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Tweco ULTRAFEED VAF-4 Service Manual

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ULTRAFEED
VAF-4
®
Wirefeeder
Service
Manual
English
Art # A-12466_AB
Revision: AA
Issue Date: March 27, 2015
Manual No.: 0-5332
Tweco.com

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Summary of Contents for Tweco ULTRAFEED VAF-4

  • Page 1 ULTRAFEED VAF-4 ® Wirefeeder Service Manual English Art # A-12466_AB Revision: AA Issue Date: March 27, 2015 Manual No.: 0-5332 Tweco.com...
  • Page 2 We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done. For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Service Manual Number 0-5332 for: Tweco ULTRAFEED VAF-4 Wirefeeder Part Number W3400002 Published by: Victor Technologies International, Inc.

  • Page 4: Table Of Contents

    4.03 Advanced Features Mode ................4-7 4.04 Wirefeeder Configuration for Different Power Sources ......... 4-15 4.05 Attaching Tweco No. 4 MIG Gun ..............4-16 4.06 Installing Handle Assembly ................4-17 4.07 Installing Lifting Eye Kit W4016701 (Optional) ..........4-18 4.08 Installing Wire Spool Cover W4016301 (optional) ........
  • Page 5 6.07 Main ON/ OFF Switch and Circuit Breakers Removal ........6-7 6.08 Gas Valve Removal ..................6-8 6.09 Removing Tweco No. 4 Adaptor ..............6-9 6.10 Division Plate and Wirefeed Plate Removal ........... 6-10 6.11 Base Panel Removal ..................6-11 SECTION 7: ASSEMBLY PROCEDURE..............
  • Page 6 TABLE OF CONTENTS SECTION 8: PARTS LIST ................... 8-1 8.01 Equipment Identification ................. 8-1 8.02 How To Use This Parts List ................8-1 8.03 Replacement Parts (without wirefeed plate) ........... 8-2 8.04 Replacement Parts- Wirefeed Plate ..............8-4 APPENDIx 1: OPTIONS AND ACCESSORIES ............A-1 APPENDIx 2: CONNECTION DIAGRAM ..............

  • Page 7: Safety Instructions And Warnings

    ULTRAFEED VAF-4 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.
  • Page 8 ULTRAFEED VAF-4 3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. 4. Wear protective clothing made from durable, WARNING flame-resistant material (wool and leather) and foot ARC RAYS can burn eyes and skin; NOISE protection.
  • Page 9 ULTRAFEED VAF-4 6. Be aware that welding on a ceiling, floor, bulkhead, 1. Keep your head out of the fumes. Do not breathe or partition can cause fire on the hidden side. the fumes. 7. Do not weld on closed containers such as tanks or 2.
  • Page 10 ULTRAFEED VAF-4 6. Turn face away from valve outlet when opening 2. Stop engine before installing or connecting unit. cylinder valve. 3. Have only qualified people remove guards or 7. Keep protective cap in place over valve except when covers for maintenance and troubleshooting as cylinder is in use or connected for use.

  • Page 11: General Safety Information For Victor Cs Regulator

    ULTRAFEED VAF-4 1.02 General Safety Information for Victor CS Regulator WARNING Fire Prevention WARNING: This product contains chemicals, including Welding and cutting operations use fire or combustion lead, known to the State of California to cause birth as a basic tool. The process is very useful when properly defects and other reproductive harm.
  • Page 12 ULTRAFEED VAF-4 Ventilation Compressed Gas Cylinders The Department of Transportation (DOT) approves the design and manufacture of cylinders that contain gases WARNING used for welding or cutting operations. Ade quately ventilate welding, heating, and 1. Place the cylinder (Figure 1-1) where you will cutting work areas to prevent accumula- use it.

  • Page 13: Principal Safety Standards

    ULTRAFEED VAF-4 4. NEVER use compressed gas cylinders without 1.03 Principal Safety Standards a pressure reducing regulator attached to the cylinder valve. Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., 5. Inspect the cylinder valve for oil, grease, and Miami, FL 33126.

  • Page 14: Symbol Chart

    ULTRAFEED VAF-4 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Wire Feed Function Single Phase Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter- Welding Gun Dangerous Voltage...

