Tweco A 2000 User Manual

60

V

50

H

Z

650

IPM

A 2000

®

ULTRAFEED

VARIAC CONTROLLED
WIRE FEEDER

Art # A-07354

Operating Manual

Version No: 1 Issue Date: May 1, 2006 Manual No.: 0-4852
Operating Features:

50
60

650

IPM

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 P
potential hazards that may exist when working with this product.

recautions. They will help you to avoid

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 developing technologically
advanced products to achieve a safer working environment within
the welding industry.

WARNINGS

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

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

Ultrafeed A 2000 Wire Feeder
Instruction Manual Number 0-4852 for:
Specification # W3200001

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermalarc.com

©Copyright 2006 by
Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.

Publication Date: May 1, 2006

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i

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 Precautions De Securite En Soudage A L’arc.................................................. 1-5

1.04 Dangers relatifs au soudage à l’arc ................................................................. 1-5

1.05 Principales Normes De Securite ..................................................................... 1-8

1.06 Declaration Of Conformity .............................................................................. 1-9

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 Symbol Chart ................................................................................................. 2-2

2.05 General Information ....................................................................................... 2-3

2.06 Features and Benefits ..................................................................................... 2-4

2.07 Options and Accessories ................................................................................ 2-4

SECTION 3:

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

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

3.02 Grounding ...................................................................................................... 3-1

3.03 EMI Considerations ........................................................................................ 3-1

3.04 Installation Of Welding Wire Spool ................................................................. 3-2

3.05 Adjustment Of Spool Tension ......................................................................... 3-2

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

3.07 Selection And Installation Of Feed Rolls ......................................................... 3-3

3.08 Welding Gun Compatibility And Installation ................................................... 3-4

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

SECTION 4:

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

4.01 Prewelding Procedure .................................................................................... 4-1

4.02 Front Panel ..................................................................................................... 4-1

4.03 Rear Panel Controls &Connections ................................................................ 4-2

4.04 Feedhead Components ................................................................................... 4-3

4.05 Power Sou

4.06 Power Source Compatability Details ............................................................... 4-4

rce Compatibility ........................................................................... 4-4

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 5:

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

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

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

5.03 Feedhead Maintenance ................................................................................... 5-1

5.04 System Maintenance ...................................................................................... 5-1

5.05 Troubleshooting Hints .................................................................................... 5-1

5.06 Troubleshooting Guide ................................................................................... 5-2

APPENDIX 1: FEED ROLL KITS ........................................................................... A-1

APPENDIX 2: OPTIONS AND ACCESSORIES ........................................................... A-2

APPENDIX 3: SYSTEM SCHEMATIC ..................................................................... A-3

APPENDIX 4: SYSTEM OUTLINE ......................................................................... A-4

LIMITED WARRANTY

WARRANTY SCHEDULE

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

SECTION 1:

!

SAFETY INSTRUCTIONS AND WARNINGS

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

WARNING

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.

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

r touch other people with the holder or electrode.

time o

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

9. Do not wrap cables around your body.

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

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

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

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

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

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.

May 1, 2006

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.

1-1

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.

WARNING

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.

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.

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.

9. Do not use welder to thaw frozen pipes.

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

1-2

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 4Non-ferrous base metal All 11

Oxygen C utting 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

May 1, 2006

WARNING

!

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

FLYING SPARKS AND HOT METAL can cause injury.

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

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

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

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

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.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

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

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

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

5. Do not spill fuel. If 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.

May 1, 2006

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.

1-3

!

1.02 Principal Safety Standards

WARNING

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

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

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

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

3. Allow pressure to escape before completely removing cap.

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

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126.

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

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

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.

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

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

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

The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power
Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E­63 (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.

3. 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:

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

doctor for complete information.

1-4

May 1, 2006

1.03 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” p
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 FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.04 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 internes de l’équipement sont aussi sous ten­sion dès la mise en marche. En soudage automatique
ou semi-automatique 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.

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 raccor
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.

8. 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.

résente les pratiques sécuritaires à suivre.

dés à deux sources de courant en

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.

