Tweco VA 4000S User Manual

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VA 4000S

ULTRAFEED

SEPARATION SEMIAUTOMATIC WIRE FEEDER

Operating Manual

Revision: AA Issue Date: July 13, 2009 Manual #: 0-5135

Operating Features:

50 60

875

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 service 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.

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 VA 4000S Separation Semiautomatic Wire Feeder Instruction Manual Number 0-5135 for: Ultrafeed VA 4000S Part Number W3430001

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: July 13, 2009

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 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 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 ....................................................................................... 2-1

3.01 Connections ................................................................................................... 2-1

3.02 Grounding ...................................................................................................... 2-1

3.03 EMI Considerations ........................................................................................ 2-1

3.04 Input And Output Wire Guide Installation ....................................................... 2-2

3.05 Selection And Installation Of Feed Rolls ......................................................... 2-3

3.06 Welding Gun Compatibility And Installation ................................................... 2-3

3.07 Threading Wire Into Feedhead ........................................................................ 2-4

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 4:

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

4.01 Front Panel ..................................................................................................... 4-1

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

4.03 Feedhead Components ................................................................................... 4-4

4.04 Power Source Compatibility ........................................................................... 4-5

4.05 Power Source Compatibility Details ................................................................ 4-6

4.06 Prewelding Procedure .................................................................................... 4-6

4.07 Welding - 2 Step Operation ............................................................................ 4-7

4.08 Welding - 4 Step Operation ............................................................................ 4-8

4.09 System DIP Switches ..................................................................................... 4-9

4.10 PTC Protection of A-B Circuit ....................................................................... 4-10

4.11 Ground Fault Operation ................................................................................ 4-10

4.12 Electronic Motor Protection.......................................................................... 4-10

4.13 Software Features......................................................................................... 4-10

4.14 Arc Signal Overide ........................................................................................ 4-10

SECTION 5:

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

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

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

5.03 System Maintenance ...................................................................................... 5-1

5.04 Troubleshooting Guide ................................................................................... 5-1

5.05 Troubleshooting Guide ................................................................................... 5-2

SECTION 6:

PARTS LISTS ......................................................................................... 6-1

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

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

6.03 Replacement Parts - VA 4000 S Controller Front............................................ 6-2

6.04 Replacement Parts - VA 4000 S Controller Rear ............................................ 6-3

6.05 Replacement Parts - VA 4000 S Separation Motor ......................................... 6-4

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

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

APPENDIX 3: SYSTEM OUTLINE ......................................................................... A-3

Statement of Warranty ........................................................................................

Warranty SCHEDULE ......................................................................................... 3

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ............................................... 5

ULTRAFEED VA 4000S

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.

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.

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.

15. Keep all panels and covers securely in place.

WARNING

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.

Manual No. 0-5135 1-1 SAFETY INSTRUCTIONS

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.

ULTRAFEED VA 4000S

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

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.

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 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) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic 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. 0-5135

WARNING

ULTRAFEED VA 4000S

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.

Engines can be dangerous.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE;

WARNING

BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

WARNING

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

2. Stop engine before disconnecting or connecting battery cables.

ENGINE EXHAUST GASES can kill.

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

Engines produce harmful exhaust gases.

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

Manual No. 0-5135 1-3 SAFETY INSTRUCTIONS

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

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

ULTRAFEED VA 4000S

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.

SAFETY INSTRUCTIONS 1-4 Manual No. 0-5135

1.03 Symbol Chart

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

ULTRAFEED VA 4000S

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. 0-5135 1-5 SAFETY INSTRUCTIONS

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

ULTRAFEED VA 4000S

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 FAIRE 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 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 raccordés à deux sources de courant en 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.

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.

SAFETY INSTRUCTIONS 1-6 Manual No. 0-5135

ULTRAFEED VA 4000S

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 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 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

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'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

épais plus de 400 amperès 14

Nuance de

filtre oculaire

Manual No. 0-5135 1-7 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000S

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

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 empêcher le courant de suivre un long parcours 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.

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, 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.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

SAFETY INSTRUCTIONS 1-8 Manual No. 0-5135

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

ULTRAFEED VA 4000S

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.

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

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

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 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.

ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.

Manual No. 0-5135 1-9 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000S

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

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

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication Hors Tension

Torch de

Purge Du Gaz

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

Soudage

Mode Continu de Soudure

Détente à 2-Temps

Détente à 4-Temps

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

115V 15A

SAFETY INSTRUCTIONS 1-10 Manual No. 0-5135

Classement de PriseSource Auxiliaire

Haute Température

Force d'Arc

Amorçage de L’arc au Contact (GTAW)

Inductance Variable

Tension

IPM

MPM

Probléme de Terre

Pouces Par Minute

Mètres Par Minute

Art # A-07639

ULTRAFEED VA 4000S

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’ (2006/95 EC) 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 Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Manual No. 0-5135 1-11 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000S

This Page Intentionally Blank

SAFETY INSTRUCTIONS 1-12 Manual No. 0-5135

ULTRAFEED VA 4000S

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page 1.

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 information concerning damage claims or shipping errors to the location in your area listed in 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 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

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.

Manual No. 0-5135 2-1 INTRODUCTION

ULTRAFEED VA 4000S

2.04 Symbol Chart

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

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

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

INTRODUCTION 2-2 Manual No. 0-5135

2.05 General Information

ULTRAFEED VA 4000S

The ULTRAFEED VA 4000S is a semiautomatic, solid state controller and Separation 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 ULTRAFEED VA 4000S sheet metal box totally encloses the solid state control circuitry. A hinged, latched feedhead cover allows quick and easy access to the feedhead featuring quick change feed rolls, and tool-less knobs and clamps for changeover of guides and guns.

