7005618 Euro Outlet Adapter, 211i

22 W7005619 Inlet Guide, 211i (not shown)

Table 8-1 Key Spare Parts

Manual 0-5226 8-1 KEY SPARE PARTS

FABRICATOR 211i KEY SPARE PARTS

Notes

KEY SPARE PARTS 8-2 Manual 0-5226

OPTIONAL ACCESSORIES

SECTION 9:

OPTIONAL ACCESSORIES

9.01 Optional Accessories

26V TIG Torch (4 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 310.090.001

Tweco TWE2 (3 m) 250A MIG Gun . . . . . . . . . . . . . . . . Part No. 161.550.307

Tweco WeldSkill 220A MIG Gun (3 m) . . . . . . . . . . . . Part No. WS220XE-10-3035

Professional 4 Wheel Cart, Dual Cylinder. . . . . . . . . . Part No. W4015002

Professional 4 Wheel Cart, Single Cylinder . . . . . . . . Part No. W4015001

Cart, Single Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. W4014700

Roll Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. W4015104

Foot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 10-4016

Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 10-4014

Tweco WeldSkill Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. WHF41001

Feed Roll 0.6/0.8mm V groove (hard), (fitted) . . . . Part No. 62020

Feed Roll 0.9/1.2mm V groove (hard) . . . . . . . . . . . . . Part No. 62022

Feed Roll 0.8/0.9mm U groove (soft) . . . . . . . . . . . . . . Part No. 62179

Feed Roll 1.0/1.2mm U groove (soft) . . . . . . . . . . . . . . Part No. 62024

Feed Roll 0.8/0.9mm V knurled (flux cored) . . . . . . Part No. 62028

FABRICAOTR 211i

Manual 0-5226 9-1 OPTIONS/ACCESSORIES

THERMAL ARC - LIMITED WARRANTY TERMS

LIMITED WARRANTY: Thermal Arc ®, Inc, A Victor Technologies Company, hereafter, “Thermal Arc” warrants to customers of its authorized distributors hereafter “Purchaser” 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 Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE

AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY

OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR

SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND

BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of

Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by

Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE

USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY

THERMAL ARC PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS

SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

TERMS OF WARRANTY – JANuARY 2011

In accordance with the warranty periods stated below, Victor Technologies guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual.

Victor Technologies welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment.

Victor Technologies will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the warranty period. The warranty period begins on the date of sale to the end user.

Thermal Arc Fabricator 211i

Component

Power Source

MIG Gun, Electrode Holder / Lead & Work Lead

MIG Gun Consumables

Warranty Period

2 Years

3 Months

NIL

If warranty is being sought, Please contact your Victor Technologies product supplier for the warranty repair procedure.

Victor Technologies warranty will not apply to:

• Equipment that has been modified by any other party other than Victor Technologies’s own service personnel or with prior written consent obtained from Victor Technologies Service Department.

• Equipment that has been used beyond the specifications established in the operating manual.

• Installation not in accordance with the installation/operating manual.

• Any product that has been subjected to abuse, misuse, negligence or accident.

• Failure to clean and maintain (including lack of lubrication, maintenance and protection), the machine as set forth in the operating, installation or service manual.

Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation.

This manual also offers basic troubleshooting, operational and technical details including application usage.

You may also wish to visit our web site www.Victor Technologies.com select your product class and then select literature. Here you will find documentation including:

• Operator manuals

• Service manuals

• Product guides

Alternatively please contact your Victor Technologies distributor and speak with a technical representative.

NOTE

Warranty repairs must be performed by either a Victor Technologies Service Centre, a Victor Technologies distributor or an Authorised Service Agent approved by the Company.

THE AMERICAS

Denton, TX USA

U.S. Customer Care

Ph: 1-800-426-1888 (tollfree)

Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph: 1-940-381-1212

Fax: 1-940-483-8178

Miami, FL USA

Sales Office, Latin America

Ph: 1-954-727-8371

Fax: 1-954-727-8376

Oakville, Ontario, Canada

Canada Customer Care

Ph: 1-905-827-4515

Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom

Customer Care

Ph: +44 1257-261755

Fax: +44 1257-224800

Milan, Italy

Customer Care

Ph: +39 0236546801

Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia

Customer Care

Ph: 6221-8990-6095

Fax: 6221-8990-6096

Rawang, Malaysia

Customer Care

Ph: +603 6092-2988

Fax: +603 6092-1085

Melbourne, Australia

Australia Customer Care

Ph: 1300-654-674 (tollfree)

Ph: 61-3-9474-7400

Fax: 61-3-9474-7391

International

Ph: 61-3-9474-7508

Fax: 61-3-9474-7488

Shanghai, China

Sales Office

Ph: +86 21-64072626

Fax: +86 21-64483032

Singapore

Sales Office

Ph: +65 6832-8066

Fax: +65 6763-5812

TECHNOLOGIES

I N N O V A T I O N T O S H A P E T H E W O R L D

U.S. Customer Care: 800-426-1888 /

FAX

800-535-0557

Canada Customer Care: 905-827-4515 /

FAX

800-588-1714

International Customer Care: 940-381-1212 /

FAX

940-483-8178

© 2 0 1 2 V i c t o r T e c h n o l o g i e s I n t e r n a it o n a l , I n c .

v i c t o r t e c h n o l o g i e s .

c o m P ir n t e d i n China

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