VA 4000

ULTRAFEED ®

SEMIAUTOMATIC
WIRE FEEDER

Service Manual
Revision No: AE Issue Date: October 14, 2009 Manual #: 0-4935B

Operating Features:

50 Hz 875
60 IPM
 WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.

Ultrafeed VA 4000 Semiautomatic Wire Feeder

Service Manual Number 0-4935B for:
Ultrafeed VA 4000 Part Number W3400001

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

www.thermalarc.com

Copyright 2006, 2007, 2008, 2009 by

Thermadyne Industries, 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: June 2, 2006

Revision AE Date: October 14, 2009

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

i
 TABLE OF CONTENTS

SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ...................................................................................... 1-1
1.02 Principal Safety Standards ............................................................................. 1-4
1.03 Precautions De Securite En Soudage A L’arc .................................................. 1-5
1.04 Dangers relatifs au soudage à l’arc ................................................................. 1-5
1.05 Principales Normes De Securite ..................................................................... 1-8
1.06 Declaration Of Conformity .............................................................................. 1-9
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart ................................................................................................. 2-2
2.05 General Information ....................................................................................... 2-3
2.06 Features and Benefits ..................................................................................... 2-4
2.07 Options and Accessories ................................................................................ 2-4
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Connections ................................................................................................... 3-1
3.02 Grounding ...................................................................................................... 3-1
3.03 EMI Considerations ........................................................................................ 3-1
3.04 Installation Of Welding Wire Spool ................................................................. 3-2
3.05 Adjustment Of Spool Tension ......................................................................... 3-2
3.06 Input And Output Wire Guide Installation ....................................................... 3-3
3.07 Selection And Installation Of Feed Rolls ......................................................... 3-4
3.08 Welding Gun Compatibility And Installation ................................................... 3-5
3.09 Threading Wire Into Feedhead ........................................................................ 3-6
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Front Panel ..................................................................................................... 4-1
4.02 Rear Panel Controls &Connections ................................................................ 4-2
4.03 Feedhead Components ................................................................................... 4-4
4.04 Power Source Compatibility ........................................................................... 4-5
4.05 Power Source Compatibility Details ................................................................ 4-5
4.06 Prewelding Procedure .................................................................................... 4-6
4.07 Welding - 2 Step Operation ............................................................................ 4-6
4.08 Welding - 4 Step Operation ............................................................................ 4-7
4.09 System DIP Switches ..................................................................................... 4-8
4.10 PTC Protection of A-B Circuit ......................................................................... 4-9
4.11 Ground Fault Operation .................................................................................. 4-9
4.12 Electronic Motor Protection............................................................................ 4-9
4.13 Software Features........................................................................................... 4-9
4.14 Arc Signal Overide ........................................................................................ 4-10
 TABLETABLE
OF CONTENTS
OF CONTENTS
(continued)

SECTION 5:
MAINTENANCE ....................................................................................... 5-1
5.01 Cleaning The Unit ........................................................................................... 5-1
5.02 Cleaning The Feed Rolls ................................................................................. 5-1
5.03 Feedhead Maintenance ................................................................................... 5-1
5.04 Gas Valve Maintenance................................................................................... 5-2
SECTION 6:
TROUBLESHOOTING ................................................................................ 6-1
6.01 Scope ............................................................................................................. 6-1
6.02 Safety ............................................................................................................. 6-1
6.03 Troubleshooting Hints .................................................................................... 6-1
6.04 Troubleshooting Guide ................................................................................... 6-1
SECTION 7:
PARTS LISTS ......................................................................................... 7-1
7.01 Equipment Identification................................................................................. 7-1
7.02 How To Use This Parts List ............................................................................ 7-1
7.03 External Parts (1) ........................................................................................... 7-2
7.04 External Parts (2) ........................................................................................... 7-4
7.05 Internal Feed Plate Assembly Parts (1) .......................................................... 7-5
7.06 Internal Feed Plate Assembly Parts (2) .......................................................... 7-6
7.07 Electrical Components .................................................................................... 7-7
7.08 Tachometer PC Board and Gas Valve Solenoid ............................................... 7-8
APPENDIX 1: FEED ROLL KITS .......................................................................... A-1

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

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

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

APPENDIX 5: CONNECTION DIAGRAM .................................................................. A-6

Statement of Warranty

Warranty SCHEDULE

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

 ULTRAFEED VA 4000
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not
strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other
guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards 7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.

WARNING 9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill. 11. Do not touch electrode while in contact with the work (ground)
circuit.
Touching live electrical parts can cause fatal shocks or 12. Use only well-maintained equipment. Repair or replace damaged
severe burns. The electrode and work circuit is electrically parts at once.
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power 13. In confined spaces or damp locations, do not use a welder with
is on. In semiautomatic or automatic wire welding, the AC output unless it is equipped with a voltage reducer. Use
wire, wire reel, drive roll housing, and all metal parts equipment with DC output.
touching the welding wire are electrically live. Incorrectly
14. Wear a safety harness to prevent falling if working above floor
installed or improperly grounded equipment is a hazard.
level.

1. Do not touch live electrical parts. 15. Keep all panels and covers securely in place.

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

3. Insulate yourself from work and ground using dry insulating mats
or covers. WARNING
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect switch ARC RAYS can burn eyes and skin; NOISE can damage
open, or remove line fuses so power cannot be turned on hearing. Arc rays from the welding process produce
accidentally. intense heat and strong ultraviolet rays that can burn
5. Properly install and ground this equipment according to its Owner’s eyes and skin. Noise from some processes can damage
Manual and national, state, and local codes. hearing.

6. Turn off all equipment when not in use. Disconnect power to 1. Wear a welding helmet fitted with a proper shade of filter (see
equipment if it will be left unattended or out of service. ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.

Manual No. 0-4935B 1-1 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
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
WARNING contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.

FUMES AND GASES can be hazardous to your health.

1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health. 2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
1. Keep your head out of the fumes. Do not breath the fumes. If this is not possible, tightly cover them with approved covers.

2. If inside, ventilate the area and/or use exhaust at the arc to remove 4. Be alert that welding sparks and hot materials from welding can
welding fumes and gases. easily go through small cracks and openings to adjacent areas.

3. If ventilation is poor, use an approved air-supplied respirator. 5. Watch for fire, and keep a fire extinguisher nearby.

4. Read the Material Safety Data Sheets (MSDSs) and the 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
manufacturer’s instruction for metals, consumables, coatings, and can cause fire on the hidden side.
cleaners.
7. Do not weld on closed containers such as tanks or drums.
5. Work in a confined space only if it is well ventilated, or while
8. Connect work cable to the work as close to the welding area as
wearing an air-supplied respirator. Shielding gases used for
practical to prevent welding current from traveling long, possibly
welding can displace air causing injury or death. Be sure the
unknown paths and causing electric shock and fire hazards.
breathing air is safe.
9. Do not use welder to thaw frozen pipes.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to 10. Remove stick electrode from holder or cut off welding wire at
form highly toxic and irritating gases. contact tip when not in use.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14

SAFETY INSTRUCTIONS 1-2 Manual No. 0-4935B

 ULTRAFEED VA 4000
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING

FLYING SPARKS AND HOT METAL can cause injury. WARNING

Chipping and grinding cause flying metal. As welds cool,

they can throw off slag. ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Wear approved face shield or safety goggles. Side shields
recommended.
1. Stop engine before checking or adding fuel.
2. Wear proper body protection to protect skin.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
WARNING 3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged. 4. Do not overfill tank — allow room for fuel to expand.
Shielding gas cylinders contain gas under high pressure. 5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to treat
them carefully. WARNING

1. Protect compressed gas cylinders from excessive heat, mechanical

shocks, and arcs. MOVING PARTS can cause injury.

2. Install and secure cylinders in an upright position by chaining

Moving parts, such as fans, rotors, and belts can cut fingers and hands
them to a stationary support or equipment cylinder rack to prevent
and catch loose clothing.
falling or tipping.
1. Keep all doors, panels, covers, and guards closed and
3. Keep cylinders away from any welding or other electrical circuits.
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and 3. Have only qualified people remove guards or covers for
fittings designed for the specific application; maintain them and maintenance and troubleshooting as necessary.
associated parts in good condition.
4. To prevent accidental starting during servicing, disconnect
6. Turn face away from valve outlet when opening cylinder valve. negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in 5. Keep hands, hair, loose clothing, and tools away from moving
use or connected for use. parts.
8. Read and follow instructions on compressed gas cylinders, 6. Reinstall panels or guards and close doors when servicing
associated equipment, and CGA publication P-1 listed in Safety is finished and before starting engine.
Standards.

WARNING WARNING

Engines can be dangerous. SPARKS can cause BATTERY GASES TO EXPLODE;

BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

WARNING 1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases. 4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas. 5. Observe correct polarity (+ and –) on batteries.

Manual No. 0-4935B 1-3 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000
1.02 Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
WARNING
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
STEAM AND PRESSURIZED HOT COOLANT can burn of Documents, U.S. Government Printing Office, Washington, D.C.
face, eyes, and skin. 20402.
The coolant in the radiator can be very hot and under Recommended Safe Practices for the Preparation for Welding and
pressure. Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
1. Do not remove radiator cap when engine is hot. Allow engine to 550 N.W. LeJeune Rd., Miami, FL 33126.
cool.
National Electrical Code, NFPA Standard 70, from National Fire
2. Wear gloves and put a rag over cap area when removing cap. Protection Association, Batterymarch Park, Quincy, MA 02269.

3. Allow pressure to escape before completely removing cap. Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-
1, from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
WARNING 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.
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the Safe Practices for Occupation and Educational Eye and Face Protection,
State of California to cause birth defects and, in some ANSI Standard Z87.1, from American National Standards Institute,
cases, cancer. (California Health & Safety code Sec. 1430 Broadway, New York, NY 10018.
25249.5 et seq.)
Cutting and Welding Processes, NFPA Standard 51B, from National
NOTE Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Considerations About Welding And The Effects of Low

Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power
Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-
63 (Washington, DC: U.S. Government Printing Office, May 1989):
“...there is now a very large volume of scientific findings based on
experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields and
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your
doctor for complete information.

