Tweco VS212 User Manual

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VS 212

PORTAFEED

CC/CV SEMIAUTOMATIC SOLID STATE CONTROLLED WIRE FEEDER

Art # A-07123

Operating Manual

Revision: AD Issue Date: March 3, 2011 Manual No.: 0-4994 Operating Features:

15-100

800

IPM

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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 ser vice agency call 1-800-752-7621, 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.

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 marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

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

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WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Portafeed VS 212 CC/CV Semiautomatic Solid State Controlled Wire Feeder Instruction Manual Number 0-4994 for: Part Numbers: W3512003 and W3512004

Published by: Thermadyne Industries Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

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: April 9, 2007 Revision AD Date: March 3, 2011

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

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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 ..................................................................... 1-9

1.07 Graphique de Symbole ................................................................................. 1-10

1.08 Declaration Of Conformity ............................................................................ 1-11

SECTION 2:

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

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

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

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

2.04 General ........................................................................................................... 2-2

2.05 Product Specifications ................................................................................... 2-3

2.06 Features/Benefits ............................................................................................ 2-4

2.07 Front Panel Controls And Connections ........................................................... 2-5

2.08 Rear Panel Controls And Connections ............................................................ 2-6

2.09 Internal Controls And Connections ................................................................. 2-7

2.10 Power Source Compatibility ........................................................................... 2-8

2.11 Options and Accessories ................................................................................ 2-8

SECTION 3:

INSTALLATION ...................................................................................... 3-1

3.01 Connections ................................................................................................... 3-1

3.02 Installation Of Wire Spool ............................................................................... 3-2

3.03 Adjustment Of Spool Tension ......................................................................... 3-3

3.04 Input And Output Wire Guide Installation ....................................................... 3-3

3.05 Selection And Installation Of Feed Rolls ......................................................... 3-4

3.06 MIG Gun Compatibility And Installation and Removal .................................... 3-4

3.07 Threading Wire Into Feedhead ........................................................................ 3-5

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 Prewelding Procedure

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 ................................................................................ 4-3

4.07 Changing Meter Functions .............................................................................. 4-4

4.08 Meter Hold Function ....................................................................................... 4-4

4.09 Operation Hours Display................................................................................. 4-5

4.10 Protection And Safety Circuits ........................................................................ 4-5

.................................................................................... 4-1

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TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 5:

SERVICE ............................................................................................. 5-1

5.01 Cleaning Of The Unit .......................................................................................5-1

5.02 Cleaning Of The Feed Rolls ............................................................................. 5-1

5.03 Troubleshooting Guide ................................................................................... 5-1

5.04 Troubleshooting Hints .................................................................................... 5-1

5.05 Common Symptoms ...................................................................................... 5-1

SECTION 6:

PARTS LIST .......................................................................................... 6-1

6.01 Equipment Identification................................................................................. 6-1

6.02 How To Use This Parts List ............................................................................ 6-1

6.03 External Replacement Parts ............................................................................ 6-2

6.04 Internal Replacement Parts ............................................................................ 6-3

6.05 Wire Feeder Replacement Parts ..................................................................... 6-4

APPENDIX 1:

DRIVE ROLL KITS ................................................................................... A-1

APPENDIX 2:

OPTIONS AND ACCESSORIES ..................................................................... A-2

APPENDIX 3:

MIG GUN CARTRIDGE SYSTEM ................................................................... A-3

APPENDIX 4: SYSTEM SCHEMATIC ..................................................................... A-4

Statement of Warranty

Warranty SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

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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.

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 American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL

INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

. Do not use worn, damaged, undersized, or poorly spliced

cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor level.

15. Keep all panels and covers securely in place.

WARNING

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

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

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

Manual No. 0-4994 1-1 SAFETY INSTRUCTIONS

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PORTAFEED VS 212

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

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

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

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

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

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 air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

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 yourself and others from flying sparks and hot metal.

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

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

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

. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

WARNING

WELDING can cause fire or explosion.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All12

Heavy Over 6 in., 150 mm 5 or 6Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

SAFETY INSTRUCTIONS 1-2 Manual No. 0-4994

Page 9

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

recommended.

2. Wear proper body protection to protect skin.

WARNING

PORTAFEED VS 212

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

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

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

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

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

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

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

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

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

2. Stop engine before installing or connecting unit.

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

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

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

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

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

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

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

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

Manual No. 0-4994 1-3 SAFETY INSTRUCTIONS

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PORTAFEED VS 212

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126.

Safety and Health Standards, OSHA 29 CFR 1910, fr om 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.

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear 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.

. Do not coil or drape cable around the body.

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

ABOUT PACEMAKERS:

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 Standar d 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.

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

SAFETY INSTRUCTIONS 1-4 Manual No. 0-4994

Page 11

1.03 Symbol Chart

Note that only some of these symbols will appear on your model.

PORTAFEED VS 212

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

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.

Burnback Time

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

Manual No. 0-4994 1-5 SAFETY INSTRUCTIONS

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

Page 12

PORTAFEED VS 212

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). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT F

AIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.05 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits inter nes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

3 Isolez-vous de la pièce à souder et de la mise à la terre au

moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porte-électrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

. N’utilisez pas de câbles électriques usés, endommagés, mal

épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

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 le circuit de soudage (terre).

12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15. Fermez solidement tous les panneaux et les capots.

SAFETY INSTRUCTIONS 1-6 Manual No. 0-4994

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PORTAFEED VS 212

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’ arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibr uit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant

relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau

Brassage for t au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

oudage á l'arc avec électrode enr obees (SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

mince moins de 1 po. (25 mm) 2 ou 3

épais plus de 6 po. (150 mm) 5 ou 6

mince moins de 1/8 po. (3 mm) 4 ou 5

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz avec fil plein (GMAW)

Soudage á l'arc sous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydr ogène atomique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

Manual No. 0-4994 1-7 SAFETY INSTRUCTIONS

Page 14

PORTAFEED VS 212

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 l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’a rc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitezles avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindr e des matér iaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

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 bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

AVERTISSEMENT

. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil au tubecontact lorsqu’inutilisé après le soudage.

11. Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

SAFETY INSTRUCTIONS 1-8 Manual No. 0-4994

Page 15

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

PORTAFEED VS 212

1. Portez toujours un écran facial en travaillant sur un accumulateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteur s ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

1.06 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, 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, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 As-

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR PEUT BRULER LA PEAU ET LES YEUX.

sociation canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

Manual No. 0-4994 1-9 SAFETY INSTRUCTIONS

Page 16

PORTAFEED VS 212

1.07 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Sous Tension

Hors Tension

Tension dangereuse

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Fusible

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur Transformateur-Redresseur

Distant

Facteur de Marche

Pourcentage

Panneau/Local

Soudage Arc Electrique Avec Electrode Enrobé (SMAW)

Soudage á L’arc Avec Fil Electrodes Fusible (GMAW)

Soudage á L’arc Avec Electrode Non Fusible (GTAW)

Decoupe Arc Carbone (CAC-A)

Courant Constant

Tension Constante Ou Potentiel Constant

Haute Température

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Torch de

Soudage

Purge Du Gaz

Mode Continu de

Soudure

Soudure Par Point

Duréc du Pulse

Appuyez pour dèruarer l’alimentation du fils et la soudure, le relâcher pour arrêter.

