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ULTRAFEED® VA 4000 - Victor Technologies

1. O 0 Art 06984 60 Figure 4 4 Feedhead Components 4 4 September 18 2012 ULTRAFEED VA 4000 4 04 Power Source Compatibility The Ultrafeed VA 4000 wire feeder will work with any Thermal Arc CV or 00 power source If the Thermal Arc power source only offers a 5 pin amphenol connector and AC voltage outlets 870000 001 adapter cable will be required to connect between the 19 pin control cable of the wire feeder and the 5 pin amphenol connector and voltage outlets of the power source 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 wire feeder and the 14 pin amphenol connector of the power source The Ultrafeed VA 4000 will also work with most competitive power sources that provide 115 and require a relay closure to become energized 4 05 Power Source Compatibility Details owerMaster 500 PowerMaster 500P xcelArc 6045 ExcelArc 8065 Fabstar 4030 rcMaster 300 MST rcMaster 400 MST rcMaster 400 MSTP September 18 2012 Power Source Compatibility Details Fully Compatible For GMAW Set Motor Control 51 Switches for Runin Speed 25 Motor Ramp Rate 0 3 S Arc Established ON For Pulse GMAW Set Motor Control 51 Switches for Runin Speed 75 Motor Ramp Rate 0 2 S Arc Established ON Fully Compatible
2. 6 2 6 04 Replacement Parts Rear 6 4 0 03 184 22884 ee 6 5 6 06 Replacement Parts Feed Head and Base i22 een 6 6 APPENDIX 1 FEED ROLL KITS s atu usan A 1 APPENDIX 2 OPTIONS AND ACCESSORIES A 2 APPENDIX 3 SYSTEM OUTLINE A 3 LIMITED WARRANTS nne 2 WARRANTY SCHEDULE ds 3 GLOBAL CUSTOMER SERVICE CONTACT 9 ULTRAFEED VA 4000 SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS A 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 ifthe 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 a
3. 1 46 po 25 4 150 mm 40 5 Soudage Ihydrog ne toutes toutes conditions atomique AHW Souda e l arc en un lectrode de carbone e Soudage avec lectrode enrobees moins de 5 32 po 4 mm Coupage l arc Plasma PAC SMAW 8824 A po 4 84 mm mons de 30 amps 9 ps de po 6 4 mm de 300 4400 amper s plus 400 amper s September 18 2012 1 7 ULTRAFEED VA 4000 7 Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones a souder ont t gratt es a fond que si l espace est bien ventil si n cessaire portez un respirateur 4 ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie BZ _ jsg ece ee Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit des particules volantes ou des projections peuvent atteindre des mat riaux
4. Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high 9 WARNING als 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 Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners 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 18 safe 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 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 cont
5. For GMAW Set Motor Control 51 Switches for Runin Speed 50 Motor Ramp Rate 0 2 S Arc Established ON 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 Fully Compatible Fully Compatible ully Compatible 4 5 ULTRAFEED VA 4000 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 1 Make sure all necessary connections have been made Refer to Connections in the Installation chapter of this manual 2 Turn ON the power source and the wire feeder 3 Push the PURGE switch of the feeder and adjust the flow of shielding gas 4 Push the INCH switch of the feeder and adjust the wire feed speed to the desired value by means of the wire feed speed control A 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 A AAA A e 5 Adjust the voltage of the power source to the desired value The gun switch must be triggered to close power source contactor A WARNING In semiautomatic or automatic wire welding the welding wire wire reel if used input guide feed rolls output guide feedhead and welding gun metal parts
6. WIRE SPEED FORCE METER VOLT METER Displays possible restriction in liner or tips 7 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 FUNCTION TIMERS These knobs provide timed control over preflow postflow gas wire burnback distance and spot weld time 2STEP 4 STEP SWITCH This switch selects 2 Step or 4 Step mode of operation 10 GAS PURGE SWITCH This switch will purge shielding gas when pressed 11 INCH SWITCH This switch will feed wire at the INCH speed default of set speed The feeder does not activate the contactor on the power source Thus the wire will be cold as long as the power source outputs are controlled by the contactor Figure 4 1 Front Panel Controls and Connections September 18 2012 4 1 ULTRAFEED VA 4000 4 02 Rear Panel Controls amp Connections 11 4 2 CONTROL CABLE SOCKET The control cable connects to the power source at this 19 pin amphenol connector of which 14 pins are used It contains the signals required to allow the welding power source and the wire feeder to work together as a system A 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 Control Cable Functio
7. tre br lant et sous pression 01 7 pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon 1 06 Principales Normes De Securite Safety in Welding and Cutting norme ANSI 249 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 287 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association
8. 043 375980 050 030 035 045 0 8 0 9 1 2mm 375980 068 375980 069 035 0 9mm 375980 080 375980 050 035 045 3 64 0 9 1 2 1 2mm 1 375980 070 375980 072 375080 083 375980082 375980 051 375980073 375980 052 375980 057 375980 083 375080074 375980 057 045 1 2mm 375980 042 375980 044 64 1 2mm 052 1 3mm 375980 081 052 1 16 1 3 1 6mm 16 1 6mm 375980 045 068 1 7mm 64 2 0mm 375980 046 32 2 4mm 7 64 2 8mm 1 8 3 2mm Notes 1 One Kit is supplied standard w ith each w ire feeder tw o kits with dual 2 Drive Roll Kits include Drive Rolls Input Output amp Center Guides 3 Narrow 30 V RE i PA 375980 064 375080 059 375980065 975880050 537598006 7980 061 37558067 March 17 2006 A 1 ULTRAFEED VA 4000 APPENDIX 2 OPTIONS AND ACCESSORIES KITS Dual Schedule Kit Advanced Interface Kit ACCESSORIES Drive Roll Kits Control Cable 6 ft 1 8m 15ft 4 5m 25ft 7 6m 50ft 15 2m 100ft 30 5m Interconnect Gable Assembly 6 ft 1 8m 15ft 4 5m 25ft 7 6m 50ft 15 2m Wire Spool Adaptor 10 Ib 4 5 0 8 spool 15 Ib 6 8kg 8 5 Spool Cover 30 Ib 13 6kg spool 60 Ib 27 2kg 5 PART NO W4008001 870379 375980 XXX 374878 006 374878 015 374878 0