  • Page 15: Precautions De Securite En Soudage A L'arc

    ULTRAFEED VAF-4 1.05 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).
  • Page 16 ULTRAFEED VAF-4 9. N’enroulez pas de câbles électriques autour de votre corps. 10. N’utilisez qu’une bonne prise de masse pour la mise AVERTISSEMENT à la terre de la pièce à souder. LE RAYONNEMENT DE L’ARC PEUT BRÛLER 11. Ne touchez pas à l’électrode lorsqu’en contact avec LES YEUX ET LA PEAU;...
  • Page 17 ULTRAFEED VAF-4 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés. 3. Entourez l’aire de soudage de rideaux ou de cloisons AVERTISSEMENT pour protéger les autres des coups d’arc ou de LE SOUDAGE PEUT CAUSER UN INCENDIE l’éblouissement;...
  • Page 18 ULTRAFEED VAF-4 7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation. 8. Lisez et respectez les consignes relatives aux AVERTISSEMENT bouteilles de gaz comprimé et aux équipements LES ETINCELLES ET LES PROJECTIONS...
  • Page 19 ULTRAFEED VAF-4 5. Utilisez la polarité correcte (+ et –) de l’accumulateur. AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT AVERTISSEMENT CAUSER DES BLESSURES. LA VAPEUR ET LE LIQUIDE DE REFROID- ISSEMENT BRULANT SOUS PRESSION Des pièces en mouvement, tels des ventila- PEUVENT BRULER LA PEAU ET LES YEUX.

  • Page 20: Informations Générales De Sécurité

    ULTRAFEED VAF-4 fondées sur des faits scientifiques visant à atténuer ou éviter des risques potentiels ». AVERTISSEMENT Pour atténuer les champs magnétiques sur les lieux de travail, respectez les procédures qui suivent : N’effectuez d’opérations de soudage JAMAIS sur un récipient qui a contenu des liquides 1.
  • Page 21 ULTRAFEED VAF-4 manches et poches boutonnés. Il ne faut pas remonter AVIS vos manches ou les pantalons à revers. Ce document CGA p. t peut être obtenu en Quand vous travaillez dans un environnement non écrivant à “Compressed Gas Association”, dédié...

  • Page 22: Principales Normes De Securite

    ULTRAFEED VAF-4 1.08 Principales Normes De Securite Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128. Safety and Health Standards, OSHA 29 CFR 1910, Su- perintendent of Documents, U.S. Government Printing Office, Washington, D.C.

  • Page 23: Graphique De Symbole

    ULTRAFEED VAF-4 1.09 Graphique de Symbole Seulement certains de ces symboles apparaîtront sur votre modèle. Déroulement du Fil Sous Tension Mono Phasé Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Trois Phasé Hors Tension Tri-Phase Statique Soudage Torch de Tension dangereuse Fréquence Convertisseur...

  • Page 24: Emf Information

    ULTRAFEED VAF-4 1.10 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the...

  • Page 25: Section 2: Introduction

    Additional copies of this manual may be obtained by contacting Tweco at the address and phone number for your location listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment iden- tification numbers.

  • Page 26: Description

    Tweco. The user of this equipment shall have the sole The Ultrafeed VAF-4’s sheet metal box totally encloses the responsibility for any malfunction which results from solid state control circuitry.

  • Page 27: Section 3: Installation

    ULTRAFEED VAF-4 SECTION 3: INSTALLATION 3.01 Duty Cycle The rated duty cycle of a wire feeder, is a statement of the time it may be operated at its rated welding current without exceeding the temperature limits of the insulation of the component parts. To explain the 10 minute duty cycle period the following example is used.

  • Page 28: Specifications

    In the interest of continuous improvement, Tweco reserves the right to change the specifications or design of any of its products without prior notice.

  • Page 29: Environment

    ULTRAFEED VAF-4 3.05 Ventilation 3.03 Environment These units are designed for use in environments with increased hazard of electric shock as outlined in IEC 60974-5. WARNING Since the inhalation of welding fumes can be A. Examples of environments with increased hazard of...
  • Page 30 ULTRAFEED VAF-4 2. Maintenance of Welding Equipment B. Assessment of Area The welding equipment should be routinely maintained Before installing welding equipment, the user shall make according to the manufacturer’s recommendations. All an assessment of potential electromagnetic problems in access and service doors and covers should be closed the surrounding area.

  • Page 31: Section 4: Operation

    ULTRAFEED VAF-4 SECTION 4: OPERATION 4.01 Front Panel Controls, Indicators and Features Art # A-12467 Figure 4-1 Front Panel View WARNING DO NOT TOUCH the electrode wire while it is being fed through the system. The electrode wire will be at welding voltage potential.
  • Page 32 ULTRAFEED VAF-4 For Factory default - The meter previews WFS When the arc is struck, it switches to current in Amps. While weld- ing, if adjustment to WFS is made, it reverts to WFS. When adjustment is complete, meter switches back to Amps.
  • Page 33 ULTRAFEED VAF-4 8. Left Digital Display Left display is a 4- digit display. In advanced programming mode, this display is used to display advanced features details or simply "----". Please refer to Section 4.03 for Advanced Features Details. When welding, this digital meter will display WFS in Inches Per Minute (IPM) or Meters Per Minute (MPM) and actual welding amperage of the power source; it can also simply display "----" when the VAF-4 is connected to a power source...
  • Page 34 ULTRAFEED VAF-4 NOTE In Advanced Features Mode Trigger Mode and SCH1-SCH2 can't be changed. In Spot Mode Stitch Mode is not available. Crater is only available in 4T Trigger Mode. 11. SCH 1-SCH 2 Button This allows the user to save parameter settings in either Schedule 1 (SCH 1) or Schedule 2 (SCH 2) locations. Press the button to select either SCH 1 or SCH 2.
  • Page 35 ULTRAFEED VAF-4 15. Remote Control Socket The 8 pin Remote Control Socket is used to connect remote control devices to the Wirefeeder. To make connections, align keyway, insert plug, and rotate threaded collar fully clockwise. Trigger Switch Remote Volts in...

