211i Operating Manual FabricatOr®

211i Operating Manual FabricatOr®
211i
Fabricator
®
Multi process welding
inverter
Operating Manual
Revision: AB
Operating Features:
Issue Date: February 29, 2012
Art # A-10934
Manual No.: 0-5225
50Hz
60
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc product. We are proud
to have you as our customer and will strive to provide you with
the best service and reliability in the industry. This product
is backed by our extensive warranty and world-wide service
network. To locate your nearest distributor or service agency call
+44 (0) 1257 261 755, or visit us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Arc product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
We have made every effort to provide you with accurate instructions,
drawings, and photographs of the product(s) while writing this manual.
However errors do occur and we apologize if there are any contained
in this manual.
Due to our constant effort to bring you the best products, we may
make an improvement that does not get reflected in the manual. If you
are ever in doubt about what you see or read in this manual with the
product you received, then check for a newer version of the manual on
our website or contact our customer support for assistance.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in
sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
!
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.
Operating Manual Number 0-5225 for:
Thermal Arc Fabricator 211i Inverter Power Supply
Thermal Arc Fabricator 211i Inverter System
Part Number W1004206
Part Number W1004207
Published by:
Thermadyne Europe
Europa Building
Chorley Industrial Park
Chorley, Lancaster,
England, PR6 7BX
www.thermalarc.com
Copyright 2011 by
Thermadyne Industries, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: December 23, 2011
Revision AB Date: February 29, 2012
Record the following information for Warranty purposes:
Where Purchased:
_____________________________________
Purchase Date:
_____________________________________
Equipment Serial #:
_____________________________________
TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1
1.01
1.02
1.03
1.04
Arc Welding Hazards........................................................................................ 1-1
Principal Safety Standards............................................................................... 1-5
Symbol Chart................................................................................................... 1-6
Declaration Of Conformity............................................................................... 1-7
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
2.04Description...................................................................................................... 2-1
2.05 User Responsibility.......................................................................................... 2-2
2.06 Transportation Methods................................................................................... 2-2
2.07 Packaged Items............................................................................................... 2-2
2.08 Duty Cycle........................................................................................................ 2-3
2.09Specifications.................................................................................................. 2-4
2.10 Optional Accessories....................................................................................... 2-5
SECTION 3: INSTALLATION OPERATION AND SETUP.................................................. 3-1
3.01Environment.................................................................................................... 3-1
3.02Location........................................................................................................... 3-1
3.03Ventilation........................................................................................................ 3-1
3.04 Mains Supply Voltage Requirements............................................................... 3-1
3.05 Electromagnetic Compatibility......................................................................... 3-2
3.06 Power Source Controls, Indicators and Features............................................. 3-4
SECTION 4:
BASIC WELDING GUIDE ............................................................................. 4-1
4.01
4.02
4.03
4.04
4.05
4.06
MIG (GMAW/FCAW) Basic Welding Technique................................................ 4-1
MIG (GMAW/FCAW) Welding Troubleshooting................................................ 4-7
STICK (MMA) Basic Welding Technique........................................................ 4-10
STICK (MMA) Welding Troubleshooting........................................................ 4-20
TIG (GTAW) Basic Welding Technique........................................................... 4-22
TIG (GTAW) Welding Problems...................................................................... 4-24
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE SERVICE REQUIREMENTS............. 5-1
5.01
5.02
5.03
5.04
Power Source Problems.................................................................................. 5-1
Routine Service and Calibration Requirements................................................ 5-2
Cleaning the Welding Power Source................................................................ 5-4
Cleaning the Feed Rolls.................................................................................... 5-5
TABLE OF CONTENTS
SECTION 6:
KEY SPARE PARTS.................................................................................... 6-1
6.01
Power Source Spare Parts............................................................................... 6-1
APPENDIX: FABRICATOR 211i CIRCUIT DIAGRAM..................................................... A-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.
6. Turn OFF all equipment when not in use.
Disconnect power to equipment if it will be left
unattended or out of service.
1.01 Arc Welding Hazards
7. Use fully insulated electrode holders. Never dip
holder in water to cool it or lay it down on the
ground or the work surface. Do not touch holders
connected to two welding machines at the same
time or touch other people with the holder or
electrode.
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.
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.
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.
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.
5. Properly install and ground this equipment
according to its Owner’s Manual and national,
state, and local codes.
Manual 0-5225
1-1
SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
SAFETY INSTRUCTIONS
2. Wear approved safety glasses. Side shields
recommended.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.
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.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection.
5. Use approved ear plugs or ear muffs if noise level
is high.
1. 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.
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
Electrode Size in.
(mm)
Arc Current
(Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
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)
Less than 60
60-160
160-250
250-550
7
10
10
10
11
12
14
Gas Tungsten arc Welding
(GTAW)
Less than 50
50-150
150-500
Less than
500
500-1000
Less than 20
20-100
100-400
400-800
8
8
10
10
12
14
10
11
12
14
6
8
10
11
6 to 8
10
12
14
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
Process
Shielded Metal Arc Welding
(SMAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Plasma Arc Cutting (PAC)
(Light)
(Heavy)
* 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 0-5225
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
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
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.
5. Watch for fire, and keep a fire extinguisher nearby.
1. Keep your head out of the fumes. Do not breathe
the fumes.
2. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding
current from travelling long, possibly unknown
paths and causing electric shock and fire hazards.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
9. Do not use welder to thaw frozen pipes.
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.
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.
10.Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
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.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to
treat them carefully.
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.
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.
3. Keep cylinders away from any welding or other
electrical circuits.
2. Do not weld where flying sparks can strike
flammable material.
Manual 0-5225
4. Never allow a welding electrode to touch any
cylinder.
1-3
SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
SAFETY INSTRUCTIONS
1. Keep all doors, panels, covers, and guards
closed and securely in place.
5. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and associated
parts in good condition.
2. Stop engine before installing or connecting
unit.
6. Turn face away from valve outlet when opening
cylinder valve.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting
as necessary.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from
battery.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
!
5. Keep hands, hair, loose clothing, and tools
away from moving parts.
6. Reinstall panels or guards and close doors
when servicing is finished and before starting
engine.
WARNING
Engines can be dangerous.
WARNING
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes
and skin.
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.
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.
2. Do not add fuel while smoking or if unit is near
any sparks or open flames.
WARNING
3. Allow engine to cool before fuelling. If possible,
check and add fuel to cold engine before beginning
job.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and skin.
4. Do not overfill tank — allow room for fuel to
expand.
The coolant in the radiator can be very hot
and under pressure.
5. Do not spill fuel. If fuelling is spilled, clean up
before starting engine.
1. Do not remove radiator cap when engine is hot.
Allow engine to cool.
WARNING
MOVING PARTS can cause injury.
2. Wear gloves and put a rag over cap area when
removing cap.
3. Allow pressure to escape before completely
removing cap.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
SAFETY INSTRUCTIONS AND WARNINGS
1-4
Manual 0-5225
SAFETY INSTRUCTIONS
FABRICATOR 211i
NOTE
1.02 Principal Safety Standards
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.
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.
4. Keep welding Power Source and cables as far
away from body as practical.
ABOUT PACEMAKERS:
The above procedures are among
those also normally recommended for
pacemaker wearers. Consult your doctor
for complete information.
Manual 0-5225
1-5
SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
SAFETY INSTRUCTIONS
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
ON
Single Phase
Wire Feed Function
OFF
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage OFF.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
X
%
t
Spot Time
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
IPM
Inches Per Minute
Line
Arc Force
MPM
Meters Per Minute
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
SAFETY INSTRUCTIONS AND WARNINGS
V
Preflow Time
t1
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
S
Burnback Time
See Note
See Note
Voltage Input
Art # A-10663
1-6
Manual 0-5225
SAFETY INSTRUCTIONS
FABRICATOR 211i
1.04 Declaration Of Conformity
Manufacturer:
Thermadyne Industries
82 Benning Street
Address:
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the
National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC
Directive” (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of
this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to
manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among
them are:
• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
• ISO/IEC 60974-1 (BS 638-PT10) (EN 60974-1) (EN50192) (EN50078) applicable to welding equipment
and associated accessories.
• For environments with increased hazard of electrical shock, Power Supplies bearing the 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.
Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve
excellence in our area of manufacture. Manufacturers responsible representative:
Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Manual 0-5225
1-7
SAFETY INSTRUCTIONS AND WARNINGS
FABRICATOR 211i
SAFETY INSTRUCTIONS
This Page Intentionally Blank
SAFETY INSTRUCTIONS AND WARNINGS
1-8
Manual 0-5225
INTRODUCTION
SECTION 2: INTRODUCTION
FABRICATOR 211i
2.01 How To Use This Manual
2.03 Receipt Of Equipment
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
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.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
These special annotations are easily recognized as
follows:
!
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning certain operating procedures.
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:
2.02 Equipment Identification
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.
2.04Description
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.
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 0-5225 2-1INTRODUCTION
FABRICATOR 211i
INTRODUCTION
2.05 User Responsibility
2.07 Packaged Items
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.
Fabricator 211i Power Source (Part No. W1004206)
• Fabricator 211i Inverter Power Source
• Shielding Gas hose assembly
• Operating Manual
Fabricator 211i System Part No. (W1004207)
• Fabricator 211i Inverter Power Source
• Feedrolls 0.6/0.8mm "V" groove (fitted),
0.9/1.2mm "V" groove,
1.0/1.2mm "U" groove,
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.
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.