9. 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 www thermadyne com
10. Check for shorted gun switch receptacle located on the wire feeder a Remove the short 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 September 18 2012 ULTRAFEED VA 4000 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 vac a Replace the display PC board No arc voltage VOLTS control 1 Make sure the local remote switch on the power source 18 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 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 Gas does not flow with PURGE button depressed 1 Check the INCH PURGE switch located on the wire feeder for loose or faulty connections a Repair or replace connection
11. are all ELECTRICALLY HOT 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 re lease 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 Gun Trigger Arc Established Gas Contactor Wire Feed Preflow 4 6 Art A 06986 September 18 2012 Figure 4 5 Welding 2 Step Operation 4 08 Welding 4 Step Operation Refer to Figure 4 6 NOTE When welding in 4 step operation the Ultrafeed VA 4000 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 receives a gun switch trigger and release while in 4 step operation and no arc 18 recognized the Ultrafeed VA 4000 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
12. 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 and make sure that there is not any restrictions or binding on the wire and that the feedrolls aren t locked by some obstruction 4 13 Software Features The Ultrafeed VA 4000 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 9 ULTRAFEED VA 4000 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 Therma
13. by or furnished by Thermal Arc whether arising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty and Thermal Arc shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in Thermal Arc s sole judgment impaired the safety or performance of any Thermal Arc product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shal
14. 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 EXAMPLE ULTRAFEED VA 4000 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 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 Arc Established Gas Contactor WireFeed Preflow Art A 06986 Figure 4 6 Welding 4 Step Operation September 18 2012 4 7 ULTRAFEED VA 4000 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 powe
15. 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 ON Marche 0 OFF Coupe ARC SIGNAL SIGNAL D ARC X CLOSED OPEN Art A 07506 Figure 4 7 System DIP Switch 4 8 September 18 2012 4 10 PTC Protection of A B Circuit The A B contactor circuit on the Ultrafeed VA 4000 provides a relay closure to the power source through pins Aand 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 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 Ifthis acceptable current range is exceeded for any reason the self reset protection circuit located on the motor control board will be
16. 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 NOTE Installation of all styles of feed rolls for this feeder is identical 3 4 3 08 Welding Gun Compatibility And Installation Refer to Figure 3 3 The Ultrafeed VA 4000 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 Output Guide Lockscrew Gun Clamp Input Guide Lockscrew Knob Art A 04326 O Input Wire Guide Output Wire Guide Center Wire Guide Figure 3 3 Welding Gun Installation September 18 2012 3 09 Threading Wire Into Feedhead Refer to Figure 3 4 1 A WARNING ELECTRIC SHOCK CAN KILL Make certain the power sour
17. 25 374878 050 374878 100 W4009200 W4009201 W4009202 W4009203 375585 001 375864 001 375582 004 375733A 001 DESCRIPTION Provides a second schedule for wire feed speed and voltage 19 pin plug start stop schedule select inch amp purge inputs arc standby amp fault outputs 0 10VDC analog input One kit 375980 083 is supplied standard with each wire feeder see drive roll kit chart to select a different drive roll style Control cable from wire feeder to power source A 6ft control cable 374878 006 is supplied with the wire feeder Complete interconnect assembly from wire feeder to power source includes control cable welding power cable and gas hose in a sheathed cover Wire Reel Kit 870059 Wire Coil Adaptor 14 Ib 6 4kg coil 375942 A 60 Ib 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 870000 001 For older style power sources 5 pin power source 19 pin wire feeder to 14 pin power source 870093B 001 For Miller or 14 pin style power sources March 17 2006 ULTRAFEED VA 4000 APPENDIX 3 SYSTEM OUTLINE Art A 07407 3 March 17 2006 LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 LI
18. A4000 Hinge Mtg Hardware VA4000 Adaptor Gas RH 1 8NPT 5 8 WF Connector 19 pin Amphenol WF Potentiometer 2 WATT 5K WF PCB Meter Display VA4000 Spacer Threaded M6 Rubber WF Gear Retainer Drive WF Gear Drive Assy WF ULTRAFEED VA 4000 Catalog 870346 001 870320 872031 870507 870309 870689PKD 7978024 402376 401428 008 870312 870729PKD 872029 870386 6 5 ULTRAFEED VA 4000 6 06 Replacement Parts 6 6 item N Qty Description Gear Idler Assy WF Center Guide Cover Mount Bolt Packaged Thumb Screw Insulator Screw mtg 4R Plate Buss Bar Fitting Swivel Hose WF Gas Nipple 10 32 UN 2R Plate Barb Extended 10 32 VA4000 Pressure Arm Cast Assy WF Feedplate Assy Left WF Base Assy VA4000 Catalog 871001PKD 375838 004 26372003 870431 872030 870428 375298 870724 870510 870502 871358WBLK September 18 2012 ULTRAFEED VA 4000 APPENDIX 1 FEED ROLL KITS DRIVE ROLL KITS 375980 Series 4 ROLL FEED ROLL STYLES ke Prime uk dee S nke FLAT KNURLED 2 DOUBLE COG DOUBLE U 10 il DOUBLE U Style 1 Style 2 Style 3 Style 4 Style 5 Style 6 Double Smooth Double Double Double Double Smooth Double Hard Soft Hard Tubular Hard Tubular Soft Aluminum 024 0 3769800 030 035 0 8 0 9mm 375980 041 375980
