Thermal Arc Excel-Arc 500, Excel-Arc 6045 Operating Manual

500

®

EXCEL-ARC

6045

TRANSFORMER-RECTIFIER
DC WELDER

Art # A-06056

Operating Manual

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

LEADER IN ARC WELDING TECHNOLOGY

We appreciate your business!

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
[phone]

www.thermalarc.com

Copyright 2001 by
Thermal Dynamics Corporation

All rights reserved.

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

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:
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.

SAFETY IN WELDING AND CUTTING.

1.01 Arc Welding Hazards

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

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.

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.

1. Do not touch live electrical parts.

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

August 22, 2005

9. Do not wrap cables around your body.

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

1-1

EXCEL-ARC 500, 6045

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.

4. Wear protective clothing made from durable, flame­resistant 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.

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.

Eye protection filter shade selector for welding or cutting

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

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

Torch soldering 2

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

Oxygen Cutting

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 w elding

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

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

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

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.

Gas metal-arc

Ferrous base metal All 12

Carbon arc welding All 12

Carbon arc air gouging

Plasma arc cutting

Heavy 300 to 400 Amp 12

Medium Over 400 Amp 14

1-2

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.

EXCEL-ARC 500, 6045

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

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.

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.

10.Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.

August 22, 2005

1-3

EXCEL-ARC 500, 6045

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

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

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.

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.

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.

1-4

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.

August 22, 2005

EXCEL-ARC 500, 6045

WARNING

This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in some
cases, cancer. (California Health & Safety code
Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects
of Low Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions
Section of the U.S. Congress, Office of Technology
Assessment,
Frequency Electric & 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 and from studies with animals and people which
clearly establish that low frequency magnetic fields and
interact with, and produce changes in, biological systems.
While most of this work is of very high quality, the results
are complex. Current scientific understanding does not
yet allow us to interpret the evidence in a single coherent
framework. Even more frustrating, it does not yet allow
us to draw definite conclusions about questions of
possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the
following procedures.

1. Keep cables close together by twisting or taping
them.

Biological Effects of Power

1.02 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from
American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent 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, American Welding Society
Standard AWS F4.1, from American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National
Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association, 1235
Jefferson Davis Highway, 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 Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.

2. Arrange cables to one side and away from the
operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away
from body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also
normally recommended for pacemaker
wearers. Consult your doctor for complete
information.

August 22, 2005

1-5

EXCEL-ARC 500, 6045

1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ
PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT
CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUC­TIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages
au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend
pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques
doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un
entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les
équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pra­tiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet
équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE
DES TRAVAUX D’INSTALLATION, DE REPARATION,
D’ENTRETIEN ET D’ESSAI.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et
non troués.

1.04 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler
gravement. L’électrode et le circuit de soudage
sont sous tension dès la mise en circuit. Le
circuit d’alimentation et les circuits internes
de l’équipement sont aussi sous tension dès
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 pièces
métalliques en contact avec le fil de soudage
sont sous tension. Un équipement
inadéquatement installé ou inadéquatement
mis à la terre est dangereux.

1-6

3 Isolez-vous de la pièce à souder et de la mise à la

terre au moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement
ou arrêtez le moteur avant de l’installer ou d’en faire
l’entretien. Bloquez le commutateur en circuit ouvert
ou enlevez les fusibles de l’alimentation afin d’éviter
une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la
terre selon le manuel d’utilisation et les codes
nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez
l’alimentation de l’équipement s’il est hors d’usage
ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne
jamais plonger les porte-électrodes dans l’eau pour
les refroidir. Ne jamais les laisser traîner par terre ou
sur les pièces à souder. Ne touchez pas aux porte­électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre
avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés,
endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre
corps.

August 22, 2005

EXCEL-ARC 500, 6045

10.N’utilisez qu’une bonne prise de masse pour la mise à
la terre de la pièce à souder.

11.Ne touchez pas à l’électrode lorsqu’en contact avec le
circuit de soudage (terre).

12.N’utilisez que des équipements en bon état. Réparez
ou remplacez aussitôt les pièces endommagées.

13.Dans des espaces confinés ou mouillés, n’utilisez pas
de source de courant alternatif, à moins qu’il soit muni
d’un réducteur de tension. Utilisez plutôt une source
de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hau­teur.

15.Fermez solidement tous les panneaux et les capots.

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER
LES YEUX ET LA PEAU; LE BRUIT PEUT
ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de
nuance appropriée (consultez la norme ANSI Z49
indiquée ci-après) pour vous protéger le visage et les
yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans
latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons
pour protéger les autres des coups d’arc ou de
l’éblouissement; avertissez les observateurs de ne pas
regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et
durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre
au chalumeau
Brassage fort
au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

moyen de 1 á 6 po. (25 á 150 mm ) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimens ions 12

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

Soudage á l'arc avec
électrode enrobees
(SMAW)

Dimens ion d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

mince moins de 1 po. (25 mm ) 2 ou 3

épais plus de 6 po. (150 mm) 5 ou 6

mince m oins de 1/8 po. (3 m m) 4 ou 5

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 am perès 9

plus de 1/4 po. (6.4 m m) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz
avec fil plein (GMAW)

Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)

Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)

Gougeage Air-Arc avec
électrode de carbone

Dimens ion d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

toutes conditions 12

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

August 22, 2005

1-7

EXCEL-ARC 500, 6045

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est
bien ventilée ou que les fumées et les vapeurs sont
aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur
à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du
fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur à adduction d’air.
Les gaz protecteurs de soudage peuvent déplacer
l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respira­tion.

6. Ne soudez pas à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La
chaleur et les rayons de l’arc peuvent réagir avec des
vapeurs et former des gaz hautement toxiques et irri­tants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb
ou au cadmium que si les zones à souder ont été
grattées à fond, que si l’espace est bien ventilé; si
nécessaire portez un respirateur à adduction d’air. Car
ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au
moment du soudage.

1. Protégez-vous, ainsi que les autres, contre les
étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules
volantes ou des projections peuvent atteindre des
matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon
de 10, 7 mètres autour de l’arc, ou couvrez-les
soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes
par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à
portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond,
un plancher, une cloison ou une paroi peut enflammer
l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou
un baril.

8. Connectez le câble de soudage le plus près possible
de la zone de soudage pour empêcher le courant de
suivre un long parcours inconnu, et prévenir ainsi les
risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10.Otez l’électrode du porte-électrode ou coupez le fil au
tube-contact lorsqu’inutilisé après le soudage.

11.Portez des vêtements protecteurs non huileux, tels
des gants en cuir, une chemise épaisse, un pantalon
revers, des bottines de sécurité et un casque.

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU
UNE EXPLOSION

L’arc produit des étincellies et des projections.
Les particules volantes, le métal chaud, les
projections de soudure et l’équipement
surchauffé peuvent causer un incendie et des
brûlures. Le contact accidentel de l’électrode
ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un
échauffement ou un incendie.

1-8

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS
BRULANTES PEUVENT CAUSER DES
BLESSURES.

Le piquage et le meulage produisent des
particules métalliques volantes. En
refroidissant, la soudure peut projeter du
éclats de laitier.

1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont
recommandés.

2. Portez des vêtements appropriés pour protéger
la peau.

August 22, 2005

EXCEL-ARC 500, 6045

1. Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER

Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles
endommagées peuvent exploser. Comme les
bouteilles font normalement partie du procédé
de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les
sources de chaleur intense, les chocs et les arcs de
soudage.

2. Enchainez verticalement les bouteilles à un support
ou à un cadre fixe pour les empêcher de tomber ou
d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de
tout soudage.

4. Empêchez tout contact entre une bouteille et une
électrode de soudage.

2. Si vous utilisez ces équipements dans un endroit
confiné, les fumées d’échappement doivent être
envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE
OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e
carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de
faire le plein de carburant ou d’en vérifier le niveau au
début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez
de l’espace pour son expansion.

5. N’utilisez que des bouteilles de gaz protecteur, des
détendeurs, des boyauxs et des raccords conçus pour
chaque application spécifique; ces équipements et les
pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet
de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en
utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles
de gaz comprimé et aux équipements connexes, ainsi
que la publication P-1 de la CGA, identifiée dans la
liste de documents ci-dessous.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS

PEUVENT ETRE MORTELS.

5. Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT
CAUSER DES BLESSURES.

Des pièces en mouvement, tels des
ventilateurs, des rotors et des courroies
peuvent couper doigts et mains, ou accrocher
des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots
et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez
le moteur.

3. Seules des personnes qualifiées doivent démonter des
protecteurs ou des capots pour faire l’entretien ou le
dépannage nécessaire.

Les moteurs produisent des gaz d’échappement nocifs.

August 22, 2005

1-9

EXCEL-ARC 500, 6045

4. Pour empêcher un démarrage accidentel pendant
l’entretien, débranchez le câble d’accumulateur à la
borne négative.

5. N’approchez pas les mains ou les cheveux de pièces
en mouvement; elles peuvent aussi accrocher des
vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les
portes après des travaux d’entretien et avant de faire
démarrer le moteur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER
UN ACCUMULATEUR; L’ELECTROLYTE D’UN
ACCUMU-LATEUR PEUT BRULER LA PEAU ET
LES YEUX.

Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un
accumu-lateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT BRULANT SOUS
PRESSION PEUVENT BRULER LA PEAU ET
LES YEUX.

Le liquide de refroidissement d’un radiateur
peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon
pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter
complètement le bouchon.

1.05 PRINCIPALES NORMES DE

SECURITE

2. Arrêtez le moteur avant de connecter ou de
déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler
sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour
charger un accumulateur ou survolter
momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

Safety in Welding and Cutting, norme ANSI Z49.1, American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and
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 02269.

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
Association canadienne de normalisation, Standards Sales, 276
Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face
Protection, norme ANSI Z87.1, American National Standards
Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.

1-10

August 22, 2005

EXCEL-ARC 500, 6045

1.06 DECLARATION OF CONFORMITY

Manufacturer: Thermadyne Corporation
Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive”
(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.

National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

• UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

• ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting
equipment and associated accessories.

• For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to
EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly
installed standoff guides.

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual
and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufac­turing process to ensure the manufactured product meets or exceeds all design specifications.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.

Manufacturers responsible representative:

Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

August 22, 2005

1-11

EXCEL-ARC 500, 6045

1.07 LIMITED WARRANTY

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of itsauthorized distributors
hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should anyfailure to conform to this warranty appear within
the time period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product
has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized
standard industry practice, and not subject to misuse, 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, INDIRECT OR CONSEQUENTIAL
DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS 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, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other
warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE
JUDGEMENT 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.

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.

