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EXCEL-ARC® 750 and 8065, TRANSMIG 650

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2. Bod ete og e dr BE a E 4 3 OPERATION 5 General A PL dot Sce eg e esee e A edt Oba de si Ro s 5 1 Preweld Operation 5 1 SMAW Stick Welding Carbon Arc Gouging 5 1 Welding Semiautomatic or Automatic 5 1 MAINTENANCE 6 Replacing SCRS ac a ae RR menu aes ad qme d duly fo k Se fume s 6 1 ubrication 13 T SUS RU Male a 6 1 Inspection and Cleaning ode x RE xo Be eee 6 1 TROUBLESHOOTING 7 Detailed Troubleshooting Instructions 7 5 PARTS LIST 8 Equipment Identification 8 1 How This Parts Listu o ee n e Mn dre 8 1 DIAGRAMS December 29 1997 430429 406 INTRODUCTION INTRODUCTION How To Use This Manual This Owner s Manual usually applies to just the underlined specification or part numbers listed on the cover If none are underlined they are all cov ered by this manual 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 rec ognized as follows WARNING gives information re garding possibl
3. No Load Input Voltage 230 460 575 230 460 575 230 460 575 No Load Input Amperage 4 4 2 4 2 0 6 3 2 4 6 3 2 4 No Load kW 1 2 KW 1 2 kW 1 2 kW No Load 1 75 2 4 2 4 Power Factor 72 82 82 Efficiency 7296 80 80 Table 3 1 Input Voltage Amperage Data June 21 1999 Revised 3 1 430429 406 DESCRIPTION OF EQUIPMENT ho Figure 3 1 Front and Rear Panel MN 3 2 December 29 1997 430429 406 DESCRIPTION OF EQUIPMENT Controls and Outlets See callouts on Figure 3 1 1 Overload Indicator Yellow L E D when lighted indicates that machine has shut down as a result of amperage overload or rectifier overtem perature S5 2 Input Contactor Control 100007 1 2 3 5 6 7 This toggle switch is the master power Switch for the welding machine and must be in the ON position before any other section will operate The primary circuit of the control transformer is energized whenever line voltage is present at the input terminals This switch closes the secondary circuit of the control transformer energizing the contactor which energizes the power transformer Do not use this switch to start or stop arc Start arc with switch ON break arc then turn switch OFF 3 Local Remote Output Control Volts Amps Selector Switch 100007 1 2 3 5 6 7 Selects either the output control Local or some remo
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5. 12 Negative Terminal Serves as a connec tion point for the lead to the workpiece when reverse polarity is desired 13 Circuit Breaker Rated at 10 amps pro vides protection to the 115 volt circuit which in cludes the fan and the 115 volt AC power receptacle Weld Amperes 430429 406 DESCRIPTION EQUIPMENT 14 Circuit Breaker Rated at 10 amps pro vides protection to the 24 volt circuit for the wire feeder and automatic equipment Duty Cycle Figure 3 3 Duty cycle is the percentage of each ten minute period of time that the welding machine may be operated under rated load conditions For example a duty cycle of 60 means that the machine can be operated at rated load for an average of 6 minutes of each 10 minute period of operation During the remaining 4 minutes the machine must idle to permit proper cooling Figure 3 3 enables the op erator to determine the duty cycle at various welding amperages DUTY CYCLE FOR EXCEL ARC 750 100007 1 DUTY CYCLE FOR EXCEL ARCO 8065 IIMNMTIN 2 AND TRANSMIG 650 50 60 BO 100 100007 2 3 5 6 7 75 Duty Cycle Chart Figure 3 3 Duty Cycle Chart June 21 1999 Revised 430429 406 DESCRIPTION OF EQUIPMENT Output Min 1 M a 80 Constant Current Muda p input 230Y 38 60 Hz Constant Voitags M
6. CC Mode Test Point TP16 to L8 16V DC meter reading CV Mode output switch to local pins A and B on Amphenol shorted together Test Point TP16 to R22 16 DC meter reading Tig position June 21 1999 Revised 7 Output Reference Circuits Test Point TP16 to TP9 10V DC meter reading reference voltage supply Test Point TP16 toL10 10 DC CC and 8065 models voltage reference supply to output pots 8 SCR Firing Circuits Test Point TP16 to TPE 4 3V DC checks ramp circuits Test Point TP 16 to 4 3V DC all readings should be very close for balance Test Point TP16 to TPB 4 3V DC all readings should be very close for balance Test Point TP16 to C69 17 19V DC checks SCR gate Test Point TP16 to C70 17 19V DC generator circuits Test Point TP16 to C71 17 19V DC all should be equal Control Circuit Board Malfunction If a board malfunction occurs the following situations will probably result 1 Loss of arc completely 2 Very noticeable rough sputtering arc 3 Loss of control and burnback 4 Minor starting problems SCR Malfunction If one or more SCRs mal function the following situations will probably result 1 Blown line fuses as the result of a shorted SCR similar to a shorted diode A shorted flyback diode will also produce this situation 2 If one SCR does not turn on either it is open or the gate signal is not being
7. Keep welding power source and cables as far away from body as practical 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 Superinten dent 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 Ameri can 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 September 22 1999 Revised Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way 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 Pro tection 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 2 3 ARC WELDING SAFETY INSTRUCTIONS AND WARNI
8. tel un r servoir ou un baril Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de LES ETINCELLES ET LES PROJEC laitier TIONS BRULANTES PEUVENT CAUSER DES BLESSURES 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau LES BOUTEILLES ENDOMMAGEES Emp chez tout contact entre une bouteille et une lectrode de PEUVENT EXPLOSER soudage 5 N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords con us pour chaque application sp cifique ces equipements et les pieces connexes doivent amp tre maintenus en bon tat 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin 1 Prot gez les bouteilles de gaz comprim contre les sources de 7 Laissez en place le chapeau de bouteille sauf si en utilisation chaleur intense les chocs et les arcs de soudage ou lorsque raccord pour utilisation 2 Enchainez verticalement les bouteilles un support ou un 8 Lisez et respectez les consignes relatives aux bouteilles de gaz cadre fixe
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11. Carbon arc gouging SMAW Stick welding X Wire Feeder Compatibility Some models of Thermal Arc wire feeders will connect onto this unit with no special preparation In some cases however an interface must be used and in other instances some rewiring must be accomplished Complete details for these excep tions will be found in the instruction manual supplied with the wire feeder PART NO 100007 1 Rated Output Amperage 600 Amps Rated Output Voltage 44 Volts Rated Duty Cycle 60 Duty Minimum Output 60 Amps Maximum Output 750 Amps Rated Input Voltage 230 460 575 Rated Input Amperage 126 62 6 50 Input KW 36 kW i Input 50 1 kVA Input Frequency 60 Hz Input Phase 3 Phase PART NO 100007 2 ITEM EXCEL ARC TRANSMIG 650 CV amp 100007 5 EXCEL ARC cv PART NO 100007 3 PART NO 100007 7 amp 100007 6 EXCEL ARC CC CV 650 Amps 600 Amps 650 Amps 44 Volts 44 Volts 44 Volts 100 Duty 60 100 75 Amps 15 Volts 75 Amps 75 Amps 15 Volts 800 Amps 40 Volts 750 Amps 800 Amps 40 Volts 7095 230 460 575 110 55 43 110 55 43 36 KW 36 kW d ORA 43 8 kVA 60 Hz 60 Hz 3 Phase 3 Phase Maximum Open Circuit Voltage 86 62 62 Auxiliary Power 1 kVA 115V 9A 1 115V 1 115
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13. P N 204248 Jumper JP 3 and JP 5 SMAW Stick Welding Carbon Arc Gouging 100007 3 amp 6 Referto Figure 3 1 for controls numbers in paren thesis refer to callouts on Figure 3 1 1 On 100007 3 and 6 set the selector switch to CC position 2 Hold electrode clear of work and set the Re mote Local Switch 3 to LOCAL position 3 Turn Input Contactor Control Switch 2 to ON position 4 Strike arc Adjust Welding Output Control 8 if required Adjust Arc Force Control 7 to desired level 5 Atthe conclusion of welding break arc and turn input Contactor Control Switch 2 to OFF position Welding Semiautomatic or Automatic Refer to Figure 3 1 for controls 1 On 100007 2 3 5 6 and 7 set Remote Local Output Control Switch 3 and Voltage Sensing Jumpers to LOCAL JP 2 and JP 4 NOTE Set Output Control Switch 3 to REMOTE when using a feeder which con trols the voltage and remote voltage con trol is desired Set Voltage Sensing Jumpers to JP 3 and JP 5 to REMOTE when using a feeder which provides volt age sensing at the actual welding location If the Voltage Sensing Jumpers are placed in the REMOTE position and the voltage sensing leads are not connected at the welding location the output of the welding machine will go to maximum amperage 5 1 430429 406 OPERATION 2 On 100007 3 6 set the CC CV Selector Switch to CV position 3 Place Input Con