Maintenez appuyez pour pré-dèbit, relailez pour initier l'arc. Appuyez pour arrêter l'arc, et mainteuir pour pré-dèbit.

Durée de Pré-Dèbit

Durée de Post-Dèbit

Détente à 2-Temps

Détente à 4-Temps

Probléme de Terre

115V 15A

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de PriseSource Auxiliaire

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Pouces Par Minute

Mètres Par Minute

Art # A-07639

SAFETY INSTRUCTIONS 1-10 Manual No. 0-4994

Page 17

PORTAFEED VS 212

1.08 Declaration Of Conformity

Manufacturer: Thermadyne Corporation Address: 82 Benning Street

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:

• CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

•

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

• ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting 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.

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 W

ard Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Manual No. 0-4994 1-11 SAFETY INSTRUCTIONS

Page 18

PORTAFEED VS 212

SAFETY INSTRUCTIONS 1-12 Manual No. 0-4994

Page 19

SECTION 2:

INTRODUCTION

PORTAFEED VS 212

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the rear panel. In some cases, the nameplate may be attached to the control panel. Equipment which does not have a name plate such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete infor mation concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful infor mation concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link:

http://www.thermalarc.com

Include all equipment identification numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to uncrate the unit.

Manual No. 0-4994 2-1 INTRODUCTION

Page 20

PORTAFEED VS 212

2.04 General

The PORTAFEED® VS 212 is a portable, solid state controlled, voltage sensing wire feeder that operates on arc voltage and can be used with most constant voltage (CV) and constant current (CC) DC-type power sources. The only connection required between the power source and the wire feeder is the welding cable.

The unique design of this wire feeder allows operation in a constant wire feed speed mode when used with CV power sources, and in a voltage sensing wire feed speed mode (wire feed speed varies with respect to arc voltage) when used with CC power sources.

The PORTAFEED VS 212’s steel-reinforced, flameretardant case totally encloses the solid state control circuitry, welding wire, and wire drive system. A hinged, latched door allows quick and easy access to the contactor, welding wire, and feedhead assembly that features quick change, gear-driven drive rolls.

ORTAFEED VS 212 comes with:

• Robust injection molded case

• Changeable MIG gun cartridge system

• Digital display (model W3512002 only)

• Heavy duty contactor

The PORTAFEED VS 212, includes the following features:

1. An on/off rocker switch

2. A wire feed speed control knob

3. A welding gun holder

4. A carrying handle

5. A contactor

6. A gas valve

7. A CC/CV mode switch

8. An input circuit breaker for complete system protection

9. An electronic controlled protection circuitry to protect against an undervoltage, an overvoltage, a voltage spike, a shorted or locked motor, a shorted contactor coil, and a shorted gas valve

10.An electronic controlled dynamic brake An electronic controlled current limit to motor

11.

12.An electronic controlled start circuit for improved arc starting

13. A low voltage gun trigger circuit for operator safety

• Internal parts storage

• Power cable and drive rolls

• Gas valve solenoid

14.A drive roll kit

15.In addition to these standard features, specification number W3512002 also includes a digital display for wire feed speed/amps and arc voltage, with 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 2-2 Manual No. 0-4994

Page 21

2.05 Product Specifications

Input Voltage Range 15-100 VDC Maximum Input Current 8 Amps Wire Speed Range

(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. (20 kg)

Drive Rolls 2 (Both Gear Driven) Welding Current (I) 425A at 60% Duty Cycle Welding Gun Inlet Size (Std)

Tweco Style #4 Maximum Shielding Gas

Inlet Pressure

PORTAFEED VS 212

Portafeed VS212 Specifications

50-800 IPM (1.27 - 20.32 MPM)

5/8'' (16mm) Nominal

100 psi (6.9 bar)

Degree of Protection IP23C Weight (Less wire) 44 lbs (20 kg)

Approvals IEC 60974-5 (CE)

CSA NRTL/C (pending) NEMA EW3

Table 2-1 Specifications

Art # A-07130

15.3 in. 289mm

21.3 in. 541mm

9.4 in. 239mm

Figure 2-1: Dimensional Information

Manual No. 0-4994 2-3 INTRODUCTION

Page 22

PORTAFEED VS 212

2.06 Features/Benefits

Robust injection molded case

Long lasting and unbreakable.

Changeable MIG gun cartridge system

Patent Pending. No external MIG gun adapters needed for other style guns with the integrated cartridge system.

Digital display (Model # W3512002) Monitor wire speed, amps, volts, arc time and meter hold. Makes parameter set-up easy.

Potted printed circuit boards

Protected from dirt, dust and moisture for longer life.

Heavy duty contactor

Longer life on higher amperage applications.

Internal parts storage

On the job storage for drive rolls, tips, nozzels, etc.

Machined feed head & tension arms

Insures wire alignment tolerances of ±002”.

Inch switch & purge switch

‘Cold’ inching of wire at set wire feed speed and purging of gas without running wire.

Gun trigger hold (2T/4T)

Allows standard or latched gun trigger.

Heavy duty, removable voltage sensing lead

Allows storage of lead with less lead breakage.

MIG gun holder

A place to hold your MIG gun while not welding.

Lifting eye

Allows for hanging or work area.

Gas valve solenoid

Controls ‘on/off’ flow of shielding gases.

Wire speed high/low range

Gives a finer dial control of larger diameter flux cored wires.

Ready to weld

Supplied with 2ft (.7m) power cable, Tweco connectors and .045in (1.2mm) drive rolls for hard/ tubular wire. Geared top & bottom drive rolls. Excellent traction on the wire.

Quick change drive rolls

Change the drive rolls without tools.

moving of the feeder over the

INTRODUCTION 2-4 Manual No. 0-4994

Page 23

2.07 Front Panel Controls And Connections

(4) Arc Voltage Meter

(3) Wire Feed Speed/Amp Meter

PORTAFEED VS 212

Art # A-07136_AB

(2) Wire Feed Speed Control

(1) On/Off Power Switch

(9) Welding Gun Cable Connection

(10) Removable MIG Gun Cartridge (Tweco style shown)

Figure 2-2: Front Panel Controls and Connections

1. POWER ON/OFF SWITCH: This switch controls input power only to the wire feeder and not to the power source.

2. WIRE FEED SPEED CONTROL: This knob controls the wire feed speed. The wire feed speed control can be adjusted during setup or actual welding.

(5) Inch/Purge Switch

(6) 2T/4T Trigger Mode Selector Switch

(7) Gun Switch Receptacle

(8) Voltage Sensing Receptacle 25mm Dinse

6. TRIGGER HOLD SWITCH: This switch selects either 2 Step or 4 Step gun switch mode.

7. GUN SWITCH RECEPTACLE: The gun switch receptacle accepts the welding gun control wires. The gun switch receptacle is where a gun switch closure is inputted to the wire feeder.