POWER SUPPLIES

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 3 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 3 YEAR
CONTROL PC BOARD 3 YEARS 3 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT
NOT LIMITED TO: CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS.
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC,

ALTHOUGH MOST ARE WARRANTED BY THE ENGINE
MANUFACTURER. SEE THE ENGINE MANUFACTURE'S 1 YEAR 1 YEAR

WARR AN TY FOR DETAIL S.
CONSOLES, CONTROL EQUIPMENT, HEAT EXCHANGES
ACCESSORY EQUIPMENT

NOTE: Dragster 85® excluded from this policy. Refer to Dragster 85 warranty in Dragster 85 Owner’s Manual.

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 purchaser’s notice of any Warranty Claim. 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 of the Purchaser. All returned goods shall be at the
Purchaser’s risk and expense. This warranty supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered Trademark of Thermadyne
Industries Inc.

September 27, 2004

ALL OTHER

POWER SUPPLIES

1 YEAR 1 YEAR

LABOR

1-12

August 22, 2005

EXCEL-ARC 500, 6045

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part
numbers listed on page i.

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 recognized as
follows:

WARNING

A WARNING gives information regarding
possible personal injury.

2.02 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 attached to the rear panel.
Equipment which does not have a control panel such as
gun and cable assemblies is identified only by the
specification or part number printed on the shipping
container. Record these numbers on the bottom of page
1 for future reference.

2.03 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 concerning damage
claims or shipping errors to the location in your area
listed in the inside back cover of this manual.

Include all equipment identification numbers as described
above along with a full description of the parts in error.

CAUTION

A CAUTION refers to possible equipment
damage.

NOTE

A NOTE offers helpful information concerning
certain operating procedures.

Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number
given in the next section. Include the Owner’s Manual
number and equipment identification numbers.

Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:

http://www.thermalarc.com

Move the equipment to the installation site before un­crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.

August 22, 2005

2-1

EXCEL-ARC 500, 6045

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

On

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

X

%

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Wire Feed Function

Wire Feed Towards
Workpiece With

t1

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld
Mode

Spot Weld Mode

Spot Time

t

Preflow Time

Postflow Time

t2

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc
Welding (GTAW)

Air Carbon Arc
Cutting (CAC-A)

Constant Current

Constant Voltage
Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger
Operation

Press to initiate wirefeed and
welding, release to stop.

4 Step Trigger
Operation

Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.

Burnback Time

t

Disturbance In
Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle Rating­Auxiliary Power

Voltage Input

V

Art # A-04130

August 22, 2005

EXCEL-ARC 500, 6045

2.05 Description

1. General

There are three basic units of the EXCEL-ARC®. The
EXCEL-ARC® 500 (CC), Part Number 100005A-1 & -5,
is a constant-current transformerrectifier type DC welding
machine that provides volt-ampere characteristic curves
that are basically drooping with a slight slope.

The EXCEL-ARC® 6045 (CV), Part Number 100005A-2
& -6, is a constant-voltage transformerrectifier type DC
welding machine that provides volt-ampere characteristic
curves that are basically flat.

The EXCEL-ARC® 6045 (CC/CV), Part Number 100005A­3 & -7, is a combination constant-current and constant­voltage transformer-rectifier type DC welding machine that
provides volt-ampere characteristic curves for each mode
of operation.

Table 2-1 gives input voltage and amperage data for all
part numbers covered by this manual.

2. Recommended Unit Applications

1. Gas metal arc welding (MIG)

2. Flux cored arc welding (with or without gas shielding)

3. Submerged arc welding

4. Electro-slag welding

5. Carbon arc gouging

6. SMAW (Stick welding)

7. GTAW (TIG welding)

3. Wire Feeder Compatibility

Some models of wire feeders will connect onto this unit
with no special preparation. In some cases, however, an
interface must be used and in other instances, some
rewiring must be accomplished. Complete details for these
exceptions will be found in the instruction manual supplied
with the wire feeder.

August 22, 2005

2-3

EXCEL-ARC 500, 6045

2.06 Specifications

PART NO. 100005A-1 PART NO. 100005A-2

ITEM

CC CV
Rated Output
Amperage

Rated Output Voltage 36 Volts 38 Volts 36 Volts 38 Volts

Rated Duty Cycle 60% Duty 100% Duty 60% Duty 100% Duty
Minimum Output 40 Amps 50 Amps @ 13 Volts 40 Amps 50 Amps @ 13 Volts
Maximum Output 500 Amps 600 Amps @ 40 Volts 500 Amps 600 Amps @ 40 Volts

Rated Input Voltage 200/230/460/575 200/230/460/575

Rated Input Amperage 78/67/33/27 70/60/30/24

Input kW 20 kW 22.5 kW
Input kVA 26.3 kVA 30.1 kVA
Input Frequency 60 Hz 60 Hz
Input Phase 3 Phase 3 Phase
Maximum Open Circuit
Voltage
Auxiliary Power 1 kVA –115V, 9 A 1 kVA –115V, 9 A
No Load Input Voltage 200/230/460/575 200/230/460/575

No Load Input
Amperage
No Load kW .9 kW 1.6 kW
No Load kVA 1.94 kVA 2.4 kVA
Power Factor .76 .75
Efficiency 72% 76% 76%

& 100005A-5

EXCEL-ARC® CC

400 Amps 450 Amps 400 Amps 450 Amps

58 58

5.6/4.9/2.45/1.9 6.9/6.0/3.0/2.4

& 100005A-6

EXCEL-ARC® CV

PART NO. 100005A-3

& 100005A-7

EXCEL-ARC® CC/CV

200/230/460/575

70/60/30/24

22.5 kW

30.1 kVA
60 Hz

3 Phase

58

1 kVA –115V, 9 A

200/230/460/575

6.9/6.0/3.0/2.4

1.6 kW

2.4 kVA
.75

2-4

Table 2-1: Volt and Amp Data

August 22, 2005

EXCEL-ARC 500, 6045

31 in.
(787 mm)

29-7/16 in.
(748 mm)

26-1/2 in.
(673 mm)

Weight (CC/CV) - 510 Lbs. (231 kg)
(CC) - 460 Lbs. (209 kg)
(CV) - 455 Lbs. (206 kg)

21-1/4 in.
(540 mm)

Art # A-06058

Figure 2-1: Excel-Arc 500 and 6045 Dimensions and Weight

August 22, 2005

2-5

EXCEL-ARC 500, 6045

11

12

1

8

9

Art # A-06057

2

5

3

7

10

NOTE:
The rear panel rubber
guard used on
Spec #100005A-3

6

14

13

is not shown for clarity
purposes

4

2-6

Figure 2-2: Front and Rear Panel

August 22, 2005

EXCEL-ARC 500, 6045

2.07 Controls and Outlets

Refer to callouts in Figure 2-2.

1. Overload Indicator (100005A-1, -2, -3, -5, -6, -7):
Yellow L.E.D., when lighted, indicates that the machine
has shut down as a result of amperage overload or
rectifier overtemperature (S2).

2. Input Contactor Control (100005A-1, -2, -3, -5, -6, -

7): This toggle switch is the master power switch for
the welding machine, and must be in the ON position
before any other section will operate. The primary
circuit of the control transformer is energized
whenever line voltage is present at the input terminals.
This switch closes the secondary circuit of the control
transformer, energizing the contactor, which energizes
the power transformer. Do not use this switch to start
or stop arc. Start arc with switch ON, break arc, then
turn switch OFF.

3. Local/Remote Output Control Volts/Amps Selector
Switch (100005A-1, -2, -3, -5, -6, -7): Selects either

the output control (Local) or some remote control
device (Remote) to control welding output.

8. Welding Voltage/Amperes Control (CV Units)
(100005A-2, -3, -6, -7): Adjusts arc welding output
and open circuit voltage. On 100005A-1, -3, -5, -7
(CC units): Adjusts the welding current.

9. Volt/Amp Meter and Switch (CV Units) (100005A-2,

-3, -6, -7): A single meter with switch that will readDC
volts when in the V. position or read DC amps in the
A. position.

10.Positive Terminal (+) (CV mode) (100005A-2, -3, -6,

-7): Serves as a connection point for the lead to the
wire feeder when reverse polarity is desired.

11.Positive Terminal (+) (CC mode) (100005A-1, -3, -5,

-7): Serves as a connection point for the lead to the
electrode holder lead for SMAW (stick) or arc gouging
mode of operation when reverse polarity is desired.

12.Negative Terminal (—): Serves as a connection point
for the lead to the workpiece when reverse polarity is
desired.

13.Circuit Breaker — Rated at 15 amps: provides
protection to the 115-volt circuit which includes the
fan and the 115-volt AC power receptacle.

4. 115-V AC Receptacles (100005A-1, -2, -3, -5, -6, -

7): Provides auxiliary power for lights, wire feeders,
water pumps, etc. — 15 amps maximum.

5. CC/CV Selector Switch (CC/CV) (100005A-3, -7):
Selects the welding mode of operation.

6. Feeder Control Receptacle Panel (Automatic) (CV
units) (100005A-2, -3, -6, -7): Amphenol (19-pin)

connector for a remote voltage control type wire
feeder.

7. Arc Force Control (CC/CV Units) (100005A-1, -3, -5,

-7): 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 softstart, smooth arc.

14.Circuit Breaker — Rated at 10 amps: provides
protection to the 24-volt circuit for the wire feeder
and automatic equipment.

NOTE

To obtain opposite welding polarity, simply
reverse the connections to the positive and
negative terminals.

August 22, 2005

2-7

EXCEL-ARC 500, 6045

2.08 Functional Block Diagram

INPUT
POWER

CONTROL
TRANSFORMER

INPUT
CONTACTOR
SWITCH

INPUT
CONTACTOR

CIRCUIT
BREAKER
24 V - 10 AMP
CV MODE

WELDING
TRANSFORMER
T1

CIRCUIT
BREAKER
115 V 15 AMP

RECEPTACLE
115 V

STABILIZER
FILTER
L2

TO AUTOMATIC
EQUIPMENT

Art # A-06059

19-PIN
GUN SWITCH
RECEPTACLE

AMPHENOL BOARD

OVERLOAD
THERMOSTAT

PHASE SIGNAL

PC CONTROL
BOARD

OUTPUT
SCR
SCR1 - SCR6

STABILIZER
FILTER
L1

Figure 2-3: Functional Block Diagram for Excel-Arc 500 and 6045

2-8

August 22, 2005

EXCEL-ARC 500, 6045

2.09 Duty Cycle

Duty cycle is the percentage of each ten-minute period of
time that the welding machine may be operated under
rated load conditions. For example, a duty cycle of 60%
means that the machine can be operated at rated load for
an average of 6 minutes of each 10 minute period of
operation. During the remaining 4 minutes, the machine
must idle to permit proper cooling. Figure 3-3 enables
the operator to determine the duty cycle at various welding
amperages.