May 1, 2006

1-5

AVERTISSEMENT

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 antibruit ou des bouchons d’oreille approuvés

rsque le niveau de bruit est élevé.

lo

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 fort
au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

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

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

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

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

Soudage á l'arc avec
électrode enrobees
(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

épais plus de 6 po. (150 mm) 5 ou 6

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

filtr e oculair e

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'hydrogène
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

toutes conditions 12

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtr e oculair e

1-6

May 1, 2006

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

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS 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.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION

L’arc 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. 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 atteindre des matériaux 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 empêche
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

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

10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con­tact 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.

r le courant de suivre un long parcours

1. Por tez un écran facial ou des lunettes protectr ices
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, traitez-les avec soin.

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

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.

May 1, 2006

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

1-7

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

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

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.

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.

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

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

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

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.

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 protecteurs
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.

AVERTISSEMENT

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

1-8

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

1.05 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 P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.

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

May 1, 2006

1.06 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 numbe

• 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. Rigo
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 Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

rous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all

r 60 for Arc welding equipment.

May 1, 2006

1-9

NOTES

1-10

May 1, 2006

ULTRAFEED A 2000

!

SECTION 2:

INTRODUCTION

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 control panel. In some cases,
the nameplate may be attached to the rear panel.
Equipment which does not have a control panel such as
gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
i for future reference.

2.03 Receipt Of Equipment

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

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

CAUTION

A CAUTION refers to possible equipment
damage.

NOTE

A NOTE offers helpful information 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 on 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

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

May 1, 2006

2-1

ULTRAFEED A 2000

2.04 Symbol Chart

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

On

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

X

%

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

t1

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld
Mode

Spot Weld Mode

Spot Time

t

Preflow Time

Postflow Time

t2

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

t

Disturbance In
Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle Rating­Auxiliary Power

Voltage Input

V

Art # A-04130

May 1, 2006

ULTRAFEED A 2000

A 2000A 2000

2.05 General Information

The ULTRAFEED A 2000 is a semiautomatic, Variac
controlled wire feeder capable of a 100% duty cycle. The
system offers both load and line voltage compensation
helping to maintain a constant wire feed speed, even with
changes in the input voltage and/or load. The wire feeder
comes complete with a wire spool support assembly.

The ULTRAFEED A 2000’s sheet metal box totally encloses
the solid state control circuitr y. A hinged, latched
feedhead cover allows quick and easy access to the
feedhead featuring tool-less quick change feed rolls.

The ULTRAFEED A 2000 comes with an abundance of
standard features including:

• an on/off rocker switch

•a circuit breaker for total system protection

•a wir e feed speed control

• an inch switch

• a gas purge switch

• electromechanical brake for precise wire stopping

• two quick change, gear-driven feed rolls

The ULTRAFEED A 2000 has been designed to comply
with CSA NRTL/C, NEMA EW 3, and IEC 60974-1
standards.

UltraFeed A 2000 Specifications

Input Voltage: 115 VAC
Input Frequency: 50/60 Hz
Input Voltage Tolerance ±10%
Maximum Input Current 1.5 Amps

Wire Speed Range
for All Filler Wire Sizes
Wire Sizes 0.024 - 5/64" / 0.6 - 2.0 mm

Maximum Wire
Coil/Spool Weight
Feed Rolls 2 (Gear Driven)
Welding Current (I) 450 A @ 100% Duty Cycle
Welding Gun/Torch Size
(Tweco #4 Std)

Maximum Shielding Gas
Inlet Pressure
Weight (Less Wire) 30 lbs. / 13.5 kg

Dimensions HxWxD

Approvals NEMA EW 3

Table 2-1: Product Specifications

30 - 650 ipm
.76 - 16.6 m/min

60 lb. / 27 kg

5-8" (15.9mm) nominal

100 P.S.I. / 6.9 Bar

10.3 x 12.4 x 19 in.
262 x 315 x 483 mm

IEC 60974-1 (CE)

May 1, 2006

A 2000

Art # A-07319

Figure 2-1: ULTRFEED A 2000 Front View

2-3

ULTRAFEED A 2000

2.06 Features and Benefits

Ready to weld!

Supplied with 6ft (2m) control cable and .030, .035,
.045 in (0.8, 0.9, 1.2mm) drive rolls for hard wire.

Inch & purge switches!

Cold wire inch and gas purge.

Precision wire alignment!

Machined feed head and tension arms ensure wire
alignment tolerances ± .002”.

Geared top & bottom drive rolls!

Optimized wire traction for improved feedability.

Quick change drive rolls!

No tools required.

Speed control fitted!

