Thermal Arc Fabricator 211i Service Manual
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Thermal Arc Fabricator 211i Service Manual

3 in 1 multi-process welding system
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211i

Service Manual

3163339
Fabricator
3 in 1 Multi-proceSS
welding SySteM
Revision: AB
Issue Date: March 1, 2013
Operating Features:
®
Art # A-11350
Manual No.: 0-5158

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Summary of Contents for Thermal Arc Fabricator 211i

  • Page 1: Service Manual

    211i Fabricator ® 3 in 1 Multi-proceSS welding SySteM Art # A-11350 Service Manual Revision: AB Issue Date: March 1, 2013 Manual No.: 0-5158 Operating Features: 3163339...
  • Page 2 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.
  • Page 3 Manufacturer assumes no liability for its use. Service Manual Number 0-5158 for: Thermal Arc Fabricator 211i Portable System Package Part Number W1004201 Thermal Arc Fabricator 211i Portable System with Cart Part Number W1004202 Thermal Arc Fabricator 211i Power Source Part Number W1004200...

  • Page 4: Table Of Contents

    Description ..................... 2-1 2.05 Transportation Methods .................. 2-2 2.06 User Responsibility ..................2-2 2.07 Fabricator 211i Portable System Package (Part No. W1004201) ....2-2 SECTION 3: safety and INSTALLATION ................3-1 3.01 Duty Cycle ....................... 3-1 3.02 Specifications ....................3-2 3.03...
  • Page 5 TABLE OF CONTENTS 4.10 Setup For MIG (GMAW) Welding With Gas Shielded MIG Wire ....4-14 4.11 Setup For MIG (FCAW) Welding With Flux Core (Gasless) Wire ....4-15 4.12 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire 4-17 4.13 Setup For LIFT TIG (GTAW) Welding .............

  • Page 7: Safety Instructions And Warnings

    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.
  • Page 8 FABRICATOR 211i SAFETY INSTRUCTIONS 3. Use protective screens or barriers to protect others 15. Keep all panels and covers securely in place. from flash and glare; warn others not to watch the arc. 4. Wear protective clothing made from durable,...
  • Page 9 SAFETY INSTRUCTIONS FABRICATOR 211i 6. Be aware that welding on a ceiling, floor, bulkhead, 1. Keep your head out of the fumes. Do not breathe or partition can cause fire on the hidden side. the fumes. 7. Do not weld on closed containers such as tanks or 2.
  • Page 10 FABRICATOR 211i SAFETY INSTRUCTIONS 6. Turn face away from valve outlet when opening 1. Keep all doors, panels, covers, and guards cylinder valve. closed and securely in place. 7. Keep protective cap in place over valve except when 2. Stop engine before installing or connecting unit.

  • Page 11: General Safety Information For Victor Cs Regulator

    SAFETY INSTRUCTIONS FABRICATOR 211i NOTE 1.02 General Safety Information For Considerations About Welding And The Victor CS Regulator Effects of Low Frequency Electric and Mag- Fire Prevention netic Fields Welding and cutting operations use fire or combustion The following is a quotation from the General Conclu- as a basic tool.
  • Page 12 FABRICATOR 211i SAFETY INSTRUCTIONS Ventilation 1. Place the cylinder (Figure 1-1) where you will use it. Keep the cylinder in a vertical position. Secure it to a cart, wall, work bench, post, etc. WARNING Ade quately ventilate welding, heating, and...

  • Page 13: Principal Safety Standards

    SAFETY INSTRUCTIONS FABRICATOR 211i 1.03 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, WARNING from American Welding Society, 550 N.W. LeJeune Rd., DO NOT use the cylinder if you find oil, Miami, FL 33126. grease or damaged parts. Inform your gas Safety and Health Standards, OSHA 29 CFR 1910, supplier of this condition immediately.

  • Page 14: Symbol Chart

    FABRICATOR 211i SAFETY INSTRUCTIONS 1.04 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- Welding Gun...