750

650

550

Weld Amperes

450

40 50 60 80 100

% Duty Cycle

Art # A-06060

DUTY CYCLE
FOR EXCEL-ARC
500 AND 6045

2.10 Volt-Amp Curves

70

60

50

40

30

LOAD/VOLTS (DC)

20

10

0

0 100 200 300 400 500 600 700 800 900

70

60

50

40

30

LOAD/VOLTS (DC)

EXCEL-ARC (CC) POSITION

LOAD/AMPS (DC)
EXCEL-ARC 500 AND 6045 CC/CV UNIT
INPUT 230V. MIN/MAX OUTPUT

EXCEL-ARC (CV) POSITION

Art # A-06061

Figure 2-4: Duty Cycle Chart

20

10

0 100 200 300 400 500 600 700 800 900

LOAD/AMPS (DC)
EXCEL-ARC 6045 CC/CV UNIT
INPUT 230V. MIN/MAX OUTPUT

Figure 2-5: Volt/Ampere Characteristic Curves

August 22, 2005

2-9

EXCEL-ARC 500, 6045

2-10

August 22, 2005

EXCEL-ARC 500, 6045

SECTION 3:

INSTALLATION

3.01 Location

For best operating characteristics and longest unit life,
take care in selecting an installation site. Avoid locations
exposed to high humidity, dust, high ambient temperature,
or corrosive fumes. Moisture can condense on electrical
components, causing corrosion 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 minimum of 12 inches
(305 mm) of free air space at both front and rear of the
unit. Make sure that the ventilator openings are not
obstructed.

3.02 Grounding

The frame of this welding machine should be grounded
for personnel safety, and to assure operation of the
overcurrent protection. The grounding method, and the
equipment grounding conductor size and type shall
conform to local and national codes.

If flexible power cable is used, use a cable assembly which
includes the equipment grounding conductor. 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 grounding
assists in providing protection against line voltage
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 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
3-1 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.

For the National Electrical Code, the equipment grounding
conductor shall be green, green with a yellow stripe, or
bare.

20-30 lbs. (9.1-13.6 kg) Soil Treating Material
(copper sulphate, magnesium sulphate or rock salt)
placed in circular trench and covered
with earth.

18 inches
(457 mm)
Approx.

Ground Rod

Not less than 8 Ft. (2438 mm)

Grounding Conductor

Fasten Grounding
Conductor to the rod
with an approved
ground clamp.

Approx. 1 Ft. (305 mm)

Be sure to replace the cabinet top to assure
adequate internal ventilation and prevent
component failure.

Art # A-06062

Fasten Grounding Conductor
to the rod with an approved
ground clamp.

Not less than 8 Ft.
(2438 mm)

6 inches (152 mm) Approx.

CAUTION

Grounding
Conductor

Removable
Cover

Floor

Ground
Rod

Soil
Treating
Material

OUTSIDE GROUND INSIDE GROUND

August 22, 2005

Figure 3-1: Grounding

3-1

EXCEL-ARC 500, 6045

COPPER LINE WIRE

COPPER GROUNDING

CONDUCTOR MIN. SIZE

IN

SIZE* LINE

FLEXIBLE

CABLE

RATED LOAD

VOLTS

200 81 100 No. 4 No. 2 No. 8
230 71 100 No. 6 No. 6 No. 8
460 35.5 40 No. 8 No. 6 No. 10
575 28 40 No. 10 No. 8 No. 10

* Conductor size shall be modified as required for line voltage drop and ambient temperature. Sizes listed for con

duit installation are based on 90° C conductor insulation, designated as FEP, FEPB, RHH, and THHN.

AMPS

APPROX. LINE

FUSE SIZE

CONDUIT

Table 3-1: Recommended Wire and Fuse Sizes

3.03 Internal Wiring Check

Refer to the product identification plate (nameplate) on
the welding machine’s rear panel to determine 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 connections
against instructions on Voltage Changeover Diagram
supplied with this manual. If necessary, rearrange internal
wiring and/or link connections.

WARNING

ELECTRIC SHOCK CAN KILL. Open the
disconnect switch, or breaker, and determine
that no voltage is present, before connecting
wires between welding machine and power
supply.

3.04 Connecting Welding Machine to
Line Voltage

The input power should be connected to the unit through
a fused disconnect switch, or other suitable disconnecting
means furnished by the user. A hole is provided in the
rear panel of the machine, near to the input connections,
for the entry of the input conductors.

Table 3-1 provides minimal information for selection of
line conductors, fuses, and the equipment grounding
conductor. This information is from the National Electrical
Code NFPA 70-1981 Edition. Install this equipment per
the latest edition, available from the National Fire
Protection Association, 470 Atlantic Avenue, Boston, MA

02210.

Connect the three-phase line leads to terminals L1, L2,
and L3 on the line contactor inside the welding machine
cabinet.

CAUTION

The method of installation, conductor size, and
overcurrent protection 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.

3-2

August 22, 2005

EXCEL-ARC 500, 6045

Art # A-06063

CUSTOMER'S
INPUT CABLE
CONNECTIONS

SHOWN CONNECTED
FOR 200V

460V 395V
500V 230V
575V 200V

BK
WT

COM.

CONTROL TRANSFORMER
MOUNTS BELOW CONTACTOR

Place links in proper position based on input voltage value.

GROUND CONNECTION
ON LIFTING YOKE

INPUT LINE CONTACTOR
MOUNTED

L1

ON LIFTING YOKE

L2
L3

TO CONTACTOR

CAUTION SEE V.C. DIAG.
FOR CONTROL TRANS.
CONNECTIONS

B1

B2

460V

575V

L1

A5

200V

230V

B3

B4

367228-11

A4

200V

C1

575V

A3

230V

L2

A2

460V

575V

C5

A1

200V

230V

L3

460V

C2

C4

C3

B5

August 22, 2005

Figure 3-2: Input Voltage Connection & Changeover

3-3

EXCEL-ARC 500, 6045

3.05 Welding Leads

Use Table 3-2 for selection of the proper size copper welding leads.

TOTAL LENGTH OF LEAD CIRCUIT IN FEET (AND METERS)

(ELECTRODE LEAD PLUS WORK LEAD) Welding Current

Amperes

100 #4 #4 #4 #3 #2
150 #3 #3 #2 #1 #1/0
200 #2 #2 #1 #1/0 #2/0
250 #1 #1 #1/0 #2/0 #3/0
300 #1/0 #1/0 #2/0 #3/0 #4/0
350 #1/0 #1/0 #3/0 #4/0 #4/0
400 #2/0 #2/0 #3/0 #4/0 2 — #2/0
450 #2/0 #2/0 #4/0 2 — #2/0 2 — #3/0
500 #3/0 #3/0 #4/0 2 — #2/0 2 — #3/0

50 Feet

(15.2 M)

100 Feet

(30.5 M)

150 Feet

(45.7 M)

200 Feet

(61.0 M)

250 Feet

(76.2 M)

Table 3-2: Length of Lead Circuit

* 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.

3-4

August 22, 2005

3.06 Installation Diagram

EXCEL-ARC 500, 6045

Negative
Terminal

Base Metal

Welding
Current/Voltage
Control

Art # A-06064

Positive (CV) Terminal
To Wire Feeder
(Shown For Reverse
Polarity-DCEP)

Stick

Work Piece Should
Be Grounded

Positive (CC) Terminal

NOTE:
The rear panel rubber guard
used on Spec # 100005A-3

To Automatic Control

is not shown for clarity purposes.

NOTE: To change polarity, reverse connections on power
output terminals on power source.

Figure 3-3: Installation Diagram

August 22, 2005

3-5

EXCEL-ARC 500, 6045

3-6

August 22, 2005

EXCEL-ARC 500, 6045

SECTION 4:

OPERATION

4.01 General

Before operating this system, be sure that all installation
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 components used with
this system before operating.

A thermostatically controlled fan motor is standard on
this unit. The fan motor starts and stops automatically
when a predetermined temperature has been reached.

4.02 Preweld Operation

1. Connect welding leads to terminals on front panel.

4.03 SMAW (Stick) Welding, Carbon Arc
Gouging

(100005A-1, -3, -5, and -7)
Refer to Section 2.06 and Figure 2-1 for controls (numbers

in parenthesis refer to callouts on Figure 2-1).

1. On 100005A-3, and -7 set the CC/CV selector switch

to CC position.

2. Hold electrode clear of work. Be sure the Remote-

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.

4.04 Welding, Semiautomatic or
Automatic

Refer to Figure 2-1 for controls.

WARNING

Disconnect line voltage from the unit before
making any connections inside unit. Turn off
fused disconnect switch that supplies power
to welding machine, and remove its fuse.
ELECTRIC SHOCK can kill! Do not touch live
electrical parts, including the output terminals
and electrode.

2. If used, connect remote control wire assembly and
gun switch to welding machine. Connect feeder
receptacle to wire electrode feeder system.

3. Refer to other manuals for component connections.

4. Set Output Control to desired value.

5. Set the remote/local control switch in the desired
mode.

1. On 100005A-2, -3, -6, and -7 set Remote/Local Output
Control Switch (3) to LOCAL.

NOTE

Set Output Control Switch (3) to REMOTE
when using a feeder which controls the
voltage, and remote voltage control is desired.

2. On 100005A-3 and -7 set the CC/CV Selector Switch
to CV position.

3. Place Input Contactor Control Switch (2) in ON position
(Power ON).

4. Inch wire electrode to position over work; see related
owner’s manuals.

5. Depress gun switch trigger and strike arc.

August 22, 2005

4-1

EXCEL-ARC 500, 6045

4.05 Overload Indicator

This unit is equipped with an overload indicator - yellow
L.E.D. When lighted, indicates that the machine has
shutdown as a result of amperage overload 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 repeatedly or often, then investigate for the cause of
overload 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:

4.06 Configuration Settings

The following settings (Table 4-1) can be made by jumper
plug changes on the main control board. Explanation of
settings:

1. Thewire sharpening feature is used to reduce the size
of the ball left on the end of the wire at the completion
of a weld. The wire sharpening circuit will reduce the
voltage below the value required to maintain an arc,
but sufficient to burn off the end of the wire. Arc
starting will be improved by reducing the size of the
ball left on the wire.

NOTE

In order for this circuit to work properly the
MIG gun must be held in place as the trigger
is released. If the MIG gun is pulled back as
the trigger is being released, the circuit will
not have the opportunity to reduce the size of
the ball left on the wire.

1) Exceeding current rating and/or duty cycle rating of
machine.

2) Blocked or restricted air inlets or outlets to machine.

JP1 - Wire Sharpening: Jumper in UP position

ON
(1-2 shorted)
Jumper in DOWN

OFF

position (2-3 shorted)

Factory setting is wire sharpening ON.