19. AFEED VA 4000 1 12 September 18 2012 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 A WARNING A WARNING gives information regarding possible personal injury CAUTION A CAUTION refers to possible equipment damage NOTE ANOTE 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 September 2012 ULTRAFEED VA 4000 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 t
20. 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 September 18 2012 1 03 Symbol Chart ULTRAFEED VA 4000 Note that only some of these symbols will appear on your model 4 Dangerous Voltage e O Circuit Breaker AC Auxiliary Power Hertz cycles sec os LN Direct Current DC Ground Doe Auxiliary Power 115V 15A YS Receptacle Rating Auxiliary Power Wire Feed Function Three Phase Static Frequency Converter Transformer Rectifier Os m Shielded Metal zt Arc Welding SMAW 17777 E Wire Feed Towards Workpiece With Output Voltage Off Purging Of Gas Continuous Weld Mode Spot Weld Mode Gas Tungsten Arc Welding GTAW 7 Air Carbon Arc Cutting CAC A Constant Current Constant Voltage Or Constant Potential EN High Temperature Fault Indication Arc Force Meters Per Minute Variable Inductance A Voltage Input Art A 04130_AB 2 Step Trigger Operation Press to initiate wirefeed and welding release to stop ga 4 Step Trigger Operation Press and hold for preflow release to start arc Press to stop arc and hold for preflow Burnback Time Inches Per Minute Note For environments with increased hazard of electrical shock Power Supplier beari
21. Batterymarch Park Quincy MA 02269 1 9 ULTRAFEED VA 4000 1 07 Graphique de Symbole Seulement certains de ces symboles apparaitront sur Sous Tension Tension dangereuse rm O Disjoncteur Source AC Auxiliaire Fusible Intensit de Courant Tension Hertz cycles sec E HIE Courant Continue DC Terre de Protection Da D DD Connexion de la Ligne Source Auxiliaire 115V 15A Nu Augmentez Diminuer Classement de Prise Source Auxiliaire votre modele Tri Phase Statique Fr quence Convertisseur Transformateur Redresseur Distant Facteur de Marche Pourcentage Panneau Local Soudage Arc Electrique Avec Electrode Enrob SMAW Soudage L arc Avec Fil Electrodes Fusible GMAW Soudage L arc Avec Electrode Non Fusible GTAW Decoupe Arc Carbone CAC A Courant Constant Tension Constante Ou Potentiel Constant Haute Temp rature Force d Arc Amorcage de L arc au Contact GTAW Inductance Variable o D roulement du Fil Alimentation du Fil Vers la Piece de Fabrication Hors Tension Torch de Soudage Purge Du Gaz Mode Continu de Soudure Soudure Par Point Dur c du Pulse Dur e de Pr Debit Dur e de Post Debit D tente a 2 Temps IM lt I Appuyez pour deruarer Palimentation du fils et la soudure le rel cher pour arr ter D tente a 4 Temps Maintenez appuyez pour pr d bit re
22. Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 MATOS 1 1 1 02 Principal Safety Standart en a 1 4 E 1 5 1 04 Precautions De Securite En Soudage 1 6 1 05 Dangers relatifs au soudage Parc cti 1 6 1 06 Principales lt 06 1 9 1 07 de Symbolen een 1 10 1 08 Declaration Of Conformity essen 1 11 SECTION 2 INTRODUCTION 2 1 2 DT This aussen sated daar 2 1 2 02 Equipment 2 1 2 03 Receipt Of Equipment anne u 2 1 2 04 MD 2 2 2 05 General ON MAREC RES 2 3 2 06 FEATURES and BENENIS A 2 4 2 07 Options and ACCESSONIGS ee 2 4 SECTION 3 L 2 1 2 0 T 2 1 2 1 3 03 EMI CONSI X 2 1 3 04 Installation Of Welding Wire Spool un 2 2 3 05 Adjustment OF Spool Tension scr en 2 2 3 06 Input And Output Wire Guide Installation 2 3 3 07 Selection And Instal
23. ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs September 18 2012 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent 2 4 AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant a ras bord pr voyez de pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur gt we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples A Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst
24. 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 5 3 ULTRAFEED VA 4000 K Wire feeds but no gas flows 5 4 1 Check to see if the gas cylinder is empty or the valve closed a Replace gas cylinder or open valve and adjust flowmeter Check for a possible restriction in the gas line or gas valve a Remove restriction Check to see ifthe welding gun nozzle is plugged a Clean the welding gun nozzle Check the connections on the gas valve for loose or faulty connections a Repair or replace connection Gas flows all the time or leaks 1 Make sure all connections are tight 2 Check for foreign material inside the gas valve 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 Referto Section 4 12 Protection Of A B Circuit September 18 2012 SECTION 6 PARTS 11515 6 01 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making in
25. Guide Input Wire Guide Output Wire Guide Figure 3 2 Wire Guide Installation September 18 2012 3 3 ULTRAFEED VA 4000 3 07 Selection And Installation Of Feed Rolls NOTE Refer to feed roll kit drawing supplied in the Appendix to order feed roll kits Kit includes 4 drive rolls an input wire guide a center guide and an output wire guide for a specific wire type and size For selection offeed 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 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
26. IHERMAL A RC VA 4 ULTRAFEED SEMIAUTOMATIG WIRE FEEDER Operating Manual evision Issue Date September 18 2012 Manual 8 0 4836 11 875 MEN ES s CV IHERMAL ARC 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 market leading dependable products that have stood the test of ti
27. MITED WARRANTY Thermal Arc Inc A Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal 5 specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct such defects by suitable repair or replacement at Thermal 5 sole option of any components or parts of the product determined by Thermal Arc to be defective This warranty is exclusive and in lieu of any warranty of merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including but not limited to lost profits and business interruption The remedies of the purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered
28. MULTI PROCESS INVERTER WELDING EQUIPMENT LABOR 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year PLASMA WELDING EQUIPMENT LABOR Ultima 150 Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years Welding Console Weld Controller Weld Timer 3 years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year 1 year SMAW Stick WELDING EQUIPMENT WARRANTY PERIOD Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 160S 300S 400S Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 day
29. activated effectively disabling the A B 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 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 September 18 2012 ULTRAFEED VA 4000 4 12 Electronic Motor Protection The Ultrafeed VA 4000 utilizes an electronic protection circuit to protect the motor against overcurrent caused
30. aining these elements can give off toxic fumes if welded Torch soldering Torch brazing Under 1 25mm C Oxygen Cutting Gas welding 1 8 to 1 2 in 3 12 mm 0 0 0 0 0 0 E Under 1 8 in 3 mm 8 Over 1 2 in 12 mm Over 1 4 in 6 4 mm goggles or helmet from AWS A6 2 73 2 Gasmetarare Ferrous base metal All 12 Under 1 in 25 mm Gas tungsten arc welding 2 Atomic hydrogen welding 1 to 6 in 25 150 mm TIG Carbon arc welding r Over 6 in 150 mm r Plasma arc welding r Carbon air gouging Shielded metal arc Under 5 32 in 4mm_ 10 14 l 5 32 to 1 4 in Plasma cutting BEE 300 to 400 Over 400 Amp 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 gt Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from weld
31. all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases Do not use welder to charge batteries or jump start vehicles Boo m 1 Use equipment outside in open well ventilated areas Observe correct polarity 4 and on batteries September 18 2012 1 3 ULTRAFEED VA 4000 EN 1 02 Principal Safety Standards WARNING Safety in Welding and Cutting ANSI Standard Z49 1 from American STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure a lt lt gt 1 Do not remove radiator cap when engine is hot Allow engine
32. ard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 05 Dangers relatifs au soudage l arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 N enroulez pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement dun la piece souder L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le
33. b Control 125 IDx 57 OD Switch Toggle Switch Rocker SP WF Door UltraFeed 4000 WF Switch 5 WF Bolt M6 x 19mm WF Foot 1 OD Rubber 600 WF Knob Torch Locking Cover Left Feedhead WF Spring Input WF Adapter Gun TWECO WF Guide Input WF Screw PHCR 10 24x1 2 Plug Lifting Eye Hole WF This part is available at any hardware store 6 2 Catalog 7 870504 870082 See Note 1 870424 870427 400562 033 See Note 1 7962029PKD 870425 872028 7962034PKD 870696 870734 Fitted to PCB3 870359 871346WBLKPKD 870358 See Note 1 NB1636PKD 10 6187 870687PKD 376037 870948 406397 See Note 1 870716PKD September 18 2012 ULTRAFEED VA 4000 September 18 2012 ULTRAFEED VA 4000 6 04 Replacement Parts 6 4 Item Qty 1 1 2 1 3 6 4 1 5 1 6 1 7 1 Description Switch Rocker SP WF Circuit Breaker 4A WF Plug Black Nylon Snap WF Cap Dust WF Spool Hub Assembly Nut Hub Wire Spool Cover Assy VA4000 WF Catalog 7 870367 203627 009 870716PKD 402128 010 871361 405377 871050CLA September 18 2012 6 05 Replacement Parts Qty el gt A N k BR po a September 18 2012 Description Motor Angle Drive Gear WF PCB Encoder Driver VA4000 Plastic Knob Latch Solenoid Assy WF PCB Motor Control V
34. ce 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 18 straight and free of burrs Place end of the welding wire into the input wire guide Feed itthrough the guide and over the drive roll groove closest to the feedhead casting 2 Loosen the spring tension knob and pull the tension lever forward to unlock the pressure arm Tension Lever 3 ULTRAFEED VA 4000 Lift the pressure arm and pass the wire through the output wire guide and into the welding gun assembly Refer to welding gun manual 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 Ifthe force applied to the wire is too great the welding wire will bird nest in the feedhead and not feed properly 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 pastthe gun nozzle Thread the contact tube over the wire an
35. changeover of guides and guns The ULTRAFEED VA 4000 comes with an abundance of standard features including e an on off rocker switch a circuit breaker for total system protection a Wire feed speed control e a power source voltage control aninch switch agas purge switch e step 4 step selector switch PC board adjustments for enhanced runin control e a solid state electronic brake for dynamic braking four quick change gear driven feed rolls agas valve solenoid alow voltage gun trigger circuit for operator safety avariety of add on options to configure the unit for any wire welding situation The ULTRAFEED VA 4000 has been designed to comply with CSA NRTL C NEMA EW 3 and IEC 60974 1 standards September 2012 ULTRAFEED VA 4000 Wire Speed Range 50 875 IPM Maximum Wire Welding Current I 500 A 100 Welding Gun Torch Size Tweco 4 Std Maximum Shielding Gas 100 PSI 6 9 Bar Inlet Pressure Weight Less Wire 41 105 18 5 kg Approvals NEMA EW 3 IEC 60974 1 Table 2 1 Product Specifications Art A 06983 Figure 2 1 Ultrafeed VA 4000 Front View 2 3 ULTRAFEED VA 4000 2 06 Features and Benefits UltraFeed VA 4000 Features amp Benefits Features Benefits A Improved wire speed accuracy B Line voltage compensation C Load compensation D Current limit to motor A Allows cold inching of wire at set wire feed spe
36. circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m talliques en contact avec le fil de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux Bm gt zz 7q xp 14 Portez un harnais de s curit si vous travaillez en hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif a moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez 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 viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et
37. d lock into place and tighten Cut wire off at about 1 4 inch 6 mm from the nozzle A WARNING The wire is electrically HOT if wire is fed by depressing the gun switch Wire contact with the workpiece will cause an arc with gun switch depressed Feed motor will run feeding HOT wire Pressure Arm Spring Tension Knob Welding Wire 8 Pa 8 Sb 4 o O 6 i Art A 07276 5 I Input Wire Guide Output Wire Guide Center Wire Guide Figure 3 4 Threading Wire Into Feedhead September 18 2012 3 5 ULTRAFEED VA 4000 3 6 September 18 2012 ULTRAFEED VA 4000 SECTION 4 OPERATION 4 01 Front Panel 1 WIRE GUN SWITCH RECEPTACLE The gun switch receptacle accepts the welding gun control wires The gun switch receptacle is where a gun switch closure is inputted to the wire feeder FAULT INDICATOR This LED indicates a fault condition exists If itis flashing a ground fault has occurred If it is on continuously the motor protection circuit has activated FEED SPEED WFS CONTROL This knob controls wire feed speed The wire feed speed control knob can be adjusted during setup or actual welding WFS AMP METER This meter displays the wire feed speed or amperage
38. deaux ou de cloisons pour prot ger et aux produits nettoyants les autres des coups d arc ou de l blouissement avertissez les 5 Ne travaillez dans un espace confin que s il est bien ventil sinon observateurs de ne pas regarder l arc portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de peuvent r agir 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 8 2 73 Op ration de coupage a Nuance de Operation de coupage ou Nuance de ou soudage p filtre oculaire ou soudage p 4 ou Intensit de courant Intensit de courant Brassage tendre Soudage l arc sous gaz toutes conditions ewe 2 avec fil plein GMAW Brassage fort toutes conditions 3 ou 4 m taux non ferreux toutes conditions au CE E l arc sous gaz avec moins de 1 po 25 mm lectrode de tungst ne GTAW toutes conditions
39. e used to diagnose and correct unsatisfactory operation or failure of the various components of the wire feeder Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem Safety To ensure safe operation and service read this entire manual before attempting to service or repair this machine The service technician may be asked to check voltage levels while the machine is turned ON To assure safety use care and follow all instructions accordingly 5 1 ULTRAFEED VA 4000 5 05 Troubleshooting Guide I 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 20 WARNINGS 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 conneclors 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 Wi
40. e 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 September 18 2012 a Referto Table in welding gun manual for correct Size 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 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 Refertothe Operation Section 4 in this manual 2 Check for shorted welding gun trigger leads a Repair or replace welding gun 3
41. ed 2 standard Inch Purge B Allows purging of gas without running wire A Allows gun switch activated control as standard 2 Step or St 2 Step 4 St SEN with preflow trigger hold and postflow 4 Step 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 Standard 6 Control Cable A Ready to weld 4 Standard Remote Voltage DIP switch located on motor control board allows operator to 6 Run In Parameter Adjustment tune starting characteristics to improve starting gt Ground A 100 protection against gramo fault currents B Signals operator of ground fault with STATUS LED Input Circuit Breaker A Provides total system protection Electronic Motor Protection A Protects Eliminates need for fuse protection 0 Small Size Takes up small amount of space Upgradable Full set of options to build feeder to your needs 12 Quick Change Feed Rolls A Allows operator to change 1660 rolls without the use of tools B Both feed rolls are gear driven 13 Botatahlls A Allows operator to modify angle of feedhead to limit severity of bends on the wire Improved feedability 14 Gun Clamp Knob A Allows operator to secure welding gun to the feedhead without the use of tools 15 Welding Gun Quick Connects Offers a quick and easy connectio
42. eme arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative NW approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX September 18 2012 ULTRAFEED VA 4000 Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur E 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
43. event falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards A WARNING Engines can be dangerous 9 WARNING ENGINE EXHAUST GASES can kill 2 ULTRAFEED VA 4000 If used in a closed area vent engine exhaust outside and away from any building air intakes 2 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine E we 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
44. he 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 future reference 2 03 Receipt Of Equipment When you receive the equipment check against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping Ifthere 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 Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 1 ULTRAFEED VA 4000 2 04 Symbol Chart Note that only some of these symbols will appear on your model Wire Feed Towards O Off 3 NL Three Phase Workpiece With Output Voltage Off Three Phase Static Dangerous Voltage Frequency Converter De gt Continuous Weld Circuit Breaker Duty Cycle Mode Shielded Metal Gas Metal Arc Gas Tungsten Arc 2 Step Trigger Hertz cycles sec Welding GTAW Operation Press to initiate wirefeed and Air Carbon Arc i welding release to stop Frequenc
45. inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque 4h AVERTISSEMENT 2 LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recomma