3. WIRE FEED SPEED/AMP METER: The wire feed speed meter displays the actual wire feed speed output of the wire feeder. This meter can be changed to display the actual amperage output of the power source by adjusting the DIP switches located on the edge of the display board inside the unit. Refer to Section 4.07 for details.

4. ARC VOLTAGE METER: The arc voltage meter displays the actual voltage output of the power source.

5. INCH/PURGE SWITCH: Depressing the INCH portion of the switch will feed wire at a speed set by the WFS control. The wire will not be electrically hot when using the INCH switch. Depressing the PURGE portion of the switch will allow shielding gas to flow out of the welding gun without feeding wire.

8. VOLTAGE SENSING RECEPTACLE: This receptacle serves as the voltage sensing point for the wire feeder and must be connected to the work piece through the voltage sensing lead for proper operation. If the voltage sensing lead from the wire feeder and the weld cable from the power source are not connected to the work piece, the wire feeder will not work.

9. WELDING GUN CABLE CONNECTION: The welding gun cable is connected to the wire feeder at this point. Connections must be tight; otherwise, arcing or overheating could result.

10.REMOVABLE MIG GUN CARTRIDGE (Patent Pending): The whole cartridge is interchangeable to accept competitive types of MIG gun connections. No external adapters required. See Appendix 2 and 3 for installation information and to select the adapter for other MIG Gun styles, ie.

, Lincoln® or Euro.

Miller

Manual No. 0-4994 2-5 INTRODUCTION

Page 24

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

1. LIFTING EYE: Allows for hanging or moving of the feeder over the work area.

2. GAS VALVE INLET: This is where the shielding gas hose (if used) is connected to the wire feeder.

3. INPUT POWER CABLE: Provides an inlet and secure fixture for the power cable from the welding power

source.

4. WELDING GUN HOLDER: This is an insulated holder used to hold the welding gun when not welding.

INTRODUCTION 2-6 Manual No. 0-4994

Page 25

2.09 Internal Controls And Connections

Art # A-07138

(14) HUB TENSION BOLT

(13) INPUT CIRCUIT BREAKER

(12) CC/CV MODE SWITCH

PORTAFEED VS 212

(1) STORAGE BOX

(2) HIGH/LOW RANGE SWITCH

High

Low

(3) WIRE SPEED/AMP METER SELECTION DIP SWITCHES

(4) CARTRIDGE GUN LEADS

(11) PRESSURE ADJUST DEVICE

(10) INPUT WIRE GUIDE

(9) INPUT GUIDE LOCKSCREW

Figure 2-4: Internal Controls and Connections.

1. STORAGE BOX: On the job storage for drive rolls, tips, nozzels, etc. To remove, lift up to release velcro and slide it up and over the side retainers.

2. HIGH/LOW RANGE SWITCH: Gives a finer dial control over the wire speed, which is especially useful with larger diameter flux-cored wires.

3. WIRE SPEED/AMP METER SELECTION DIP SWITCHES: Set these switches to change the lower

meter display from wire speed to amperage output of the power source. Refer to Section 2.08, item 3 and section 4.07 for DIP switch setting information.

4. CARTRIDGE GUN LEADS: These two spade terminals provide the MIG gun switch connection.

5. UPPER RETAINING KNOB: This knob is used to secure the bearing feed roll. Remove this knob to change the bearing feed roll.

6. GUN CLAMP KNOB: Tighten this knob to secure the welding gun to the wire feeder.

(5) UPPER RETAINING KNOB

(6) GUN CLAMP KNOB

(7) OUTPUT GUIDE LOCKSCREW

(8) LOWER RETAINING KNOB

9. INPUT GUIDE LOCKSCREW: Tighten this screw to secure the input wire guide.

10.INPUT WIRE GUIDE: This guide is required to direct the welding wire from the wire spool to the drive feed roll.

11.SPRING TENSION KNOB: Use the spring tension knob to adjust the amount of force the bearing feed roll exerts on the welding wire.

12.CC/CV MODE SWITCH: The CC position provides a voltage sensing wire feed speed mode of operation for use with constant current (CC) power sources. The CV position provides a constant wire feed speed mode of operation for use with constant voltage (CV) power sources.

NOTE

This switch does not select a CC or CV mode of operation. The mode of operation is set by the type of power source being used.

7. OUTPUT GUIDE LOCKSCREW: T

ighten this screw

to secure the output wire guide.

8. LOWER RETAINING KNOB: This knob is used to secure the drive feed roll. Remove this knob to change the drive feed roll.

13.INPUT CIRCUIT BREAKER: This circuit breaker provides complete system protection for the wire feeder in the case of a fault or overload condition.

14.HUB TENSION BOLT: The hub tension bolt is used to adjust the wire spool tension which acts as a mechanical brake to assist in the stopping of the welding wire at the completion of a weld.

Manual No. 0-4994 2-7 INTRODUCTION

Page 26

PORTAFEED VS 212

2.10 Power Source Compatibility

Since the PORTAFEED VS 212 operates on arc voltage, it will work with most constant current (CC) or constant voltage (CV) DC type power sources.

When connected to a PORTAFEED VS 212, the maximum allowed open circuit voltage (OCV) of the power source is 100 VDC. Open circuit voltages exceeding 100 VDC will damage or shorten the life of the unit.

NOTE

Because of the high open circuit voltage associated with most CC power sources, it is recommended to place the PORTAFEED VS 212 power switch in the OFF position when not welding. This procedure will prolong the life of electrical components connected to the power input lines.

When using the PORTAFEED VS 212, there must be at least 15 VDC between the output terminals of the power source during standby and while welding. Otherwise, the unit will not have enough input voltage to operate properly.

2.11 Options and Accessories

Refer to the Appendix section of this manual for the list of available options and accessories for this product.

A contactor is a standard component of the PORTAFEED VS 212 and allows the welding wire to remain electrically cold until the gun switch trigger is depressed. This contactor is rated for 425 amps of welding current at a 60% duty cycle. If the weld current or duty cycle rating is exceeded, the contactor will be damaged or its life shortened.

Compatible Thermal Arc Power Sources

ArcMaster 400S, 300MST, 400MST, 400MSTP Fabstar® 4030 PowerMaster® Series Excel-Arc® Series Scout, Raider 10000 (engine driven)

INTRODUCTION 2-8 Manual No. 0-4994

Page 27

3.01 Connections

PORTAFEED VS 212

SECTION 3:

INSTALLATION

WARNING

CAUTION

Make sure all connections are tight; otherwise, arcing or overheating could result.

1. Using the supplied adapter, connect a weld cable from the power source to the power cable connection on the rear of the VS 212.

2. Connect a weld cable from the power source to the work connection.

3. Connect the voltage sensing lead from the wire feeder to the work connection.

GAS SUPPLY

GAS LINE

REAR VIEW

ELECTRIC SHOCK CAN KILL! DO NOT touch the metal portions of the voltage sensing lead when the power source output is on.