SAFETY INSTRUCTIONS 1-4 Manual No. 0-4935B

 ULTRAFEED VA 4000
1.03 Precautions De Securite En Soudage A L’arc

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de
sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.04 Dangers relatifs au soudage à l’arc 6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
AVERTISSEMENT
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
L’ELECTROCUTION PEUT ETRE MORTELLE.
9. N’enroulez pas de câbles électriques autour de votre corps.

Une décharge électrique peut tuer ou brûler gravement. 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
L’électrode et le circuit de soudage sont sous tension la pièce à souder.
dès la mise en circuit. Le circuit d’alimentation et les 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
circuits internes de l’équipement sont aussi sous ten- soudage (terre).
sion dès la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le rouleau ou 12. N’utilisez que des équipements en bon état. Réparez ou remplacez
la bobine de fil, le logement des galets d’entrainement aussitôt les pièces endommagées.
et toutes les pièces métalliques en contact avec le fil de
soudage sont sous tension. Un équipement 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
inadéquatement installé ou inadéquatement mis à la terre de courant alternatif, à moins qu’il soit muni d’un réducteur de
est dangereux. tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.

Manual No. 0-4935B 1-5 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000

AVERTISSEMENT AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX LES VAPEURS ET LES FUMEES SONT DANGEREUSES
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE. POUR LA SANTE.
L’arc de soudage produit une chaleur et des rayons Le soudage dégage des vapeurs et des fumées
ultraviolets intenses, susceptibles de brûler les yeux et dangereuses à respirer.
la peau. Le bruit causé par certains procédés peut
endommager l’ouïe. 1. Eloignez la tête des fumées pour éviter de les respirer.

1. Portez une casque de soudeur avec filtre oculaire de nuance 2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour ou que les fumées et les vapeurs sont aspirées à l’arc.
vous protéger le visage et les yeux lorsque vous soudez ou que 3. Si la ventilation est inadequate, portez un respirateur à adduction
vous observez l’exécution d’une soudure. d’air approuvé.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux 4. Lisez les fiches signalétiques et les consignes du fabricant rela-
sont recommandés. tives aux métaux, aux produits consummables, aux revêtements
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger et aux produits nettoyants.
les autres des coups d’arc ou de l’éblouissement; avertissez les 5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
observateurs de ne pas regarder l’arc. portez un respirateur à adduction d’air. Les gaz protecteurs de
4. Portez des vêtements en matériaux ignifuges et durables (laine et soudage peuvent déplacer l’oxygène de l’air et ainsi causer des
cuir) et des chaussures de sécurité. malaises ou la mort. Assurez-vous que l’air est propre à la respi-
ration.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé. 6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou Dimension d'électrode ou
Opération de coupage Nuance de Opération de coupage Nuance de
Epiasseur de métal ou Epiasseur de métal ou
ou soudage filtre oculaire ou soudage filtre oculaire
Intensité de courant Intensité de courant
Brassage tendre Soudage á l'arc sous gaz
toutes conditions 2
au chalumeau avec fil plein (GMAW)
Brassage fort
toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11
au chalumeau
Oxycoupage métaux ferreux toutes conditions 12
Soudage á l'arc sous gaz avec
mince moins de 1 po. (25 mm) 2 ou 3 toutes conditions 12
électrode de tungstène (GTAW)
Soudage á l'hydrogène
moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5 toutes conditions 12
atomique (AHW)
Soudage á l'arc avec
épais plus de 6 po. (150 mm) 5 ou 6 toutes conditions 12
électrode de carbone (CAW)
Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12
Gougeage Air-Arc avec
mince moins de 1/8 po. (3 mm) 4 ou 5
électrode de carbone
moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12
épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14
Soudage á l'arc avec
électrode enrobees moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)
(SMAW)
5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9
plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12
épais plus de 400 amperès 14

SAFETY INSTRUCTIONS 1-6 Manual No. 0-4935B

 ULTRAFEED VA 4000
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que si
AVERTISSEMENT
l’espace est bien ventilé; si nécessaire portez un respirateur à ad-
duction d’air. Car ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au moment du
LES ETINCELLES ET LES PROJECTIONS BRULANTES
soudage.
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
AVERTISSEMENT métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE 1. Portez un écran facial ou des lunettes protectrices
EXPLOSION approuvées. Des écrans latéraux sont recommandés.
L’arc produit des étincellies et des projections. Les 2. Portez des vêtements appropriés pour protéger la peau.
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
AVERTISSEMENT
peut provoquer des étincelles, un échauffement ou un
incendie.
LES BOUTEILLES ENDOMMAGEES PEUVENT
1. Protégez-vous, ainsi que les autres, contre les étincelles et du EXPLOSER
métal chaud.
Les bouteilles contiennent des gaz protecteurs sous
2. Ne soudez pas dans un endroit où des particules volantes ou des haute pression. Des bouteilles endommagées peuvent
projections peuvent atteindre des matériaux inflammables. exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées. 1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures 2. Enchainez verticalement les bouteilles à un support ou à un cadre
ou fissures. fixe pour les empêcher de tomber ou d’être renversées.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la 3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
main.
4. Empêchez tout contact entre une bouteille et une électrode de
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, soudage.
une cloison ou une paroi peut enflammer l’autre côté.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril. des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
8. Connectez le câble de soudage le plus près possible de la zone maintenus en bon état.
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie. 6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
9. Ne dégelez pas les tuyaux avec un source de courant.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con- lorsque raccordé pour utilisation.
tact lorsqu’inutilisé après le soudage.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
11. Portez des vêtements protecteurs non huileux, tels des gants en comprimé et aux équipements connexes, ainsi que la publication
cuir, une chemise épaisse, un pantalon revers, des bottines de P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
sécurité et un casque.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.

Les moteurs produisent des gaz d’échappement nocifs.

Manual No. 0-4935B 1-7 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien Les accumulateurs contiennent de l’électrolyte acide et
ventilées. dégagent des vapeurs explosives.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin 1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
des prises d’air du bâtiment.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.

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

accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE accumulateur ou survolter momentanément un véhicule.
EXPLOSION.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e

carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles AVERTISSEMENT
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
de carburant ou d’en vérifier le niveau au début du soudage. BRULANT SOUS PRESSION PEUVENT BRULER LA
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace PEAU ET LES YEUX.
pour son expansion. Le liquide de refroidissement d’un radiateur peut être
5. Faites attention de ne pas renverser de carburant. Nettoyez tout brûlant et sous pression.
carburant renversé avant de faire démarrer le moteur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
AVERTISSEMENT
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
bouchon.
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains, 1.05 Principales Normes De Securite
ou accrocher des vêtements amples.
Safety in Welding and Cutting, norme ANSI Z49.1, American
1. Assurez-vous que les portes, les panneaux, les capots et les Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
protecteurs soient bien fermés. Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
2. Avant d’installer ou de connecter un système, arrêtez le moteur. 20402.
3. Seules des personnes qualifiées doivent démonter des protecteurs Recommended Safe Practices for the Preparation for Welding and
ou des capots pour faire l’entretien ou le dépannage nécessaire. Cutting of Containers That Have Held Hazardous Substances,
norme AWS F4.1, American Welding Society, 550 N.W. LeJeune
4. Pour empêcher un démarrage accidentel pendant l’entretien, Rd., Miami, FL 33128.
débranchez le câble d’accumulateur à la borne négative.
National Electrical Code, norme 70 NFPA, National Fire Protection
5. N’approchez pas les mains ou les cheveux de pièces en Association, Batterymarch Park, Quincy, MA 02269.
mouvement; elles peuvent aussi accrocher des vêtements amples Safe Handling of Compressed Gases in Cylinders, document P-1,
et des outils. Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur. Code for Safety in Welding and Cutting, norme CSA W117.2
Association canadienne de normalisation, Standards Sales, 276
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face
Protection, norme ANSI Z87.1, American National Standards
AVERTISSEMENT Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-
LATEUR PEUT BRULER LA PEAU ET LES YEUX.
SAFETY INSTRUCTIONS 1-8 Manual No. 0-4935B
 ULTRAFEED VA 4000
1.06 Declaration Of Conformity
Manufacturer: Thermadyne Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council
Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive” (European Council Directive
89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of
manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:

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

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

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

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

• For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192 when used in
conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process.
This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as
specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all
design specifications.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

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

Manual No. 0-4935B 1-9 SAFETY INSTRUCTIONS

ULTRAFEED VA 4000

SAFETY INSTRUCTIONS 1-10 Manual No. 0-4935B

 ULTRAFEED VA 4000
SECTION 2: 2.02 Equipment Identification
INTRODUCTION The unit’s identification number (or part number), model,
and serial number usually appear on a nameplate attached
to the rear panel. In some cases, the nameplate may be
2.01 How To Use This Manual attached to the control panel. Equipment which does not
have a name plate such as gun and cable assemblies is
This Service Manual applies to just the part numbers listed
identified only by the specification or part number printed
on page i.
on the shipping container. Record these numbers on the
To ensure safe operation, read the entire manual, including bottom of page i for future reference.
the chapter on safety instructions and warnings.
2.03 Receipt Of Equipment
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention When you receive the equipment, check it against the
to the information provided under these headings. These invoice to make sure it is complete and inspect the
special annotations are easily recognized as equipment for possible damage due to shipping. If there
follows: 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
WARNING listed in the inside back cover of this manual.
Include all equipment identification numbers as described
A WARNING gives information regarding above along with a full description of the parts in error.
possible personal injury.
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
CAUTION
the unit.

A CAUTION refers to possible equipment

damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
in your area listed in the inside back cover of this manual.
Include the Owner’s Manual number and equipment
identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com

Manual No. 0-4935B 2-1 INTRODUCTION

ULTRAFEED VA 4000
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.

On Single Phase Wire Feed Function

Wire Feed Towards

Off Three Phase Workpiece With
Output Voltage Off.
Three Phase Static
Dangerous Voltage Frequency Converter- Welding Gun
Transformer-Rectifier

Increase/Decrease Remote Purging Of Gas

Continuous Weld
Circuit Breaker
X Duty Cycle
Mode

AC Auxiliary Power % Percentage Spot Weld Mode

Fuse Panel/Local Spot Time

t

Shielded Metal
Amperage t1 Preflow Time
Arc Welding (SMAW)

Gas Metal Arc

Voltage t2
Postflow Time
Welding (GMAW)

Gas Tungsten Arc 2 Step Trigger

Hertz (cycles/sec) Welding (GTAW) Operation
Press to initiate wirefeed and
Air Carbon Arc welding, release to stop.
Frequency
Cutting (CAC-A)

Negative Constant Current 4 Step Trigger

Operation
Press and hold for preflow, release
Constant Voltage to start arc. Press to stop arc, and
Positive
Or Constant Potential hold for preflow.

