Related Manuals for Thermal Arc PORTAFEED VS 212
Summary of Contents for Thermal Arc PORTAFEED VS 212
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Page 1: Wire Feeder
VS 212 ® PORTAFEED CC/CV SEMIAUTOMATIC SOLID STATE CONTROLLED WIRE FEEDER Art # A-07123_AB Operating Manual Issue Date: March 3, 2011 Revision: AH Manual No.: 0-4845 Operating Features: 15-100... - Page 2 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.
- Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Portafeed VS 212 CC/CV Semiautomatic Solid State Controlled Wire Feeder Instruction Manual Number 0-4845 for: Part Numbers: W3512001, W3512002 and W35120L2 Published by: Thermadyne Industries Inc.
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 Principal Safety Standards ................1-4 1.03 Symbol Chart ....................1-5 1.04 Precautions De Securite En Soudage A L’arc ..........1-6 1.05 Dangers relatifs au soudage à l’arc ..............1-6 1.06 Principales Normes De Securite .............. - Page 5 TABLE OF CONTENTS (continued) TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Prewelding Procedure ..................4-1 4.02 Welding Procedure ..................4-2 4.03 Welding In CC Mode vs. CV Mode ..............4-2 4.04 Theory Of Operation ..................4-2 4.05 Adjusting Burnback Time ................4-3 4.06 Wire Feed Speed Ranges ................
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Page 7: Safety Instructions And Warnings
SAFETY INSTRUCTIONS PORTAFEED VS 212 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. -
Page 8: Safety Instructions
PORTAFEED VS 212 SAFETY INSTRUCTIONS 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. WARNING 4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection. - Page 9 SAFETY INSTRUCTIONS PORTAFEED VS 212 2. If used in a closed area, vent engine exhaust outside and away from any building air intakes. WARNING WARNING FLYING SPARKS AND HOT METAL can cause injury. Chipping and grinding cause flying metal. As welds cool, they can throw off slag.
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Page 10: Principal Safety Standards
PORTAFEED VS 212 SAFETY INSTRUCTIONS 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American WARNING Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S. -
Page 11: Symbol Chart
SAFETY INSTRUCTIONS PORTAFEED VS 212 1.03 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter-... -
Page 12: Precautions De Securite En Soudage A L'arc
PORTAFEED VS 212 SAFETY INSTRUCTIONS 1.04 Precautions De Securite En Soudage A L’arc MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). - Page 13 SAFETY INSTRUCTIONS PORTAFEED VS 212 AVERTISSEMENT AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX POUR LA SANTE. ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. Le soudage dégage des vapeurs et des fumées L’arc de soudage produit une chaleur et des rayons...
- Page 14 PORTAFEED VS 212 SAFETY INSTRUCTIONS 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si AVERTISSEMENT l’espace est bien ventilé; si nécessaire portez un respirateur à ad- duction d’air.
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Page 15: Principales Normes De Securite
SAFETY INSTRUCTIONS PORTAFEED VS 212 Les accumulateurs contiennent de l’électrolyte acide et 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées. dégagent des vapeurs explosives. 2. Si vous utilisez ces équipements dans un endroit confiné, les 1. Portez toujours un écran facial en travaillant sur un accumu-lateur. -
Page 16: Graphique De Symbole
PORTAFEED VS 212 SAFETY INSTRUCTIONS 1.07 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique... -
Page 17: Declaration Of Conformity
SAFETY INSTRUCTIONS PORTAFEED VS 212 1.08 Declaration Of Conformity Manufacturer: Thermadyne Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 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. - Page 18 PORTAFEED VS 212 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 1-12 Manual No. 0-4845...
