Thermal Arc Excel-Arc 500 Bedienungsanleitung

EXCEL-ARC®

Version No: 1Issue Date: August 22, 2005 Manual No.: 430429-451

Operating Features:

TRANSFORMER-RECTIFIER

DC WELDER

Operating Manual

Art # A-06056

500

6045

We appreciate your business!

LEADER IN ARC WELDING TECHNOLOGY

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

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

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

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

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

on the web at www.Thermalarc.com.

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

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

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

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

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

exist when working with this product.

YOU ARE IN GOOD COMPANY

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is the Global Brand of Arc Welding Products for

Thermadyne Industries Inc.

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

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

Manufacturing, Construction, Mining, Automotive, Engineering, Rural

and DIY.

We distinguish ourselves from our competition through market leading

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

competitive prices, excellent delivery, superior customer service and

technical support, together with excellence in sales and marketing

expertise.

We are committed to develop technologically advanced products to

achieve a safer working environment for industry operators.

WARNINGS

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

operating, or servicing the equipment.

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

the Manufacturer assumes no liability for its use.

Excel-Arc 500 (CC) and 6045 (CV and CC/CV) Transformer-Rectifier DC Welder

Instruction Manual Number 430429-451 for:

Excel-Arc 500 (CC) Spec Number 100005A-1

Excel-Arc 6045 (CV) Spec Number 100005A-2

Excel-Arc 6045 (CC/CV) Spec Number 100005A-3

Excel-Arc 500 (CC) Spec Number 100005A-5

Excel-Arc 6045 (CV) Spec Number 100005A-6

Excel-Arc 6045 (CC/CV) Spec Number 100005A-7

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermalarc.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written permission of the pub-

lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any

loss or damage caused by any error or omission in this Manual, whether such error

results from negligence, accident, or any other cause.

Publication Date: August 22, 2005

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________ i

TABLE OF CONTENTS

SECTION 1:

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

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

1.02 PRINCIPAL SAFETY STANDARDS .................................................................. 1-5

1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC .................................... 1-6

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

1.05 PRINCIPALES NORMES DE SECURITE ........................................................ 1-10

1.06 DECLARATION OF CONFORMITY ................................................................. 1-11

1.07 LIMITED WARRANTY ................................................................................... 1-12

SECTION 2:

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

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

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

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

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

2.05 Description ..................................................................................................... 2-3

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

2.07 Controls and Outlets ....................................................................................... 2-7

2.08 Functional Block Diagram ............................................................................... 2-8

2.09 Duty Cycle ...................................................................................................... 2-9

2.10 Volt-Amp Curves ............................................................................................ 2-9

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Location ......................................................................................................... 3-1

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

3.03 Internal Wiring Check ..................................................................................... 3-2

3.04 Connecting Welding Machine to Line Voltage ................................................ 3-2

3.05 Welding Leads ................................................................................................ 3-4

3.06 Installation Diagram ....................................................................................... 3-5

SECTION 4:

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

4.01 General ........................................................................................................... 4-1

4.02 Preweld Operation .......................................................................................... 4-1

4.03 SMAW (Stick) Welding, Carbon Arc Gouging ................................................. 4-1

4.04 Welding, Semiautomatic or Automatic ........................................................... 4-1

4.05 Overload Indicator .......................................................................................... 4-2

4.06 Configuration Settings.................................................................................... 4-2

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 5:

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

5.01 Replacing SCRs .............................................................................................. 5-1

5.02 Lubrication ..................................................................................................... 5-1

5.03 Inspection and Cleaning ................................................................................. 5-1

5.04 Troubleshooting Guide ................................................................................... 5-2

5.05 Detailed Troubleshooting Instructions ............................................................ 5-4

SECTION 6:

PARTS LIST .......................................................................................... 6-1

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

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

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

APPENDIX 2: EXCEL-ARC 500 CONNECTION DIAGRAM (1 OF 2) (100005A-1, 100005A-5) .... A-2

APPENDIX 2: EXCEL-ARC 500 CONNECTION DIAGRAM (2 OF 2) (100005A-1, 100005A-5) .... A-4

APPENDIX 3: EXCEL-ARC 500 SCHEMATIC DIAGRAM (100005A-1, 100005A-5) ....... A-6

APPENDIX 4: EXCEL-ARC 6045 CONNECTION DIAGRAM (1 OF 2) (100005A-2, 100005A-6)... A-8

APPENDIX 4: EXCEL-ARC 6045 CONNECTION DIAGRAM (2 OF 2) (100005A-2, 100005A-6).. A-10

APPENDIX 4: EXCEL-ARC 6045 SCHEMATIC DIAGRAM (100005A-2, 100005A-6) ........ A-12

APPENDIX 4: EXCEL-ARC 6045 CONNECTION DIAGRAM (1 OF 2) (100005A-3, 100005A-7).. A-14

APPENDIX 5: EXCEL-ARC 6045 CONNECTION DIAGRAM (2 OF 2) (100005A-3, 100005A-7).. A-16

APPENDIX 5: EXCEL-ARC 6045 SCHEMATIC DIAGRAM (100005A-3, 100005A-7) ........ A-18

APPENDIX 6: EXCEL-ARC 500 & 6045 VOLTAGE CHANGEOVER DIAGRAM (ALL) ............... A-20

EXCEL-ARC 500, 6045

1-1

August 22, 2005

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal

shocks or severe burns. The electrode and

work circuit is electrically live whenever the

output is on. The input power circuit and

machine internal circuits are also live when

power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll

housing, and all metal parts touching the

welding wire are electrically live. Incorrectly

installed or improperly grounded equipment

is a hazard.

1. Do not touch live electrical parts.

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

protection.

3. Insulate yourself from work and ground using dry

insulating mats or covers.

4. Disconnect input power or stop engine before

installing or servicing this equipment. Lock input

power disconnect switch open, or remove line fuses

so power cannot be turned on accidentally.

5. Properly install and ground this equipment according

to its Owner’s Manual and national, state, and local

codes.

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

power to equipment if it will be left unattended or out

of service.

7. Use fully insulated electrode holders. Never dip holder

in water to cool it or lay it down on the ground or the

work surface. Do not touch holders connected to two

welding machines at the same time or touch other

people with the holder or electrode.

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

spliced cables.

9. Do not wrap cables around your body.

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

ground.

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

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

PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS.

READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property,

if the operator does not strictly observe all safety rules and take precautionary actions.

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

learned through study and training before using this equipment. Anyone not having extensive training in welding and

cutting practices should not attempt to weld. Certain of the practices apply to equipment connected to power lines;

other practices apply to engine driven equipment.

Safe practices are outlined in the American National Standard 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.

EXCEL-ARC 500, 6045

1-2 August 22, 2005

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

(ground) circuit.

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

damaged parts at once.

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

welder with AC output unless it is equipped with a

voltage reducer. Use equipment with DC output.

14.Wear a safety harness to prevent falling if working

above floor level.

15.Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can

damage hearing.

Arc rays from the welding process produce

intense heat and strong ultraviolet rays that

can burn eyes and skin. Noise from some

processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of

filter (see ANSI Z49.1 listed in Safety Standards) to

protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields

recommended.

3. Use protective screens or barriers to protect others

from flash and glare; warn others not to watch the

arc.

4. Wear protective clothing made from durable, flame-

resistant material (wool and leather) and foot

protection.

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

high.

WARNING

FUMES AND GASES can be hazardous to your

health.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to

your health.

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

fumes.

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

arc to remove welding fumes and gases.

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

respirator.

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

the manufacturer’s instruction for metals,

consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated,

or while wearing an air-supplied respirator. Shielding

gases used for welding can displace air causing injury

or death. Be sure the breathing air is safe.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2 Gas metal-arc

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Heavy 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Medium Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Heavy 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Medium Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Heavy 300 to 400 Amp 12

Medium Over 400 Amp 14

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

EXCEL-ARC 500, 6045

1-3

August 22, 2005

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

spraying operations. The heat and rays of the arc can

react with vapors to form highly toxic and irritating

gases.

7. Do not weld on coated metals, such as galvanized,

lead, or 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.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding

arc. The flying sparks and hot metal, weld

spatter, hot workpiece, and hot equipment can

cause fires and burns. Accidental contact of

electrode or welding wire to metal objects can

cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and

hot metal.

2. Do not weld where flying sparks can strike flammable

material.

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

welding arc. If this is not possible, tightly cover them

with approved covers.

4. Be alert that welding sparks and hot materials from

welding can easily go through small cracks and

openings to adjacent areas.

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

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

partition can cause fire on the hidden side.

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

drums.

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

area as practical to prevent welding current from

traveling long, possibly unknown paths and causing

electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10.Remove stick electrode from holder or cut off welding

wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause

injury.

Chipping and grinding cause flying metal. As

welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side

shields recommended.

2. Wear proper body protection to protect skin.

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the

welding process, be sure to treat them

carefully.

1. Protect compressed gas cylinders from excessive heat,

mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by

chaining them to a stationary support or equipment

cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other

electrical circuits.

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

5. Use only correct shielding gas cylinders, regulators,

hoses, and fittings designed for the specific

application; maintain them and associated parts in

good condition.

6. Turn face away from valve outlet when opening

cylinder valve.

7. Keep protective cap in place over valve except when

cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas

cylinders, associated equipment, and CGA publication

P-1 listed in Safety Standards.

EXCEL-ARC 500, 6045

1-4 August 22, 2005

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

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

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

and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

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

sparks or open flames.

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

and add fuel to cold engine before beginning job.

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

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

starting engine.

WARNING

MOVING PARTS can cause injury.

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

fingers and hands and catch loose clothing.

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

and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or

covers for maintenance and troubleshooting as

necessary.

4. To prevent accidental starting during servicing,

disconnect negative (-) battery cable from battery.

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

from moving parts.

6. Reinstall panels or guards and close doors when

servicing is finished and before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO

EXPLODE; BATTERY ACID can burn eyes and

skin.

Batteries contain acid and generate explosive gases.

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

2. Stop engine before disconnecting or connecting

battery cables.

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

a battery.

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

vehicles.

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

WARNING

STEAM AND PRESSURIZED HOT COOLANT

can burn face, eyes, and skin.

The coolant in the radiator can be very hot

and under pressure.

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

engine to cool.

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

removing cap.

3. Allow pressure to escape before completely removing

cap.

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