14. de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main 6 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 L arc produit des tincellies et des projections Les 5 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 8 Connectez le c bie de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et 1 Prot gez vous ainsi que les autres contre les tincelles et du d incendie m tal chaud 9 Ne d gelez pas les tuyaux avec un source de courant 2 Pu 20227 2 0 10 Otezl lectrode du porte lectrode ou coupez le fil au tube con es proj p aeia tact lorsqu inutilis apr s le soudage levez toutes mati res inflammables dans un rayon de 10 7 5 gt Fare dde edi ee dieses 11 Portez des v tements protecteurs non huileux tels des gants g en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque soudez pas un r cipient ferm
15. in contact with the work ground circuit Use only well maintained equipment Repair or replace dam aged parts at once confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output Wear a safety harness to prevent falling if working above floor level Keep all panels and covers securely in place __ ARC RAYS can burn eyes and skin NOISE can damage hearing Arc ays from the welding pracess produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 Electrode Size Filter i Metal Thickness Shade or Welding Current No Le 2 4 Underiin 25mm 3or4 1 to 6 in 25 150 mm 40r5 Over 8 in 150 mm 5 Under 1 8 in 3 mm 4075 1 8 to 1 2 in 3 12 mm 50r6 Over 1 2 12mm 80r8 Under 5 32 in 4 mm 10 5132 to 1 4 4106 4 12 i Overi 4in G 4mm 14 i il 2 Wear approved safety glasses Side shields recommenzad 5 Wear a welding helmet fitted with a proper shade of filter see Use Wear protective clothing made from durable flame resistant ANSI Z49 1 listed in Safety Standards to protect your face and eyes when welding or watching rotective screens cr barr
16. listed in this and related system manuals The operating instructions in this manual pertain only to the EXCEL ARC 8065 and TRANSMIG 650 welding machines Consult operating instructions for components used with this system before oper ating A thermostatically controlled fan motor is standard on this unit The fan motor starts and stops automat ically when a predetermined temperature has been reached Preweld Operation 1 Connect welding leads to terminals on front panel WARNING Disconnect line volt age from the unit before making any connections inside unit Turn off fused disconnect switch that supplies power to welding machine and remove its fuse ELECTRIC SHOCK can kill Do not touch live electrical parts including the output terminals and electrode 2 If used connect remote control wire assembly and gun switch to welding machine Connect feeder receptacle to wire electrode feeder system 3 Refer to other manuals for component connec tions 4 Set Output Control to desired value 5 Setthe remote local control switch in the desired mode 6 Place the voltage sensing jumpers 100007 2 8 5 6 and 7 on the main P C control board to June 21 1999 Revised the desired mode Local voltage sensing from the power source which comes from the factory Jumper JP 2 and JP 4 For remote voltage sensing going out to the optional terminal strip Thermal Arc
17. 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 Specification or Assembly numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts ofthe equipment are listed except commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded PART NUMBER 100007 1 100007 2 100007 3 100007 5 100007 6 100007 7 June 21 1999 Revised to another part The part descriptions may be indented to show part relationships To determine the part number description quan 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 An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate Application Codes for the Spec
18. pacemaker wearers Consult your doctor for complete information 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 Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine 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 Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing Allow pressure to escape before completely removing cap California Health amp Safety Code Sec 25249 5 et seq To reduce magnetic fields in the workplace use the following procedures 3 Do not coil or drape cables around the body 4
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20. pour les emp cher de tomber ou d tre renvers es comprim et aux quipements connexes ainsi que la publica 3 Eloignez les bouteilles de tout circuit lectrique ou de tout tion P 1 de la CGA identifi e dans la liste de documents soudage ci dessous rd MISE EN GARDE os LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES 1 Utilisez l quipement l ext rieur dans des aires ouvertes et MOTEURS PEUVENT ETRE MORTELS bien ventil es 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent Les moteurs produisent des gaz d chappement nocifs 2 Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue LE CARBURANT PEUR CAUSER UN IN 3 Si c est possible laissez e moteur refroidir avant de faire le CENDIE OU UNE EXPLOSION plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein 8 V 96 2 3 PRECAUTIONS DE SECURITE SOUDAGE A L ARC instruction 830002 DES PI
21. received by the SCR gate circuit open a very small change will occur atthe arc and will be difficultto notice by the average operator Generally when this happens it will be necessary to adjust the voltage control on the front of the welding machine turn it up to obtain the same arcthat was being produced before the defect occurred 3 If two SCRs do not turn on the arc becomes more erratic and unstable Component Testing 1 the case of a severe malfunction such as a shorted SCR or diode do not turn on the unit Disconnect the leads from the transformer to the heat sink assembly and check with a VOM for shorted SCRs or a shorted flyback diode 2 If the welding machine is suspected a very simple test can tell you a great deal about it Simu late gun switch closing and observe the open circuit voltage This can be done by putting the Process 7 5 430429 406 TROUBLESHOOTING Selection Switch Fig 3 1 item 5 in the CV position and shorting terminals A and B together on the 5 pin connector on the rear panel This voltage should vary from 19V DC to 59V DC 10 as the voltage control is rotated from min to max slowly If this voltage varies smoothly there is a strong possibility that nothing has malfunctioned in the welding ma chine If the voltage varies erratically and does not come close to the values listed you probably have a control circuit board problem If the voltage vari ation is somewhat smoo
22. repair neglect alteration or accident 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 THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal Arc shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Purchaser for service 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 negligence strike tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THER
23. toxic and irritating gases 1 Keep your Bead of the fumes De not Breath Ie fumes 7 Do not weld on coated metals such as galvanized lead or 2 If inside ventilate the area and or use exhaust at the arc to cadmium plated steel unless the coating is removed from the remove welding fumes and gases weld area the area is well ventilated and if necessary while 3 If ventilation is poor use an approved air supplied respirator wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded WELDING can cause fire or explosion 5 Watch for fire and Keep a fire extinguisher nearby Z AX Sparks and spatter fly off from the welding arc The 6 Be aware that welding on a ceiling floor bulkhead or partition flying sparks and hot metal weld spatter hot work can cause fire on the hidden side piece and hot equipment can cause fires and bums Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire 3 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 7 Do not weid on closed containers such as tanks or drums 1 Protect yourself and others from flying sparks and hot metal 2 Do not weld where flying sparks can strike flammable material 3 Remove ail flammables