NOTE: For wire sharpening to work, "Burnback"

JP5 - Burnback: Jumper in UP position

OFF
(1-2 shorted)
Jumper in DOWN

ON

position (2-3 shorted)

Factory setting is burnback ON.
JP7 - MIG Hot Start: Jumper in UP position

OFF
(1-2 shorted)
Jumper in DOWN

ON

position (2-3 shorted)

Factory setting is hot start OFF.

2. The burnback feature willmaintain contactor closure
for approximately .25 seconds after the gun trigger is
released. The primary function of this feature is the
prevention of wire sticking to the weld puddle
uponcompletion of aweld. This is especially important
at higher wire feed speeds with feeders that have a
tendency for wire coasting. If wire sharpening is OFF
then the arc voltage during the burnback time will be
at the preset weld voltage. If wire sharpening is ON
then the arc voltage will be reduced to a lower value
to reduce the ball on the end of the wire.

3. The hot start feature provides a higher open circuit
voltage for the initial arc strike in MIG. The primary
purpose of this feature is to provide more energy
during the start for larger diameter wires athigh wire
feed speed. This feature if enabled, is only active for
MIG.

Table 4-1: Configuration Settings

4-2

August 22, 2005

EXCEL-ARC 500, 6045

SECTION 5:

SERVICE

5.01 Replacing SCRs

Replacing an SCR is a critical task but it can be
accomplished in the field by following the instructions in
the Detailed Troubleshooting section of the
Troubleshooting chapter of this manual.

5.02 Lubrication

The fan motor incorporates a sleeve bearing and therefore
will need periodic lubrication. The following table will
furnish a recommended guide to the frequency of this
lubrication.

Type of Duty

Light (up to 6 hrs./day) Every 12 months

Moderate (7 to 15

hrs./day)

Heavy (16 to 24

hrs./day)

Lubrication

Interval

Every 6 months

Every 3 months

5.03 Inspection and Cleaning

For uninterrupted, satisfactory service from this welding
machine, it is necessary to keep the machine clean, dry,
and well ventilated. At least every three months, or more
often as necessary, wipe and blow out all dirt from the
machine’s internal components, 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 insulation on wiring.

CAUTION

The flow of air through the welding machine
is carefully directed by baffles. Never operate
the welding machine with any of the side or
top panels removed or open, as serious
damage to the rectifiers might result.

Table 5-1: Lubrication

NOTE

Apply 1-12 drops of 20W non-detergent oil at
each end of bearing.

August 22, 2005

5-1

EXCEL-ARC 500, 6045

5.04 Troubleshooting Guide

General:

(Also refer to Troubleshooting in wire feeder and gun
manuals.)

1. Welding machine will not start.

A. Power switch OFF.

1) Place power switch in ON position.

B. Power lines dead.

1) Check voltage.

C. Broken power lead.

1) Repair.

D. Wrong line voltage.

1) Check power supply.

E. Incorrect input power connections at welding

machine.

1) Check connections against wiring diagram.

F. Open circuit to power switch or control

transformer.

1) Repair. Check for broken wire or loose
connections at terminals.

4. Contactor operates and blows link fuses.

A. Wrong line voltage.

1) Check nameplate of welding machine for
line voltage to use; check line voltage.

B. Links on voltage changeover board incorrectly

connected.

1) Check Voltage Changeover diagrams for
link positions; connect links correctly. See
Diagrams chapter.

C. Line fuse too small.

1) Install proper size fuse.

D. SCR failure or shorted flyback diode.

1) Refer to Detailed Troubleshooting
Instructions.

E. Short circuit in primary connections.

1) Remove short circuit.

F. Transformer failed.

1) Repair or replace.

5. Unit delivers welding current but soon shuts down
(Thermal overload trips).

A. Welding machine overloaded.

G. Fuse on control transformer blown.

1) Remedy cause. Replace fuse.

2. Line contactor fails to close.

A. Defective NVR coil.

1) Replace.

B. Mechanical obstruction on contactor.

1) Remove.

C. Broken leads at line contactor.

1) Repair.

3. Contactor chatters.

A. Line leads too small.

1) Use larger leads.

B. Low line voltage.

1) Check line voltage.

1) Reduce load, overload can be carried only
for a short time.

B. Duty cycle too high.

1) Do not operate continually at overload
currents.

C. Power leads too long or too small in cross

section.

1) Replace with larger diameter cable.

D. Ambient temperature too high.

1) Operate at reduced loads when
temperature exceeds 104° F (40° C).

E. Ventilation blocked.

1) Check air intake and exhaust openings to
be unobstructed.

F. Fan not operating after machine is loaded

down.

1) Check fan thermostat. Check bearings,
disconnect leads and apply motor
nameplate voltage to test.

5-2

August 22, 2005

EXCEL-ARC 500, 6045

6. Solid-state contactor operates, but welding machine
will not deliver welding current, and open circuit
voltage is present at the output when gun switch is
depressed.

A. No ground connections at work.

1) Make connections.

B. Welding cables not connected.

1) Make connections.

7. Voltage/amps dial does not control welding voltage.

A. Potentiometer burned out.

1) Replace.

B. Loose connections in voltage control circuit.

1) Check connections.

C. Control circuit board failure.

1) Replace control board.

8. Fan not operating (also see causes and remedies
under “Welding machine will not start”).

10.Abnormal current fluctuation, voltage nearly
constant.

A. Irregular wire feed speed.

1) See welding head manual.

B. Inadequate shielding of arc by flux or gas.

1) Increase shielding by trial and error. See
welding head manual.

C. Wire feed rate too slow.

1) Increase wire feed. See wire burn-off rate
charts.

D. Too much shielding gas.

1) Decrease by trial and error. See welding
head manual.

E. Loose cable connections.

1) Check for overheated connections and
tighten.

F. Welding contact tube (tip) on wire feeder

makes poor contact with electrode.

NOTE

Fan will not operate until rectifier heats up.

A. Motor failed.

1) Replace or repair.

B. Broken lead or connection to fan motor.

1) Repair wiring.

C. Blown circuit breaker on rear panel of welding

machine.

1) Reset circuit breaker. 115-volt receptacle
may be overloaded.

9. Operator gets shock when welding machine case,
ground cable, work, or work table is touched.

A. Case of welding machine not grounded.

1) Ground welding machine case.

1) Check contact tube hole size and replace
with proper tube.

11.Contactor fails to open.

A. Contactor contacts sticking.

1) Clean contacts.

12.Very noticeable, rough, sputtering arc. Loss of
control and burnback. Minor starting problems.

A. Control circuit board failure.

1) Replace Control P.C. Board.

B. Work table and work not grounded.

1) Ground work and work table to plant
ground.

August 22, 2005

5-3

EXCEL-ARC 500, 6045

5.05 Detailed Troubleshooting
Instructions

· Is the shielding gas flow correct?

· Is the line voltage correct for the machine, blown
fuses?

The first step in troubleshooting this power source should
be to eliminate any external equipment or conditions as
the source of the problem. The following can be used as
a general guideline for troubleshooting:

· Are any cables frayed or damaged or connections
loose?

· Is the gun liner worn or plugged?

· Is the air flow in and around the machine
unobstructed?

Once external conditions have been eliminated as the
source of the problem the following guide can be used
for specific checks on the machine. As in the case of all
electrical equipment, loose connections can often be the
cause of malfunction. Examine the machine for any loose
or broken connections internally especially connections

· Are the drive rolls tight?

· Does the wire feed smoothly, is the gun cable
kinked?

· Check for worn contact tubes (tips)?

· Is the machine set correctly, or has a setting been
changed?

Test Point

R192 to TP19 17 VAC AC voltage input to board
R193 to TP19 17 VAC AC voltage input to board
R194 to TP19 17 VAC AC voltage input to board
R195 to TP19 17 VAC AC voltage input to board
R196 to TP19 17 VAC AC voltage input to board
R197 to TP19 17 VAC AC voltage input to board

TP16 to TP19 +18 VDC Power Supply
TP17 to TP19 -15 VDC Power Supply
TP18 to TP19 +15 VDC Power Supply

TP11 to TP19 +10 VDC Reference voltage
TP1 to TP19 0 VDC (for no Arc established) Arc Established signal for 1>30 Amps TP1 = +14 VDC
TP2 to TP19 +5.4 VDC for CV Vfb = Varc/10
+6.2 VDC for CC
TP3 to TP19 +8.8 VDC for CV Firing angle control signal
+13.5 VDC for CC
TP4 to TP19 0 VDC (for gun switch on) Gun Switch signal
TP6 to TP19 0 VDC IFB = 1V per 100 Amps
TP7 to TP19 -9.56 VDC Negative reference voltage
TP8 to TP19 +4.4 VDC for CV SCR gate signal
+11.65 VDC for CC
TP9 to TP19 +4.4 VDC for CV SCR gate signal
+11.65 VDC for CC
TP10 to TP19 +4.4 VDC for CV SCR gate signal
+11.65 VDC for CC
TP12 to TP19 +14.6 VDC SCR gate signal
TP13 to TP19 +14.6 VDC SCR gate signal
TP14 to TP19 +14.6 VDC SCR gate signal

Expected Reading

to the control circuit board. To gain access to the control
board, remove the control panel from the front panel of
the power source.

1. Control Board 830267:

All readings taken at nominal line voltage with maximum
OCV on the machine.

Remark

5-4

Table 5-2: Test Points

August 22, 2005

EXCEL-ARC 500, 6045

Art # A-06065

Force Gage, shown in
position (903878)

Clamp (405140)

Heat Sink

Heat Sink

2. SCR Malfunction:

A failed or defective SCR will normally result in one of
two situations.

1. SCR shorted: Normally results in blown line fuse and
shorted output on the machine. To isolate which SCR
has failed it will be necessary to disconnect the
transformer leads from the SCR heatsinks and check
each SCR individually with a VOM.

2. SCR open: Normally results in a reduction in output
voltage and/or an erratic or unstable arc. The same
effect will be caused by the lack of a gate drive signal
to an SCR. Check all gate leads from the control board
and suppressor board to the SCRs. The following table
gives typical values for open circuit voltage with one
or more SCRs not firing.

NOTE

For CV machines disconnect cable #103 from
the capacitor bank assembly and insulate the
lug to prevent it from touching chassis, prior
to measuring open circuit voltage. These
values were recorded at nominal line voltage
with voltage/current control set to maximum.

CC Mode CV Mode
All SCRs firing 61 VDC 48 VDC
1 SCR not firing 55 VDC 46 VDC
2 SCR not firing 48 VDC 43 VDC
3 SCR not firing 41 VDC 39 VDC

3. Mounting Procedure for SCRs:

1. Thoroughly clean heat sink surface to eliminate any
dirt or contamination.

2. Apply a thin coat of Alcoa #2 compound to cleaned
surface. Alcoa #2 is available from Thermal Arc, part
number 903870.