Figure 2-1: Fabricator 211i System Packaged W1004207
Lift unit with handles built into the top of the front and
rear moulded panels.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
INTRODUCTION
2-2 Manual 0-5225
INTRODUCTION
FABRICATOR 211i
2.08 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated welding
current output without exceeding the temperature limits of the insulation of the component parts. To explain the
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.
Duty Cycle (PERCENTAGE)
100
90
FABRICATOR 211i
80
70
STICK / TIG
60
MIG
50
40
SAFE OPERATING REGION
(MIG, TIG & STICK)
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200 210 220
Welding Current (AMPS)
Art # A-10935
Figure 2-2: Fabricator 211i Duty Cycle on 230VAC
100
FABRICATOR 211i
Duty Cycle (PERCENTAGE)
90
80
TIG
STICK
70
60
50
40
SAFE OPERATING REGION
(MIG, TIG & STICK)
30
20
MIG
10
0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150
Welding Current (AMPS)
Art # A-10936
Figure 2-3: Fabricator 211i Duty Cycle on 110VAC
Manual 0-5225 2-3INTRODUCTION
FABRICATOR 211i
INTRODUCTION
2.09Specifications
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)
Wirefeed Speed Range
Effective Input Current (I1eff)
Maximum Input Current (I1max)
Single Phase Generator Requirement
MIG (GMAW/FCAW) Welding Output, 40ºC, 10
min
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%
110V±15%
50/60Hz
50/60Hz
10-210A
10-140A
2.5 - 18 MPM
2.5 - 18 MPM
15 Amps
19.6 Amps
30 Amps
39 Amps
7 k VA
4.5 k VA
210A @ 20%, 24.5V
140A @ 20%, 21.0V
130A @ 60%, 20.5V
99A @ 60%, 19.0V
101A @ 100%, 19.1V
77A @ 100%, 17.9V
STICK (MMA) Welding Output, 40ºC, 10 min.
200A @ 25%, 28.0V
125A @ 25%, 25.0V
130A @ 60%, 25.2V
80A @ 60%, 23.2V
101A @ 100%, 24.0V
60A @ 100%, 22.4V
TIG (GTAW) Welding Output, 40ºC, 10 min.
200A @ 25%, 18.0V
150A @ 35%, 16.0V
130A @ 60%, 15.2V
115A @ 60%, 14.6V
101A @ 100%, 14.0V
90A @ 100%, 13.6V
Open circuit voltage
79V
Protection Class
IP23S
Table 2-1: 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.
INTRODUCTION
2-4 Manual 0-5225
INTRODUCTION
FABRICATOR 211i
2.10 Optional Accessories
Manual 0-5225 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
2-5INTRODUCTION
FABRICATOR 211i
INTRODUCTION
This Page Intentionally Blank
INTRODUCTION
2-6 Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
SECTION 3: INSTALLATION OPERATION AND SETUP
3.01Environment
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.
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.
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.
3.02Location
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.
Manual 0-5225
WARNING
This equipment should be electrically connected by a qualified electrician.
3.03Ventilation
!
WARNING
Since the inhalation of welding fumes can
be harmful, ensure that the welding area is
effectively ventilated.
3.04 Mains Supply Voltage
Requirements
The Mains supply voltage
should be within ± 15% of the rated Mains supply 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 tradesperson. Damage to the PCA (Power Control
Assembly) could occur if 276 VAC or higher
is applied to the Primary Power Cable
3-1INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
50/60 Hz
Primary Supply
Single Phase
Lead Size
Yes
Yes
Minimum
Minimum
Current & Duty Cycle
Primary Current Plug Size
MIG
TIG
STICK
Circuit Size
(Vin/Iin)
2.5mm²
230V/15A
15A
20%@210A 25%@200A 25%@200A
2.5mm²
110V/32A
20A
20%@140A 35%@150A 25%@125A
Table 3-1: 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 3-1.
WARNING
Any electrical work must be carried out by a qualified Electrical Tradesperson.
3.05 Electromagnetic Compatibility
!
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.
INSTALLATION/SETUP
3-2
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
B. Assessment of Area
2. Maintenance of Welding Equipment
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.
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.
2. Radio and television transmitters and receivers.
3. Welding Cables
3. Computer and other control equipment.
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. Safety critical equipment, e.g. guarding of industrial
equipment.
5. The health of people around, e.g. the use of pacemakers 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.
C. Methods of Reducing Electromagnetic Emissions
1. Mains Supply
Welding equipment should be connected to the
mains supply according to the manufacturer’s
recommendations. If interference occurs, it may
be necessary to take additional precautions such
as filtering of the mains supply. Consideration
should be given to shielding the supply cable
of permanently installed welding equipment in
metallic conduit or equivalent. Shielding should be
electrically continuous throughout its length. The
shielding should be connected to the Welding Power
Source so that good electrical contact is maintained
between the conduit and the Welding Power Source
enclosure.
Manual 0-5225
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.
3-3INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
3.06 Power Source Controls, Indicators and Features
2
1
3
14
13
POWER FAULT
MIG
IG
L
LIFT TIG
STICK
4
12
2T
4
A
6
4
7
3
2
WIRESPEED
9
10
6
2
8
1
DOWNSLOPE (S)
ARC FORCE (%)
9
10
16
6
4
7
3
8
1
V
4T
11
8
2
SOFT
HARD
INDUCTANCE
10
15
5
21
6
7
9
8
Art # A-10937
Figure 3-1: Fabricator Front and Control Panel
Figure 3-2: Fabricator Front Connections
17
Art # A-10938
Figure 3-3: Wire Feed Compartment Control
1. Power Indicator
The power indicator is illuminated when the correct mains power is applied to the power source and when the
ON/OFF switch located on the rear panel is in the ON position.
INSTALLATION/SETUP
3-4
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
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).
When welding, this digital meter will display actual welding amperage in all modes.
At the completion of welding, the digital meter will hold the last recorded amperage value for a period of
approximately 10 seconds in all modes. The amperage meter will hold the value until; (1) any of the front
panel controls are adjusted in which case the unit will revert to preview mode, (2) welding is recommenced,
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.
Manual 0-5225
3-5INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
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.
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.
1
2
2
1
5
4
3
8
7
6
Negative
Trigger Switch
3
4
Spool Gun Motor
Positive
5
W
6
V
Remote Volts in
MIG (GMAW/FCAW)
7
8
Art # A-10421_AB
Remote Wirespeed in MIG (GMAW/FCAW) mode
Remote Amps in LIFT TIG (GTAW) mode
Figure 3-4: Remote Control Socket
INSTALLATION/SETUP
3-6
Manual 0-5225
INSTALLATION/SETUP
Socket Pin
FABRICATOR 211i
Function
1
Spool Gun Motor Negative
2
Trigger Switch Input
3
Trigger Switch Input
4
Spool Gun Motor Positive
5
5k ohm (maximum) connection to 5k ohm remote control potentiometer.
6
Zero ohm (minimum) connection to 5k ohm remote control potentiometer.
7
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 3-2
Note that the remote local switch (item 18) located in the wirefeed compartment should be set to remote for
the amperage/voltage controls to be operative.
10.Multifunction Control - Voltage, Down Slope & Arc Force
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.
Manual 0-5225
3-7INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
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 of the torch trigger between 2T (normal)
and 4T (latch mode)
2T Normal Mode
In this mode, the torch trigger must remain depressed for the welding output to be active. Press and hold the
torch trigger to activate the power source (weld). Release the torch trigger switch to cease welding.
4T Latch Mode
This mode of welding is mainly used for long welding runs to reduce operator fatigue. In this mode the 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 3.14, 3.15 or 3.16 for MIG
(GMAW/FCAW) set up details, section 3.17 for LIFT TIG (GTAW) set-up details or section 3.18 for STICK
(MMA) set-up details.
Note that when the unit is powered off the mode selection control will automatically default to 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.
INSTALLATION/SETUP
3-8
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
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 3.15
set up details.
!
WARNING
Only Inert Shielding Gases specifically designed for welding applications should be used.
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.
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.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 remote / local 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 remote/local switch set to remote, the maximum setting of the
power source will be determined by the respective front panel control, irrespective of the remote control device
setting. As an example, if the output current on the power source front panel is set to 50% and the remote
control device is set to 100%, the maximum achievable output from the unit will be 50%. Should 100% output
be required, the respective front panel control must be set to 100%, in which case the remote device will then
be able to control between 0-100% output.
Manual 0-5225
3-9INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
19.Burnback Control (located in wirefeed compartment)
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.
3.07 Attaching MIG Gun
Fit the MIG gun to the power source by pushing the MIG gun connector into the MIG gun adaptor and screwing
the plastic nut clockwise to secure the MIG gun to the MIG gun adaptor.
MIG Gun Adaptor
MIG Gun Connector
Art # A-10423_AB
Figure 3-5: Attaching MIG Gun
INSTALLATION/SETUP
3-10
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
3.08 Installing 15kg Spool (300mm diameter)
As delivered from the factory, the unit is fitted with a 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.
300mm
Wire Spool
Retaining Clip
Use inner holes on
Pin
Spool Hub
Fibre Washer
Flat Washer
Large Hole
Wire Spool
Hub Nut
Flat Washer
Small Hole
Spring
Keyed Washer
Spool Hub
Art # A-10939
Figure 3-6: 300mm 15kg Spool Installation
3.09 Installing 5kg Spool (200mm diameter)
Remove the locking pin from the spool hub.
Install the 5kg Spool over the spool hub, locating the hole in the 5kg Spool, with the alignment pin on the Spool Hub.
Insert the locking pin back into the spool hub, in the “rear” position, as shown, ensuring the wire spool is firmly
secured in position.