Variac speed control ensured lower operating and repair
cost with improved reliability.

Electromechanical brake!

Electromechanical control of the motor brake offers pre­cise stopping of the wire.

Circuit breaker fitted!

Built-in input circuit breaker provides total system
protection.

Welding gun quick disconnect

Quick and easy connection and disconnection of the
welding gun.

2.07 Options and Accessories

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

2-4

May 1, 2006

ULTRAFEED A 2000

SECTION 3:

INSTALLATION

3.01 Connections

Refer to the System Outline drawing in the Appendix of
this manual for details.

1. Make the proper welding cable connections
between the power source and wire feeder and
between the power source and work connection.

2. Connect the control cable from the feeder to the
power source. Control cable extensions are
available; Refer to Available Options.

NOTE

An optional 870000-001 adapter cable will be
required for connection to a power source with

only a 5 pin amphenol connection and AC
voltage outlets. An optional 870093B-001
adapter cable will be required for connection
to a power source with only a 14 pin amphenol
connection. These options are only applicable
to 19 pin plug units.

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

3.03 EMI Considerations

Electromagnetic interference (EMI) is common in today’s
complex industrial environment. At times, EMI levels can
become great enough to affect the operation of the
machinery. To help reduce and safeguard against EMI
levels in the welding area, follow these simple guidelines:

1. Firmly secure all sheet metal panels on the power
source and wire feeder. Repair or replace heavily
corroded or damaged panels and/or fasteners.

2. Keep the welding cables and control cables as
short as possible.

3. Route the ‘+’ and ‘-’ welding cables from a
particular power source together.

4. Keep the welding cables as straight as possible;
avoid coiling up the cables.

5. Route the control cable away from the welding
cables.

NOTE

Grounding of the workpiece may reduce
emissions in some, but not all circumstances.
To prevent the risk of injury or damage to other
electrical equipment when grounding the
workpiece, take care to follow all local laws
and regulations.

4. Attach the welding gun to the wire feeder.

5. Connect the welding gun control leads to the wire
feeder gun switch terminals located on the front
of the feeder.

3.02 Grounding

To assure operator safety in the case of a fault condition,
the frame of the power source (welding machine) must
be grounded. The wire feeder sheet metal frame is
grounded only through pin G (for 19 pin plug) of the
control cable that connects to the power source.
Therefore, if the power source frame is not grounded,
then, the wire feeder sheet metal frame is not grounded,
and a shock hazard could possibly develop. Follow the
instructions found in the power source Owner’s Manual
for correct grounding methods.

May 1, 2006

3-1

ULTRAFEED A 2000

3.04 Installation Of Welding Wire Spool

Refer to Figure 3-1.

NOTE

The wire spool hub supplied with the unit is
provided for mounting a 12" diameter spool
of wire. Optional adapters are available
allowing an 8" diameter spool of wire or a 14
pound coil of wire to be used.

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

2. Orient and slide the spool of wire over the wire
spool hub so that the wire will feed off the bottom
of the spool as the spool rotates counter
clockwise. Make sure that the alignment pin on
the hub enters the hole in the backside of the wire
spool.

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

NOTE

The wire must feed from the bottom of the
spool. If it comes off the top the spool will
have to be removed and turned around.

Wire Spool Hub Nut

Hub Tension Bolt

Alignment Pin

1

Additional Wire Spool Support
Shaft Holes (with plugs)

2

3.05 Adjustment Of Spool Tension

Adjust the wire spool tension so that 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 (Refer to Figure 3-1).

NOTE

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

Art # A-07264

3

Figure 3-1: Installing Welding Wire Spool

3-2

May 1, 2006

ULTRAFEED A 2000

3.06 Input And Output Wire Guide Installation

Refer to Figure 3-2.
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 toward the wire spool. Adjust the
guide so that it is clear of the feed rolls and tighten the
input guide lockscrew.

Install the output wire guide in the same manner, with
the conical end toward the feed rolls. The tip of the conical
end 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 roll to help in the
alignment of the wire guides.

Input Guide Lockscrew

Output Guide Lockscrew

3.07 Selection And Installation Of Feed Rolls

NOTE

Refer to feed roll kit drawing (supplied in the
Appendix) to order feed roll kits. Kit includes
2 drive rolls, an input wire guide, a center
guide, and an output wire guide for a specific
wire type and size.

