Home

EXCEL-ARC® 500 and 6045

Contents

1. 4 52 2 5 s 5 gt 8 25 d 08 08 TONSHdAY gavos lt T 038 62 9 OL 5 NHL 12 50931 OL 8 18 e or 5 501931 RES 2 3 02222424 5 TH ZE z S gt 9908 N3AOJONVHO OL Y IV P 3 50 31 AMV BLYNYALTV LINN 40 L 4 3 WOHi ONINOOT 154 02 55 2 alu aw er 3831419398 indino 838 38 E ela cn 2 ot d I n vi 85 cao ve d oF ia moo Wu gt 714 27 8 m Ta z 6 5 vex 35 8 40 L O Q3INDON 5 8 0 3NIHOV 1 083 NOUS 9NDIOO1 z g i 390A INULAN A389S 434 52 bag ar Oty OP 35 5 2 5 lt lt 3015 1331 WON3 wis Ov TM ty tt 508908 905530995 9 53 3 51 A 00 N3AHOJSNVMHI TONLNOD YOLOVLNOO 6 0 28 98 21 CENT 4 ANON 2100008 34 3003 HSINU
2. T LORS 88925 55 Pe se maim 1 2 TIU ONMYYO SIHL NO 0350 LON SERE EE AE Bae 38V ONY bZ BL TL 6 Z SON ALLNSG LN3NOdNOD ILON Mi Sri SCAT SIN N S 45 mam 242345 5571 8685 55 71 13512058 mim cam NON 100008 34 3903 ETS TETE gi use lt 35 8 NO NAOQ SLINN LNZYYND LNVLSNOD NO E 1 SX 50 31 6 a 2 5 D gt z B 8 08 N3AO39NVH2 9 2 OL 5 50931 ANVWBd z n 9 3 5 OL 8 NAHL LE a 50931 k 2 9 9 2 T 5 lt v gt QNVOB z 52 OL LV 0931 ANVAId THEN 44 S 3 21 JINN 30 ANOH4 NOUS 9NIXOO1 587112 3 418 55 559 isd 3 4303 Indino 218 E 5 9 p 507 9 4 PS 2 B 55 893 sr NaS TET OE wants q109 ER cuu E
3. 81 9 zx 3 80 8 5 V TX 901 9 Zx 10 1 91 TX GNNOYD 1 91 INYA opp ow 189 3 9 ZX 81 9 ow 12 HINNOIN vall d 19 3 24 Sx H T T 2 9 0 n 5 or tr 12058 12345 ms pipe aes 02902 Jmm ER 559798 eim 5 1 E mu ert mra 3sv8 40 ZH 09 05 AS 708 2 223 3 WRB 3 NO dalNnow re men DILVAGHOS NOLOGNNOO F 3 54 NAO O ONMYYG NO 0356 LON 7852 2 ONY OL 6 S ON 1 30 LNSNOdNOD ILON 58 2 SIOM 38 SACRO Incas 02 2335 ISMAGHLO SSTWA 00 7 5 12098 d rum PEE ave ROT 3NON 100008 3002 HSIN 040038 81 2 VERT Fee 09 9NDIOOT1 3 89 87 91 2 NEO 21719 Ex H 0209708 ION3HdAV 9 01 62 12 50931 ANVAIBid 08 08 N3AO3ONVHO OL 8 18 54 31 St LNOMJ SNDV3 13NVd
4. RS 1N3SNI JO 2 Y a lt 5 9 OL orem ae 95512558 mon WWOO V A 1 339 t r NIJO 5 1n3N OWA LOH OVA PZ doer Nad 8153 Wr WAOD TOMLNOD 1 9 NIN 310838 A r 438A 12 3lOW3N 310838 OND SISSYHO 9 9 1 OVA gt LOH OVA St 3 6 10H OVA eZ 0 SUINA 2 9 HOLMS NNI G3 100008 Mid 3003 HSINU C S S S S Sa S S S S SC CCS 3 29v1d393M 310W38 Nid 61 QuvOB 34 1 e 21 YUI Fd 4 389 3 m 1 t TOYLNOD H3NNO4SNVML HIMOS H3NHOJSNVMI NOOMIS 881338 NO NYAL LYILSONHJHL 1 83 0 LYISOWM3HE NL 83A0 3LOWaY TOMLNOD HILMS vvv 440 NO 81 03 MOIOVINOO LINGNI HOIWS Et eee amp 55 LINIM LIOA SH 80553449065 SSSSSSSSS Ebdg 34093 23 4 154 3 M 222969 NA 3
5. 1 1 Equipment Identification 1 1 Receipt OF Equipment ae pin nee Shes 1 1 Meanings Of Markings And Graphical Symbols 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 G n ral SE RSE GU Bue amp 3 1 Recommended Unit Applications 3 1 Wire Feeder Compatibility 3 1 Controls and Outlets 3 3 Duty Cycle xes oto ELA LA SEA Mie ADS epe E TES 3 5 INSTALLATION 4 668106115 S Sual A eye 4 1 Grounding 5 55 Rab A 4 1 Internal Wiring Check ee gin d 4 2 Connecting Welding Machine to Line Voltage 4 2 Welding Leads 525 dag ans gah Ae 4 3 OPERATION 5 err ORAS eras EARS oe E 5 1 Preweld Operation 5 1 SMAW Stick Welding Carbon Arc Gouging 5 1 Welding Semiautomatic or 0 13 5 1 MAINTENANCE 6 Replacing SCRS k ere be SD ee eae Be ee nad Med 6 1 LUBrCAation SSL SA et b
6. UN SLYM S OS 4015532405 0151532 MMN 8033 AWOOL dNv O09 LNAHS yvt r sa SLIVM 006 SWHO O 80151539 dei cr N E P SLIVM SWHO SZ NOISIS3N zer Jd 9r SLIVM Z SWHO XG SdNY 1 OA NOILNALOd xr AD WUT YOLOYIY oier 40191409 6 g JOA SL 13 143338 EUM 8 0 8 dO 01 EL 3 3 133338 9 tr 5 HAN 318 2 NOSE Nid 01 310Y1d323M 08 08 TOULNOD Nid Ot 3107143038 I g TOULNOS Nid 312 14323 ver 008 WULNOD een E 6 63 Nid 3 3 13338 2 ONO Nid fi 3 3 14333 5 QuvOH TOMLNOD 1 313 1 333 8 NAYI NOGA Nid 9 313 143233 S 3 1 HANNOJSNYHL OMINOO ISNA MOTI3A HOLVOIONI 1 388 3 0 218 3 gt er er 2216 67 m 04 6 SON BESS 2 81 91 eX 3 81 81 py x 7108 961 Ave Sx X 8 219881 91 zx 2 81 91 X 4 ua gt 278941 59 OVABI 9H Xx 108 019 5 3578 BAILISOd NOIMS 300 9 01 MDDIV3N8 ASH Of u3 v358 LION 20 4 00 74 07 NOISSIUddNS JH WOLIDYdv2 20 OG GAN 000522
7. 0 m SIHL NO 4350 LON 28 1 ONY Ur S ON MUNI IN3NOgNOO TBNvd 193SNI 30 3 9NIDV4 8g neva 8019200805 01 Sv OL QUVOSB TOHLNOO T3NVd 4 0 4 5 9 018 98 CZ V 150110088 9 5 E 8813 ho 5 9 2 se 93908 0 3 Oi CLR 1 1 5 xx 5 urn 2 8 oL L 51 1041405 738686 35 sim 83803 WINUOISNVEL NON 26 89 21 889 SDH JOULNOD 3313410938 g t 25 2825 27 73 22 09 33 3 5 7 4 56 NO NUCL LYISOWH3HL 95 5 31 3 0 LYLSONUGHL 55 Pus C3 9 08 VIN Dd A9 29 HOLS 5 pa mam vtr 1 201 3LON3Y 01 03 HOLMS 55 E 340345 ITMGHIO 553 2 3 0 0 IOMINOO YOLOVINOD 1 4 HOLS 15 88 55612059 LINDYID 130A 514 80552844405 Z
8. 33804 H3I3NOLN3LOd ANON 100008 3 3002 HSINU SLLYM S SWHO OG 6553844 HOLSIS3M 913 54 INIYYNI YNO wovedaas AW001 SAWY 009 INAHS k A hq SILYM 096 SWHO 01 80151534 u t tk F k SUVA SZ SRHO SZ 0 15153 M ss SLIYM Z SWHO MS SANV 1T0A H3L3NOUN310d 1 ERIS yn A0 99 YILT OLIV 1 zi en JOA 511 313 143238 52078 3 dO 01 Nid EL 3 3 144333 6r uer 318 3 Nid 01 313143338 ar GNYOB IOYLNOD OL 313 143338 WWOO V A 5 0 08 IONLNOD Nid S 310 19393 or vOOL AL lOMINO2 Nid 8 10 93039 gr N3d0 1 ger 8 1OMINOO Nid TY0VId3O3N 340 5 5 5 0 68 1031409 Nid Ft 313 14333 1 er ININ OVA SU Yer g er 59 8 1OMINOO Nid vi 313 333 LOH OWA eZ 4 9 WOOT _____ ee TOMLNOD 18 NOBBIY 313 14333 wer ee ouo 3 02 1041409 1 Q 97207145934 8 2 WOTI3A MOLVOIONI ANAL 180 310438 4312 30838 rte gt 1 8 38 8 JAUISOd NODNIS 30010 10 3 H r 455 A Z OL
9. 3 388 LINDO 283 GND 5155 2 9 9 Q 8 O IIn289 63 1 38 OVA 4 Q we 2486 10H OVA SIL 3 gt JGAM NOISS3YddNS dH 922 512 OYA 2 9 OS OJN 000 89 19 MAN 9 OOF 94 NOISS3HddfIS HOLD VAT 2 69 8 6 24 3 44 de 008 NOISS3HddhS WOlIlDvdv2 3 13 voor 18 GN3531 e E 283 19 8 3nvu3 Ku wo 2 29 2 1 91 25 71 2 81 91 5 9 108 8 8 223 ord noe LAdN 5 T or T t z 826706 133945 325 ST OND ej 2 UL 26 92 8 pauser CMON goze 4 26 41 8 HYF ELA W M3AO3ONVHO AVMOVIO Tus Gamo 86 61 6 0512 8 65 40 65 315706 ES es ni 246 02 9 Cort 3NON 100008 Yad 3002 HSIN 040239 39NYH2 7640 002 NO 031931335 38 LSNW SiHL OL S3ONVHO MOA 3Hi NO ONNOY O 4 GJHAVN M3JNOS 01 9 15 5
10. Examples Less than rated force Tighten nuts alternately 1 4 turn at a time until points cide Top edges lined up B Correct rated force E 488 Excessive force Loosen both nuts and start over Never adjust force by backing off the nuts Fric tion will pro duce a false reading ways start from Step 1 Figure 7 1 Figure 7 2 To Calibrate Force Gauge If the gauge is suspected of being out of calibration due to wear or damage check it on a flat surface as shown below True flat surface or straight edge 7277 7 7 If the calibration edges do not line up calibrate the gauge by filing the bottom contact points Figure 7 3 May 18 1998 7 7 430429 409 TROUBLESHOOTING This page intentionally left blank 7 8 May 18 1998 430429 409 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the 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 of the equipment are listed except fo