  • Page 15: Precautions De Securite En Soudage A L'arc

    SAFETY INSTRUCTIONS FABRICATOR 211i 1.05 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 16 FABRICATOR 211i SAFETY INSTRUCTIONS 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder. 11. Ne touchez pas à l’électrode lorsqu’en contact avec AVERTISSEMENT le circuit de soudage (terre). LE RAYONNEMENT DE L’ARC PEUT BRÛLER 12.
  • Page 17 SAFETY INSTRUCTIONS FABRICATOR 211i 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. 3. Entourez l’aire de soudage de rideaux ou de cloisons AVERTISSEMENT pour protéger les autres des coups d’arc ou de LE SOUDAGE PEUT CAUSER UN INCENDIE l’éblouissement;...
  • Page 18 FABRICATOR 211i SAFETY INSTRUCTIONS 7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation. 8. Lisez et respectez les consignes relatives aux AVERTISSEMENT bouteilles de gaz comprimé et aux équipements LES ETINCELLES ET LES PROJECTIONS...

  • Page 19: Informations Générales De Sécurité

    SAFETY INSTRUCTIONS FABRICATOR 211i 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT AVERTISSEMENT CAUSER DES BLESSURES. LA VAPEUR ET LE LIQUIDE DE REFROID- Des pièces en mouvement, tels des ventila- ISSEMENT BRULANT SOUS PRESSION teurs, des rotors et des courroies peuvent PEUVENT BRULER LA PEAU ET LES YEUX.
  • Page 20 FABRICATOR 211i SAFETY INSTRUCTIONS Portez en permanence des gants de protection et des vête ments ignifuges pour la protection de la peau et des AVERTISSEMENT vêtements contre les étincelles et le laitier. Gardez col, manches et poches boutonnés. Il ne faut pas remonter N’effectuez...

  • Page 21: Principales Normes De Securite

    SAFETY INSTRUCTIONS FABRICATOR 211i Mise en Garde AVERTISSEMENT Ouvrez la vanne de bouteille légèrement. Les bouteilles sont sous haute pression. Manip- Si vous l’ouvrez trop en grand, la bouteille ulez-les avec précautions. Des accidents sérieux pourrait se renverser. Quand vous ouvrez/ peuvent résulter d’une mauvaise manutention...

  • Page 22: Graphique De Symbole

    FABRICATOR 211i SAFETY INSTRUCTIONS 1.09 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 23: Declaration Of Conformity

    Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Tom Wermert Senior Brand Manager Thermal Arc Victor Technologies International, Inc 16052 Swingley Ridge Road Chesterfield, Missouri 63017 USA...

  • Page 24: Emf Information

    FABRICATOR 211i SAFETY INSTRUCTIONS 1.11 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the...

  • Page 25: Introduction

    WARNING A WARNING gives information regarding pos- 2.04 Description sible personal injury. The Thermal Arc Fabricator 211i is a self contained single phase multi process welding system that is capable of performing MIG (GMAW/FCAW), STICK (SMAW) and CAUTION LIFT TIG (GTAW) welding processes. The Power Source...

  • Page 26: Transportation Methods

    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...

  • Page 27: Safety And Installation

    STICK / TIG 100 110 120 130 140 150 160 170 180 190 200 210 220 Welding Current (AMPS) Art # A-11265 Figure 3-1: Fabricator 211i Duty Cycle on 208/230V AC FABRICATOR 211i STICK SAFE OPERATING REGION (MIG, TIG & STICK)

  • Page 28: Specifications

    FABRICATOR 211i SAFETY/INSTALLATION 3.02 Specifications Description Fabricator 211i Multi Process 3 in 1 Welder Power Source Part No. W1004200 Power Source Dimensions H17.12" x W10.47" x D 24.29" (435mm x 266mm x D617mm) Power Source Mass 57.3lb (26kg) Cooling Fan Cooled...
  • Page 29 Source (Based on Article 630, National Electrical Code) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such...

  • Page 30: Environment

    FABRICATOR 211i SAFETY/INSTALLATION 3.03 Environment This Power Source is designed for use in environments with increased hazard of electric shock. 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.

  • Page 31: Electricity Supply

    • Correctly earthed (electrically) in accordance with local regulations. • Connected to the correct size power point and fuse as per the Specifications on page 3-2. WARNING The Fabricator 211i must be electrically connected by a qualified electrical trades-person. Damage to the PCA (Power Control Assembly) could occur if 265 VAC or higher is applied to the Primary Power Cable WARNING ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power. DO NOT TOUCH live electrical parts.
  • Page 32 FABRICATOR 211i SAFETY/INSTALLATION Electrical Input Requirements Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and inspection required.
  • Page 33 SAFETY/INSTALLATION FABRICATOR 211i 208/230V, 50A, 1Ø 20A, 1Ø The Adapter enable connection to all these 115 VAC Adapter power outlets 15A, 1Ø Primary Power Cable Art# A-11240 Figure 3-4: Electrical Input Connections Manual 0-5158 SAFETY/INSTALLATION...