Style 1: Feed rolls consist of flat smooth top rolls and
double smooth, vee grooved bottom rolls. They feed .024

- .068" hard and tubular wire.

Style 2: Feed rolls consist of flat knurled top rolls and a
double smooth, vee grooved bottom rolls. They feed .030

- .045" hard and tubular wire.

Style 3: Feed rolls consist of double smooth, vee grooved
drive rolls. This style supports 0.035 to 1/16” soft wire.

Style 4: Feed rolls consist of double knurled, vee grooved
grooved drive rolls. They feed .045 - 5/64" hard and tubular
wire.

Style 5: Feed rolls consist of double cog top and bottom
rolls. They feed .045 - 5/64" tubular wire.

Input Wire Guide

Figure 3-2: Wire Guide Installation

Output Wire Guide

Art # A-07265

Style 6: Feed rolls consist of double U-grooved top and
bottom feed rolls. They feed .035 - 1/16" soft wire.

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.

Feed rolls are removed by twisting the feed roll retainer
cap and aligning the retaining knob splines/tabs with the
drive gear splines. Feedrolls are installed by putting the
feedroll onto the drive gear splines and twisting the
feedroll retainer cap so that the splines/tabs rest against
the face of the feedroll where they will click into place.

NOTE

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

May 1, 2006

3-3

ULTRAFEED A 2000

3.08 Welding Gun Compatibility And Installation

Refer to Figure 3-3.
The ULTRAFEED A 2000 wire feeder is designed to be

used with most welding guns. In some cases, a special
adapter may be required.

To install the welding gun, simply loosen the gun clamp
knob and insert the welding gun into the feedhead until it
stops. Tighten the gun clamp knob and connect the
welding gun control wires to the gun switch receptacle.

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

Check for gas leaks. If leaking gas, gun is not
all the way into the feedhead.

Gun Adapter

Gun Clamp Knob

Art # A-07266

Figure 3-3: Welding Gun Installation

3-4

May 1, 2006

ULTRAFEED A 2000

3.09 Threading Wire Into Feedhead

Refer to Figure 3-4.

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.

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.

3. Lift the pressure arm and pass the wire through the
output wire guide and into the welding gun assembly
(Refer to welding gun manual).

4. Close the pressure arm, and lock in position with the
tension lever. To adjust the amount of force the roll
exerts on the welding wire, turn the spring tension
knob clockwise for increased for ce 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.

5. Turn the welding machine and wire feeder ON, and
set the wire feed speed control to midrange (Refer to
Figure 4-1). 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. Thread
the contact tube over the wire and lock into place and
tighten. Cut wire off at about 1/4 inch (6 mm) from
the nozzle.

WARNING

2. Loosen the spring tension knob and pull the tension
lever forward to unlock the pressure arm.

Spring Tension Knob

Tension Lever

Welding Wire

Art # A-07273

The wire is electrically “HOT” if wire is fed by
depressing the gun switch. Wire contact with the
workpiece will cause an arc with gun switch
depressed. Feed motor will run feeding “HOT” wire.

Pressure Arm

May 1, 2006

Input Wire Guide

Figure 3-4: Threading Wire Into Feedhead

Output Wire Guide

3-5

ULTRAFEED A 2000

NOTES

3-6

May 1, 2006

ULTRAFEED A 2000

!

A 2000A 2000

SECTION 4:

OPERATION

4.01 Prewelding Procedure

Follow all installation instructions for the wire feeder, the
welding power source, and the welding gun before
attempting to operate the ULTRAFEED A 2000.

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. Push the PURGE switch of the feeder and adjust
the flow of shielding gas.

4. Push the INCH switch of the feeder and adjust
the wire feed speed to the desired value by means
of the wire feed speed control.

WARNING

If the gun switch is depressed, the electrode
(welding wire) is electrically “hot”. Do not
permit it to touch any metal or a welding arc
may be established which may be injurious to
someone’s eyes (flash) or skin (burn).

4.02 Front Panel Controls and
Connections

1. GUN SWITCH RECEPTACLE: The gun switch recep-

tacle accepts the welding gun control wires. The gun
switch receptacle is where a gun switch closure is
inputted to the wire feeder.

2. 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 elecrically 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.

3. POWER ON/OFF SWITCH: This switch is for the wire

feeder only and not the power source (welding ma­chine). It is used as an on/off switch and also serves
as a circuit breaker.