200mm
Wire Spool
Retaining Clip
Use inner holes on
Spool Hub
Fibre Washer
Pin
Flat Washer
Large Hole
Wire Spool
Hub Nut
Flat Washer
Small Hole
Spring
Keyed Washer
Spool Hub
Art # A-10940
Figure 3-7: 200mm 5kg Spool Installation
Manual 0-5225
3-11INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
3.10 Inserting Wire into the Wire Feed Mechanism
Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti-clockwise
direction. Then to release the pressure roller arm push the tension screw toward the front of the machine which
releases the pressure roller arm (Figure 3-8). With the MIG welding wire feeding from the bottom of the spool
(Figure 3-9) pass the electrode wire through the inlet guide, between the rollers, through the outlet guide and into
the MIG gun. Re-secure the pressure roller arm and wire drive tension screw and adjust the pressure accordingly
(Figure 3-8). Remove the contact tip from the MIG gun. With the MIG gun lead reasonably straight, feed the wire
through the MIG gun by depressing the trigger switch. Fit the appropriate contact tip.
WARNING
Before connecting the work clamp to the work make sure the mains power supply 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 3-8: Wire Drive Assembly Components
MIG Welding Wire
Art # A-10427_AB
Figure 3-9: MIG Welding Wire - Installation
INSTALLATION/SETUP
3-12
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
3.11 Feed Roller Pressure Adjustment
The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These
devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. 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.
3.12 Changing the Feed Roll
To change feed roll remove the feed roll retaining screw by turning in an anticlockwise direction. Once the feed
roll is removed then to replace feed roll simply reverse these directions.
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” SIZE
GROOVE “B”
GROOVE “A” SIZE
A-09583
Figure 3-10: Dual Groove Feed Roller
Feed Roll Retaining Screw
Art # A-10428
Figure 3-11: Changing the Feed Roll
Manual 0-5225
3-13INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
3.13 Wire Reel Brake
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 3-12: Wire Reel Brake
3.14 Setup for MIG (GMAW) Welding with Gas Shielded MIG Wire
A. Select MIG mode with the process selection control. (refer to Section 3.06.13 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 3.07 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.
INSTALLATION/SETUP
3-14
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
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 3-13: Setup for MIG Welding with Gas Shielded MIG Wire
Manual 0-5225
3-15INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
3.15 Setup for MIG (FCAW) Welding with Gasless MIG Wire
A. Select MIG mode with the process selection control (refer to Section 3.06.13 for further information).
B. Connect the MIG polarity lead to the negative welding terminal (-). If in doubt, consult the electrode wire 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.
MIG Gun
Positive Welding
Terminal (+)
Negative Welding
Terminal (-)
MIG Polarity Lead
Work Lead
Art # A-10431_AB
Figure 3-14: Setup for MIG Welding with Gasless MIG Wire
INSTALLATION/SETUP
3-16
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
3.16 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded MIG Wire
A. Select MIG mode with the process selection control (refer to Section 3.06.13 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 3.07
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 3.06.13 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
Remote Control
Socket
Spool Gun Switch
MIG polarity lead
Spool Gun
Negative Welding
Terminal (-)
Positive Welding
Terminal (+)
Work Lead
Art # A-10576
Figure 3-15: Setup for Spool Gun Welding with Gas Shielded MIG Wire
Manual 0-5225
3-17INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
3.17 Setup for TIG (GTAW) Welding
A. Select LIFT TIG mode with the process selection control (refer to Section 3.06.13 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 3.06.9 Remote Control Socket for further information).
E. Fit the welding grade shielding gas regulator/flowmeter to the shielding gas cylinder (refer to Section 3.14)
then connect the shielding gas hose from the TIG torch to the regulator/flowmeter outlet. Note that the TIG
torch shielding gas hose is connected directly to the regulator/flowmeter. The power source is not fitted with
a shielding gas solenoid to control the gas flow in LIFT 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.
INSTALLATION/SETUP
3-18
Manual 0-5225
INSTALLATION/SETUP
FABRICATOR 211i
Positive Welding
Terminal (+)
Work Lead
Negative Welding
Terminal (-)
TIG Remote Control
TIG Torch
Art # A-10432_AB
Figure 3-16: Setup for TIG Welding
Manual 0-5225
3-19INSTALLATION/SETUP
FABRICATOR 211i
INSTALLATION/SETUP
3.18 Setup for STICK (MMA) Welding
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 3.06.13 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.
Positive Welding
Terminal (+)
Electrode Holder
Negative Welding
Terminal (-)
Work Lead
Art # A-10433
Figure 3-17: Setup for Manual Arc Welding.
INSTALLATION/SETUP
3-20
Manual 0-5225
BASIC WELDING
SECTION 4:
BASIC WELDING GUIDE
FABRICATOR 211i
4.01 MIG (GMAW/FCAW) Basic Welding Technique
Two different welding processes are covered in this section GMAW and FCAW, with the intention of providing
the very basic concepts in using the MIG mode of welding, where a welding gun is hand held, and the electrode
(welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert
welding grade shielding gas mixture.
GAS METAL ARC WELDING (GMAW): This process, also known as MIG welding, CO2 welding, Micro Wire
Welding, short arc welding, dip transfer welding, wire welding etc., is an electric arc welding process which
fuses together the parts to be welded by heating them with an arc between a solid continuous, consumable
electrode and the work. Shielding is obtained from an externally supplied welding grade shielding gas or welding
grade shielding gas mixture. The process is normally applied semi automatically; however the process may
be operated automatically and can be machine operated. The process can be used to weld thin and fairly thick
steels, and some non-ferrous metals in all positions.
Shielding Gas
Nozzle
Molten Weld Metal
Electrode
Arc
Solidified
Weld Metal
Base Metal
GMAW Process
Art # A-8991_AB
Figure 4-1
FLUX CORED ARC WELDING (FCAW): This is an electric arc welding process which fuses together the parts to
be welded by heating them with an arc between a continuous flux filled electrode wire and the work. Shielding
is obtained through decomposition of the flux within the tubular wire. Additional shielding may or may not be
obtained from an externally supplied gas or gas mixture. The process is normally applied semi automatically;
however the process may be applied automatically or by machine. It is commonly used to weld large diameter
electrodes in the flat and horizontal position and small electrode diameters in all positions. The process is used
to a lesser degree for welding stainless steel and for overlay work.
Shielding Gas
(Optional)
Nozzle
(Optional)
Molten Metal
Slag
Flux Cored
Electrode
Molten
Slag
Arc
Solidified
Weld Metal
Base Metal
FCAW Process
Art # A-08992_AB
Figure 4-2
Manual 0-5225
4-1
BASIC WELDING GUIDE
FABRICATOR 211i
BASIC WELDING
Position of MIG Gun
The angle of MIG gun to the weld has an effect on the width of the weld.
Vertical
Push
Drag/Pull
Art # A-07185_AB
Figure 4-3
The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below)
Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter
lenses and use the proper safety equipment.
CAUTION
Do not pull the welding gun back when the arc is established. This will create excessive wire
extension (stick-out) and make a very poor weld.
The electrode wire is not energized until the gun trigger switch is depressed. The wire may therefore be placed
on the seam or joint prior to lowering the helmet.
5° to 15°
Longitudinal
Angle
Direction of
Travel
90°
Transverse
Angle
Art # A-08993
Butt & Horizontal
Welds
Figure 4-4
5° to 15°
Longitudinal Angle
30° to 60°
Transverse Angle
Direction of
Travel
Art # A-08994
4-5
HorizontalFigure
Fillet Weld
BASIC WELDING GUIDE
4-2 Manual 0-5225
BASIC WELDING
FABRICATOR 211i
10° to 20° Longitudinal
Angle
10°
Longitudinal Angle
30° to 60°
Transverse
Angle
30° to 60°
Transverse
Angle
Direction of Travel
Vertical Fillet Welds
Art # A-08995
Figure 4-6
Direction of Travel
30° to 60°
Transverse Angle
5° to 15°
Longitudinal
Angle
Art # A-08996
Overhead Figure
Weld 4-7
Distance from the MIG Gun Nozzle to the Work Piece
The electrode wire stick out from the MIG gun nozzle should be between 10mm to 20.0mm. This distance
may vary depending on the type of joint that is being welded.
Travel Speed
The speed at which the molten pool travels influences the width of the weld and penetration of the welding
run.
MIG Welding (GMAW) Variables
Most of the welding done by all processes is on carbon steel. The items below describe the welding variables
in short-arc welding of 24gauge (0.024”, 0.6mm) to ¼” (6.4mm) mild sheet or plate. The applied techniques
and end results in the GMAW process are controlled by these variables.
Preselected Variables
Preselected variables depend upon the type of material being welded, the thickness of the material, the welding
position, the deposition rate and the mechanical properties. These variables are:
• Type of electrode wire
• Size of electrode wire
• Type of gas (not applicable to self shielding wires FCAW)
• Gas flow rate (not applicable to self shielding wires FCAW)
Primary Adjustable Variables
These control the process after preselected variables have been found. They control the penetration, bead
width, bead height, arc stability, deposition rate and weld soundness. They are:
• Arc Voltage
• Welding current (wire feed speed)
• Travel speed
Secondary Adjustable Variables
These variables cause changes in primary adjustable variables which in turn cause the desired change in the
bead formation. They are:
Manual 0-5225
4-3
BASIC WELDING GUIDE
FABRICATOR 211i
BASIC WELDING
1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain
at about 10mm stick-out
2. Wire Feed Speed. Increase in wire feed speed increases weld current, Decrease in wire feed speed
decreases weld current.
