Thermal Arc EXCEL-ARC 750 CC Owner's Manual
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Thermal Arc EXCEL-ARC 750 CC Owner's Manual

Thermal Arc EXCEL-ARC 750 CC Owner's Manual

Transformer-rectifier dc welding machine
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®
EXCEL-ARC
750 and 8065
Transformer-Rectifier DC
Welding Machine
For the Following Specs:
• 500016-1
• 500016-2
• 500016-3
• 500016A-1
• 500016A-2
• 500016A-3
OWNER'S MANUAL Number 430429-174
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
750 CC, 60 Hz
8065 CV, 60 Hz
8065 CC/CV, 60 Hz
750 CC, 60 Hz
8065 CV, 60 Hz
8065 CC/CV, 60 Hz
Revised December 1, 1997

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  • Page 1 750 CC, 60 Hz • 500016A-2 8065 CV, 60 Hz • 500016A-3 8065 CC/CV, 60 Hz OWNER’S MANUAL Number 430429-174 Revised December 1, 1997 IMPORTANT: Read these instructions before installing, operating, or servicing this system. THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

  • Page 3: Table Of Contents

    430429-174 Table of Contents INTRODUCTION How To Use This Manual ........1-1 Equipment Identification .

  • Page 4: Introduction

    Additional copies of this manual may be pur- have a control panel such as gun and cable assem- chased by contacting Thermal Arc at the address blies are identified only by the specification or part given above. Include the Owner’s Manual number number printed on the shipping container.
  • Page 5 430429-174 INTRODUCTION This page intentionally left blank. April 7, 1997 Revised...

  • Page 6: Arc Welding Safety Instructions And Warnings

    ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ARC WELDING can be hazardous. 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.
  • Page 7 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES can be hazardous 4. Read the Material Safety Data Sheets (MSDSs) and the manu- to your health. facturer’s instruction for metals, consumables, coatings, and cleaners. 5. Work in a confined space only if it is well ventilated, or while Welding produces fumes and gases.
  • Page 8 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ENGINE FUEL can cause fire or 2. Do not add fuel while smoking or if unit is near any sparks or open explosion. flames. 3. Allow engine to cool before fueling. If possible, check and add Engine fuel is highly flammable.
  • Page 9 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 This page intentionally left blank. May 8, 1996...
  • Page 10 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 ′ PRECAUTIONS DE SECURITE EN SOUDAGE A L LE SOUDAGE A L′ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
  • Page 11 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE ( selon AWS A 8.2-73 ) Opération Dimension d’électrode ou Nuance de Epaisseur de métal ou de filtre Coupage ou soudage Intensité...
  • Page 12 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN- 4. Méfiez-vous des projections brulantes de soudage susceptibles CENDIE OU UNE EXPLOSION de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures. L’arc produit des étincellies et des projections. Les 5.
  • Page 13 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU- 3. Seules des personnes qualifiées doivent démonter des protec- VENT CAUSER DES BLESSURES. teurs ou des capots pour faire l’entretien ou le dépannage nécessaire. Des pièces en mouvement, tels des ventilateurs, des 4.

  • Page 14: Description Of Equipment

    The EXCEL-ARC 8065 (CC/CV), Part Number 500016-3 & 500016A-3, is a combination constant- Some models of Thermal Arc wire feeders will current and constant-voltage transformer-rectifier connect onto this unit with no special preparation. type DC welding machine that provides volt-ampere In some cases, however, an interface must be used characteristic curves for each mode of operation.
  • Page 15 430429-174 DESCRIPTION OF EQUIPMENT Figure 3-1 Front and Rear Panel April 7, 1997 Revised...

  • Page 16: Controls And Outlets

    430429-174 DESCRIPTION OF EQUIPMENT Controls and Outlets 5. CC/CV Selector Switch (CC/CV) (500016-3 & 500016A-3) — Selects the welding mode of opera- See callouts on Figure 3-1. tion. 6. Feeder Control Receptacle Panel (Automat- 1. Pilot Light (500016-1, -2, -3 & 500016A-1, -2, ic) (CV units) (500016-2, -3 &...
  • Page 17 430429-174 DESCRIPTION OF EQUIPMENT TO AUTOMATIC EQUIPMENT TO FEEDER 5-PIN 19-PIN GUN SWITCH GUN SWITCH RECEPTACLE RECEPTACLE CIRCUIT BREAKER 24 V - 10 AMP CV MODE AMPHENOL BOARD OVERLOAD THERMOSTAT INPUT INPUT WELDING POWER CONTACTOR TRANSFORMER PHASE SIGNAL PC CONTROL BOARD CONTROL BACKGROUND...