  • Page 34: Electromagnetic Compatibility

    FABRICATOR 211i SAFETY/INSTALLATION 3.07 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.

  • Page 35: Victor Regulator

    SAFETY/INSTALLATION FABRICATOR 211i 2. Maintenance of Welding Equipment The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions.
  • Page 36 FABRICATOR 211i SAFETY/INSTALLATION NOTE Regulators purchased with open 1/8”, 1/4”, 3/8”, or 1/2” NPT ports must be assembled to their intended system. 1. Note the maximum inlet pressure stamped on the regulator. DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator.
  • Page 37 SAFETY/INSTALLATION FABRICATOR 211i 7. Relief Valve (where provided): The relief valve is designed to protect the low pressure side of the regulator from high pres sures. Relief valves are not intended to protect down stream equipment from high pressures. WARNING DO NOT tamper with the relief valve or remove it from the regulator.

  • Page 38: Leak Testing The System

    FABRICATOR 211i SAFETY/INSTALLATION 3.09 Leak Testing The System Leak test the system before putting into operation. 1. Be sure that there is a valve in the downstream equipment to turn off the gas flow. 2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure.

  • Page 39: Volt-Ampere Curves

    SAFETY/INSTALLATION FABRICATOR 211i 3.12 Volt-Ampere Curves Voltage-Amperage Curves shows maximum voltage and amperage output capabilities of welding power source. Curves of other settings fall between curves shown. Art # A-11297 Figure 3-8: Fabricator 211i Volt-Ampere Curves Manual 0-5158 3-13 SAFETY/INSTALLATION...
  • Page 40 FABRICATOR 211i SAFETY/INSTALLATION Notes SAFETY/INSTALLATION 3-14 Manual 0-5158...

  • Page 41: Operation

    INSTALLATION/SETUP FABRICATOR 211i SECTION 4: OPERATION 4.01 Fabricator 211i Power Source Controls, Indicators And Features POWER FAULT 24.5 LIFT TIG STICK SOFT HARD WIRESPEED DOWNSLOPE (S) ARC FORCE (%) INDUCTANCE Art # A-11241_AB Figure 4-1: Front and Control Panel Figure 4-2: Rear Panel Connections...
  • Page 42 FABRICATOR 211i INSTALLATION/SETUP 1. Power Indicator The power indicator is illuminated when the correct mains power is applied to the power source and when the ON/OFF switch located on the rear panel is in the ON position. 2. Thermal Overload Indicator (Fault Indicator) This welding power source is protected by a self resetting thermostat.
  • Page 43 INSTALLATION/SETUP FABRICATOR 211i 4. Wirespeed/Amperage Control In MIG mode, the Wirespeed/Amperage control 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 depends upon the material type and the welding application.
  • Page 44 FABRICATOR 211i INSTALLATION/SETUP 8. Negative Welding Output Terminal The negative welding terminal is used to connect the welding output of the power source to the appropriate weld- ing 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.
  • Page 45 INSTALLATION/SETUP FABRICATOR 211i 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.
  • Page 46 FABRICATOR 211i INSTALLATION/SETUP 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 released, thus eliminating the need for the operator to hold the torch trigger.
  • Page 47 21. Cooling Fan When the Fabricator 211i is powered up, the fan turns on for approximately 3 seconds and turns off. At the time of welding, the fan turns on when welding is started, and will stay on for 10 minutes after you stop welding. After the 10 minutes has elapsed, the fan will turn off.

  • Page 48: Attaching The Tweco Fusion 220A Mig Gun

    FABRICATOR 211i INSTALLATION/SETUP 4.02 Attaching The TWECO Fusion 220A MIG Gun Fit the Fusion MIG gun to the power source by pushing the MIG gun connector into the MIG gun adapter and screwing the locking screw clockwise to secure the MIG gun to the MIG gun adapter.

  • Page 49: Installing 33/44 Lb Spool (12" Diameter)

    INSTALLATION/SETUP FABRICATOR 211i 4.03 Installing 33/44 lb Spool (12" diameter) As delivered from the factory, the unit is fitted with a Wire Spool Hub which accepts a Spool of 33/44 lb. or 12" diameter. Installation of wire spool, Refer to Figure 4-6.