NOTE:

If the circuit breaker trips, it turns the power
switch to the OFF position. A short cooling
period must be allowed before an attempt is
made to reset the unit by placing the switch in
the ON position.

4. Wire Feed Speed CONTROL: This knob controls wire

feed speed. The wire feed speed can be adjusted dur-
ing setup or actual welding.

5. Adjust the voltage of the power source to the
desired value. The gun switch must be triggered
to close power source contactor.

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”.

3

2

1

4

A 2000

Art # A-07320

Figure 4-1: Front Panel Controls and Connections

May 1, 2006

4-1

ULTRAFEED A 2000

4.03 Rear Panel Controls &Connections

1. CONTROL CABLE SOCKET: The control cable connects

to the power source at this 19-pin connector (of which
5 pins are used). It contains the signals required to
allow the welding power source and the wire feeder to
work together as a system. (Refer to Fig 4-2 and 4-3).

WARNING

The protective earth ground (pin G) of the
control cable is established
power source is properly grounded. See the
power source owner’s manual for proper
grounding methods.

Cont r o l Cab le

Pin

only when the

Function

If the power source only has a 5 pin amphenol and AC
voltage outlets, an 870000-001 adapter cable will be
required for proper hookup with the ULTRAFEED A 2000
wire feeder.

If the power source only has a 14 pin amphenol, an
870093B-001 adapter cable will be required for proper
hookup with the ULTRAFEED A 2000 wire feeder. Refer
to section 2.07 Options and Accessories.

Keyway

AML

KUNB

CPVTJ

HSRD

A
B Co ntac tor Neutral Power S ource

C Not Used
D Not Used
E 120 VAC Hot

F 120 VAC Neut ral
G Protective Earth Ground
H Not Used

J Not Used

K Not Us ed

L Not Us ed

M Not Used

N Not Used
P Not Us ed
R Not Used
S Not Us ed

T Not Us ed
U Not Used
V Not Us ed

Cont actor Ho t Rel ay Cl o sure To

Energize

Table 4-1: 19-Pin Control Cable Connections

EFG

Figure 4-2: Rear Panel 19 pin connections

2. GAS VALVE INLET: This is where the shielding gas
hose is connected to the wire feeder. The gas valve
inlet controls the “on/off” flow of shielding gas
through the welding gun.

3. WIRE FEED ACCESS: This is where the welding wire
feeds through the sheet metal housing to the wire
feeder.

4. WELDING CURRENT LEAD ACCESS: This is where
the welding current lead from the power supply feeds
through the sheet metal housing.

2

3

CAUTION

The relay contacts between pins A and B have
a maximum rating of 1/3 Horsepower (HP),
115 VAC or 10A, 230 VAC.

4-2

1

Art # A-07322

Figure 4-3: Rear Panel Connections

4

May 1, 2006

ULTRAFEED A 2000

4.04 Feedhead Components

1. INPUT GUIDE LOCKSCREW: Tighten this lockscrew to secure the input wire guide.

2. SPRING TENSION KNOB: Use the spring tension knob to adjust the amount of force the feed rolls exert on the

welding wire.

3. FEEDROLL GEAR / KNOB : This knob is used to secure the feedroll to the pressure arm. Rotate the knob to change
the feedroll.

4. PRESSURE ARM: This arm pivots off the front of the feedhead to allow access to the wire guides and wire path.

5. GUN CLAMP KNOB: This knob is used to tighten the welding gun into the feedhead.

6. WELD CABLE CONNECTION: This is where the power source welding cable is connected to the feeder. Make sure

this connection is tight or arcing could occur.

7. INPUT WIRE GUIDE: This guide is required to direct the welding wire from the drive roll to the welding gun cable.

8. WIRE SPOOL HUB NUT: The wire spool hub nut is used to secure the spool of welding wire.

9. 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 when the gun switch is r

eleased.

9

1

8

7

6

Art # A-07326

2

Figure 4-4: Feedhead Components

4

3

5

May 1, 2006

4-3

ULTRAFEED A 2000

4.05 Power Source Compatibility

The Ultrafeed VA 2000 wire feeder will work with any Ther-
mal Arc CV or CC/CV power source. If the Thermal Arc
power source only offers a 5 pin amphenol connector
and AC voltage outlets, an 870000-001 adapter cable will
be required to connect between the 19 pin control cable
of the wire feeder and the 5 pin amphenol connector and
AC voltage outlets of the power source.