24. 02 Vvanvitg Tout NOS ni 83234 9 1 HOS TRUM EC dde xous 9u HOLS 5 M omaes xvn NO JVISOWMIH 8 MESES Roms meam wua 0220345 7487410 SSTND dd AS s 78 92 11 6 A ET m real DN V A OBLNOO HOJVAS 15 NON 100009 2002 wmf 440 N0 YOLIVINOD INANE HOLMS 15 Y YY Y AA a 130A YOSSINASNS 1A8 O 8 WHO ES Snare SILVA 9 09 NOISS3Nddn VOISISAY OIN SY ss 2 80334 ANOOL 009 INNES F SLIYAM 94 SWMD SZ WOISIS3U 58 Q ARA 1 I L er Z SAO SdNY 130A 10 3NOLN3IOd n 2 AQ YOLDVIY GS A MS 18 95 WAIN OLIV n d YOLOYINNO ix 9 SMO L q 10A tt 3IDY143938 or x 25 NI t 7310143234 M zr cue un WM ER LON OVA FT de s 1ONINOO Nid S JIDY143238 9n N3d0 al ___ ONYOB lOMINOO Nid 9 JIOVId323N sr RISI Ov 9 Zu 8 QUYOG JOMINOO Nid Ct 312VL 43238 WHOD lOMINOO VOYLNO Nid 1 J12Y143238 er 3LON3Y P OYYO8 WULNOD Nid Y 14 ONIY 3 3072 Nid 97 310193939 ir ILONAN TAD NE HOMMES EE 2 1 IOMINOO ISNI 14 OND SISSYHD D P 103N OYA GET
25. 3AHOJ3SNVHL I0 1 NOI MOLOVINOO OL YOLOVINO9 Ol YOLOVINOD OL vl BZZL9E NOLLISNNOD 170A SLS 1 013 NOLLOZNNOD 170 09 YOLOVLNOOD MOTIE N3JANOJSNVMHL TONINOO MOLOVINOO OL S MOLOVINOO OL 38 36 qAOPZ AO0SpD q Woo ASZSD qAS6 P 1 82249 525 O NOU23NNO2 LWA OCZ YSN ELESY OHO sepa pod CEL VOT SMALL 9 pag evades pode d e TIFGY ong jo 8 WEBBER cates maso moe oem 133HS ox up o gane TIBOO S s vou EL 26 1 EN SENI HOLIVINOO MOISE YIAYOISNVHL TIOHLNOO MOLOVINOO MOT38 H3WHOJSNV3HL 3AL408 0831 WvHOVIO YOLIVINO9 OL YOLOVLNOD OL ASLSP YeE gE7 NOLOVINOO OL A0OS b YOLOWLNCS 01 656 40 65 20 3NON 100008 Y3d 3002 HSINIS 80338 3ONVHO 7 11 82298 11 82297 22600 NO 0411931434 38 ISAW OL L LON O 330A JHL NO 3AVMj 8 5 FHL OL ONNOYO 4 F31SAS M3MOd JHL 193 02 75 3ND 9N
26. 4 48 MONA 10114 HOLIVINOD INANI 150 LOW IVA 611 3 P OVA 92 35Y8 Wutsod NOIMIS 3000 HM A 2 9 AZ 01 NIXVING 1 5 NI ASTU 01 YIAV IXA UNITY 182 VOB Od anvo 3 DOAK 00 NOlSS3HddhS JH HOLIOVdYO 129 919 DOM 50 NOISS3HddnS MOIDYdYO 69 60 GMM 5282206 HOLIDYdYO 2 19 YOION NYA 18 gN3931 1 512 YARI v 7 2 913 Y 13 EX us 7 108 6 12 2 9 25 su 019 9x AS LX P 9X B Arz 2 4 sx 8 16 ix V OYABI 91 X S 92 2 81 91 LY ER tX E Ere L 2 tyo CH e 89 YARI 2 1 91 LEU TX D fe 3 91 YINYO JSNY ME 21 Lane WHO T T T y X t T 1 T 1 i 4 YS RIFLE pde pod 4 a 4 6 9 0 9 Sas A pong ropas ap m vac p el CICS OO ayy je UOJDOLOD 3A Pwa E Ve pos oq w etm peme 123 5 080 x15 go Suae 6 6 41 YA SNIAVEO 31YIS ION 000 000 000 Tina 6 8 tl SMY muyo Y DO CROS 0 vic 22 09 Juv 32X3 mann
27. 4302 Heat Sink Rectifier 1 BCDEF 369639 Heat Sink Rectifier 1 A 15 204303 Heat Sink SCR 6 BCDEF 369642 Heat Sink SCR 6 A 16 409639 Rectifier Silicon 6 BCDEF 405139 Rectifier Silicon 6 A 17 16DA 954 12 Spring 6 18 405140 4 Clamp Mtg 6 BCDEF 405140 1 Clamp Mtg 6 A 19 204210 Board Suppressor 2 All 20 W 10931 3 Diode Flyback 1 BCDEF 21 404044 6 Thermostat Fan 1 All 22 404044 3 Thermostat Overload 1 All 23 204575 Shunt 1 All 24 W 10080 5 Clamp Cable 1 All 204038 6 Cable Ribbon Amphenol 1 BCDEF 903914 1 Cap Protective 1 BCDEF 903914 2 Cap Protective 1 BCDEF 403091 14 Plug Hole 1 June 21 1999 Revised Not Illustrated 8 9 430429 406 PARTS LIST This page intentionally left blank 8 10 December 29 1997 430429 406 DIAGRAMS e Note the model and part number shown on the equipment nameplate Locate these numbers the model part number columns below e Use only those diagrams and instructions that are applicable VOLTAGE MODEL PART CONNECTION SCHEMATIC CHANGEOVER NO NUMBER DIAGRAM DIAGRAM DIAGRAM T 100007 2 830177 Sheet4 amp 5 830177 Sheet 6 204322 100007 5 EXCEL ARC 8065 100007 3 830177 Sheet 7 amp 8 830177 Sheet 9 204322 100007 6 EXCEL ARC 750 100007 1 830177 Sheet1 amp 2 830177 Sheet 3 204697 TRANSMIG 650 100007 7 830177 Sheet 4 amp 5 830177 Sheet
28. 5 6 7 Serves as a connection point for the lead to the wire feeder when reverse polarity is o0 26 1 2 in 675 mm desired 24 in 610 mm 29 7 16 in 748 mm LL J CC CV Weight 625 Lbs 284 kg CV Weight 560 Lbs 254 kg CC Weight 574 Lbs 260 kg Figure 3 2 EXCEL ARC 8065 And TRANSMIG 650 Dimensions and Weight June 21 1999 Revised 430429 406 DESCRIPTION EQUIPMENT INPUT POWER INPUT CONTACTOR CONTROL TRANSFORMER INPUT CONTACTOR SWITCH TO AUTOMATIC EQUIPMENT 19 PIN GUN SWITCH RECEPTACLE AMPHENOL BOARD CIRCUIT BREAKER 24 V 10 AMP CV MODE OVERLOAD THERMOSTAT TRANSFORMER PHASE SIGNAL T1 PC CONTROL BOARD CIRCUIT BACKGROUND BREAKER REGULATOR 115 V 10 AMP OUTPUT PC BOARD SCR CC MODE SCR1 SCR6 RECEPTACLE 115V STABILIZER FILTER STABILIZER FILTER L1 L2 CV UNITS CC UNITS CC UNITS CV UNITS Functional Block Diagram for EXCEL ARC 8065 3 4 And TRANSMIG 650 June 21 1999 Revised 11 Positive Terminal CC mode 100007 1 3 6 Serves as a connection point for the lead to the electrode holder lead for SMAW stick or arc gouging mode of operation when reverse polarity is desired NOTE To obtain opposite welding polarity simply reverse the connections to the posi tive and negative terminals
29. 6 204322 June 21 1999 Revised 1 YER Fee 441058 INAOVWHSHL V ENS 8 39 IIHS D 2 Tera Wy SMEG Jis Beo 00 v NON 6526 aad S58 waw 60 Wr E 30 NO ann dpi Q Tro 3 ANS INNOVO ZH 08 22 OSL Su Bod p cen ria OUVW3HOS NOILO3NNOO WvuoviQ 5 ws ONMYHO NO 035 JON 33v vz 8 Z 6 8 4 S ON IN3NOdAOD 99 Y CS 760 SHIENIIN 38M N3HL3901 3U L SALON uu TORRES DURE ei 803 020 MODA INEA 4 yee ann 09 61 18471628 gma FEM m ayo pee 100008 Nid 3002 HSIN 050519 TONO Ta Sh Ne cH St um Co E A i E ISAL 3 V8 NO NMOQ Se STE Su S e gt Salo RSR 62 ouvos mS 5 A 99 OL S9 19 sos 5 2 62 50 31 ANVIIBd MIE EN a 8 v el 5 gt 0 mg ss mae vc val 5 gt gt 3 2 s LE QNVOG N3AO3ONVHO 5 z gt OL 58
30. ABLE MIN SIZE 230 _ 180 No 2 No1 No6 460 55 75 No 6 No 4 No 8 Conductor size shall be modified as required for line voltage drop and ambient temperature Sizes listed for conduit installation are based on 90 C conductor insulation designated as FEP FEPB RHH and THHN Table 4 1 Recommended Wire and Fuse Size Table painful shock and lead to the erroneous conclusion that an electrical fault exists in the equipment if a system ground is not available consult the electrical code enforcement body for instructions The welding machine should be connected to an adequate driven ground rod or to a water pipe that enters the ground not more than 10 feet 30 meters from the machine The equipment grounding conductor size is listed in Table 4 1 as a guide if no local or national code is applicable Attach the equipment grounding conductor to the stud provided on the yoke Determine that the ground wire size is adequate before the machine is operated CAUTION Be sure to replace the cabinet top to assure adequate internal ventila tion and prevent component failure Internal Wiring Check Refer to the product identification plate name plate on the welding machine s rear panel to deter mine the power input voltages and frequency at which it will be operated Remove left side panel for access to Line Voltage Changeover circuitry Check line voltage connec tion
31. DONVH 380338 340 Si 1NMANI NIVIN3O 38 NOILAVD y 914 NI NMOHS SV HOLIMS N340d NIV OL 53 LNdNI 123 00 7 IVANVA S H3NMO JO 5 1 15 3Hi Ni 1JVHO 3HL 350 N3HL SISIX3 3009 ON d 31914 3WNVN NO NMOHS 1 388012 403 3215 INdNI H3dOMd 53000 2 12313 1V201 1 MO Old 3iviidONddV NI NMOHS SY SYIJANP NOILO3NNOO NOA SLS NOU23NNOO 1704 097 M3AHOJSNVHI 123NNOO 1 04 SNM YIdONA YOLOVLNOD 138 Y3NYHOASNVYL 3NIHOVW 20 4 3AVN A93H9 L 39VLIOA 04 SNOILONYLSNI YOLOVINOO OL YOLOVINOD OL SE 330A NO 1 826498 3825 310N 33S NEYI 1 NOU23NNOO 10A OFZ Statement of Warranty LIMITED WARRANTY Thermal Arc Thermadyne Company warrants that its products will be free of defects workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse
32. ECES EN MOUVEMENT PEU we VENT 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 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER 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 LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 3 Seules des personnes qualifi es doivent d monter des protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mou vement elles peuvent aussi accrocher des v tements amples et des outils 6 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 1 Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecte
33. EXCEL ARC 750 and 8065 TRANSMIG 650 Transformer Rectifier DC Welding Machine For the Following Specs e 100007 1 750 CC 60 Hz e 100007 2 8065 CV 60 Hz e 100007 3 8065 CC CV 60 Hz e 100007 5 8065 CV 60 Hz e 100007 6 8065 CC CV 60 Hz e 100007 7 TRANSMIG 650 CV IHERMAL A THERMADYNE Company OWNER S MANUAL Number 430429 406 Rev AC Revised May 1 2000 IMPORTANT Read these instructions before installing operating or servicing this system THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 406 Table of Contents INTRODUCTION How To Use This 1 1 Equipment Identification 1 1 Receipt Of Equipment ue e y dr GAS 1 1 SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 General Soto Ne temm PAR 3 1 Recommended Unit Applications IIT PH EE 3 1 Wire Feeder Compatibility 3 1 Controls and ea TEs RA 3 3 Duty Cycle iode at cte us d s Wen cete Be AS 3 5 INSTALLATION 4 LOCATION A 4 1 Grounditid 2 5 sa ve deett Lake Web a MR mk 4 1 internal Wiring Chlieck eem ES x AE 4 2 Connecting Welding Machine to Line Voltage 4 2 Welding beads