  • Page 36: Rear Panel Controls And Features

    ULTRAFEED VAF-4 Keyway 4.02 Rear Panel Controls and Features Figure 4-5 Pin Identification Art # A-12468 Control Cable Function Figure 4-4 Rear Panel View Contactor + (Shorted to B 17. ON/ OFF Switch to turn ON Power Source) Press this switch to turn ON or turn OFF the Wirefeeder.

  • Page 37: Advanced Features Mode

    ULTRAFEED VAF-4 4.03 Advanced Features Mode Enter Advanced Features Mode by pressing both the left knob and right knob at the same time for more than 2 seconds. NOTE In Advanced Features Mode the Trigger Mode Control Button, SCH 1-SCH 2 button is inactive.
  • Page 38 ULTRAFEED VAF-4 Advanced Feature Left Display Right Display Feature Description Parameter / Selection Ramp Time This is used to set the time to ramp from the creep wire feed speed to the selected wirefeed speed setting. 0.1 to 1.0 seconds Default Ramp Time = 0.2 sec...
  • Page 39 ULTRAFEED VAF-4 Advanced Feature Left Display Right Display Feature Description Parameter / Selection Crater Wirefeed Speed (only if Crater mode is ON) This sets the reduced wire speed during crater operation in 4T at the 0 – 100% of end of the weld.
  • Page 40 ULTRAFEED VAF-4 Advanced Feature Left Display Right Display Feature Description Parameter / Selection Wirefeed Speed Units This allows setting of the Wirefeed Speed Meter to display in IPM or MPM units. Default Wirefeed Speed = IPM IPM (inches per minute)
  • Page 41 ULTRAFEED VAF-4 Advanced Feature Left Display Right Display Feature Description Parameter / Selection Restore Factory Defaults This resets all the user adjustable values in this table (except Arc Hour Accumulated Runtime) to the Factory Default Values. Restore Factory Default No / YES CAUTION Schedule SCH1 &...
  • Page 42 ULTRAFEED VAF-4 Advanced Feature Left Display Feature Description User Type Setting Then press the LEFT KNOB This is used to set up the VAF- 4 when a Power Source is not on the list in Subsection 4.04) 3. The LEFT DISPLAY will show VDSP / MIN. Adjust the RIGHT KNOB to display the minimum welding output voltage the power source can provide.
  • Page 43 ULTRAFEED VAF-4 6. Turn the LEFT KNOB clockwise to save the VSET MIN setting and advance to the next menu item. Advanced Feature Left Display Right Display Feature Description Parameter / Selection Power Source Control Voltage Maximum The LEFT DISPLAY will now Vset Min to 12.0...
  • Page 44 ULTRAFEED VAF-4 Factory Default Setting Advanced Feature Left Display Right Display Comments Feature (Default) Description MIG Control MIG/CNTR LOCL Pre Flow PRE/FLOW Run In RUN/IN Ramp Time RAMP/TIME Post Flow POST/FLOW Burn Back BURN/BACK 0.15 Crater CRAT Only in 4T Mode...

  • Page 45: Wirefeeder Configuration For Different Power Sources

    NOTE When S6=ON(1), calibration functions in Advanced Features Mode is enabled; when S6=OFF(0), calibration functions are disabled. WARNING Only when S1=OFF(0),S2=ON(1), WFS Setting is applicable for Ultrafeed VAF-4 and it ranges from 50 IPM to 875 IPM. Manual 0-5332 OPERATION...

  • Page 46: Attaching Tweco No. 4 Mig Gun

    1. Insert the 4 pin plug into the 4 Pin Trigger Socket, and rotate threaded collar fully clockwise to lock the plug into position. 2. Fit the Tweco No. 4 MIG Gun to the Wirefeeder by pushing the MIG Gun Connector into the Tweco No. 4 GUN Adaptor and secure it by tightening the Thumb Screw supplied.

  • Page 47: Installing Handle Assembly

    ULTRAFEED VAF-4 4.06 Installing handle Assembly WARNING This handle is not designed to lift Wirefeeder by mechanical means. Handle is to be used for Lifting by Hand Only. For Mechanical Lifting use Lifting Eye Kit W4016701. The following components are included:...

  • Page 48: Installing Lifting Eye Kit W4016701 (Optional)

    ULTRAFEED VAF-4 4.07 Installing Lifting Eye Kit W4016701 (Optional) The following components are included: Description Quantity Lifting Eye Insulator Plate Bolt, M8 × 40 (with torque 45~59 N.m.) Flat Washer (smaller), M8 (with torque 45~59 N.m.) Flat Washer (larger), M8 (with torque 45~59 N.m.) Insulator Washer, M8 (with torque 45~59 N.m.)

  • Page 49: Installing Wire Spool Cover W4016301 (Optional)

    ULTRAFEED VAF-4 4.08 Installing Wire Spool Cover W4016301 (optional) The following components are included in this kit: Item Description Quantity Bolt, M12 x 30 Star Washer, M12 Flat Washer, M12 Screw, Countersunk, M5 x 12 Spool Cover Mounting Bracket Spool Cover...
  • Page 50 ULTRAFEED VAF-4 Spool cover is assembled in the following steps: 1. Remove the spool hub assembly. a. Remove the clip from the spool hub. b. Unscrew the 3-lobe screw. c. Remove the spool hub parts and the spacer in the following sequence. Note that the spacer is not required when fitting the spool cover.
  • Page 51 ULTRAFEED VAF-4 4. Install the spool hub component parts over the spool hub shaft in the following sequence. Spool Hub Spring 3-lobe Screw Flat Washer Retaining Clip Keyed Washer Friction Washer Art # A-12478 Figure 4-15 Spool Hub Assembly WARNING Fully tighten all fasteners.

  • Page 52: Installing Welding Wire Spool

    ULTRAFEED VAF-4 4.09 Installing Welding Wire Spool WARNING Fully tighten all fasteners. There are 3 holes on the spool hub support. The top screw hole is for installing a coil of 16" (66lbs) diameter. In this case a 66lbs coil holder must be used. The 66lbs coil holder is attached to the spool hub support in the same way as for a 12" spool, then the coil is placed over the 66lbs coil holder & locked in place. The middle hole is for installing a spool of 12" diameter (as shown in Figure 4-17). The bottom hole is for installing a spool of 8" diameter. As delivered from the factory, the unit has the spool hub fitted into the middle (12" spool) position.

  • Page 53: Wire Spool Brake

    ULTRAFEED VAF-4 4.10 Wire Spool Brake The wire spool hub incorporates a 3-lobe screw which is adjusted during manufacture for optimum braking. If it is considered necessary, adjustment can be made by turning the 3-lobe Screw inside the open end of the hub clockwise to tighten the brake.

  • Page 54: Inserting Wire Into Feed Mechanism

    ULTRAFEED VAF-4 4.11 Inserting Wire into Feed Mechanism WARNING ELECTRIC SHOCK CAN KILL! Make certain the input power is disconnected from the power source before proceeding. Do not reattach the input power until told to do so in these instructions.

  • Page 55: Installing And Changing The Feed Roll / Removing Inlet Guide & Gun Adaptor

    10. To remove the Tweco No. 4 GUN adaptor remove the thumb screw as shown in the figure below then use the 3mm allen key to remove the set screw that fixes the GUN adaptor.

  • Page 56: Shielding Gas Regulator/ Flowmeter Operating Instructions

    ULTRAFEED VAF-4 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. WARNING The welding wire is electrically Hot if it is fed by depressing MIG Gun switch.
  • Page 57 ULTRAFEED VAF-4 User Responsibilities This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and reliable performance. Defective equipment should not be used. Parts that are broken, missing, obviously worn, distorted, or contaminated should be replaced immediately.
  • Page 58 ULTRAFEED VAF-4 Operation With the regulator/ flowmeter connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of regulator/ flowmeter and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator/ flowmeter parts.

  • Page 59: Wire Feeder Set Up Mig (Gmaw) Welding With Gas Shielded Mig Wire

    ULTRAFEED VAF-4 4.15 Wire Feeder Set Up MIG (GMAW) Welding with Gas Shielded MIG Wire Power Source Connections A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work lead to the negative welding terminal (-) [positive welding terminal(+) for flux cored electrode wire].
  • Page 60 Connection to ArcMaster 401MST Positive Welding Terminal (+) ARCMASTER 401MST Negative Welding Terminal (-) Work Lead 19 Pin Control Socket Art # A-12552_AB Wirefeeder Tweco No. 4 MIG GUN Figure 4-23 Setup for Wirefeeder with MIG (GMAW) Welding 4-30 OPERATION Manual 0-5332...

  • Page 61: Wire Feeder Set Up Mig (Gmaw) Welding With Gasless Mig Wire

    ULTRAFEED VAF-4 4.16 Wire Feeder Set Up MIG (GMAW) Welding with Gasless MIG Wire Power Source Connections A. Remove all packaging materials. Do not block the air vents at the front or rear of the Power Source. B. Connect the work lead to the positive welding terminal(+). If in doubt, consult the electrode wire manufacturer.
  • Page 62 Positive Welding Terminal (+) Work Lead Negative Welding Terminal (-) 19 Pin Control Socket Art # A-12553_AB Wirefeeder Tweco No. 4 MIG GUN Figure 4-24 Setup for Wirefeeder with MIG (GMAW) Welding with Gasless MIG Wire 4-32 OPERATION Manual 0-5332...

  • Page 63: Pre-Welding Procedure

    Follow all installation instructions for the wire feeder, the welding power source, and the welding gun before attempt- ing to operate the Ultrafeed VAF-4. 1. Make sure all necessary connections have been made (Refer to Section 3.03 of this manual).

  • Page 64: Welding- 2T Operation

    ULTRAFEED VAF-4 4.19 Welding- 2T Operation Position the welding gun above the workpiece and depress the gun switch trigger. Depressing the gun switch trigger enables the gas valve. When preflow ends, wire feed motor and power source are enabled; the welding process begins.

  • Page 65: Welding- 4T Operation

    ULTRAFEED VAF-4 4.21 Welding- 4T Operation Welding- 4T Operation (Crater=ON) Position the welding gun above the workpiece, depress the gun switch trigger, it enables power source and gas valve, and the wire will begin feeding. Welding arc is established. Release the gun switch trigger and the welding process continues.

  • Page 66: Stitch Operation

    ULTRAFEED VAF-4 4.22 Stitch Operation After selecting stitch operation in advanced features menu, select 2T Stitch or 4T Stitch by pressing 2T/ 4T button on front panel. 2T Stitch Operation Position the welding gun above the workpiece and depress the gun switch trigger. Depressing the gun switch trigger enables the gas valve.

  • Page 67: Ptc (Positive Temperature Coefficient) Protection Of Power Source Contactor Control Output

    Control Output The Power Source Contactor control circuit on the Ultrafeed VAF-4 provides a relay closure to the power source through pins A and B of the 19 pin control cable. This allows the welding wire to become electrically ‘HOT’ when the gun switch trigger on the welding gun is pulled.
  • Page 68 ULTRAFEED VAF-4 Notes 4-38 OPERATION Manual 0-5332...

  • Page 69: Section 5: Troubleshooting

    ULTRAFEED VAF-4 SECTION 5: TROUBLEShOOTING 5.01 Error Codes and Remedies Error Code Description Cause Remedy Left Right Display Display 1. Look for metallic dust build up 01-- This protection Weld current is detected between the wirefeed plate assembly/ circuit is activated...
  • Page 70 ULTRAFEED VAF-4 Error Code Description Cause Remedy Left Right Display Display 06-- Output current of 1. Current running through 1. Turn OFF Wirefeeder and allow it to Wirefeeder exceeds Wirefeeder exceeds 650A for cool for 10 minutes then reduce voltage allowed maximum 4 minutes.

  • Page 71: Troubleshooting

    ULTRAFEED VAF-4 5.02 Troubleshooting WARNING ELECTRIC SHOCK can kill. Follow all safety precautions. Do not touch live electrical parts. Turn OFF input power before servicing the machine unless otherwise noted. Only qualified technicians are to service the machine. WARNINGS PC boards and their components are static sensitive devices.
  • Page 72 ULTRAFEED VAF-4 FAULT CAUSE REMEDY Error Code is Error condition present. Refer to Error Codes and Remedies Table displayed and yellow in Section 5.01. fault indicator is lit when Wirefeeder is turned ON. Power Indicator light Faulty Indicator light on Display Replace PCB2.
  • Page 73 ULTRAFEED VAF-4 FAULT CAUSE REMEDY Wire feeds when the Poor or no work lead contact. Clean work clamp area and ensure good Gun trigger switch electrical contact. is depressed but arc Open power cable between Feeder Measure continuity and replace if open.
  • Page 74 ULTRAFEED VAF-4 FAULT CAUSE REMEDY 11 Wire continues to Wirefeeder in 4T (LATCH) mode Change to 2T (NORMAL) mode. feed when Gun trigger Torch trigger leads shorted. Repair or replace Torch / trigger lead. released Trigger circuit shorted. Remove trigger cord from front of feeder and see if wire feed ceases.

  • Page 75: Wirefeeder Faults

    ULTRAFEED VAF-4 5.03 Wirefeeder Faults Fault Possible Cause Remedy There is no wire The main Power Switch is set to OFF. Set main Power Switch to ON. feed and all front Circuit Breaker has tripped. Reset Circuit Breaker. If it trips again,...
  • Page 76 ULTRAFEED VAF-4 Fault Possible Cause Remedy The wirefeed motor Internal wiring fault. Check continuity of internal wiring and the weld output from Gun adaptor through to boards. do not operate FAULT light is on. Correct Fault. when the Gun Trigger wires shorted to weld voltage Repair trigger wires in Gun.

  • Page 77: Advanced Troubleshooting

    ULTRAFEED VAF-4 5.04 Advanced Troubleshooting If the problem cannot be solved by the basic (external) troubleshooting guide, the Wirefeeder cover will have to be removed to allow the technician to analyse failures with a few common tools. WARNING Turn off power and disconnect interconnection plug from receptacle before working on the unit. Allow 30 seconds for capacitors to discharge after disconnection.

  • Page 78: Preliminary Check Of The Motor Control Pcb1 (Main Power Off)

    ULTRAFEED VAF-4 5.07 Preliminary Check of the Motor Control PCB1 (Main Power OFF) WARNING Check DC bus voltage has discharged to less than 5VDC before servicing. Ensure the interconnection lead is disconnected from the receptacle. Art # A-12017_AB Figure 5-2 Preliminary Check of the Motor Control PCB1...

  • Page 79: Check Main On / Off Switch (Main Power Off)

    ULTRAFEED VAF-4 5.08 Check Main ON / OFF Switch (Main Power OFF) TP18 TP16 TP17 TP15 Art # A-12018_AB Figure 5-3 Main ON / OFF Switch Power Switch Testing Multimeter Lead Placement Diode Voltage Switch ON Positive meter lead to TP 15...

  • Page 80: Check Main Input Rectifiers (Main Power Off)

    ULTRAFEED VAF-4 5.09 Check Main Input Rectifiers (Main Power OFF) Art # A-12019 Figure 5-4 Main Input Rectifiers Input Rectifier Testing Multimeter Lead Placement Diode Voltage AC1 to DC POS Positive meter lead to AC1 0.2 – 0.8 VDC Negative meter lead to testpoint DC POS...

  • Page 81: Preliminary Check Of The Power Supplies (Main Power On)

    ULTRAFEED VAF-4 5.10 Preliminary Check of the Power Supplies (Main Power ON) With the wirefeeder powered up, there are LED’s placed on the Motor Control PCB1 to indicate if the individual power supplies are present. There are also test points to measure the actual power supply voltages.
  • Page 82 ULTRAFEED VAF-4 Power Supply Testing Multimeter Lead Placement Voltage 15VDC ISO (trigger Positive meter lead to TP 4 15 ± 0.5 VDC input) Negative meter lead to TP 5 Main 15VDC supply Positive meter lead to TP 6 15 ± 0.2 VDC...

  • Page 83: Pcb Connectors

    ULTRAFEED VAF-4 Power Supply Testing Multimeter Lead Placement Voltage Main 15VDC supply Positive meter lead to TP 19 15 ± 0.2 VDC Negative meter lead to TP 20 Main 5VDC supply Positive meter lead to TP 21 5 ± 0.2 VDC Negative meter lead to TP 20 Main 3.3VDC supply...
  • Page 84 ULTRAFEED VAF-4 P2 Header Pin Pin function Signal +5VDC 5 VDC Tacho signal (pulse train) 5 VDC pk No connection 0 VDC Table 5-11 P2 Header pin function (connects to Motor Tacho) P3 Header Pin Pin function Signal Trigger (15VDC when trigger open)
  • Page 85 ULTRAFEED VAF-4 P6 Header Pin Pin function Signal No connection 8 pin (2) – Trigger (15VDC when trigger open) 15 VDC 8 pin (3) – Trigger (0VDC when trigger open) 0 VDC No connection 8 pin (5) – Remote control 5k W pot maximum terminals 15 VDC 8 pin (6) –...
  • Page 86 ULTRAFEED VAF-4 2. Display PCB2 Art # A-12023 Figure 5-8 Display PCB2 Connectors P1 Header Pin Pin function Signal +15V 15 VDC 0 VDC Can Bus “high” signal 5 VDC pk Can Bus “low” signal 5 VDC pk Can Bus shield...

  • Page 87: Main Circuit Description

    ULTRAFEED VAF-4 5.12 Main Circuit Description WARNING Turn off power and disconnect interconnection plug from receptacle before working on the unit. Allow 30 seconds for capacitors to discharge after disconnection. +5.0V TACHO +24V SOLENOID TRIGGER A Motor Control PCB TRIGGER B...
  • Page 88 ULTRAFEED VAF-4 This protection circuit will also operate if there is a short circuit from the 110VAC or 42VAC supply down to earth. Generally if this happens, the circuit breakers CB1 or CB2 would also trip removing all power from the wirefeeder.

  • Page 89: Section 6: Disassembly Procedure

    ULTRAFEED VAF-4 SECTION 6: DISASSEMBLY PROCEDURE 6.01 Safety Precautions for Disassembly NOTE Read and follow safety information in Section 5.04 before proceeding. Unplug unit before beginning Disassembly procedure. Manual 0-5332 DISASSEMBLY PROCEDURE...

  • Page 90: Cover Panel Removal

    ULTRAFEED VAF-4 6.02 Cover Panel Removal 1. Remove the ten screws M5× 1.4-13 securing the Cover Panel. 2. Disconnect the Earth Wire connected to the Cover Panel. Art # A-12815 Figure 6-1 Removing Cover Panel DISASSEMBLY PROCEDURE Manual 0-5332...