If the Thermal Arc power source only offers a 14 pin
amphenol connector, an 870093B-001 adapter cable will
be required to connect between the 19 pin control cable
of the wire feeder and the 14 pin amphenol connector of
the power source.

The Ultrafeed VA 2000 will also work with most competi­tive power sources that provide 115 VAC and
relay closure to become energized.

4.06 Power Source Compatability Details

require a

Power Source Compatibility Details

Machine Details

PowerMaster 500 Fully Compatible
PowerMaster 500P Fully Compatible
ExcelArc 6045 Fully Compatible
ExcelArc 8065 Fully Compatible
Fabstar 4030 Fully Compatible
Arc Master 300 MST Fully Compatible
Arc Master 400 MST Fully Compatible
Arc Master 400 MSTP Fully Compatible

Figure 4-5: Power Source Compatability

4-4

May 1, 2006

SECTION 5:

SERVICE

ULTRAFEED A 2000

5.01 Cleaning The Unit

Periodically, clean the inside of the wire feeder and feedhead
assembly by using a vacuum cleaner or clean, dry,
compressed air of not more than 25 psi/172 kPa/1.72 bar
pressure. After cleaning the unit, check all electrical
components for loose or faulty connections and correct if
necessary.

5.02 Cleaning The Feed Rolls

Clean the grooves on the lower drive roll frequently. This
cleaning operation can be done by using a small wire
brush. Also, wipe off or clean the grooves on the upper

roll. After cleaning the feed rolls, tighten the feed roll
retaining knobs accordingly.

5.03 Feedhead Maintenance

The only point of maintenance in the feedhead assembly
is the motor brushes. Inspect these about every 300 hours
of operation. When these brushes are worn to about 1/8"
(3.2 mm), new brushes should be installed.

CAUTION

Neglect in brush maintenance may cause
damage to the drive motor commutator
resulting in a shorter motor operating life.

Cap

407190-1

Brush

407191-2

Feed Motor

5.04 System Maintenance

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.

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.

5.05 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.

Faulty connections or wiring problems are often the cause
of an equipment malfunction!

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.

May 1, 2006

Art # A-04195

Figure 5-1: Brush Maintenance

Brush Holders

Prior to disassembly or servicing of the machine, note
the wiring and connections in the machine. Reassembling
should place the wires in the same location and routing
as received from the factory. Keep wires and leads away
from hot parts and sharp objects.

All signals referenced in the following troubleshooting
guide can be measured with a digital multimeter (DMM).

5-1

ULTRAFEED A 2000

5.06 Troubleshooting Guide

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.

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.

WARNINGS

PC boards and their components are static sensitive devices.
Use static proof bags.
Use grounded wrist strap.
Only qualified personnel should test or handle these devices.

NOTES

Refer to the Appendix 3 Connection and Schematic Diagrams in the Appendix Section of this manual for
graphical assistance in disassembling and troubleshooting the wire feeder.

The acceptable tolerance (in most cases) on resistance and voltage measurements made with the DMM is
±10%.

Use only genuine replacement parts.

5-2

May 1, 2006

FAULT CAUSE REMEDY

A. Unit is completely
inoperative ­ nothing functions

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

1. Power is not on.

2. No connection or
loose connection
between the power
supply and the wire
feeder.

3. Circuit b
wire feeder is tripped.

1. Too little or too much
feed roll pressure.

2. Incorrect feed roll
size.

3. Wire spool tension is
too great.

4. Restriction in gun
or tip

reaker on the

ULTRAFEED A 2000

a. Check the power supply and wire feeder ON/Off
switches and make sure they are ON.
b. Check the input power to the power supply.

a. Connect the 19 pin power source control cable
to the power supply and wire feeder Amphenol
connectors.
b. With the power source turned ON, check for 120
VAC at power source amphenol pins E and F.
(Refer to the power source owner’s manual).
c. Check continuity of pins E and F of the 19 pin
power source control cable. Replace the cable
as needed.
d. Check connections on the power switch of the
wire feeder for loose or faulty connections.
Replace or repair as needed.
a. With the power turned off, check all cables for
defects, loose or worn connections. Change or
replace as needed. Allow cool down time before
resetting the breaker.
b. Check wire size and guides for proper application
and control settings. Allow cool down time before
resetting the breaker.

a. Increase or decrease feed roll pressure
as needed.
a. Check size stamped on outside of the feedroll.
(Visible when installed). Wire size must match
roll size.

a. Decrease the wire spool tension

a. Check tip for wear and proper size. Replace as
needed.
b. Check gun cable for kinks or wear. Replace as
needed.
C. Check for swarf build up. Clean out gun cable as
needed.