Direct Current (DC) High Temperature

t Burnback Time

Protective Earth
Fault Indication
(Ground) IPM Inches Per Minute

Line Arc Force

MPM Meters Per Minute

Line Connection Touch Start (GTAW)

Auxiliary Power Variable Inductance

115V 15A Receptacle Rating-

V Voltage Input
Auxiliary Power
Art # A-04130

INTRODUCTION 2-2 Manual No. 0-4935B

 ULTRAFEED VA 4000
2.05 General Information UltraFeed VA 4000 Specifications
The ULTRAFEED VA 4000 is a semiautomatic, solid state Input Voltage: 115 VAC
controlled wire feeder capable of a 100% duty cycle. The Input Frequency: 50/60 Hz
system offers both load and line voltage compensation Input Voltage Tolerance ±10%
helping to maintain a constant wire feed speed, even with Maximum Input Current 4.0 Amps
changes in the input voltage and/or load. The wire feeder Wire Speed Range 50 - 875 IPM
comes complete with a wire spool support assembly that
for All Filler Wire Sizes 1.25 - 22.1 MPM
must be installed in the field.
Wire Sizes 0.024 - 1/8" / 0.6 - 3.2
The ULTRAFEED VA 4000’s sheet metal box totally Maximum Wire
encloses the solid state control circuitry. A hinged, latched 60 lb. / 27 kg
Coil/Spool Weight
feedhead cover allows quick and easy access to the
Feed Rolls 4 (All Driven)
feedhead featuring quick change feed rolls, and tool-less
knobs and clamps for changeover of guides and guns. Welding Current (I) 500 A @ 100%
Welding Gun/Torch Size Tweco #4 Std
The ULTRAFEED VA 4000 comes with an abundance of Maximum Shielding Gas
standard features including: 100 P.S.I. / 6.9 Bar
Inlet Pressure
• an on/off rocker switch Weight (Less Wire) 41 lbs. / 18.5 kg
• a circuit breaker for total system protection Approvals NEMA EW 3
• a wire feed speed control IEC 60974-1
• a power source voltage control
• an inch switch
• a gas purge switch Table 2-1: Product Specifications
• a 2 step / 4 step selector switch
• PC board adjustments for enhanced runin control
• a solid state electronic brake for dynamic braking
• four quick change, gear-driven feed rolls
• a gas solenoid valve
• a low voltage gun trigger circuit for operator safety
• a variety of add-on options to configure the unit for
any wire-welding situation.
The ULTRAFEED VA 4000 has been designed to comply
with CSA NRTL/C, NEMA EW 3, and IEC 60974-1
standards.

Art # A-06983

Figure 2-1: Ultrafeed VA 4000 Front View

Manual No. 0-4935B 2-3 INTRODUCTION

ULTRAFEED VA 4000
2.06 Features and Benefits

UltraFeed VA 4000 Features & Benefits

Features Benefits
A. Improved wire speed accuracy.
B. Line voltage compensation.
1. Solid State Control
C. Load compensation.
D. Current limit to motor.
A. Allows “cold” inching of wire at set wire feed speed.
2. Standard Inch/Purge
B. Allows purging of gas without running wire.
A. Allows gun switch activated control as standard (2 Step) or
3. Standard 2 Step / 4 Step
with preflow, trigger hold, and postflow (4 Step).
A. Allows adjustment of power source arc voltage from the wire
feeder.
4. Standard Remote Voltage
B. Operator has full control of welding parameters at the wire
feeder; can remotely operate the power source.
5. Standard 6’ Control Cable A. Ready to weld.
A. DIP switch located on motor control board allows operator to
6. Run-In Parameter Adjustment
tune starting characteristics to improve starting.
A. Provides protection against ground fault currents.
7. Ground Fault Protection
B. Signals operator of ground fault with STATUS LED.
8. Input Circuit Breaker A. Provides total system protection.
A. Protects motor.
9. Electronic Motor Protection
B. Eliminates need for fuse protection.
10. Small Size A. Takes up small amount of space.
11. Upgradable A. Full set of options to build feeder to your needs.
A. Allows operator to change feed rolls without the use of tools.
12. Quick Change Feed Rolls
B. All four feed rolls are gear-driven.
A. Allows operator to modify angle of feedhead to limit severity
13. Rotatable Feedhead
of bends on the wire. Improved feedability.
A. Allows operator to secure welding gun to the feedhead
14. Gun Clamp Knob
without the use of tools.
15. Welding Gun Quick Connects A. Offers a quick and easy connection for welding guns.
16. Hinged Feedhead Cover A. Permits quick and easy access to the wire drive system.
A. Solid State control of motor brake offers precise stopping of
17. Dynamic Brake
the wire.
18. Replaceable Motor Brushes A. Extends motor life.
19. Needle Bearing Construction A. Reduces friction and extends bearing life over a sleeve
On Motor Output Shaft bearing.
20. Gas Solenoid Valve A. Controls the “on / off” flow of shielding gas.
21. 100% Duty Cycle A. 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.

INTRODUCTION 2-4 Manual No. 0-4935B

 ULTRAFEED VA 4000
SECTION 3: 3.03 EMI Considerations
INSTALLATION 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
3.01 Connections machinery. To help reduce and safeguard against EMI
levels in the welding area, follow these simple guidelines:
Refer to the System Outline drawing in the Appendix of
this manual for details. 1. Firmly secure all sheet metal panels on the power
source and wire feeder. Repair or replace heavily
1. Make the proper welding cable connections
corroded or damaged panels and/or fasteners.
between the power source and wire feeder and
between the power source and work connection. 2. Keep the welding cables and control cables as
short as possible.
2. Connect the control cable from the feeder to the
power source. Control cable extensions are 3. Route the ‘+’ and ‘-’ welding cables from a
available; Refer to Available Options. particular power source together.
NOTE 4. Keep the welding cables as straight as possible;
avoid coiling up the cables.
An optional 870000-001 adapter cable will be
required for connection to a power source with 5. Route the control cable away from the welding
only a 5 pin amphenol connection and AC cables.
voltage outlets. An optional 870093B-001
NOTE
adapter cable will be required for connection
to a power source with only a 14 pin amphenol Grounding of the workpiece may reduce
connection. These options are only applicable emissions in some, but not all circumstances.
to 19 pin plug units. To prevent the risk of injury or damage to other
electrical equipment when grounding the
3. Make the proper gas line connection from the gas
workpiece, take care to follow all local laws
supply to the wire feeder gas valve (if gas will be
and regulations.
used).
4. Attach the welding gun to the wire feeder.
5. Connect the welding gun control leads to the wire
feeder gun switch terminals located on the front
of the feeder.

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

Manual No. 0-4935B 3-1 INSTALLATION

 ULTRAFEED VA 4000
3.04 Installation Of Welding Wire Spool 3.05 Adjustment Of Spool Tension
Refer to Figure 3-1. Adjust the wire spool tension so that the wire will feed
freely into the input wire guide. However, the spool of
NOTE
welding wire must not “coast” when wire feeding stops.
The wire spool hub supplied with the unit is To adjust the wire spool tension, tighten or loosen the
provided for mounting a 12 inch diameter hub tension bolt accordingly (Refer to Figure 3-1).
spool of wire. Optional adapters are available
NOTE
allowing a 8 in diameter spool of wire or a 14
pound coil of wire to be used. Excessive tightening of the hub tension bolt
will result in a shorter motor life.
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 nut and 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

Hub Tension Bolt

Additional Wire Spool Support

Shaft Holes (with plugs)

Art # A-07375

Figure 3-1: Installing Welding Wire Spool

INSTALLATION 3-2 Manual No. 0-4935B

 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

Art # A-07376

Center Wire Guide

Input Wire Guide Output Wire Guide

Figure 3-2: Wire Guide Installation

Manual No. 0-4935B 3-3 INSTALLATION

 ULTRAFEED VA 4000
3.07 Selection And Installation Of Feed
Rolls Rotate retainer cap
to align splines
NOTE
Refer to feed roll chart (supplied in the
Appendix) to order feed roll kits. Kit includes
1
2 drive rolls, an input wire guide, and an output
wire guide for a specific wire type and size.
For selection of feed roll styles, refer to 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 Drive Gear
- .068" hard and tubular wire. Retainer Cap
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 upper and lower double
smooth, vee grooved drive rolls. This style supports 0.035 2
to 1/16” soft wire.
Style 4: Feed rolls consist of of upper and lower double
knurled, vee grooved grooved drive rolls. They feed .045
- 5/64" hard and tubular wire.
Style 5: Feed rolls consist of double cog top and bottom
rolls. They feed .045 - 5/64" tubular wire.
Style 6: Feed rolls consist of double U-grooved top and
bottom feed rolls. They feed .035 - 1/16" soft wire. Feedroll
NOTE
All grooved feed rolls have their wire size or Line up 3 grooves
range stamped on the side of the roll. On rolls with 3 splines
Art # A-07579
with different size grooves, the outer (visible
when installed) stamped wire size indicates
the groove in use.
REMOVING OR INSTALLING FEED ROLLS
INSTALLING 3
Refer to Figure 3-3
1. Twisting the feed roll retainer cap and align the retain-
ing knob splines with the drive gear splines.
2. Place the new feedroll onto the drive gear splines and
push it abainst the edge of the gear
3. Twist the feedroll retainer cap about 1/4 turn so that
the splines rest against the face of the feedroll.
Twist retainer cap
NOTE to lock feed roll
in place
The retainer caps can often be very tight and
may require pliers to turn.
Figure 3-3: Feed Roll Installation

INSTALLATION 3-4 Manual No. 0-4935B

 ULTRAFEED VA 4000
3.08 Welding Gun Compatibility And
Installation
Output Guide
Refer to Figure 3-4. Lockscrew Gun Clamp
Input Guide Lockscrew
The Ultrafeed VA 4000 wire feeder is designed to be used Knob
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 Art # A-04326
welding gun cannot be properly inserted.
NOTE Input Wire Guide Output Wire Guide
Check for gas leaks. If leaking gas, gun is not Center Wire Guide
all the way into the feedhead.