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Page 19: Introduction
Include the Owner’s Manual number and equipment identification numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link: http://www.thermalarc.com Manual No. 0-4845... -
Page 20: General
• Gas valve solenoid arc time and memory hold. 16. Trigger Hold Switch The PORTAFEED VS 212 has been designed to comply with IEC 60974-1 (CE), CSA NRTL/C, and NEMA EW 3 standards. INTRODUCTION... -
Page 21: Product Specifications
PORTAFEED VS 212 2.05 Product Specifications Portafeed VS212 Specifications Input Voltage Range 15-100 VDC Maximum Input Current 10 Amps Wire Speed Range 50-800 IPM (1.27 - 20.32 MPM) (dependent on arc voltage) Wire Sizes 0.024 - 5/64'' (0.6 - 2.0 mm) Max Wire Spool Capacity 12'' (304.8 mm) 44 Lbs. -
Page 22: Features/Benefits
PORTAFEED VS 212 2.06 Features/Benefits Heavy duty, removable voltage sensing lead Robust injection molded case Long lasting and unbreakable. Allows storage of lead with less lead breakage. MIG gun holder Changeable MIG gun cartridge system Patent Pending. No external MIG gun adapters needed A place to hold your MIG gun while not welding. -
Page 23: Front Panel Controls And Connections
PORTAFEED VS 212 2.07 Front Panel Controls And Connections Art # A-07136_AB (4) Arc Voltage Meter (3) Wire Feed Speed/Amp Meter (2) Wire Feed Speed Control (5) Inch/Purge Switch (1) On/Off Power Switch (6) 2T/4T Trigger Mode Selector Switch (9) Welding Gun Cable Connection... -
Page 24: Rear Panel Controls And Connections
PORTAFEED VS 212 2.08 Rear Panel Controls And Connections (4) MIG Gun Holder Art # A-07137 (1) Lifting Eye (2) Gas Valve Inlet (3) Input Power Cable Figure 2-3: Rear Panel Connections 3. INPUT POWER CABLE: Provides an inlet and secure 1. -
Page 25: Internal Controls And Connections
PORTAFEED VS 212 2.09 Internal Controls And Connections Art # A-07138 (1) STORAGE BOX (2) HIGH/LOW RANGE SWITCH (13) INPUT CIRCUIT High (14) HUB TENSION (3) WIRE SPEED/AMP METER BREAKER BOLT SELECTION DIP SWITCHES (12) CC/CV MODE (4) CARTRIDGE GUN LEADS... -
Page 26: Power Source Compatibility
2.10 Power Source Compatibility voltage sensing wire feed speed mode of operation Since the PORTAFEED VS 212 operates on arc voltage, it for use with constant current (CC) power sources. The will work with most constant current (CC) or constant... -
Page 27: Installation
PORTAFEED VS 212 SECTION 3: INSTALLATION 3.01 Connections WARNING CAUTION ELECTRIC SHOCK CAN KILL! DO NOT touch the metal portions of the voltage sensing lead Make sure all connections are tight; otherwise, when the power source output is on. arcing or overheating could result. -
Page 28: Installation Of Wire Spool
PORTAFEED VS 212 3.02 Installation Of Wire Spool NOTE The wire spool hub supplied with the unit is provided for mounting a 44 pound (20 kg) spool of wire. Optional adapters are available Wire Spool allowing a 10 (4.5 kg) or 15 (6.8 kg) pound Hub Nut spool of wire or a 14 (6.4 kg) pound coil of... -
Page 29: Adjustment Of Spool Tension
PORTAFEED VS 212 3.03 Adjustment Of Spool Tension 3.04 Input And Output Wire Guide Installation Adjust the wire spool tension so the wire will feed freely into the input wire guide. However, the spool of welding 1. Install the input wire guide (the longer one) by wire must not coast when wire feeding stops. -
Page 30: Selection And Installation Of Feed Rolls
Installation and Removal Refer to feed roll kit chart in the Appendix chapter for the The Portafeed VS 212 wire feeder is designed to be used proper selection and ordering of feed roll kits. Kit includes with most MIG welding guns. Model numbers W3512001... -
Page 31: Threading Wire Into Feedhead
PORTAFEED VS 212 3.07 Threading Wire Into Feedhead 2. Pass the wire through the output wire guide and into the welding gun assembly. Refer to Figure 3-6. 3. Lock in position with the spring tension knob. To adjust the amount of force the bearing feed roll exerts on the... - Page 32 PORTAFEED VS 212 NOTES INSTALLATION Manual No. 0-4845...
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Page 33: Operation
PORTAFEED VS 212 SECTION 4: OPERATION 4.01 Prewelding Procedure 5. Depress the inch switch (if equipped) or gun switch Follow all installation instructions for the welding power and adjust the wire feed speed to the desired value by source, the welding gun, and the VS 212 CC/CV wire feeder means of the wire feed speed control. -
Page 34: Welding Procedure
PORTAFEED VS 212 4.02 Welding Procedure 4.03 Welding In CC Mode vs. CV Mode WARNING 1. Welding in CC Mode: When welding with a constant current (CC) power source, changes in wire feed speed will affect welding voltage. In semiautomatic or automatic wire welding,... -
Page 35: Adjusting Burnback Time
PORTAFEED VS 212 3. Locate component R68 (Burnback) on the motor con- 4.05 Adjusting Burnback Time trol printed circuit board (refer to Figure 4-3). The best Burnback time is set at the factory, but the motor control procedure is to make only slight adjustments until the printed circuit board contains a component that permits amount of burnback is acceptable. -
Page 36: Changing Meter Functions
High Range Figure 4-5: Low and High Feed Speed Ranges 4.07 Changing Meter Functions The Portafeed VS 212 has two digital meters on the front Art # A-07257_AB panel. The top meter always displays the welding power supply's voltage output. However, the lower meter can... -
Page 37: Meter Hold Function
PORTAFEED VS 212 3. Using Table 4-1 as a reference, carefully slide each white DIP switch left or right to change the meter to the desired function. DIP Switch # LEFT Position Hold Function "Off" Wire Feed Speed Displayed Wire Feed Speed in IPM Currently Not In Use Hold Function "On"... - Page 38 PORTAFEED VS 212 4. Motor Overcurrent Protection: If the drive motor becomes locked or shorted, an electronic circuit will activate, and the motor will not operate. If this circuit activates, a light on the motor control printed circuit board labeled [Fault 2] will turn on. The motor...