  • Page 50: Installing 12.5 Lb Spool ( 8" Diameter)

    FABRICATOR 211i INSTALLATION/SETUP 4.04 Installing 12.5 lb Spool ( 8" diameter) In order to fit a 12.5 lb spool (8" diameter) assemble parts in the sequence shown in Figure 4-7. Installation of wire spool: 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

  • Page 51: Installing 1 Lb Spool (4" Diameter)

    INSTALLATION/SETUP FABRICATOR 211i 4.05 Installing 1 lb Spool (4" diameter) In order to fit a 1 lb spool (4" diameter) assemble parts in the sequence shown in Figure 4-8. Installation of wire spool: 1. Remove Wire Spool Hub Retaining Clip. Grasp the loop and pull.

  • Page 52: Inserting Wire Into The Wire Feed Mechanism

    FABRICATOR 211i INSTALLATION/SETUP 4.06 Inserting Wire Into The Wire Feed Mechanism Release the tension from the pressure arm by turning the adjustable wire drive tension knob in an anti-clockwise direction. Then push the tension knob toward the back of the machine to releases the pressue arm (Figure 4-9). With the MIG welding wire feeding from the bottom of the spool (Figure 4-10) pass the electrode wire through the inlet guide, between the rolls, through the outlet guide and into the MIG gun.

  • Page 53: Feed Roll Pressure Adjustment

    INSTALLATION/SETUP FABRICATOR 211i 4.07 Feed Roll Pressure Adjustment The pressure (top) roll applies pressure to the grooved feed roll via an adjustable pressure knob. 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.

  • Page 54: Wire Reel Brake

    FABRICATOR 211i INSTALLATION/SETUP 4.09 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.

  • Page 55: Setup For Mig (Fcaw) Welding With Flux Core (Gasless) Wire

    INSTALLATION/SETUP FABRICATOR 211i WARNING Before connecting the work clamp to the work make sure the Electricity 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.
  • Page 56 FABRICATOR 211i INSTALLATION/SETUP E. Switch the LOCAL/REMOTE switch inside the wire feed compartment to LOCAL to use the Power Sources Wirespeed and Voltage controls. F. Switch the MIG GUN/SPOOL GUN switch inside the wire feed compartment to MIG GUN. WARNING Before connecting the work clamp to the work make sure the Electricity Supply is switched off.

  • Page 57: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    INSTALLATION/SETUP FABRICATOR 211i 4.12 Setup For SPOOL GUN MIG (GMAW) Welding With Gas Shielded MIG Wire Select MIG mode with the Process Selection Control. For setup and operation of the spool gun, please refer to the spool gun operations manual.

  • Page 58: Setup For Lift Tig (Gtaw) Welding

    NOTE A Thermal Arc 26V TIG torch with an 8 pin plug must be used to turn the weld current on/off via the TIG torch trigger switch to TIG weld OR a Thermal Arc Foot Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.
  • Page 59 8 pin plug must be used to turn the TIG Torch weld current on/off via the TIG torch trigger switch to TIG weld OR a Thermal Arc Foot TIG Remote Control Control with an 8 pin plug must be used to turn the weld current on/off as well as providing remote control of the weld current.

  • Page 60: Setup For Stick (Smaw) Welding

    FABRICATOR 211i INSTALLATION/SETUP 4.14 Setup For STICK (SMAW) Welding A. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufac- turer. 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.

  • Page 61: Troubleshooting

    TROUBLESHOOTING FABRICATOR 211i SECTION 5: TROUBLESHOOTING 5.01 Basic Troubleshooting-Power Source Faults NOTE In the table below, words "Faulty Power PCB, Control PCB or Display PCB" will appear, refer to relative sections to detect and confirm the fault. Refer to Section 5.06, 5.08, 5.09 and 5.10/Item 1/Power PCB to detect whether the Power PCB is defective.

  • Page 62: Routine Service And Calibration Requirements

    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.
  • Page 63 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.

  • Page 64: Check Unit Before Applying Power

    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...

  • Page 65: Test Equipment And Tools Needed For Troubleshooting And Servicing

    TROUBLESHOOTING FABRICATOR 211i Checking Unit Before Applying Power Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit. Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing case.

