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ARCAIR N6000 Automatic System Safety And Operating Instructions Manual

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N6000
Automatic
System
English
Français
Español
Safety and Operating
Instructions
Issue Date: October 1, 2007
Manual No: 89210000

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Summary of Contents for ARCAIR N6000 Automatic System

  • Page 1 N6000 Automatic System English Français Español Safety and Operating Instructions Issue Date: October 1, 2007 Manual No: 89210000...
  • Page 2 This Manual has been designed to instruct you on the correct ® installation and use of your Arcair product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time to read the entire manual, especially the Safety Precautions.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no liability for its use. Arcair N6000 Automatic Gouging System Set-up and Safe Operating Procedures Instruction Guide Number 89210000 Published by: Thermadyne Industries, Inc.

  • Page 4: Table Of Contents

    SECTION 4: GENERAL INFORMATION...............4-9 THE AIR CARBON-ARC METAL REMOVAL PROCESS (CAC-A) ..........4-9 N6000 SYSTEM CONTROL - GENERAL ....... 4-9 SECTION 5: THE N6000 AUTOMATIC SYSTEM COMPONENT DESCRIPTION ............... 5-10 N6000 TORCH HEAD ............5-10 FIGURE 1 - N6000 Torch Head ........... 5-10 AUTOMATIC CONTROLLER ..........
  • Page 5 GENERAL ................9-31 POWER ................9-31 CONTROL PANEL............... 9-31 TITAN SETUP AND ASSEMBLY .......... 9-32 SECTION 10: ARCAIR CLIMBER V-A TRAVEL SYSTEM ......10-34 SECTION 11: TROUBLE SHOOTING GUIDE ..........11-38 N6000 Automatic System ..........11-38 CLIMBER V-A TRACTOR ..........11-43 TITAN MACHINE CARRIAGE ..........

  • Page 6: Section 1: Safety Precautions

    SECTION 1: SAFETY PRECAUTIONS WARNING SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly installed, used, and maintained. Misuse of this equipment and other unsafe practices can be hazardous. The operator, supervisor, and helper must read and understand the following safety warnings and instructions before installing or using any welding or cutting equipment, and be aware of the dangers of the welding or cutting process.
  • Page 7 SET-UP AND SAFE OPERATING PROCEDURES ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN Welding and cutting processes produce extreme localized heat and strong ultraviolet rays. Never attempt to weld/cut without a federally compliant welding helmet with the proper lens. A number 12 to 14 shade filter lens provides the best protection against arc radiation.
  • Page 8 SET-UP AND SAFE OPERATING PROCEDURES SAFETY AND OPERATING REFERENCES 1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254 and 1000. U.S. Government Printing Office, Washington, DC 20402. 2. ANSI Z49.1 “Safety in Welding and Cutting”. 3.

  • Page 9: Section 2: Features

    LIGHT WEIGHT TORCH HEAD Streamlined and loaded with efficiency, yet with all the proven features of ruggedness, dependability and Arcair quality. The lightweight of only 9-3/4 pounds (4.4 kg) allows the head to be used for robotic and controlled manipulated applications.

  • Page 10: Section 3: Introduction

    In addition, this manual illustrates the operation of the Titan Machine Carriage and Climber V-A Travel Systems. These systems manufactured by the Arcair Company, are designed to be used, where appropriate, with the N6000 system or may be applied to other cutting and welding systems, such as GMAW, GTAW, Submerged Arc, Plasma and Oxy-Fuel equipment.

  • Page 11: Section 4: General Information

    GENERAL INFORMATION THE AIR CARBON-ARC METAL REMOVAL PROCESS (CAC-A) The Arcair Company developed air carbon-arc gouging and cutting in the 1940’s and early 50’s. Since then, industry has enthusiastically adopted the process. Its many uses in metal fabrication and casting finishing, in chemical and petroleum technology, in construction, mining, general repair, and maintenance have become well known.

  • Page 12: Section 5: The N6000 Automatic System Component Description

    SET-UP AND SAFE OPERATING PROCEDURES SECTION 5: THE N6000 AUTOMATIC SYSTEM COMPONENT DESCRIPTION N6000 TORCH HEAD FIGURE 1 - N6000 Torch Head The N6000 TORCH HEAD feeds the jointed electrodes down to the work surface. The Controller controls and signals the motor on the Torch Head to feed or retract the electrode. This action maintains arc voltage or current set on the Controller.
  • Page 13 For this system to operate the Pendant Assembly or Jumper Connector must be attached to the Controller. 7. ARC LEVEL CONTROL: Sets arc voltage when the Controller is in the “CC” mode. When the Controller is set in the “CP” mode, this dial sets the amperage. The N6000 Automatic System 5-11 89210000...
  • Page 14 Controller. A mounting plate holds the Controller when separated from the Contactor. Use hold-down clamps with the mounting plate to clamp the Controller in place. FIGURE 4 – Right Side Automatic Controller The N6000 Automatic System 5-12 89210000...