Figure 3-4: Welding Gun Installation

Manual No. 0-4935B 3-5 INSTALLATION

 ULTRAFEED VA 4000
3.09 Threading Wire Into Feedhead 3. Lift both pressure arms and pass the wire through the
output wire guide and into the welding gun assembly
Refer to Figure 3-5. (Refer to welding gun manual).
4. Close the pressure arms, and lock in position with the
WARNING tension lever. To adjust the amount of force the top
roll exerts on the welding wire, turn the spring tension
knob clockwise for increased force or
ELECTRIC SHOCK CAN KILL! Make certain the counterclockwise for decreased force.
power source and wire feeder are turned OFF.
Do not turn the power ON until told to do so in NOTE
these instructions. If the force applied to the wire is too great, the
welding wire will “bird nest” in the feedhead
and not feed properly.
CAUTION
5. Turn the welding machine and wire feeder ON, and
set the wire feed speed control to midrange (Refer to
Use care when handling the spooled wire as Figure 4-1). Remove contact tube (or tip) and nozzle
the wire tends to “unravel” when loosened from welding gun. Refer to Gun Manual. Press the
from the spool. Grasp the end of the wire gun switch or INCH switch until wire feeds out past
firmly, and don’t let it get away from you. Make the gun distributor. Thread the contact tube over the
sure that the end of the wire is straight and wire and lock into place and tighten. Install nozzle and
free of burrs. cut wire off at about 1/4 inch (6 mm) from the nozzle.
1. Place end of the welding wire into the input wire guide.
Feed it through the guide and over the drive roll groove
closest to the feedhead casting. WARNING

2. Loosen the spring tension knob and pull the tension

The wire is electrically “HOT” if wire is fed by
lever toward you to unlock the pressure arm.
depressing the gun switch. Wire contact with the
workpiece will cause an arc with gun switch
depressed. Feed motor will run feeding “HOT” wire.
Tension Lever

Pressure Arm Spring Tension Knob

Welding Wire

Art # A-07276

Input Wire Guide Output Wire Guide

Center Wire Guide

Figure 3-5: Threading Wire Into Feedhead

INSTALLATION 3-6 Manual No. 0-4935B
 ULTRAFEED VA 4000
SECTION 4:
OPERATION
4.01 Front Panel
1. GUN SWITCH RECEPTACLE: The gun switch receptacle 7. ARC VOLTAGE CONTROL: This knob controls arc
accepts the welding gun control wires. The gun switch voltage or pulse frequency from the power source.
receptacle is where a gun switch closure is inputted to The arc voltage (or pulse reference) control can be
the wire feeder. adjusted during setup or actual welding.
2. FAULT INDICATOR: This LED indicates a fault condition 8. FUNCTION TIMERS: These knobs provide timed
exists. If it is flashing, a ground fault has occurred. If control over preflow/postflow gas, wire burnback
it is on continuously, the motor protection circuit has distance and spot weld time.
activated.
9. 2 STEP / 4 STEP SWITCH: This switch selects 2 Step
3. WIRE FEED SPEED (WFS) CONTROL: or 4 Step mode of operation.
This knob controls wire feed speed. The wire feed
10.GAS PURGE SWITCH: This switch will purge shielding
speed control knob can be adjusted during setup or
gas when pressed.
actual welding.
11.INCH SWITCH: This switch will feed wire at the INCH
4. WFS/AMP METER: This meter displays the wire feed
speed (default of set speed). The feeder does not
speed or amperage.
activate the contactor on the power source. Thus,
5. WIRE SPEED FORCE METER: Feed monitor display the wire will be cold as long as the power source
for preventative maintenance. outputs are controlled by the contactor.
6. VOLT METER: Displays the amount of arc voltage 12.METER STATUS LEDS: Indicate the function of WFS/
present. Amp Meter – Inches/Min, Meters/Min, or Amperage.

12 4 5 6

3
7
2

11 10 9 Art # A-06982

Figure 4-1: Front Panel Controls and Connections

Manual No. 0-4935B 4-1 OPERATION
ULTRAFEED VA 4000
4.02 Rear Panel Controls &Connections
11.CONTROL CABLE SOCKET: The control cable connects ! CAUTION

to the power source at this 19-pin amphenol connector

The relay contacts between pins A and B have
(of which 14 pins are used). It contains the signals
a maximum rating of 1/3 Horsepower (HP),
required to allow the welding power source and the
115 VAC or 10A, 230 VAC.
wire feeder to work together as a system.
If the power source only has a 5 pin amphenol and AC
voltage outlets, a 870000-001 adapter cable will be
WARNING required for proper hookup with the Ultrafeed VA 4000
wire feeder.
The protective earth ground (pin G) of the If the power source only has a 14 pin amphenol, a
control cable is established only when the 870093B-001 adapter cable will be required for proper
power source is properly grounded. See the hookup with the Ultrafeed VA 4000 wire feeder. Refer to
power source owner’s manual for proper Appendix 2 Options and Accessories.
grounding methods.

Keyway
Control Cable
Function
Pin
Contactor + (Shorted to B to L M A
A
turn on Power Source)
Contactor - (Shorted to A to K U N B
B
turn on Power Source)
Voltage Feedback ( 1 Volt is J T V P C
C 10 Arc Volts), or ‘+’ Power
Source Terminal
H S R D
D Not Used
E 115 VAC Hot
F 115 VAC Neutral
G F E
G Protective Earth Ground
H Remote Control Maximum
J Remote Control Signal
Figure 4-2: Pin Identification
K Remote Control Minimum
L Control Circuit Common
M Arc Established (= +15 VDC)
N Power Source Select Line
P Not Used
R Not Used
S Not Used
T Not Used
Current Feedback (1 Volt is
U
100 Arc Amps)
V ‘-’ Power Source Terminal

Table 4-1: 19-Pin Control Cable Descriptions

OPERATION 4-2 Manual No. 0-4935B

 ULTRAFEED VA 4000
12.AUXILIARY INTERFACE PORT (J3): Interface for 16.CIRCUIT BREAKER: This breaker protects the unit
automation through a 19 pin connector for stop/start, from electrical faults.
schedule select, inch/purge inputs; arc standby and
NOTE
fault outputs; 0-10 VDC analog inputs for wire speed
and voltage control. This is available with the advanced If the circuit breaker trips, it turns the power
interface kit. switch to the OFF position. A short cooling
period must be allowed before an attempt is
13.CAN INTERFACE PORT (J2): This connection allows
made to reset the unit by pressing the circuit
the ULTRAFEED VA 4000 to communicate with other
breaker reset switch. Check the
select Thermal Arc power sources. This is available
Troubleshooting Section if the circuit breaker
with the advanced interface kit.
continues to trip.
14.SERIAL PORT (J1): This RS232 serial port connection
17.GAS VALVE INLET: This is where the shielding gas
allows the ULTRAFEED VA 4000 to communicate with
hose is connected to the wire feeder. The gas valve
a personal computer. This feature is available with
inlet controls the “on/off” flow of shielding gas through
the advanced interface kit.
the welding gun.
15.POWER ON/OFF SWITCH: This switch controls only
18.WELD CABLE CONNECTION: This is where the power
the wire feeder and not the power source.
source welding cable is connected to the feeder. Make
sure this connection is tight or arcing could occur.

16 17

Art # A-06985

15

14

13

12

11

18

Figure 4-3: Rear Panel Controls and Connections

Manual No. 0-4935B 4-3 OPERATION
ULTRAFEED VA 4000
4.03 Feedhead Components 25.GUN ADAPTER: This adapter accepts the welding gun
plug. It can optionally be replaced with different
18.INPUT GUIDE LOCKSCREW: Tighten this lockscrew adapters for a variety of different guns. See Apppendix
to secure the input wire guide. 2 Options and Accessories for available MIG gun
adapters.
19.SPRING TENSION KNOB: Use the spring tension knob
to adjust the amount of force the feed rolls exert on 26.FEEDHEAD POSITIONING SCREW (3x): These screws
the welding wire. are tightened to position the rotation angle of the
feedhead. To change the angle of the feedhead,
20.FEEDROLL GEAR / KNOB : This knob is used to secure
LOOSEN these 3 screws and turn the feedhead to the
the feedroll to the gear assembly. Rotate the knob to
desired angle. Then tighten the 3 screws to secure.
change the feedroll.
27.INPUT WIRE GUIDE: This guide is required to direct
21.PRESSURE ARMS: These arms pivot off the feedhead
the welding wire from the wire reel to the drive roll.
to allow access to the wire guides and wire path.
28.WELD CABLE CONNECTION: This is where the power
22.CENTER GUIDE LOCKSCREW: Tighten this lockscrew
source welding cable is connected to the feeder. Make
to secure the center wire guide.
sure this connection is tight or arcing could occur.
23.OUTPUT GUIDE LOCKSCREW: Tighten this lockscrew
29.HUB TENSION BOLT: The hub tension bolt is used to
to secure the output wire guide.
adjust the wire spool tension which acts as a
24.GUN CLAMP KNOB: This knob is used to tighten the mechanical brake to assist in the stopping of the
welding gun into the feedhead. welding wire when the gun switch is released.
30.WIRE SPOOL HUB NUT: The wire spool hub nut is
used to secure the spool of welding wire.

18 21 20 22 19 21 23

24

25

Art # A-06984

30 29 28 27 26

Figure 4-4: Feedhead Components

OPERATION 4-4 Manual No. 0-4935B

 ULTRAFEED VA 4000
4.04 Power Source Compatibility
The Ultrafeed VA 4000 wire feeder will work with any Thermal Arc CV or CC/CV power source. If the Thermal Arc power
source only offers a 5 pin amphenol connector and AC voltage outlets, a 870000-001 adapter cable will be required to
connect between the 19 pin control cable of the wire feeder and the 5 pin amphenol connector and AC voltage outlets
of the power source.
If the Thermal Arc power source only offers a 14 pin amphenol connector, 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 VAC and require a relay
closure to become energized.

4.05 Power Source Compatibility Details

Power Source Compatibility Details

Machine Details
PowerMaster 500 Fully Compatible
PowerMaster 500P For GMAW - Set Motor Control S1 Switches for:
Runin Speed 25%, Motor Ramp Rate 0.3 S, Arc Established ON.
For Pulse GMAW - Set Motor Control S1 Switches for:
Runin Speed - 75%, Motor Ramp Rate - 0.2 S, Arc Established - ON
ExcelArc 6045 Fully Compatible
ExcelArc 8065 For GMAW - Set Motor Control S1 Switches for:
Runin Speed 50%, Motor Ramp Rate 0.2 S, Arc Established ON.
Fabstar 4030 Fully Compatible except: Actual arc amps on the wire feeder will not be show
and preset volts on the power source will not be displayed.
ArcMaster 300 MST Fully Compatible
ArcMaster 400 MST Fully Compatible
ArcMaster 400 MSTP Fully Compatible

Manual No. 0-4935B 4-5 OPERATION

ULTRAFEED VA 4000
4.06 Prewelding Procedure
WARNING
Follow all installation instructions for the wire feeder, the
welding power source, and the welding gun before
attempting to operate the Ultrafeed VA 4000. In semiautomatic or automatic wire welding, the
welding wire, wire reel (if used), input guide, feed
1. Make sure all necessary connections have been rolls, output guide, feedhead, and welding gun
made (Refer to “Connections” in the Installation metal parts are all ELECTRICALLY “HOT”.
chapter of this manual).
2. Turn ON the power source and the wire feeder. 4.07 Welding - 2 Step Operation
3. Push the PURGE switch of the feeder and adjust
Refer to Figure 4-5.
the flow of shielding gas.
Position the welding gun above the workpiece and de-
4. Push the INCH switch of the feeder and adjust
press the gun switch trigger. Depressing the gun switch
the wire feed speed to the desired value by means
trigger enables the gas valve, wire feed motor, and power
of the wire feed speed control.
source; the welding process begins. To end the weld, re-
lease the gun switch trigger which disables the gas valve,

! WARNING wire feed motor, and power source.

NOTE
If the gun switch is depressed, the electrode When the gun switch is released, gas will
(welding wire) is electrically “hot”. Do not continue to flow for approximately 0.5
permit it to touch any metal or a welding arc seconds. This is a feature of the system and
may be established which may be injurious to is normal.
someone’s eyes (flash) or skin (burn).

5. Adjust the voltage of the power source to the

desired value. The gun switch must be triggered
to close the power source contactor.

Art # A-06986

Gun Trigger

Arc Established

Gas

Contactor

Runin % Ramp Rate

WireFeed

Preflow Postflow

Figure 4-5: Welding - 2 Step Operation

OPERATION 4-6 Manual No. 0-4935B

 ULTRAFEED VA 4000
4.08 Welding - 4 Step Operation To end the weld, depress the gun switch trigger again.
The wire will stop feeding, and the power source output
Refer to Figure 4-6. will go off. The gas will continue to flow for as long as
the gun switch is depressed. Release the gun switch to
NOTE
shut off the gas, ending the postflow period.
When welding in 4 step operation, the
NOTE
Ultrafeed VA 4000 must recognize an arc
(based on Arc Established or current feedback In 4-Step welding, the user can independently
from the power source) within 1.5 seconds control the amount of preflow and postflow
after the wire begins feeding. If the Ultrafeed time by adjusting the amount of time the gun
VA 4000 receives a gun switch trigger and switch is depressed.
release while in 4 step operation and no arc is
EXAMPLE:
recognized, the Ultrafeed VA 4000 will feed
wire for 1.5 seconds and then stop. This is For no preflow, depress and release the gun switch trig-
done to prevent the possible injury that could ger as quickly as possible. For 5 seconds preflow, de-
result with the unwanted feeding of wire while press the gun switch trigger for 5 seconds before releas-
not welding. ing the gun switch trigger. The procedure is the same for
postflow.
Position the welding gun above the workpiece and depress
the gun switch trigger. The gas will begin to flow. Release
the gun switch trigger while maintaining the welding gun
in the same position. At this point, the contactor to the
power source will enable its output, and the wire will begin
feeding, and an arc will get established. The time from
releasing the switch to establishing an arc is allowed to
be 1.5 seconds, after which the feeder will return to
Standby.

Art # A-06986

Gun Trigger

Arc Established

Gas

Contactor

Runin % Ramp Rate

WireFeed

Preflow Postflow

Figure 4-6: Welding - 4 Step Operation

Manual No. 0-4935B 4-7 OPERATION

ULTRAFEED VA 4000
4.09 System DIP Switches PROCEDURE

The 870309 Motor Control Board contains a 5 position

DIP switch that allows the user to (1) optimize the run-in WARNING
wire feed characteristics for optimal starting, (2) ramp
rate adjustment and (3) override the Arc Established signal ELECTRIC SHOCK CAN KILL. Remove input
so that the 4 Step Operation can be used on power sources power from the wire feeder before making an
that do not have an Arc Established signal or current adjustment to the system DIP switches.
feedback.
RUN-IN SPEED ADJUSTMENT
ADJUSTMENT:: 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 is located in the feeder control box
(refer to Figure 4-8). This board contains a 5 position
Art # A-07507 DIP switch labelled S1 (refer to Figure 4-7 below).
The run-in speed adjustment controls the speed the wire To open any of the DIP switches, push the switch toward
approaches the work at. These switches select a the word OPEN, which is labelled on the switch. To close
percentage of the set speed. The selectable percentages any of the DIP switches, push the switch away from the
are 25%, 50%, 75% (default), and 100%. For example, word OPEN.
if you have 400 IPM set speed, and have 50% selected
After the settings have been made, reattach the sheet
here, then the speed of the wire will be 200 IPM until an
metal cover and reapply power to the power source and
arc gets established. Once an arc is established, the speed
wire feeder.
ramps to the set speed at the rate set with Ramp Rate as
described in the next paragraph.
RAMP RATE ADJUSTMENT
RATE ADJUSTMENT::
Art # A-07508

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

S1
1 2 3 4 5
100% 0 0 0.4 S 0 0 ON/Marche 0
75% 0 X 0.3 S 0 X OFF/Coupe X
50% X 0 0.2 S X 0
25% X X 0.1 S X X ARC
SIGNAL
SIGNAL
S D'ARC
X = CLOSED O = OPEN
Art: A-07506

Figure 4-7: System DIP Switch

OPERATION 4-8 Manual No. 0-4935B
 ULTRAFEED VA 4000
4.10 PTC Protection of A-B Circuit 4.12 Electronic Motor Protection
The A-B contactor circuit on the Ultrafeed VA 4000 The Ultrafeed VA 4000 utilizes an electronic protection
provides a relay closure to the power source through pins circuit to protect the motor against overcurrent caused
A and B of the 19 pin control cable. This allows the welding by excessive load on the motor. This protection will
wire to become electrically ‘HOT’ when the gun switch normally trip if the motor stays in current limit for about
trigger on the welding gun is pulled. If this relay closure 10 seconds. Should this occur, the protection circuit will
is NOT provided for any reason, the welding wire WILL trip which will cause the FAULT indicator LED to light
NOT be electrically ‘HOT’. The wire will feed, but there continuously. In order to reset this condition, cycle power
will be NO arc when the wire touches the work. on the unit.
The Ultrafeed VA 4000 has a thermal, self reset protection NOTE
device in the A-B contactor circuit to protect the circuitry
Should this condition occur, check the wire
against a fault or overload condition. This protection
feeding path, and make sure that there is not
device will only allow a maximum steady state current in
any restrictions or binding on the wire, and
the range of 180 to 450 milliamps (dependent on ambient
that the feedrolls aren’t locked by some
temperature) to flow through pins A and B of the 19 pin
obstruction.
control cable to the A-B contactor circuit on the Ultrafeed
VA 4000.
4.13 Software Features
If this acceptable current range is exceeded for any reason,
the self-reset protection circuit located on the motor The Ultrafeed VA 4000 is designed to be upgraded with
control board will be activated effectively disabling the A- various options. One of the options (Advanced Interface
B contactor circuit. Once the fault or overload condition Kit) allows many features (including timer times, and wire
has been corrected and the current has returned to an speed limits) to be programmed via one of the serial ports
acceptable level, the protection device will automatically on the feeder through the optional Graphical User Software
reset and normal operation can resume. (GUS) package.

NOTE If some of the features on the feeder aren’t working

correctly, they may have been set to a different value with
The protection circuit will remain activated GUS. To reset the machine to its default state, turn the
(there will be NO arc when the wire touches unit on while holding the gun trigger, and holding the
the work) as long as the acceptable current PURGE and INCH buttons in. After about 10 seconds,
range is exceeded. the unit should be reset to factory defaults.

4.11 Ground Fault Operation NOTE

Take wire feed tension off so that the wire will
The Ultrafeed VA 4000 has been equipped with a ground
not feed.
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.

Manual No. 0-4935B 4-9 OPERATION

ULTRAFEED VA 4000
4.14 Arc Signal Overide
Switch #5 on the motor control board configures the wire Making a switch adjustment:
feeder for the presence of Arc Established signals from a
To make an adjustment to the system DIP switches,
power source. If the power source has either an Arc
remove the 8 sheet metal screws from the control box
Established (as most Thermal Arc power sources have),
and remove the sheet metal cover and door by gently
or a Current Feedback signal has (as most competitive
rocking it forward to pull it free from the feeder assembly.
power sources have), then this switch should be CLOSED.
Locate the 870309 Motor Control Board on the opposite
If the power source does not have these ‘Arc Signals’,
side of the feeder assembly as shown in Figure 4-8 below.
then this switch should be OPEN. This switch allows the
The DIP switches are locate at the top of the board as
2 Step / 4 Step and timer features to work, although they
shown. Set switch # 5 according to your set up and replace
will not be timed from the true start of the arc, but instead
the cover.
from when the gun trigger is pulled.

Switch # 5

1 2 3 4 5
CLOSED

OPEN

Art # A-07381

Front

Figure 4-8: Arc Signal Overide DIP Switch Location and Settings

OPERATION 4-10 Manual No. 0-4935B

 ULTRAFEED VA 4000
SECTION 5:
MAINTENANCE
5.01 Cleaning The Unit Rear Motor Brush
Refer to Figure 5-2
Periodically, clean the inside of the wire feeder and feed-
head assembly by using a vacuum cleaner or clean, To access the rear motor brush:
dry compressed air of not more than 25 psi (172 kPa)
pressure. After cleaning the unit, check all electrical 1. Remove the 3 screws from the rear panel as
components for loose or faulty connections and cor- indentified in figure 5-2.
rect if necessary. 2. Remove the gas fitting from the gas solenoid.