3. Positively locate the SCR in place in the heat sink. A
small spring pin in the extruded heat sink will locate
the SCR.

4. Place the clamp in position with the bolts through the
holes in the heat sink, and proceed in following
manner.

5. Tighten the nuts evenly until finger tight.

6. Tighten each bolt in 1/4 turn increments using correct
size hex key.

7. 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 deflection
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. All clamps to be set at 4° mark. This corresponds to
the VE3000-VE2500 section on the gauge label.

Table 5-3: SCRs

The best way to isolate the particular SCR which is
malfunctioning is as follows. Refer to Connection Diagram
while inspecting the unit. On the output rectifier there are
gate leads coming off of the SCRs. Each of these leads
are connected to a quick-disconnect terminal on the
suppressor board. Turn the voltage control pot to
maximum. Disconnect one lead to one SCR and observe
the OCV. If the OCV drops to a lower value, this indicates
that this particular SCR is working properly.

this lead

and do the same thing with the remaining leads
until you discover which disconnection does
the OCV to drop to a lower level. This is the malfunctioning
SCR. See Mounting Procedures for SCRs which follows.

August 22, 2005

Reconnect

not

cause

Figure 5-1: SCR with Force Gauge Shown in Position

5-5

EXCEL-ARC 500, 6045

To Calibrate Force Gauge:

Art # A-06066

Less than
rated force.
Tighten nuts
alternately 1/4
turn at a time
until points
coincide.

Top edges lined up

Correct rated
force.

Excessive
force. Loosen
both nuts and
start over. Never
adjust force by
backing off the
nuts. Friction
will produce a
false reading.
Always start
from Step 1.

Figure 5-2: Adjusting Nuts to Correct 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.

o

o

3

4

Art # A-06067

True flat surface
(or straight edge)

If the calibration edges do not line up, calibrate
the gauge by filing the bottom contact points.

Figure 5-3: Force Gauge Calibration

5-6

August 22, 2005

SECTION 6:

PARTS LIST

6.01 Equipment Identification

All identification numbers as described in the Introduction
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.

6.02 How To Use This Parts List

The Parts List is a combination of an illustration 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
for commercially available hardware, bulk items such as
wire, cable, sleeving, tubing, etc., and permanently
attached items which are soldered, riveted, or welded to
other parts. The part descriptions may be indented to show
part relationships.

EXCEL-ARC 500, 6045

To determine the part number, description, quantity, 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.

Part Number Application Code

Excel-Arc 500 (CC) 100005A-1 A
Excel-Arc 6045 (CV) 100005A-2 B
Excel-Arc 6045 (CC/CV) 100005A-3 C
Excel-Arc 500 (CC) 100005A-5 D
Excel-Arc 6045 (CV) 100005A-6 E
Excel-Arc 6045 (CC/CV) 100005A-7 F

August 22, 2005 6-1

EXCEL-ARC 500, 6045

12

39

17

18

36

18

20

20

8

19

13

15

35

14

16

11

29

22

7

10

Art # A-06068

32

31

30

28

27

34

33

26

2

3

7

1

5

4

25

21

24

23

6

8

9

6-2

Figure 6-1: Parts 1

August 22, 2005

EXCEL-ARC 500, 6045

Item

No

Part

Number

Description

Qty per

Assy

Application

Code

100005A-1 Excel-Arc Welder® - 500 CC, 60 Hz 1 A
100005A-2 Excel-Arc Welder® - 6045 CV, 60 Hz 1 B
100005A-3 Excel-Arc Welder® - 6045 CC/CV, 60 Hz 1 C
100005A-5 Excel-Arc Welder® - 500 CC, 60 Hz 1 D
100005A-6 Excel-Arc Welder® - 6045 CV, 60 Hz 1 E

100005A-7 Excel-Arc Welder® - 6045 CC/CV, 60 Hz 1 F
1 830698-1 . Panel - Control 1 All
2 204212 . Board - PC, Digital Display 1 BCEF
3 204600-2 . Spacer 4 BCEF
4 409000-1 . Bezel - Meter 1 BCEF
5 204053-11 . Panel - Control Module 1 AD

204053-8 . Panel - Control Module 1 BE

830207 . Panel - Control Module 1 CF
6 406806-3 . Knob - Control 1 ACDF
7 401428-8 . Potentiometer - Volt/Amp Ctl, Arc Force 2 ACDF

401428-8 . Potentiometer - Volt/Amp Ctl, Arc Force 1 BE
8 405365-1 . Switch - Toggle, ON/OFF 2 All
9 408850-5 . Knob - Black 1 All

10 402682 . Switch - Toggle, RMT/LC1 1 All
11 830710-1 . Light - Indicator 1 All
12 204052-6 . Panel - Output, Blank 1 ABDE
13 204052-5 . Panel - Output, Terminal 2 ABDE

204052-5 . Panel - Output, Terminal 3 CF

14 400614-1 . Nut - 1/2-13, Hex, Flanged 2 ABDE

400614-1 . Nut - 1/2-13, Hex, Flanged 3 CF

15 5CW-974 . Bus - Cable Stud 2 ABDE

5CW-974 . Bus - Cable Stud 3 CF

16 5CW-975 . Bushing - Insulator 2 ABDE

5CW-975 . Bushing - Insulator 3 CF

17 No Number . Screw -1/2-13 x 3/4, HHC, ST. 2 ABDE

No Number . Screw -1/2-13 x 3/4, HHC, ST. 3 CF

18 No Number . Washer - LK, Std, ST. 1/2 4 ABDE

No Number . Washer - LK, Std, ST. 1/2 6 CF

19 5CW-976A . Washer - Insulator Stud 4 ABDE

5CW-976A . Washer - Insulator Stud 6 CF

20 No Number . Washer - FL, ST. 1/2 4 ABDE

No Number . Washer - FL, ST. 1/2 6 CF

August 22, 2005 6-3

Table 6-1: Parts List for Figure 6-1

EXCEL-ARC 500, 6045

12

39

17

18

36

18

20

20

8

19

13

15

35

14

16

11

29

22

7

10

Art # A-06068

32

31

30

28

27

34

33

26

2

3

7

1

5

4

25

21

24

23

6

8

9

6-4

Figure 6-1: Parts 1 (continued)

August 22, 2005

EXCEL-ARC 500, 6045

Item

No

Part

Number

Description

Qty per

Assy

Application

Code

21 830627 . Board - PC, Control 1 All
22 171086-1 . Stand-off - PC Board 8 All
23 W-9956 . Knob - Switch, Range 1 CF
24 367880 . Sleeve - Sw. 1 CF
25 400562-24 . Spring - Compression 1 CF

367260-1 . Switch - Range 1 CF
26 405478 . . Rivet 1 CF
27 W-11291-3 . . Nut - Speed, Push on 1 CF
28 410602-1 . . Bracket 1 CF
29 410589 . . Contact - Stationary 1 CF
30 12RT-238 . . Contact - Movable 2 CF
31 410541 . . Spring 1 CF
32 910061 . . Guide 1 CF
33 W-9549-21 . . Rod - Threaded, 1/4 Dia. 1 CF
34 No Number . . Nut - 1/4-20 SCR, MH, Hex, ST 1 CF
35 830040-1 . . Box - Control Board 1 All

— 204247-1 . Cable - Ribbon, Meter 1 BCEF

36 351505 . Screw -1/2-13 x 1-3/4, HHC, ST. 2 ABDE

351505 . Screw -1/2-13 x 1-3/4, HHC, ST. 3 CF
37 . Delete
38 . Delete
39 No Number . Screw -#6-32 x 1/4 Rd. Hd. MH. ST. 2 ABDE

. Screw -#6-32 x 1/4 Rd. Hd. MH. ST. 3 CF

August 22, 2005 6-5

Table 6-1 (continued): Parts List for Figure 6-1

EXCEL-ARC 500, 6045

24

11

26

27

25

12

19

20

23

33

22

14
13

21

29

28

Art # A-06069

30

18

34

33

15

5

4

3

2

6

10

6-6

32

31

1

Figure 6-2: Parts 2

9

8

7

August 22, 2005

EXCEL-ARC 500, 6045

Item

No

Part

Number

Description

Qty per

Assy

Application

Code

1 204054-1 . Base - Welder 1 All
2 204124 . Transformer - Power 1 BCEF

830313 . Transformer - Power 1 AD
3 367228-11 . . Board - Voltage Changeover 1 All
4 CW-811 . Link - Voltage Changeover 3 All
5 204301-1 . Bracket - Mtg. 2 All
6 204194 . Choke -Filter, CC 1 ACDF
7 204193 . Choke -Filter, CV 1 BCEF
8 204061-2 . Door 1 All
9 203453 . Hinge - Door 2 All

10 830038-1 . Panel - Side, Left 1 ABC

830038-5 . Panel - Side, Left 1 DEF

11 406358-4 . Resistor - Fixed, 175 W 1 BCEF
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 ABC

830037-5 . Panel - Side, Right 1 DEF

204099-1 . Capacitor - Assembly 1 BCEF

19 204152 . . Bus - Capacitor 2 BCEF
20 405278-15 . . Capacitor 5 BCEF
21 204301-1 . . Bracket - Mtg. 2 BCEF
22 409870 . . Washer - Insulating 4 BCEF
23 409869 . . Bushing - Insulating 4 BCEF
24 830039-1 . Box - Contactor 1 All
25 405402 . Contactor 1 All
26 406392-2 . Transformer - Control 1 All

27

W-11166­11

. Fuse - 1/2 Amp

1 All

28 830036-1 . Panel - Top 1 ABC

830036-4 . Panel - Top 1 DEF

29 12CW-2170 . Boot -Lifting Eye 1 All
30 204036 . Label - Precautionary 1 All
31 402900 . Terminal - Quick Connect 2 ABDE

402900 . Terminal - Quick Connect 3 CF

August 22, 2005 6-7

Table 6-2: Parts List for Figure 6-2

EXCEL-ARC 500, 6045

24

11

26

27

25

12

19

20

23

33

22

14

13

21

29

28

Art # A-06069

30

18

34

33

15

5

4

3

2

6

10

6-8

32

31

1

7

Figure 6-2: Parts 2 (continued)