The ULTRAFEED VA 4000S comes with an abundance of standard features including:

• an on/off rocker switch

• a circuit breaker for total system protection

• a wire feed speed control

• a power source voltage control

• an inch switch

• a gas purge switch

• a 2 step / 4 step selector switch

UltraFeed VA 4000S Specifications

Input Voltage: Input Frequency: 50/60 Hz Input Voltage Tolerance ±10% Maximum Input Current 4.0 Amps Wire Speed Range for All Filler Wire Sizes Wire Sizes Maximum Wire Coil/Spool Weight Feed Rolls 4 (All Driven) Welding Current (I) 500 A @ 100% Welding Gun/Torch Size Tweco #4 Std Maximum Shielding Gas Inlet Pressure

Weight (Less Wire)

Weight (Less Wire) Approvals NEMA EW 3

115 VAC

50 - 875 IPM

1.25 - 22.1 MPM

0.024 - 1/8" / 0.6 - 3.2

60 lb. / 27 kg

100 P.S.I. / 6.9 Bar

35 lbs. / 15.9 kg VA4000S 28 lbs. / 12.7 kg Separation Unit

IEC 60974-1

• PC board adjustments for enhanced runin control

• a solid state electronic brake for dynamic braking

• four quick change, gear-driven feed rolls

• a gas valve solenoid

• a low voltage gun trigger circuit for operator safety

• a variety of add-on options to configure the unit for any wire-welding situation.

The ULTRAFEED VA 4000S has been designed to comply with CSA NRTL/C, NEMA EW 3, and IEC 60974-1 standards.

Table 2-1: Product Specifications

Art # A-09220

Figure 2-1: Ultrafeed VA 4000S Front View

Manual No. 0-5135 2-3 INTRODUCTION

ULTRAFEED VA 4000S

(

2.06 Features and Benefits

UltraFeed VA 4000S Features & Benefits

Features Benefits

A. Improved wire speed accuracy.

1. Solid State Control

2. Standard Inch/Purge

3. Standard 2 Step / 4 Step

4. Standard Remote Voltage

5. Standard 6'Control Cable A. Ready to weld.

6. Interface Cable, 32' A. Provides communication to Separation Unit

B. Line voltage compensation. C. Load compensation. D. Current limit to motor. A. Allows “cold” inchin

B. Allows purging of gas without running wire. A. Allows gun switch activated control as standard (2 Step) or with preflow, trigger hold, and postflow

A. Allows adjustment of power source arc voltage from the wire feeder.

B. Operator has full control of welding parameters at the wire feeder; can remote power source.

of wire at set wire feed speed.

4 Step).

7. Run-In Parameter Adjustment

8. Ground Fault Protection

9. Input Circuit Breaker A. Provides total system protection.

10. Electronic Motor Protection

11. Small Size A. Takes up small amount of space.

12. Upgradable A. Full set of options to build feeder to your needs.

13. Quick Change Feed Rolls

14. Rotatable Feedhead

15. Gun Clamp Knob

16. Welding Gun Quick Connects A. Offers a quick and easy connection for welding guns.

17. Hinged Feedhead Cover A. Permits quick and easy access to the wire drive system.

18. Dynamic Brake

19. Replaceable Motor Brushes A. Extends motor life.

20. Needle Bearing Construction On MotorOutput Shaft

21. Gas Valve Solenoid A. Controls the “on / off” flow of shielding gas.

22. 100% Duty Cycle A. Eliminates shutdowns due to overtemperature.

A. DIP switch located on motor control board allows operator to tune starting characteristics to improve starting.

A. Provides protection against ground fault currents. B. Signals operator of ground fault with STATUS LED.

A. Protects motor. B. Eliminates need for fuse

A. Allows operator to change feed rolls without the use of tools. B. Both feed rolls are gear-driven. A. Allows operator to modify angle of feedhead to limit severity of bends on the wire. Improved feedability. A. Allows operator to secure welding gun to the feedhead without the use of tools.

A. Solid State control of motor brake offers precise stopping of the wire.

A. Reduces friction and extends bearing life over a sleeve bearing.

rotection.

2.07 Options and Accessories

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

INTRODUCTION 2-4 Manual No. 0-5135

ULTRAFEED VA 4000S

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 controller and between the controller and 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.

Manual No. 0-5135 3-1 INSTALLATION

ULTRAFEED VA 4000S

3.04 Input And Output Wire Guide Installation

Refer to Figure 3-1. 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 toward the wire spool. Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew.

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.

Output Wire Lockscrew

Art # A-07376

Center Wire Guide

Input Wire Guide

Figure 3-1: Wire Guide Installation

INSTALLATION 3-2 Manual No. 0-5135

Output Wire Guide

ULTRAFEED VA 4000S

3.05 Selection And Installation Of Feed Rolls

NOTE

Refer to feed roll kit drawing (supplied in the Appendix) to order feed roll kits. Kit includes 4 drive rolls, an input wire guide, a center guide, and an output wire guide for a specific wire type and size.

For selection of feed roll styles, refer to Feedroll Drive Kit Drawing 171435 and Feedroll Chart 375980 in the Appendix section of this manual.

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.

3.06 Welding Gun Compatibility And Installation

Refer to Figure 3-2. The Ultrafeed VA 4000 S Separation Unit 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.

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 - 1/8" tubular wire.

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 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 rest against the face of the feedroll.

Input Guide Lockscrew

Art # A-04326

Input Wire Guide

Center Wire Guide

Figure 3-2: Welding Gun Installation

Output Guide Lockscrew

Output Wire Guide

Gun Clamp Knob

NOTE

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

Manual No. 0-5135 3-3 INSTALLATION

ULTRAFEED VA 4000S

3.07 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 bearing 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.

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.

Tension Lever

Pressure Arm

Welding Wire

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.