  • Page 15: 1600 Amp Contactor

    AC line and the DC signal voltages between the two units. The cable also delivers the arc-voltage signal from the workpiece to the Contactor. This delivery energizes the contacts and the air solenoid. The N6000 Automatic System 5-13 89210000...

  • Page 16: Electrodes

    DC power, the electrodes must be formulated and manufactured for use exclusively with Direct Current. The use of Arcair Jointed Jetrod Copperclad DC Electrodes is highly recommended. These electrodes are manufactured to Arcair specifications to provide the best electrical conductivity, to maintain proper electrode diameter at the point of the arc, and to minimize carbon sublimation.

  • Page 17: Power Sources (Supplied By User)

    Recommended Number and Size of Secondary Cables 25ft. / 7,5m 50ft. / 15m 100ft. / 30m 150ft. / 46m 200ft. / 61m 250ft. / 76m Amps Size Size Size Size Size Size 1000 1200 1400 1600 1800 2000 The N6000 Automatic System 5-15 89210000...

  • Page 18: Compressed Air

    The inside diameter of the main air line varies with the length of the line between compressor and regulator. LINE LENGTH UP TO 25’ (7.6 m): 1/2” (12.7 mm) INSIDE DIAMETER LINE LENGTH ABOVE 26’ (7.9 m): 5/8” (15.9 mm) INSIDE DIAMETER The N6000 Automatic System 5-16 89210000...

  • Page 19: Section 6: Assembly And Installation

    CAUTION Be sure to read this manual completely before trying to install or use this equipment. Call your Arcair Representative or Distributor if you have any questions. RECEIVING AND HANDLING Remove all components from skids and boxes. Using the packing lists, check to be sure you have all parts.
  • Page 20 SET-UP AND SAFE OPERATING PROCEDURES NOTE It is recommended to use two Power Cable Assemblies with the N6000 Torch Complete Package. The cables should be paralleled: connected at the same points on the Torch Head and the Contactor. 6. Connect the positive (+) cable(s) of the DC power source to the buss-bar terminal on the back of the Contactor labeled “Power Supply In.”...
  • Page 21 SET-UP AND SAFE OPERATING PROCEDURES Table 4 shows recommended parameters (amperage, voltage) by electrode sizes. The travel speeds listed for each size carbon and gouge depth were derived in the laboratory using a 1500 amp power source. Your results may vary depending on the arc current, voltage and other parameters you use.
  • Page 22 SET-UP AND SAFE OPERATING PROCEDURES NOTE If you want a groove depth that is greater than 1-1/2 times the diameter of the electrode being used, make the groove in two or more passes. Assembly And Installation 7-20 89210000...

  • Page 23: Section 7: Operating The N6000 System

    SET-UP AND SAFE OPERATING PROCEDURES SECTION 7: OPERATING THE N6000 SYSTEM Find out whether you will use a constant current (CC) or constant potential (CP) power source. The Controller must be properly set to match the power source. CHANGING MODE OF OPERATION (CC OR CP) To change the mode of operation do these things: WARNING DISCONNECT ALL POWER!
  • Page 24 SET-UP AND SAFE OPERATING PROCEDURES gauge sets the correct electrode stickout “3” (7.62 cm) from the torch head, sets the torch angle, and aligns the air nozzle. Tables, graphs and other data in this manual are based on a 45° electrode angle, but you can use electrode angles from 45°...
  • Page 25 SET-UP AND SAFE OPERATING PROCEDURES • “OUTPUT LEVEL” setting = 850/2 = 425. 10. Turn on the power source. Set the power source at 40 to 44 volts. In some cases the “drooping curve” effect on CP power sources will produce enough arc volts at the 40- 44 volt setting.

  • Page 26: No-Current Detect Function

    SET-UP AND SAFE OPERATING PROCEDURES NOTE If a short out interrupts the operation; check the air nozzle and vee block in the torch head for signs of arcing. If arcing is evident make appropriate repairs. If no signs of arcing are present, retry starting the gouge procedure by pressing the “Start”...

  • Page 27: Premature Shutdown

    SET-UP AND SAFE OPERATING PROCEDURES SUMMARY On either “CC”(constant current) or “CP”(constant potential) power sources the cardinal rule is: Air carbon arc gouging performs best when the dc volt meter on the controller panel reads between 40 and 44 volts and the dc ampere meter on the controller panel reads the correct amperage for the electrode being used.

  • Page 28: Section 8: Uses Of The N6000 System

    SECTION 8: USES OF THE N6000 SYSTEM The section briefly describes some uses for the N6000 System. If you have any questions concerning a specific application for this system contact Tweco-Arcair Technical Services Department at 800.426.1888 or 940.566.2000 GOUGING NON-FERROUS METALS The N6000 System can be connected to DC Straight Polarity (DCEN) to gouge non-ferrous metals, such as nickel, copper alloys, etc.

  • Page 29: Operating The N6000 System

    SET-UP AND SAFE OPERATING PROCEDURES 5. Connect the positive (+) cable(s) from the DC power source to the buss bar terminal, marked “POWER SUPPLY IN”, on the back of the contactor. Connect the negative (-) cable(s) of the DC power source to the N6000 Torch Head buss bar. Connect the signal wire to the ground post of the contactor and the buss bar on the torch head.
  • Page 30 SET-UP AND SAFE OPERATING PROCEDURES J-Groove Weld Preparation Data Material Electrode / Torch Data Electrode Overhang Travel System Data Pass Pass Pass Pass Pass Pass Overall Size Size Angle Stickout Speed 3/ 8 ” 5/ 1 6” 3” .063” 1/2” 5/ 1 6”...

  • Page 31: Material Up To 4" Wide

    SET-UP AND SAFE OPERATING PROCEDURES FIRST STEP: Make a U-groove with a 3/4” electrode, 7/16” (1.11 cm) deep. Location of electrode from the top surface should be 1-13/16” (4.60 cm). SECOND STEP: Relocate the electrode 2-1/4” (5.72 cm) from the top surface and make the gouge.

  • Page 32: Backgouging Of Web To Flange Plates

    SET-UP AND SAFE OPERATING PROCEDURES BACKGOUGING OF WEB TO FLANGE PLATES ON FABRICATED GIRDERS Backgouging the web to flange section on fabricated bridge girders is easier when using the Titan Machine Carriage and N6000 System. The outrigger assembly, specifically designed for this application, allows the system to track off the side of the flange plate while gouging.

  • Page 33: Section 9: Arcair Titan Machine Carriage

    SET-UP AND SAFE OPERATING PROCEDURES SECTION 9: ARCAIR TITAN MACHINE CARRIAGE GENERAL The Titan Machine Carriage is portable, rugged, and heavy duty. It is for low - maintenance and high straight-line work. Light carriage weight and easier-to-handle track permit fast, simple setup.

  • Page 34: Titan Setup And Assembly

    GENERAL Before trying to set up, assemble, or run the TITAN MACHINE CARRIAGE, be sure to read and study this instruction manual. Call Tweco-Arcair, Technical Service Department at 800.426.1888 or 940.566.2000 if you have questions. When asking for information about equipment, be sure to give complete serial and model numbers.
  • Page 35 To run Torch Assemblies attached to the Titan Machine Carriage see the manufacturer’s instruction manual(s). If the Titan Machine Carriage is running automatically (as when used with an Arcair N6000 Torch), control movement of this carriage by that system. CAUTION Manually check the travel system when using it in a particular way for the first time.

  • Page 36: Section 10: Arcair Climber V-A Travel System

    SET-UP AND SAFE OPERATING PROCEDURES SECTION 10: ARCAIR CLIMBER V-A TRAVEL SYSTEM GENERAL The CLIMBER V-A travel system consists of a tractor and aluminum track available in three lengths. The track is attached to the work by quick release magnetic clamps. The tractor has flat, overhead, vertical and horizontal uses.
  • Page 37 SET-UP AND SAFE OPERATING PROCEDURES CLIMBER V-A TRACTOR Model V-A increases rigidity over previous models. Use four-wheel assemblies spaced farther apart for greater stability. Adjustment for track width is easier to perform. This tractor must be attached at the end of the track, then freewheeled into position. When using the tractor out of position, in a particular vertical position, be sure to restrain the tractor when in the freewheel mode.
  • Page 38 CAUTION Attach safety clamps to the track when working out of position. (Not supplied by Tweco-Arcair) MOUNT TRACTOR TO TRACK Lift the drive-gear lever to the disengage position to raise the motor and gear for freewheeling. Slide the tractor onto the end of the track. Freewheel the tractor to the position you want it and lower the drive-gear lever to engage the motor and gear to the rack (Fine adjustment for track width may be necessary).
  • Page 39 SET-UP AND SAFE OPERATING PROCEDURES The tractor needs little maintenance. To keep the Climber tractor running well, do these things: • Oil track-roller assemblies once a month with light grade machine oil. • Twice a year place Moly-Kote “G” on the drive gears. • Wear may cause the tractor to loosen on the track.

  • Page 40: Section 11: Trouble Shooting Guide

    SET-UP AND SAFE OPERATING PROCEDURES SECTION 11: TROUBLE SHOOTING GUIDE N6000 AUTOMATIC SYSTEM Problem Possible Cause Possible Remedy Absence of appropriate power Check power continuity from source to control panel Tripped circuit breaker Reset breaker Defective transformer in Check or replace transformer...
  • Page 41 SET-UP AND SAFE OPERATING PROCEDURES Problem Possible Cause Possible Remedy Electrode not properly inserted Check, re-insert electrode physical contact with drive system not optimum. Defective contact shoe Repair shoe surface by surface due to prior arcing sanding if minor damage, between shoe and electrode, otherwise replace shoe resulting in pitted surface.
  • Page 42 SET-UP AND SAFE OPERATING PROCEDURES Problem Possible Cause Possible Remedy Clean filter thoroughly Clogged filter Contactor overheating (air (replace if necessary) not circulating properly). Fan not operating, or not Overheat indicators “ON” Replace fan operating efficiently No open circuit voltage See proceeding problem present Manual remote control “Start/...
  • Page 43 SET-UP AND SAFE OPERATING PROCEDURES Problem Possible Cause Possible Remedy Check air regulator Insufficient air pressure (PSI) and solenoid for proper or volume (CFM) operation. Molten metal not being Air stream from torch head Air stream must be directed removed from gouge or misdirected (air nozzle between the electrode and groove...
  • Page 44 SET-UP AND SAFE OPERATING PROCEDURES Problem Possible Cause Possible Remedy DC power source (welding Turn on power source power source) not energized Check signal wire “Signal Wire” between continuity between contactor and workpiece contactor and workpiece. If unattached or not functioning wire is defective, replace.

  • Page 45: Climber V-A Tractor

    SET-UP AND SAFE OPERATING PROCEDURES CLIMBER V-A TRACTOR Problem Possible Cause Possible Remedy Engagement lever is not Place lever in engage engaged position Absence of appropriate power Check power continuity from source to tractor Tripped breaker on the tractor Reset breaker Break in the power cable Repair/replace power Tractor will not run with...

  • Page 46: Titan Machine Carriage

    SET-UP AND SAFE OPERATING PROCEDURES Problem Possible Cause Possible Remedy Defective motor speed control Replace motor speed control Engagement of drive gear to Check/reset drive gear to track too tight track properly Debris edged in between the Remove any debris from track teeth track Circuit breaker for the...
  • Page 47 SET-UP AND SAFE OPERATING PROCEDURES Problem Possible Cause Possible Remedy Absence of appropriate power Check power continuity from the source to tractor Blown fuse Replace fuse No power to the aux/ Loose connection on the outlet Check connections on convenient outlet the inside enclosure and secure Defective outlet...

  • Page 48: Section 12: Replacement Parts

    SET-UP AND SAFE OPERATING PROCEDURES SECTION 12: REPLACEMENT PARTS N6000 CONTROLLER REPLACEMENT PARTS Description Part no. Description Part no. 120 Volt 60 Hz Automatic Controller 72-008-014 “Head Motor Cord” Connector 96-196-002 220 Volt 50 Hz Automatic Controller 72-008-018 Travel Delay Potentiometer 96-645-174 Circuit Board Assembly 96-162-760 Arc Level Potentiometer...
  • Page 49 SET-UP AND SAFE OPERATING PROCEDURES N6000 TORCH REPLACEMENT PARTS DESCRIPTION PART NO. DESCRIPTION PART NO N6000 Torch Head 05-124-000 19 Lever Spring 94-800-183 1 Torch Housing 94-395-105 20 Nozzle Spring 94-800-182 2 Cover 94-171-278 21 Lever 94-476-067 3 Molded Lock Nut 94-565-092 22 Lever Tube 94-893-192...

  • Page 50: Climber V-A Tractor Replacemant Parts

    SET-UP AND SAFE OPERATING PROCEDURES SYSTEM CABLES Remote Pendant Assembly Part No. Interconnect Assembly Part No. 10” Remote Pendant Assembly 96-620-001 14 Inch Interconnect Cable 96-170-049 25” Remote Pendant Assembly 96-620-003 30 Inch Interconnect Cable 96-170-055 50” Remote Pendant Assembly 96-620-002 7’...

  • Page 51: Titan Machine Carriage Replacement Parts

    SET-UP AND SAFE OPERATING PROCEDURES TITAN MACHINE CARRIAGE REPLACEMENT PARTS Description Part no. 120 Volt 60 Hz Titan Carriage 71-022-501 Front Wheel Assembly 95-949-022 Speed Control Board 96-174-061 Cleaning Brushes 94-122-055 Relacement Parts 12-49 89210000...
  • Page 52 U.S. Customer Care: 800-426-1888 / 800-535-0557 International Customer Care: 905-827-9777 / 905-827-9797 • www.tweco.com A Global Cutting & Welding Market Leader ™ W O R L D H E A D Q U A R T E R S : 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 •...

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