34. H OYA bZ A Nid e Nid J10YId323N r NIJO N bC ONVO8 TOULNOD Nid 1 43 3 er 8153 ov 8 QNYOG 10MIND2 Mid 3797143039 NOD 1 TBYI NOVAN Nid 92 TIv1 43029 in NIN 31035 br D rs SS u 2 1 W3PIUOJSNYMI TOMINOD ISU u io SERVIS 53 TON NOE SM MONIA IHON 1074 MOLIVINOD 1 150 NJ SISS 19 ININ IVA 4 b 3SYA MILISOd NOOfIIS 30010 10H IVA 5002 06 10H OYA 92 0 6 SAY 01 M3MY3MS LIMON ta NAN A 9 Pr GAY 01 LINDY 185 Bob HOLAS NOD 4 ue DOM 00 LO NOISSIUIANS 4H 179 619 SOM 240 NOISS3HddOS HOilDYdYv2 12 82 OAM OOF NDISSIYADOS QUvOS 2d GN3931 Sto 9 282 M010Y3N YUNA 8 ZM 9 NOLOY3N 192 1 5 ot fp 61 19 AM evo 100091 NO ANO 10 mv T Suayss 105 52 vou Ens mame roo 000 Y v 3NON 156 396 880 Soy 00 ms EN ml 9 ZHO9
35. IX a lite Tels m 4 se Bf B 5 3 N 1 ES 2 219 ek Jp 7 Hs ANO gt 889 le le 2395 07 BS 8 SRE 3NIHOVA 30 305 1431 9NDIOO1 909 le NEO Gz OF 13 TA cb 182 I TAN os gt M Ko x j ec iS NN8 6S mu vz S 5 co w lt a 3 4 ma 89 ne 34 z E 76 98 3SV4 20 NO O3INnOM M3YOS OL E E EF 61 THiS 5 5 N3AHOJSNVML P YOLOWLNOO 3015 1431 NONI SOYVOB YOSSIVIANS n 1 5 L L 1 Di m L n 11068 1095 wwe PEEL CR AR er ES 09 AD 5909 2X3 sce a eer DUA INOS NOUDINNOD MEO NEN x ovium 146 97 14 LO 3NON 100008 34 3002 MSINU M A SIMI NO 035 10N 38 Gf SON AIUNJOI 1IN3NOdNOD Z 799 S 62 Su38MON 3901 3U of 8 col 5 U ARE 6f 9r zr 1 9 GUVOB Jd N313 13 4 183SNi JO ONIIVS 22 ET re 0 3 lo 5 E Sv 01 sr 6c 13 4 INON4 g LE 9c yn tr 71694199 HEZI S
36. Illustrated 8 5 430429 406 PARTS LIST ere ynnnnannnn d nnn Z de NS Figure 8 2 Base and Lifting Yoke Group December 29 1997 8 6 430429 406 PARTS LIST Parts List for Figure 8 2 Item Part Description Qty Application No Number per Code Assy 1 204306 Transformer Power 1 BCDEF 204595 Transformer Power 1 A 2 367228 13 Board Voltage Changeover 1 All 3 204318 1 Bracket Voltage Changeover 1 All 4 CW 811 Link Voltage Changeover 3 All 5 204301 1 Bracket Mtg 1 All 6 204326 Choke Filter CC 1 CE 368084 6 Transformer Interphase 1 A 7 204304 Choke Filter CV 1 BCDEF 367718 6 Reactor Filter CC 1 A 8 204772 1 Door 1 All 9 203453 Hinge Door 2 10 830045 1 Panel Side Left 1 ABC 830045 5 Panel Side Left 1 DEF 11 Deleted 12 406358 1 Resistor 25 Ohm 175 W 1 BCDEF 406358 2 Resistor 50 Ohm 175 W 1 A 13 204285 1 Yoke Lifting 1 14 402037 33 Grommet Rubber 3 All 15 402037 11 Grommet Rubber 2 All 402037 15 Grommet Rubber 1 16 830044 1 Panel Side Right 1 ABC 830044 5 Panel Side Right 1 DEF 17 830046 1 Box Contactor 1 All 18 404132 1 Contactor 1 All 19 406392 2 Transformer Control 1 All 20 W 11166 11 Fuse 1 2 Amp 1 All 21 830043 1 Panel Top 1 ABC 830043 4 Panel Top 1 DEF 22 12CW 2170 Boot L
37. LTILIOLE aL q rezi nays HOLONONOS 92 QuvOS OL 1 n 1 1 1 8 1 8 l GE 1 Em LLOCH 3 ns os e Peres Ey Wo TW HINO z cn 76225 800 E wap wm M3MOd W3MHOJSNYHI 1 bed xm Ld TI 908 m aye e zr COMNINOO NOIS 8344234 8 1 405 NOU23NNOO vtr ds 0 08 39 NO VISOWN3HU 95 QYO783AO IVISOWNJHI 55 9 27 1 201 10038 V A JOMINOO HOLS ts OMHLNOO MO1OYINOO LMANI HILMS 15 LInONO 1304 SH 78055344405 NAN AVN IVISOMY ZA AV VOGT MOLOV3Y YOLSISIN 5555 5 55 SLIVA SHINO 95 NOISSNddDS 90191933 CITRON w 1 334 ANDO 009 jNnHS y CR EAR 55 SLLYA SL SWHO SZ 0151539 ty S11VM SWHO NS SdWY 13OA W313WOl N3IDd AD YOLIVIY 21 T YOLOYENOD NNOO 170 43 3 vo01 A1 AJ 30v143238 er 1 67 313m Tayo Md TYI 43238 gr N3dO 31OV14353M g O YOR WOMLNOD OF 9143238 LAIN OVA Sti A be IONIN 8 QUYUB 0MLNOO Nid S 710 14323 9r JO
38. M i T z gt z EE s T or T Li E enr Y L H 21 X SYAg1 9t 2 EX LLIOCB 0 axe o gt H3NHOJSNYHI AY Sard FS DUM Od N3NNOJSNYMI vemm 83404 H3NWOJSNYHI 1 sme peas m es x gt T 0 99 066 E E JOULNOD NOOMIS H3 038 9 1 BOS DUYNINIS P NOIOIJNNOO x aw E NO 1YISOWUSHI 95 SERVA OA OYOAM3AO LYISONNIHL 5 JS WO ssymn 71v201 310W3H V A HOLMS 25 16280 11 430 NO IOMINOO NANI HOLPAS 15 I IYISONY3HL vows v JI3LM3AO LINDHID LIOA SIL 4055399975 39955595995 95 bud A LIYA Z XS 32H04 3HOU N310d S SHHO 05 055384415 80151539 019 6H 152 AM FOL 008 INNHS yu S s or SLYM SL SWHO OG JOLSISJH tu SLYM Z AS SdWY 110A W313 OUN3LOd ty rk z 2 9 L L t 9r 99 YOLIYIY 11 w201 bier cer zl u ze SION SH 710v1432389 9er
39. MAL ARC S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT 15 SOLD TO PURCHASER BY NON AUTHORIZED PERSONS Except with regards to the products listed below this warranty shall remain effective three 3 years from the date Thermal Arc s authorized distributor delivers the product to Purchaser but in no event more than 4 years from the date Thermal Arc delivers the product to the authorized distributor Shorter warranty periods apply to the products listed below On these products 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 Thermai Arc delivered the product to the authorized distributor ALL OTHER P WEE PRO LITE POWER SUPPLIES POWER SUPPLIES PRO PLUS PRO WAVE LABOR MAIN POWER MAGNETICS STATIC amp ROTATING 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOID PUMPS POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURES WARRANTY FO
40. N WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez connaitre 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 L ELECTROCUTION PEUT ETRE 6 Arr tez tout quipement apr s usage Coupez l alimentation de MORTELLE l quipement s il est hors d usage ou inutilis 2 TEES 4 Une d charge lectrique peut tuer ou br ler grave 7 N utilisez que des porte lectrodes bien isol s Ne jamais pion 15 er les porte lectrodes dans l eau pour les refroidir Ne jamais ment L lectrode et le circuit de soudage sont sous Mois Sam an VITA A les laissertrainer parterre ou surles pi ces souder Netouchez tension d s la mise en circuit Le circuit d alimenta A E pas aux porte lectrodes raccord s deux sources de courant tion et les circuits internes de l quipement sont A 5 en m me temps jamais toucher quelqu un d autre avec aussi sous tension d s la mise en marche En 3 y l lectrode ou le porte lectrode soudage automatique ou semi automatique avec b 8 ce dernier le rouleau ou la bobine de fil le 8 N utilisez pas de c bles lectriques us s endommag s mal logement des galets d entrainement et toutes le
41. NGS Instruction 830001 This page intentionally left blank ________________________ __________________ 2 4 8 1996 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A LARC nivis MISE GAR DE ig LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme Z49 1 de l American National Standard intitul e SAFETY I
42. R DETAILS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shail be the responsibility ofthe customer All returned goods shall be atthe customer s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Thermal Arc Inc Effective January 4 1999 Troy Ohio 45373 830538
43. ard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection 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 8 V 96 430429 406 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT General There are three basic units of the EXCEL ARC The EXCEL ARC 750 CC Part Number 100007 1 is a constant current transformer rectifier type DC welding machine that provides volt ampere characteristic curves that are basically drooping with a slight slope The EXCEL ARC 8065 CV Part Number 100007 2 amp 5 and TRANSMIG 650 CV 100007 7 are constant voltage transformer rectifier type DC welding machines that provides volt ampere char acteristic curves that are basically flat The EXCEL ARC 8065 CC CV Part Number 100007 3 amp 6 are combination constant current and constant voltage transformer rectifier type DC welding machines that provides volt ampere char acteristic curves for each mode of operation Table 3 1 gives input voltage and amperage data for all part numbers covered by this manual Recommended Unit Applications APPLICATIONS Gas metal arc weldin MIG Flux cored arc welding with or without gas shieldin Submerged arc welding Electro slag welding
44. ause Replace fuse Line contactor fails to close Defective NVR Replace Mechanical obstruction on contactor Remove Broken leads at line contactor Repair Contactor chatters Line leads too small Use larger leads Low line voltage Check line voltage es et ee T December 29 1997 7 1 430429 406 TROUBLESHOOTING Contactor operates and blows link fuses Wrong line voltage Check nameplate of welding machine for line voltage to use check line voltage Links on voltage changeover board incorrectly connected Check Voltage Changeover diagrams for link positions connect links correctly See Diagrams chapter Line fuse too small Install proper size fuse SCR failure or shorted flyback diode Refer to Detailed Troubleshooting Instructions Short circuit in primary connections Remove short circuit Transformer failed Repair or replace Unit delivers welding current but soon shuts down Thermal overload trips Welding machine overloaded Reduce load overload can be carried only for a short time Duty too high Do not operate continually at overload currents Power leads too long or too small in cross section Replace with larger diameter cable Ambient temperature too high Operate at reduced loads when temperature exceeds 104 F 40 C Ventiation blocked Check air intake and exhaust openings to be unobstructed Fan not operating after machine is loaded down Check fan thermostat Check bear