Spring Tension Knob

Art # A-07276

Input Wire Guide

Center Wire Guide

Figure 3-3: Threading Wire Into Feedhead

INSTALLATION 3-4 Manual No. 0-5135

Output Wire Guide

4.01 Front Panel

ULTRAFEED VA 4000S

SECTION 4:

OPERATION

1. FAULT INDICATOR: This LED indicates a fault condition

exists. If it is flashing, a ground fault has occurred. If it is on continuously, the motor protection circuit has activated.

2. WIRE FEED SPEED (WFS) CONTROL:

This knob controls wire feed speed. The wire feed speed control knob can be adjusted during setup or actual welding.

3. WFS/AMP METER: This meter displays the wire feed speed or amperage.

4. WIRE SPEED FORCE METER

5. VOLT METER: Displays possible restriction in liner or

tips.

6. ARC VOLTAGE CONTROL: This knob controls arc voltage or pulse frequency from the power source. The arc voltage (or pulse reference) control can be adjusted during setup or actual welding.

7. FUNCTION TIMERS: These knobs provide timed control over preflow/postflow gas, wire burnback distance and spot weld time.

8. 2 STEP / 4 STEP SWITCH: This switch selects 2 Step or 4 Step mode of operation.

Art # A-09218

Figure 4-1: Front Panel Controls and Connections

Manual No. 0-5135 4-1 OPERATION

ULTRAFEED VA 4000S

4.02 Rear Panel Controls &Connections

11.6' CONTROL CABLE PLUG: The control cable connects

to the power source at the bottom 19-pin amphenol connector (of which 14 pins are used). It contains the signals required to allow the welding power source and the Separation unit to work together as a system. Refer to figure 4-2 and 4-4.

WARNING

CAUTION

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

If the power source only has a 5 pin amphenol and AC voltage outlets, a 870000-001 adapter cable will be required for proper hookup with the Ultrafeed VA 4000 S wire feeder.

The protective earth ground (pin G) of the control cable is established

only when the power source is properly grounded. See the power source owner’s manual for proper grounding methods.

Control Cable

D Not Used E 115 VAC Hot

F 115 VAC Neutral G Protec tive Earth Ground H Remote Control Maximum

J Remote Control Signal

K Remote Control Minimum

L Control Circuit Common

M Arc Established (= +15 VDC)

N Power Source Select Line P Not Used R Not Used S Not Used

T Not Used

V ‘-’ Power Source Terminal

Contactor + (Short ed to B to turn on Power Source) Contactor - (Shorted to A to turn on Power Source) Voltage Feedback ( 1 Volt is 10 Arc Volts), or ‘+’ Power Source Terminal

Current Feedback (1 Volt is 100 Arc Amps)

Function

If the power source only has a 14 pin amphenol, a 870093B-001 adapter cable will be required for proper hookup with the Ultrafeed VA 4000S wire feeder. Refer to section 2.07 Options and Accessories.

Keyway

KUNB

H S RD

CPVTJ

EFG

Figure 4-2: Pin Identification Male Plug

Table 4-1: 19-Pin Control Cable Descriptions

OPERATION 4-2 Manual No. 0-5135

ULTRAFEED VA 4000S

12.32' CONTROL CABLE SOCKET: The 32' control cable connects to the VA 4000 S controller at the upper 19-pin amphenol connector socket (of which 14 pins are used). It contains the signals required to allow the welding power source, controller and the wire feeder to work together as a system. Refer to figure 4-3 and 4-4

WARNING

The protective earth ground (pin G) of the control cable is established

only when the power source is

properly grounded. See the power source owner’s manual for proper grounding methods.

19 PIN CONNECTOR FOR VA4000S

PIN LETTER DESCRIPTION WIRE COLOR WIRE NUMBER

A Motor Plus RED 17 B Motor Negative BLACK 16 CGas Valve BLUE 14 DGas Valve WHITE 15 E Board Pin 4 BLACK N/A

F Dual Schedule Receptacle-not used N/A N/A G Inch/Purge Common RED 11 H Purge BROWN 10

J Inch YELLOW 9

K Gun Switch ORANGE 7

L NOT USED N/A N/A M Board Pin 3 RED N/A N Board Pin 2 YELLOW N/A P Board Pin 1 WHITE N/A R Board Pin 5 BROWN N/A S Dual Schedule Receptacle-not used N/A N/A

T Gun Switch BLUE 8 U Ground GREEN/YELLOW FRAME GROUND V Board Pin 6 ORANGE N/A

Keyway

AML

KUNB

CPVTJ

HSRD

EFG

Figure 4-3: Pin Identification Female Receptacle

Manual No. 0-5135 4-3 OPERATION

ULTRAFEED VA 4000S

13.CAN INTERFACE PORT (J2): This connection allows the ULTRAFEED VA 4000 S to communicate with other select Thermal Arc power sources. This is available with the advanced interface kit.

14.SERIAL PORT (J1): This connection allows the ULTRAFEED VA 4000 S to communicate with a personal computer. This feature is available with the advanced interface kit.

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

16.CIRCUIT BREAKER: This breaker protects the unit from electrical faults.

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 pressing the circuit breaker reset switch.

18.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.

19.32' CONTROL CABLE PLUG: The 32' control cable connects to the VA 4000 S Separation wire feeder/ motor to this 19-pin amphenol connector plug(of which 14 pins are used). It contains the signals required to allow the welding power source, controller and the wire feeder to work together as a system. Refer to Previous Chart and figure 4-2 and 4-5.

20.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.

AML

CPVTJ

EFG

AML

KUNB

H S RD

EFG

Art # A-09225

Figure 4-5: Separation Motor Connections

4.03 Feedhead Components

KUNB

HSRD

CPVTJ

Art # A-09223

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

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

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

24.PRESSURE ARM: This arm pivots off the front of the

Figure 4-4: Rear Panel Controls and Connections

feedhead to allow access to the wire guides and wire path.