Gas Nozzle
Contact Tip (Tube)
Tip to
Work Distance
Electrode Wire
Actual Stick-out
Average Arc Length
Electrode Stick-Out
Figure 4-8
Art # A-08997_AD
3. Nozzle Angle. This refers to the position of the welding gun in relation to the joint. The transverse angle
is usually one half the included angle between plates forming the joint. The longitudinal angle is the
angle between the centre line of the welding gun and a line perpendicular to the axis of the weld. The
longitudinal angle is generally called the Nozzle Angle and can be either trailing (pulling) or leading
(pushing). Whether the operator is left handed or right handed has to be considered to realize the
effects of each angle in relation to the direction of travel.
Transverse
Angle
Longitudinal
Angle
Axis of Weld
Art # A-08998_AB
Transverse and Longitudinal
Nozzle Axes
Figure 4-9
Direction of Gun Travel
Leading or “Pushing”
Angle
(Forward Pointing)
90°
Trailing or “Pulling”
Angle
(Backward Pointing)
Nozzle Angle, Right Handed Operator
Art # A-08999_AC
Figure 4-10
Establishing the Arc and Making Weld Beads
Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a
sample metal of the same material as that of the finished piece.
BASIC WELDING GUIDE
4-4 Manual 0-5225
BASIC WELDING
FABRICATOR 211i
The easiest welding procedure for the beginner to experiment with MIG welding is the flat position. The
equipment is capable of flat, vertical and overhead positions.
For practicing MIG welding, secure some pieces of 16 gauge(1.6mm) or 18 gauge (1.2mm) mild steel plate
150 x 150mm. Use 0.8mm flux cored gasless wire or a solid wire with shielding gas.
Setting of the Power Source
Power source setting requires some practice by the operator, as the welding plant has two control settings
that have to balance. These are the Wirespeed control (refer to section 3.06.4) and the welding Voltage Control
(refer to section 3.06.10). The welding current is determined by the Wirespeed control, the current will increase
with increased Wirespeed, resulting in a shorter arc. Less wire speed will reduce the current and lengthen the
arc. Increasing the welding voltage hardly alters the current level, but lengthens the arc. By decreasing the
voltage, a shorter arc is obtained with a little change in current level.
When changing to a different electrode wire diameter, different control settings are required. A thinner electrode
wire needs more Wirespeed to achieve the same current level.
A satisfactory weld cannot be obtained if the Wirespeed and Voltage settings are not adjusted to suit the
electrode wire diameter and the dimensions of the work piece.
If the Wirespeed is too high for the welding voltage, “stubbing” will occur as the wire dips into the molten
pool and does not melt. Welding in these conditions normally produces a poor weld due to lack of fusion. If,
however, the welding voltage is too high, large drops will form on the end of the wire, causing spatter. The
correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth
regular arc sound. Refer to the Weld Guide located on the inside of the wirefeed compartment door for setup
information.
Electrode Wire Size Selection
The choice of Electrode wire size and shielding gas used depends on the following
• Thickness of the metal to be welded
• Type of joint
• Capacity of the wire feed unit and Power Source
• The amount of penetration required
• The deposition rate required
• The bead profile desired
• The position of welding
• Cost of the wire
Manual 0-5225
4-5
BASIC WELDING GUIDE
FABRICATOR 211i
BASIC WELDING
Art # A-10941
Thermal Arc MIG, Lift TIG, Stick Wire Selection Chart
Table 4-1
BASIC WELDING GUIDE
4-6 Manual 0-5225
BASIC WELDING
FABRICATOR 211i
4.02 MIG (GMAW/FCAW) Welding Troubleshooting
Solving Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then
work through to the MIG gun. There are two main areas where problems occur with GMAW, Porosity and
Inconsistent wire feed
Solving Problems Beyond the Welding Terminals - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from
some contaminant within the molten weld pool which is in the process of escaping during solidification of
the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface.
Porosity can be reduced by checking the following points.
FAULT
CAUSE
1
Shielding gas cylinder contents
and flow meter.
Ensure that the shielding gas cylinder is not empty and the
flow meter is correctly adjusted to 15 litres per minute.
2
Gas leaks.
Check for gas leaks between the regulator/cylinder connection and in the gas hose to the Power Source.
3
Internal gas hose in the Power
Source.
Ensure the hose from the solenoid valve to the Euro adaptor
has not fractured and that it is connected to the Euro adaptor.
4
Welding in a windy environment.
Shield the weld area from the wind or increase the gas flow.
5
Welding dirty, oily, painted,
oxidised or greasy plate.
Clean contaminates off the work piece.
6
Distance between the MIG gun
nozzle and the work piece.
Keep the distance between the MIG gun nozzle and the work
piece to a minimum.
7
Maintain the MIG gun in good
working order.
A Ensure that the gas holes are not blocked and gas is exiting
out of the MIG gun nozzle.
B Do not restrict gas flow by allowing spatter to build up inside
the MIG gun nozzle.
C Check that the MIG gun O-rings are not damaged.
Table 4-2: Solving Problems beyond the Welding Terminals-Porosity
!
WARNING
Disengage the feed roll when testing for gas flow by ear.
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BASIC WELDING
Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed
Wire feeding problems can be reduced by checking the following points.
FAULT
CAUSE
1
Feed roller driven by motor in the
cabinet slipped.
Wire spool brake is too tight.
2
Wire spool unwinded and tangled.
Wire spool brake is too loose.
3
Worn or incorrect feed roller size
4
Wire rubbed against the mis-aligned
guides and reduced wire feedability.
5
Liner blocked with swarf
6
Incorrect or worn contact tip
A
Use a feed roller matched to the size you are welding.
B
Replace feed roller if worn.
Mis-alignment of inlet/outlet guides
A
Increased amounts of swarf are produced by the wire
passing through the feed roller when excessive pressure is applied to the pressure roller adjuster.
B
Swarf can also be produced by the wire passing
through an incorrect feed roller groove shape or size.
C
Swarf is fed into the conduit liner where it accumulates thus reducing wire feedability.
A
The contact tip transfers the weld current to the electrode wire. If the hole in the contact tip is too large
then arcing may occur inside the contact tip resulting
in the wire jamming in the contact tip
B
When using soft wire such as aluminium it may
become jammed in the contact tip due to expansion of
the wire when heated. A contact tip designed for soft
wires should be used.
7
Poor work lead contact to work piece
If the work lead has a poor electrical contact to the
work piece then the connection point will heat up and
result in a reduction of power at the arc.
8
Bent liner
This will cause friction between the wire and the liner
thus reducing wire feedability
Table 4-3: Wire Feeding Problems
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Basic MIG (GMAW/FCAW) Welding Troubleshooting
FAULT
1 Undercut
CAUSE
REMEDY
A Welding arc voltage too A Decrease voltage or increase the wire feed speed.
high.
B Incorrect MIG gun angle B Adjust angle.
C Excessive heat input
C Increase the MIG gun travel speed and/or decrease
welding current by decreasing the voltage or
decreasing the wire feed speed.
2 Lack of penetration A Welding current too low A Increase welding current by increasing wire feed
speed and increasing voltage.
B Joint preparation too
B Increase joint angle or gap.
narrow or gap too tight
C Shielding gas incorrect C Change to a gas which gives higher penetration.
3 Lack of fusion
4 Excessive spatter
Voltage too low
Increase voltage.
A Voltage too high
A Decrease voltage or increase the wirespeed
control.
B Voltage too low
B Increase the voltage or decrease wirespeed.
5 Irregular weld shape A Incorrect voltage and
current settings. Convex, voltage too low.
Concave, voltage too
high.
A Adjust voltage and current by adjusting the voltage
control and the wirespeed control.
B Wire is wandering.
B Replace contact tip.
C Incorrect shielding gas
C Check shielding gas.
D Insufficient or excessive D Adjust the wirespeed control or the voltage
heat input
control.
6 Weld cracking
A Weld beads too small
A Decrease travel speed
B Weld penetration narrow B Reduce current and voltage and increase MIG gun
and deep
travel speed or select a lower penetration shielding
gas.
C Excessive weld stresses C Increase weld metal strength or revise design
7 Cold weld puddle
8 Arc does not have
a crisp sound that
short arc exhibits
when the wirefeed
speed and voltage
are adjusted correctly.
D Excessive voltage
D Decrease voltage.
E Cooling rate too fast
E Slow the cooling rate by preheating part to be
welded or cool slowly.
A Loose welding cable
connection.
A Check all welding cable connections.
B Low primary voltage
B Contact supply authority.
C Fault in power source
C Have an Accredited Thermal Arc Service Provider
to test then replace the faulty component.
The MIG gun has been
connected to the wrong
voltage polarity on the
front panel.
Connect the MIG Polarity Cable to the positive (+)
welding terminal for solid wires and gas shielded
flux cored wires. Refer to the electrode wire
manufacturer for the correct polarity.
Table4-4: MIG (GMAW/FCAW) Welding Problems
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BASIC WELDING
4.03 STICK (MMA) Basic Welding Technique
Size of Electrode
The electrode size is determined by the thickness of metals being joined and can also be governed by the type
of welding machine available. Small welding machines will only provide sufficient current (amperage) to run
the smaller size electrodes.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job.
A little practice will soon establish the most suitable electrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
Electrode Polarity
Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive
polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult
the electrode data sheet or your nearest Accredited Thermal Arc Distributor.
Effects of Arc Welding Various Materials
A. High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone in the weld
area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks may result.
Hardened zone and under-bead cracks in the weld area may be reduced by using the correct electrodes,
preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode
deposits or tempering in a furnace.