11. fond que si l espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui con tient ces l ments peuvent d gager des fum es toxiques au moment du soudage 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie 1 Prot gez vous ainsi que les autres contre ies tincelles et du m tal chaud 2 Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables 3 Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es LES ETINCELLES ET LES PROJEC TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteiiles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin 1 Prot gez les bou
12. 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 6 1 430429 409 MAINTENANCE This page intentionally left blank 6 2 May 18 1998 430429 409 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 voltage 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 cause Replace fuse Line contactor fails to close Defective NVR coil Replace Mechanical obstruction on contactor Remove Broken leads at line contactor Repair Contactor chatters Line leads too small Use lar
13. 100002A 1 100002A 2 100002 3 830698 1 204212 204600 2 409000 1 204053 11 204053 8 830207 406806 3 401428 8 401428 8 405365 1 408850 5 402682 830710 1 830709 1 204052 6 204052 7 204052 7 408049 1 408049 1 204207B 1 171086 1 W 9956 367880 400562 24 367260 1 405478 W 11291 3 410602 1 410589 12RT 238 410541 910061 W 9549 21 No Number 830040 1 Description Qty Application per Code Assy Excel Arc 500 CC 50 60 Hz 1 A Excel Arc 6045 CV 50 60 Hz 1 B Excel Arc 6045 CC CV 50 60 Hz 1 C Panel Control 1 All Board PC Digital Display 1 BC Spacer 4 BC Bezel Meter 4 BC Panel Control Module 1 Panel Control Module 1 B Panel Control Module 1 Knob Control 1 AC Potentiometer Volt Amp Ctl Arc Force 2 AC Potentiometer Volt Amp Ctl Arc Force 1 B Switch Toggle ON OFF 2 All Knob Black 1 All Switch Toggle RMT LC1 1 All Light Indicator Overload 1 All Clip Retainer 1 All Panel Output Blank 1 AB Panel Output Terminal 2 AB Panel Output Terminal 3 C Connector Locking 2 AB Connector Locking 3 C Board PC Control 1 All Stand off PC Board 8 All Knob Range Switch 1 C Sleeve Sw 1 C Spring Compression 1 Switch Range 1 C Rivet 1 C Nut Speed Push on 1 C Bracket 1 C Contact Stationary 1 Contact Movable 2 C Spring 1 C Guide 1 Rod Threaded 1 4 Dia
14. 80151534 018 9 URIS 0 iul 30Y80334 001 009 INhHS 38 SENSE Dri er 9 SLLVA SLI SAHO SZ 15853 ZH 06863 Set er N is 2 SNHO X SdNY 110A H313AOU N310d tu dV 104 1 3 L 12 3 n ur 210100 1 1 2 s er 1 SIOA Stt 213 14333 a g er 823018 TWNOUdO OL Nid t 13 192338 er er 3 ee heer 08 Nid 01 10 03930 5 1031402 Nid S 213 1433738 gr s er 8 95908 1041405 Nid 9 3107103038 sr 8 QNvOB 1 Nid 313 1 3338 gt g 08 08 TOULNOD Nid t 3 3 1 333 er 5 9 4 ONVOB Nid 14333 zr 2 s zr ver 8 zr 1 TOMINOO ISNA 8 2 2 ANAL 159 gt Ve 35 8 3AU SOd NONIS 30014 483 AGLI JAY Ol H3 Y3H8 183 DIAM 00 7 07 5 3 33 4H 143 4 3 5 3 1 2 JOM 005 Q3W yO NOISS3MddDS 12 62 OOM 00 06553844 5 WOJIOYdvO 18
15. ES NEB ET Se maz 82 5 gi 9 5 5 57795 5 iem mE DE Nia S 8 NO e A x Wwe N Y E m mas QNnONO 02 AD 16 3015 1431 A 80553444065 A 00 N3AHOJSNVME P 0 T 2 3 5 9 8 5 61 n zi 1 22 2 saga lo id Z 13385 wow ee tt v TIY 2799 LON OO wur 1 For 48 880 ro Dre 3098 1 3 Ute 09 05 792 004 24 132 3 Xue OUVYGHOS 7 NOUO3NNOO 9 1 Bc 5 01 m 1 zi ONMYHO 5 8 NO 9350 LON r ONY Sr Or Sf S ON 1 1301 IN3NOdNOD il UON a mans el smo RC jee es 887 2 8 1 8 m ss 100008 W3d 3003 HSINU 886258 3ONYHO ELE Mi i LL 105 96 354 3 1 Z 9 6011 211 5 py 9 gy y sr 1 101402 NIYAN 3 18084 8g 8829 13 4 1
16. 0908 3 039 3 TEE OL V NAHL LV 3 50931 T3Nvd 1 4 30 401 50 30 414053 WONJ 9 0 19355 43141934 LAUNO 78 11 Sc se 8 3Sv8 30 NO GULNAOW 3NIHOWW JO 14084 NOUS 9 001 x 3304 SNUSM NN 3825 0 0089 305 13 NOM n A 00 ONIHM HANMOISNYAL TOMINOO 7 NOIOVINOO 8 Dt u EET n 1 H p 5 1 TES oe AD 2068 2 nb ue gt S imus ve m TUERI F5 ms suem pam pan v ANON 16 89 21 880 52 DA 05 05 409 WY TIX 9 3 35 ONMAVYO 5 NO 0351 LON us 9 it SON ALUN3G 1N3NOdAOO 1 HON Da mom we 8 2 SSCIZOCS FT uruw ow INON 2100008 Mid 3002 HSINU m 5 cvs t 9 08 08 JAN er 29 S z 8 St sr HAN OL sr QMVOB 1051409 65 13 4 19033 05849895 PEZ 71210006 p 9 S r zi
17. 1 Nut 1 4 20 SCR MH Hex ST 4 C Box Control Board 1 8 3 430429 409 PARTS LIST This page intentionally left blank 8 4 May 18 1998 430429 409 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 30 Delete 31 Delete 204247 1 Cable Ribbon Meter 1 BC 32 405362 3 Bushing Snap 2 All Not Illustrated May 18 1998 8 5 430429 409 PARTS LIST Figure 8 2 Base and Lifting Yoke Group 8 6 May 18 1998 430429 409 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application Number per Code Assy 1 204054 1 Base Welder 1 All 2 204254 Transformer Power 1 BC 830268 Transformer Power 1 3 367228 12 Board Voltage Changeover 1 4 CW 811 Link Voltage Changeover 3 All 5 204301 1 Bracket Mtg 2 All 6 204194 Choke Filter CC 1 A 7 204193 Choke Filter CV 4 B 8 830021 Choke Filter CC CV 1 C 9 Deleted 10 830038 1 Panel Side Left 1 All 11 406358 4 Resistor Fixed 175 W 1 BC 12 406358 1 Resistor 25 Ohm 175 W 1 All 13 204060 1 Yoke Lifting 1 All 14 402037 33 Grommet Rubber 2 All 15 402037 11 Grommet Rubber 3 All 16 Deleted 17 Deleted 18 830037 1 Panel Side Right 1 Ali 204099 1 Capacitor Assembly 1 BC 19 204152 Bus Capacitor 2 BC 20 405278 15 Capacitor 5 BC 21 204301 1 Bracket Mtg 2 BC 2
18. CV VOLT AMP CURVES EXCEL ARC CC MODE VOLTS DC t B00 900 AMPS DC EXCEL ARC CV MODE VOLTS DC 1 s 1 T 1 1 1 a 0 100 200 300 400 500 600 700 800 900 AMPS DC 3 6 May 18 1998 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 Dirt 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 30 155 9 1 13 6 kg Soil Treating Material copper sulphate magnesium sulphate or rock salt ploced in circular trench and covered with earth Grounding Conductor N Approx Ft 305 mm 18 Inches 457 mm Approx A Ground Rod z Outside Ground asten Grounding Conductor to the rod with an opproved ground clamp ot less thon 8 Ft 2438 mm 6 Inches 152 mm Approx 430429 409 INSTALLATION method and t