25.CENTER GUIDE LOCKSCREW: Tighten this lockscrew to secure the center wire guide.

26.OUTPUT GUIDE LOCKSCREW: Tighten this lockscrew to secure the output wire guide.

OPERATION 4-4 Manual No. 0-5135

ULTRAFEED VA 4000S

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

28.GUN ADAPTER: This adapter accepts the welding gun plug. It can optionally be replaced with different adapters

for a variety of different guns.

29.FEEDHEAD POSITIONING SCREW (3x): These screws are tightened to position the rotation angle of the feedhead. To change the angle of the feedhead, LOOSEN these 3 screws and turn the feedhead to the desired angle. Then tighten the 3 screws to secure.

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

31.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.

Figure 4-6: Separation Feedhead Components

4.04 Power Source Compatibility

3031

Art # A-09224

If the Thermal Arc power source only offers a 14 pin amphenol connector, a 870093B-001 adapter cable will be required to connect between the 19 pin control cable of the VA 4000 S contoller and the 14 pin amphenol connector of the power source.

The Ultrafeed VA 4000 S will also work with most competitive power sources that provide 115 VAC and require a relay closure to become energized.

Manual No. 0-5135 4-5 OPERATION

ULTRAFEED VA 4000S

4.05 Power Source Compatibility Details

Power Source Compatibility Details

Machine Details PowerMaster 500 Fully Compatible PowerMaster 500P For GMAW - Set Motor Control S1 Switches for:

Runin Speed 25%, Motor Ramp Rate 0.3 S, Arc Established ON. For Pulse GMAW - Set Motor Control S1 Switches for: Runin Speed - 75%, Motor Ramp Rate - 0.2 S, Arc Established - ON

ExcelArc 6045 Fully Compatible ExcelArc 8065 For GMAW - Set Motor Control S1 Switches for:

Runin Speed 50%, Motor Ramp Rate 0.2 S, Arc Established ON.

Fabstar 4030 Fully Compatible except: Actual arc amps on the wire feeder will not be show

and preset volts on the power source will not be displayed.

ArcMaster 300 MST Fully Compatible ArcMaster 400 MST Fully Compatible ArcMaster 400 MSTP Fully Compatible

4.06 Prewelding Procedure

Follow all installation instructions for the wire feeder, the welding power source, and the welding gun before attempting to operate the Ultrafeed VA 4000 S.

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, contoller and the wire feeder.

OPERATION 4-6 Manual No. 0-5135

ULTRAFEED VA 4000S

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).

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

WARNING

4.07 Welding - 2 Step Operation

Refer to Figure 4-5. Position the welding gun above the workpiece and de-

press the gun switch trigger. Depressing the gun switch trigger enables the gas valve, wire feed motor, and power source; the welding process begins. To end the weld, release the gun switch trigger which disables the gas valve, wire feed motor, and power source.

NOTE

When the gun switch is released, gas will continue to flow for approximately 0.5 seconds. This is a feature of the system and is normal.

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”.

Gun Trigger

ArcEstablished

Gas

Contactor

WireFeed

Art # A-09232

Ramp Rate

Preﬂow

Figure 4-7: Welding - 2 Step Operation

Manual No. 0-5135 4-7 OPERATION

Runin

Postﬂow

ULTRAFEED VA 4000S

4.08 Welding - 4 Step Operation

Refer to Figure 4-6.

NOTE

When welding in 4 step operation, the Ultrafeed VA 4000 S must recognize an arc (based on Arc Established or current feedback from the power source) within 1.5 seconds after the wire begins feeding. If the Ultrafeed VA 4000 S receives a gun switch trigger and release while in 4 step operation and no arc is recognized, the Ultrafeed VA 4000 S will feed wire for 1.5 seconds and then stop. This is done to prevent the possible injury that could result with the unwanted feeding of wire while not welding.

Position the welding gun above the workpiece and depress the gun switch trigger. The gas will begin to flow. Release the gun switch trigger while maintaining the welding gun in the same position. At this point, the contactor to the power source will enable its output, and the wire will begin feeding, and an arc will get established. The time from releasing the switch to establishing an arc is allowed to be 1.5 seconds, after which the feeder will return to Standby.

To end the weld, depress the gun switch trigger again. The wire will stop feeding, and the power source output will go off. The gas will continue to flow for as long as the gun switch is depressed. Release the gun switch to shut off the gas, ending the postflow period.

NOTE

In 4-Step welding, the user can independently control the amount of preflow and postflow time by adjusting the amount of time the gun switch is depressed.

EXAMPLE:EXAMPLE:

EXAMPLE:

EXAMPLE:EXAMPLE:

For no preflow, depress and release the gun switch trigger as quickly as possible. For 5 seconds preflow, depress the gun switch trigger for 5 seconds before releasing the gun switch trigger. The procedure is the same for postflow.

Gun Trigger

ArcEstablished

Gas

Contactor

Wire Feed

Ramp Rate

Preﬂow

Figure 4-8: Welding - 4 Step Operation

Runin %

Art # A-09233

Postﬂow

OPERATION 4-8 Manual No. 0-5135

4.09 System DIP Switches

The 870309 Motor Control Board contains a 5 position DIP switch that allows the user to (1) optimize the runin wire feed characteristics for optimal starting, and (2) override the Arc Established signal so that the 4 Step Operation can be used on power sources that do not have an Arc Established signal or current feedback.

RUN-IN SPEED RUN-IN SPEED

RUN-IN SPEED

RUN-IN SPEED RUN-IN SPEED

The run-in speed adjustment controls the speed the wire approaches the work at. These switches select a percentage of the set speed. The selectable percentages are 25%, 50%, 75% (default), and 100%. For example, if you have 400 IPM set speed, and have 50% selected here, then the speed of the wire will be 200 IPM until an arc gets established. Once an arc is established, the speed ramps to the set speed at the rate set with Ramp Rate as described in the next paragraph.