B. Austenitic manganese steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this reason
it is absolutely essential to keep manganese steel cool during welding by quenching after each weld or
skip welding to distribute the heat.
C. Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
generally cracks when attempts are made to weld it. Trouble may also be experienced when welding whiteheart malleable, due to the porosity caused by gas held in this type of iron.
D. Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and base metal.
Arc Welding Practice
The techniques used for arc welding are almost identical regardless of what types of metals are being joined.
Naturally enough, different types of electrodes would be used for different metals as described in the preceding
section.
Welding Position
The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in
flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions
intermediate between these. Some of the common types of welds are shown in Figures 4-15 through 4-22.
Art # A-07687
Figure 4-11: Flat Position, Down Hand Butt Weld
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Art # A-07688
Figure 4-12: Flat Position, Gravity Fillet Weld
Art # A-07689
Figure 4-13: Horizontal Position, Butt Weld
Art # A-07690
Figure 4-14: Horizontal-Vertical (HV) Position
Art A-07691
Figure 4-15: Vertical Position, Butt Weld
Art # A-07692
Figure 4-16: Vertical Position, Fillet Weld
Art# A-07693
Figure 4-17: Overhead Position, Butt Weld
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Art # A-07694
Figure 4-18: Overhead Position, Fillet Weld
Joint Preparations
In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections
and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being
joined to ensure proper penetration of the weld metal and to produce sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be
removed from oxy-cut surfaces. Typical joint designs are shown in Figure 4-19.
Single Vee Butt Joint
Open Square Butt
Joint
Not less than
70°
1.6mm (1/16” ) max
Gap varies from
1.6mm (1/16”) to 4.8mm (3/16”)
depending on plate thickness
1.6mm (1/16”)
Single Vee Butt Joint
Not less than
45°
Double Vee Butt Joint
Lap Joint
Not less than
70°
1.6mm (1/16”) max
1.6mm (1/16”)
Tee Joints
(Fillet both sides of the
joint)
Fillet Joint
Corner Weld
Edge Joint
Plug Weld
Plug Weld
Art # A-07695_AE
Figure 4-19: Typical Joint Designs for Arc Welding
Arc Welding Technique - A Word to Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of
scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode. Clean any paint, loose scale or
grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand
position. Make sure that the work clamp is making good electrical contact with the work, either directly or
through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a
poor circuit will probably result.
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The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as
much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body
will soon make you feel tired. Relax and you will find that the job becomes much easier. You can add much to
your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt
or sparks setting alight to your clothes.
Place the work so that the direction of welding is across, rather than to or from, your body. The electrode
holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode
burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of
weight off your hand. Be sure the insulation on your cable and electrode holder is not faulty, otherwise you
are risking an electric shock.
Striking the Arc
Practice this on a piece of scrap plate before going on to more exacting work. You may at first experience
difficulty due to the tip of the electrode "sticking" to the work piece. This is caused by making too heavy a
contact with the work and failing to withdraw the electrode quickly enough. A low amperage will accentuate it.
This freezing-on of the tip may be overcome by scratching the electrode along the plate surface in the same
way as a match is struck. As soon as the arc is established, maintain a 1.6mm to 3.2mm gap between the
burning electrode end and the parent metal. Draw the electrode slowly along as it melts down.
Another difficulty you may meet is the tendency, after the arc is struck, to withdraw the electrode so far that
the arc is broken again. A little practice will soon remedy both of these faults.
20°
Art # A-07696_AB
1.6 mm (1/16”)
Figure 4-20: Striking an Arc
Arc Length
The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will
find that a long arc produces more heat. A very long arc produces a crackling or spluttering noise and the
weld metal comes across in large, irregular blobs. The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being
blanketed by slag and the electrode tip being solidified in. If this should happen, give the electrode a quick
twist back over the weld to detach it. Contact or "touch-weld" electrodes such as E7014 do not stick in this
way, and make welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards
the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the
plate to form a bead. The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel
has to be adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual
globules. If the travel is too slow, the weld metal piles up and the bead will be too large.
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BASIC WELDING
Making Welded Joints
Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded
joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in Figure 4-21, allowing 1.6mm to 2.4mm gap between
them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal
pulling the plates out of alignment. Plates thicker than 6.0mm should have their mating edges bevelled to
form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 3.2mm
E7014 electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady rate of travel along the joint sufficient to produce a
well-formed bead. At first you may notice a tendency for undercut to form, but keeping the arc length
short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help
eliminate this. The electrode needs to be moved along fast enough to prevent the slag pool from getting
ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and
deposit a similar weld.
20°-30°
Electrode
Tack Weld
Tack Weld
Art # A-07697_AB
Figure 4-21: Butt Weld
Art # A-07698
Figure 4-22: Weld Build up Sequence
Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag
out and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the
second run. Subsequent runs are then deposited using either a weave technique or single beads laid down
in the sequence shown in Figure 4-22. The width of weave should not be more than three times the core
wire diameter of the electrode. When the joint is completely filled, the back is either machined, ground or
gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing
the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar
purpose to the backing run in securing proper fusion at the root of the weld.
B. Fillet Welds
These are welds of approximately triangular cross-section made by depositing metal in the corner of two
faces meeting at right angles. Refer to Figure 4-14.
A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be
tacked together at right angles. Using a 3.2mm E7014 electrode at 100 amps, position angle iron with
one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV) fillet. Strike the arc
and immediately bring the electrode to a position perpendicular to the line of the fillet and about 45º from
the vertical. Some electrodes require to be sloped about 20º away from the perpendicular position to
prevent slag from running ahead of the weld. Refer to Figure 4-23. Do not attempt to build up much larger
than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base, and
undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 4-24. Weaving in HV fillet
welds is undesirable.
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45° from
vertical
60° - 70° from line
of weld
Art # A-07699_AB
Figure 4-23: Electrode Position for HV Fillet Weld
Art # A-07700_AB
6
3
5
1
2
4
Figure 4-24: Multi-runs in HV Fillet Weld
C. Vertical Welds
1. Vertical Up
Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm
E7014 electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of the
job and strike the arc in the corner of the fillet. The electrode needs to be about 10º from the horizontal
to enable a good bead to be deposited. Refer Figure 4-25. Use a short arc, and do not attempt to weave
on the first run. When the first run has been completed de-slag the weld deposit and begin the second
run at the bottom. This time a slight weaving motion is necessary to cover the first run and obtain
good fusion at the edges. At the completion of each side motion, pause for a moment to allow weld
metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in
the centre of the weld. Figure 4-26 illustrates multi-run technique and Figure 4-27 shows the effects
of pausing at the edge of weave and of weaving too rapidly.
Art # A-07701
Figure 4-25: Single Run Vertical Fillet Weld
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Art # A-07702
Figure 4-26: Multi Run Vertical Fillet Weld
Art # A-07703
Figure 4-27: Examples of Vertical Fillet Welds
2. Vertical Down
The E7014 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100
amps. The tip of the electrode is held in light contact with the work and the speed of downward travel
is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point
upwards at an angle of about 45º.
3. Overhead Welds
Apart from the rather awkward position necessary, overhead welding is not much more difficult that
downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at
right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench
or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.
The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 4-28). The tip of
the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique
is not advisable for overhead fillet welds. Use a 3.2mm E6013 electrode at 100 amps, and deposit the
first run by simply drawing the electrode along at a steady rate. You will notice that the weld deposit
is rather convex, due to the effect of gravity before the metal freezes.
Art # A-07704
Figure 4-28: Overhead Fillet Weld
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Distortion
Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely
perceptible, but in other cases allowance has to be made before welding commences for the distortion that will
subsequently occur. The study of distortion is so complex that only a brief outline can be attempted hear.
The Cause of Distortion
Distortion is caused by:
A. Contraction of Weld Metal:
Molten steel shrinks approximately 11 per cent in volume on cooling to room temperature. This means
that a cube of molten metal would contract approximately 2.2 per cent in each of its three dimensions. In
a welded joint, the metal becomes attached to the side of the joint and cannot contract freely. Therefore,
cooling causes the weld metal to flow plastically, that is, the weld itself has to stretch if it is to overcome
the effect of shrinking volume and still be attached to the edge of the joint. If the restraint is very great,
as, for example, in a heavy section of plate, the weld metal may crack. Even in cases where the weld
metal does not crack, there will still remain stresses "Locked-up" in the structure. If the joint material is
relatively weak, for example, a butt joint in 2.0mm sheet, the contracting weld metal may cause the sheet
to become distorted.
B. Expansion and Contraction of Parent Metal in the Fusion Zone:
While welding is proceeding, a relatively small volume of the adjacent plate material is heated to a very
high temperature and attempts to expand in all directions. It is able to do this freely at right angles to the
surface of the plate (i.e., "through the weld", but when it attempts to expand "across the weld" or "along the
weld", it meets considerable resistance, and to fulfil the desire for continued expansion, it has to deform
plastically, that is, the metal adjacent to the weld is at a high temperature and hence rather soft, and, by
expanding, pushes against the cooler, harder metal further away, and tends to bulge (or is "upset". When
the weld area begins to cool, the "upset" metal attempts to contract as much as it expanded, but, because
it has been "upset" it does not resume its former shape, and the contraction of the new shape exerts a
strong pull on adjacent metal. Several things can then happen.
The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the
powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain "lockedup" stresses in the job. Figures 4-29 and 4- 30 illustrate how distortion is created.