19. N approchez pas les mains ou les cheveux de pi ces en mou 6 R installez les capots ou les protecteurs et fermez les portes 2 Arr tez le moteur avant de connecter ou de d connecter des 3 N utilisez que des outils anti tincelles pour travailler sur un 4 N utilisez pas une source de courant de Soudage pour charger 5 Utilisez la polarit correcte et de l accumulateur 2 Mettez des gants et posez un torchon sur ie bouchon pour l ter 3 Laissez pression s chapper avant d ter compl tement le Seules des personnes qualifi es doivent d monter des protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire d branchez le c ble d accumulateur la borne n gative vement elles peuvent aussi accrocher des v tements amples et des outils apr s des travaux d entretien et avant de faire d marrer le moteur Portez toujours un cran facial en travaillant sur un accumu lateur cables d accumulateur accumulateur un accumulateur ou survolter momentan ment un v hicule N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANS 749 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 2
20. complex Current scientific understanding does not yet allow us to interpret the evidence a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator About Pacemakers The above procedures are among those also normally recommended for pacemaker wearers Consuit your doctor for complete information 3 Do not coil or drape cables around the body 4 Keep welding power source and cables as far away from body as practical PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 749 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 0226
21. welding current 9 Volt Amp Meter and Switch CV Units 100002A 2 3 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 100002A 2 3 Serves as a connection point for the lead to the wire feeder when reverse polarity is desired 21 1 4 in bim 540mm gt E 29 7 6 in 748mm Weight CC CV 510 Ib 231 kg CC 460 Ib 209 kg CV 455 Ib 206 kg Figure 3 2 EXCEL ARC 500 and 6045 Dimensions and Weight May 18 1998 430429 409 DESCRIPTION OF EQUIPMENT TO WATER CIRCULATOR RECEPTACLE 2 GROUND CIRCUIT BREAKER 230 V 5 AMP INPUT CONTACTOR INPUT POWER CONTROL TRANSFORMER INPUT CONTACTOR SWITCH CIRCUIT BREAKER 24 V 10 AMP CV MODE WELDING TRANSFORMER CIRCUIT BREAKER 115 V 15 AMP RECEPTACLE 115 V STABILIZER FILTER L1 CV UNITS CC UNITS OVERLOAD THERMOSTAT PHASE SIGNAL T1 TO AUTOMATIC EQUIPMENT 19 PIN GUN SWITCH RECEPTACLE AMPHENOL BOARD PC CONTROL BOARD OUTPUT SCR SCR1 SCR6 STABILIZER FILTER 12 CC UNITS CVUNITS Functional Block Diagram for EXCEL ARC 500 and 6045 3 4 May 18 1998 11 Positive Terminal CC mode 100002A 1 3 Serves as a connection point for the lead to the electrode holder lead for SM
22. 0402 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 02268 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 Boulevard 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 515 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 2 4 8 V 96 430429 409 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT General Recommended Unit Applications There are three basic units of the EXCEL ARC 1 Gas metal arc welding MIG The EXCEL ARC 500 CC Part Number 100002A FI red arc welding with or with 1 isa constant current transformer rectifier type DC ing gas shielding welding machine that provides volt ampere charac teristic curves that are basically drooping with a 3 S
23. 2 409870 Washer Insulating 4 BC 23 409869 Bushing Insulating 4 BC 24 830039 1 Box Contactor 1 All 25 405402 Contactor 1 All 26 406392 2 Transformer Control 1 All 27 W 11166 11 Fuse 1 2 Amp 1 All 28 830036 1 Panel Top 1 All 29 12CW 2170 Boot Lifting Eye 1 AI 30 204036 Label Precautionary 1 AI 31 402900 Terminal Quick Connect 2 AB 402900 Terminal Quick Connect 3 C 32 368705 36 Capacitor W Leads 2 AB 368705 36 Capacitor W Leads 3 C 33 830116 Label Frame Ground 1 AI 34 408891 Label Warning 1 All 204279 Label Voltage Changeover 1 All 406484 Label Fuse 1 All Not Illustrated May 18 1998 8 7 430429 409 PARTS LIST Figure 8 3 Rear Panel Group May 18 1998 8 8 430429 409 PARTS LIST Parts List for Figure 8 1 Item Part Description Qty Application No Number per Code Assy 4 830173 2 Board P C Amphenol 1 BC 2 Deleted 3 Deleted 4 203627 7 Breaker Circuit 10 2 BC 203627 7 Breaker Circuit 10 1 A 5 Delete 6 402670 Receptacle 115 V 1 All 7 366826 1 Suppressor Assembly 1 All 8 830212 1 Panel Rear 1 All 9 8RT 609 Blade Fan 1 All 10 369650 1 Shroud Fan 1 All 11 369640 1 Bracket Mtg Fan 2 All 12 12TW 595 1 Motor Fan 1 All 13 369641 Insulator Mtg 2 All 14 369639 Heat Sink Rectifier 4 All 15 369642 Heat Sink SCR 6 All 16 405139 Rectifier Silicon 6 Al
24. 2 Input Voltage Connection amp Changeover from the National Fire Protection Association 470 Atlantic Avenue Boston 02210 Welding Leads Connect the three phase line leads to terminals L1 L2 and L3 on the line contactor inside the welding machine cabinet Use Table 4 2 for selection of the proper size copper welding leads June 4 1999 Revised 4 3 430429 409 INSTALLATION 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 2 M 30 5 M 45 7 M 61 0 M 76 2 M 100 4 4 4 3 2 150 3 3 2 1 1 0 200 2 2 1 1 0 250 1 1 1 0 2 0 300 1 0 1 0 2 0 3 0 350 1 0 1 0 3 0 4 0 400 2 0 2 0 3 0 4 0 450 2 0 2 0 4 0 2 2 0 500 34 3 0 3 0 4 0 2 2 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 4 4 Table 4 2 May 18 1998 430429 409 INSTALLATION Welding Current Noltage Control j Positive CV Terminal To Wire Feeder Shown For Reverse Polarity DCEP Negative Terminal Stick Base Metal a Positive CC Terminal Work Piece Should Be Grounded To Automatic C
25. 9 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 ANS 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 WARNINGS Instruction 830001 This page intentionally left blank 2 4 May 8 1996 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE AL ARC MISE EN GARDE LE SOUDAGE L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES O 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
26. 9358 30 3 1 1 t p 3 n 9 1 ores 8 1 5 En 1 8 ur UL Vd leet que 0 8 y en oy TEER VAR ates iss Sims o T anne YINYOISNYAL Rett 945 358109 85 RP 80d b TOHLNOD N30U23N 6 1 482 uo eed D IW 09 09 99 009 O I een NO 5 35 OUYWAHOS NOWOINNGD Wvuovid dW t 340 N31 H3AO 1VISOWH3HL es ox 5529 509675 AL EE QW siwe TROBO WI 50 moon N GIONE WOOV ALOWAY TOMINOO HILMS 25 Pe merum saevae CROWS ISRO ssa i indNI 21 5 15 88 5512058 Le x VN NV MNN 1IN9H19 1704 SLE YOSS3HddNS s A m SSSSSSSSSS Z SWHO HS 33804 H313WOU NiLOd us JNON 10000 iid 3003 HSINU 11 111111 SLLVM S SWHO 05 055386 5
27. AW 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 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 430429 409 DESCRIPTION OF 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 per mit proper cooling Figure 3 3 enables the operator to determine the duty cycle at various welding am perages 750 680 5 DUTY CYCLE 5 FOR E EXCEL ARC 500 lt 550 v 2 DUTY CYCLE 111 3 EEE 80 100 Duty Cycle Chart Figure 3 3 Duty Cycle Chart May 18 1998 3 5 430429 409 DESCRIPTION OF EQUIPMENT EXCEL ARC 500 AND 6045 CC