46. ing can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use gt Light 12 Light Under 300 Amp 9 September 18 2012 B WARNING FLYING SPARKS AND HOT METAL can cause injury NY Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin hr 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 ofthe welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to pr
47. ion from the gas supply to the wire feeder gas valve if gas will be used 4 Attach the welding gun to the wire feeder 5 Connectthe 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 September 18 2012 ULTRAFEED VA 4000 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 s
48. l 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 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 itforward 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 Leas m CLOSED m OPEN Art A 07381 Figure 4 8 Arc Signal Overide DIP Switch Location and Settings September 18 2012 ULTRAFEED VA 4000 SECTION 5 SERVICE 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
49. l pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW MIG WELDING EQUIPMENT Fabricator 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year GTAW TIG amp
50. lailez pour initier l arc Appuyez pour arr ter et mainteuir pour pre debit Probl me de Terre Pouces Par Minute M tres Par Minute Voir Note Voir Note Art A 07639_AB Note Pour les environnements avec des risques de choc lectrique le fournisseur d nergie portant la marque conforme a EN50192 lorsqu utilis en conjonction avec des lampes de poche avec des conseils expos s si quip s avec des guide a l hauteur de buse correctement install Y Ne pas d poser avec les d chets m nagers 1 10 September 18 2012 ULTRAFEED VA 4000 1 08 Declaration Of Conformity Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the Directive European Council Directive 89 336 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
51. lation Of Feed Rolls a 2 4 3 08 Welding Gun Compatibility And Installation 2 4 3 09 Threading Wire Into 660620 irradia 2 5 TABLE OF CONTENTS SECTION 4 OPERATION e 4 1 4 1 4 02 Rear Panel Controls 4 2 4 03 Feedhead Components aaa ae 4 4 4 04 Power Source ConpatibIllly un 4 5 4 05 Power Source Compatibility Details 4 5 4 06 Prewelding Procedure 4 6 an ee eu 4 6 4 09 Welding 4 Step Operation anni 4 7 A09 Systemi 89 Ao 4 8 4 10LIC Protection of A B ar en aaa 4 9 Op rati n ti 4 9 4 12 Electronic MOTOR Preieclion aense aan 4 9 ns Ra 4 9 4 14 Arc Signal Overide 4 10 SECTION 5 SERV CE circa 5 1 A rv c de 5 1 5 02 Gleanirig The Feed Rolls ana ea a 5 1 A 5 1 5 04 Troubleshooting GUINE 2c ee a a 5 1 5 05 Tro bleshooting GUUS 2 22 5 2 SECTION 6 PARIS LS Sen een eines 6 1 6 01 Equipment Identification 6 1 6 02 How To Use This Parts List nennen 6 1 0 03 Replacement Parts
52. les codes nationaux provinciaux et locaux applicables 1 6 September 18 2012 ULTRAFEED VA 4000 y 9 gt 3 AVERTISSEMENT AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE POUR LA SANTE de soudage produit une chaleur et des rayons Le soudage d gage des vapeurs et des fum es ultraviolets intenses susceptibles de br ler les yeux et dangereuses respirer la peau Le bruit caus par certains proc d s peut A A A A A endommager 1 Eloignez la t te des fum es pour viter de les respirer gt gt 0 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apr amp s pour vous prot ger le visage et les yeux lorsque vous soudez ou que 3 Sila ventilation est inadequate portez un respirateur a adduction vous observez l ex cution d une soudure d air approuv 2 l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc 2 Portez des lunettes de s curit approuv es Des crans lat raux Lisez les fiches signal tiques et les consignes du fabricant rela sont recommand s tives aux m taux aux produits consummables aux rev tements 3 Entourez l aire de soudage de ri
53. me 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 N 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 ts use Ultrafeed VA 4000 Semiautomatic Wire Feeder Instruction Manual Number 0 4836 for Ultrafeed VA 4000 Part Number W3400001 Published by Victor Technologies Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2008 by Victor Technologies Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date March 17 2006 Revision AE Date September 18 2012 Record the following information for Warranty purposes Where Purchased Purchase
54. n Pin Contactor Shorted 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 Remote Control Signal Remote Control Minimum Control Circuit Common Arc Established 15 VDC Power Source Select Line Not Used Not Used Not Used Current Feedback 1 Volt is 100 Arc Amps Power Source Terminal z zlirixicirzioimim o 43 Table 4 1 19 Pin Control Cable Descriptions A CAUTION The relay contacts between pins A and B have a maximum rating of 1 3 Horsepower HP 115 VAC 103 230 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 wire feeder lf the power source only has a 14 pin amphenol a 870093B 001 adapter cable will be required for proper hookup with the Ultrafeed VA 4000 wire feeder Refer to section 2 07 Options and Accessories Keyway Figure 4 2 Pin Identification September 18 2012 12 AUXILIARY INTERFACE PORT 43 These connections are used by the advanced interface kit 13 CAN INTERFACE PORT J2 This connection allows the ULTRAFEED VA 4000 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 to communicate with a personal com