Upsetting
Weld
Art # A-07705_AB
Expansion with
compression
Hot
Hot
Cool
Figure 4-29: Parent Metal Expansion
Art # A-07706_AB
Weld
Permanent Upset
Contraction
with tension
Figure 4-30: Parent Metal Contraction
Overcoming Distortion Effects
There are several methods of minimizing distortion effects.
A.Peening
This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of
this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable
on the last layer.
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B. Distribution of Stresses
Distortion may be reduced by selecting a welding sequence which will distribute the stresses suitably so
that they tend to cancel each other out. See Figures 4-30 through 4-33 for various weld sequences. Choice
of a suitable weld sequence is probably the most effective method of overcoming distortion, although an
unsuitable sequence may exaggerate it. Simultaneous welding of both sides of a joint by two welders is
often successful in eliminating distortion.
C. Restraint of Parts
Forcible restraint of the components being welded is often used to prevent distortion. Jigs, positions, and
tack welds are methods employed with this in view.
D.Presetting
It is possible in some cases to tell from past experience or to find by trial and error (or less frequently, to
calculate) how much distortion will take place in a given welded structure. By correct pre-setting of the
components to be welded, constructional stresses can be made to pull the parts into correct alignment.
A simple example is shown in Figure 4-31.
E.Preheating
Suitable preheating of parts of the structure other than the area to be welded can be sometimes used to
reduce distortion. Figure 4-32 shows a simple application. By removing the heating source from b and c as
soon as welding is completed, the sections b and c will contract at a similar rate, thus reducing distortion.
Art # A-07707
Figure 4-31: Principle of Presetting
Art # A-07708
B
Preheat
C
Preheat
Weld
Dotted lines show effect if no preheat is used
Figure 4-32: Reduction of Distortion by Preheating
Art # A-07709
Figure 4-33: Examples of Distortion
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3
2
1
Art # A-07710_AB
Block Sequence.
The spaces between the welds are
filled in when the welds are cool.
Figure 4-34: Welding Sequence
4
3
2
1
Art # A-07711_AB
Figure 4-35: Step back Sequence
Art # A-07428_AB
Figure 4-36: Chain Intermittent Welding
Art # A-07713_AB
Figure 4-37: Staggered Intermittent Welding
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4.04 STICK (MMA) Welding Troubleshooting
FAULT
1 Welding current
varying
CAUSE
REMEDY
ARC FORCE control knob
is set at a value that
causes the welding current
to vary excessively with
the arc length.
A Welding current too low
2 A gap is left by
failure of the weld B Electrode too large for
metal to fill the
joint.
root of the weld.
C Insufficient gap.
Reduce the ARC FORCE control knob until welding current is reasonably constant while prohibiting the electrode from sticking to the work piece
when you “dig” the electrode into the workpiece.
A Increase welding current.
B Use smaller diameter electrode.
C Allow wider gap.
3 Non-metallic par- A Non-metallic particles may A If a bad undercut is present clean slag bout and
ticles are trapped
be trapped in undercut
cover with a run from a smaller gauge electrode.
in the weld metal.
from previous run.
B Joint preparation too
restricted.
B Allow for adequate penetration and room for
cleaning out the slag.
C Irregular deposits allow
slag to be trapped.
C If very bad, chip or grind out irregularities.
D Lack of penetration with D Use smaller electrode with sufficient current to
slag trapped beneath weld
give adequate penetration. Use suitable tools to
bead.
remove all slag from comers.
E Rust or mill scale is preventing full fusion.
E Clean joint before welding.
F Wrong electrode for posi- F Use electrodes designed for position in which
tion in which welding is
welding is done, otherwise proper control of slag
done.
is difficult.
Art # A-05866_AC
Incorrect Sequence
Insufficient Gap
Figure 1-Example of insufficient gap or incorrect sequence
4 A groove has been A Welding current is too
formed in the base
high.
metal adjacent to B Welding arc is too long.
the toe of a weld
and has not been
filled by the weld C Angle of the electrode is
incorrect.
metal (undercut).
D Joint preparation does not
allow correct electrode
angle.
E Electrode too large for
joint.
A Reduce welding current.
B Reduce the length of the welding arc.
C Electrode should not be inclined less than 45° to
the vertical face.
D Allow more room in joint for manipulation of the
electrode.
E Use smaller gauge electrode.
F Insufficient deposit time at F Pause for a moment at edge of weave to allow
edge of weave.
weld metal buildup.
G Power source is set for
MIG (GMAW/FCAW)
welding.
BASIC WELDING GUIDE
G Set power source to STICK (MMA) mode.
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5 Portions of the
A Small electrodes used on A Use larger electrodes and preheat the plate.
weld run do not
heavy cold plate.
fuse to the surface
B Welding current is too low. B Increase welding current.
of the metal or
C Adjust angle so the welding arc is directed more
edge of the joint. C Wrong electrode angle.
into the base metal.
D Travel speed of electrode
is too high.
D Reduce travel speed of electrode.
E Scale or dirt on joint
surface.
E Clean surface before welding.
Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high
Lack of
inter-run fusion
Art # A-05867_AC
Lack of side fusion,
scale dirt, small electrode,
amperage too low
6 Gas pockets or
voids in weld
metal (porosity)
Lack of root fusion
Figure 2: Example of Lack of Fusion
A High levels of sulphur in
steel.
A Use an electrode that is designed for high sulphur steels.
B Electrodes are damp.
B Dry electrodes before use.
C Welding current is too
high.
C Reduce welding current.
D Surface impurities such as D Clean joint before welding.
oil, grease, paint, etc.
E Welding in a windy environment.
E Shield the weld area from the wind.
F Electrode damaged ie flux F Discard damaged electrodes and only use eleccoating incomplete.
trodes with a complete flux coating.
7 Crack occurring in A Rigidity of joint.
weld metal soon
after solidification B Insufficient throat thickcommences
ness.
C Weld current is too high.
Not cleaned,
or incorrect
electrode
A Redesign to relieve weld joint of severe stresses
or use crack resistance electrodes.
B Travel slightly slower to allow greater build up in
throat.
C Decrease welding current.
Slag
trapped in
undercut
Slag trapped in root
Art # A-05868_AC
Figure 3: Example of Slag Inclusion
Table 4-5: Welding Problems STICK (MMA)
Manual 0-5225
4-21
BASIC WELDING GUIDE
FABRICATOR 211i
BASIC WELDING
4.05 TIG (GTAW) Basic Welding Technique
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding
process in which fusion is produced by an electric arc that is established between a single tungsten (nonconsumable) electrode and the work piece. Shielding is obtained from a welding grade shielding gas or welding
grade shielding gas mixture which is generally Argon based. A filler metal may also be added manually in some
circumstances depending on the welding application.
A-09658_AB
Work Piece
Can Be Any Commercial
Metal
Gas Cup
Either Ceramic,
High-lmpact or
Water Cooled
Metal
Tungsten Electrode
Non-Consumable
Welds Made With or Without
Addition of Filler Metal
Inert Gas
Shields Electrode
and Weld Puddle
Figure 4-38: TIG Welding Application Shot
Tungsten Electrode Current Ranges
Electrode Diameter
DC Current (Amps)
0.040” (1.0mm)
30-60
1/16” (1.6mm)
60-115
3/32” (2.4mm)
100-165
1/8” (3.2mm)
135-200
5/32” (4.0mm)
190-280
3/16” (4.8mm)
250-340
Table 4-6: Current Ranges for Various Tungsten Electrode Sizes
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter DC Current Range (Amps)
1/16” (1.6mm)
20-90
3/32” (2.4mm)
65-115
1/8” (3.2mm)
100-165
3/16” (4.8mm)
200-350
Table 4-7: Filler Wire Selection Guide
BASIC WELDING GUIDE
4-22 Manual 0-5225
BASIC WELDING
FABRICATOR 211i
Tungsten Electrode Types
Electrode Type
(Ground Finish)
Welding Application
Features
Colour Code
Thoriated 2%
DC welding of mild
steel, stainless steel
and copper
Excellent arc starting,
Long life, High current
carrying capacity
Red
Zirconated 1%
High quality AC welding of aluminium,
magnesium and their
alloys.
Self cleaning, Long
life, Maintains balled
end, High current carrying capacity.
White
Ceriated 2%
AC & DC welding of
mild steel, stainless
steel, copper, aluminium, magnesium and
their alloys
Longer life, More
stable arc, Easier
starting, Wider current
range, Narrower more
concentrated arc.
Grey
Table 4-8
NOTE
The Fabricator 211i Inverter is not suited for AC TIG welding.
Base Metal
Thickness
DC Current DC Current
for Mild for Stainless
Steel
Steel
Tungsten
Electrode
Diameter
Filler Rod
Diameter (if
required)
Argon Gas
Flow Rate
Litres/min
Joint Type
0.040”
1.0mm
35-45
40-50
20-30
25-35
0.040”
1.0mm
1/16”
1.6mm
5-7
Butt/Corner
Lap/Fillet
0.045”
1.2mm
45-55
50-60
30-45
35-50
0.040”
1.0mm
1/16”
1.6mm
5-7
Butt/Corner
Lap/Fillet
1/16”
1.6mm
60-70
70-90
40-60
50-70
1/16”
1.6mm
1/16”
1.6mm
7
Butt/Corner
Lap/Fillet
1/8”
3.2mm
80-100
90-115
65-85
90-110
1/16”
1.6mm
3/32”
2.4mm
7
Butt/Corner
Lap/Fillet
3/16”
4.8mm
115-135
140-165
100-125
125-150
3/32”
2.4mm
1/8”
3.2mm
10
Butt/Corner
Lap/Fillet
1/4”
6.4mm
160-175
170-200
135-160
160-180
1/8”
3.2mm
Table 4-9
5/32”
4.0mm
10
Butt/Corner
Lap/Fillet
TIG Welding is generally regarded as a specialised process that requires operator competency. While many of
the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG
Welding process is outside the scope of this Operating Manual. For further information please refer to www.
thermadyne.com or contact Thermal Arc.