ADJUSTMENTADJUSTMENT

ADJUSTMENT

ADJUSTMENTADJUSTMENT

Art # A-07507

ULTRAFEED VA 4000S

PROCEDUREPROCEDURE

PROCEDURE

PROCEDUREPROCEDURE

WARNING

ELECTRIC SHOCK CAN KILL. Remove input power from the wire feeder before making an adjustment to the system DIP switches.

Turn the power source and wire feeder power switches OFF. Remove the eight (8) screws holding the sheet metal cover and carefully remove it from the unit. The 870309 Motor Control Board will contain a 5 position DIP switch labelled S1 (Refer to Figure 4-7 below).

To open any of the DIP switches, push the switch toward the word OPEN, which is labelled on the switch. To close any of the DIP switches, push the switch away from the word OPEN.

After the settings have been made, reattach the sheet metal cover and reapply power to the power source and wire feeder.

RAMP RARAMP RA

RAMP RA

RAMP RARAMP RA

TE TE

ADJUSTMENTADJUSTMENT

ADJUSTMENT

TE TE

ADJUSTMENTADJUSTMENT

Art # A-07508

The ramp rate adjustment sets how fast the wire feeder accelerates the wire. This setting is the amount of time it takes to go from 0 to 875 inches per minute. The times are .1, .2 (default), .3, or .4 seconds. This setting works together with the runin speed adjustment to tune the wire starting characteristic with the power source being used to offer optimal starting.

100%

75%

50%

25%

X 0

X XX

0.4 S

0.3 S

0.2 S

0.1 S

34 0

0 X

ON/Marche OFF/Coupe

ARC

SIGNAL SIGNAL

D'ARC

X = CLOSED O = OPEN

Art: A-07506

Figure 4-9: System DIP Switch

Manual No. 0-5135 4-9 OPERATION

ULTRAFEED VA 4000S

4.10 PTC Protection of A-B Circuit

The A-B contactor circuit on the Ultrafeed VA 4000 S provides a relay closure to the power source through pins A and B of the 19 pin control cable. This allows the welding wire to become electrically ‘HOT’ when the gun switch trigger on the welding gun is pulled. If this relay closure is NOT provided for any reason, the welding wire WILL NOT be electrically ‘HOT’. The wire will feed, but there will be NO arc when the wire touches the work.

The Ultrafeed VA 4000 S has a thermal, self reset protection device in the A-B contactor circuit to protect the circuitry against a fault or overload condition. This protection device will only allow a maximum steady state current in the range of 180 to 450 milliamps (dependent on ambient temperature) to flow through pins A and B of the 19 pin control cable to the A-B contactor circuit on the Ultrafeed VA 4000 S.

If this acceptable current range is exceeded for any reason, the self-reset protection circuit located on the motor control board will be activated effectively disabling the AB contactor circuit. Once the fault or overload condition has been corrected and the current has returned to an acceptable level, the protection device will automatically reset and normal operation can resume.

NOTE

The protection circuit will remain activated (there will be NO arc when the wire touches the work) as long as the acceptable current range is exceeded.

4.11 Ground Fault Operation

The Ultrafeed VA 4000 S has been equipped with a ground fault protection circuit. This protection circuit is activated whenever excessive current flow in the protective earth ground is detected. If the ground fault protection circuit is activated, the yellow FAULT indicator on the front of the feeder will flash at a rate of approximately 1 second on, 1 second off. When a ground fault occurs, the feeder will immediately shut down the feeder, gas valve, and power source contactor. Once the ground fault protection circuit has been set, the wire feeder will not respond to a gun switch closure until the power is reset by turning the feeder off and back on.

NOTE

Before resetting power to the wire feeder after a ground fault occurrence, determine what caused the ground fault and correct the problem before attempting to weld again.

4.12 Electronic Motor Protection

The Ultrafeed VA 4000 S utilizes an electronic protection circuit to protect the motor against overcurrent caused by excessive load on the motor. This protection will normally trip if the motor stays in current limit for about 10 seconds. Should this occur, the protection circuit will trip which will cause the FAULT indicator LED to light continuously. In order to reset this condition, cycle power on the unit.

NOTE

Should this condition occur, check the wire feeding path including the feed rolls. Make sure there are no restrictions or binding of the wire or rolls.

4.13 Software Features

The Ultrafeed VA 4000 S is designed to be upgraded with various options. One of the options (Advanced Interface Kit) allows many features (including timer times, and wire speed limits) to be programmed via one of the serial ports on the feeder through the optional Graphical User Software (GUS) package.

If some of the features on the feeder aren’t working correctly, they may have been set to a different value with GUS. To reset the machine to its default state, turn the unit on while holding the gun trigger, and holding the PURGE and INCH buttons in. After about 10 seconds, the unit should be reset to factory defaults.

NOTE

Take wire feed tension off so that the wire will not feed.

4.14 Arc Signal Overide

Switch #5 on the motor control board configures the wire feeder for the presence of Arc Established signals from a power source. If the power source has either an Arc Established (as most Thermal Arc power sources have), or a Current Feedback signal has (as most competitive power sources have), then this switch should be CLOSED. If the power source does not have these ‘Arc Signals’, then this switch should be OPEN. This switch allows the 2 Step / 4 Step and timer features to work, although they will not be timed from the true start of the arc, but instead from when the gun trigger is pulled.