45. cuit is electrically live wheneverthe output is on The input power circuit and machine internal circuits are also live when power is on in semiautomatic or auto matic wire welding the wire wire reel drive roll housing and ali metal parts touching the welding wire are electrically live Incorrectly installed or im properly grounded equipment is a hazard 1 Do not touch live electrical parts 2 Wear dry hole free insulating gioves 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 servicing 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 9 10 AT 14 15 Use fully insulated electrode holders Never dip holder in water Do not use worn damaged undersized or poorly spliced ca Turn off ail equipment when not in use Disconnect power to 1 equipment if it will be left unattended or out of service 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 bles Do not wrap cables around your body Ground the workpiece to a good electrical earth ground Do not touch electrode while
46. dage Intensit de courant oculaire Hrasageiendreaucnalumeau utescond ons 2 Brasage fort au chalumeau toutes conditions 3 ou 4 Oxycoupage mince moins de 1 po 25 mm 2043 de po 25 150 mm 4005 plus de 6 150 mm 50u6 Soudage aux gaz mince moins de 1 8 po 3 mm Aou 5 moyen de 1 8 1 2 12 mm 5005 pais plus de 1 2 po 12 mm 6 ou 8 Soudage l arc avec moins de 5 32 po 4 mm 10 electrode enrob es SMAW de 5 32 1 4 po 4 6 4 mm 12 plus de 1 4 po 6 4 mm 14 Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux toutes conditions 11 m taux ferreux toutes conditions 12 Soudage l arc sous gaz avec lectrode de tungstene GTAW toutes conditions 12 Soudage l hydrog ne atomique AHW toutes conditions 42 Soudage l arc avec i lectrode de carbone CAW toutes conditions 12 Soudage l arc Plasma toutes dimensions 42 Gougeage Air Arc avec lectrode de carbone mince 12 pais 14 Coupage l arc Plasma moins de 300 amp res 9 moyen de 300 400 amp res 12 pais plus de 400 amperes 14 _ Y n LES VAPEURS ET LES FUMEES SONT 5 Ne travaillez cans un espace confin que s il est bien ventil DANGEREUSES POUR LA SANTE sinon portez un respirateur adduction d air Les gaz protec ER teurs de soudage pe
47. der pressure of California to cause birth defects and in some cases cancer 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator About Pacemakers WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular levei and from studies with animals and people which clearly establish that low frequency magnetic fields can 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 The above procedures are among those also normally recommended for
48. des nationaux provinciaux et locaux applicables o pour vous prot ger le visage et les yeux lorsque vous soudez ou LE RAYONNEMENT DE L ARC PEUT que vous observez l ex cution d une soudure 2 Portez des lunettes de s curit approuv es Des crans lat raux BR LER LES YEUX ET LA PEAU LE np eso andes 1 BRUIT PEUT ENDOMMAGER L QUIE 3 Entourez l aire de soudage de rideaux ou de cloisons pour m L arc de soudage produit une chaleur et des prot ger les autres des coups d arc ou de l blouissement rayons ultraviolets intenses susceptibles de avertissez les observateurs de ne pas regarder l arc br ler les yeux et ia peau Le bruit caus par 4 Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager l ouie et cuir et des chaussures de s curit 5 Portezun casque antibruit ou des bouchons d oreille approuv s 1 Portez une casque de soudeur avec fiitre oculaire de nuance 4 c lorsque le niveau de bruit est lev appropri e consultez la norme ANSI 249 indiqu e 8 V 96 2 1 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS A 8 2 73 f e de m oa ee ee ee Op ration Dimension d lectrode ou Nuance de de Epaisseur de m tal ou de filtre Coupage ou sou
49. e in firm contact with the springs The gauge notch location will indicate the spring deflection or force Correct mounting force is indi cated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 All clamps to be set at 4 mark This corre sponds to the VE3000 VE2500 section on the gauge label June 21 1999 Revised 430429 406 TROUBLESHOOTING Force Gage shown in position 903878 Clamp 40514 0 tt Sink 1 wc Sink Figure 7 1 To Calibrate Force Gauge Examples Less than rated force Tighten nuts alternately 1 4 turn at a time until points coin cide edges lined up Correct rated force Figure 7 2 E 488 Excessive force Loosen both nuts and start over Never adjust force backing off the nuts Fric tion will pro duce a false reading Al ways start from Step 1 If the gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as shown below If the calibration edges do not line up calibrate the gauge by filing the bottom contact points Figure 7 3 True flat surface or straight edge December 29 1997 7 7 430429 406 TROUBLESHOOTING This page intentionally left blank 7 8 December 29 1997 430429 406 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter
50. e personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concern ing certain operating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification part number model and serial number usuaily appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment which does not have a control panel such as gun and cable assem blies are identified only by the specification or part number printed on the shipping container Record these numbers for future reference 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 Ifthere is any damage notify the carrier immediately to file a claim Furnish complete information con cerning damage claims or shipping errors to Thermal Arc Order Department 2200 Corporate Drive Troy Ohio 45373 1085 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 uncrating the unit A lifting eye on the top ofthe case has been provided so that the equipment may be carried or lifted with a crane or hoist Use care to av
51. ept 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 1 Protect compressed gas cylinders from excessive heat me chanical shocks and arcs 8 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 WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases ENGINES can be hazardous 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 2 2 May 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS instruction 830001 ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 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 SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and un
52. f the proper size Connect the three phase line leads to terminals Li copper welding leads L2 and L3 on the line contactor inside the welding machine cabinet TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS Welding __ ELECTRODE LEAD PLUS WORK LEAD Current 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet Amperes 15 2M 305 467 81 0M 76 2 100 4 4 4 3 2 150 3 3 2 1 1 0 200 2 2 1 0 250 1 1 0 2 0 3 0 300 1 0 1 0 2 0 3 0 4 0 350 1 0 ___ 70 3 0 4 0 40 400 420 2 0 3 0 40 2 20 450 20 20 4 0 2 20 2 3 0 500 3 0 3 0 4 0 2 2 0 2 3 0 For 60 duty cycle NOTE Lead size shown is for 90 C cable insulation 30 C 86 F ambient and not over 4 5 volts lead drop Table 4 2 AAA A A A A A December 29 1997 4 3 430429 406 INSTALLATION Place links in proper position based on input voltage value GROUND CONNECTION ON LIFTING YOKE INPUT LINE CONTACTOR MOUNTED ON LIFTING YOKE CUSTOMER S INPUT CABLE CONNECTIONS SHOWN CONNECTED FOR 230V O 575v O TO CONTACTOR CONTROL TRANSFORMER 367228 14 MOUNTS BELOW CONTACTOR FOR 100007 1 Figure 4 2 input V
53. g Light Medium Heavy Shielded metai arc welding stick electrodes PROTECT YOU RSELF 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 INSTRUC TION 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 Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard 249 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 ARC WELDING can be hazardous ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work cir