9

8

August 22, 2005

EXCEL-ARC 500, 6045

Item

No

Part

Number

Description

Qty per

Assy

Application

Code

32 368705-36 . Capacitor - W/Leads 2 ABDE

368705-36 . Capacitor - W/Leads 3 CF

Not

—

Illustrated
830116 . Label - Frame Ground

33
34 408891

. Label - Warning

2 All
1 All

Not

—

Illustrated
204204 . Label - Voltage Changeover

—

1All

— 406484 . Label - Fuse 1 All

Table 6-2 (continued): Parts List for Figure 6-2

August 22, 2005 6-9

EXCEL-ARC 500, 6045

24

4

Art # A-06070

6-10

Figure 6-3: Parts 3

August 22, 2005

EXCEL-ARC 500, 6045

1

Item

No

1
2
3
4

5
6
7
8
9

10
11
12
13
14
15
16
17
18
19
20
21
22
23

Part

Number

Description

830173-2 . Board P.C. - Amphenol

. Deleted

. Deleted
203627-7 . Breaker - Circuit, 10 A
203627-1 . Breaker - Circuit, 10 A
. Delete
402670 . Receptacle - 115 V.
366826-1 . Suppressor - Assembly
830212-1 . Panel - Rear
8RT-609 . Blade - Fan
369650-1 . Shroud - Fan
369640-1 . Bracket - Mtg. Fan
12TW-595-

. Motor - Fan
369641 . Insulator - Mtg.
369639 . Heat Sink - Rectifier
369642 . Heat Sink - SCR
405139 . Rectifier - Silicon
16DA-954-1 . Pin -Spring
405140-1 . Clamp - Mtg.
204210 . Board - Suppressor
402832-3 . Diode - Flyback
404044-6 . Thermostat - Fan
404044-3 . Thermostat - Overload
367732 . Shunt

Qty per

Application

Assy

1 BCEF

1 AD
2 BCEF

1 All
1 All
1 All
1 All
1 All
2 All
1 All
2 All
1 All
6 All
6 All
6 All
6 All
2 All
1 All
1 All
1 All
1 All

24 11574253 . Guard, Rubber 1 C

204038-1 . Cable - Ribbon, Amphenol

—

903914-1 . Cap - Protective

—

903914-2 . Cap - Protective

—

403091-14 . Plug - Hole

—

170919-2 . Plug - Hole

—

1 BCEF
1 BCEF
1 BCEF
1 All
1 AD

Not

—

Illustrated

Code

August 22, 2005 6-11

Table 6-3: Parts List for Figure 6-3

EXCEL-ARC 500, 6045

6-12

August 22, 2005

APPENDIX 1: GENERAL INFORMATION

• Note the model and specification number shown on the equipment nameplate.

• Locate these numbers in the model and specification number columns below.

• Use only those diagrams and instructions that are applicable.

EXCEL-ARC 500, 6045

MODEL NO.

EXCEL-ARC® 500

EXCEL-ARC® 6045

PART

NUMBER

100005A-1
100005A-5
100005A-2
100005A-6
100005A-3
100005A-7

CONNECTION

DIAGRAM

830700 Sheet 1 & 2 830700 Sheet 3

830700 Sheet 4 & 5 830700 Sheet 6 204203

830700 Sheet 7 & 8 830700 Sheet 9 204203

SCHEMATIC

DIAGRAM

VOLTAGE

CHANGEOVER

DIAGRAM

204203

August 22, 2005

A-1

EXCEL-ARC 500, 6045

APPENDIX 2: EXCEL-ARC 500 CONNECTION DIAGRAM (1 OF 2)

(100005A-1, 100005A-5)

CONTACTOR & CONTROL TRANSFORMER WIRING (400 V)

789101112

H

G

F

E

D

11

11

10

11

REAR PANEL

42 BLK

10

42

29

35 WHT

36 BLK

RED

BLK

DS1

Y

1

5

TOP OF FRONT PANEL

41 WHT

42 BLK

R1

27 WHT

28 GRY

39

3

YEL

2

22 VLT

37

40 BLK

COIL

K1

38 BLK

395V
230V
200V

COM.

T2

F1

LOOKING FROM LEFT SIDE OF MACHINE

460V

500V
575V

L3

L2

L1

S1

33 YEL

34 RED

11

10

37 BLU

41 WHT

33 YEL

38

21 VLT

14 BRN

38

37 BLU

39 BLK

34 RED

28 GRY

32

32

5

10

10

2

37

43 WHT

S2

23 LT BL

39

39

88 BLK

11

32

2

39

19 ORN

60 BLK

GROUND SCREW (LINE)

39

44 YEL

3

4

6

12

PE

YOKE

MOUNTED ON REAR

OF BASE

30 BLU

15

31 ORN

30

13

R2

14

100

TOP

X1 (A)

7 BRN

X2 (B)

X2 (C)

8 WHT

BOT.

9 BLK

10 YEL

*
*

17
34

TOP

11 RED

12 ORN

42

30

42

TOP

42

30
42

BOT.

13

42

30

42

C1

C3

32 LT BL

29 RED

37

PRIMARY LEADS
A1 THRU A5 TO
CHANGEOVER BOARD

PRIMARY LEADS
B1 THRU B5 TO
CHANGEOVER BOARD

PRIMARY LEADS
C1 THRU C5 TO

37

CHANGEOVER BOARD

X2 (A)

A

X3 (A)

15

X1 (B)

B

T1

C

X3 (B)

X1 (C)

X3 (C)

X4
X5

X6
X7

30 BLU

7

C

9

B

NOTE 1: COMPONENT IDENTITY NO.S 7, 8, 9, 12, 14, 18, 24 AND 35 ARE

A

NOT USED ON THIS DRAWING.

Art # A-06071

12 11 10 9 8 7

A-2

L1

BLANK

8

PANEL

16

101

17

GROUND SCREW

ON FRONT OF YOKE

NOTE: LEADS X4 & X5 ARE NOT USED

*

ON CONSTANT CURRENT UNITS

LOOKING DOWN ON BASE

90 WHT
91 WHT
92 WHT

X6

50 WHT

47 WHT

46 GRN-YEL

31
43
46

15

26

33

33

BOT.

18

August 22, 2005

456 123

EXCEL-ARC 500, 6045

FACING SUPPRESSOR BOARDS

FROM LEFT SIDE

19

J1J3J5

J2

WT

WT

LOOKING FROM FRONT

19

19

C15

BOTTOM

C16

C17

6 YEL

2 RED

4 WHT

424242

OUTPUT RECTIFIER

ASSEMBLY

OF UNIT

B1

50 WHT

17

76 BLK

30

77 BLU

27

78 BRN

23

R7

R5 R9

49 GRY

C11C9 C13

75 YEL

28

74 WHT

25

73 RED

22

CR1

J8

J9

J10

J11
J12

J13

J6 J4

WT

SCR5 SCR6

22

73 RED

25

26

SCR3

74 WHT

28

SCR1

75 YEL

19

J7

R10

WTWTWT

J8

J9

J10

J11

J12

J13

51 GRY

R8 R6

C12C14 C10

J5 J3 J1

SCR4

SCR2

J2J4J6

21

21

20

C18

C19

C20

3 BLU

5 BLK

424242

S6

S5

1 BRN

51 GRY

23

78 BRN

76 BLK

52 RED

31 ORN

X2 (A)

X2 (B)
X2 (C)

79 GRY

TOP

77 BLU

TOP

85 YEL

35 WHT

72 BLK

H

34

45 BLK

27

52 RED

15

33

X7

45 BLK

G

RV1

33

J10

SILVER

47 WHT

46 GRN-YEL

17

17

CB1

34

F

GOLD

93 BLK

20

20

24

34

27

20

29

37

1

TWIST

43

20

13

30

15

15

15

43

REAR PANEL FACING FROM FRONT

35

E

D

101

15

15

A415B1

A4

A3

200V

B1

A4

B2

15
15

15
15

38 BLK

10

15

6 5 4 3 2 1

B2

B2

460V

L1

B3

A5

230V

B3

B3

A5

367228-11

575V

200V

B4

B4B4C1

15

1510151515

C1

575V

40 BLK

C5

C2

B5

15

August 22, 2005

31

17 GRY

Art # A-06071

R4

90 WHT

C22

17

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

PLOT DATE

FILE NAME

830700S1 7-23-03

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

ANGLES

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

± 3˚

A THERMADYNE Company

R

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

DWG. NO.SIZE

R

D

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 500 CC, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

TROY, OHIO 45373 , U.S.A.

140

OUTSIDE DISTR.

830700

DISTRIBUTION TABLE

COMM. CLS.

SHEET

16 RED

39

17 GRY

39

A3
A3
A2

230V

A2

L2

A2

460V

575V

A1

A1
C5

39 BLK

C4
C4

C4

200V

B5

C3

230V

L3

C3

460V

C3

C2

C2

16 RED

15
15
15
15

32

15
15

10
15
15

15
15

1 OF 9

C

8/99

B

NONEVOGEL BESECKER 8-2-99

A

A-3

EXCEL-ARC 500, 6045

APPENDIX 2: EXCEL-ARC 500 CONNECTION DIAGRAM (2 OF 2)

(100005A-1, 100005A-5)

789101112

H

G

27 WHT

5

5

23 LT BL

3

88 BLK

3

44 YEL

3

81 BLK

19 ORN

3

69 BRN

F

17 GRY

31

16 RED

31

46

17 GRY

16 RED

14

13

12

11

10

9

8
7

6

5

4

3

2

1

36

39

J3

4

43 WHT

32 LT BL

2

1

3

6

29 RED

81 BLK

81 BLK

3

7

4

6

5

J4

37

FRONT PANEL

MAIN CONTROL BOARD

5

29

85 YEL

22 VLT

11

8

10

9

13

12

46

70 GRY

3

4

2

1

38

4633

71 RED

14 BRN

21 VLT

8

7

10

9

6

5

J7

41

J5

40

E

42

J2

J6

43

44

J9

D

C

B

NOTE 1: COMPONENT IDENTITY NO.S 36, 40, 41, 45 AND 47 ARE

NOT USED ON THIS DRAWING.

A

Art # A-06072

12 11 10 9 8 7

3

2

1

1 BRN

2 RED

4 WHT

19

20

192019201515151515

4

3 BLU

5

6 YEL

6

5 BLK

7

36 BLK

1

8

12 ORN

9

11 RED

KEY

11

10

13

14

12

9 BLK

8 WHT

7 BRN

10 YEL

15

KEY

3

3

2

2

1

1

79 GRY

72 BLK

30

29

13

4

4

5

5

C21

91 WHT

17

8

11

10

9

12

7

81 BLK

3

4

6

5

2

1

A-4

August 22, 2005

456 123

FACING REAR OF INSERT PANEL

EXCEL-ARC 500, 6045

H

G

45

46

69 BRN

39

70 GRY

38
38

71 RED

R11

47

F

E

C23

92 WHT

17

D

C

6 5 4 3 2 1

August 22, 2005

Art # A-06072

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

FILE NAME

830700S2 8-2-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

140

OUTSIDE DISTR.

DISTRIBUTION TABLE

R

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

DWG. NO.SIZE

R

SHEET

D

830700

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 500 CC, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

COMM. CLS.