5.02 Cleaning The Feed Rolls 3. Slightly pry open the rear panel enough to gain
access to the brush cap with a right-angled
Clean the grooves on the lower drive roll frequently. straight slot screwdriver.
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. 1

5.03 Feedhead Maintenance Art # A-07583

Refer to Figure 5-1 for details.

The only point of maintenance in the feedhead assem-
bly 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 in-
stalled.

CAUTION

Neglect in brush maintenance may cause

damage to the motor commutator resulting
in a shorter motor operating life.

Cap Brush Feed Motor

407190-2 407191-3
2 Gas Fitting 3

Figure 5-2: Opening the Rear Panel

Art # A-04169 Brush Holders

Figure 5-1: Motor Brush Details

Manual No. 0-4935B 5-1 SERVICE

ULTRAFEED VA 4000
5.04 Gas Valve Maintenance threads of gas valve or first two threads of
male fittings. Also, make sure the inlet port
Refer to Figure 5-3 for details. (marked IN) side of the gas valve is con-
nected to the main gas supply; otherwise,
Foreign material inside the valve body is the major cause
the gas valve will leak.
of gas valve failure or improper operation. Foreign ma-
terial usually enters the valve body when disconnected After maintenance, operate the gas valve a few times
gas lines are allowed to come in contact with the floor to be sure of proper operation. If the gas valve contin-
or ground before being connected or reconnected to ues to show signs of improper operation, replace the
the gas valve. gas valve assembly.
In general, sluggish operation and/or gas leakage are
signs the gas valve needs to be cleaned internally. To
clean the gas valve internally, follow these simple steps:
Art # A-04202

NOTE
Coil Yoke
Before disassembly of the gas valve, take
note of the orientation of inlet (marked IN)
and outlet ports with respect to electrical con- Body Gasket
nections. The reassembled gas valve should
have the same orientation. Plugnut / Core Tube
Sub-Assembly
1. Remove input power from the wire feeder, and
depressurize the gas valve. Bracket Core Assembly
2. Remove the gas valve from the wire feeder.
Core Spring
3. Remove the (2) bracket screws and bracket
from the yoke of the gas valve.
4. Slip the yoke (containing coil) off the plugnut/ Valve Body
core tube subassembly.
5. Remove the plugnut/core tube subassembly
Bracket Screws (2)
with the body gasket attached.
6. Remove the core assembly and core spring.
Figure 5-3 Gas Valve Maintenance
7. All parts should now be inspected for foreign
material and cleaned with a lint-free cloth. Do
not nick or scratch any internal parts of the gas
valve.
8. Reassemble the gas valve in reverse order of
disassembly paying careful attention to Figure
5-3.
NOTE
Tighten (2) bracket screws evenly to Ensure
proper body gasket compression. Torque
bracket screws to 20 inch-pounds.
9. Assemble the gas valve to the wire feeder.
NOTE
It may be necessary to apply pipe compound
sparingly to the gas adapter male threads
only. Do not apply compound to female

SERVICE 5-2 Manual No. 0-4935B

 ULTRAFEED VA 4000
SECTION 6:
TROUBLESHOOTING
6.01 Scope 6.04 Troubleshooting Guide
The troubleshooting guide is intended to be used by NOTES
qualified service technicians. The troubleshooting guide
(1) Refer to the Connection/Schematic
contains information which can be used to diagnose and
Diagram in the Appendix of this manual for
correct unsatisfactory operation or failure of the various
graphical assistance in disassembling and
components of the wire feeder. Each symptom of trouble
troubleshooting the wire feeder. Reference
is followed by a list of probable causes and the procedure
designators (such as S1 - power switch) refer
necessary to correct the problem.
to the schematic diagram.
6.02 Safety (2) The acceptable tolerance (in most cases)
on resistance and voltage measurements
To ensure safe operation and service, read this entire made with the DMM is ±10%.
manual before attempting to service or repair this
machine. The service technician may be asked to check (3) Use only genuine replacement parts.
voltage levels while the machine is turned ON; to assure
safety, use care and follow all instructions accordingly.
WARNING
6.03 Troubleshooting Hints
ELECTRIC SHOCK can kill.
Examine connections for proper assembly and contact
before replacing a component. Wire lugs should be in
Follow all safety precautions.
tight contact with the lead’s conductor and should be
crimped to the lead’s insulation. The mating surfaces of Do not touch live electrical parts.
the connection should be clean and free of oxidation.
Turn OFF input power before servicing the
Faulty connections or wiring problems are often the cause
machine unless otherwise noted.
of an equipment malfunction.
Only qualified technicians are to service the
Do not pull on wires to disassemble connections. Firmly
machine.
grasp each lug or connector when disconnecting. Pulling
on wires for disassembly can damage the integrity of the
connection and cause future malfunctions.
Prior to disassembly or servicing of the machine, note WARNINGS
the wiring and connections in the machine. Reassembling
should place the wires in the same location and routing PC boards and their components are static
as received from the factory. Keep wires and leads away sensitive devices.
from hot parts and sharp objects.
Use static proof bags.
All signals referenced in the following troubleshooting
guide can be measured with a digital multimeter (DMM). Use grounded wrist strap.
Only qualified personnel should test or handle
these devices.
Use only genuine replacement parts.

Manual No. 0-4935B 6-1 TROUBLESHOOTING

ULTRAFEED VA 4000
A. Unit is completely inoperative - nothing functions B. Wire feed motor operates but wire does not feed
or feeds erratically
1. Make sure all connections have been made to both
the power source and wire feeder. Refer to 1. Check for too little or too much pressure on feed
Installation - Connections section of this manual. rolls.
2. Make sure both the power source and wire feeder a. Increase or decrease the pressure accordingly
are turned ON. with the spring tension knob (refer to Section
3.09 Threading Wire Into Feedhead).
3. Check for a damaged control cable (P1) that
connects between the power source and wire 2. Check for incorrect feed roll sizes.
feeder.
a. Check size stamped on outside of feed roll.
4. Check for a tripped circuit breaker (CB1). Match to wire size.
NOTE 3. Check to see if wire spool tension is too great.
If the circuit breaker trips, it turns the power a. Decrease wire spool tension (refer to Section
switch (S1) to the OFF position. A short cooling 3.05 Adjustment Of Spool Tension).
period must be allowed before an attempt is
4. Check for restriction in welding gun and cable
made to reset the unit by placing switch S1 in
assembly.
the ON position.
a. Repair or replace gun, cable, liner, or contact
5. Check on/off switch (S1) for loose or faulty
tip.
connections.
b. Check for the correct size welding gun liner and
a. With input power supplied to the wire feeder
contact tip for welding wire being used.
and the on/off switch ON, measure the AC
voltage from TP-E to TP-F on the 870309 5. Check for failed insulator on drive gear assembly
board. — motor shaft turning inside insulator.
b. The measured voltage should be 120 VAC. If a. Replace drive gear assembly.
not, check for an “activated” protection device
in the power source. 6. Check for incorrect voltage and/or wire feed speed
settings.
c. Repair or replace connection.
7. Make sure all connections to the wire feeder are
6. Connect the 19 pin power source control cable to tight.
the power source and wire feeder Amphenol
connectors. 8. Make sure feed rolls are of the correct size and
properly installed.
7. Check the ground fault indicator light.
a. Remove ground fault (refer to Section 4.13
Ground Fault Operation).
8. With the power source turned ON, check for 115
VAC at power source amphenol pins E and F.
a. Refer to the power source owner’s manual.
9. Check continuity of pins E and F of the 19 pin power
source control cable.
a. Replace the 19 pin power source control cable.

TROUBLESHOOTING 6-2 Manual No. 0-4935B

 ULTRAFEED VA 4000
C. Wire wraps around the feed rolls 7. Check all components for loose or faulty
connections. With input power supplied to the wire
1. Check for too much pressure on the welding wire.
feeder and the on/off switch ON, check the
a. Decrease the pressure with the spring tension following items:
knob (refer to Section 3.09 Threading Wire Into
a. Measure the AC voltage on 870309 board, TP-
Feedhead).
E to TP-F. If < 120 VAC, check continuity of
2. Check alignment of input and output wire guides. Amphenol Pin E to TP-E (through CB1, S1).
Repair and replace defective component or
a. Re-align wire guides (refer to Section 3.06 open component or wire. Check continuity of
Input And Output Wire Guide Installation). Amphenol Pin F to TP-F. Repair and replace
3. Check to see if correct cable liner and contact tip open component or wire.
are being used. b. Measure wire feed speed setting. Set maximum
a. Refer to Table in welding gun manual for correct wire feed speed. Check DC voltage on 870309
size. J2-2 to J2-3. Should be about 10.0 VDC. If
closer to 0 VDC, check wiring from 870309 J2
4. Worn or damaged contact tip. to Potentiometer R1.
a. Replace contact tip. Refer to Options and c. Set maximum wire feed speed. Depress the
Accessories chart in the Appendix section of welding gun trigger. Check DC voltage between
this manual. J8-6 to J8-8. If less than 100 VDC, replace
D. Wire does not feed with gun switch depressed 870309 board.

1. Check the ground fault indicator light. d. Check wear on motor brushes. Refer to
Feedhead Maintenance in the Maintenance
a. If Flashing - remove ground fault (refer to chapter of this manual.
Section 4.13 Ground Fault Operation).
E. Motor continues to run after gun switch has been
b. If ON - cycle power on unit and check for released
blocked / bound wire path.
1. Check to see if wire feeder is in proper mode (two
2. Check the continuity of the welding gun trigger step or four step).
leads with the trigger depressed.
a. Check the continuity of the welding gun trigger
a. If no continuity, repair or replace the welding leads with the trigger released. If shorted, repair
gun. or replace the welding gun.
3. Check the gun switch receptacle located on the 2. Check for shorted welding gun trigger leads.
feeder for loose or faulty connections.
a. Repair or replace welding gun.
a. Repair or replace connection.
3. Check for a shorted gun switch receptacle (S5 &
4. Check the motor lead connections for loose or J5), inch switch (S3), or purge switch (S4).
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 ).
6. Check that wire feed speed high limit is not set too
low (Graphical User Software Feature).
a. If unsure, reset machine to factory defaults.
Refer to Software Features section 4.13 for
details.

Manual No. 0-4935B 6-3 TROUBLESHOOTING

ULTRAFEED VA 4000
F. No wire feed speed (WFS) control G. No arc voltage (VOLTS) control
1. Check for a loose WFS control knob. 1. Make sure the local/remote switch on the power
source is in the remote position.
a. Tighten the WFS control knob.
a. Refer to the power source owner’s manual.
2. Make sure the ribbon cable assembly is connected
to both J1 of the display PC board assembly and 2. Check for a loose VOLTS control knob.
J1 of the motor control board assembly.
a. Tighten the VOLTS control knob.
a. Repair or replace ribbon cable assembly.
3. Make sure the ribbon cable assembly is connected
3. With the power switch ON, measure the DC voltage to both J1 of the display PC board assembly and
on the motor control PC board from white wire #2 J1 of the motor control board assembly.
(+) to blue wire #1 (-) while adjusting the WFS
a. Repair or replace ribbon cable assembly.
control knob (refer to Figure 6-1). The reading
should vary from approximately 1 to 10 VDC. H. Wire feeds but there is no arc
a. Replace the WFS potentiometer. 1. Make sure all connections have been made to both
the power source and wire feeder.
2. Refer to Installation - Connections section of this
manual. Check for a damaged control cable (P1)
that connects between the power source and wire
feeder.
I. 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.
J. Gas does not flow with PURGE button depressed
1. Check purge switch (S4), inch switch (S3) and
870309 J6 for loose or faulty connections
Art # A-09348 a. Repair or replace connection.
K. Feed Monitor Display does not function
1. Make sure the ribbon cable assembly is connected
White #2 to both J1 of the display PC board assembly and
J1 of the motor control board assembly.
Blue #1
a. Repair or replace ribbon cable assembly.

Figure 6-1: Test Points for WFS Potentiometer

4. Check plug J2 on the 870309 board for loose or

faulty connections.
5. Check wire feed speed setting.
a. Set maximum wire feed speed.
b. Check DC voltage on 870309 J2-2 to J2-3.
Should be about 10.0 VDC.
c. If closer to 0 VDC, check wiring from 870309
J2 to Potentiometer R1. Check R1.

TROUBLESHOOTING 6-4 Manual No. 0-4935B

 ULTRAFEED VA 4000
L. Wire feeds but no gas flows
1. Check to see if the gas cylinder is empty or the
valve closed.
a. Replace gas cylinder or open valve and adjust
flowmeter.
2. Check for a possible restriction in the gas line or
gas valve.
a. Remove restriction.
3. Check to see if the welding gun nozzle is plugged.
a. Clean the welding gun nozzle.
4. Check the connections on the gas valve (L1) for
loose or faulty connections.
a. Repair or replace connection.
5. Check the connections on the purge switch (S3)
for loose or faulty connections.
a. Repair or replace connection.
6. Make sure the proper gas flow rate has been set.
7. With input power supplied to the wire feeder and
the on/off switch ON, measure the DC voltage
across the gas valve terminals with the welding
gun trigger depressed.
a. The measured voltage should be 12VDC.
b. If 12VDC is present on the gas valve terminals
and gas does not flow, replace the gas valve
(L1).
M. Gas flows all the time or leaks
1. Make sure all connections are tight.
2. Check for foreign material inside the gas valve.
a. Refer to Maintenance - Gas Valve section of
this manual.
N. Wire feeds but electrode wire is not hot – there is
no arc
1. Check continuity of pins A and B of the 19 pin
power source control cable.
a. Replace the 19 pin power source control cable.
2. Make sure the power source control cable is not
damaged. A damaged power source control cable
could be activating a protection circuit on the motor
control PC board.
a. Refer to Section 4.12 Protection Of A-B Circuit.

Manual No. 0-4935B 6-5 TROUBLESHOOTING

ULTRAFEED VA 4000

TROUBLESHOOTING 6-6 Manual No. 0-4935B

 ULTRAFEED VA 4000
SECTION 7:
PARTS LISTS

7.01 Equipment Identification

All identification numbers as described in the Introduction
chapter must be furnished when ordering parts or making
inquiries. This information is found on the nameplate
attached to the equipment. Be sure to include any dash
numbers following the Specification or Assembly
numbers.
PART NUMBER
W3400001

7.02 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.

Manual No. 0-4935B 7-1 PARTS LIST

ULTRAFEED VA 4000
7.03 External Parts (1)
Item Qty
Qty.. Ref
Ref.. Des. Description Part Number
A 1 Rod, Tension Subassembly, WF 870504
A1 1 Knob,Control,1/4" IDx3/4" 870082
A2 2 Washer,6.4mm,Flat See Note 1
A3 1 Insulator, Plastic Top , WF 870424
A4 1 Insulator, Plastic Bottom, WF 870427
A5 1 Spring,Pressure Adj,2R Plate 400562-033
A6 1 Washer,1/4" IDx0.73" OD,Flat See Note 1
A7 1 Pin, Roll, 3/32" ODx1/2" 7962029PKD
A8 1 Rod,Tension Arm,2R & 4R Plate 870425
A9 1 Tension Arm, U Bushing, WF 870511
A10 1 Pin, Roll, 0.1" ODx.75" 7962034PKD
11 2 Knob, Control, 1/4" IDx1.65" 870696
12 4 Knob,Control,.125" IDx.57" OD 870734
13 1 S5 Switch, Toggle Fitted to PCB3
14 2 S2 Switch, Rocker,SP, WF 870359
15 1 Door, UltraFeed 4000, WF 871346WBLKPKD
16 2 S3,S4 Switch, Rocker,SP,Mom, WF 870358
17 4 Bolt, M6 x 19mm, WF See Note 1
18 4 Foot, 1" OD Rubber .600", WF NB1636PKD
20 1 Knob, Torch Locking 10-6187
21 1 Cover, Left Feedhead, WF 870687PKD
22 1 Spring, Input , WF 376037
23 1 Adapter, Gun TWECO, WF 870948
24 1 Guide, Input, WF 406397
25 1 Screw,PHCR,#10-24x1/2" See Note 1
26 2 Plug, Lifting Eye Hole, WF 870716PKD
27 1 Label, Precaution, Arc Equip 204036

Note 1
This part is available at most hardware stores.

PARTS LIST 7-2 Manual No. 0-4935B

 ULTRAFEED VA 4000

27

Art # A-07584

1
2
3

4
A
5
6
26 7
8
9
10

22

25

21 11
24

12
15
13
23
14
20
16
18
16
17

Manual No. 0-4935B 7-3 PARTS LIST

ULTRAFEED VA 4000
7.04 External Parts (2)
Item Qty
Qty.. Ref
Ref.. Des. Description Part Number
1 1 S1 Switch, Rocker,SP, WF 870367
2 1 CB1 Circuit Breaker, 4A, WF 203627-009
3 6 Plug, Black Nylon Snap, WF 870716PKD
4 1 Cap, Dust, WF 402128-010
5 1 Connector, 19-PIN Amphenol, WF 402376
6 4 Spacer, Threaded M6 Rubber, WF 870729PKD
8 1 Base Assembly, VA4000 871358WBLK
9 1 Cover, Assy, VA4000, WF 871050CLA
10 1 Adaptor, Gas RH 1/8NPT-5/8, WF 7978024
11 1 Screw, Hexwasher,M5X1.4-13, WF See Note 1
12 1 Spool Hub Assembly 871361
13 1 Nut, Hub, Wire Spool 405377

Note 1
This part is available at most hardware stores.

Art # A-07585_AB

13
1 2
11

12
9

6
8 5 7
10

PARTS LIST 7-4 Manual No. 0-4935B

 ULTRAFEED VA 4000
7.05 Internal Feed Plate Assembly Parts (1)
Item Qty
Qty.. Ref
Ref.. Des. Description Part Number
1 2 Pressure Arm, Cast Assy, WF 870510
2 2 Tubing, Neopreme, WF See Note 1
3 2 Pin,#6x50mm,2R & 4R Plate See Note 1
4 1 Nut, Hex 9/16-18, WF See Note 1
5 1 Gas Nipple, #10-32 UN,2R Plate 375298
6 2 Wire Tie, Nylon, 4" See Note 1
7 1 Hose 5/32" ID See Note 1
8 1 Fitting, Swivel Hose, WF 870428
9 2 Insulator,Screw,mtg,4R Plate 870431
10 2 Thumbscrew, #8-32 X 3/4, WF See Note 1
11 2 Gear, Idler Assembly, WF 871001PKD
12 1 Screw,Hex HD,3/8"-16x3/4,STZP See Note 1
13 1 Washer,3/8”,Flat, WF See Note 1
14 1 Washer, 3/8",Flat See Note 1

Note 1
This part is available at most hardware stores.

1
2

14 4
13
12 5

6
7

10
9
8
11

Manual No. 0-4935B 7-5 PARTS LIST

ULTRAFEED VA 4000
7.06 Internal Feed Plate Assembly Parts (2)
Item Qty
Qty.. Ref
Ref.. Des. Description Part Number
1 1 Feedplate, Assembly Left, WF 870502
2 1 Motor, Angle Drive Gear, WF 870346-001
3 1 Barb Extended,#10-32,VA4000 870724
4 3 Screw,Hex M6-1.0x40, STZP See Note 1
5 1 Gear, Drive Assembly, WF 870386
6 1 Gear, Retainer, Drive, WF 707156PKD

Note 1
This part is available at most hardware stores.

2
1

6
3

PARTS LIST 7-6 Manual No. 0-4935B

 ULTRAFEED VA 4000
7.07 Electrical Components
Item Qty
Qty.. Ref
Ref.. Des. Description Part Number
1 1 PCB2 PCB, Meter Display, VA4000 870312
2 2 R1 Potentiometer, 2 WATT, 5K, WF 401428-008
3 1 PCB3 PCB, Timer, VA4000 870315
4 1 PCB1 PCB, Motor Control, VA4000 870309

Art # A-08332

Manual No. 0-4935B 7-7 PARTS LIST

ULTRAFEED VA 4000
7.08 Tachometer PC Board and Gas Valve Solenoid
Item Qty
Qty.. Ref
Ref.. Des. Description Part Number

1 1 PCB4 PCB, Encoder Driver, VA4000 870320

2 1 SOL 1 Solenoid, Assembly, WF 870507

PARTS LIST 7-8 Manual No. 0-4935B

 ULTRAFEED VA 4000
APPENDIX 1: FEED ROLL KITS

DRIVE ROLL KITS (#375980-Series) 4 ROLL

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

Double Smooth Double
Top Flat Flat Knurled "V" Knurled "V" Double Cog Double "U"
Double Double Double Smooth Double
Bottom Smooth "V" Smooth "V" "V" Knurled "V" Double Cog Double "U"
Wire Type Hard Hard Soft/Hard/Tubular Hard/Tubular Tubular Soft (Aluminum)
Wire Size
.024" / 0.6mm 375980-071 - - - - -
.030", .035" / 0.8, 0.9mm 375980-041 375980-043 375980-050 - - -
.030", .035", .045" / 0.8, 0.9, 1.2mm 375980-068* 375980-069 - - - -
.035" / 0.9mm 375980-080* - 375980-050 - - 375980-072
.035", .045" 3/64" / 0.9, 1.2, 1.2mm - - 375980-070 - - -
.045" / 1.2mm 375980-042* 375980-044 - 375980-083 375980-062 -
3/64 / 1.2mm - - 375980-051 - - 375980-073
.052" / 1.3mm 375980-081* - - - - -
.052", 1/16" / 1.3, 1.6mm - - 375980-052 375980-057 375980-083 -
1/16" / 1.6mm 375980-045* - - - - 375980-074
.068" / 1.7mm - - - 375980-057 - -
5/64" / 2.0mm 375980-046* - - 375980-058 375980-064 -
3/32" / 2.4mm - - - 375980-059 375980-065 -
7/64" / 2.8mm - - - 375980-060 375980-066 -
1/8" / 3.2mm - - - 375980-061 375980-067 -
Notes: 1) One Kit is supplied standard w ith each w ire feeder (tw o kits w ith dual).
2) Drive Roll Kits include: Drive Rolls; Input, Output & Center Guides
3) Narrow 30° "V"

Manual No. 0-4935B A-1 APPENDIX

ULTRAFEED VA 4000
APPENDIX 2: OPTIONS AND ACCESSORIES

KITS PART NO. DESCRIPTION

Dual Schedule Kit W4008001 Provides a second schedule for wire feed speed and voltage
19 pin plug; start/stop; schedule select; inch & purge inputs; arc
Advanced Interface Kit 870379
standby & fault outputs; 0-10VDC analog input
ACCESSORIES
Drive Roll Kits 375980-XXX 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
Control Cable 6 ft (1.8m) 374878-006 cable #374878-006 is supplied with the wire feeder)
15ft (4.5m) 374878-015
25ft (7.6m) 374878-025
50ft (15.2m) 374878-050
100ft (30.5m) 374878-100
Interconnect Cable Assembly Complete interconnect assembly from wire feeder to power
source, includes control cable, welding power cable and gas
6 ft (1.8m) W4009200 hose in a sheathed cover.
15ft (4.5m) W4009201
25ft (7.6m) W4009202
50ft (15.2m) W4009203
Wire Spool Adaptor 10 lb (4.5kg), 8”
spool 375585-001

15 lb (6.8kg), 8” spool 375864-001

Spool Cover 30 lb (13.6kg) spool 375582A-004

60 lb (27.2kg) spool 375733A-001

Wire Reel Kit 870059
Wire Coil Adaptor 14 lb (6.4kg) coil 375942A

60 lb (27.3kg) coil 407142A

Wire Feeder Cart W4000001
Lift Eye Kit W4002001 Electrically isolated
MIG Gun 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
870093B-001 For Miller® or 14 pin style power sources
source

APPENDIX A-2 Manual No. 0-4935B

 ULTRAFEED VA 4000
APPENDIX 3: SYSTEM OUTLINE

Art # A-07407

Manual No. 0-4935B A-3 APPENDIX

ULTRAFEED VA 4000
APPENDIX 4: SYSTEM SCHEMATIC

1 2 3 4 5

TACH DRIVER
P.C.BOARD
870320

PCB 4
E

PCB 3
Art # A-07590

1 2 3 4 5

APPENDIX A-4 Manual No. 0-4935B

 ULTRAFEED VA 4000

6 7 8 9 10

PCB 1

C
PCB 2

Rev R e visions By D ate P CB No:

A s sy No:
S cale S u persedes

D ate:
F
I n f o r m a t i o n P r oprietary to THERMAL DYNAMICS CORPORATION.
N o t F o r R e l e a s e, Reproduction, or Distribution without Written Consent.
D rawn: R e ferences
N OTE:
U n l e s s O t h e r wise Specified, Resistors are in Ohms 1/4W 5%.
C a p a c i t ors are in Microfarads (UF) C hk: App: S heet
1 of 2
Art # A-07590 TITLE: Size D W G No:
SYSTEM SCHEMATIC,
SEMI-AUTOMATIC WIRE FEEDER,
ULTRAFEED 4000 870344

6 7 8 9 10

Manual No. 0-4935B A-5 APPENDIX

ULTRAFEED VA 4000
APPENDIX 5: CONNECTION DIAGRAM

Art # A-07591

APPENDIX A-6 Manual No. 0-4935B

Statement of Warranty
(as of March 15, 2009)
LIMITED WARRANTY:
THERMADYNE warrants that its products will be free of defects in workmanship or material. Should any failure to
conform to this warranty appear within the time period applicable to the THERMADYNE products as stated below,
THERMADYNE shall, upon written notification thereof and substantiation that the product has been stored, installed,
operated, and maintained in accordance with THERMADYNE’s specifications, instructions, recommendations and
recognized standard industry practice, and not been subject to misuse, repair, neglect, alteration, or accident, correct
such defects by suitable repair or replacement, at THERMADYNE’s sole option, of any components or parts of the
product determined by THERMADYNE to be defective.

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

LIMITATION OF LIABILITY:
THERMADYNE shall not under any circumstances be liable for special, indirect or consequential
damages, such as, but not limited to, damage or loss of purchased or replacement goods, business interruption or
loss of profit, or claims of customers of distributor (hereinafter the “Purchaser”) for service interruption. The rem-
edies of the Purchaser set forth herein are exclusive and the liability of THERMADYNE with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by THERMADYNE whether arising out of contract,
negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the
price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR
THE SAFETY OR PERFORMANCE OF ANY THERMADYNE PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized
distributor delivers the products to the Purchaser.
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized THERMADYNE
repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty.
Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the
Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous
THERMADYNE warrantiesWarranty SCHEDULE
 Warranty SCHEDULE
(as of March 15, 2009)
The warranty is effective below for the time stated in the Warranty Schedule beginning on the date that the authorized
distributor delivers the products to the purchaser. THERMADYNE reserves the right to request documented evidence
of date of purchase.

ENGINE DRIVEN WELDERS Parts / Labor

Scout®, Raider®, Explorer™
Original Main Power Stators and Inductors 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year
Engines and Associated Components are NOT Warranted by Thermal Arc®, See the Engine
Although Most are Warranted by the Engine Manufacturer. SEE THE ENGINE Manufacturers’ Warranty
MANUFACTURERS’ WARRANTY FOR DETAILS. for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT Parts / Labor
Fabricator® 140, 180, 190, 210, 251, 281; Fabstar® 4030;
PowerMaster® 350, 350P, 500, 500P, 320SP, 400SP, 500SP; Excel-Arc® 6045;
Wire Feeders: Ultrafeed®, Porta-feed®
Original Main Power Transformer and Inductor 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT Parts / Labor
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Electric Motors 1 year / 1 year
PLASMA WELDING EQUIPMENT Parts / Labor
Ultima® 150
Original Main Power Magnetics 5 years / 3 years
Original Main Power Rectifiers, Control P.C. Boards, Power Switch Semi-Conductors 3 years / 3 years
Welding Console, Weld Controller, Weld Timer 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Electric Motors, Coolant Recirculators 1 year / 1 year
SMAW (Stick) WELDING EQUIPMENT Parts / Labor
Dragster™ 85; 95S
Original Main Power Magnetics 1 year / 1 year
Original Main Power Rectifiers, Control P.C. Boards 1 year / 1 year
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year

Original Main Power Magnetics 5 years / 3 years

Original Main Power Rectifiers, Control P.C. Boards 3 years / 3 years
All Other Original Circuits and Components Including, but not Limited to, Relays,
Switches, Contactors, Solenoids, Fans, Power Switch Semi-Conductors 1 year / 1 year
GENERAL ARC EQUIPMENT Parts / Labor
FirePower® MIG Welders 5-2-1 years / NA
Water Recirculators 1 year / 1 year
Plasma Welding Torches 180 days / 180 days
Gas Regulators (Supplied with Power Sources) 180 days / NA
MIG and TIG Torches (Supplied with Power Sources) 90 days / NA
Replacement Repair Parts 90 days / NA
MIG, TIG and Plasma Welding Torch Consumable Items NA / NA
 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA Thermadyne Asia Sdn Bhd

2800 Airport Road Lot 151, Jalan Industri 3/5A
Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang
Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan
800-426-1888 West Malaysia
Fax: 800-535-0557 Telephone: 603+ 6092 2988
Email: [email protected] Fax : 603+ 6092 1085

Thermadyne Canada Cigweld, Australia

2070 Wyecroft Road 71 Gower Street
Oakville, Ontario Preston, Victoria
Canada, L6L5V6 Australia, 3072
Telephone: (905)-827-1111 Telephone: 61-3-9474-7400
Fax: 905-827-3648 Fax: 61-3-9474-7510

Thermadyne Europe Thermadyne Italy

Europe Building OCIM, S.r.L.
Chorley North Industrial Park Via Bolsena, 7
Chorley, Lancashire 20098 S. Giuliano
England, PR6 7Bx Milan, Italy
Telephone: 44-1257-261755 Tel: (39) 02-36546801
Fax: 44-1257-224800 Fax: (39) 02-36546840

Thermadyne, China Thermadyne International

RM 102A 2070 Wyecroft Road
685 Ding Xi Rd Oakville, Ontario
Chang Ning District Canada, L6L5V6
Shanghai, PR, 200052 Telephone: (905)-827-9777
Telephone: 86-21-69171135 Fax: 905-827-9797
Fax: 86-21-69171139
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX: (636) 728-3010
Email: [email protected]
www.thermalarc.com