  • Page 66: Preliminary Dc Bus Measurement Of The Power Pcb

    FABRICATOR 211i TROUBLESHOOTING 5.06 Preliminary DC Bus Measurement of the Power PCB WARNING Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the mains supply plug is disconnected from receptacle. Art # A-10750 Voltage with Supply...

  • Page 67: Preliminary Check Of The Control Pcb

    TROUBLESHOOTING FABRICATOR 211i 5.07 Preliminary Check of the Control PCB Read and follow safety information in Section 5.03 before proceeding. Art # A-10757_AB IGBT Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 3 IGBT V8 & V8-1 0.2 –...

  • Page 68: Check Main Input Rectifier

    FABRICATOR 211i TROUBLESHOOTING DIODE Testing Multimeter Lead Placement Diode Voltage Positive meter lead to testpoint 10 DIODE V7 & V7-1 0.2 – 0.8 VDC Negative meter lead to testpoint 11 Positive meter lead to testpoint 12 DIODE T18, T19, T20, T21 0.2 –...

  • Page 69: Dc Bus Voltage Measurement

    TROUBLESHOOTING FABRICATOR 211i 5.09 DC Bus Voltage Measurement Apply voltage to the Power Source. There are extremely dangerous voltage and power levels present inside these Power Sources. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

  • Page 70: Pcb Connectors

    FABRICATOR 211i TROUBLESHOOTING 5.10 PCB Connectors Power PCB Art # A-10753 IN Header Pin Pin function Signal +15V 15 VDC IGBT 1 pwm drive signal, 15V p-p square wave 15 VDC pk IGBT 2 pwm drive signal, 15V p-p square wave...
  • Page 71 TROUBLESHOOTING FABRICATOR 211i DY2 Header Pin Pin function Signal +24V 24 VDC 0 VDC -24V -24 VDC Table 5-14 DY2 Header pin function (connects to SOURCE header on control PCB) DY1 Header Pin Pin function Signal +24V (solenoid positive) 24 VDC...
  • Page 72 FABRICATOR 211i TROUBLESHOOTING Spoolgun PCB Art # A-10754 MT-IN Header Pin Pin function Signal Motor positive from Power PCB 24 VDC Motor negative from Power PCB 0 VDC Motor negative 0 VDC Motor positive 24 VDC Table 5-21 MT-IN Header pin function (Connects to MD header on Power PCB & to Motor)
  • Page 73 TROUBLESHOOTING FABRICATOR 211i Display PCB Art # A-10755 GUN Header Pin Pin function Signal +24V trigger positive (0V when trigger closed) 24 VDC 0VDC 0 VDC Table 5-26 GUN Header pin function (connects to GUN header on control PCB) GUN1 Header Pin...
  • Page 74 FABRICATOR 211i TROUBLESHOOTING R-G Header Pin Pin function Signal Spool gun motor negative 24 VDC +24V trigger positive (0V when trigger closed) 24 VDC 0VDC 0 VDC Spool gun motor 0 VDC -12VDC -12 VDC +12VDC +12 VDC Remote amps...
  • Page 75 TROUBLESHOOTING FABRICATOR 211i PFC Header Pin Pin function Signal +5 VDC PFC OK signal, 1= PFC OK Table 5-35 PFC Header pin function (connects to JC header on Power PCB) QF/DY Header Pin Pin function Signal +24V (VRD positive) 24 VDC...
  • Page 76 FABRICATOR 211i TROUBLESHOOTING OT1 Header Pin Pin function Signal Diode thermostat Diode thermostat Table 5-43 OT1 Header pin function (connects to igbt thermostat) OT2 Header Pin Pin function Signal Igbt thermostat (0VDC when thermostat closed) 0 VDC Table 5-44 OT2 Header pin function (connects to NTCS header on Power PCB)

  • Page 77: Dip Switch Settings, Control Pcb

    5.11 DIP Switch Settings, Control PCB DIP Switch SW0, control PCB Art # A-10757_AB SW0 No. SW0 Position Set to OFF for Fabricator 211i Set to ON for Fabricator 211i Table 5-46 SW0 Dip Switch Position Manual 0-5158 5-17 TROUBLESHOOTING...