4. Make the proper gas line connection from the gas supply to the wire feeder gas valve (if gas will be used).

5. Attach the welding gun to the wire feeder.

6. Connect the welding gun control leads to the wire

feeder gun switch terminals located on the front of the wire feeder.

VOLTAGE SENSING

WIRE FEEDER

WELDING GUN

WORK TABLE

POWER SOURCE

WELDING CABLE

Figure 3-1: System Hook-up Outline

FRONT VIEW

WELDING CABLES

GUN SWITCH LEADS

VOLTAGE SENSING LEAD

Art # A-07194

Manual No. 0-4994 3-1 INSTALLATION

Page 28

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 allowing a 10 (4.5 kg) or 15 (6.8 kg) pound spool of wire or a 14 (6.4 kg) pound coil of wire to be used.

1. Remove the wire spool hub nut by turning counterclockwise.

2. Slide the spool of wire over the wire spool hub.

3. Make sure that the alignment pin on the hub enters

the hole in the backside of the wire spool.

4. Replace the wire spool hub nut and turn clockwise to a snug position.

NOTE

Wire Spool Hub Nut

Step

Art # A-07195

Install the welding wire spool so the wire feeds from the bottom of the spool into the input wire guide.

Alignment Pin

Wire Spool Hub

Step

Wire

Spool

Step

Figure 3-2: Wire Spool Installation

INSTALLATION 3-2 Manual No. 0-4994

Page 29

PORTAFEED VS 212

3.03 Adjustment Of Spool Tension

Adjust the wire spool tension so the wire will feed freely into the input wire guide. However, the spool of welding wire must not coast when wire feeding stops. To adjust the wire spool tension, tighten or loosen the hub tension bolt accordingly.

NOTE

Excessive tightening of the hub tension bolt will result in a shorter motor life.

Art # A-07196

3.04 Input And Output Wire Guide Installation

1. Install the input wire guide (the longer one) by

loosening the input guide lockscrew and inserting the guide into the hole in the feedhead assembly. The recessed end of the guide should be towards the wire spool. Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew.

2. Install the output wire guide (with the conical end

towards the feed rolls) in the same manner as the input guide. The conical end of the guide should be as close to the feed rolls as practical. Tighten the output guide lockscrew.

NOTE

Before tightening the input and output guide lockscrews, install the drive feed roll to help in the alignment of the wire guides.

Hub Tension Bolt

Figure 3-3: Hub Tension Bolt

Art # A-07197

Input Wire Guide

Input Guide Lockscrew

Output Wire Guide (inside)

Output Guide Lockscrew

Figure 3-4: Wire Guide Installation

Manual No. 0-4994 3-3 INSTALLATION

Page 30

PORTAFEED VS 212

3.05 Selection And Installation Of Feed Rolls

Refer to feed roll kit chart in the Appendix chapter for the proper selection and ordering of feed roll kits. Kit includes a bearing roll, a drive roll, an input wire guide, and an output wire guide for a specific wire type and size.

NOTE

All grooved feed rolls have their wire size or range stamped on the side of the roll. On rolls with different size grooves, the outer (visible when installed) stamped wire size indicates the groove in use.

Bearing feed rolls are installed by unscrewing the upper retaining knob and removing the idler gear. The bearing feed roll retaining knob is then removed from the idler gear, and the bearing feed roll is placed over the lobes on the idler gear. The bearing feed roll

retaining knob is replaced, and this assembly is returned and secured with the upper retaining knob.

Drive feed rolls are installed by removing the lower retaining knob, placing the drive feed roll over the lobes on the drive gear, and securing with the lower retaining knob.

3.06 MIG Gun Compatibility And Installation and Removal

The Portafeed VS 212 wire feeder is designed to be used with most MIG welding guns. It comes configured from the factory to work with all Tweco guns. Refer to the Section 2.11 Available Options for the ordering information of other MIG gun adapter cartridges.

1. To install the welding gun, loosen the gun clamp

knob and insert the welding gun cable end into the feedhead until it stops.

2. Tighten the gun clamp knob and connect the

welding gun control wires to the gun switch receptacle.

3. To remove, loosen the gun clamp knob and pull

the gun cable end out.

NOTE

Before inserting the welding gun into the feedhead, make sure the gun clamp does not extend into the feedhead; otherwise, the welding gun cannot be properly inserted.

NOTE

Installation of all styles of feed rolls for this feeder is identical.

WARNING

The welding wire is electrically Hot if wire is fed by depressing gun switch. Electrode contact to work piece will cause an arc with gun switch depressed.

Welding Gun Cable

Art # A-07198

Gun Clamp Knob

Figure 3-5: Installing Welding Gun

INSTALLATION 3-4 Manual No. 0-4994

Page 31

PORTAFEED VS 212

3.07 Threading Wire Into Feedhead

Refer to Figure 3-6.

WARNING

ELECTRIC SHOCK CAN KILL! Make certain the power source and wire feeder are turned OFF. Do not turn the power ON until told to do so in these instructions.

CAUTION

Use care when handling the spooled wire as the wire tends to unravel when loosened from the spool. Grasp the end of the wire firmly, and don’t let it get away from you. Make sure that the end of the wire is straight and free of burrs.

3. Lock in position with the spring tension knob. To adjust the amount of force the bearing feed roll exerts on the welding wire, turn the spring tension knob clockwise for increased force or counterclockwise for decreased force.

NOTE

If the force applied to the wire is too great, the welding wire will bird nest in the feedhead and not feed properly.

4. Turn the welding machine and wire feeder ON, and set the wire feed speed control to midrange (refer to Figure 3-7). Remove contact tube from welding gun. Refer to Gun Manual. Press the gun switch or INCH switch until wire feeds out past the gun nozzle. Place contact tube over the wire and screw into place and tighten. Cut wire off at about 1/4 inch (6 mm) from the nozzle.

1. Place end of the welding wire into the input wire guide. Feed it through the guide and over the drive roll groove closest to the feedhead casting.

2. Pass the wire through the output wire guide and into the welding gun assembly.

Art # A-07253

Wire Feed Speed Control

Figure 3-7: Wire Feed Speed Control

Pressure Adjustment Device

Pressure Arm

Output Wire GuideInput Wire GuideWelding Wire

Figure 3-6: Wire Threaded Through Guides and Locked In Position

Manual No. 0-4994 3-5 INSTALLATION

Page 32

PORTAFEED VS 212

NOTES

INSTALLATION 3-6 Manual No. 0-4994

Page 33

4.01 Prewelding Procedure

PORTAFEED VS 212

SECTION 4:

OPERATION

Follow all installation instructions for the welding power source, the welding gun, and the VS 212 CC/ CV wire feeder before attempting to weld.

1. Make sure all necessary connections have been made (refer to Connections in the Installation chapter of this manual).

2. Turn ON the power source and the wire feeder.

3. Set the CC/CV mode switch on the wire feeder to

the proper position (refer to paragraph 12, CC/CV Mode Switch on page 2-9 and figure 4-1).