54. iers to protect others flash and glare warn others not to watch the arc material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Electrode Size Filter Welding or Cutting Metal Thickness Shade Operation or Welding Current No Gas metal arc welding MIG Non ferrous base metal All 11 Ferrous base metal 12 Gas tungsten arc welding TIG All 12 Atomic hydrogen welding 12 Carbon arc welding All 12 Plasma arc welding All 12 Carbon arc air gouging Light 12 14 Plasma arc cutting Light Under300Amp 9 Medium 300 to 400 Amp 12 Heavy Over 400 Amp 14 8 1996 2 1 WELDING SAFETY INSTRUCTIONS AND WARNINGS instruction 830001 Read the Material Safety Data Sheets MSDSs and the manu facturer s instruction for metals consumables coatings and FUMES AND GASES can be hazardous to your health cleaners 5 Work in a confined space only if it is well ventilated or while Welding produces fumes and gases Breathing wearing an air supplied respirator Shielding gases used for these fumes and gases can be hazardous to your welding can displace air causing injury or death Be sure the health 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
55. ifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual APPLICATION CODE A nmoou 430429 406 PARTS LIST Figure 8 1 EXCEL ARC Control Panel Group 8 2 December 29 1997 430429 406 PARTS LIST Item No N 10 11 12 13 Number 100007 1 100007 2 100007 3 100007 5 100007 6 100007 7 830761 1 830184 4 204212 204600 2 409000 1 204053 11 204053 8 830185 1 406806 3 401428 8 401428 8 405365 1 405365 1 408850 5 402682 830710 1 830709 1 204052 6 204052 5 204052 5 400614 1 400614 1 5CW 974 5CW 974 5CW 975 5CW 975 No Number No Number No Number No Number 5CW 976A 5CW 976A Not Illustrated Description Excel Arc Welder 750 CC Excel Arc Welder 8065 CV Excel Arc Welder 8065 CC CV Excel Arc Welder 8065 CV Excel Arc Welder 8065 CC CV Transmig 650 CV Panel Control Panel Control Board PC Digital Display Spacer Bezel Meter Panel Control Module Panel Control Module Panel Control Module Knob Control Potentiometer Volt Amp Arc Force Potentiometer Ctl Arc Force Switch Toggle ON OFF CC CV Switch Toggle ON OFF CC CV Knob Black Switch Toggle RMT LCL Light Overload Clip Retainer Panel Output Blank Panel Output Ter
56. ifting Eye 1 All 23 204036 Label Precautionary 1 24 402900 Terminal Quick Connect 2 ABDF 402900 Terminal Quick Connect 3 CE 25 368705 36 Capacitor W Leads 2 ABDF 368705 36 Capacitor W Leads 3 CE 26 830116 Label Frame Ground 1 All 27 408891 Label Ground 1 All 204698 Label Voltage Changeover 1 A 204323 Label Voltage Changeover 1 BCDEF 406484 Label Fuse 1 All 28 204280 1 Base Weider 1 June 21 1999 Revised Not Illustrated 8 7 430429 406 PARTS LIST a YEA NN NE Y AN s E December 29 1997 Figure 8 3 Rear Panel Group 8 8 430429 406 PARTS LIST Parts List for Figure 8 2 Part Description Qty Application Number per Code ASSy 1 203968 1 Panel Amphenol Blank 1 A 2 Deleted 3 830173 2 Board P C Amphenol 1 BCDEF 4 203627 7 Breaker Circuit 10 A 2 BCDEF 203627 7 Breaker Circuit 10 A 1 A 5 170919 2 Plug Hole 1 A 6 402670 Receptacle 115 V 1 All 7 366826 1 Suppressor Assembly 1 All 8 830130 1 Panel Rear 1 All 9 406991 Blade Fan 1 BCDEF 8RT 609 Blade Fan 1 A 10 201016 1 Shroud Fan 1 BCDEF 204055 8 Shroud Fan 1 A 369650 1 Shroud Fan 1 A 11 201015 1 Bracket Mtg Fan 2 BCDEF 369640 1 Bracket Mtg Fan 2 A 12 406992 1 Motor Fan 1 BCDEF 12TW 595 1 Motor Fan 1 A 13 369641 Insulator Mtg 2 Ali 14 20
57. ings disconnect leads and apply motor name plate voltage to test Solid state contactor operates but welding machine will not deliver welding cur rent and open circuit voltage is present at the output when gun switch is de pressed No ground connections at work Make connections Welding cables not connected Make connections RIRs aaa 7 2 December 29 1997 430429 406 TROUBLESHOOTING Voltage amps dial does not control welding voltage Potentiometer burned out Replace Loose connections in voltage control circuit Check connections Control circuit board failure Replace contro board Fan not operating also see causes and remedies under Welding machine will not start NOTE Fan will not operate until rectifier heats Up Motor failed Replace or repair Broken lead or connection to fan motor Repair wiring Blown circuit breaker on rear panel of welding machine Reset circuit breaker 115 volt receptacle may be overloaded Operator gets shock when welding machine case ground cable work or work ta ble is touched Case of welding machine not grounded Ground welding machine case Work table and work not grounded Ground work and work table to plant ground Abnormal current fluctuation voltage nearly constant Irregular wire feed speed See welding head manual Inadequate shielding of arc by flux or gas Increase shielding by trial and error See welding head manual Wire feed rate too slow Increase wire feed See w
58. ire burn off rate charts Too much shielding gas Decrease by trial and error See welding head manual Loose cable connections Check for overheated connections and tighten Welding contact tube tip on wire feeder makes poor contact with electrode Check contact tube hole size and replace with proper tube December 29 1997 7 3 430429 406 TROUBLESHOOTING Contactor fails to open Contactor contacts sticking Clean contacts Very noticeable rough sputtering arc Loss of control and burnback Minor start ing problems Control circuit board failure Replace Control P C Board Output of welding machines goes to maximum and there is no control Voltage sensing lead not connected Connect lead Jumper JP 2 and JP 4 on Control P C Board not connected Add jumpers JP 2 and JP 4 on Control P C Board 7 4 December 29 1997 430429 406 TROUBLESHOOTING Detailed Troubleshooting Instructions The EXCEL ARC 8065 and TRANSMIG 650 are solid state welding machines The method of trou bleshooting is different but is not more difficult than troubleshooting a conventional unit Do not overlook the obvious As in the case of all electrical equip ment loose connections are the primary cause of malfunction both internal and external to the welding machine Do not overlook bad grounds worn con tact tubes tips dirty cable liners shorted control cables wrong settings blown fuses worn contac tors
59. minal Panel Output Terminal Nut 1 2 13 Hex Flanged Nut 1 2 13 Hex Flanged Bus Cable Stud Bus Cable Stud Bushing Insulator Bushing Insulator Screw 1 2 13 x 1 HHC ST Screw 1 2 13 x 1 HHC ST Washer LK Std ST 1 2 Washer LK Std ST 1 2 Washer Insulator Stud Washer Insulator Stud May 1 2000 Revised Qty Application per Ob OAR G N WH WN N QO N N ANY R Code m 9 gt ABCDE BCDEF BCDEF BCDEF BDF CE ACE BDF ACE ABDF CE All All All ABDF ABDF CE ABDF CE ABDF CE ABDF CE ABDF CE ABDF CE ABDF CE 8 3 430429 406 PARTS LIST This page intentionally left blank 8 4 B December 29 1997 430429 406 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 20 No Number Washer FL ST 1 2 4 ABDF No Number Washer FL ST 1 2 6 CE 21 204207B 1 Board PC Control 1 All 22 171086 1 Stand off PC Board 8 All 23 830040 1 Box Control Board 1 204247 1 Cable Ribbon Meter 1 BCDEF 24 351505 Screw 1 2 13 x 1 3 4 HHC ST 2 ABDEF 351505 Screw 1 2 13 x 1 3 4 HHC ST 3 CE 25 No Number Screw 6 32 x 1 4 Rd Hd MH ST 2 ABDEF No Number Screw 86 32 x 1 4 Rd Hd MH ST 3 CE 26 405362 3 Bushing Snap 2 All June 21 1999 Revised Not
60. misconnections from feeding equipment mis application etc To check the Control P C Board take control module panel off the front panel Check the control board for loose connectors broken or loose wires Inspect the P C Board for broken com ponents scorched or burned components The only equipment needed to properly detect a problem on this welding machine is simple voltohmmeter although an oscilloscope is the best method to quickly see the problem Voltages of Interest Refer to Connection Dia gram 1 Across the secondary on all three phases 92 0 V AC 1096 2 From the center bus bar on secondaries to the top or bottom of the secondary 46 0 V AC 10 NOTE The x 1096 refers to the possibility of having a high or low input line voltage 3 115 V Receptacles 115 V AC 10 4 AC Input Voltage Test Points R206 to R207 36V AC voltage reading AC voltage input to P C Board Test Points R208 to R209 36V AC voltage reading AC voltage input to P C Board Test Points R210 to R211 36V AC voltage reading AC voltage input to P C Board 5 Power Supply Checks Test Points 16 to TP18 22V DC meter reading power supply reading Test Points TP16 to 17 15V DC meter reading power supply reading Test Points TP16 to TP19 15V DC meter reading power supply reading 6 Output Contactor Checks Test Point TP16 to Anode L9 16V DC meter reading
61. oda 2 60 250 SN gt 5 NEMA Curve 40 g o 40 20 20 0 9 200 400 500 800 1000 100 200 500 400 500 600 700 800 DC Load Amperes DC Load Amps Figure 3 4 Volt Ampere Characteristic Curves S A SE Se NEN MES 3 6 December 29 1997 430429 406 INSTALLATION INSTALLATION Location For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high am bient temperature or corrosive fumes Moisture can condense on electrical components causing corro sion or shorting of circuits Dit on components helps retain this moisture Adequate air circulation is needed at all times in order to assure proper operation Provide a mini mum of 12 inches 305 mm of free air space at both front and rear of the unit Make sure that the ventila tor openings are not obstructed Grounding The frame of this welding machine should be grounded for personnel safety and to assure opera tion of the overcurrent protection The grounding 20 30 lbs 9 1 15 6 kg 591 Traating Material copper sulphate magnesium sulphate or rock salt placed circular trench and coverad ith earth 1 Grounding Conductor NUT 41 1 py NM tl SO AT ground clamp Approx Ft 305 mm 18 inches 457 mm Approx Ground Outside Ground asten Grounding C