May 1, 2006

Table 5-1a: Trouble Shooting

5-3

ULTRAFEED A 2000

FAULT CAUSE REMEDY

C. Wire w
feed rolls.

D. Wire does not feed
with gun switch
depressed.

E. Motor continues to
run after gun switch
has been released.

F. No arc voltage
(Volts) control.

G. Wire does not
feed with INCH
butt on depressed.

H. Gas does not flow
with PURGE button
depressed.

I. W ire feeds but
no gas flows.

J. Gas flows all the
time or leaks.

raps around

1. Too much pressure
on feed rolls.

2. Input and output wire
guides misaligned.

3. Incorrect cable liner
or contact tip.

1. Faulty gun trigger
switch or connection.

2. Faulty feed drive
motor or connections.

1. Electrical short with
gun leads.

1. WSP/Local switch in
wrong position.

1. Lo ose or faul ty
connections.

1. S wit ch c onnec tion

1. Gas cy l i nder flow
rest rict ed or empt y .

1. Lo ose or faul ty
connections.

2. Regulat or/F l ow
Meter problem

a. Decrease feed roll pressure.

a. Realign wire guides. Refer to
section 3.06.
a. Refer to table in welding
gun manual for correct size.
a. Check gun switch recepticle connection.
b. Check continuity of gun trigger switch leads
with trigger depressed. Repair or replace
as needed.
a. Check feed drive motor connections.
Repair or replace as needed.
b. Check motor brushes for excessive wear.
Replace as needed.

a. Check for shorted welding gun trigger
leads. Repair or replace welding gun.
b. Check the gun switch recepticle on
the feeder for a shorted condition.
a. Make sure the WSP/Local switch on the power
supply is in the "local" position. Refer to the
power supply owner's manual.

a. Chec k t he INCH/PURGE s wi t ch located
on the wire feeder for l oos e or faulty
connec tions . Repair or replace as needed.

a. Chec k t he INCH/PURGE s wi t ch located
on the wire feeder for l oos e or faulty
connec tions . Repair or replace as needed.

a. Chec k t he gas c yli nder for gas. Replace
as needed.
b. Chec k for possibl e restrict ion i n t he gas
line. Repair or replace as needed.
c. Check to see if welding gun noz z l e is
plugged. Clean or replace as needed.
D. Check c onnec tions on the gas valve for
faulty or loose c onnec t i ons . Tighten or
replace as needed.

a. Chec k al l c onnecti ons from gas cy l i nder
to welding gun. Tighten or replac e
as needed.

a. Chec k for foreign material i n gas valve.
Clean or replace as needed.

5-4

K. Wi re feeds but
electrode wire is not
hot - there is no arc.

1. F a ul ty po wer supp ly
cont rol cable.

a. Chec k conti nui t y of pins A and B of the
19 pin power supply control c able.
Replace c abl e as needed.

Table 5-1b: Trouble Shooting Continued

May 1, 2006

APPENDIX 1: FEED ROLL KITS

DRIV E ROL L KI TS ( #3759 80- Series) 2 ROLL

ULTRAFEED A 2000

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

Double Smooth

Top

Bottom

Wire 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 - - 3759 8 0-030 - - ­.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
5/64" / 2.0mm 375980-006* - - 375980-018 - ­Notes: 1) One Kit (# 375980-028) is supplied standard w ith each w ire feeder.