  • Page 78: Calibration

    FABRICATOR 211i TROUBLESHOOTING 5.12 Calibration Calibration Art # A-10757_AB Set SW0 position 1 to ON while the power source is turned off, to allow calibration of output volts & amps. Output Current Calibration Select STICK mode on the front panel.
  • Page 79 TROUBLESHOOTING FABRICATOR 211i Wire Speed Calibration NOTE: these adjustments are on the wiring side of the main Power module circuit board. Art # A-10758 Select MIG mode on the front panel. Remove the load from the output terminals. Set MIG output voltage to maximum.

  • Page 80: Circuit Diagram

    FABRICATOR 211i TROUBLESHOOTING 5.13 Circuit Diagram 1 +24VDC BLACK BLACK +24CDC 1 N/A 2 WHITE WHITE WHITE WHITE +24VDC WHITE WHITE 1 +5VDC INPUT 230V/115V YELLOW OUTPUT CONTROL SIGNAL 2 TO U15 PIN6 1 PWM RETURN BLACK 2 PWM (MOTOR DRIVER 5VDC PEAK)

  • Page 81: Main Circuit Description

    TROUBLESHOOTING FABRICATOR 211i 5.14 Main Circuit Description Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage. The mains supply voltage is connected via a double pole switch to the input rectifier Q1 through an EMC filter. Overvoltage protection is provided by varistor CY1.
  • Page 82 FABRICATOR 211i TROUBLESHOOTING Notes TROUBLESHOOTING 5-22 Manual 0-5158...

  • Page 83: Disassembly Procedure

    DISASSEMBLY PROCEDURE FABRICATOR 211i SECTION 6: DISASSEMBLY PROCEDURE 6.01 Safety Precautions for Disassembly Read and follow safety information in Section 5.03 before proceeding. Unplug unit before beginning Disassembly procedure. Manual 0-5158 DISASSEMBLY PROCEDURE...

  • Page 84: Control Pcb Removal

    FABRICATOR 211i DISASSEMBLY PROCEDURE 6.02 Control PCB Removal Read and follow safety information in Section 5.03 before proceeding with disassembly. Remove cover panel before remove the control PCB. 1. M4 Screw. Remove 4 screws from Control PCB. 2. Disconnect DRIVE harness from DRIVE connector.

  • Page 85: Front Panel Assembly Removal

    DISASSEMBLY PROCEDURE FABRICATOR 211i 6.03 Front Panel Assembly Removal Read and follow safety information in Section 5.03 before proceeding with disassembly 1. Screws on front panel. 2. Positive output terminal bolts. Unscrew output terminal bolts. 3. Negative output terminal bolts. Unscrew Negative output terminal bolts.

  • Page 86: Display Pcb Removal

    FABRICATOR 211i DISASSEMBLY PROCEDURE 6.04 Display PCB Removal Read and follow safety information in Section 5.03 before proceeding with disassembly. 1. Remove Control Panel screw (4). 2. Display PCB. 3. Disconnect the harnesses from the connectors. Art # A-11352 DISASSEMBLY PROCEDURE...

  • Page 87: Back Panel Removal

    DISASSEMBLY PROCEDURE FABRICATOR 211i 6.05 Back Panel Removal Read and follow safety information in Section 5.03 before proceeding with disassembly. 1. Remove the screws on the back . 2. Remove Rear Panel screws . 3. Remove The Ground Wire. 4. Wire from Power PCB.

  • Page 88: Power Switch S1 And Power Cord Removal

    FABRICATOR 211i DISASSEMBLY PROCEDURE 6.06 Power Switch S1 and Power Cord Removal Read and follow safety information in Section 5.03 before proceeding with disassembly. 1. Gas inlet. Remove gas inlet from rear panel. 2. Remove The Ground Wire. 3. Remove the screws which control the supply cord.

  • Page 89: Base Panel Removal

    DISASSEMBLY PROCEDURE FABRICATOR 211i 6.07 Base Panel Removal Read and follow safety information in Section 5.03 before proceeding with disassembly. 1. Remove Wire Feeder Screws. 2. Remove inductor assembly Screws. 3. Remove Power PCB assembly Screws. 4. Remove Center Panel Screws.
  • Page 90 FABRICATOR 211i DISASSEMBLY PROCEDURE Notes DISASSEMBLY PROCEDURE Manual 0-5158...

  • Page 91: Assembly Procedures

    ASSEMBLY PROCEDURE FABRICATOR 211i SECTION 7: ASSEMBLY PROCEDURES 7.01 Installing Base Panel 1. Power PCB assembly. 2. Install Power PCB assembly screws. 3. Install inductor assembly Screws. 4. Install Wire Feeder Screws. 5. Install Center Panel Screws. Art # A-10766...