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Page 39: Service
PORTAFEED VS 212 SECTION 5: Prior to disassembly or servicing of the machine, note the wiring and connections in the machine. Reassembling SERVICE should place the wires in the same location and routing as received from the factory. Keep wires and leads away 5.01 Cleaning Of The Unit... - Page 40 PORTAFEED VS 212 D. Check for a damaged power switch. C. Check for a locked or shorted motor. E. Check for a damaged or tripped circuit breaker. D. An electronic protection circuit may have activated. 2. Wire feed motor operates but wire does not feed or feeds erratically.
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Page 41: Parts List
PORTAFEED VS 212 SECTION 6: PARTS LIST 6.01 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specification or Assembly numbers. -
Page 42: External Replacement Parts
PORTAFEED VS 212 6.03 External Replacement Parts Item # Item # Item # Item # Item # Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Control Knob 870696PKD Rocker Switch, Single Pole, Black... -
Page 43: Internal Replacement Parts
PORTAFEED VS 212 6.04 Internal Replacement Parts Item # Item # Item # Item # Item # Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Case, Internal Parts Storage 870865PKD Circuit Breaker PB 10A... -
Page 44: Wire Feeder Replacement Parts
PORTAFEED VS 212 6.05 Wire Feeder Replacement Parts Item # Item # Item # Item # Item # Description Description Description Description Description Part Number Part Number Part Number Part Number Part Number Tension Rod Subassembly 870933PKD Pressure Arm, Machined, Two Roll (see note 2) -
Page 45: Drive Roll Kits
PORTAFEED VS 212 APPENDIX 1: DRIVE ROLL KITS DRIVE ROLL KITS (#375980-Series) 2 ROLL Style 1 Style 2 Style 3 Style 4 Style 5 Style 6 Double Smooth Double Flat Flat Knurled "V" Knurled "V" Double Cog Double "U" Double... -
Page 46: Appendix 1: Drive Roll Kits
PORTAFEED VS 212 APPENDIX 2: OPTIONS AND ACCESSORIES Product Part No. Description One kit (#375980-092) is supplied standard with each wire Drive Roll Kits 375980-XXX feeder, see drive roll kit chart to select a different drive roll style Wire Spool / Coil Adapters 10 lb (4.5kg), 8”... -
Page 47: Appendix 3
PORTAFEED VS 212 APPENDIX 3: MIG GUN CARTRIDGE SYSTEM Removable Gun Cartridge System (Patent Pending) The MIG gun cartridge can easily be removed and replaced with a different cartridge that will fit other brands of MIG guns (Miller®, Lincoln®, Euro). Refer to Appendix 2 for specific models. -
Page 48: Appendix 4: System Schematic
PORTAFEED VS 212 APPENDIX 4: SYSTEM SCHEMATIC FEEDHEAD J2-5 CONTACTOR, 400 AMP BREAKER, CIRCUIT, 8 AMP J2-2 J2-3 J1-1 TO POWER J2-1 SOURCE J1-3 SWITCH POWER RECTIFIER, BRIDGE J1-4 J1-5 TO WORK J1-2 J3-1 J1-9 J1-8 SWITCH, CC/CV J1-10 J1-12... - Page 49 PORTAFEED VS 212 DISPLAY BOARD J4-11 VOLTMETER PCB3 J4-10 VOLTMETER SWITCH, TRIGGER MODE SELECTOR J4-9 J2-1 J4-8 J4-12 WFS POT MAX J2-4 J4-13 WFS POT WIPER SWITCH, GUN J4-14 WFS POT MIN J2-2 J4-7 MOTOR BOARD ENABLE INCH J4-5 OVER VOLTAGE FAULT...
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Page 50: Statement Of Warranty
Statement of Warranty (as of March 15, 2009) LIMITED WARRANTY: THERMADYNE warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below, THERMADYNE shall, upon written notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and recognized standard industry practice, and not been subject to misuse, repair, neglect, alteration, or accident, correct... -
Page 51: Warranty Schedule
All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year Engines and Associated Components are NOT Warranted by Thermal Arc®, See the Engine Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE Manufacturers’... -
Page 53: Global Customer Service Contact Information
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988... - Page 54 World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017 Telephone: (636) 728-3000 FAX: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.com...
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