OPERATION 4-10 Manual No. 0-5135

ULTRAFEED VA 4000S

Making a switch adjustment:Making a switch adjustment:

Making a switch adjustment:

Making a switch adjustment:Making a switch adjustment:

To make an adjustment to the system DIP switches, remove the 8 sheet metal screws from the control box and remove the sheet metal cover and door by gently rocking it forward to pull it free from the feeder assembly. Locate the 870309 Motor Control Board on the opposite side of the feeder assembly as shown in Figure 4-8 below. The DIP switches are locate at the top of the board as shown. Set switch # 5 according to your set up and replace the cover.

Switch # 5

12345

CLOSED

OPEN

Art # A-09244

Front

Figure 4-10: Arc Signal Overide DIP Switch Location and Settings

Manual No. 0-5135 4-11 OPERATION

ULTRAFEED VA 4000S

This Page Intentionally Blank

OPERATION 4-12 Manual No. 0-5135

SECTION 5:

SERVICE

ULTRAFEED VA 4000S

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) pressure. After cleaning the unit, check all electrical components for loose or faulty connections and correct if necessary.

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

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 motor commutator resulting in a shorter motor operating life.

5.03 System Maintenance

The user has been given a visual tool in the feed monitor display. Use the feed monitor display in determining when a new contact tip, liner, and/or wire guide is needed.

5.04 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.

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

5.02 Cleaning The Feed Rolls

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.

Manual No. 0-5135 5-1 SERVICE

ULTRAFEED VA 4000S

5.05 Troubleshooting Guide

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. Use only genuine replacement parts.

A. Unit is completely inoperative - nothing functions

1. Connect the 19 pin power source control cable to the power source and wire feeder Amphenol connectors.

2. Turn the power source ON.

3. Place the power switch of the wire feeder to the ON position.

4. Check the ground fault indicator light.

a. Remove ground fault (refer to Section 4.13

Ground Fault Operation).

5. With the power source turned ON, check for 115 VAC at power source amphenol pins E and F.

a. Refer to the power source owner’s manual.

6. Check continuity of pins E and F of the 19 pin power source control cable.

a. Replace the 19 pin power source control cable.

7. Check to see why the circuit breaker on the wire feeder power switch trips.

a. Allow a short cool down period before

attempting to turn the power switch ON again..

8. Check connections on the power switch of the wire feeder for loose or faulty connections.

a. Repair or replace connection.

B. Wire feed motor operates but wire does not feed

or feeds erratically

1. Check for too little or too much pressure on feed rolls.

a. Increase or decrease the pressure accordingly

with the spring tension knob (refer to Section

3.09 Threading Wire Into Feedhead).

2. Check for incorrect feed roll sizes.

a. Check size stamped on outside of feed roll.

Match to wire size.

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

a. Decrease wire spool tension (refer to Section

3.05 Adjustment Of Spool Tension).

4. Check for restriction in welding gun and cable assembly.

a. Repair or replace gun, cable, liner, or contact

tip.

5. Check for failed insulator on drive gear assembly — motor shaft turning inside insulator.

a. Replace drive gear assembly.

C. Wire wraps around the feed rolls

1. Check for too much pressure on the welding wire.

a. Decrease the pressure with the spring tension

knob (refer to Section 3.09 Threading Wire Into Feedhead).

2. Check alignment of input and output wire guides.

a. Re-align wire guides (refer to Section 3.06

Input And Output Wire Guide Installation).

3. Check to see if correct cable liner and contact tip are being used.

a. Refer to Table in welding gun manual for correct

size.

SERVICE 5-2 Manual No. 0-5135

ULTRAFEED VA 4000S

4. Worn or damaged contact tip.

a. Replace contact tip. Refer to Options and

Accessories chart in the Appendix section of this manual.

D. Wire does not feed with gun switch depressed

1. Check the ground fault indicator light.

a. Remove ground fault (refer to Section 4.13

Ground Fault Operation).

2. Check the continuity of the welding gun trigger leads with the trigger depressed.

a. Repair or replace the welding gun.

3. Check the gun switch receptacle located on the feeder for loose or faulty connections.

a. Repair or replace connection.

4. Check the motor lead connections for loose or faulty connections.

a. Repair or replace connection.

5. Check for a blown fuse on the motor control PC board.

a. Replace the blown fuse (refer to Section 4.11

Replacing Motor Fuse ).

3. With the power switch ON, measure the DC voltage on the motor control PC board from FT2-5 (+) to FT1-5 (-) while adjusting the WFS control knob. The reading should vary from approximately 1 to 10 vdc.

a. Replace the display PC board.

G. No arc voltage (VOLTS) control

1. Make sure the local/remote switch on the power source is in the remote position.

a. Refer to the power source owner’s manual.

2. Check for a loose VOLTS control knob.

a. Tighten the VOLTS control knob.

3. Make sure the ribbon cable assembly is connected to both J1 of the display PC board assembly and J1 of the motor control board assembly.

a. Repair or replace ribbon cable assembly.

H. Wire does not feed with INCH button depressed

1. Check the INCH/PURGE switch located on the wire feeder for loose or faulty connections.

a. Repair or replace connections.

I. Gas does not flow with PURGE button depressed

E. Motor continues to run after gun switch has been

released

1. Check to see if wire feeder is in proper mode (two step or four step).

a. Refer to the Operation Section 4 in this manual.

2. Check for shorted welding gun trigger leads.

a. Repair or replace welding gun.

3. Check for shorted gun switch receptacle located on the wire feeder.

a. Remove the short.

F. No wire feed speed (WFS) control

1. Check for a loose WFS control knob.

a. Tighten the WFS control knob.

2. Make sure the ribbon cable assembly is connected to both J1 of the display PC board assembly and J1 of the motor control board assembly.

a. Repair or replace ribbon cable assembly.

1. Check the INCH/PURGE switch located on the wire feeder for loose or faulty connections.

a. Repair or replace connection.