Manual 0-5225
4-23
BASIC WELDING GUIDE
FABRICATOR 211i
BASIC WELDING
4.06 TIG (GTAW) Welding Problems
FAULT
CAUSE
REMEDY
1 Excessive bead build up or
poor penetration or poor
fusion at edges of weld.
Welding current is too
low
Increase weld current and/or faulty joint
preparation.
2 Weld bead too wide and
flat or undercut at edges
of weld or excessive burn
through.
Welding current is too
high
Decrease weld current.
3 Weld bead too small or
insufficient penetration or
ripples in bead are widely
spaced apart.
Travel speed too fast
Reduce travel speed.
4 Weld bead too wide or
excessive bead build up or
excessive penetration in
butt joint.
Travel speed too slow
Increase travel speed.
5 Uneven leg length in fillet
joint
Wrong placement of
filler rod
Re-position filler rod.
6 Electrode melts or oxidises A Torch lead connected
when an arc is struck.
to positive welding
terminal.
A Connect torch lead to negative welding
terminal.
B No gas flowing to weld- B Check the gas lines for kinks or breaks
ing region.
and gas cylinder contents.
C Torch is clogged with
dust or dirt.
C Clean torch.
D Gas hose is cut.
D Replace gas hose.
E Gas passage contains
impurities.
E Disconnect gas hose from the rear of
Power Source then raise gas pressure
and blow out impurities.
F Gas regulator turned
off.
F Turn on.
G Torch valve is turned
off.
G Turn on.
H The electrode is too
small for the welding
current.
H Increase electrode diameter or reduce the
welding current.
I Power source is set for I Set Power Source to LIFT TIG mode.
MIG welding.
BASIC WELDING GUIDE
4-24 Manual 0-5225
BASIC WELDING
7 Dirty weld pool
FABRICATOR 211i
A Electrode contaminated A Clean the electrode by grinding off the
by contact with work
contaminates.
piece or filler rod material.
B Work piece surface has B Clean surface.
foreign material on it.
C Gas contaminated with C Check gas lines for cuts and loose fitting
air.
or change gas cylinder.
8 Poor weld finish
9 Arc start is not smooth.
Inadequate shielding
gas.
Increase gas flow or check gas line for
gas flow problems.
A Tungsten electrode is A Select the right size electrode. Refer to
too large for the weldTable 4-6.
ing current.
B The wrong electrode
is being used for the
welding job.
B Select the right electrode type. Refer to
Table 4-8.
C Gas flow rate is too
high.
C Select the right rate for the welding job.
Refer to Table 4-9.
D Incorrect shielding gas D Select the right shielding gas.
is being used.
E Poor work clamp con- E Improve connection to work piece.
nection to work piece.
10 Arc flutters during TIG
welding.
Tungsten electrode is
too large for the welding current.
Select the right size electrode. Refer to
Table 4-6.
Table 4-10: TIG (GTAW) Welding Problems
Manual 0-5225
4-25
BASIC WELDING GUIDE
FABRICATOR 211i
BASIC WELDING
This Page Intentionally Blank
BASIC WELDING GUIDE
4-26 Manual 0-5225
PROBLEMS/SERVICE
FABRICATOR 211i
SECTION 5: POWER SOURCE PROBLEMS AND ROUTINE
SERVICE REQUIREMENTS
5.01 Power Source Problems
FAULT
CAUSE
REMEDY
1 Mains supply voltage is ON, A Power source is not in the
power indicator is illumicorrect mode of operation.
nated however unit will not
commence welding when
B Faulty torch trigger.
the torch trigger switch is
depressed.
A Set the power source to the correct mode of operation with the
process selection switch.
Duty cycle of power source
has been exceeded.
Leave the power source
switched ON and allow it to cool.
Note that fault indicator must
be extinguished prior to commencement of welding.
2 Fault Indicator is illuminated and unit will not
commence welding when
the torch trigger switch is
depressed.
3 Unit will not feed wire in
MIG mode.
4 Welding wire continues to
feed when torch trigger is
released.
B Repair or replace torch trigger
switch/lead.
A Electrode wire stuck in
conduit liner or contact tip
(burn-back jam).
A Check for clogged / kinked MIG
gun conduit liner or worn contact tip. Replace faulty components.
B Internal fault in power
source
B Have an Accredited Thermal Arc
Service Provider investigate the
fault.
A Trigger mode selection
switch is in 4T latch mode.
A Change the trigger mode selection switch from 4T latch mode
to 2T normal mode.
B Torch trigger leads shorted. B Repair or replace torch trigger
switch/lead.
5 Welding arc cannot be
established in MIG mode.
6 Inconsistent wire feed.
7 No gas flow in MIG mode.
Manual 0-5225 A MIG gun polarity lead is not A Connect the MIG gun polarconnected into a welding
ity lead to either the positive
output terminal.
welding output terminal or the
negative welding output terminal
as required.
B Poor or no work lead
contact.
B Clean work clamp area and ensure good electrical contact.
A Worn or dirty contact tip.
A Replace if necessary.
B Worn feed roll.
B Replace.
C Excessive brake tension on
wire reel hub.
C Reduce brake tension on spool
hub
D Worn, kinked or dirty conduit liner
D Clean or replace conduit liner
A Gas hose is damaged.
A Replace or repair.
B Gas passage contains
impurities.
B Disconnect gas hose from the
rear of power source and blow
out impurities.
C Gas regulator turned off.
C Turn on regulator.
D Empty gas cylinder.
D Replace gas cylinder.
5-1
PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i
PROBLEMS/SERVICE
8 Gas flow continues after
the trigger switch has been
released (MIG mode).
Gas valve has jammed open
due to impurities in the gas
or the gas line.
Have an accredited Thermal
Arc service provider repair or
replace gas valve.
9 Power indicator will not
illuminate and welding arc
cannot be established.
The mains supply voltage
has exceeded voltage limits
of the power source.
Ensure that the mains supply
voltage is within 230VAC ± 15%.
10 TIG electrode melts when
arc is struck.
TIG torch is connected to
the (+) VE terminal.
Connect the TIG torch to the (-)
VE terminal.
11 Arc flutters during TIG
welding.
Tungsten electrode is too
Select the correct size of tunglarge for the welding cursten electrode. Refer to Table
rent.
4-6.
Table 5-1: Power Source Problems
5.02 Routine Service and Calibration Requirements
WARNING
There are extremely dangerous voltage and power levels present inside this Inverter Power Source.
Do not attempt to open or repair unless you are an accredited Thermal Arc Service Provider. 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.
B. Insulation Resistance
Minimum insulation resistance for in-service Thermal Arc Inverter Power Sources shall be measured at
a voltage of 500V between the parts referred to in Table 5-2 below. Power sources that do not meet the
insulation resistance requirements set out below shall be withdrawn from service and not returned until
repairs have been performed such that the requirements outlined below are met.
PROBLEMS AND ROUTINE SERVICE
5-2
Manual 0-5225
PROBLEMS/SERVICE
FABRICATOR 211i
Minimum Insulation
Resistance (MΩ)
Components to be Tested
Input circuit (including any connected control circuits) to welding circuit
(including any connected control circuits)
5
All circuits to exposed conductive parts
2.5
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage exceeding extra low voltage
10
Welding circuit (including any connected control circuits) to any auxiliary
circuit which operates at a voltage not exceeding extra low voltage
1
1
Separate welding circuit to separate welding circuit
Table 5-2: 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 0-5225 5-3
PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i
PROBLEMS/SERVICE
Power Source Calibration
A.Schedule
Output testing of all Thermal Arc Inverter Power Sources and applicable accessories shall be conducted at
regular intervals to ensure they fall within specified levels. Calibration intervals shall be as outlined below 1. For transportable equipment, at least once every 3 months; and
2. For fixed equipment, at least once every 12 months.
If equipment is to be used in a hazardous location or environments with a high risk of electrocution as
outlined in EN 60974-1, then the above tests should be carried out prior to entering this location.
B. Calibration Requirements
Where applicable, the tests outlined in Table 6-3 below shall be conducted by an accredited Thermal Arc
service agent.
Testing Requirements
Output current (A) to be checked to ensure it falls within applicable Thermal Arc power source specifications
Output Voltage (V) to be checked to ensure it falls within applicable Thermal Arc power source specifications
Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Thermal Arc power
source / wire feeder specifications
Accuracy of digital meters to be checked to ensure it falls within applicable Thermal Arc power source
specifications
Table 5-3: Calibration Parameters
Periodic calibration of other parameters such as timing functions are not required unless a specific fault
has been identified.
C. Calibration Equipment
All equipment used for Power Source calibration shall be in proper working condition and be suitable for
conducting the measurement in question. Only test equipment with valid calibration certificates (NATA
certified laboratories) shall be utilized.
5.03 Cleaning the Welding Power Source
WARNING
There are dangerous voltage and power levels present inside this product. Do not attempt to open
or repair unless you are a qualified electrical tradesperson. Disconnect the Welding Power Source
from the Mains Supply Voltage before disassembling.
To clean the Welding Power Source, open the enclosure and use a vacuum cleaner to remove any accumulated
dirt, metal filings, slag and loose material. Keep the shunt and lead screw surfaces clean as accumulated foreign
material may reduce the welders output welding current.