28. EXCEL ARC 500 and 6045 Transformer Rectifier DC Welding Machine For the Following Specs e 100002A 1 500 CC 50 60 Hz 100002 2 6045 CV 50 60 Hz e 100002A 3 6045 CC CV 50 60 Hz IHERMAL G THERMADYNE Company OWNER S MANUAL Number 430429 409 Rev AB 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 DECLARATION OF CONFORMITY Thermal Arc Inc 2200 Corporate Drive Troy Ohio USA 45373 1085 The equipment described in this manual including all options and accesso ries to which this declaration relates is are in conformity with the following standard s or other normative document s 1 EMC Directive 89 336 EEC of 3 May 1989 as amended by 92 31 EEC of 28 April 1992 and 93 68 EEC of 22 July 1993 by meeting the provisions of 50199 EMC Product Standard for Arc Welding Equipment 2 Low Voltage Directive 73 23 EEC of 19 February 1973 as amended by 93 68 EEC of 22 July 1993 by meeting the provisions EN60974 1 Safety requirements for arc welding equipment Part 1 Welding Power Sources IEC 974 1 1989 and the Draft Revision 974 1 of October 1996 Manufacturer s Responsible Representative David Ashworth Vice President amp Managing Director Thermadyne Europe Chorley England 430429 409 TABLE OF CONTENTS INTRODUCTION How To Use This Manual
29. HOllOYdv2O JGAM 03 50 NOISS3MddOS 011 3 00 0553844 5 SOLIOYvdvo HOLON 3 UN3911 9 1 5 THO 283 483 072 412 82 72 63 95 18 2 566 UVWH3HI 8 vay opa us m Basay CLLRS omo 14 je x 15058 d li 4 13365 ow 58 ms psy asse pears en ter oe ul ee ler JNIMVHQ SIHL 035 LON ZH 09 09 45 22 5609 388 9255 tn uv 905 ON 1 OUVW3H2S AvuoviQ lt s uu FRS 8208685238 FR 330A 30 NO 3805 ONDnOND man 904 4330 HOTS Sa fb 05 ON wayuy 1149345 INAYO SS3INn 00 25012078 pong coum m 19 5 77 INON 100008 Nid 3003 HSIN TRIOS SNES oi Si LT a ____ Fi z NEC 7 pre i NO NMOG O9NDIQOT1 2 9 8
30. M3MOd 3 1 103NNOO S 380338 N3dO SI LINDYID 833 3 9 4 NI NMOHS SV HOLMS 834404 NIVW OL S3NI1 LOZNNOO v S J3NMO 30 NOU 23S NOLVTIVISNL 3Hi NI LYVHO 3H 3SN SISIX3 3003 ON 3 31V d3AVN NO NMOHS IN33SfO JNN 803 3215 LNANI 34084 53003 214 19313 WOOT YNOA f INdNI 834084 913 31VISdONddY NI NMOHS SV 5834 M3WHOJSNYML TOULNOD LO3NNOO Z 3991108 JNN M3dOMd 303 JNIHOVW 30 3 SNOUINALSNI 3X0A NO 5 8 6 i g 318V2 1 ALON 335 NEYI 1 u 3LON YOLOVLNOD OL 2 ou MOLOVINOO 0138 N3JAHOJSNVSL TOHLNOO 5 8 9 33 03 110 009 HOIOVINO9 OL SOLOVLNOD OL 1 913 YOLOVLNOD 0138 YINYOISNVEL 1091405 21 229 0 NOU23NNO2 1700 Statement of Warranty LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof an
31. MITED 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 FOR 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 shall be the responsibility ofthe customer Ail returned goods shall be atthe customer s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal is a Registered Trademark of Thermadyne Industries Inc Thermal Arc Inc Effective January 4 1999 Troy Ohio 45373 830538
32. act tube hole size and replace with proper tube May 18 1998 7 3 430429 409 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 May 18 1998 Detailed Troubleshooting Instructions The EXCEL ARC 500 AND 6045 are solid state welding machines The method of troubleshooting is different but is not more difficult than trou bleshooting a conventional unit Do not overlook the obvious As in the case of all electrical equipment loose connections are the primary cause of malfunc tion both internal and external to the welding ma chine Do not overlook bad grounds worn contact tubes tips dirty cable liners shorted contro ca bles wrong settings blown fuses worn contactors misconnections from feeding equipment misappli cation etc To check the Control P C Board take contro module panel off the front panel Check the control board for loose connectors broken or loose wires Inspect the P C Board for broken compo nents scorched or burned components The only equipment needed to prope
33. ations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire cn the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields recommended Wear proper body protection to protect skin cuits fittings designed for the specific application maintain them and associated parts in good condition in use or connected for use associated equipment and CGA publication P 1 listed in Safety Standards ENGINES can be hazardous from any building air intakes 2 2 M
34. ay 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 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 under pressure of California to cause birth defects and in some cases cancer 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 Instruction 830001 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 n
35. 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 a 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 May 18 1998 430429 409 INSTALLATION GROUND CONNECTION ON LIFTING YOKE INPUT LINE CONTACTOR MOUNTED ON LIFTING YOKE CUSTOMER S INPUT CABLE CONNECTIONS e CAUTION SEE V C DIAG FOR CONTROL TRANS O CONNECTION SHOWN CONNECTED FOR 230V TO CONTACTOR WT CONTROL TRANSFORMER MOUNTS BELOW CONTACTOR 8 O 567228 12 Figure 4
36. connections at work Make connections Welding cables not connected Make connections 7 2 May 18 1998 430429 409 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 control 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 wire 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 cont
37. d 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 tions 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
38. d or overtemperature and take steps to correct the causes Some causes of overload are 1 Gun contact tip shorted to workpiece 2 Diameter of filler wire too large for machine rating can cause overload to trip on weld starts Some causes of overtemperature are 1 Exceeding current rating and or duty cycle rating of machine 2 Blocked or restricted air inlets or outlets to machine 5 2 May 18 1998 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 da Every 12 months Moderate 7 to 15 hrs da Heavy 16 to 24 hrs day Every 6 months Every 3 months NOTE Apply 1 12 drops of 20Wnon deter gent oil at each end of bearing May 18 1998 430429 409 MAINTENANCE Inspection and Cleaning For uninterrupted satisfactory service from this 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
39. d 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 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 employ