55. n for welding guns 16 Hinged Feedhead Cover A Permits quick and easy access to the wire drive system 17 Dynamic Brake Solid State control of motor brake offers precise stopping of the wire 18 Replaceable Motor Brushes Extends motor life 19 Needle Bearing Construction Reduces friction and extends bearing life over a sleeve On Motor Output Shaft bearing 0 Gas Valve Solenoid Controls the on off flow of shielding gas 1 100 Duty Cycle Eliminates shutdowns due to overtemperature 2 07 Options and Accessories Refer to the Appendix section of this manual for the list of available options and accessories for this product 2 4 September 18 2012 SECTION 3 INSTALLATION 3 01 Connections Refer to the System Outline drawing in the Appendix of this manual for details 1 Make the proper welding cable connections between the power source and wire feeder and between the power source and work connection 2 Connect the control cable from the feeder to the power source Control cable extensions are available Refer to Available Options NOTE An optional 870000 001 adapter cable will be required for connection to a power source with only a 5 pin amphenol connection and AC voltage outlets An optional 870093B 001 adapter cable will be required for connection to a power source with onlya 14 pinamphenol connection These options are only applicable to 19 pin plug units 3 Make the proper gas line connect
56. n the workplace use the following procedures 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cable around the body oO UN Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS Dd The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 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 P 1 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
57. nd s 2 Portez des v tements appropri s pour prot ger la peau 7 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser les bouteilles font normalement partie du proc d de soudage traitez les avec soin En rjYo ms Ij Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles a un support ou a un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pieces connexes doivent maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous wv AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D
58. nd cutting practices should not attempt to weld Safe practices are outlined in the American National Standard 749 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 m gt Arc Welding Hazards a 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch Open or remove line fuses 50 power cannot be turned on accidentally Properly install and ground this equipment according to its Owner s Manual and national state and local codes Turn off all equipment when no
59. ng the mark conform to EN50192 when used in conjunction with hand torches with exposed tips if equipped with properly installed standoff guides Cannot be disposed with household garbage September 18 2012 ULTRAFEED VA 4000 1 04 Precautions De Securite En Soudage A L arc A 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 proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Stand
60. 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 e CENELEC EN50199 EMC Product Standard for Arc Welding Equipment e ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories 9 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 September 18 2012 1 11 ULTR
61. of the hub tension bolt will result in a shorter motor life Art A 07375 LJ Figure 3 1 Installing Welding Wire Spool 3 2 September 18 2012 ULTRAFEED VA 4000 3 06 Input And Output Wire Guide Installation Refer to Figure 3 2 Install the input wire guide the longer one by loosening the input guide lockscrew and inserting the guide into the hole in the feedhead assembly The recessed end of the guide should be toward the wire spool Adjust the guide so that it is clear of the feed rolls and tighten the input guide lockscrew Install the output wire guide in the same manner with the conical end toward the feed rolls The tip of the conical end should be as close to the feed rolls as practical Tighten the output guide lockscrew NOTE Before tightening the input and output guide lockscrews install the drive roll to help in the alignment of the wire guides Input Guide Lockscrew Output Wire Lockscrew 0 L 6 D I II O I Sig gt 7 O Art A 07376 0 0 CI gt Center Wire
62. puter 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 ULTRAFEED VA 4000 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 17 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 18 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 e V Art A 06985 1111 Figure 4 3 Rear Panel Controls and Connections September 18 2012 4 3 ULTRAFEED VA 4000 4 03 Feedhead Components 18 INPUT GUIDE LOCKSCREW Tighten this lockscrew to secure the input wire guide 19 SPRING TENSION KNOB Use the spring tension knob to adjust the amount of force the feed rolls exert on the welding wire 20 FEEDROLL GEAR KNOB This knob is used to secure the feedroll to the pressure arm Rotate the knob to change the feedroll 21 PRESSURE ARM This a
63. quiries 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 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 September 18 2012 ULTRAFEED VA 4000 6 1 ULTRAFEED VA 4000 6 03 Replacement Parts Item Qty A Al A2 A3 A4 A5 A6 A7 A8 A9 10 11 12 13 14 19 16 17 18 20 21 22 23 24 25 26 Note 1 N 2 M BEN MH HR PO od as 0 4 a ND Description Rod Tension Subassembly WF Knob Control 1 4 IDx3 4 Washer 6 4mm Flat Insulator Plastic Top WF Insulator Plastic Bottom WF Spring Pressure Adj 2R Plate Washer 1 4 IDx0 73 OD Flat Pin Roll 3 32 ODx1 2 Rod Tension Arm 2R amp AR Plate Tension Arm U Bushing WF Pin Roll 0 1 00 75 Knob Control 1 4 IDx1 65 Kno
64. r sources that do not have an Arc Established signal or current feedback RUN IN SPEED ADJUSTMENT 4 Y Art A 07507 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 15 established the speed ramps to the set speed at the rate set with Ramp Rate as described in the next paragraph RAMP RATE ADJUSTMENT Art A 07508 5 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 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 A 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