62. of this a significant reduction in the ball size of the end of the wire CAUTION In order for this circuit to work properly the MIG torch must re main stationary for the complete wire sharpening cycle TM Wire Sharpening situations is preferred in the following Automatic welding operations Robotic applica tions C Inhibit The inhibit selection disables both the wire sharpening circuit and the burnback circuit This feature may be useful in situations where an external control is used to control power source functions with the burnback circuit mentioned ear lier June 21 1999 Revised 430429 406 MAINTENANCE MAINTENANCE Replacing SCRs Replacing a SCR is a critical task but it can be accomplished in the field by following the instruc tions in the Detailed Troubleshooting section of the Troubleshooting chapter of this manual Lubrication The fan motor incorporates a sleeve bearing and therefore will need periodic lubrication The follow ing table will furnish a recommended guide to the frequency of this lubrication Lubrication Type of Duty Interval Light up to 6 hrs day Every 12 months Moderate 7to15hrs day Every 6 months i Heavy 16 to 24 hrs day Every 3 months NOTE Apply 1 12 drops of 20W non deter gent oil at each end of bearing Inspection and Cleaning For uninterrupted satisfactory service from thi
63. oid damaging the equipment when using bars hammers etc to uncrate the unit WARNING Falling machine due to lifting eye failure may cause death or serious injury e Lifting device fail when overloaded This lifting device is designed to lift the power source ONLY if the machine is equipped with a trailer or accessories over 100 pounds DO NOT LIFT by lifting eyes Avoid sudden jerks drops or swinging Check lifting device components visually for looseness and signs of metal fatigue Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade Additional copies ofthis manual may be purchased by contacting Thermal Arc at the address given above Include the Owners Manual number and equipment identification numbers Output Control Increase Decrease 2 P anm F O O Circuit Breaker y Input Voltage Switch olo Wire Feed 115V AC UO AMES Receptacle Rating For Auxiliary Power L NON _ Meroe December 29 1997 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Welding or Cutting Operation Torch soldering Torch brazing Oxygen cutting Light Medium Heavy Gas weldin
64. oltage Connection amp Changeover For 100007 1 4 4 June 4 1999 Revised 430429 406 INSTALLATION Place links in proper position based on input voltage value GROUND CONNECTION ON LIFTING INPUT LINE CONTACTOR MOUNTED ON LIFTING YOKE CUSTOMER S INPUT CABLE CONNECTIONS SHOWN CONNECTED FOR 230V 567228 11 TO CONTACTOR WT CONTROL TRANSFORMER MOUNTS BELOW CONTACTOR FOR 100007 2 3 5 6 amp 7 Figure 4 3 Input Voltage Connection amp Changeover For 100007 2 3 5 6 7 June 21 1999 Revised 4 5 430429 406 INSTALLATION Welding Current Voltage Control h 97 SO E a 6 1 EN 26 b Negative Positive CV Terminal Terminal Wire Feeder f am ES olarity DAT CV Base Metal Positive CC T Terminal Work Piece Should Be Grounded To Automatic d gt 23 O e To Semiautomatic Wire Feeder NOTE To change polarity reverse connections on power output terminals on power source Figure 4 4 Installation Diagram 4 6 December 29 1997 430429 406 OPERATION OPERATION General Before operating this system be sure that all in stallation instructions have been accomplished When operating this system observe all applicable Safety Warnings
65. onductor to the rod with an approved Not less than 8 Ft 2438 mm 6 Inches 152 mm Approx method and the equipment grounding conductor size and type shall conform to local and national codes For the National Electrical Code the equipment grounding conductor shall be green green with a yellow stripe or bare If flexible power cable is used use a cable assem bly which includes the equipment grounding con ductor If metallic armored cable or conduit is used the metal sheathing or conduit must be effectively grounded per local and national codes Rubber tire mounted equipment shall be grounded to conform to local and nationai codes The ground ing assists in providing protection against line volt age electrical shock and static shock The grounding serves to discharge the static electric charge which tends to build up on rubber tire mounted equipment This static charge can cause Fasten Grounding Conductor Grounding to the rod with an approvad Conductor ground clamp Removable Cover Floor FE zT x PES 225 52 revs 3 5 2 j Not less than 8 Ft 2438 mm Rod Soil Treating Material inside Ground Figure 4 1 December 29 1997 4 1 430423 406 INSTALLATION COPPER COPPER RATED APPROX LINE WIRE SIZE GROUNDING LINE LOAD LINE FLEXIBLE CONDUCTOR VOLTS AMPS FUSE SIZE IN CONDUIT C
66. pen circuit voltage The best way to isolate the particular SCR which is malfunctioning is as follows Refer to Connection Diagram while inspecting the unit On the output rectifier there are gate leads coming off ofthe SCRs Each of these leads are connected to a quick dis connect terminal on the suppressor board Turn the voltage control pot to maximum Disconnect one lead to one SCR and observe the OCV If the OCV drops to a lower value this indicates that this par ticular SCR is working properly Reconnect this lead and do the same thing with the remaining leads until you discover which disconnection does not cause the OCV to drop to a lower level This is the mal functioning SCR See Mounting Procedures for SCRs which follows Mounting Procedure for SCRs 1 Thoroughly clean heat sink surface to eliminate any dirt or contamination 2 Apply a thin coat of Alcoa 2 compound to cleaned surface Alcoa 2 is available from Thermal Arc part number 903870 3 Positively locate the SCR in place in the heat sink A small spring pin in the extruded heat sink will locate the SCR 4 Place the clamp in position with the bolts through the holes in the heat sink and proceed in following manner 5 Tighten the nuts evenly until finger tight 6 Tighten each bolt in 1 4 turn increments using correct size hex key 7 Placethe Force indicator Gauge 903878 firmly against the springs as shown Be sure both ends and the center ar
67. r ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 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 l accumulateur 1 N tez 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 ter 3 Laissez la pression s chapper avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI Z49 1 American Weld ing 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 Cutina f Conta ers 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 2 4 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 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulev
68. s piss s ou de section trop petite pi ces m talliques en contact avec le fil de soudage 9 N enroulez pas de cables lectriques autour de votre corps sont sous tension Un quipement inad quatement 10 N utilisez qu une bonne prise de masse pour la mise la terre install ou inad quatement mis la terre est dangereux de la pi ce souder 1 Ne touchez pas des pieces sous tension 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 N utilisez que des quipements en bon tat R parez ou rem placez aussit t les pi ces endommag es 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 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l ali mentation afin d viter une mise en marche accidentelle 14 Portez ur harnais de s curit si vous travailiez en hauteur Veuillez installer cet quipement et le mettre la terre selon 15 Fermez solidement tous les panneaux et les capots manuel d utilisation et les co