PROBLEMS AND ROUTINE SERVICE
5-4
Manual 0-5225
PROBLEMS/SERVICE
FABRICATOR 211i
5.04 Cleaning the Feed Rolls
Clean the grooves in the drive rolls frequently. This can be done by using a small wire brush. Also wipe off, or
clean the grooves on the upper feed roll. After cleaning, tighten the feed roll retaining knobs.
CAUTION
Do NOT use compressed air to clean the Welding Power Source. Compressed air can force metal
particles to lodge between live electrical parts and earthed metal parts within the Welding Power
Source. This may result in arcing between these parts and their eventual failure.
Manual 0-5225 5-5
PROBLEMS AND ROUTINE SERVICE
FABRICATOR 211i
PROBLEMS/SERVICE
This Page Intentionally Blank
PROBLEMS AND ROUTINE SERVICE
5-6
Manual 0-5225
REPLACEMENT PARTS
FABRICATOR 211i
SECTION 6:
KEY SPARE PARTS
6.01 Power Source Spare Parts
3
20
4
5
11
16 12
9
19
10
2
21
7
8
15
6
14
13
Item
Part Number
W7005600 PCB Power
2
W7005601 PCB Control
3
W7005602 PCB Display
4
W7005607 PCB Spool Gun
5
W7004902 PCB EMC Filter
6
W7005603 Wiredrive Assembly
7
W7004906 Feed Roll Retaining Thumbscrew
62020
Art # A-11234
Description
1
8
1
17
Feed Roll 0.6/0.8mm V groove (fitted as standard)
(Refer to options and accessories table for other feed rolls available).
9
W7005604 Fan
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
W7004942 Control Socket 8 pin (Note that 8 pin control plug part number is UOA706900).
16
17
18
W7005606 Supply Circuit Breaker / Mains Supply Switch
W7004911 CT, Output
W7004930 Shielding Gas Hose Assembly (not shown)
19
20
21
22
W7005608
W7005609
W7005618
W7005619
Friction Washer for Spool Hub
Spool Hub
Euro Outlet Adaptor, 211i
inlet Guide, 211i (not shown)
Table 6-1 Key Spare Parts
Manual 0-5225
6-1
KEY SPARE PARTS
FABRICATOR 211i
REPLACEMENT PARTS
This Page Intentionally Blank
KEY SPARE PARTS
6-2
Manual 0-5225
CIRCUIT DIAGRAM
FABRICATOR 211i
APPENDIX: FABRICATOR 211i CIRCUIT DIAGRAM
50/60Hz
L2
GND
INPUT 230VAC/110VAC L1
SHEETMETAL COVER
60W3Ω
J14
1
RX
ACOUT
RED
FAN
BR1
J23
FJ
BR2
ACOUT
1 +24VDC
VR
1
BLACK
DC -
BLACK
DC +
PFC CIRCUIT
RED
POT1
BURN BACK PCB 5
W7004940
J15
1
CON3
+24CDC 1
N/A 2
J16
1
DY1
1
Main Power PCB1
75ć
J5
1
J6
1
OT2
J1
DRIVE
J2
J3
CR
ON
J4
Funs
J5
OT2
J10
MB
CONNECTOR LAYOUT DIAGRAM
SOURCE
J13
1 2
J11
1
SEIAL DISPLAY DATA (CLK) 3
SEIAL DISPLAY DATA (LOAD) 2
STICK 6
2T/4T PUSHBUTTON 4
+15VDC 9
PROCESS PUSHBUTTON 8
POT3 B 11
MB
POT2 WIPER 12
GND
+
GUN
+24VDC 1
4 GND
POT1 WIPER 14
+15VDC 15
IFB
1
J12
2 -15V
3 Current Feedback
POT3 A (PANEL DEMAND) 13
3 + OUTPUT
1 +15V
DISPLAY DATA &EPROM (D-IN) 1
1
-J35
1
J34
1
J33
Current Sensor
SGM
PP
1
SERIAL DISPLAY DATA (EPROM) 5
J9
J22
K1
15V
J6
OT1
J7
J5
J8
J9
1
W7005607
WVIN
SPOOL GUN PCB3
1 - OUTPUT
RED
RED
GUN
7 GND
BLACK
WHITE
QF / DY
6 Over Current Signal
WHITE
YELLOW
WVIN
5 IGBT Driver A
WHITE
GRAY
PWM
J1
DRIVE
2 IGBT Driver A
4 IGBT Driver B
WHITE
GND 7
1 +15V
3 IGBT Driver B
WHITE
IGBT Driver A 5
W7005601
1
3 -24VDC
WHITE
Over Current Signal 6
1 +24VDC
2 GND
WHITE
IGBT Driver B 4
Control PCB2
J2
WHITE
SOURCE
BLACK
MT
RED
RED
J21
1
IN
J31
1
RED
BLACK
1
J32
BLACK
FUSE
+15V 1
IGBT Driver A 2
PFC
2 PWM (MOTOR DRIVER 5VDC PEAK)
WHITE
IGBT Driver B 3
J12
1
J20
1
DY2
WHITE
IFB
J11
PWM
1
PWM
J19
Fuse 8A/250V
Wirefeeder
MOTOR PWM CONTROL
CIRCUIT
1 PWM RETURN
WHITE
GND 2
-24VDC 3
OT1
2 TO U15 PIN6
BLACK
+24VDC 1
3 POT MAX (+5VDC)
2 WIPER
1 POT MIN
CR
1 +5VDC
YELLOW
RED
75ć
J3
1
1 +24CDC
RED
JC
1
INPUT 230V/115V
J13
1
JC
+
J18
+
+
GND
+
WHITE
OUTPUT CONTROL SIGNAL
RED
YEL
J4
1
WHITE
BLK
RED
WHITE
YELLOW
+
+
WHITE
+24VDC
Funs
1
GND
J8
J17
1
QF/FJ
WHITE
QF / DY
GAS
SOLENOID
W7005600
WHITE
WHITE
J10
J7
1
-
NEG
+
POS
RED
BLACK
SPOOL GUN
MIG GUN
J24
J25
1
J26
1
GND
Display PCB4
J28
1
J27
1
W7005602
1 +15VDC
Power
Fault
Process
GND
LOCAL
1
REMOTE
1 +15VDC
MIG
LIFT TIG
J29
STICK
J30
Trigger
(REMOVE AMPS/WIRESPEED) POT WIPER 8
Amps / Wirefeed Display
(REMOVE VOLTAGE) POT WIPER 7
Volts Display
2T Normal
TORCH SWITCH RIN (0VDC) 6
3 -15VDC
TORCH SWITCH RIN (0VDC) 5
SPOOL GUN (+2VDC) 4
4T Latch
TORCH SWITCH RIN (0VDC) 3
TORCH SWITCH (+24V) 2
Volts
1
SPOOL GUN (0V) 1
Wirefeed / Amps
2
4
7
1
3
6
8 Pin Remote Control
Spool Gun
5
8
Front View
Manual 0-5225 Down Slope / Arc Force(%)
Arc Control
Art # A-11233
A-1APPENDIX
THERMAL ARC - LIMITED WARRANTY TERMS
LIMITED WARRANTY: Thermal Arc ®, Inc, A Thermadyne 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, Thermadyne guarantees the proposed product to be
free from defects in material or workmanship when operated in accordance with the written instructions as
defined in this operating manual.
Thermadyne 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.
Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects
in material or workmanship within the warranty period. The warranty period begins on the date of sale to the
end user.
Thermal Arc Fabricator 211i
Component
Warranty Period
Power Source
MIG Gun, Electrode Holder / Lead & Work Lead
MIG Gun Consumables
2 Years
3 Months
NIL
If warranty is being sought, Please contact your Thermadyne product supplier for the warranty repair procedure.
Thermadyne warranty will not apply to:
• Equipment that has been modified by any other party other than Thermadyne’s own service personnel or
with prior written consent obtained from Thermadyne 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.thermadyne.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 Thermadyne distributor and speak with a technical representative.
NOTE
Warranty repairs must be performed by either a Thermadyne Service Centre, a Thermadyne distributor or an
Authorised Service Agent approved by the Company.
Printed in: China
Customer Care UK: +44 (0)1257 261 755 / Fax: +44 (0)1257 224 800
Customer Care Italy +39 02 36546801 / Fax: +39 02 36546480
www.thermadyne.com
A Global Cutting & Welding Market Leader™
WORLD HEADQUARTERS:
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
16052 Swingley Ridge Road, Suite 300
EUROPE
ASIA/PACIFIC
Miami, FL USA
Sales Office, Latin America
Ph:
1-954-727-8371
Fax:
1-954-727-8376
Chorley, United Kingdom
Customer Care
Ph:
+44 1257-261755
Fax:
+44 1257-224800
Cikarang, Indonesia
Customer Care
Ph:
6221-8990-6095
Fax:
6221-8990-6096
Oakville, Ontario, Canada
Canada Customer Care
Ph:
1-905-827-4515
Fax:
1-800-588-1714 (tollfree)
Milan, Italy
Customer Care
Ph:
+39 0236546801
Fax:
+39 0236546840
Rawang, Malaysia
Customer Care
Ph:
+603 6092-2988
Fax:
+603 6092-1085
© 2010, 2011, 2012 ThermadyneIndustries,Inc.
•
St. Louis, Missouri 63017
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
U.S.A.
Shanghai, China
Sales Office
Ph:
+86 21-64072626
Fax:
+86 21-64483032
Singapore
Sales Office
Ph:
+65 6832-8066
Fax:
+65 6763-5812
www.thermadyne.com
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