2

8/99

B

NONEVOGEL BESECKER 8-2-99

A

A-5

EXCEL-ARC 500, 6045

APPENDIX 3: EXCEL-ARC 500 SCHEMATIC DIAGRAM

(100005A-1, 100005A-5)

789101112

INPUT

FRAME

GROUND

COM.

CABLE

200

4

230

K1

460

L1

L2

PE

L3

575

L3

T2

200

230

395

460

500

120V

K1

1/2 A

S1

OFF

ON

F1

575

3

C

2

1

5

200

H

G

F

E

L2

575

5

1

T1

460

2

3

A

230

200

4

5

B

4

3

1

2

L1

460

230

575

T1

POWER

TRANSFORMER

C

B

A

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1

X7

115V

X6

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1

J2-8

J2-11

J2-9

J2-12

J2-13

J2-14

J2-6

J2-5

J6-3

J2-4

J2-3

J2-2

J2-1

LEGEND

B1

D

C1,C3,
C9-C14

C15-C23

CB1

CR1

DS1

F1

C

J3

J5 RECEPTACLE, 8 PIN CONTROL BOARD
J6 RECEPTACLE, 5 PIN CONTROL BOARD

J9
J10 RECEPTACLE, 115 VOLTS

K1

L1

B

R1
R2

R4
R5-R10
R11

RV1

S1
S2

S5

S6

A

SCR 1-6 RECTIFIER SILICON CONTROL

T1
T2

FAN MOTOR

CAPACITOR, SUPPRESSION, .47 MFD, 400 WVDC
CAPACITOR, SUPPRESSION, .047 MFD, 400 WVDC

CAPACITOR, H.F. SUPPRESSION, .047, 400 WVDC

CIRCUIT BREAKER 10 AMP 115V

DIODE, SILICON POSITIVE BASE

OVERTEMP./OVERCURRENT INDICATOR (YELLOW)

FUSE, CONTROL TRANSFORMER, 1/2 AMP

RECEPTACLE, 14 PIN CONTROL BOARDJ2
RECEPTACLE, 14 PIN CONTROL BOARD
RECEPTACLE, 13 PIN CONTROL BOARDJ4

RECEPTACLE, 10 PIN CONTROL BOARDJ7

RECEPTACLE, 13 PIN (TO OPTIONAL TERMINAL BLOCK)

CONTACTOR

REACTOR, FILTER CC

POTENTIOMETER, VOLT/AMPS 5K OHMS, 2 WATTS
RESISTOR, 25 OHMS, 175 WATTS

SHUNT 600 AMP 100MV FEEDBACK
RESISTOR, SUPPRESSION, 50 OHMS, 5 WATTS
POTENTIOMETER, ARC FORCE 5K OHMS, 2 WATT

SUPPRESSOR, 115 VOLT CIRCUIT

SWITCH, INPUT CONTACTOR CONTROL, 0N-OFF
SWITCH, CONTROL V/A, REMOTE/LOCAL

THERMOSTAT, OVER-TEMP.
THERMOSTAT, FAN TURN ON

TRANSFORMER, POWER
TRANSFORMER, CONTROL

Art # A-06073

12 11 10 9 8 7

J2-1

J2-2

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

J2-9
J2-11

J2-12

J2-13

J2-14
J6-2

J6-3

J6-5

J8

CIRCUIT COMMON

C21

J7-2

J7-5

J7-3

J7-1

J7-4

S5

Y

DS1

OVER-TEMP.
OVER-CURRENT

J7-10

J7-9

J7-8

J7-7

J7-6

ARC

FORCE
R11 5K

MAX

C23

A-6

August 22, 2005

456 123

EXCEL-ARC 500, 6045

C14

R10

SCR2

SCR1

R5

R2

C16

CR1

C9

C19

C12

R8

R4

C22

L1

C3

H

G

SCR4

C11

R7

C20

C10

R6

SCR3

C17

C1

F

CB1

SCR6

C13

R9

C18

SCR5

J10

RV1

S6

E

B1

C15

J9-4

J9-3

J9-2

J9-1

+22

RMT VS

RMT VS

P.C. CONTROL BOARD

+22

J4-1

J4-2

J4-3

J4-4

J9-13

J9-12

J9-11

J9-10

J9-9

J9-8

J9-7

J9-6

J9-5

J1

J3-1

CIRCUIT COM

J3-2

J3-3

J3-4

J3-5

J3-6

J3-7

J3-8

J3-9

J3-10

J3-11

J3-12

J3-13

J3-14

J4-5

J4-6

J4-7

J4-8

J4-9

J4-10

J4-11

J4-12

J4-13

6 5 4 3 2 1

MAX

VOLT/AMP
CONTROL

R1 5K

LOCAL

LOCAL

S2

REMOTE

Art # A-06073

LOCAL

REMOTE

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

PLOT DATE

FILE NAME

830700S3 8-2-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

ANGLES

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

± 3˚

A THERMADYNE Company

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 500 CC, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

R

TROY, OHIO 45373 , U.S.A.

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

DWG. NO.SIZE

R

D

140

OUTSIDE DISTR.

830700

DISTRIBUTION TABLE

SHEET

COMM. CLS.

3

D

C

8/99

B

NONEVOGEL BESECKER 8-2-99

A

August 22, 2005

A-7

EXCEL-ARC 500, 6045

APPENDIX 4: EXCEL-ARC 6045 CONNECTION DIAGRAM (1 OF 2)

(100005A-2, 100005A-6)

789101112

CONTACTOR & CONTROL TRANSFORMER WIRING (400 V)

H

G

F

E

D

C

11

11

10

11

REAR PANEL

42 BLK

10

29

36 BLK4235 WHT

BLK

RED

DS1

Y

1

5

TOP OF FRONT PANEL

7

41 WHT

42 BLK

L3

L2

L1

460V
500V
575V

YEL

LOOKING FROM LEFT SIDE OF MACHINE

2

40 BLK

COIL

K1

38 BLK

395V
230V
200V

COM.

T2

F1

S1

33 YEL

34 RED

11

10

R1

27 WHT

28 GRY

22 VLT

3

39

37

37 BLU

41 WHT

33 YEL

38

21 VLT

14 BRN

38

37 BLU

39 BLK

34 RED

28 GRY

32

32

5

10

10

2

S2

23 LT BL

39

11

32

GROUND SCREW (LINE)

2

3

60 BLK

-

+

103

26 BLK

102

25 RED

MOUNTED ON REAR

OF BASE

30 BLU

15

31 ORN

30

X1 (A)

X2 (A)

X3 (A)

X1 (B)

X3 (B)

X4
X5

X6
X7

30 BLU

X1 (C)

X3 (C)

BOT.

13

18

31

18

X2 (B)

X2 (C)

34

17

34

R2

TOP

7 BRN

8 WHT

BOT.

9 BLK

10 YEL

80 BLU

13

TOP

11 RED

12 ORN

TOP

BOT.

42

30

42

42

30
42

35

42

30

42

103

15

PE

YOKE

-

+

LIFTING YOKE

LOOKING FROM FRONT OF MACHINE

12

-

-

+

­C7 C8

C6C5C4
+

+

14

106

8

101

31

L2

4

C1

32 LT BL

6

BLANK
PANEL

37

PRIMARY LEADS
A1 THRU A5 TO
CHANGEOVER BOARD

PRIMARY LEADS
B1 THRU B5 TO
CHANGEOVER BOARD

PRIMARY LEADS
C1 THRU C5 TO
CHANGEOVER BOARD

16

C3

8

29 RED

37

12

100

A

15

B

T1

C

14

9

B

NOTE 1: COMPONENT IDENTITY NO.S 6, 7, 9, 16 AND 24 ARE

NOT USED ON THIS DRAWING.

A

Art # A-06074

12 11 10 9 8 7

A-8

106

14

LOOKING DOWN ON BASE

25 RED

12

43

15

26

33

33

26 BLK

12

MOUNTED ON REAR

OF BASE

18

R3

17

GROUND SCREW

ON FRONT OF YOKE

91 WHT

X6

50 WHT

47 WHT

46 GRN-YEL

August 22, 2005

456 123

EXCEL-ARC 500, 6045

FACING SUPPRESSOR BOARDS

FROM LEFT SIDE

51 GRY

21

19

J7

R7

49 GRY

75 YEL

28

74 WHT

25

73 RED

22

J8
J9

J10

J11
J12
J13

J5

J6

89 BLK

WT

CR1

SCR5 SCR6

25

22

73 RED

26

SCR3

74 WHT

28

SCR1

75 YEL

19

101

R9R5

C13C9 C11

J3 J1

J2J4

WT

WT

OUTPUT RECTIFIER

LOOKING FROM FRONT

19

19

151515

C15

C16

C17

6 YEL

39

39

2 RED

4 WHT

424242

ASSEMBLY

OF UNIT

B1

16 RED

17 GRY

BOTTOM

30

27

23

(USED ON

-4 SPEC
ONLY)

50 WHT

17

76 BLK

77 BLU

78 BRN

J7

R10

WTWTWT

16 RED

102

12

J8

J9

J10

J11

J12
J13

J6 J4 J2

SCR4

SCR2

17 GRY

J5 J3 J1

A4B1A4

A3

A3

230V

L2

200V

B1

A4

C5

B2

B2

15

B2

15

15
15

38 BLK

10

15

460V

575V

L1

B3
B3

A5

367228-11

200V

A5

230V

B3

B4

B4

15

575V

200V

B5

575V

230V

L3

C1

460V

C2

B4

B5C2C2

40 BLK

15C115

15

15

10

6 5 4 3 2 1

15

A3

15

A2

15

A2

15

A2

460V

A1

A1
C5

39 BLK

C4
C4

C4

C3
C3

C3

32

15
15

10
15
15

15
15

15

Art # A-06074

20

C18

R6R8

C19

C10C14 C12

TOP

C20

34

45 BLK

33

27

52 RED

15

X7

RV1

83 BLK

35

J10

48 GRN-YEL

35

SILVER

47 WHT

46 GRN-YEL

17

17

82 WHT

35

CB1

CB2

X5

21

5 BLK

3 BLU

1 BRN

51 GRY

23

78 BRN

GOLD

93 BLK

424242

20

20

24

52 RED

S6

S5

31

R4

34

27

77 BLU

20

TOP

85 YEL

35 WHT

72 BLK

76 BLK

31 ORN

X2 (A)

X2 (B)
X2 (C)

79 GRY

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

29

37

1

43

20

13

30

15

15

15

43

TWIST

FILE NAME

830700S4 7-23-03

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

82 WHT

33

J8

AMPHENOL BOARD

REAR PANEL FACING FROM FRONT

35

J7J6J3

48 GRN-YEL

83 BLK

80 BLU

33

33

15

FINISH CODE PER

ACTIVITY

PLOT DATE

MATERIAL NO.