  • Page 92: Installing Back Panel

    FABRICATOR 211i ASSEMBLY PROCEDURES 7.02 Installing Back Panel 1. Install gas inlet. 2. Install the power supply cord and the screws. 3. Install fan. 4. Reconnect the pipe to gas inlet and the screw. 5. Reconnect the supply wires. 6. Reconnect the supply wires which connect to power PCB.

  • Page 93: Installing Front Panel

    ASSEMBLY PROCEDURE FABRICATOR 211i 7.03 Installing Front Panel 1. Reinstall output Dinse on front panel with 27mm wrench. Reconnect positive output terminal bolts and tighten with 17mm wrench. ( Note: reconnect wires, pay attention to the wire colour.) Reconnect negative output terminal bolts and tighten with 17mm wrench. (note: reconnect wires and pay at- tention to the wire colour.)

  • Page 94: Installing Control Pcb And Clear Cover Sheet

    FABRICATOR 211i ASSEMBLY PROCEDURES 7.04 Installing Control PCB and Clear Cover Sheet Refer to diagram on page 7-5. 1. Install 4 screws. 2. Plug harness into DRIVE connector. 3. Plug harness into SOURCE connector. 4. Plug harness into CR connector.
  • Page 95 ASSEMBLY PROCEDURE FABRICATOR 211i Art # A-10760 Art # A-10769 Manual 0-5158 ASSEMBLY PROCEDURES...

  • Page 96: Installing Cover Panel And Door Panel

    FABRICATOR 211i ASSEMBLY PROCEDURES 7.05 Installing Cover Panel and Door Panel 1. Install Ground Screw, which connects the ground wire to the cover. 2. Install cover panel and door panel. Install Screws. Tighten screws. Art # A-11363_AB Install Screws Tighten Screws Front&Rear...

  • Page 97: Key Spare Parts

    REPLACEMENT PARTS FABRICATOR 211i SECTION 8: KEY SPARE PARTS 8.01 Tweco Weldskill 220A MIG Gun (Used until January, 2013) MIG Gun Part No: WS220TA-15-3035 Art # A-11248_AB Figure 8-1: Tweco WeldSkill 220 MIG Gun TWECO WELDSKILL 220A MIG GUN PARTS ITEM PART NO.

  • Page 98: Tweco Fusion 220A Mig Gun

    Conduit Assembly* WS42-3035-15 Tweco Rear Connector 350-174H Tweco Control Wire & Plug 35K-350-1 Thermal Arc Control Wire WS-354-TA-LC Table 8-2: Tweco Fusion 220A MIG Gun Parts Figure 8-2 ** Patent Pending * Refer to Tweco Catalog No. 64-2103 for additional options.

  • Page 99: Power Source Spare Parts

    REPLACEMENT PARTS FABRICATOR 211i 8.03 Power Source Spare Parts Figure 8-3 Manual 0-5158 REPLACEMENT PARTS...
  • Page 100 Shroud, WF Motor, 211i W7005616 Label, Identification, Fab 211i (not shown) W7005634 Setup Chart English Version (not shown) 7978044PKD Large Spring, for One Pound Spool (not shown) W7005635 Latch, door, slide (not shown) Table 8-2: Fabricator 211i Parts REPLACEMENT PARTS Manual 0-5158...

  • Page 101: Optional Accessories

    OPTIONAL ACCESSORIES FABRICAOTR 211i SECTION 9: OPTIONAL ACCESSORIES 9.01 Optional Accessories 26V TIG Torch & Accessories (required for TIG welding). Part No. W4014603 12.5 ft cable length; 12.5 ft gas hose length; 8 pin control plug; 1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8"...

  • Page 102: Statement Of Warranty

    STaTEMENT OF WaRRaNTY Effective 08/01/2011 This warranty supersedes all previous VICTOR TECHNOLOGIES® warranties. LIMITED WARRANTY: Victor Technologies 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 VICTOR TECHNOLOGIES®...

  • Page 103: Warranty Schedule

    WaRRaNTY SCHEDULE 5 Years Parts* / 3 Years Labor ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster Portafeed, Ultrafeed, Ultima 150, WC 100B * 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards. * 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Victor Regulator for Fabricator 181i (No labor)
  • Page 104 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph: 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph: 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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