Art # A-07254

High

Low

5. Depress the inch switch (if equipped) or gun

switch and adjust the wire feed speed to the desired value by means of the wire feed speed control. The wire feed speed control can be adjusted during setup or while welding.

WARNING

If the gun switch is depressed, the wire feeder will feed electrically hot welding wire. If this hot welding wire touches the work piece, a welding arc will be established.

6. Adjust the voltage control (on a CV machine) or

current control (on a CC machine) to the desired value. The voltage or current control can be adjusted during setup or while welding.

7. If using a CV power source, the output contactor

on the power source will have to be energized. In most cases, this will require a jumper to be added to the power source or a switch on the power source to be turned on. Read the power source owner’s manual for proper connections or settings required.

Figure 4-1: CC/CV Switch Location

4. If shielding gas will be used, depress the purge switch (if equipped) or gun switch and adjust the flow of gas.

WARNING

If the gun switch is depressed, the wire feeder will feed electrically hot welding wire. If this hot welding wire touches the work piece, a welding arc will be established.

Gun Switch

Gas Valve

Wire Feed

Power Source

Figure 4-2: Functional Timing Diagram

Art # A-05126

OFF

Manual No. 0-4994 4-1 OPERATION

Page 34

PORTAFEED VS 212

4.02 Welding Procedure

WARNING

In semiautomatic or automatic wire welding, the welding wire, wire reel (if used), input guide, feed rolls, output guide, feedhead, and welding gun metal parts are all ELECTRICALLY HOT.

Refer to Functional Timing Diagram on the previous page.

1. To start the weld, position the welding gun above

the work piece and depress the gun switch trigger. The solid state control then enables the gas valve, wire feed motor, and power source.

2. To end the weld, release the gun switch trigger while

pulling the welding gun away from the work piece. The solid state control then disables the gas valve, wire feed motor, and power source.

NOTE

After the weld is completed, it is recommended to pull the welding gun away from the work while releasing the gun switch. This allows the welding arc to partially extinguish at the work piece which reduces the arcing at the contactor contacts. Using this procedure will lengthen the life of the contactor contacts especially when welding at high amperage.

4.03 Welding In CC Mode vs. CV Mode

1. Welding in CC Mode: When welding with a

constant current (CC) power source, changes in wire feed speed will affect welding voltage.

To adjust the amount of welding current from the CC power source, a control knob on the power source or an optional control knob on the wire feeder will have to be adjusted.

The solid state control of a “slow run-in” circuit automatically reduces the initial wire feed speed when operating with a CC power source. This initial reduction in wire feed speed will compensate for the high open circuit voltage associated with CC power sources and improve arc starting performance.

B. Welding in CV Mode: When welding with a

constant voltage (CV) power source, changes in wire feed speed will affect welding current. Changes in wire feed speed can be obtained by adjusting the wire feed speed control knob.

To adjust the amount of welding voltage from the CV power source, a control knob on the power source or an optional control knob on the wire feeder will have to be adjusted.

4.04 Theory Of Operation

Refer to the Connection and Schematic Diagram in theAppendix chapter of this manual.

3. At the end of the work day or when welding has

been completed, it is recommended that the gas be SHUT OFF at the cylinder, and the wire feeder and power source be turned OFF.

Input power is supplied through the on/off switch (S1) and input circuit breaker (CB1) to the bridge rectifier (CR1). CR1 ensures that the proper polarity input voltage is fed into the PC boards independent of the welding polarity.

When the gun switch on the welding gun is pulled, a short is provided on the gun switch receptacle (J4) causing the wire feed motor (B1) to turn feeding wire, the gas valve (L1) to open allowing gas flow, and the contactor (K1) to close making the welding wire electrically hot.

When the gun switch on the welding gun is released, the short on the gun switch receptacle is removed causing the wire feed motor to stop feeding wire, the gas valve to close stopping gas flow, and the contactor to open making the welding wire electrically cold.

OPERATION 4-2 Manual No. 0-4994

Page 35

PORTAFEED VS 212

4.05 Adjusting Burnback Time

Burnback time is set at the factory, but the motor control printed circuit board contains a component that permits adjustment of burnback time.

Burnback time relates to the amount of welding wire remaining at the end of the welding gun after the welding process ends. Increasing burnback time results in less wire remaining at the end of the welding gun at the end of the weld. Decreasing burnback time results in more wire remaining at the end of the welding gun after the welding process ends.

WARNING

ELECTRIC SHOCK CAN KILL. Make certain the power source and wire feeder are both turned OFF before beginning the procedure.

3. Locate component R68 (Burnback) on the motor control printed circuit board (refer to Figure 4-3). The best procedure is to make only slight adjustments until the amount of burnback is acceptable. Component R68 has a single turn (300°) range of adjustment.

To increase burnback time, adjust component R68 clockwise.

To decrease burnback time, adjust component R68 counterclockwise.

4. Replace the internal cover.

5. Replace the wire spool hub (refer to 3.03 Adjustment Of Spool Tension in Section 3 of this manual).

4.06 Wire Feed Speed Ranges

The range of the wire feed speed adjustment knob on the front panel can be set to either High or Low. The High/Low switch is located on the inside panel next to the CC/CV switch. Refer to figure 4-4.

1. Using a nut driver or socket, remove the wire spool hub .

2. Remove the internal cover (refer to Figure 4-3).

Artr # A-09406

R68 located on this PCB

Art # A-07254

High

Low

Figure 4-4: High/Low Switch Location

Remove the four screws and Internal Cover

Figure 4-3: Accessing PCB for Burnback

Manual No. 0-4994 4-3 OPERATION

Page 36

PORTAFEED VS 212

The low setting provides greater knob sensitivity, but over a narrower range. The high setting provides less sensitivity but yields a wider range.

The ranges are as follows:

Low 50 - 400 ipm (1.27 - 10.16 mpm)

High 50 - 800 ipm (1.27 - 20.32 mpm)

Voltage Output

Wire Feed Speed

(ipm or mpm)

Current Output

Art # A-07255

50 400 50 800

Low Range 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 panel. The top meter always displays the welding power supply's voltage output. However, the lower meter can be set to display either the wire feed speed

the welding power supply's current output. Furthermore, when it is set to display the wire feed speed, an additional setting can be made to display this parameter in either inches per minute (ipm) or in meters per minute (mpm). Refer to Figure 4-6.

Art # A-07256

Figure 4-6: Digital Meter Functions

Changing The Lower Meter Functions:

1. Open the VS 212 case door.

NOTE

The power does not need to be turned off to change these settings.

2. Locate the 4 white DIP switches on the side of the meter display's printed circuit board. The LEFT/ RIGHT diagram in Figure 4-7 indicates the factory default positions of the lower meter DIP switches.