2) Drive Roll Kits include: Drive Rolls; Input & Output 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"

Double

Knurled "V"

Double Cog Double "U"

Double Cog Double "U"

May 1, 2006

A-1

APPENDIX 2: OPTIONS AND ACCESSORIES

Product Part No. Description

KITS

Ground Fault Interrupt Kit 870081
ACCESSORIES

Drive Roll Kits 375980-028

Control Cable

6 ft (1.8m) 374878-006
15ft (4.5m) 374878-015
25ft (7.6m) 374878-025
50ft (15.2m) 374878-050
100ft (30.5m) 374878-100

Interconnect Cable Assembly

6 ft (1.8m) W4009200
15ft (4.5m) W4009201
25ft (7.6m) W4009202
50ft (15.2m) W4009203

Wire Spool Adaptor

10 lb (4.5kg), 8” spool 375585-001
15 lb (6.8kg), 8” spool 375864-001

Spool Cover

30 lb (13.6kg) spool 375582A-004
60 lb (27.2kg) spool 375733A-001

Wire Reel Kit 870059
Wire Coil Adaptor

14 lb (6.4kg) coil 375942A

60 lb (27.3kg) coil 407142A
Wire Feeder Cart W4000001
Lift Eye Kit W4002001 Electrically isolated
MIG Gun Holder Kit 171463

MIG Gun Adaptor Kits

Tweco® #5 870395

Miller® 870397

Euro-style 171449
Cable Adapters

19 pin wire feeder to 5 pin power source 870000-001 For older style power sources

19 pin wire feeder to 14 pin power source 870093B-001 For Miller® or 14 pin style power sources

One kit (#375980-028) is supplied standard with
each wire feeder, see drive roll kit chart to select a
different drive roll style

Control cable from wire feeder to power source (A

6ft. control cable, #374878-006 is supplied with
the wire feeder)

Complete interconnect assembly from wire feeder

to power source, includes control cable, welding
power cable and gas hose in a sheathed cover.

APPENDIX 3: SYSTEM SCHEMATIC

APPENDIX 4: SYSTEM OUTLINE

Art # A-07403

LIMITED WARRANTY

y

r

t

f

f

r

y

y

This information applies to Thermal Arc products that were purchased in the USA and Canada.

April 2006

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company ("Thermal Arc"),
warrants to customers of authorized distributors ("Purchaser") that its products will be free
of defects in workmanship or material. Should any failure to conform to this warrant
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendat ions and recogn ized standard ind ustry practice, and not subjec t to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair o
replacement, at Thermal Arc's sole option, of any components or parts of the produc
determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty o
merchantability, fitness for any particular purpose, or other warranty o
quality, whether express, implied, or statutory.

Limitation of liability: The rmal Arc shall no t under any circum stances be liable for sp ecial,
indirect, incidental, or consequential damag es, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe
arising out of contract, tort, including n egligence or strict liability, or under any war ranty,
or otherwise, shall not exceed the price of the goods u pon which such liability is based.

No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound b
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.

This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warrant
are void if the product is sold to purchaser by unauthorized persons.

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

Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind 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 risk and expense. This warranty dated April 1
supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered
Trademark of Thermal Arc, Inc.

st

2006

WARRANTY SCHEDULE

This information applies to Thermal Arc products that were purchased in the USA and Canada.

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer

Original Main Power Stators and Inductors .................................................................................. 3 years

Origina l Main Power Rectifiers, Control P.C. Boards .......... ......................................................... 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

Engines and associated components are NOT warranted by Thermal Arc, although

most are warranted by the engine manufacturer............................................................. See the Engine Manufactures Warranty for

Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor............................................................................5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDIN G EQUIPMEN T WARRANTY PERIOD 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-conductors .................3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR
Ultima 150

Original Main Power Magnetics.................................................................................................... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years 3 years

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 Recirculator................................1 year

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Dragster 85

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-conductors..........................................1 year

160S, 300S, 400S

Original Main Power Magnetics....................................................................................................5 years 3 years

Origina l M a i n P ower Recti fie r s , Control P .C . B o a rds ...... .. .. .. .. .. ... .... .. .. .. .. .. .. .. ... .. .. .... .. .. .. .. .. .. ... .. .. 3 years 3 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year

GENERAL ARC EQUIPMENT WARRANTY PERIOD LABOR

Water Recirculators................. ......................................................................................................1 year 1 year

Plasma Welding Torches.............................................................................................................180 days 180 days

Gas Regulators (Supplied with power sources)..........................................................................180 days Nil

MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil

Replacement repair parts.............................................................................................................90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years
3 years

1 year

1 year

1 year

1 year

1 year

1 year

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

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: [phone]
Fax: [phone]

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

World Headquarters

Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017

Telephone: [phone]
Fascimile:
Email: [e-mail]

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