J. Feed Monitor Display does not function

1. Make sure the ribbon cable assembly is connected to both J1 of the display PC board assembly and J1 of the motor control board assembly.

a. Repair or replace ribbon cable assembly.

Manual No. 0-5135 5-3 SERVICE

ULTRAFEED VA 4000S

K. Wire feeds but no gas flows

1. Check to see if the gas cylinder is empty or the valve closed.

a. Replace gas cylinder or open valve and adjust

flowmeter.

2. Check for a possible restriction in the gas line or gas valve.

a. Remove restriction.

3. Check to see if the welding gun nozzle is plugged.

a. Clean the welding gun nozzle.

4. Check the connections on the gas valve for loose or faulty connections.

a. Repair or replace connection.

L. Gas flows all the time or leaks

1. Make sure all connections are tight.

2. Check for foreign material inside the gas valve.

M. Wire feeds but electrode wire is not hot – there is

no arc

1. Check continuity of pins A and B of the 19 pin power source control cable.

a. Replace the 19 pin power source control cable.

2. Make sure the power source control cable is not damaged. A damaged power source control cable could be activating a protection circuit on the motor control PC board.

a. Refer to Section 4.12 Protection Of A-B Circuit.

SERVICE 5-4 Manual No. 0-5135

SECTION 6:

PARTS LISTS

6.01 Equipment Identification

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

PART NUMBER

W3400001

6.02 How To Use This Parts List

ULTRAFEED VA 4000S

The Parts List is a combination of an illustration (Figure Number) and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All user-serviceable parts are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc. The part descriptions may be indented to show part relationships.

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

Manual No. 0-5135 6-1 PARTS LIST

ULTRAFEED VA 4000S

6.03 Replacement Parts - VA 4000 S Controller Front

Item #Item #

Item #

Item #Item #

QtyQty

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QtyQty

DescriptionDescription

Description

DescriptionDescription

1 2 Knob, Control, 1/4" IDx1.65" 870696 2 4 Knob,Control,.125" IDx.57" OD 870734 3 1 Switch, Toggle Fitted to PCB3 4 1 Switch, Rocker,SP, WF 870359 5 1 Door, UltraFeed 4000, WF 871346WBLKPKD 6 4 Bolt, M6 x 19mm, WF See Note 1 7 4 Foot, 1" OD Rubber .600", WF NB1636PKD 8 2 Plug, Lifting Eye Hole, WF 870716PKD

Note 1

This part is available at most hardware stores.

Catalog #Catalog #

Catalog #

Catalog #Catalog #

Art # A-09219

PARTS LIST 6-2 Manual No. 0-5135

6.04 Replacement Parts - VA 4000 S Controller Rear

ULTRAFEED VA 4000S

Item #Item #

Item #

Item #Item #

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Catalog #Catalog #

Catalog #

Catalog #Catalog #

1 1 S1 Switch, Rocker,SP, WF 870367 2 1 CB1 Circuit Breaker, 4A, WF 203627-009 3 7 Cap, Dust, WF 402128-010 4 1 Connector, 19-PIN Amphenol, Male plug WF 402376 5 1 Connector, 19-PIN Amphenol, Female socket WF 872068 6 4 Spacer, Threaded M6 Rubber, WF 870729PKD 7 1 Base Assembly, VA4000 871358WBLK 8 1 Cover, Assy, VA4000, WF 870521CLA

9 14 Screw, Hexwasher,M5X1.4-13, WF See Note 1 10 1 Spool Hub Assembly 871361 11 1 Nut, Hub, Wire Spool 405377

Art # A-09221

Manual No. 0-5135 6-3 PARTS LIST

ULTRAFEED VA 4000S

6.05 Replacement Parts - VA 4000 S Separation Motor

Item #Item #

Item #

Item #Item #

A 1 Rod, Tension Subassembly, WF 870504

A1 1 Knob,Control,1/4" IDx3/4" 870082 A2 2 Washer,6.4mm,Flat See Note 1 A3 1 Insulator, Plastic Top , WF 870424 A4 1 Insulator, Plastic Bottom, WF 870427 A5 1 Spring,Pressure Adj,2R Plate 400562-033 A6 1 Washer,1/4" IDx0.73" OD,Flat See Note 1 A7 1 Pin, Roll, 3/32" ODx1/2" 7962029PKD A8 1 Rod,Tension Arm,2R & 4R Plate 870425 A9 1 Tension Arm, U Bushing, WF 870511

A10 1 Pin, Roll, 0.1" ODx.75" 7962034PKD

11 1 Cover, Left Feedhead, WF 871949 12 1 Spring, Input , WF 376037 13 1 Screw,PHCR,#10-24x1/2" See Note 1 14 1 Guide, Input, WF 406397 15 1 Adapter, Gun TWECO, WF 870948BB

QtyQty

Qty

QtyQty

DescriptionDescription

Description

DescriptionDescription

Catalog #Catalog #

Catalog #

Catalog #Catalog #

16 1 Knob, Torch Locking 10-6187 17 1 Hose 5/32" ID See Note 1 18 4 Foot, 1" OD Rubber .600", WF 872078 19 4 Bolt, M6 x 19mm, WF See Note 1 20 2 S3,S4Switch, Rocker,SP,Mom, WF 870358 21 1 Connector, 19-PIN Amphenol, Male plug WF 402376 22 4 Adaptor, Gas RH 1/8NPT-5/8, WF 7978024

Not shown 1 Cover 870519CLA

1 Base 870518WBLK 1 Motor Mount Plate 870520WBLK 1 Feeder Cover, Latch 871621

Note 1

This part is available at most hardware stores.