Hour Display Button

High

Low

Art # A-08353

Figure 4-7: Meter DIP Switches

1234

LEFT

RIGHT

OPERATION 4-4 Manual No. 0-4994

Page 37

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 # 1 2 3 4

LEFT Position Hold Function "Off" Wire Feed Speed Displayed Wire Feed Speed in IPM Currently Not In Use

Hold Function "On"

RIGHT Position

(refer to 4.0 7 )

Output Current Displayed Wire Feed Speed in MPM Currently Not In Use

Table 4-1: Lower Meter Switch Settings

4.08 Meter Hold Function

The meter hold function is enabled when DIP switch number 1 is set to the "RIGHT" position as defined in the table above. When this function is activated, the meter's displays are retained for 5 seconds after the last welding operation has ended. This provides the time needed for the operator to remove his welding shield and read the meters before the display goes blank.

4.09 Operation Hours Display

The total number of arc hours that the VS 212 has been operating can be displayed by pressing and holding the small black button located directly above the 4 DIP switches shown in Figure 4-7. The reading is displayed over both meters as follows:

Hundreds

Ones

Thousands

12 3

4.5 6

Tens

4.10 Protection And Safety Circuits

The following protection and safety circuits come standard with this wire feeder and are designed to protect (by disabling the wire feeder) against unfavorable operation and/or equipment damage.

1. Undervoltage Protection: If the input voltage

drops below the specified voltage range for an extended period of time, an electronic circuit will activate, and the wire feeder will not operate. The undervoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range.

2. Overvoltage Protection: If the input voltage rises

above the specified voltage range for an extended period of time, an electronic circuit will activate, and the wire feeder will not operate. The overvoltage protection circuit will automatically deactivate when the input voltage enters an acceptable range.

3. Input Current Protection: If the input current rises

above the specified maximum input current for an extended period of time, the input circuit

Hundreths Tenths

Art # A-07258

Figure 4-8: Displaying Operation Hours

For example, the above display would be read as:

1,234.56 hours

Manual No. 0-4994 4-5 OPERATION

Page 38

PORTAFEED VS 212

breaker will trip, and the wire feeder will not operate. The input circuit breaker will have to be manually reset if it were to trip.

4. Motor Overcurrent Protection: If the drive motor

becomes locked or shorted, an electronic circuit will activate, and the motor will not operate. If this circuit activates, a light on the motor control printed circuit board labeled [Fault 2] will turn on. The motor overcurrent protection circuit will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds.

CAUTION

If this protection circuit activates and the drive motor is not locked, the drive motor is most likely shorted and will have to be replaced (refer to ‘Troubleshooting Guide’ section of this manual).

5. Contactor And Gas Valve Overcurrent Protection:

If the contactor or gas valve becomes shorted, an electronic circuit will activate, and both the contactor and gas valve will not operate. If this circuit activates, a light on the 12 V driver printed circuit board labeled [Fault 1] will turn on. The contactor and gas valve overcurrent protection circuit will have to be manually reset by placing the power switch on the wire feeder in the off position for at least 60 seconds.

CAUTION

If this protection circuit activates, the contactor or gas valve is most likely shorted and one or both will have to be replaced (refer to section 5.06 Troubleshooting Guide in this manual).

OPERATION 4-6 Manual No. 0-4994

Page 39

PORTAFEED VS 212

SECTION 5:

SERVICE

5.01 Cleaning Of The Unit

About every 6 months, remove the interior panel cover to expose the printed circuit boards and other components. Using a vacuum cleaner or clean, dry, compressed air of not more than 25 psi (172 kPa,

1.72 bar) pressure, vacuum or blow out the interior of the wire feeder. While the interior panel cover is removed, check all electrical components for loose connections and correct if necessary.

5.02 Cleaning Of The Feed Rolls

About every 3 months, clean the grooves on the feed rolls using a small wire brush. If the feed roll has a

smooth surface, wipe off the feed roll with a clean, dry cloth. After cleaning the feed rolls, tighten the upper and lower feed roll retaining knobs accordingly.

location and routing as received from the factory. Keep wires and leads away from hot parts and sharp objects.

5.05 Common Symptoms

WARNING

ELECTRIC SHOCK can kill.

· Follow all safety precautions.

· Do not touch live electrical parts.

· Turn OFF input power before servicing the machine unless otherwise noted.

· Only qualified technicians are to service the machine.

WARNING

5.03 Troubleshooting Guide

1. Scope: The troubleshooting guide is intended to

be used by qualified service technicians. The troubleshooting guide contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the wire feeder. Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem.

2. Safety: To ensure safe operation and service, read this entire manual before attempting to service or repair this machine. The service technician may be asked to check voltage levels while the machine is turned ON; to assure safety, use care and follow all instructions accordingly!

5.04 Troubleshooting Hints

Examine connections for proper assembly and contact before replacing an electrical component or printed circuit board. Wire lugs should be in tight contact with the lead’s conductor and should be crimped to the lead’s insulation. The mating surfaces of the connection should be clean and free of oxidation.

This machine contains static sensitive devices.

· Use static proof bags to store electronic components.

· Use grounded wrist strap.

· Use qualified personnel when testing or handling device.

NOTE

Refer to the Connection Diagram and the Schematic Diagram in the Appendix chapter of this manual for graphical assistance in disassembling and troubleshooting the wire feeder.

Use only genuine replacement parts.

1. Unit is completely inoperative - nothing functions.

A. Make sure all connections have been made

to both the power source and wire feeder.

B. Make sure both the power source and wire

feeder are turned ON.

Do not pull on wires to disassemble connections. Firmly grasp each lug or connector when disconnecting. Pulling on wires for disassembly can damage the integrity of the connection and cause future malfunctions.

Prior to disassembly or servicing of the machine, note the wiring and connections in the machine. Reassembling should place the wires in the same

Manual No. 0-4994 5-1 SERVICE

C. Check 18 ga. wire connection on rear bus

bar of the contactor for loose or faulty

connections. D. Check for a damaged power switch. E. Check for a damaged or tripped circuit

breaker.

Page 40

PORTAFEED VS 212

2. Wire feed motor operates but wire does not feed or feeds erratically.

A. Incorrect voltage/current and/or wire feed

speed settings.

1) Make sure all connections to the wire feeder are tight.

2) Make sure feed rolls are tight.

B. Check for too little or too much pressure

on the feed rolls.

1) Refer to spring tension knob in section

2.09 Internal Controls and Connections in this manual.

2) Check for correct feed roll size for welding wire being used.

3) Check to see if wire spool tension is too great.

4) Refer to hub tension bolt in section

2.09 Internal Controls and Connections in this manual.

C. Check for restriction in welding gun and/

or contact tip.

D. Check for correct gun liner and contact

tip sizes for welding wire being used.

3. Wire wraps around the feed rolls.

A. Check for too much pressure on the feed

rolls.

1) Refer to spring tension knob in section

2.09 Internal Controls And Connections in this manual.

B. Check alignment of input and output

guides.

C. Check for correct gun liner and contact

tip sizes for welding wire being used.

D. Worn or damaged contact tip.

4. Wire does not feed with gun switch depressed.

D. An electronic protection circuit may have

activated.

1) Reset by placing power switch in the off position for at least 60 seconds.

5. Wire feed motor continues to run after gun switch has been released.

A. Check Trigger Hold switch (see section

2.08).

B. Check for shorted welding gun trigger

leads while the gun switch on the welding gun is released.

1) If shorted, repair or replace the welding gun.

6. Wire feeds but no gas flows.

A. Check to see if the gas cylinder is empty

or the valve closed.

1) Make sure proper gas flow rate has been set.

B. Check for a possible restriction in the gas

line or gas valve.

1) Check to see if the welding gun nozzle is plugged.

7. Gas flows all the time or leaks.

A. Make sure all connections are tight. B. Check for foreign material inside the gas

valve.

8. Wire feeds, contactor closes, but welding wire is not hot - there is no arc.

A. Make sure all connections have been made

to both the power source and wire feeder.

B. Make sure the cable between the contactor

and feedhead is properly connected.

1) If using a CV power source, make sure the output contactor has been energized.

A. Check power supply input to the VS 212

and cable connection.

B. Check for continuity of the welding gun

trigger leads with the trigger depressed.

1) If no continuity, repair or replace the welding gun.

9. Meters do not function.

C. Check for a locked or shorted motor.

SERVICE 5-2 Manual No. 0-4994

2) Refer to section 4.01 Prewelding Procedure in this manual.

C. Work lead not connected.

A. Check meters (M1 and M2) and plug J2

on the motor control PC board for loose, faulty, or reversed connections.

Page 41

SECTION 6:

PARTS LIST

6.01 Equipment Identification

All identification numbers as descr ibed in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specification or Assembly numbers.

6.02 How To Use This Parts List

The Parts List is a combination of an illustration and a corresponding list of parts which contains a br eakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to other parts. The part descriptions may be indented to show part relationships.

PORTAFEED VS 212

To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.

PART NUMBERS:

W3512006

W3512005

April 9, 2007

6-1

Page 42

PORTAFEED VS 212

6.03 External Replacement Parts

Item #Item #

Item #

Item #Item #

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 1 Control Knob 870696PKD 2 2 Rocker Switch, Single Pole, Black 870359PKD 3 1 Rocker Switch, Single Pole,Momentary, Black 870863PKD 4 2 Door Latch Assembly, VS 212 870969PKD 5 1 Assembly, Handle, VS 212 870972PKD 6 1 Assembly, Door, VS 212 870953PKD 7 1 Lifting Eye, VS 212 871351PKD 8 1 Power Input Pigtail Assembly, VS 212 871032PKD 9 1 Rocker Switch, Single Pole, Black. On/off 870367PKD

4 5

6-2

Art# A-07606

April 9, 2007

Page 43

6.04 Internal Replacement Parts

PORTAFEED VS 212

Item #Item #

Item #

Item #Item #

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 1 Case, Internal Parts Storage 870865PKD 21 Circuit Breaker PB 10A 7978049PKD 3 2 Rocker Switch, Single Pole, Black 870946PKD 41 Torch Locking Screw OTWAK/1PKD 5 1 Clamp, Gun Tube 171362PKD 61 Wire Spool Hub Assembly 871616PKD

4 5

Art #A-07607_AB

April 9, 2007

6-3

Page 44

PORTAFEED VS 212

6.05 Wire Feeder Replacement Parts

Item #Item #

Item #

Item #Item #

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Part NumberPart Number

Part Number

Part NumberPart Number

1 1 Tension Rod Subassembly 870933 21 Pressure Arm, Machined, Two Roll (see note 2) 870679 3 1 Idler Gear Assembly 871001PKD 4 2 M4x10 Pan Head Screw See note 1 5 3 M6x1 Pan Head, 30 MM long See note 1 6 1 Gear Retainer 870733 71 Drive Gear Assembly 870560 8 2 M8 X 16 Hex Head Cap Screw See note 1

9 1 M6x1 Socket Head Cap Screw, 35MM Long See note 1 10 1 Clamp, Gun Tube (see note 2) 171362 11 1 Feedplate, 2 Roll, Machined (see note 2) 870558 12 1 Insulator, Motor (see note 2) 870695 13 1 Dowel Pin, #6x50, Pressure Arm hinge (see note 2) 870509

Art # A-07608

NOTES:

1. This part may be purchased at a local hardware store.

2. This part is shown for reference purposes only. It is not available individually.

6-4

April 9, 2007

Page 45

PORTAFEED VS 212

APPENDIX 1:

DRIVE ROLL KITS

DRIV E ROL L KI TS ( #375980- S eries) 2 ROL L

Style 1 Style 2 Style 3 Style 4 Style 5 Style 6

Double Smooth

Top

Bottom

Wi re Type Wire Size

.024" / 0.6mm 375980-031 - - - - .030", .035" / 0.8, 0.9mm 375980-001 375980-003 375980-010 - - .030", .035", .045" / 0.8, 0.9, 1.2mm 375980-028* 375980-029 - - - .035" / 0.9mm 375980-040* - - - - 375980-032 .035", .045" 3/64" / 0.9, 1.2, 1.2mm - - 375980-030 - - .045" / 1.2mm 375980-002* 375980-004 - 375980-092 375980-022 3/64 / 1.2mm - - 375980-011 - - 375980- 033 .052" / 1.3mm 375980-090* - 375980-012 - - .052", 1/16" / 1.3, 1.6mm - - - 375980-017 375980-023 1/16" / 1.6mm 375980-005* - - - - 375980-034 .068" / 1.7mm - - - - - 5/64" / 2.0mm 375980-006* - - 375980-018 - Notes: 1) One Kit is supplied standard w ith each wire feeder.

2) Drive Rol l Kits include: Drive Rolls; Input, Output , #375980-092 Guides

3) Narrow 30° "V"

Flat Flat Knurled

Double

Smooth "V"

Hard Hard Soft/Hard/Tubular Hard/Tubular Tubular Soft (Aluminum)

Double

Smooth "V"

"V"

Double Smooth

"V"

Double

Knurled "V" Doub le Cog Double "U"

Double

Knurled "V" Doub le Cog Double "U"

Manual No. 0-4994 A-1 APPENDIX

Page 46

PORTAFEED VS 212

APPENDIX 2:

OPTIONS AND ACCESSORIES

Product

Drive Roll Kits 375980-XXX

Wire Spool / Coil Adapters 10 lb (4.5kg), 8” spool 375585-001

15 lb (6.8kg), 8” spool 375864-001 14 lb (6.4kg) coil, Lincoln® 375942A Wire Feeder Cart W4000001 Low profile, large caster cart Roll Cage W4003001 Protective tube steel roll cage MIG Gun Adaptor Cartridge Integrated cartridge to accept other style MIG guns. Wire feeder

Tweco® #4 W4004001 Miller® W4005001 Lincoln® (gasless) W4006001 Lincoln® W4006002 Euro-style W4007001

Part No. Description

One kit (#375980-092) is supplied standard with each wire feeder, see drive roll kit chart to select a different drive roll style

comes with Tweco #4 cartridge installed

APPENDIX A-2 Manual No. 0-4994

Page 47

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.

Art # A-07414

Manual No. 0-4994 A-3 APPENDIX

Page 48

PORTAFEED VS 212

APPENDIX 4: SYSTEM SCHEMATIC

TO FEEDHEAD

CONTACTOR, 400 AMP

TO POWER SOURCE

SWITCH POWER

BREAKER, CIRCUIT, 8 AMP

SW1

CB1

RECTIFIER, BRIDGE

BR1

J2-5

J2-2

J1-1

J2-3

J2-1

J1-3

J1-4

TO WORK

12V

REGULATOR

SWITCH, CC/CV

SW2

J1-5

J1-2

J1-9

J3-1

J1-8

J1-10

J1-12

J3-3

J3-4

V_CAP +

V_CAP -

J1-11

PCB1

MOTOR

CONTROL PCB

376395C

CONTACTOR BOARD ENABLE

12 VDC DRIVER PCB

170046B-001PKD

PCB2

SOL1

GAS VALVE, 12 VDC

11A

Art # A-07595_AB

APPENDIX A-4 Manual No. 0-4994

Page 49

PORTAFEED VS 212

MOTOR BOARD ENABLE

OVER VOLTAGE FAULT

MOTOR, WIRE FEED

VOLTMETER

WFS

WFS POT MAX

WFS POT WIPER

WFS POT MIN

J4-11

J4-10

J4-9

J4-8

J4-12

J4-13

J4-14

J4-7

J4-5

DISPLAY BOARD

PCB3

J2-1

J2-4

J2-2

J2-5

J4-2

SWITCH, TRIGGER MODE SELECTOR

SW3

SW4

SWITCH, GUN

INCH

PURGE

J2-3

SW5

SWITCH, INCH/ PURGE

SWITCH, HIGH/ LOW

PURGE / TRIGGER LOW

11A

J4-6

J4-4

J4-3

Art # A-07595_AB

SW6

J4-1

J1-3 J1-2

J1-1

2 3

TRANSDUCER

J5J5

CS1

CURRENT

SENSE

DIGITAL

DISPLAY

PCB3

VS 212 SCHEMATIC DIAGRAM

Manual No. 0-4994 A-5 APPENDIX

Page 50

Statement of Warranty

(as of March 15, 2009)

LIMITED WARRANTY:

THERMADYNE warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below, THERMADYNE shall, upon written notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and recognized standard industry practice, and not been subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at THERMADYNE’s sole option, of any components or parts of the product determined by THERMADYNE to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

THERMADYNE shall not under any circumstances be liable for special, indir ect or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, business interruption or loss of profit, or claims of customers of distributor (hereinafter the “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, 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.

resale, or use of any goods covered by or furnished by THERMADYNE whether arising out of contract,

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s THERMADYNE warrantiesWarranty SCHEDULE

risk and expense. This warranty supersedes all previous

Page 51

Warranty SCHEDULE

(as of March 15, 2009) The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized

distributor delivers the products to the purchaser. THERMADYNE reserves the right to request documented evidence of date of purchase.

ENGINE DRIVEN WELDERS Parts / Labor

Scout®, Raider®, Explorer™

Original Main Power Stators and Inductors5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors1 year / 1 year Engines and Associated Components are NOT Warranted by Thermal Arc®, Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE MANUFACTURERS’ WARRANTY FOR DETAILS.

GMAW/FCAW (MIG) WELDING EQUIPMENT Parts / Labor

Fabricator® 140, 180, 190, 210, 251, 281; Fabstar® 4030; PowerMaster® 350, 350P, 500, 500P, 320SP, 400SP, 500SP; Excel-Arc® 6045; Wire Feeders: Ultrafeed®, Porta-feed®

Original Main Power Transformer and Inductor 5 years / 3 years Original Main Power Rectifiers All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors1 year / 1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT Parts / Labor

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors1 year / 1 year

PLASMA WELDING EQUIPMENT Parts / Labor

Ultima® 150

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 Welding Console, Weld Controller, Weld Timer 3 years / 3 years All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year

SMAW (Stick) WELDING EQUIPMENT Parts / Labor

Dragster™ 85; 95S

Original Main Power Magnetics 1 year / 1 year Original Main Power Rectifiers, Control P.C. Boards 1 year / 1 year All Other Original Circuits and Components Including, but not Limited to, Relays, Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors1 year / 1 year

, Control P.C. Boards, Power Switch Semi-Conductors3 years / 3 years

See the Engine

Manufacturers’ Warranty

for Details

years / 3 years

Original Main Power Magnetics 5 years / 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years Al

l Other Original Circuits and Components Including, but not Limited to, Relays,

Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors1 year / 1 year

GENERAL ARC EQUIPMENT Parts / Labor

FirePower® MIG Welders 5-2-1 years / NA Water Recirculators1 year / 1 year Plasma Welding Torches 180 days / 180 days Gas Regulators (Supplied with Power Sources) 180 days / NA MIG and TIG Torches (Supplied with Power Sources) 90 days / NA Replacement Repair Parts 90 days / NA MIG, TIG and Plasma Welding Torch Consumable Items NA / NA

Page 52

Page 53

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Bolsena, 7 20098 S. Giuliano Milan, Italy Tel: (39) 02-36546801 Fax: (39) 02-36546840

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

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

Tweco VS212 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Symbol Chart

1.06 Principales Normes De Securite

1.07 Graphique de Symbole

1.08 Declaration Of Conformity

2.01 How To Use This Manual

2.02 Equipment Identification

2.03 Receipt Of Equipment

2.04 General

2.05 Product Specifications

2.06 Features/Benefits

2.07 Front Panel Controls And Connections

2.08 Rear Panel Controls And Connections

2.09 Internal Controls And Connections

2.10 Power Source Compatibility

2.11 Options and Accessories

3.01 Connections

3.02 Installation Of Wire Spool

3.03 Adjustment Of Spool Tension

3.04 Input And Output Wire Guide Installation

3.05 Selection And Installation Of Feed Rolls

3.06 MIG Gun Compatibility And Installation and Removal

3.07 Threading Wire Into Feedhead

4.01 Prewelding Procedure

4.02 Welding Procedure

4.03 Welding In CC Mode vs. CV Mode

4.04 Theory Of Operation

4.05 Adjusting Burnback Time

4.06 Wire Feed Speed Ranges

4.07 Changing Meter Functions

4.09 Operation Hours Display

4.10 Protection And Safety Circuits

5.01 Cleaning Of The Unit

5.02 Cleaning Of The Feed Rolls

5.05 Common Symptoms

5.03 Troubleshooting Guide

5.04 Troubleshooting Hints

6.01 Equipment Identification

6.02 How To Use This Parts List

6.03 External Replacement Parts

6.04 Internal Replacement Parts

6.05 Wire Feeder Replacement Parts

APPENDIX 4: SYSTEM SCHEMATIC

Statement of Warranty

Warranty SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION