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ULTRAFEED® A 2000 Service Manual

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1. 3 APPENDIX 4 WIRE DIAGRAM 4 LIMITED WARRANTY WARRANTY SCHEDULE GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover ULTRAFEED 2000 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 ifthe operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Some of these practices apply to equipment connected to power lines other practices apply to engine driven equipment Anyone not having extensive training in welding 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 safe
2. avec lectrode de carbone Nuance de filtre oculaire Op ration de coupage ou soudage mince May 30 2006 Ne soudez des t les galvanis es ou plaqu es au plomb ou cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil n cessaire portez un respirateur ad duction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie AAA Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur
3. 1 2 3 4 Style 5 6 Double Smooth Double Flat Flat Knurled V Knurled V Double Cog Double U Double Double Double Smooth Double Smooth V Smooth V V Knurled V Double Cog Double U 24 0 6mm 876980 081 Ez 030 035 0 8 0 9mm 375980 001 375980 003 375980 010 V 375980 032 030 035 045 0 8 0 9 1 2mm 375980 028 375980 029 035 0 9mm 375980 040 C 1 __ 376080 002 376980 004 _____ 375960292 375980 022 31647 1 2mm So ss CES Brno om Emo _375080 023 E AG fesses o __375080 034 _ etre om fw ____ 375980018 _____ _____ Notes 1 One Kit 375980 028 is supplied standard w ith each w ire feeder 2 Feed Roll Kits include Drive Rolls Input amp Output Guides 3 Narrow 309 V 035 045 3 64 0 9 1 2 1 2mm 375980 030 30 2006 1 ULTRAFEED 2000 APPENDIX 2 OPTIONS AND ACCESSORIES Product Part No Description KITS Ground Fault Interrupt Kit 870081 ACCESSORIES One kit 375980 028 is supplied standard with Drive Roll Kits 375980 028 each wire feeder see drive roll kit chart to select a different drive roll style Control cable from wire feeder to power source A Control Cable 6ft control cable 374878 006 is supplied with
4. Hub Tension Bolt Alignment Pin O mn Additional Wire Spool Support Shaft Holes with plugs Art A 07264 Figure 3 1 Installing Welding Wire 5 May 30 2006 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 towards 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 May 30 2006 ULTRAFEED 2000 Input Guide Lockscrew Output Guide Lockscrew O O Input Wire Guide Output Wire Guide Art A 07265 Figure 3 2 Wire Guide Installation 3 3 ULTRAFEED 2000 3 07 Selection And Installation 0f Feed Rolls NOTE Refer 10 feed roll kit drawing supplied in the Appendix 1 to order feed roll kits Kit includes 2 drive rolls an input wire guide and an output wire guide for a specific
5. Safety Standards 1 4 1 03 Precautions De Securite En Soudage 1 5 1 04 Dangers relatifs au soudage a 1 5 1 05 Principales Normes De Securite 1 8 1 06 Declaration Of Conformity annassa 1 9 SECTION 2 INTRODUCTI0N 2 1 2 01 How To Use This Manila neunten 2 1 EA sisi a aaa 2 1 2 09 Syimbol Ca ana etes 2 2 2 al tweet ic 2 3 2 00 Features 2 4 2 06 Options and Accessories a a 2 4 SECTION 3 INSTALLATION ia a a 3 1 3 01 nn ni 3 1 9 02 A 3 1 3 03 Considerations een ehe 3 1 3 04 Installation Of Welding Wire Spool J sasa 3 2 3 05 Adjustment Of Spool Tension ee 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 3 6 SECTION 4 OPERATION saa a a M
6. 1 Check for incorrect voltage and or wire feed speed settings Make sure all connections to the wire feeder are tight Make sure feed rolls are of the correct size and properly installed Check for too little or too much pressure on the welding wire a See spring tension knob in the Interior Components section of this manual Check to see if wire spool tension is too great a See Adjustment Of Spool Tension section of this manual Check for restriction in welding gun and or contact tip Check for the correct size welding gun liner and contact tip for welding wire being used Check for failed insulator on drive gear assembly motor shaft turning inside insulator a Replace drive gear assembly C Wire wraps around the feed rolls 1 Check for too much pressure on the welding wire a See spring tension knob in the Interior Components section of this manual Check for proper alignment ofthe inputand output wire guides Check for the correct size welding gun liner and contact tip for welding wire being used May 30 2006 D Wire does not feed with gun switch depressed 1 Check to see if the feed rolls are mechanically restricted Move the WFS control knob on the front panel off the minimum setting Check the continuity of the welding gun trigger leads with the trigger depressed a If no continuity repair or replace the welding gun Check all components f
7. port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant 0167 l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque May 30 2006 ULTRAFEED A 2000 4h AVERTISSEMENT gt LES ETINCELLES ET LES PR0JECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau 2 LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER AVERTISSEMENT Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommagees peuvent exploser Comme les bouteilles font normalement partie du proc d
8. 1 72 bar pressure After cleaning the unit check all electrical components for loose or faulty connections and correct if necessary 5 02 Cleaning The Feed Rolls Clean the grooves on the lower drive roll frequently This cleaning operation can be done by using a small wire brush Also wipe off or clean the grooves on the upper roll After cleaning the feed rolls tighten the feed roll retaining knobs accordingly 5 03 Feedhead Maintenance The only point of maintenance in the feedhead assembly is the motor brushes Inspect these about every 300 hours of operation When these brushes are worn to about 1 8 3 2 mm new brushes should be installed CAUTION Neglect in brush maintenance may cause damage to the drive motor commutator resulting in a shorter motor operating life Cap Brush 407190 1 Feed Mot 407191 2 Art A 04195 Brush Holders Figure 5 1 Brush Maintenance May 30 2006 5 04 System Maintenance Scope The troubleshooting guide is intended to be used by qualified service technicians The troubleshooting guide contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the wire feeder Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem Safety To ensure safe operation and service read this entire manual before attempting to service or repair this mac
9. de soudage traitez les avec soin a s Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords con us pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous f AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs ULTRAFEED 2000 1 1 8 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envo
10. 3 12 mm oo A Bto 12 Plasma arc cutting I VI 14 goggles or helmet from AWS A6 2 73 Filter 2 Gasmetarare Ferrous base metal 12 Atomic hydrogen welding Plasma arc welding Carbon arc air gouging Pp Lightl or 110 6 in 25 150 mm IG Over 6 in 150 mm 300 to 400 Amp Over 400 Amp WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire _ _ _ Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area
11. Use care when handling the spooled wire as the wire tends to unravel when loosened from the spool Grasp the end of the wire firmly and don t let it get away from you Make sure that the end of the wire is straight and free of burrs Place end ofthe welding wire into the input wire guide Feed it through the guide and over the drive roll groove closest to the feedhead casting 2 Loosen the spring tension knob and pull the tension 3 6 lever toward you to unlock the pressure arm Spring Tension Knob Lift the pressure arm up and pass the wire through the output wire guide and into the welding gun assembly refer to welding gun manual Close the pressure arm and lock in position with the tension lever To adjust the amount of force the roll exerts on the welding wire turn the spring tension knob clockwise for increased force or counterclockwise for decreased force NOTE Ifthe force applied to the wire is too great the welding wire will bird nest in the feedhead and not feed properly Turn the welding machine and wire feeder ON and set the wire feed speed control to midrange Refer to Figure 4 1 Remove contact tube from welding gun Refer to the Gun Manual Press the gun switch or INCH Switch until wire feeds out past the gas diffuser Thread the contact tube over the wire and lock into place and tighten Cut wire off at about 1 4 inch 6 mm from the nozzle WARNING The wire is electri
12. a See Connections section of this manual 2 Check for a damaged control cable P1 that connects between the power source and wire feeder 3 Check relay K1 inch purge switch ST and terminal block TB1 for loose or faulty connections 4 With input power supplied to the wire feeder and the on off switch ON depress the welding gun trigger Make sure all relay K1 contacts properly operating a If not replace relay K1 Wire does not feed with inch switch depressed or gas does not flow with purge switch depressed 1 Check inch purge switch S1 and terminal block TB1 for loose or faulty connections 2 Check for defective inch purge switch 51 May 30 2006 SECTION 7 PARTS LIST 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 usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Part or Assembly numbers 7 02 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted
13. and foot protection Use approved ear plugs or ear muffs if noise level is high 0 WARNING e FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases II ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded Torch soldering Cd Torch brazing Under 1in 25mm Oxygen Cutting Under 1 in 25 mm Gas welding 1 8 to 1 2 in
14. doctor for complete information Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 GFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Gontainers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Gylinders CGA Pamphlet 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 30 2006 ULTRAFEED 2000 1 03 Precautions De Securite En Soudage A MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRA
15. or welded to other parts The part descriptions may be indentedto show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List PART NUMBER VV3200001 May 30 2006 ULTRAFEED 2000 7 1 ULTRAFEED 2000 7 03 External Components and Labels Qty Ref Des Description Plug Black Nylon Snap WF Label Precaution Arc Equip Label Electric Shock US WF Label Feeder WF 2000 2000 Spacer Threaded 6 Rubber WF Label Moving Parts WF Bushing Snap WF Base Assembly VA2000 A2000 Spool Hub Assembly WF Spool Hub Locking Nut WF Screw Hex HD 3 8 16x1 STZP Hub Spool Spacer WF Spring Spool Hub Spacer Spool Tension WF Hub Wire Spool Shaft Wire Spool WF O O NO u a tons it er it ee IND er Er Note This may purchased locally 7 2 Part Number 870716PKD 204036 407099 170101 871242PKD 870729PKD 406636 405362 002 870731WBLKPKD 870987PKD 170201 002 See Note 405449 400562 027 375683 405376 375176 May 30 2006 May 30 2006 ULTRAFEED 2000 ULTRAFEED 2000 7 04 Electrical Compon
16. 4 1 AO PreweldirigiPIOC8dufe 4 1 4 02 ONE PANE anga 4 1 4 03 Rear Panel Controls amp Connections a aaa 4 2 4 04 Feedhead Components 2 aclara 4 3 4 05 Power Source Compatibility zen 4 4 4 06 Power Source Compatability D tails 4 4 TABLE OF CONTENTS SECTION 5 MENN un ne 5 1 5 01 Cleaning The Unit 5 1 5 02 Cleaning The Feed OS les 5 1 5 03 Feedhead Maintenance u a dba 5 1 5 04 System Maintenance 5 1 3 05 0085 Valve ai a a 5 2 SECTION 6 TROUBLESHOOTING M M _ 1 6 01 Troubleshooting Hints 6 1 6 02 Troubleshooting Guide 2 2 2 22 6 1 SECTION 7 7 1 KOLLEGAR 7 1 How Use This Parts List een ee 7 1 7 03 External Components and Labels A it 7 2 7 4 1 05 Feedhgad COmMPOnNeMS ti a ahead 7 6 DAM s nata R EOE 7 8 APPENDIX 1 FEED ROLL RUS u u 1 APPENDIX 2 OPTIONS AND ACCESSORIES 2 APPENDIX 3 SYSTEM OUTLINE
17. as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use a Light Under 300 Amp 9 May 30 2006 WARNING FLYING SPARKS AND H0T METAL can cause injury NY Chipping and grinding cause flying metal As welds cool they can throw off slag Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve K
18. can often be very tight and may require pliers to turn 3 4 Rotate retainer cap to align splines Drive Gear Retainer Gap Feedroll Line up 3 grooves with 3 splines Art A 07579 Twist retainer cap to lock feed roll in place Figure 3 3 Feed Roll Installation May 30 2006 3 08 Welding Gun Compatibility And Installation Refer to Figure 3 4 The ULTRAFEED A 2000 wire feeder is designed to be used with most welding guns In some cases a special adapter may be required To install the welding gun simply loosen the gun clamp knob and insert the welding gun into the feedhead until it stops Tighten the gun clamp knob and connect the welding gun control wires to the gun switch receptacle NOTE Before inserting the welding gun into the feedhead make sure the gun clamp knob does not extend into the feedhead otherwise the welding gun cannot be properly inserted NOTE Check for gas leaks Ifleaking gas gun is not all the way into the feedhead Art A 07266 O ET Feed Head Gun Clamp Knob Gun Switch Receptacle Figure 3 4 Welding Gun Installation May 30 2006 ULTRAFEED A 2000 3 9 ULTRAFEED 2000 3 09 Threading Wire Into Feedhead Refer to Figure 3 5 1 WARNING ELECTRIC SHOCK CAN KILL Make certain the power source and wire feeder are turned OFF Do not turn the power ON until told to do so in these instructions CAUTION
19. gun control leads to the wire feeder gun switch terminals located on the front of the feeder 3 02 Grounding To assure operator safety in the case of a fault condition the frame of the power source welding machine must be grounded The wire feeder sheet metal frame is grounded only through pin G for 19 pin plug of the control cable that connects to the power source Therefore if the power source frame is not grounded then the wire feeder sheet metal frame is not grounded and a shock hazard could possibly develop Follow the instructions found in the power source Owner s Manual for correct grounding methods May 30 2006 3 03 EMI Considerations Electromagnetic interference EMI is common in today s complex industrial environment Attimes EMI levels can become great enough to affect the operation of the machinery To help reduce and safeguard against levels in the welding area follow these simple guidelines 1 Firmly secure all sheet metal panels on the power source and wire feeder Repair or replace heavily corroded or damaged panels and or fasteners 2 Keep the welding cables and control cables as Short as possible 3 Route the and welding cables from a particular power source together 4 Keep the welding cables as straight as possible avoid coiling up the cables 5 Route the control cable away from the welding cables NOTE Grounding of the workpiece may reduce emissions in
20. 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 4h 3 Insulate yourself from work and ground using dry insulating mats 0L 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 eyes and skin Noise from some processes can damage hearing 5 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 6 Turn off all equipment when not in use Disconnect power to Wear a welding helmet fitted with a proper shade of filter see equipment if it will be left unattended or out of service ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended May 30 2006 1 1 ULTRAFEED 2000 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant material wool and leather
21. maintained in accordance with Thermal Arcs specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or damage correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective This warranty is exclusive and in lieu of any warranty of merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including but not limited to lost profits and business interruption The remedies of the purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty and Thermal Arc shall not be bound by any such attempt Correction of
22. moving parts 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine 5 WARNING SPARKS can cause BATTERY GASES T0 EXPL0DE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Engines produce harmful exhaust gases Do not use welder to charge batteries or jump start vehicles 1 Use equipment outside in open well ventilated areas Observe correct polarity and on batteries May 30 2006 1 3 ULTRAFEED 2000 gt 1 02 Principal Safety Standards WARNING Safety in Welding and Cutting ANSI Standard Z49 1 from American STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health amp Safety code Sec 25249 5 et 500 NOTE Considerations Abou
23. rectifier CR1 and terminal block TB1 for loose or faulty connections With input power supplied to the wire feeder and the on off switch ON measure the volt age from the wiper of the variable transformer T1 to 1 2 The measured voltage should change from 0 to 120 VAC while adjusting the WFS control knob from minimum to maximum If not replace the variable transformer T1 Wire feeds but no gas flows 1 Check to see if the gas cylinder is empty or the valve closed Make sure the proper gas flow rate has been set 3 Check for a possible restriction in the gas line or gas valve 4 Check to see ifthe welding gun nozzle is plugged 5 Check gas valve LT terminal block TB1 and inch purge switch ST for loose or faulty connections With input power supplied to the wire feeder and the on off switch ON measure the AC volt age across the gas valve terminals with the welding gun trigger depressed The measured voltage should be 24 VAC a 1 24 VAC is present on the gas valve terminals and gas does not flow replace the gas valve L1 6 3 ULTRAFEED 2000 H Gas Flows all the time or leaks 1 Make sure all connections are tight 2 Check for foreign material inside the gas valve a See Gas Valve Maintenance in the Maintenance chapter of this manual I Wire feeds but there is no arc 6 4 1 Make sure all connections have been made to both the power source and wire feeder
24. some but not all circumstances To prevent the risk of injury or damage to other electrical equipment when grounding the workpiece take care to follow all local laws and regulations 3 1 ULTRAFEED 2000 3 04 Installation Of Welding Wire Spool Refer to Figure 3 1 NOTE The wire spool hub supplied with the unit is provided for mounting a 12 inch diameter spool of wire Optional adapters are available allowing an 8 in diameter spool of wire or a 14 pound coil of wire to be used 1 Remove the wire spool hub nut by turning counterclockwise 2 Orient and slide the spool of wire over the wire spool hub so that the wire will feed off the bottom of the spool as the spool rotates counter clockwise Make sure that the alignment pin on the hub enters the hole the backside of the wire spool 3 Replace the wire spool hub nut and turn clockwise to a snug position NOTE The wire must feed from the bottom of the spool If it comes off the top the spool will have to be removed and turned around 3 2 3 05 Adjustment Of Spool Tension Adjust the wire spool tension so that the wire will feed freely into the input wire guide However the spool of welding wire must not coast when wire feeding stops To adjust the wire spool tension tighten or loosen the hub tension bolt accordingly Refer to Figure 3 1 NOTE Excessive tightening of the hub tension bolt will result in a shorter motor life Wire Spool Hub Nut
25. talliques en contact avec le III de soudage sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux BZ SESSA 14 0IL07 harnais de s curit vous travaillez hauteur 1 Ne touchez pas des pi ces sous tension 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 15 Fermez solidement tous les panneaux et les capots 2 Portez des gants et des v tements isolants secs et non trou s Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables May 30 2006 1 5 ULTRAFEED 2000 7 7 AVERTISSEMENT ele gt LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L 0LI de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par certai
26. the wire feeder 6 ft 1 8m 374878 006 15ft 4 5m 374878 015 25ft 7 6m 374878 025 50ft 15 2m 374878 050 100ft 30 5m 374878 100 Complete interconnect assembly from wire feeder to power source includes control cable welding power cable and gas hose in a sheathed cover W4009200 4009201 W4009202 50ft 15 2m W4009203 Wire Spool Adaptor 10 Ib 4 5kg 8 spool 375585 001 15 Ib 6 8kg 8 spool 375864 001 Spool Cover 30 Ib 13 6kg spool 375582A 004 60 Ib 27 2kg spool 375733A 001 Wire Reel Kit 870059 Wire Coil Adaptor 14 Ib 6 4kg coil 375942A 407142A Wire Feeder Cart W4000001 Lift Eye Kit W4002001 Electrically isolated MIG Gun Holder Kit 171463 Tweco 5 870395 Miller 870397 Euro style 171449 Cable Adapters 19 pin wire feeder to 5 pin power source 870000 001 For older style power sources 19 pin wire feeder to 14 pin power source 870093B 001 For Miller or 14 pin style power sources 2 30 2006 ULTRAFEED 2000 APPENDIX 3 SYSTEM OUTLINE lo y 9 st S I ML A 07403 May 30 2006 A 3 ULTRAFEED 2000 APPENDIX 4 DIAGRAM FRONT PANEL BOTTOM PANEL SEE NOTE 1 4 30 2006 ULTRAFEED 2000 6 5 4 3 2 1 4 WH BK T H C 1 5 7RD 9 4YL 7 68M 9WT 2 5 BK M SK Bei 5RD VIEWED FROM TOP OF FEEDER 14
27. I BK C i 12 13 n GROUND SCREW REAR PANEL NOTES 1 WRAP GREEN GROUND WIRE FROM CONTROL CABLE AROUND THE REED SWITCH ON THE GROUND FAULT BOARD 4 TIMES AND THEN SECURE GROUND WIRE TO GROUND FAULT BOARD WITH WIRE TIE LEGEND 81 MOTOR WIRE FEED CRI RECTIFIER BRIDGE RECEPTACLE GUN SWITCH M RELAY CONTROL 24 VAC DPDT GAS VALVE 24 VAC pl PLUG CONTROL 19 PIN AMPHENOL RI RESISTOR 5 6 OHM 30W RVI SUPPRESSOR 51 SWITCH INCH PURGE 52 ON OFF SWITCH CIRCUIT BREAKER 1 5 T TRANSFORMER VARIABLE 12 TRANSFORMER STEPDOWN mear a 181 TERMINAL STRIP A CHANGE RECORD USER FINISH CODE PER CE LE REV AA A 870143 AAA DIAGRAM CONNECTION amp SCHEMATIC a Art A 07580 E SHEET SHEET M MOTORLEAD T TRANSFORMER LEAD C CONTROL CABLE LEAD P1 870143 6 5 4 3 2 1 May 30 2006 A 5 LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 LIMITED WARRANTY Thermal Arc Inc Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and
28. IHERMAL 2000 ULTRAFEED VARIAG CONTROLLED WIRE FEEDER Art A 07354 Service Manual Version No AC 01 Issue Date May 30 2006 Manual No 0 4893B Operating Features 115 Kea IHERMAL RC WARNINGS Read and understand this entire Manual and your employers safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Ultrafeed A 2000 Wire Feeder Service Manual Number 0 4893B for Part W3200001 Published by Thermadyne Industries 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 by Thermadyne Industries rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date May 30 2006 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 A Welding Hazards ua a nement 1 1
29. OR Ultima 150 Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years Welding Console Weld Controller Weld Timer 3 years 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year 1 year SMAW Stick WELDING EQUIPMENT WARRANTY PERIOD Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 160S 300S 400S Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 days 180 days Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton IX 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Therma
30. VES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser equipement Toute personne n ayant pas suivi un entra nement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI 1 04 Dangers re
31. ains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de accumulateur ta AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon 1 05 Principales Normes De Securite Safety Welding and Cutting norme ANSI 749 1 A
32. cally HOT if wire is fed by depressing the gun switch Wire contact with the workpiece will cause an arc with the gun switch depressed Feed motor will run feeding HOT wire Pressure Arm O Tension Lever Welding Wire 5 gt Art A 07273 Input Wire Guide Output Wire Guide Figure 3 5 Threading Wire Into Feedhead May 30 2006 SECTION 4 OPERATION 4 01 Prewelding Procedure Follow all installation instructions for the wire feeder the welding power source and the welding gun before attempting to operate the ULTRAFEED A 2000 1 Make sure all necessary connections have been made Refer to Connections in the Installation chapter of this manual 2 Turn ON the power source and the wire feeder 3 Push the PURGE switch of the feeder and adjust the flow of shielding gas 4 Push the INCH switch of the feeder and adjust the wire feed speed to the desired value by means of the wire feed speed control A WARNING If the gun switch is depressed the electrode welding wire is electrically hot Do not permit it to touch any metal or a welding arc may be established which may be injurious to someone eyes flash or skin burn 5 Adjust the voltage of the power source to the desired value The gun switch must be triggered to close power source contactor WARNING In semiautomatic or automatic wire welding the welding w
33. connects to the power source atthis 19 pin connector of which 5 pins are used It contains the signals required to allow the welding power source and the wire feeder to work together as a system Refer to Fig 4 2 and 4 3 WARNING The protective earth ground pin G of the control cable is established only when the power source is properly grounded See the power source owners manual for proper grounding methods Also refer to page 3 1 Control Cable Pin A Contactor Hot Relay Closure To Energize _ 8 Contactor Neutral Power Source D x E RIVAS Hot 6 Protectie Earth Ground vot Used Table 4 1 19 Pin Control Cable Connections The relay contacts between pins and B have a maximum rating of 1 3 Horsepower HP 115 VAC or 10A 230 VAC If the power source only has 5 pin amphenol and AC voltage outlets an 870000 001 adapter cable will be required for proper hookup with the ULTRAFEED A 2000 wire feeder If the power source only has 14 pin amphenol a 870093B 001 adapter cable will be required for proper hookup with the ULTRAFEED A 2000 wire feeder Refer to Appendix 2 Options and Accessories Keyway Figure 4 2 Rear Panel 19 pin connections 2 GAS VALVE INLET This is where the shielding gas hose is connected to the wire feeder The gas valve controls the on off flow of shielding gas through the welding gun 3 WIRE FEED ACCESS This is where the welding wi
34. dyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters IHERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE AK i St Louis M0 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com
35. e gas valve in reverse order of disassembly paying careful attention to Figure 5 2 NOTE Tighten 2 bracket screws evenly to insure proper body gasket compression Torque bracket screws to 20 inch pounds 2 3 Newton Meters 9 Assemble the gas valve to the wire feeder NOTE II may be necessary to apply pipe compound sparingly to the gas adapter male threads only Do not apply compound to female threads of gas valve or first two threads of male fittings Also make sure the inlet port marked IN side of the gas valve is connected to the main gas supply otherwise the gas valve will leak 5 2 After maintenance operate the gas valve a few times to be sure of proper operation If the gas valve continues to show signs of improper operation replace the gas valve assembly Art A 04202 Coil Plugnut Core Tube Sub Assembly Core Assembly Core Spring Valve Body Bracket Screws 2 Figure 5 2 Gas Valve Assembly May 30 2006 ULTRAFEED 2000 SECTION 6 TROUBLESHOOTING 6 01 Troubleshooting Hints Examine connections for proper assembly and contact before replacing an electrical component or printed circuit board Wire lugs should be in tight contact with the lead s conductor and should be crimped to the lead s insulation The mating surfaces of the connection should be clean and free of oxidation Faulty connections or wiring problems are often the cause of an equipment malfunction Do no
36. e offers pre cise stopping of the wire Circuit breaker fitted Built in input circuit breaker provides total system protection Welding gun quick disconnect Quick and easy connection and disconnection of the welding gun 2 4 2 06 Options and Accessories Refer to the Appendix 2 section in the back of this manual for the list of available options and accessories for this product May 30 2006 ULTRAFEED 2000 SECTION 3 INSTALLATION 3 01 Connections Refer to the System Outline drawing in the Appendix of this manual for details 1 Make the proper welding cable connections between the power source and wire feeder and between the power source and work connection 2 Connect the control cable from the feeder to the power source Control cable extensions are available Refer to the Appendix 2 section in the back ofthis manual for the list of available options and accessories for this product NOTE An optional 870000 001 adapter cable will be required for connection to a power source with only a 5 pin amphenol connection voltage outlets An optional 870093B 001 adapter cable will be required for connection to a power source with only a 14 pin amphenol connection These options are only applicable to 19 pin plug units 3 Make the proper gas line connection from the gas supply to the wire feeder gas valve if gas will be used 4 Attach the welding gun to the wire feeder 5 Connectthe welding
37. e tolerance in most cases on resistance and voltage measurements made with the DMM is 10 Use only genuine replacement parts 6 1 ULTRAFEED 2000 A Unit is completely inoperative nothing functions 6 2 1 Make sure allconnections have been made to both the power source and wire feeder a See Connections section of this manual Make sure both the power source and wire feeder are turned ON Make sure ground fault protection circuit has not activated a lf the ground fault protection has activated input power will have to be reset before normal operation can resume Check for a damaged control cable P1 that connects between the power source and wire feeder Check for a tripped circuit breaker S2 a Ifthe circuit breaker trips it turns the power switch 52 to the OFF position A short cooling period must be allowed before an attempt is madeto reset the unit by placing switch S2 in the ON position 6 Check for a damaged power on off switch 52 Check on off switch 52 terminal block TB1 variable transformer T1 and stepdown transformer T2 for loose or faulty connections a With input power supplied to the wire feeder and the on off switch ON measure the AC volt age from TB1 1 to TB1 2 The measured voltage should be 120 VAC b Ifnot check for an activated protection device the power source B Wire feed motor operates but wire does not feed or feeds erratically
38. eep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING Engines can be dangerous f WARNING ENGINE EXHAUST GASES can kill 2 ULTRAFEED 2000 If used in a closed area vent engine exhaust outside and away from any building air intakes Vt M 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine E w WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 Keep hands hair loose clothing and tools away from
39. eflow release Constant Voltage to start arc Press to stop arc and Positive Or Constant Potential hold for preflow Direct Current DC High Temperature Burnback Time Protective Earth Disturbance In Ground ault Indication Ground System Die Auxiliary Power Variable Inductance wi Receptacle Rating 2 2 May 30 2006 L Inches Per Minute Art A 04130 2 04 General Information The ULTRAFEED A 2000 is a semiautomatic Variac controlled wire feeder capable of a 100 duty cycle The system offers both load and line voltage compensation helping to maintain a constant wire feed speed even with changes in the input voltage and or load The wire feeder comes complete with a wire spool support assembly The ULTRAFEED A 20005 sheet metal box totally encloses the solid state control circuitry A hinged latched feedhead cover allows quick and easy access to the feedhead featuring 1001 1655 quick change feed rolls The ULTRAFEED A 2000 comes with an abundance of standard features including e on off rocker switch e a circuit breaker for total system protection e feed speed control aninch switch agas purge switch e electromechanical brake for precise wire stopping e two quick change gear driven feed rolls The ULTRAFEED A 2000 has been designed to comply with CSA NRTL C NEMA EW 3 and IEC 60974 1 standards May 30 2006 ULTRAFEED A 2000 Ul
40. ents Item Qiy Ref Des aon O1 u C 7 4 M M M M S1 S2 Ti L1 Description Switch Rocker 1 5 Amps WF Switch 4 Inch Purge WF Knob Control 1 4 1Dx1 6 PCB Ground Circuit WF Transformer Control 120V 24V Transformer Powerstat WF Resistor 5 6 Ohm 30W WF Suppressor W Lug AY WF Rectifier Bridge 35A 800V Relay Enclosed WF Wire Harness A2000 WF Adaptor Gas RH 1 8NPT 5 8 WF Valve Solenoid 24VAC WF Fitting Elbow street 90 WF Fitting Barbed Polypro WF Wire Tie Nylon 4 Tube Water or Gas WF Part Number 870032 001 407135 001 870696PKD 375581 16DA3134 400244 405626 003 202258 001 409554 002 403056 011 870980PKD 7978024PKD 404162 008 7978025PKD 203846 002 See Note 16DA3304 017 May 30 2006 ULTRAFEED 2000 Art A 07509 May 30 2006 ULTRAFEED 2000 7 05 Feedhead Components Hem Qiy Ref Des AN DO N D D po os DAN O O 7 6 ooo odo dodo ND oo a dd Description Knob Control 1 4 3 4 Rod Tension Arm 2R amp AR Plate Washer 1 4 Flat WF Sp
41. hine The service technician may be asked to check voltage levels while the machine is turned ON To assure safety use care and follow all instructions accordingly 5 1 ULTRAFEED A 2000 5 05 Gas Valve Maintenance Foreign material inside the valve body is the major cause of gas valve failure or improper operation Foreign material usually enters the valve body when disconnected gas lines are allowed to come in contact with the floor or ground before being connected or reconnected to the gas valve In general sluggish operation and or gas leakage signs the gas valve needs to be cleaned internally To clean the gas valve internally follow these steps NOTE Before disassembly of the gas valve take note of the orientation of inlet marked IN and outlet ports with respect to electrical connections The reassembled gas valve should have the same orientation 1 Remove input power from the wire feeder and depressurize the gas valve 2 Remove the gas valve from the wire feeder 3 Remove the 2 bracket screws and bracket from the yoke of the gas valve 4 Slip the yoke containing coil off the plugnut core tube subassembly 5 Remove the plugnut core tube subassembly with the body gasket attached 6 Remove the core assembly and core spring 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 th
42. information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 1 year Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW WELDING EQUIPMENT Fabricator 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT LABOR 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year PLASMA WELDING EQUIPMENT LAB
43. ire wire reel if used input guide feed rolls output guide feedhead and welding gun metal parts are all ELECTRICALLY HOT May 30 2006 ULTRAFEED A 2000 4 02 Front Panel 1 GUN SWITCH RECEPTACLE The gun switch recep tacle accepts the welding gun control wires The gun switch receptacle is where a gun switch closure is inputted to the wire feeder 2 INCH PURGE SWITCH Depressing the INCH switch which is in the up position will feed wire at a speed set by the WFS control The wire will not be elecrically hot when using the INCH switch Depressing the PURGE switch which is in the down position will allow shielding gas to flow out of the welding gun without feeding wire POWER ON OFF SWITCH This switch only the wire feeder and not the power source welding machine It is used as an on off switch and also serves as a circuit breaker NOTE If the circuit breaker trips it turns the power switch to the OFF position A short cooling period must be allowed before an attempt is made to reset the unit by placing the switch in the ON position Wire Feed Speed CONTROL This knob controls wire feed speed The wire feed speed can be adjusted dur ing setup or actual welding FEED Art A 07320 U Figure 4 1 Front Panel Controls and Connections 4 1 ULTRAFEED A 2000 4 03 Rear Panel Controls amp Connections 1 4 2 CONTROL CABLE SOCKET The control cable
44. 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 May 30 2006 1 9 ULTRAFEED 2000 NOTES 1 10 May 30 2006 ULTRAFEED 2000 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Service Manual applies to justthe part numbers listed on page I To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows N WARNING A WARNING gives information regarding possible personal injury UTION 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 pho
45. latifs au soudage l arc 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser tra ner par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode AVERTISSEMENT 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite L ELECTROCUTION PEUT ETRE MORTELLE 9 N enroulez pas de c bles lectriques autour de votre corps 10 N utilisez qu une bonne prise de masse pour la mise la terre de Une d charge lectrique peut tuer ou br ler gravement PENA la piece a souder L lectrode et le circuit de soudage sont sous tension des la mise en circuit Le circuit d alimentation et les 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de circuits internes de l quipement sont aussi sous ten soudage terre sion d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou 12 N utilisez que des quipements en bon tat R parez ou remplacez la bobine de fil le logement des galets d entrainement aussit t les pi ces endommag es et toutes les pi ces m
46. merican Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Association canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 183 Safe Practices for Occupation and Educational Eye and Face Protection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 May 30 2006 ULTRAFEED 2000 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 Europea
47. n Council Directive 73 23 as amended by Council Directive 93 68 EEC 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 e CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment LI Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used e CENELEC 50199 EMC Product Standard for Arc Welding Equipment e ISO IEC 60974 1 BS 638 PT10 60 974 1 50192 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
48. ne number in your area listed in the inside back cover of this manual Include the Service 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 May 30 2006 2 02 Equipment Identification The unit s identification number or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as the gun and cable assemblies are identified only by the part number printed on the shipping container Record these numbers on the bottom of page i for future reference 2 1 ULTRAFEED A 2000 2 03 Symbol Chart Note that only some of these symbols will appear on your model Wire Feed Towards Off 3 NU Three Phase lo Workpiece With Output Voltage Three Phase Static Dangerous Voltage Frequency Converter Welding Gun Transformer Rectifier Continuous Weld 6 Circuit Breaker X Duty Cycle Mode 47 Shielded Metal Gas Metal Arc LE Gas Tungsten Arc 6 2 Step Trigger Z Hertz cycles sec 2 Welding GTAW I 1 Operation Press to initiate wirefeed and Air Carbon Arc A welding release to stop enn DIET o Press and hold for pr
49. non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in Thermal Arc s sole judgment impaired the safety or performance of any Thermal Arc product Purchaser s rights under this warranty are void if the product is sold to purchaser by unauthorized persons The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This
50. ns proc d s peut endommager 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que 3 vous observez l ex cution d une soudure 2 Portez des lunettes de s curit approuv es Des crans lat raux 4 sont recommand s 3 Entourezl aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les 5 observateurs de ne pas regarder l arc 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev QP AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer CE 1 Eloignez la t te des fum es pour viter de les respirer 2 A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ne travaillez dans un espace confin que s il est bien ve
51. ntil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respi ration 6 Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Brassage terdre toutes conditions 2 au chalumeau Brassage fort toutes conditions 3 ou 4 au chalumeau moins de 1 po 25 mm de 1 6 po 25 150 mm moins de 1 8 po 3 mm 4ou5 de 1 8 1 2 3412 5ou6 pais plus de 1 2 po 12 60u8 Soudage avec lectrode enrobees SMAW Operation de coupage ou soudage 2ou3 40u5 5 ou 6 moins de 5 32 po 4 mm fs 5 32 1 4 po 4 46 4 mm 12 plus de 1 4 po 6 4 mm 14 1 6 Nuance de filtre oculaire Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Soudage l arc sous gaz Soudage l arc sous gaz avec Ai lectrode de tungst ne GTAW toutes conditions Soudage l hydrog ne toutes conditions 12 atomique AHW Soudage l arc avec toutes conditions 12 Gougeage
52. or loose or faulty connections With the wires removed from resistor RT measure the resistance The measured resistance should be in the range of 4 6 to 6 6 ohms a If not replace resistor R1 With input power supplied to the wire feeder and the on off switch ON check the following items a Measure the AC voltage across the secondary of the stepdown transformer T2 The measured voltage should be 24 VAC If not replace the stepdown transformer T2 b Depress the welding gun trigger relay K1 should operate If not replace relay K1 c With the WFS control set to maximum measure the AC voltage from the wiper of the variable transformer T1 to TB1 2 The measured voltage should be 120 VAC If not replace the variable transformer T1 Check wear on motor brushes a See Feedhead Maintenance in the Maintenance chapter of this manual Replace bridge rectifier 1 if necessary May 30 2006 E ULTRAFEED A 2000 Wire feed motor continues to run after gun switch has been released 1 3 No wire feed speed WFS control 2 Check the continuity of the welding gun trigger leads with the trigger released a Ifshorted repair or replace the welding gun Check for a shorted gun switch receptacle J1 terminal block TB1 or inch purge switch 51 Check to see if relay K1 is functioning properly Check for a loose WFS control knob Check variable transformer T1 bridge
53. re feeds through the sheet metal housing to the wire feeder 4 WELDING CURRENT LEAD ACCESS This is where the welding current lead from the power supply feeds through the sheet metal housing u A 07322 Figure 4 3 Rear Panel Connections May 30 2006 ULTRAFEED 2000 4 04 Feedhead Components 1 INPUT GUIDE LOCKSCREW Tighten this lockscrew to secure the input wire guide 2 SPRING TENSION KNOB Use the spring tension knob to adjust the amount of force the feed rolls exert on the welding wire 3 FEEDROLL GEAR KNOB This knob is used to secure the feedroll to the pressure arm Rotate the knob to change the feedroll 4 PRESSURE ARM This arm pivots off the front of the feedhead to allow access to the wire guides and wire path 5 GUN CLAMP KNOB This knob is used to tighten the welding gun into the feedhead 6 WELD CABLE CONNECTION This is where the power source welding cable is connected to the feeder Make sure this connection is tight or arcing could occur 7 INPUT WIRE GUIDE This guide is required to direct the welding wire from the wire reel to the drive roll 8 OUTPUT WIRE GUIDE This guide is required to direct the welding wire from the drive roll to the welding gun cable 9 WIRE SPOOL HUB NUT The wire spool hub nut is used to secure the spool of welding wire 10 HUB TENSION BOLT The hub tension bolt is used to adjust the wire spool tension which acts as a mechanical brake to assist in the s
54. ring Pressure Adj 2R Plate Pin Roll 3 32 ODx1 2 Guide Input 030 045 2R Plate Screw PHCR 8 32x1 2 STZP Screw Hex HD 3 8 16x3 4 STZP Washer 3 8 Lock WF Washer 3 8 Flat WF Knob Clamp 2R Plate Clamp MIG gun 2R Plate Spring Clamp 2R Plate Gas Nipple 10 32 UN 2R Plate Guide Output 2R Plate Pressure Arm 2R M C WF Feed Plate 2 Roll Tweco 4 Pin 6x50mm 2R amp 4R Plate Screw PHCR 1 4 20x3 4 STZP Insulator Screw mtg 2R Plate Retainer Drive Gear 2R Plate Gear Drive Roll 2R Plate Note This part may be purchased locally Part Number 870082 870425 See Note 400562 033 7962029PKD 377941 See Note See Note See Note See Note 171380 171362 400562 048 375298 375655 870679PKD 870932PKD 870509 See Note 171374 870733PKD 870560PKD May 30 2006 ULTRAFEED 2000 Art A 07581 NO sa e A He Be AYVA lt SSS May 30 2006 ULTRAFEED 2000 7 06 Feed Drive Motor item Qty Ref Des Description 1 1 81 Motor Feed Drive 20 VDC WF 2 1 Insulator Motor 28 7 ID 2R Plate 3 1 Plate MTG Feedhead WF 7 8 Part Number 204994 002 870695 002PKD 870122CLAPKD Art A 07503 May 30 2006 ULTRAFEED 2000 APPENDIX 1 FEED 0LL KITS FEED ROLL KITS 375980 Series 2 ROLL FEED ROLL STYLES TUBULAR WIRE SOFT WIRE DOUBLE COG DOUBLE U DOUBLE U TUBULAR WIRE
55. t Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence 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 Arrange cables to one side and away from the operator Do not coil or drape cable around the body Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS 333 The above procedures are among those also normally recommended for pacemaker wearers Consult your
56. t pull on wires to disassemble connections Firmly grasp each lug or connector when disconnecting Pulling wires for disassembly can damage the integrity of the connection and cause future malfunctions Prior to disassembly or servicing of the machine note the wiring and connections in the machine Reassembling should place the wires in the same location and routing as received from the factory Keep wires and leads away from hot parts and sharp objects All signals referenced in the following troubleshooting guide be measured with a digital multimeter DMM May 30 2006 6 02 Troubleshooting Guide NOTE Refer to the Connection Diagram and the Schematic Diagram in the Appendix chapter of this manual for graphical assistance in disassembling and troubleshooting the wire feeder gt WARNING ELECTRIC SHOCK can kill Follow all safety precautions Do not touch live electrical parts Turn OFF input power before servicing the machine unless otherwise noted Only qualified technicians are to service the machine lt WARNINGS PC boards and their components are static sensitive devices Use static proof bags Use grounded wrist strap Only qualified personnel should test or handle these devices NOTE Refer to the Appendix 3 Connection and Schematic Diagrams in the Appendix Section of this manual for graphical assistance in disassembling and troubleshooting the wire feeder The acceptabl
57. topping of the welding wire when the gun switch is released CS Art A 07326 Figure 4 4 Feedhead Components May 30 2006 4 3 ULTRAFEED 2000 4 05 Power Source Compatibility The Ultrafeed A 2000 wire feeder will work with any Ther mal Arc CV or CC CV power source If the Thermal Arc power source only offers a 5 pin amphenol connector and AC voltage outlets 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 870093 001 adapter cable will be required to connect between the 19 pin control cable ofthe wire feeder and the 14 pin amphenol connector of the power source The Ultrafeed A 2000 will also work with most competi tive power sources that provide 115 VAC and require a relay closure to become energized 4 06 Power Source Compatability Details Power Source Compatibility Details PowerMaster 500 Fully Compatible PowerMaster 500P Fully Compatible ExcelArc 6045 Fully Compatible Figure 4 5 Power Source Compatability 4 4 May 30 2006 ULTRAFEED 2000 SECTION 5 MAINTENANCE 5 01 Cleaning The Unit Periodically clean the inside of the wire feeder and feedhead assembly by using a vacuum cleaner or clean dry compressed air of not more than 25 psi 172
58. traFeed 2000 Specifications Input Voltage 115 Input Frequency 50 60 Hz Input Voltage Tolerance 10 Maximum Input Current 1 5 Amps Wire Speed Range 30 650 ipm for All Filler Wire 51705 76 16 6 m min Wire Sizes 020 024 5 64 0 6 2 0 mm Maximum Wire 60 Ib 27 kg Coil Spool Weight Feed Rolls 2 Gear Driven Welding Current I 450 A 100 Duty Cycle Welding Gun Torch Size Tweco 4 Std 5 8 15 9mm nominal Maximum Shielding Gas 100 PS1 69 Bar Inlet Pressure Weight Less Wire 30 Ibs 13 5 kg 10 3x12 4x19in Dimensions HxWxD 262 x 315 x 483 mm Approvals NEMA EW 3 2 IEC60974 1 Table 2 1 Product Specifications Art A 07319 Figure 2 1 ULTRFEED A 2000 Front View 2 3 ULTRAFEED 2000 2 05 Features and Benefits Ready to weld Supplied with 6ft 2m control cable with 19 pin male amphenol plug and 030 035 045 in 0 8 0 9 1 2mm drive rolls for hard wire Inch amp purge switches Cold wire inch and gas purge Precision wire alignment Machined feed head and tension arms ensure wire alignment tolerances 002 Geared top amp bottom drive rolls Optimized wire traction for improved feedability Quick change drive rolls No tools required Speed control fitted Variac speed control ensured lower operating and repair cost with improved reliability Electromechanical brake Electromechanical control of the motor brak
59. ty 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 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 installed or improperly grounded equipment is a hazard 14 Wear a safety harness to prevent falling if working above floor
60. wire type and size Style 1 Feed rolls consist of flat smooth top rolls and double smooth vee grooved bottom rolls They feed 024 068 hard and tubular wire Style 2 Feed rolls consist oftop and bottom 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 top and bottom double smooth vee grooved drive rolls This style supports 0 035 to 1 16 soft wire Style 4 Feed rolls consist of top and bottom double knurled vee grooved grooved drive rolls They feed 045 5 64 hard and tubular wire Style 5 Feed rolls consist oftop and bottom double cog top and bottom rolls They feed 045 5 64 tubular wire Style 6 Feed rolls consist of top and bottom double U grooved top and bottom feed rolls They feed 035 1 16 soft wire NOTE All grooved feed rolls have their wire size or range stamped on the side of the roll On rolls with different size grooves the outer visible when installed stamped wire size indicates the groove in use REMOVING OR INSTALLING FEED ROLLS 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 NOTE The retainer caps
61. y es l ext rieur loin des prises d air du b timent 4 AVERTISSEMENT LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable Arr tez le moteur avant de v rifier le niveau carburant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur w AVERTISSEMENT DES PIEGES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst me arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les m

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