PARTS LIST 6-4 Manual No. 0-5135

ULTRAFEED VA 4000S

1 2 3

5 6 7

8 9 10

Art # A-09238

Manual No. 0-5135 6-5 PARTS LIST

ULTRAFEED VA 4000S

This Page Intentionally Blank

PARTS LIST 6-6 Manual No. 0-5135

ULTRAFEED VA 4000S

APPENDIX 1: FEED ROLL KITS

DRIVE ROLL KITS (#375980-Series) 4 ROLL

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

Double Smooth

Top

Bottom Wire Type Wir e Size

.024" / 0.6mm 375980-071 - - - - .030", .035" / 0.8, 0.9mm 375980-041 375980-043 375980-050 - - .030", .035", .045" / 0.8, 0.9, 1.2mm 375980-068* 375980-069 - - - .035" / 0.9mm 375980-080* - 375980-050 - - 375980- 072 .035", .045" 3/64" / 0.9, 1.2, 1.2mm - - 375980-070 - - .045" / 1.2mm 375980-042* 375980-044 - 375980-083 375980-062 3/64 / 1.2mm - - 375980-051 - - 375980-073 .052" / 1.3mm 375980-081* - - - - .052", 1/16" / 1.3, 1.6mm - - 375980- 052 375980-057 375980-083 1/16" / 1.6mm 375980-045* - - - - 375980-074 .068" / 1.7mm - - - 375980-057 - 5/64" / 2.0mm 375980-046* - - 375980-058 375980-064 3/32" / 2.4mm - - - 375980-059 375980-065 7/64" / 2.8mm - - - 375980-060 375980-066 1/8" / 3.2mm - - - 375980-061 375980-067 -

Notes: 1) One Kit is supplied standard w ith each w ire feeder (tw o kits w ith dual).

2) Drive Roll Kits include: Drive Rolls; Input, Output & Center Guides

3) Narrow 30° "V"

Flat Flat Kn ur led

Double

Smooth "V"

Hard Hard Sof t/Hard/Tubular Hard/Tubular Tubular Sof t (A luminum)

Double

Smooth "V"

"V"

Double Smooth

"V"

Double

Knurled "V" Double Cog Double "U"

Double

Knurled "V" Double Cog Double "U"

Manual No. 0-5135 A-1 APPENDIX

ULTRAFEED VA 4000S

APPENDIX 2: OPTIONS AND ACCESSORIES

KITS

Dual Schedule Kit W4008001 Provides a second schedule for wire feed speed and voltage Advanced Interface Kit 870379

ACCESSORIES

Drive Roll Kits 375980-XXX One kit (#375980-083) is supplied standard with each wire

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

Control Cable 32ft (9.8 m) 871950 Wire Spool Adaptor 10 lb (4.5kg), 8” spool 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 Adaptor Kits Tweco® #5 870395

Miller® 870397 Euro-style 171449 Cable Adapters 19 pin wire feeder to 5 pin power source 19 pin wire feeder to 14 pin power source

PART NO.

375585-001

870000-001 For older style power sources

870093B-001 For Miller® or 14 pin style power sources

19 pin plug; start/stop; schedule select; inch & purge inputs; arc standby & fault outputs; 0-10VDC analog input

feeder, see drive roll kit chart to select a different drive roll style Control cable from Power Source to Controller ONLY (A 6ft.control cable #374878-006 is supplied with the system)

Connects Controller to Separation Unit ONLY.

DESCRIPTION

APPENDIX A-2 Manual No. 0-5135

APPENDIX 3: SYSTEM OUTLINE

6’

ULTRAFEED VA 4000S

Customer

Wire

32’

Art # A-09222

Manual No. 0-5135 A-3 APPENDIX

ULTRAFEED VA 4000S

This Page Intentionally Blank

APPENDIX A-4 Manual No. 0-5135

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, indirect 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, resale, or use of any goods covered by or furnished by THERMADYNE whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

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 risk and expense. This warranty supersedes all previous THERMADYNE warrantiesWarranty SCHEDULE

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 Inductors 5 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-Conductors 1 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, 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 / 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-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 / 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 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 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-Conductors 1 year / 1 year

See the Engine

Manufacturers’ Warranty

for Details

Original Main Power Magnetics 5 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-Conductors 1 year / 1 year

GENERAL ARC EQUIPMENT Parts / Labor

FirePower® MIG Welders 5-2-1 years / NA Water Recirculators 1 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

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

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 VA 4000S 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 Symbol Chart

2.05 General Information

2.06 Features and Benefits

2.07 Options and Accessories

3.01 Connections

3.03 EMI Considerations

3.02 Grounding

3.04 Input And Output Wire Guide Installation

3.05 Selection And Installation Of Feed Rolls

3.06 Welding Gun Compatibility And Installation

3.07 Threading Wire Into Feedhead

4.01 Front Panel

4.02 Rear Panel Controls &Connections

4.03 Feedhead Components

4.04 Power Source Compatibility

4.05 Power Source Compatibility Details

4.06 Prewelding Procedure

4.07 Welding - 2 Step Operation

4.08 Welding - 4 Step Operation

4.09 System DIP Switches

4.10 PTC Protection of A-B Circuit

4.11 Ground Fault Operation

4.12 Electronic Motor Protection

4.13 Software Features

4.14 Arc Signal Overide

5.01 Cleaning The Unit

5.03 System Maintenance

5.04 Troubleshooting Guide

5.02 Cleaning The Feed Rolls

5.05 Troubleshooting Guide

6.01 Equipment Identification

6.02 How To Use This Parts List

6.03 Replacement Parts - VA 4000 S Controller Front

6.04 Replacement Parts - VA 4000 S Controller Rear

6.05 Replacement Parts - VA 4000 S Separation Motor

APPENDIX 1: FEED ROLL KITS

APPENDIX 2: OPTIONS AND ACCESSORIES

APPENDIX 3: SYSTEM OUTLINE

Statement of Warranty

Warranty SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION