ESAB VA 28 PORTAFEED® Wire Feeder User manual

Art # A-09328

PORTAFEED

®

WIRE FEEDER

VA 28

Operating Manual

Revision: AC Issue Date: September 27, 2011 Manual No.: 0-5137

Operating Features:

We appreciate your business!

Congratulations on your new Thermal Arc product. We are proud to

have you as our customer and will strive to provide you with the best

service and reliability in the industry. This product is backed by our

extensive warranty and world-wide service network. To locate your

nearest distributor or service agency call 1-800-752-7621, or visit us

on the web at www.Thermalarc.com.

This Operating Manual has been designed to instruct you on the correct

use and operation of your Thermal Arc product. Your satisfaction with

this product and its safe operation is our ultimate concern. Therefore

please take the time to read the entire manual, especially the Safety

Precautions. They will help you to avoid potential hazards that may

exist when working with this product.

YOU ARE IN GOOD COMPANY

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is the Global Brand of Arc Welding Products for

Thermadyne Industries Inc.

We are a mainline supplier to major welding industry sectors in the

USA, Asia Paciﬁc, Europe and emerging global markets including;

Manufacturing, Construction, Mining, Automotive, Engineering, Rural

and DIY.

We distinguish ourselves from our competition through market

leading dependable brands that have stood the test of time, technical

innovation, competitive prices, excellent delivery, superior customer

service and technical support, together with excellence in sales and

marketing expertise.

We are committed to develop technologically advanced products to

achieve a safer working environment for industry operators.

LEADER IN ARC WELDING TECHNOLOGY

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,

operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s best judgement,

the Manufacturer assumes no liability for its use.

PORTAFEED VA 28 Wire Feeder (NASSCO version)

Operators Manual Number 0-5137 for:

Spec Number W3608001

Published by:

Thermadyne Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermalarc.com

Thermadyne Corporation

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: February 10, 2011

Revision Date: September 27, 2011

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

i

TABLE OF CONTENTS

SECTION 1:

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

1.01 Arc Welding Hazards ....................................................................................... 1-1

1.02 Principal Safety Standards .............................................................................. 1-4

1.03 Symbol Chart .................................................................................................. 1-5

1.04 Precautions De Securite En Soudage A L’arc .................................................. 1-6

1.05 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.06 Principales Normes De Securite ..................................................................... 1-9

1.07 Graphique de Symbole .................................................................................. 1-10

SECTION 2:

INTRODUCTION ..................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identiﬁcation ................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart .................................................................................................. 2-2

2.05 General Information ........................................................................................ 2-3

2.06 Product Speciﬁcations .................................................................................... 2-4

2.07 Features/Beneﬁts ............................................................................................ 2-4

2.08 Power Source Compatibility ............................................................................ 2-6

2.09 Available Options ............................................................................................ 2-6

SECTION 3: INSTALLATION ............................................................................... 3-1

3.01 Connections .................................................................................................... 3-1

3.02 Grounding ....................................................................................................... 3-1

3.03 EMI Considerations ......................................................................................... 3-1

3.04 Installation Of Welding Wire Spool ................................................................. 3-2

3.05 Adjustment Of Spool Tension .......................................................................... 3-2

3.06 Input And Output Wire Guide Installation ....................................................... 3-3

3.07 Selection And Installation Of Feed Rolls ......................................................... 3-4

3.08 Welding Gun Compatibility And Installation .................................................... 3-4

3.09 Threading Wire Into Feedhead ........................................................................ 3-6

SECTION 4:

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

4.01 Front Panel Controls And Connections ........................................................... 4-1

4.02 Internal Panel Controls And Connections ........................................................ 4-2

4.03 Rear Panel Connections .................................................................................. 4-2

4.04 Prewelding Procedure ..................................................................................... 4-4

4.05 Welding — 2 Step Operation .......................................................................... 4-4

4.06 Welding — 4 Step Operation .......................................................................... 4-5

4.07 Feed Monitor Operating Procedure ................................................................. 4-6

4.08 System DIP Switches ...................................................................................... 4-6

4.09 Ground Fault Operation ................................................................................... 4-7

4.10 Wire Feed Speed Calibration .......................................................................... 4-8

TABLE OF CONTENTS

SECTION 5:

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

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

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

5.03 Feedhead Maintenance ................................................................................... 5-1

5.04 System Maintenance ....................................................................................... 5-1

5.05 Gas Valve Maintenance ................................................................................... 5-2

5.06 Troubleshooting Guide .................................................................................... 5-3

5.07 Troubleshooting Hints ..................................................................................... 5-3

5.08 Troubleshooting Guide .................................................................................... 5-4

SECTION 6: PARTS LIST ................................................................................... 6-1

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

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

6.03 Portafeed VA28 Replacement Parts ................................................................ 6-2

APPENDIX 1: GENERAL INFORMATION ................................................................. A-1

APPENDIX 2: SYSTEM SCHEMATIC DIAGRAM ......................................................... A-2

APPENDIX 3: SYSTEM OUTLINE ......................................................................... A-4

APPENDIX 4: FEED ROLL CHART ........................................................................ A-5

LIMITED WARRANTY AND SCHEDULE .................................................................. R-2

TABLE OF CONTENTS

PORTAFEED VA28

Manual No. 0-5137 1-1 SAFETY INSTRUCTIONS

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal

shocks or severe burns. The electrode and

work circuit is electrically live whenever the

output is on. The input power circuit and

machine internal circuits are also live when

power is on. In semi-automatic or automatic

wire welding, the wire, wire reel, drive roll

housing, and all metal parts touching the

welding wire are electrically live. Incorrectly

installed or improperly grounded equipment

is a hazard.

1. Do not touch live electrical parts.

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

3. Insulate yourself from work and ground using dry insulating mats

or covers.

4. Disconnect input power or stop engine before installing or servic-

ing this equipment. Lock input power disconnect switch open, or

remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s

Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to

equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to

cool it or lay it down on the ground or the work surface. Do not

touch holders connected to two welding machines at the same

time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground)

circuit.

12. Use only well-maintained equipment. Repair or replace damaged

parts at once.

13. In conﬁned spaces or damp locations, do not use a welder with AC

output unless it is equipped with a voltage reducer. Use equipment

with DC output.

14. Wear a safety harness to prevent falling if working above ﬂoor

level.

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can

damage hearing. Arc rays from the welding

process produce intense heat and strong

ultraviolet rays that can burn eyes and skin.

Noise from some processes can damage

hearing.

1. Wear a welding helmet ﬁtted with a proper shade of ﬁlter (see

ANSI Z49.1 listed in Safety Standards) to protect your face and

eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from ﬂash

and glare; warn others not to watch the arc.

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP

AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE

INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not

strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and

training before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine

driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other

guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

PORTAFEED VA28

SAFETY INSTRUCTIONS 1-2 Manual No. 0-5137

4. Wear protective clothing made from durable, ﬂame-resistant

material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

FUMES AND GASES can be hazardous to your

health.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to

your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manu-

facturer’s instruction for metals, consumables, coatings, and

cleaners.

5. Work in a conﬁned space only if it is well ventilated, or while wear-

ing an air-supplied respirator. Shielding gases used for welding

can displace air causing injury or death. Be sure the breathing air

is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying

operations. The heat and rays of the arc can react with vapors to

form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cad-

mium 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.

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.

1. Protect yourself and others from ﬂying sparks and hot metal.

2. Do not weld where ﬂying sparks can strike ﬂammable material.

3. Remove all ﬂammables within 35 ft. (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

5. Watch for ﬁre, and keep a ﬁre extinguisher nearby.

6. Be aware that welding on a ceiling, ﬂoor, bulkhead, or partition

can cause ﬁre on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and ﬁre hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Eye protection ﬁlter shade selector for welding or cutting (goggles or helmet), from AWS/ANSI Z49.1:2005

Welding or Cutting

Operation

Electrode Size Metal Thickness or

Welding Current

Filter

Shade No.

Welding or Cutting Operation Electrode Size Metal Thickness or

Welding Current

Filter

Shade No.

Torch Soldering All 2 Gas Tungsten Arc Welding

Torch Brazing All 3 or 4 Light Under 50 Amp 10

Oxygen Cutting Medium 50 to 150 Amp 12

Light Under 1 in., 25 mm 3 or 4 Heavy 150 to 500 Amp 14

Medium 1 – 6 in., 25 – 150 mm 4 or 5 Atomic Hydrogen Welding All 12

Heavy Over 6 in., 150 mm 5 or 6 Carbon Arc Welding All 14

Gas Welding Carbon Arc Gouging

Light Under 1/8 in., 3 mm 4 or 5 Light 12

Medium 1/8 – 1/2 in., 3 – 12 mm 5 or 6 Heavy 14

Heavy Over 1/2 in., 12 mm 6 or 8 Plasma Arc Welding

Shielded Metal-Arc Welding (Stick) Electrodes Light Under 20 Amp 6 to 8

Light Under 5/32 in., 4 mm 10 Light 20 to 100 Amp 10

Medium Under 5/32 to ¼ in., 4 to 6.4mm 12 Medium 100 to 400 Amp 12

Heavy Over ¼ in., 6.4 mm 14 Heavy 400 to 800 Amp 14

Gas Metal Arc Welding Plasma Arc Cutting

Light Under 60 Amp 7 Light Under 300 Amp 9

Light 60 to 160 Amp 11 Medium 300 to 400 Amp 12

Medium 160 to 250 Amp 12 Heavy 400 to 800 Amp 14

Heavy 250 to 500 Amp 14

PORTAFEED VA28

Manual No. 0-5137 1-3 SAFETY INSTRUCTIONS

WARNING

FLYING SPARKS AND HOT METAL can cause

injury.

Chipping and grinding cause ﬂying metal. As

welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recom-

mended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under

high pressure. If damaged, a cylinder can

explode. Since gas cylinders are normally

part of the welding process, be sure to treat

them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical

shocks, and arcs.

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

them to a stationary support or equipment cylinder rack to prevent

falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and

ﬁttings designed for the speciﬁc application; maintain them and

associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in

use or connected for use.

8. Read and follow instructions on compressed gas cylinders, as-

sociated equipment, and CGA publication P-1 listed in Safety

Standards.

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

2. If used in a closed area, vent engine exhaust outside and away

from any building air intakes.

WARNING

ENGINE FUEL can cause ﬁre or explosion.

Engine fuel is highly ﬂammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open

ﬂames.

3. Allow engine to cool before fueling. If possible, check and add fuel

to cold engine before beginning job.

4. Do not overﬁll tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut ﬁngers and hands

and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in

place.

2. Stop engine before installing or connecting unit.

3. Have only qualiﬁed people remove guards or covers for mainte-

nance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative

(-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving

parts.

6. Reinstall panels or guards and close doors when servicing is

ﬁnished and before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO

EXPLODE; BATTERY ACID can burn eyes and

skin.

Batteries contain acid and generate explosive gases.

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

2. Stop engine before disconnecting or connecting battery cables.

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

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

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

PORTAFEED VA28

SAFETY INSTRUCTIONS 1-4 Manual No. 0-5137

WARNING

STEAM AND PRESSURIZED HOT COOLANT

can burn face, eyes, and skin.

The coolant in the radiator can be very hot and

under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to

cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

LEAD WARNING

This product contains chemicals, including

lead, or otherwise produces chemicals known

to the State of California to cause cancer, birth

defects and other reproductive harm. Wash

hands after handling. (California Health &

Safety Code § 25249.5 et seq.)

NOTE

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Ofﬁce of Technology Assessment, Biological Effects

of Power Frequency Electric & Magnetic Fields - Background Paper,

OTA-BP-E-63 (Washington, DC: U.S. Government Printing Ofﬁce, May

1989): “...there is now a very large volume of scientiﬁc ﬁndings based

on experiments at the cellular level and from studies with animals

and people which clearly establish that low frequency magnetic ﬁelds

interact with, and produce changes in, biological systems. While most

of this work is of very high quality, the results are complex. Current

scientiﬁc understanding does not yet allow us to interpret the evidence

in a single coherent framework. Even more frustrating, it does not

yet allow us to draw deﬁnite conclusions about questions of possible

risk or to offer clear science-based advice on strategies to minimize

or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body

as practical.

ABOUT PACEMAKERS:

The above procedures are among those

also normally recommended for pacemaker

wearers. Consult your doctor for complete

information.

1.02 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent

of Documents, U.S. Government Printing Ofﬁce, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection,

ANSI Standard Z87.1, from 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.

PORTAFEED VA28

Manual No. 0-5137 1-5 SAFETY INSTRUCTIONS

1.03 Symbol Chart

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

Gas Tungsten Arc

Welding (GTAW)

Air Carbon Arc

Cutting (CAC-A)

Constant Current

Constant Voltage

Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth

(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating-

Auxiliary Power

Art # A-04130_AB

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld

Mode

Press to initiate wirefeed and

welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release

to start arc. Press to stop arc, and

hold for preflow.

4 Step Trigger

Operation

2 Step Trigger

Operation

S

See Note

S

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192

when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.

Cannot be disposed with household garbage.

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PORTAFEED VA28

Manual No. 0-5137 1-9 SAFETY INSTRUCTIONS

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles

ou d’une ﬂamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein

de carburant ou d’en vériﬁer le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace

pour son expansion.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout

carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT

CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventila-

teurs, des rotors et des courroies peuvent

couper doigts et mains, ou accrocher des

vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les

protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualiﬁées doivent démonter des protecteurs

ou des capots pour faire l’entretien ou le dépannage nécessaire.

4. Pour empêcher un démarrage accidentel pendant l’entretien,

débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouve-

ment; elles peuvent aussi accrocher des vêtements amples et des

outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après

des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER

UN ACCUMULATEUR; L’ELECTROLYTE D’UN

ACCUMU-LATEUR PEUT BRULER LA PEAU

ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte

acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles

d’accumulateur.

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

cumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un

accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSE-

MENT BRULANT SOUS PRESSION PEUVENT

BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur

peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas

refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

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

bouchon.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques,

comme le plomb, ou engendre des produits

chimiques, reconnus par l’état de Californie

comme pouvant être à l’origine de cancer, de

malformations fœtales ou d’autres problèmes

de reproduction. Il faut se laver les mains

après toute manipulation. (Code de Californie

de la sécurité et santé, paragraphe 25249.5 et

suivants)

1.06 Principales Normes De Securite

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding

Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of

Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances, norme

AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,

FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1,

Compressed Gas Association, 1235 Jefferson Davis Highway, Suite

501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Association

canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard,

Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protec-

tion, norme ANSI Z87.1, American National Standards Institute, 1430

Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

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PORTAFEED VA28

Manual No. 0-5137 2-1 INTRODUCTION

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just speciﬁcation or 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:

!

WARNING

A WARNING gives information regarding

possible personal injury.

CAUTION

A CAUTION refers to possible equipment

damage.

NOTE

A NOTE offers helpful information concerning

certain operating procedures.

Additional copies of this manual may be purchased by

contacting Thermal Arc at the address and phone number

in your area listed in the inside back cover of this manual.

Include the Owner’s Manual number and equipment

identiﬁcation numbers.

Electronic copies of this manual can also be downloaded

at no charge in Acrobat PDF format by going to the

Thermal Arc web site listed below and clicking on the

Literature Library link:

http://www.thermalarc.com

2.02 Equipment Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation or part

number), model, and serial number usually appear on

a nameplate attached to the control panel. In some

cases, the nameplate may be attached to the rear panel.

Equipment which does not have a control panel such

as gun and cable assemblies is identiﬁed only by the

speciﬁcation or part number printed on the shipping

container. Record these numbers on the bottom of page

i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the

invoice to make sure it is complete and inspect the

equipment for possible damage due to shipping. If there is

any damage, notify the carrier immediately to ﬁle a claim.

Furnish complete information concerning damage claims

or shipping errors to the location in your area listed in

the inside back cover of this manual.

Include all equipment identiﬁcation numbers as described

above along with a full description of the parts in error.

Move the equipment to the installation site before

un-crating the unit. Use care to avoid damaging the

equipment when using bars, hammers, etc., to un-crate

the unit.

PORTAFEED VA28

INTRODUCTION 2-2 Manual No. 0-5137

2.04 Symbol Chart

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

Gas Tungsten Arc

Welding (GTAW)

Air Carbon Arc

Cutting (CAC-A)

Constant Current

Constant Voltage

Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

Voltage Input

Single Phase

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth

(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating-

Auxiliary Power

Art # A-04130_AB

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld

Mode

Press to initiate wirefeed and

welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release

to start arc. Press to stop arc, and

hold for preflow.

4 Step Trigger

Operation

2 Step Trigger

Operation

S

See Note

S

Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192

when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.

Cannot be disposed with household garbage.

PORTAFEED VA28

Manual No. 0-5137 2-3 INTRODUCTION

2.05 General Information

The Portafeed VA28 is a semiautomatic, solid state

controlled wire feeder capable of 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 Portafeed VA28’s steel-reinforced polyethylene case

totally encloses the solid state control circuitry, welding

wire, and wire drive system. A hinged, latched door allows

quick and easy access to the welding wire and feedhead

assembly that features quick change, gear-driven feed

rolls and a hand operated plastic knob for clamping the

welding gun into the feedhead.

The standard features of the Portafeed VA28 include:

1. An on/off rocker switch with circuit breaker.

2. A wire feed speed control knob.

3. A power source arc voltage control knob.

4. An inch/purge momentary switch.

5. A Wire Feed Speed meter capable of displaying

either preset wire feed speed or arc voltage.

6. A 2 Step/4 Step trigger hold process.

7. A PC board adjusted run-in time setting.

8. A solid state electronic brake for dynamic braking.

9. A Feed Monitor Display.

10. A gas valve solenoid.

11. Quick change, gear-driven feed rolls.

12. A feed roll kit for .035/.045 size ﬁller wire.

13. Up to 15 lb. wire spool.

14. Easy access to motor control PCB for DIP switch

settings and wire speed feed calibration.

The Portafeed VA28 includes the following safety and

protection features:

1. A circuit breaker for total system protection.

2. A solid state circuit for current limit to the motor.

3. A thermal self-reset device for A/B contactor

protection.

4. A low voltage gun trigger circuit for operator

safety.

5. A ground fault feature to protect the operator and

equipment from welding current ﬂowing through

the ground system of the feeder.

6. A panel mounted circuit breaker to protect the

remote voltage control lines.

The Portafeed VA28 has been designed to comply with

NRTL/C and NEMA EW 3 standards.

PORTAFEED VA28

INTRODUCTION 2-4 Manual No. 0-5137

2.06 Product Speciﬁcations

Portafeed VA28 Speciﬁcations

Input Voltage 120VAC

Input Frequency 50/60 Hz

Input Voltage Tolerance ± 10%

Maximum Input Current 4 Amps

Wire Speed Range

(for all ﬁller wire sizes)

70 - 660 ipm

(178 - 1677 cpm

NOTE: Maximum wire feed speeds may vary from

feeder to feeder but will always be at least 660 IPM.

Wire Sizes 0.024 - 5/64”

(0.61 - 1.98 mm)

Feed Rolls 2 (Both Driven)

Welding Current (I) 475A = 60%

425A = 100%

Welding Gun / Torch Size 5/8” Nominal

Maximum Shielding Gas

Inlet Pressure

100 psi (6.9 bar)

Degree of Protection IP21C

Weight (Less wire) 29 lbs (13 kg)

Table 2-1: Speciﬁcations

FEED

MONITOR

2

V MPM IPM

46810

V

PORTAFEED

VA28

23.35

in / 56.7 cm

29 lbs. / 13 kg

12.15 in/

305 mm

9.19 in/

233 mm

Art # A-09252

Figure 2-1: Dimensions

2.07 Features/Beneﬁts

1. Solid State Circuitry

A. Improves wire speed accuracy.

B. Line voltage compensation.

C. Load compensation.

D. Current limit to motor.

2. 4A resetable Input Circuit Breaker

A. Provides total system protection.

3. 1A resetable In-Line Motor Circuit Breaker.

A. Provides protection against a locked motor

condition.

4. A/B Contactor Protection

A. Provides self-reset protection against overload

conditions.

5. 100% Duty Cycle

A. Eliminates nuisance shutdowns due to over

temperature.

6. Polarity Insensitive

A. Weld with straight or reverse polarity.

7. Standard Wire Feed Speed Meter

A. Clearly displays operator input in all environ-

ments.

B. Displays preset wire feed speed (in IPM or

MPM) or arc voltage (preset in standby, actual

when welding).

8. Standard Trigger Hold

A. Allows 2 Step operation for short welds or 4

Step operation (trigger hold) for long welds.

B. Shuts off 4 Step operation if no arc establish

signal is received; done for safety reasons.

9. Standard Remote Voltage

A. Allows adjustment of power source arc voltage

from the wire feeder.

B. Operator has full control of welding parameters

at the wire feeder; can remote power source.

10. Standard Inch/Purge

A. Allows cold inching of wire at set wire feed

speed.

PORTAFEED VA28

Manual No. 0-5137 2-5 INTRODUCTION

B. Allows purging of gas without running wire.

11. Feed Monitor Display

A. Provides visual indication on amount of force

required to push the wire through the wire

drive system.

B. Can monitor ﬂuctuations in wire feed during

welding.

12. Electronic Brake

A. Solid state control of an electronic brake offers

precise stopping of the wire.

13. Run-In Time Adjustment

A. DIP switch located on the PC board allows

choice of 0.1, 0.2, 0.3, or 0.4 second run-in

times.

14. Convenient Hinged Door

A. Permits quick and easy access to the feedhead

and drive rolls.

15. Quick Change Feed Rolls

A. Allows operator to change feed rolls without

the use of tools.

B. Both feed rolls are gear driven for better feed-

ing of wire.

16. Gun Clamp Knob

A. Permits operator to secure welding gun with-

out the need for tools.

17. Welding Gun Quick Connects

A. Offers a quick and easy connection for the

welding guns. CPC and Fast On.

18. Small Size/Light Weight

A. Unit is small; takes up a small amount of space.

B. Unit only weighs 29 pounds (less wire), pro-

moting ease of portability.

19. Replaceable Motor Brushes

A. Extends motor life.

20. Needle Bearing Construction On Motor Output

Shaft

A. Reduces friction and extends bearing life over

a sleeving bearing.

21. Feed Roll Pressure Release

A. Allows operator to change feed rolls or wire

while retaining preset feed roll pressure.

22. Ground Fault Protection

A. Provides protection against ground fault cur-

rents.

B. Signals operator of ground fault with an indica-

tor lamp.

23. Designed In USA

A. Local support for parts and technical assis-

tance.

24. Gas Valve Solenoid

A. Controls the on/off ﬂow of shielding gas.

25. Welding Gun Holder

A. Provides a convenient storage place for the

welding gun.

26. Carrying Handle

A. Promotes portability.

27. Circuit Breaker protection

A. Protects boards with circuit breakers.

PORTAFEED VA28

INTRODUCTION 2-6 Manual No. 0-5137

2.08 Power Source Compatibility

The Portafeed VA28 wire feeder will function with any

Thermal Arc CV or CC/CV power source with a 19 pin

amphenol connector. Cable adapters are available to

connect the Portafeed VA28 to a power source that only

offers a 5 pin amphenol connector and AC voltage outlets

or a 14 pin amphenol connector.

These cable adapters must be used in conjunction with

the 19 pin control cable (refer to Section 2.09 Available

Options for part numbers).

NOTE

When using the cable adapters with the

Portafeed VA28, the remote voltage, 4 Step

(trigger hold), and volt meter features will

not function.

2.09 Available Options

The following options are available for use with the

Portafeed VA28 wire feeder. Some options are kits while

others are individual items.

Portafeed VA28 Options

Feed Roll Kits (See Appendix) 171435-X

Dual Feeder Interlock 870008-1

Pigtail Adapter 171293-001

Table 2-2: Available Options

NOTE

For installation and operation instructions on

the above options, refer to the drawings and

instructions furnished with each kit.

PORTAFEED VA28

Manual No. 0-5137 3-1 INSTALLATION

SECTION 3: INSTALLATION

3.01 Connections

See the System Outline drawing in the Appendix section

of this manual for details.

CAUTION

Make sure ll connections are tight; otherwise,

arcing or overheating could result.

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 power source control cable to the wire

feeder.

NOTE

An optional adapter cable will be required for

connection to a power source not having a 19

pin amphenol (see Section 2.08 Power Source

Compatibility in this manual).

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. Connect the welding gun control leads to the wire

feeder gun switch terminals located inside the wire

feeder.

3.02 Grounding

WARNING

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 internal sheet metal frame is

grounded only through Pin G of the 19 pin con-

trol cable that connects the wire feeder to the

power source. Therefore, if the power source

frame is not grounded, then the wire feeder

internal 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.

3.03 EMI Considerations

Electromagnetic interference (EMI) is common in today’s

complex industrial environment. At times, EMI levels can

become great enough to affect the operation of machinery.

To help reduce and safeguard against EMI levels in the

welding area, follow these simple guidelines:

1. Firmly secure all sheet metal panels on the power

source and wire feeder. Repair or replace heavily

corroded or damaged panels and/or fasteners.

2. Keep the welding cables and control cable as short as

possible.

3. Route the weld cables together.

4. Keep the welding cables as straight as possible; avoid

coiling up the weld cables.

5. Route the control cable away from the welding cables.

NOTE

Grounding of the workpiece may reduce emis-

sions in some, but not all instances. To prevent

the risk of injury or damage to other electrical

equipment when grounding the workpiece,

take care and follow all local laws and regula-

tions.

PORTAFEED VA28

INSTALLATION 3-2 Manual No. 0-5137

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.

1

Hub Tension Bolt

2

3

Alignment Pin

Wire Spool

Art # A-09253-AB

Finger Locks

Figure 3-1: Wire Spool Installation

3.04 Installation Of Welding Wire Spool

Refer to Figure 3-1.

NOTE

The VA28 is capable of using up to and

including a 15 pound spool of wire without

any special adapters.

1. Squeeze and hold the ﬁnger locks together and slide

the spool of wire off from the spool hub.

NOTE

Install the welding wire spool so that the wire

feeds from the bottom of the spool into the

input wire guide.

2. Make sure that the alignment pin on the hub enters

the hole in the backside of the wire spool.

3. Replace the wire spool hub clip closest to the wire

spool.

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ESAB VA 28 PORTAFEED® Wire Feeder User manual

ESAB VA 28 PORTAFEED® Wire Feeder User manual

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