40. 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 entra nement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez 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 6 Arr tez tout quipement apr s usage Coupez l alimentation de L ELECTROCUTION PEUT ETRE MORTELLE l quipement s il est hors d usage ou inutilis deen slectri tt br l 7 N utilisez que des porte lectrodes bien isol s Ne jamais plon 21996150110 016 UE ger les porte lectrodes dans l eau pour les refroidir Ne jamais ment L lectrode et le circuit de soudage sont sou
41. ecessary 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 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 cap Allow pressure to escape before completely removing cap California Health amp Safety Code Sec 25249 5 et seq The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level 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
42. ed Input Voltage 230 400 230 400 230 400 230 400 Rated Input Amperage 83 47 77 44 83 47 77 44 Input kW 27 2 kW 21 8 kW 27 2 kW 218 kW Input 32 8 30 7 kVA 32 8 30 7 kVA input Frequency 50 60 Hz 50 60 Hz 50 60 Hz Input Phase 3 Phase 3 Phase 3 Phase Maximum Open Circuit Voltage 61 61 61 Auxiliary Power 1kVA 115V 9A 1 115 9A 1 115 9 No Load Input Voltage 230 400 230 400 230 400 No Load Input Amperage 3 0 1 8 4 3 3 0 3 0 1 8 No Load kW 9 kW 1 1 kW 9 kW No Load kVA 1 94 kVA 2 4 kVA 2 4 kVA Power Factor 80 85 80 Efficiency 73 78 Table 3 1 Input Voltage Amperage Data May 48 1998 3 1 430429 409 DESCRIPTION OF EQUIPMENT 10 Figure 3 1 Front and Rear Panel 3 2 May 18 1998 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 S2 2 Input Contactor Control 100002A 1 2 3 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 when ever line voltage is present at the input terminals This switch closes the secondary circuit of the con trol transformer energizing the contactor which energizes the power transform
43. ee 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 THERMAL 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 IS 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 Thermal 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 LI
44. er 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 100002A 1 2 3 Selects either the output control Local or some remote control device Remote to control welding output 4 115 V AC Receptacies 100002A 1 2 3 Provides auxiliary power for lights wire feeders water pumps etc 10 amps maximum 5 CCICV Selector Switch CC CV 100002A 3 Selects the welding mode of operation 51 in lt 787mm 430429 409 DESCRIPTION OF EQUIPMENT 6 Feeder Control Receptacle Panel Automat CV units 100002A 2 3 Amphenol 19 connector for a remote voltage control type wire feeder 7 Arc Force Control CC CV Units 100002A 1 3 This potentiometer controls short circuit welding current to produce an increase in current as the 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 100002A 2 3 Adjusts arc welding output and open circuit voltage Open circuit voltage is approxi mately 1 5 times the welding voltage for constant voltage welding On 100002 1 3 CC units Adjusts the
45. er 400 Amp 14 May 8 1996 2 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 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 WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high sure If damaged a cy
46. f metal fatigue e Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade Additional copies of this manual may be purchased by contacting Thermal Arc at the address given above Include the Owner s Manual number and equipment identification numbers Meanings Of Markings And Graphical Symbols f Output Control Increase Decrease Circuit Breaker Input Voltage Switch ojo Wire Feed 115V AC 10 AMPS 5 Receptacle Rating For Auxiliary Power rN 1 1 430429 409 INTRODUCTION This page intentionally left blank 1 2 May 18 1998 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING 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 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
47. ger leads Low line voltage Check line voltage May 18 1998 7 1 430429 409 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 connectlinks 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 cycle 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 Ventilation blocked Check air intake and exhaust openings to be unobstructed Fan not operating after machine is loaded down Check fan thermostat Check bearings 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
48. h 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 If there is any damage notify the carrier immediately to file a claim Furnish complete information con cerning damage claims or shipping errors to May 18 1998 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 of the case has been provided so that the equipment may be carried or lifted with a crane or hoist Use care to avoid 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 Lifting device may fail when overloaded e 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 e Avoid sudden jerks drops or swinging Check lifting device components visually for looseness and signs o
49. he 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 national 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 to the rod with an approved ground clamp Grounding Conductor Removable Not less than 8 Ft 2438 mm Soil Treating gt Material Inside Ground Figure 4 1 May 18 1998 4 1 430429 409 INSTALLATION COPPER COPPER RATED APPROX LINE WIRE SIZE GROUNDING LINE LOAD LINE FLEXIBLE CONDUCTOR VOLTS AMPS FUSE SIZE IN CONDUIT CABLE MIN SIZE 220 79 100 No 6 No 6 No 8 400 45 60 No 8 6 No 10 Conductor size shall be modified as required for line voltage drop and ambient temperature Sizes liste
50. l 17 16DA 954 12 Pin Spring 6 All 18 405140 1 Clamp Mtg 6 All 19 204210 Board Suppressor 2 All 20 402832 3 Diode Flyback 4 All 21 404044 6 Thermostat Fan 1 All 22 404044 3 Thermostat Overload 1 All 23 367732 Shunt 1 All 204038 1 Cable Ribbon Amphenol 1 BC 903914 1 Cap Protective 1 BC 903914 2 Protective 1 BC 403091 14 Plug Hole 1 All 24 Delete 25 Delete 170919 2 Plug Hole 1 W 10080 5 Clamp Cable 1 All Not Illustrated May 18 1998 8 9 430429 409 PARTS LIST This page intentionally left blank 8 10 May 18 1998 430429 409 DIAGRAMS e Note the model and part number shown on the equipment nameplate e Locate these numbers in the model and part number columns below Use only those diagrams and instructions that are applicable VOLTAGE MODEL PART CONNECTION SCHEMATIC CHANGEOVER NO NUMBER DIAGRAM DIAGRAM DIAGRAM 100002A 1 830213 Sheet 1 amp 2 830213 Sheet 3 204278 EXCEL ARC 500 100002 2 830213 Sheet 4 8 5 830213 Sheet 6 204278 EXCEL ARC 6045 100002A 3 830213 Sheet 7 amp 8 830213 Sheet 9 204278 May 18 1998 1 8 9 8 i 5 oF m 1 zi je sid pe QUO 5 Pise ANG
51. linder 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 me chanical 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 WARNING ENGINE EXHAUST GASES kill Engines produce harmful exhaust gases Read the Material Safety Data Sheets MSDSs and the manu Work in a confined space only if it is well ventilated or while Do not weld in locations near degreasing cleaning or spraying Do not weld on coated metals such as galvanized lead or Keep cylinders away from any welding or other electrical cir Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is Read and follow instructions on compressed gas cylinders Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away facturer s instruction for metals consumables coatings and cleaners wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe oper
52. lue this indicates that this par ticular SCRis 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 malfunc tioning 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 Asmall 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 Place the Force Indicator Gauge 903878 firmly against the springs as shown Be sure both ends and the center are in firm contact with the springs The gauge notch location will indicate the spring deflec tion or force Correct mounting force is indicated as shown below 8 Spring deflection over 2 1 4 inches of spring is 037 002 for all clamps 9 Allclamps to be set at 4 mark This corresponds to the VE3000 VE2500 section on the gauge label May 18 1998 Force Gage shown in position 903878 430429 409 TROUBLESHOOTING
53. mince moins de 300 amp res 9 moyen de 300 400 amp res 12 pais plus de 400 amp res 14 LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer Eloignez la t te des fum es pour viter de les respirer 2 A l int rieur assurez vous que l aire de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc 3 Si la ventilation est inadequate portez un respirateur adduc tion d air approuv 4 Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS A 8 2 73 5 Ne travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la 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 peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants 7 Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es
54. n the desired mode 6 Place the voltage sensing jumpers 100002A 2 3 on the main P C control board to 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 May 18 1998 430429 409 OPERATION out to the optional terminal strip Thermal Arc P N 204248 Jumper JP 3 and JP 5 SMAW Stick Welding Carbon Arc Gouging 100002A 1 3 Refer to Figure 3 1 for controls numbers in paren thesis refer to callouts on Figure 3 1 1 On 100002A 3 set the CC CV selector switch to CC position 2 Hold electrode clear of work Be sure the Re mote Local Switch 3 is set 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 At the 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 100002A 2 3 set Remote Local Output Con trol Switch 3 and Voltage Sensing Jumpers to LOCAL JP 2 and JP 4 NOTE Set Output Control Switch 3 to RE MOTE when using a feeder which controls the voltage and remote voltage control is desired Set Voltage Sensing Jumpers to JP 3 and JP 5 to REMOTE when using a feeder which provides voltage sensing at the actual weldi
55. ng location If the Voltage Sensing Jumpers are placed in the RE MOTE position and the voltage sensing leads are not connected at the welding location the output of the welding machine will go to maximum amperage 2 On 100002A 3 set the CC CV Selector Switch to CV position 3 Place Input Contactor Control Switch 2 in ON position Power ON 5 1 430429 409 OPERATION 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 weld termination sequence is fully ad justable Three simple jumper changes on the main circuit board allow the following weld termination treatments A Burnback Delay JP 1 B Wire Sharpening 9 C Inhibit JP 1 A Burnback Delay The burnback setting calls the Excel Arc to maintain a contactor 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 is used with older wire feeders which do not have dynamic braking and would show a tendency to wire coasting When Excel Arc is used on high cycle short weld applications or if a great deal of tack welding is done B Wire Shar
56. 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 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 ELECTRIC SHOCK can kill Turn off all equipment when not in use Disconnect power to LOU equipment if it will be left unattended or out of service Touching live electrical parts can cause fatal shocks 5 m The electr de atid work circuits 7 Use insulated electrode hoiaers Never dip holder in water electrically live whenever the output is on The input to cool it or lay it down on the ground or the work surface Do power circuit and machine internal SF also not touch holders connected to two weiding machines at the live when power is on In semiautomatic or auto same time or touch other people with the holder or electrode matic wire welding the wire wire reel drive roll 8 Do not use worn damaged undersized or poorly spliced ca housing and all metal parts touching the welding bles wire are electrically live incorrectly ins
57. ns or barriers to protect others from flash heat and strong ultraviolet rays that can burn eyes and glare warn others not to watch the arc and skin Noise from some processes can damage 4 Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high hearing Electrode Size Filter Electrode Size Filter Welding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shade Operation Welding Current Operation i or Welding Current No Torch soldering 2 Gas metal arc welding MIG Torch brazing 3or4 Non ferrous base metal All 11 Oxygen cutting Ferrous base metal All 12 Light Under 1 18 25mm 4 Gastungsten arc welding TIG i 12 Medium 1106in 25 150 mm 40 5 Atomic hydrogen welding All 12 Heavy Over6in 150mm 56 Carbon arc welding All 12 Gas welding Plasma arc welding All 12 Light 1 8 3mm 4or5 Carbon arc air gouging Medium 1 80 1 2 8 3 12 5076 Light 12 Over 1 2in 12 6081 Heavy 14 Shielded metal arc welding Under 5 32 4mm 10 Plasma arc cutting stick electrodes 5 32 to 1 4 in 4 to 6 4mm 12 Light Under 300 9 Overt 4in 64mm 44 Medium i 300 to 400 Amp 12 Heavy Ov
58. oard 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 VOM 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 a All SCRs firing properly max OCV 57VDC b 1 SCR not firing max OCV 51V DC c 2 SCRs not firing max OCV 45V DC d 3 SCRs not firing max OCV 39V DC NOTE These voltages were recorded at nominal line voltage with voltage control adjustment at MAXIMUM setting unit ad justed for high open 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 7 6 rectifier there are gate leads coming off of the 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 lead to one SCR and observe the OCV If the drops to a lower va
59. oltage control on the front of the welding machine turn it up to obtain the same arc that 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 In 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 aboutit Simulate gun switch closing and observe the open circuit voltage This can be done by putting the Process 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 57V DC 10 as the voltage 7 5 430429 409 TROUBLESHOOTING 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 control circuit board problem the voltage vari ation is somewhat smooth but does not reach the maximum value remember the 10 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 b
60. ontrol Figure 4 3 Installation Diagram 4 5 May 18 1998 430429 409 INSTALLATION This page intentionally left blank 4 6 May 18 1998 OPERATION General Before operating this system be sure that all instal lation instructions have been accomplished When operating this system observe all applicable Safety Warnings listed in this and related system manuals The operating instructions in this manual pertain only to the EXCEL ARC 500 and 6045 welding machines Consult operating instructions for com ponents used with this system before operating Athermostatically 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 e 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 Set the remote local control switch i
61. oss LS en FT e 6 1 Inspection Cleaning 6 1 TROUBLESHOOTING 7 Detailed Troubleshooting Instructions 7 5 PARTS LIST 8 Equipment Identification 8 1 How To Use This me a c er ee 8 1 DIAGRAMS May 18 1998 430429 409 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 possible 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 or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment whic
62. pening Serves the same func tion as burnback However in addition to maintain ing contactor closure for 25 seconds Excel Arc also lowers weld voltage to a value too low to main tain an arc but sufficient enough to burn off the remaining wire The effect of this a significant reduc tion in the ball size of the end of the wire CAUTION in order for this circuit to work properly the MIG torch must remain sta tionary for the complete wire sharpening cycle Wire Sharpening is preferred in the following situations 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 This unit is equipped with an overload indicator yellow L E D When lighted indicates that the ma chine has shutdown as a result of amperage over load or overtemperature To reset the overload indicator release the gun trigger switch If the indicator light goes out the indication was due to amperage overload If the light does not go out the indication was due to an overtemperature condition The unit will not weld until the overtemperature condition has dissipated and the light goes out If the light comes on repeat edly or often then investigate for the cause of over loa
63. r 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 100002A 1 100002A 2 100002A 3 to another part The part descriptions may be indented to show part relationships To determine the part number description quan tity 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 Specifications 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 May 18 1998 8 1 430429 409 PARTS LIST Figure 8 1 EXCEL ARC Control Panel Group 8 2 May 18 1998 430429 409 PARTS LIST Item No 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 May 1 2000 Revised Parts List for Figure 8 1 Part Number
64. r du b timent Ne faites pas le plein en fumant ou proche d une source d tincelles o d une flamme nue 3 Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage 4 Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 5 Faites attention de nepas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 PRECAUTIONS DE SECURITE SOUDAGE A L ARC instruction 830002 DES PIECES EN MOUVEMENT PEU 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 UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 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 4 Pour emp cher un d marrage accidentel pendant l entretien 5
65. rly 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 88 0 10 2 From the center bus bar on secondaries to the top or bottom of the secondary 44 0VAC 10 NOTE The 10 refers to the possibility of having a high or low input line voltage 3 115 V Receptacles 115 10 4 AC Input Voltage Test Points R206 to R207 36 V AC voltage reading AC voltage input to P C Board Test Points R208 to R209 36 V AC voltage reading voltage input to P C Board Test Points R210 to R211 36 VAC voltage reading AC voltage input to P C Board 5 Power Supply Checks Test Points TP16 to TP18 22 V DC meter reading power supply reading Test Points TP16 to TP17 15 V 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 16 VDC meter reading for CC Mode Test Point TP16 to L8 16V DC meter reading for CV Mode output switch to local pins A and B on Amphenol shorted together Test Point TP16 to R22 gt 16V DC meter reading for Tig position 7 Output Reference Circuits Test Point TP16 to 10 V DC meter reading reference voltage Ma
66. s tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension des la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le rouleau ou la bobine de fil le logement des galets d entrainement et toutes les les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode 8 N utilisez pas de c bles lectriques us s endommag s mal piss s ou de section trop petite ________ pi ces m talliques en contact avec le fil de soudage 9 N enroulez pas de c bles 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 pi ces sous tension 1 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 le moteur avant de l installer ou d en faire l entretien Bloquez le de courant alternatif moins qu il soit muni d un r ducteur de commutateur en circuit ouvert ou enlevez les fu
67. sibles de l ali tension Utilisez plut t une source de courant continu mentation afin d viter une mise en marche accidentelle 14 Portez un harnais de s curit si vous travaillez en hauteur 5 Veuillez installer cet quipement et le mettre la terre selon 15 Fermez solidement tous les panneaux et les capots le manuel d utilisation et les codes nationaux provinciaux et locaux applicables 2 Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la pi ce souder et de mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure LE RAYONNEMENT DE L ARC PEUT 2 Portez des lunettes de s curit approuv es Des crans lat raux BR LER LES YEUX ET LA PEAU LE sont recommand s BRUIT PEUT ENDOMMAGER LOUIE 3 Entourez l aire de soudage de rideaux ou de cloisons pour de soudage produit une chaleur et des prot ger les autres des coups d arc ou de l blouissement eM rayons ultraviolets intenses susceptibles de avertissez les observateurs de ne pas regarder l arc br ler les yeux et la peau Le bruit caus par 4 Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager et cuir et des chaussures de s curit 5 Portez un casq
68. talled or im 9 Do not wrap cables around your body properly grounded equipment is a hazard 10 Ground the workpiece to a good electrical earth ground 1 Do not touch live electrical parts 11 Do not touch electrode while in contact with the work ground circuit 2 Weat 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 12 Use only well maintained equipment Repair or replace dam aged parts at once 13 in confined spaces or damp locations do not use a welder with servicing this equipment Lock input power disconnect switch Fe QD Les iS ed ipped wilt a voltage aduer Use open or remove line fuses so power cannot be turned on equipment with DC output accidentally 14 Wear a safety harness to prevent falling if working above floor 5 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 15 Keep all panels and covers securely in place ARC RAYS can burn eyes and skin Wear a welding helmet fitted with a proper shade of filter see NOISE can damage hearing ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense 3 Use protective scree
69. teilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage 2 Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es 3 Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein M fiez vous des projections brulantes de soudage suscep tibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures 5 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 7 Ne soudez pas un r cipient ferm tel un r servoir ou un baril 8 Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et d incendie 9 Ne d gelez pas les tuyaux avec un source de courant 10 Otezl lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage 11 Por
70. tez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de 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 quipements et les pi ces connexes doivent tre maintenus en bon tat 6 Ne placez pas le visage face l ouverture du robinet de 18 bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation 8 Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tion P 1 de la CGA identifi e dans ia liste de documents ci dessous LES MOTEURS PEUVENT ETRE DANGEREUX Utilisez l quipement l ext rieur dans des aires ouvertes et 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 ai
71. ubmerged arc welding 4 Electro slag welding The EXCEL ARC 6045 CV Part Number 100002A 5 Carbon are gouging 2 isa constant voltage transformer rectifier type DC welding machine that provides volt ampere 6 SMAW Stick welding teristic curves that are basically flat 7 GTAW TIG welding The EXCEL ARC 6045 CC CV Part Number 100002A 3 is a combination constant current and con stant voltage transformer rectifier type DC welding ma Wire Feeder Com patibility chine that provides volt ampere characteristic curves for Some models of wire feeders will connect onto this each mode of operation 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 exceptions will be found Table 3 1 gives input voltage and amperage data in the instruction manual supplied with the wire for all part numbers covered by this manual feeder PART NO 100002A 1 PART NO 100002A 2 PART NO 100002A 3 ITEM EXCEL ARC EXCEL ARC CV EXCEL ARC CV Rated Output Amperage 500 Amps 450 Amps 500 Amps 450 Amps Rated Output Voltage 40 Volts 38 Volts 40 Volts 38 Volts Rated Duty Cycle 40 Duty 100 Duty 60 Duty 100 Duty Minimum Output 50 Amps 50 Amps 13 Volts 50 Amps 50 Amps 13 Volts Maximum Output 500 Amps 450 Amps 38 Volts 500 Amps 450 Amps 40 Volts Rat
72. ue antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI 249 indiqu e ci apr s 8 V 96 2 1 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 Op ration Dimension d lectrode ou Nuance de de paisseur de m tal ou de filtre Coupage ou soudage Intensit de courant oculaire rasage tendre au chalumeau outes conditions Brasage fort au chalumeau toutes conditions 3ou4 Oxycoupage mince moins de 1 po 25 mm 2 ou 3 moyen de 1 6 po 25 150 mm 4005 plus de 6 150 mm 5 ou 6 Soudage aux gaz mince moins de 1 8 po 3 mm 4ou 5 moyen de 1 8 1 2 po 5 12 mm 50 6 pais plus de 1 2 12 6 ou 8 Soudage 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 a sous gaz avec lectrode de tungst ne GTAW toutes conditions 12 Soudage l hydrog ne atomique AHW toutes conditions 12 Soudage l arc avec lectrode de carbone CAW toutes conditions 42 Soudage l arc Plasma PAW toutes dimensions 12 Gougeage avec lectrode de carbone mince 12 pais 14 Coupage l arc Plasma PAC
73. y 18 1998 430429 409 TROUBLESHOOTING supply Test Point TP16 to L10 9 50 meter read ing Voltage reference supply to output pots 8 SCR Firing Circuits Test Point TP16 to TPE 4 3 V DC meter reading Checks ramp circuits Test Point TP16 to TPD 4 3 V DC meter reading All readings should be very close for balance Test Point TP16 to TPB 4 3 V DC meter reading All readings should be very close for balance Test Point TP16 to C69 17 19 V DC meter reading Checks SCR Gate Test Point TP16 to C70 17 19 V DC meter reading Generator Circuits Test Point TP16 to C71 17 19 V DC meter reading 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 malfunc tion 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 received by the SCR gate circuit open a very small change will occur at the arc and will be difficult to notice by the average operator Generally when this happens it will be necessary to adjust the v

Download Pdf Manuals

Related Search

Related Contents

Instructions  Digitus DN-19 FAN-4-B-N hardware cooling accessory  5 - American Standard  Clarion DB336MP User's Manual  J-3671-2 AutoMate Local I/O Head  Frigidaire FFBD2411NM Product Specifications Sheet  PENSEBEM® - Datassette  Playmobil 5428  Samsung 931C Kullanıcı Klavuzu  Bedienungsanleitung  

Copyright © All rights reserved. Failed to retrieve file