  • Page 91: Front Panel Removal

    ULTRAFEED VAF-4 6.03 Front Panel Removal 1. Remove the two screws M6× 16 securing the Front Panel. 2. Disconnect the Cable Assembly connecting Display PCB2 and Motor Control PCB1. 3. Disconnect the Earth Wire from the Front Panel. Art # A-12816...

  • Page 92: Display Pcb2 Removal

    ULTRAFEED VAF-4 6.04 Display PCB2 Removal 1. Remove the four screws M4× 8 securing the Display PCB2. 2. Disconnect P1 connector. Art # A-11606_AB Figure 6-3 Removing Display PCB2 DISASSEMBLY PROCEDURE Manual 0-5332...

  • Page 93: Motor Control Pcb1 Removal

    ULTRAFEED VAF-4 6.05 Motor Control PCB1 Removal 1. Disconnect P4 Head Pin from Motor Control PCB1. 2. Disconnect P1 Head Pin from Motor Control PCB1. 3. Disconnect P2 Head Pin from Motor Control PCB1. 4. Disconnect P6 Head Pin from Motor Control PCB1.

  • Page 94: Main Input Rectifier Removal

    ULTRAFEED VAF-4 6.06 Main Input Rectifier Removal 1. Disconnect the terminals connected to the Main Input Rectifier. 2. Remove the two screws M4× 20 securing the Main Input Rectifier. Art # A-11608 Figure 6-5 Removing Main Input Rectifiers DISASSEMBLY PROCEDURE...

  • Page 95: Main On/ Off Switch And Circuit Breakers Removal

    ULTRAFEED VAF-4 6.07 Main ON/ OFF Switch and Circuit Breakers Removal 1. Disconnect the terminals connected to the Main ON/ OFF Switch. 2. Push the Main ON/ OFF Switch forward and remove it. 3. Disconnect the terminals connected to the Circuit Breaker.

  • Page 96: Gas Valve Removal

    ULTRAFEED VAF-4 6.08 Gas Valve Removal 1. Remove the two screws M4× 8 securing the Gas Valve. 2. Remove the two hose clamps over the gas hose and disconnect the gas hose. 3. Disconnect the two terminals connected to the Gas Valve.

  • Page 97: Removing Tweco No. 4 Adaptor

    3. Remove the M10 lock washer and M10 lock nut securing Tweco No. 4 Adaptor. 4. Remove the thumb screw and the M6 × 6 set screw and then remove the Tweco No. 4 Adaptor. *Note: M6 × 6 set screw not shown.

  • Page 98: Division Plate And Wirefeed Plate Removal

    ULTRAFEED VAF-4 6.10 Division Plate and Wirefeed Plate Removal 1. Remove the two screws M5× 1.4-13 on Rear Panel securing Division Plate. 2. Remove the screw M5× 12 and remove the Earth Wire connected to Division Plate. 3. Remove the screw M5× 1.4-13 securing Division Plate.

  • Page 99: Base Panel Removal

    ULTRAFEED VAF-4 6.11 Base Panel Removal 1. Remove the four screws M8× 30 securing Base Panel and remove the Base Panel. Art # A-11613 Figure 6-10 Removing Base Panel Manual 0-5332 DISASSEMBLY PROCEDURE 6-11...
  • Page 100 ULTRAFEED VAF-4 Notes 6-12 DISASSEMBLY PROCEDURE Manual 0-5332...

  • Page 101: Section 7: Assembly Procedure

    ULTRAFEED VAF-4 SECTION 7: ASSEMBLY PROCEDURE 7.01 Installing Base Panel 1. Install the four screws M8× 30 securing Base Panel. Art # A-11613 Figure 7-1 Installing Base Panel Manual 0-5332 ASSEMBLY PROCEDURE...

  • Page 102: Installing Tweco No. 4 Adaptor

    Art # A-12820 Figure 7-2 Reconnecting Gas Hose 2. Reconnect the welding cable. a. Attach the welding cable lug to Tweco No. 4 Adaptor, using the M10 Flat Washer, M10 Spring Washer and M10 × 18 Hex Bolt. Gas Hose...
  • Page 103 ULTRAFEED VAF-4 3. Place the M10 Lock Washer and M10 Lock Nut over the threaded end of the Tweco No. 4 Adaptor. Tighten the M10 Lock Nut securely. 4. Install the M6 × 6 set screw in the Wirefeed Plate, and then install the thumb screw.

  • Page 104: Installing Division Plate And Wirefeed Plate

    ULTRAFEED VAF-4 7.03 Installing Division Plate and Wirefeed Plate 1. Install the four screws M6× 16 and secure the Wirefeed Plate to the Division Plate. 2. Install the two screws M6× 30 and secure the Wirefeed Plate to the Base Panel.