69. s welding machine it is necessary to keep the ma chine clean dry and well ventilated At least every three months or more often as necessary wipe and blow out all dirt from the machine s internal compo nents with air pressure of not over 25 psi 172 kPa Be sure to wipe the fan blades clean Check and tighten all electrical connections as necessary to eliminate unnecessary losses and to avoid subsequent trouble from overheating or open circuits Check for broken wiring or damaged insu lation on wiring CAUTION The flow of air through the welding machine is carefully directed by baffles Never operate the welding ma chine with any of the side or top panels removed or open as serious damage to the rectifiers might result December 29 1997 6 1 430429 406 MAINTENANCE This page intentionally left blank 6 2 December 29 1997 430429 406 TROUBLESHOOTING TROUBLESHOOTING General Also refer to Troubleshooting in wire feeder and gun manuals Troubleshooting Guide Welding machine will not start Power switch OFF Place power switch in ON position Power lines dead Check voltage Broken power lead Repair Wrong line voitage Check power supply Incorrect input power connections at welding machine Check connections against wiring diagram Open circuit to power switch or control transformer Repair Check for broken wire or loose connections at terminals Fuse on control transformer blown Remedy c
70. s against instructions on Voltage Changeover Diagram supplied with this manual If necessary rearrange internal wiring and or link connections 4 2 Connecting Welding Machine to Line Voltage The input power should be connected to the unit through a fused disconnect switch or other suitable disconnecting means furnished by the user A hole is provided in the rear panel of the machine near to the input connections for the entry of the input conductors eec e mA DANGER ELECTRIC SHOCK CAN KILL Open the discon nect switch or breaker and determine that no voltage is present before connecting wires between welding ma chine and power supply CAUTION The method of installation conductor size and overcurrent protec tion shall conform to the requirements of the local electrical code the National Electrical Code or other national codes as applicable All installation wiring and machine reconnections shall be done by qualified persons Table 4 1 provides minimal information for selec tion of line conductors fuses and the equipment grounding conductor This information is from the National Electrical Code NFPA 70 1981 Edition In stall this equipment per the latest edition available December 29 1997 430429 406 INSTALLATION from the National Fire Protection Association 470 Welding Leads j 10 BORON MA E Use Table 4 2 for selection o
71. tactor Control Switch 2 in ON position Power ON 4 Inch wire electrode to position over work see related owner s manuals 5 Depress gun switch trigger and strike arc 6 The Excel Arc and TRANSMIG weld termina tion sequence is fully adjustable Three simple jumper changes on the main circuit board allow the following weld termination treatments A Burnback Delay JP 1 B Wire Sharpening JP 9 C Inhibit JP 1 A Burnback Delay The burnback setting calls the Excel Arc or TRANSMIG to maintain a contac tor closure for 25 seconds after the gun trigger has been released and wire feeding has stopped The features primary function is the prevention of wire sticking to the weld puddle upon completion of a weld Another term commonly used to describe burnback is the term anti stick The burnback option is preferred in the following situations When Excel Arc or TRANSMIG is used with older wire feeders which do not have dynamic brak ing and would show a tendency to wire coasting When Excel Arc or TRANSMIG is used on high cycle short weld applications or if a great deal of tack welding is done B Wire Sharpening Serves the same func tion as burnback However in addition to maintain ing contactor closure for 25 seconds Excel Arc or TRANSMIG also lowers weld voltage to a value too low to maintain an arc but sufficient enough to burn off the remaining wire The effect
72. te control device Remote to control welding output 4 115 V AC Receptacles 100007 1 2 3 5 6 7 Provides auxiliary power for lights wire feed ers water pumps etc 9 amps maximum 5 Selector Switch CC CV 100007 3 6 Selects the welding mode of operation 56 in 914 mm 6 Feeder Control Receptacle Panel Automat ic CV units 100007 2 3 5 6 7 Amphenol 19 pin connector for a remote voltage control type wire feeder 7 Arc Force Control CC CV Units 100007 1 3 6 This potentiometer controls short circuit welding current to produce an increase in current asthe arc length is shortened The control is present to provide the degree of hard start required and the additional dynamic change for welding tight grooves etc Turn clockwise to increase hard start characteristics counterclockwise to obtain a soft start smooth arc 8 Welding Voltage Amperes Control CV Units 100007 2 3 5 6 7 Adjusts arc weld ing output and open circuit voltage Open circuit voltage is approximately 1 5 times the welding volt age for constant voltage welding On 100007 1 3 6 CC units Adjusts the welding current 9 Volt K Amp Meter and Switch CV Units 100007 2 3 5 6 7 A single meter with switch that will read DC volts when in the V position or read DC amps in the A position 10 Positive Terminal CV mode 100007 2 8
73. th but does not reach the maximum value remember the 1096 refers to a high or low line voltage you probably have an SCR problem 3 The next step is to go inside the unit and check the control circuit board See the instructions pro vided for this test It is important to run through the tests in the order they are listed If an interface box is being used it will be necessary to switch the welding machine local remote switch to the local position 4 If nothing is found defective on the board the next step is to go to the SCRs First of all an open gate or an open SCR cannot be checked with a If an SCR is not firing the open circuit voltage OCV will shift down Check the following table for typical values Disconnect cable 103 from the capacitor bank assembly Insulate the lug end of cable 103 to prevent it from touching chassis or any other sur face 100007 1 All SCRs firing properly All SCRs firing properly imax OCV 85V DC max OCV 57V DC 11 SCR not firing max OCV 77V DC 1 SCR not firing max OCV 51V DC 2 5 not firing max OCV 69V DC 2 SCRs not firing max OCV 45V DC 3 SCRs not firing max 61V DC 3 SCRs not firing max DC NOTE These voltages were recorded at nominal line voltage with voltage control adjustment at MAXIMUM setting unit ad justed for high o
74. uvent d placer l oxyg ne de l air et ainsi Le soudage d gage des vapeurs et des fum es causer des malaises ou la mort Assurez vous que l air est dangereuses respirer propre la respiration 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 1 Eloignez la t te des fum es pour viter de les respirer peuvent r agir avec des vapeurs et former des gaz hautement 2 A l int rieur assurez vous que Faire de soudage est bien ven toxiques et irritants til e ou que les fum es et les vapeurs sont aspir es l arc 7 Ne soudez des t les galvanis es ou plaqu es au plomb ou au 3 Si la ventilation est inadequate portez un respirateur adduc cadmium que si les zones souder ont t gratt es fond que tion d air approuv si l espace est bien ventil si n cessaire portez un respirateur 4 Lisez les fiches signal tiques et les consignes du fabricant adduction d air Car ces rev tements et tout m tal qui con relatives aux m taux aux produits consummables aux rev te tient ces l ments peuvent d gager des fum es toxiques au ments et aux produits nettoyants moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC instruction 830002 LE SOUDAGE PEUT CAUSER UN IN 4 M fiez vous des projections brulantes de soudage suscep CENDIE OU UNE EXPLOSION tibles de p n trer dans des aires adjacentes par
75. 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 11 Wear oil free protective garments such as leather gloves heavy 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 easily go through small cracks and openings to adjacent areas shirt cuffless trousers high shoes and a cap FLYING SPARKS AND HOT METAL can cause injury 1 Wear approved face shield or safety goggles Side shields 22 Chipping and grinding cause flying metal As welds recommended gt cool they throw off slag 2 Wear proper body protection to protect skin CYLINDERS can explode if damaged 3 Keep cylinders away from any welding or other electrical cir cuits 4 Never allow a electrode to touch any cylinder VCE Shielding gas cylinders contain gas under high pres 5 Use only correct shielding cas cylinc ers regulators hoses ard gt Z sure If damaged a cylinder can explode Since gas fittings designed for the specific application maintain them and Soo cylinders are normaily part of the welding process associated parts in good condition be sure to treat them carefully 6 Turn face away from valve outlet when opening cylinder valve SS 7 Keep protective cap in place over valve exc

EXCEL-ARC® 750 and 8065, TRANSMIG 650

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EXCEL-ARC&reg; 750 and 8065, TRANSMIG 650

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EXCEL-ARC® 750 and 8065, TRANSMIG 650