65. rm pivots off the front of the feedhead to allow access to the wire guides and wire path 22 CENTER GUIDE LOCKSCREW Tighten this lockscrew to secure the center wire guide 23 OUTPUT GUIDE LOCKSCREW Tighten this lockscrew to secure the output wire guide 24 GUN CLAMP KNOB This knob is used to tighten the welding gun into the feedhead 25 GUN ADAPTER This adapter accepts the welding gun plug It can optionally be replaced with different adapters for a variety of different guns 18 21 20 26 FEEDHEAD POSITIONING SCREW 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 27 INPUT WIRE GUIDE This guide is required to direct the welding wire from the drive roll to the welding gun cable 28 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 29 HUB TENSION BOLT The hub tension bolt is used to adjust the wire spool tension which acts as a mechanical brake to assist in the stopping of the welding wire when the gun switch is released 30 WIRE SPOOL HUB NUT not shown The wire spool hub nut is used to secure the spool of welding wire 27 A 24 8 AM
66. s 180 days Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil U S Customer Care 800 426 1888 FAX 800 535 0557 Printed in International Customer Care 940 381 1212 FAX 940 483 8178 THERMADYNE WORLD HEADQUARTERS THE AMERICAS Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA Sales Office Latin America Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree 2010 Thermadyne Industries Inc EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Canada Customer Care 905 827 4515 FAX 800 588 1714 www thermalarc com A Global Cutting amp Welding Market Leader 16052 Swingley Ridge Road Suite 300 St Louis Missouri 63017 U S A Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61
67. t in use Disconnect power to equipment if it will be left unattended or out of service September 18 2012 7 Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode Do not use worn damaged undersized or poorly spliced cables Do not wrap cables around your body Ground the workpiece to a good electrical earth ground Do not touch electrode while in contact with the work ground circuit Use only well maintained equipment Repair or replace damaged parts at once 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 Wear a safety harness to prevent falling if working above floor level Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing Wear a welding helmet fitted with a proper shade of filter see ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended ULTRAFEED VA 4000 3
68. th the power source turned ON check for 115 VAC at power source amphenol pins E and E a Referto the power source owner s manual 6 Check continuity of pins E and of the 19 pin power source control cable a Replace the 19 pin power source control cable 5 2 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 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 Wire wraps around the feed rolls 1 Check for too much pressure on the welding wire a Decrease the pressur
69. 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 A CAUTION Neglect in brush maintenance may cause damage to the motor commutator resulting in a shorter motor operating life 5 02 Cleaning The Feed Rolls Clean the grooves on the lower drive roll frequently This Cleaning operation can be done by using a small wire brush Also wipe off or clean the grooves on the upper bearing roll After cleaning the feed rolls tighten the feed roll retaining knobs accordingly September 18 2012 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 b
70. to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing A 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 amp Safety code Sec 25249 5 et seq NOTE 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 amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpretthe 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 i
71. traight 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 3 1 ULTRAFEED VA 4000 3 04 Installation Of Welding Wire Spool Refer to Figure 3 1 NOTE The wire spool hub supplied with the unit is provided for mounting a 12 inch diameter spool of wire Optional adapters are available allowing a 8 in diameter spool of wire or a 14 pound coil of wire to be used 1 Remove the wire spool hub nut by turning counterclockwise 2 Slide the spool of wire over the wire spool hub making sure that the alignment pin on the hub enters the hole in the backside of the wire spool 3 Replace the wire spool hub nutand turn clockwise to a snug position NOTE Install the welding wire spool so that the wire feeds from the bottom of the spool into the input wire guide Wire Spool Hub Nut Alignment Pin 3 05 Adjustment Of Spool Tension Adjust the wire spool tension so that the wire will feed freely into the input wire guide However the spool of welding wire must not coast when wire feeding stops To adjust the wire spool tension tighten or loosen the hub tension bolt accordingly Refer to Figure 3 1 NOTE Excessive tightening
72. y Cutting CAC A 9 Zu Press and hold for preflow release Positive Constant Voltage to start arc Press to stop arc and Or Constant Potential hold for preflow Direct Current DC High Temperature Burnback Time Protective Earth Fault Indicati Ground Inches Per Minute Line Arc Force Meters Per Minute 115V 15A Receptacle Rating Voltage Input Auxiliary Power Art A 04130 AB Note For environments with increased hazard of electrical shock Power Supplier bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed tips if equipped with properly installed standoff guides Cannot be disposed with household garbage Wire Feed Function Welding Gun 2 2 September 18 2012 2 05 General Information The ULTRAFEED VA 4000 is a semiautomatic solid state controlled wire feeder capable of a 100 duty cycle The system offers both load and line voltage compensation helping to maintain a constant wire feed speed even with changes in the input voltage and or load The wire feeder comes complete with a wire spool support assembly that must be installed in the field The ULTRAFEED VA 4000 s 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

ULTRAFEED® VA 4000 - Victor Technologies

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ULTRAFEED&reg; VA 4000 - Victor Technologies

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ULTRAFEED® VA 4000 - Victor Technologies