  • Page 105: Installing Gas Valve

    ULTRAFEED VAF-4 7.04 Installing Gas Valve 1. Reconnect the two terminals to the Gas Valve. 2. Reconnect the gas hose. 3. Install the two screws M4× 8 and secure the Gas Valve. Art # A-11616 Figure 7-6 Installing Gas Valve...

  • Page 106: Installing Main On/ Off Switch And Circuit Breakers

    ULTRAFEED VAF-4 7.05 Installing Main ON/ OFF Switch and Circuit Breakers 1. Push the Main ON/ OFF Switch forward. 2. Reconnect the terminal to the Main ON/ OFF Switch. 3. Place the Circuit Breaker and install the plastic caps to secure it.

  • Page 107: Installing Main Input Rectifiers

    ULTRAFEED VAF-4 7.06 Installing Main Input Rectifiers 1. Reapply Heat Sink compound on the rear of Main Input Rectifiers. 2. Install the two screws M4× 20 with torque 0.912-1.277 ft lbs (1.236-1.731 Nm) to secure the Main Input Rectifiers. 3. Reconnect the terminals to the Main Input Rectifiers.

  • Page 108: Installing Motor Control Pcb1

    ULTRAFEED VAF-4 7.07 Installing Motor Control PCB1 1. Install the five screws M4× 8 to secure the Motor Control PCB1. 2. Reconnect P1 Head Pin to Motor Control PCB1. 3. Reconnect P2 Head Pin to Motor Control PCB1. 4. Reconnect P6 Head Pin to Motor Control PCB1.

  • Page 109: Installing Front Panel

    ULTRAFEED VAF-4 7.08 Installing Front Panel 1. Install the four screws M4× 8 and secure Display PCB2 to Front Panel. 2. Reconnect Cable Assembly connecting Display PCB2 and Motor Control PCB1. 3. Reconnect the Earth Wire to the Front Panel.

  • Page 110: Installing Cover Panel

    ULTRAFEED VAF-4 7.09 Installing Cover Panel 1. Install the ten screws M5× 1.4-13 to secure the Cover Panel. 2. Reconnect the Earth Wire to the Cover Panel. Art # A-12815 Figure 7-11 Installing Cover Panel 7-10 ASSEMBLY PROCEDURE Manual 0-5332...

  • Page 111: Section 8: Parts List

    ULTRAFEED VAF-4 SECTION 8: PARTS LIST 8.01 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.

  • Page 112: Replacement Parts (Without Wirefeed Plate)

    Socket, 19 Pin, Male, Panel Mtg W7005715 Socket Panel, Dinse, Male, 50mm W7005716 SPOOL HUB ASSY W7005609 Wire Guide, Outlet, 0.8-1.2, WF W4017700 Adaptor, Tweco No. 4 W4017800 Handle Kit W7005717 Top and Right Side Panel with label W7000651 Door Panel with label W7000652...
  • Page 113 ULTRAFEED VAF-4 Art # A-12485_AB Figure 8-1 Replacement Parts (without wirefeed plate) Manual 0-5332 PARTS LIST...

  • Page 114: Replacement Parts- Wirefeed Plate

    ULTRAFEED VAF-4 8.04 Replacement Parts- Wirefeed Plate Item # Description Part Number Motor, 42V, WF W7005713 Wire Drive Assy, 4R, WF W7005707 Wire Guide, Inlet, 0.8-1.6, WF W7005710 Wire Guide, Center, 0.8-1.6, WF W7005711 Feed Roll Refer to Appendix 1...

  • Page 115: Appendix 1: Options And Accessories

    ULTRAFEED VAF-4 APPENDIx 1: OPTIONS AND ACCESSORIES Feed Rolls Part Number Description Wire Type W4017019 Drive Roll .023” & .030” V groove Hard Wire (Gas) W4017020 Drive Roll .035” & .045” V groove* Hard Wire (Gas) W4017021 Drive Roll .045” & 1/16” V groove...

  • Page 116: Appendix 2: Connection Diagram

    ULTRAFEED VAF-4 APPENDIx 2: CONNECTION DIAGRAM APPENDIX Manual 0-5332...
  • Page 117 “Purchaser” 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 Tweco products as stated below, Tweco shall, upon notification thereof and substantiation that the product has been stored, installed, oper- ated, and maintained in accordance with Tweco’s specifications, instructions, recommendations and recognized...
  • Page 118 This Page Intentionally Blank...

  • Page 119: Warranty Schedule

    Warranty SCHEDULE 5 Years Parts* / 3 Years Labor ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster Portafeed, Ultrafeed, Ultima 150, WC 100B * 5 years on the Original Main Power Transformer and Inductors not mounted on PCBoards. * 3 years on Power Supply Components 2 Years Parts and Labor Unless specified Auto-Darkening Welding Helmet (electronic Lens), ** 1 Month Harness Assy Victor Regulator for Fabricator 141i (No labor)
  • Page 120 THE AMERICAS Denton, TX USA U.S. Customer Care Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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