  • Page 18: Duty Cycle

    430429-174 DESCRIPTION OF EQUIPMENT 9. Volt/Amp Meter and Switch (CV Units) cludes the fan and the 115-volt AC power recepta- (500016-2, -3 & 500016A-2, -3) — A single meter cle. with switch that will read DC volts when in the V. 14.
  • Page 19 430429-174 DESCRIPTION OF EQUIPMENT Figure 3-4 Volt/Ampere Characteristic Curves April 7, 1997 Revised...

  • Page 20: Installation

    430429-174 INSTALLATION INSTALLATION Location method, and the equipment grounding conductor size and type shall conform to local and national For best operating characteristics and longest unit codes. life, take care in selecting an installation site. Avoid For the National Electrical Code, the equipment locations exposed to high humidity, dust, high am- grounding conductor shall be green, green with a bient temperature, or corrosive fumes.

  • Page 21: Internal Wiring Check

    430429-174 INSTALLATION COPPER COPPER RATED APPROX. LINE WIRE SIZE* GROUNDING LINE LOAD LINE CONDUCTOR FLEXIBLE VOLTS AMPS FUSE SIZE MIN. SIZE IN CONDUIT CABLE No. 2 No. 1 No. 6 No. 6 No. 4 No. 8 No. 8 No. 6 No.

  • Page 22: Welding Leads

    430429-174 INSTALLATION able from the National Fire Protection Association, Welding Leads 470 Atlantic Avenue, Boston, MA 02210. Use Table 4-2 for selection of the proper size Connect the three-phase line leads to terminals copper welding leads. L1, L2, and L3 on the line contactor inside the welding machine cabinet.
  • Page 23 430429-174 INSTALLATION Figure 4-2 Input Voltage Connection & Changeover For 500016-1 & 500016A-1 April 7, 1997 Revised...
  • Page 24 430429-174 INSTALLATION Figure 4-3 Input Voltage Connection & Changeover For 500016-2, -3 & 500016A-2, -3 April 7, 1997 Revised...
  • Page 25 430429-174 INSTALLATION Figure 4-4 Installation Diagram April 7, 1997 Revised...

  • Page 26: Operation

    Jumper JP-2 (–) and JP-4 (+). For remote Safety Warnings listed in this and related system voltage sensing, going out to the optional terminal manuals. strip – Thermal Arc P/N 204248 Jumper JP-3 (–) and JP-5 (+ ). The operating instructions in this manual pertain ®...
  • Page 27 430429-174 OPERATION 2. On 500016-3 & 500016A-3 set the CC/CV Se- ® – When Excel-Arc is used on high cycle short lector Switch to CV position. weld applications or if a great deal of tack welding is done. 3. Place Input Contactor Control Switch (2) in ON position (Power ON).

  • Page 28: Maintenance

    430429-174 MAINTENANCE MAINTENANCE Replacing SCRs Inspection and Cleaning Replacing a SCR is a critical task but it can be For uninterrupted, satisfactory service from this accomplished in the field by following the instruc- welding machine, it is necessary to keep the ma- tions in the Detailed Troubleshooting section of the chine clean, dry, and well ventilated.
  • Page 29 430429-174 MAINTENANCE This page intentionally left blank. April 7, 1997 Revised...

  • Page 30: Troubleshooting

    430429-174 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.
  • Page 31 430429-174 TROUBLESHOOTING Contactor operates and blows link fuses. Wrong line voltage Check nameplate of welding machine for line voltage to use; check line voltage. Links on voltage changeover board incorrectly connected Check Voltage Changeover diagrams for link positions; connect links correctly. See Diagrams chapter.
  • Page 32 430429-174 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.
  • Page 33 430429-174 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.

  • Page 34: Detailed Troubleshooting Instructions

    430429-174 TROUBLESHOOTING Detailed Troubleshooting 7. Output Reference Circuits — Test Point TP16 to TP9 – +10V DC meter reading – reference Instructions voltage supply; Test Point TP16 to L10 – –10V DC ® The EXCEL-ARC 8065 is a solid-state welding (CC and 8065 models) –...
  • Page 35 430429-174 TROUBLESHOOTING and shorting terminals A and B together on the 5-pin The best way to isolate the particular SCR which connector on the rear panel. This voltage should is malfunctioning is as follows. Refer to Connection vary from 19V DC to 59V DC ± 10%, as the voltage Diagram while inspecting the unit.
  • Page 36 430429-174 TROUBLESHOOTING Examples: L e s s t ha n Correct rated E x c e s s i v e r a te d f or c e . force. force. Loosen Tighten nuts al- both nuts and ternately 1/4 s t a r t o v e r .
  • Page 37 430429-174 TROUBLESHOOTING This page intentionally left blank. April 7, 1997 Revised...

  • Page 38: Parts List

    430429-174 PARTS LIST PARTS LIST to another part. The part descriptions may be Equipment Identification indented to show part relationships. All identification numbers as described in the In- troduction chapter must be furnished when ordering To determine the part number, description, quan- parts or making inquiries.
  • Page 39 430429-174 PARTS LIST ® Figure 8-1 EXCEL-ARC Control Panel Group April 7, 1997 Revised...
  • Page 40 430429-174 PARTS LIST Parts List for Figure 8-1 Item Part Description Qty Application Number Code Assy ® 500016-1 Excel-Arc Welder - 750 CC ® 500016-2 Excel-Arc Welder - 8065 CV ® 500016-3 Excel-Arc Welder - 8065 CC/CV ® 500016A-1 Excel-Arc Welder - 750 CC ®...
  • Page 41 430429-174 PARTS LIST This page intentionally left blank. April 7, 1997 Revised...
  • Page 42 430429-174 PARTS LIST Parts List for Figure 8-1 Item Part Description Qty Application Number Code Assy No Number . Screw - 1/2-13 x 1, HHC, ST. ABDE No Number . Screw - 1/2-13 x 1, HHC, ST. No Number . Washer - LK, Std, ST. 1/2 ABDE No Number .
  • Page 43 430429-174 PARTS LIST Figure 8-2 Base and Lifting Yoke Group April 7, 1997 Revised...
  • Page 44 430429-174 PARTS LIST Parts List for Figure 8-2 Item Part Description Qty Application Number Code Assy 204306 . Transformer - Power BCEF 204595 . Transformer - Power 367228-13 . . Board - Voltage Changeover 204318 . . Bracket - Voltage Changeover 204318-1 .
  • Page 45 430429-174 PARTS LIST This page intentionally left blank. April 7, 1997 Revised...
  • Page 46 430429-174 PARTS LIST Parts List for Figure 8-2 Item Part Description Qty Application Number Code Assy 406392-2 . Transformer - Control W-11166-11 . Fuse - 1/2 Amp 204281-3 . Panel - Top 204281A-3 . Panel - Top 12CW-2170 . Boot - Lifting Eye 204036 .
  • Page 47 430429-174 PARTS LIST Figure 8-3 Rear Panel Group 8-10 April 7, 1997 Revised...
  • Page 48 430429-174 PARTS LIST Parts List for Figure 8-3 Item Part Description Qty Application Number Code Assy 204109-2 . Panel - Amphenol, Blank 204109-4 . Panel - Amphenol, Blank 204109-1 . Panel - Amphenol 204109-3 . Panel - Amphenol 204184 . Board - P.C. Amphenol BCEF 203627-7 .
  • Page 49 430429-174 PARTS LIST Parts List for Figure 8-3 Item Part Description Qty Application Number Code Assy — 204038-6 . Cable - Ribbon, Amphenol BCEF — 903914-1 . Cap - Protective BCEF — 903914-2 . Cap - Protective BCEF — 403091-14 .

  • Page 50: Diagrams

    430429-174 DIAGRAMS DIAGRAMS • Note the model and part number shown on the equipment nameplate. • 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...

  • Page 62: Statement Of Warranty

    , 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 and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice,...

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Excel-arc 8065 cc/cvExcel-arc 8065 cv

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