MATERIAL SPEC.

TITLE

ANGLES

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

DIAGRAM, CONNECTION & SCHEMATIC

± 3˚

DESCRIPTIVE DATA

METRIC

EXCEL-ARC 6045 CV, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

R

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

BJV 8-2-99

R

J1

RIBBON

OUTSIDE DISTR.

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

DWG. NO.SIZE

D

33

45 BLK

34

15

CABLE

36

140

DISTRIBUTION TABLE

SHEET

830700

COMM. CLS.

4

H

G

F

E

D

C

8/99

B

NONEVOGEL BESECKER 8-2-99

A

August 22, 2005

A-9

EXCEL-ARC 500, 6045

APPENDIX 4: EXCEL-ARC 6045 CONNECTION DIAGRAM (2 OF 2)

(100005A-2, 100005A-6)

789101112

14

13

12

11

10

9

8
7

6

5

4

3

2

1

TO AMPENOL BOARD

35

26 CONDUCTOR

CABLE

RIBBON

J1

36

39

J3

4

19 ORN

32 LT BL

2

1

39

29 RED

3

8

81 BLK

81 BLK

7

4

6

5

J4

37

FRONT PANEL

MAIN CONTROL BOARD

TO METER

RIBBON

8

9

45

10 CONDUCTOR

CABLE

5

29

22 VLT

85 YEL

11

10

13

12

2

1

38

3

3

21 VLT

14 BRN

3

8

7

10

4

9

6

5

J7

41

J5

H

G

27 WHT

5

23 LT BL

3

81 BLK

19 ORN

37

F

31

31

17 GRY

16 RED

17 GRY

16 RED

J8

40

E

42

J2

3

4

5

2

1

D

1 BRN

5 BLK

3 BLU

6 YEL

4 WHT

2 RED

19

20

19

KEY

8

11

7

10

9

15

11 RED

15

10 YEL

15

12

9 BLK

13

8 WHT

14

7 BRN

151515

6

36 BLK

12 ORN

201920

1

J6

43

KEY

3

4

5

2

1

C21

79 GRY

72 BLK

30

29

91 WHT

17

11

10

13

12

44

J9

8

9

3

7

4

6

5

2

1

81 BLK

C

B

COMPONENT IDENTITY NO.S 41, 46, AND 47 ARENOTE 1:
NOT USED ON THIS DRAWING.

A

Art # A-06075

12 11 10 9 8 7

A-10

August 22, 2005

FACING REAR OF INSERT PANEL

81 BLK

J1

1

2

3

45

4

5

6

J2

7

8

METER P.C. BOARD

456 123

40

CABLE

RIBBON

EXCEL-ARC 500, 6045

H

G

F

46

6 5 4 3 2 1

47

Art # A-06075

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

FILE NAME

830700S5 8-2-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

140

OUTSIDE DISTR.

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 6045 CV, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

R

R

DISTRIBUTION TABLE

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

SHEET

DWG. NO.SIZE

D

830700

COMM. CLS.

5

E

D

C

8/99

B

NONEVOGEL BESECKER 8-2-99

A

August 22, 2005

A-11

EXCEL-ARC 500, 6045

APPENDIX 4: EXCEL-ARC 6045 SCHEMATIC DIAGRAM

INPUT

CABLE

H

G

FRAME

GROUND

PE

F

COM.

200

230

395

460

500

E

D

C

B

A

575

B1

C1,C3 CAPACITOR, SUPPRESSION, .47 MFD, 400 WVDC
C9-C14

C15-C20

CB1
CB2

CR1

DS1

F1

J1
J2
J3

J8
J9
J10 RECEPTACLE, 115 VOLT

K1

R1
R2

R4
R5-R10

S1
S2

S5

S6

SCR 1-6 RECTIFIER SILICON CONTROL

T1
T2

Art # A-06076

12 11 10 9 8 7

K1

L1

L2

L3

L3

T2

K1

S1

120V

F1

1/2 A

OFF

ON

LEGEND

FAN MOTOR

CAPACITOR, SUPPRESSION, .047 MFD, 400 WVDC
CAPACITOR, 23,000 MFD. 50 WVDCC4-C8
CAPACITOR, H.F. SUPPRESSION, .047, 400 WVDC

CIRCUIT BREAKER 10 AMP 115V
CIRCUIT BREAKER 10 AMP 24V

DIODE, SILICON POSITIVE BASE

OVERTEMP./OVERCURRENT INDICATOR (YELLOW)

FUSE, CONTROL TRANSFORMER, 1/2 AMP

RECEPTACLE, 26 PIN RIBBON CABLE (AMPHENOL)
RECEPTACLE, 14 PIN CONTROL BOARD
RECEPTACLE, 14 PIN CONTROL BOARD
RECEPTACLE, 13 PIN CONTROL BOARDJ4

RECEPTACLE, 5 PIN CONTROL BOARDJ6
RECEPTACLE, 10 PIN CONTROL BOARDJ7
RECEPTACLE, 10 PIN RIBBON CABLE (METER)
RECEPTACLE, 13 PIN (TO OPTIONAL TERMINAL BLOCK)

CONTACTOR

REACTOR, FILTER CVL2

POTENTIOMETER, VOLT/AMPS 5K OHMS, 2 WATTS
RESISTOR, 25 OHMS, 175 WATTS
RESISTOR, 10 OHMS, 300 WATTSR3
SHUNT 600 AMP 100MV FEEDBACK
RESISTOR, SUPPRESSION, 50 OHMS, 5 WATTS

SUPPRESSOR, 115 VOLT CIRCUITRV1

SWITCH, INPUT CONTACTOR CONTROL, 0N-OFF
SWITCH, CONTROL V/A, REMOTE/LOCAL

THERMOSTAT, OVER-TEMP.
THERMOSTAT, FAN TURN ON

TRANSFORMER, POWER
TRANSFORMER, CONTROL

(100005A-2, 100005A-6)

789101112

L2

575

200

230

3

460

575

2

1

5

4

C

1

T1

460

2

A

230

3

200

4

5

B

5

4

3

1

2

L1

460

Y

575

J1

P.C. METER BOARD

200

230

DS1

S5

OVER-TEMP.
OVER-CURRENT

TRANSFORMER

J2-1

J2-2

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

J2-9
J2-11

J2-12

J2-13

J2-14

J6-2
J6-3

J6-5

C21

J2-6

J2-4

T1

POWER

C

B

A

J8

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1
X5

24V

X4

X7

115V

X6

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1

P.C. CONTROL BOARD

J7-1

J2-8

J2-11

J7-2

J7-3

J7-4

J2-6

J2-5

J6-3

J2-9

J2-4

J2-3

J2-12

J2-2

J2-13

J2-1

J2-14

CIRCUIT COMMON

J7-10

J7-9

J7-8

J7-7

J7-6

J7-5

A-12

August 22, 2005

456 123

EXCEL-ARC 500, 6045

C14

R10

SCR2

C19

C12

R8

SCR4

C20

ON -4 ONLY

R4

C9

R5

L2

C3

SCR1

C16

R2

CR1

+++++

C11

R7

C4 C5 C6 C7 C8

R3

SCR3

C17

C1

CB2

H

G

F

CB1

C10

SCR6

R6

C13

R9

C18

SCR5

J10

S6

RV1

B1

E

C15

J8

AMPHENOL PC BOARD

J9-1

J9-13

J1

J1

J9-12

J9-11

J9-10

J9-9

J9-8

J9-7

J9-6

J9-5

J9-4

J9-3

J9-2

+22

RMT VS

RMT VS

+22

J4-1

J4-2

J4-3

J4-4

J4-5

J4-6

J4-7

J4-8

J4-9

J4-10

6 5 4 3 2 1

J4-11

CIRCUIT COM

J4-12

J4-13

J3-1

J3-2

J3-3

J3-4

J3-5

J3-6

J3-7

J3-8

J3-9

J3-10

J3-11

J3-12

J3-13

J3-14

R1 5K

MAX

VOLT/AMP
CONTROL

LOCAL

LOCAL

S2

REMOTE

Art # A-06076

LOCAL

REMOTE

CHANGE RECORD

E.C. No. DATE

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.
INCH

DECIMAL-INCH

.000 ± .003

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

FILE NAME

830700S6 8-2-99

±

.0 ± .1

.00 ± .02

DO NOT SCALE DRAWING

J3J7J6

19 PIN

REMOTE

RECEPTACLE

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

J4-A
J4-B
J4-C
J4-D
J4-E
J4-F
J4-G
J4-H
J4-J
J4-K
J4-L
J4-M
J4-N
J4-P
J4-R
J4-S
J4-T
J4-U
J4-V

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 6045 CV, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

R

GUN SWITCH

V METER +
24 VAC HOT
115 VAC HOT
115 VAC NEUT
CHASSIS GND
REMOTE MAX
REMOTE CT(VREF)
REMOTE MIN
CONTROL COMM
ARC ESTB

OPEN
24 VAC HOT
115 VAC NEUT
OPEN

OPEN
IFB (1V/100A)
V/A COMM

OUTSIDE DISTR.

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

DWG. NO.SIZE

R

D

140

DISTRIBUTION TABLE

SHEET

830700

COMM. CLS.

D

C

8/99

B

NONEVOGEL BESECKER 8-2-99

A

6

August 22, 2005

A-13

EXCEL-ARC 500, 6045

APPENDIX 4: EXCEL-ARC 6045 CONNECTION DIAGRAM (1 OF 2)

(100005A-3, 100005A-7)

789101112

CONTACTOR & CONTROL TRANSFORMER WIRING (400 V)

H

G

F

E

D

REAR PANEL

DS1

TOP OF FRONT PANEL

41 WHT

11

42 BLK

11

10

11

42 BLK

10

YEL

LOOKING FROM LEFT SIDE OF MACHINE

29

36 BLK4235 WHT

RED

BLK

Y

2

1

5

R1

28 GRY

22 VLT

27 WHT

3

39

37

44

39

20 ORN

19 ORN

460V

500V
575V

39

88 BLK

3

67 BLK

40 BLK

32

COIL

38 BLK

37 BLU

41 WHT

33 YEL

37 BLU

39 BLK

34 RED

11

32

GROUND SCREW (LINE)

2

32

10

10

2

PE

L3

L2

K1

L1

395V
230V
200V

COM.

T2

F1

YOKE

103

15

-

+

LOOKING FROM FRONT OF MACHINE

LIFTING YOKE

14

CR2

67 BLK

7

106

5

39

38

28 GRY

44 YEL

21 VLT

S1

33 YEL

14 BRN

34 RED

11

10

38

31

12

104

105

S2

23 LT BL

39

3

60 BLK

8

101

31

L2

4

32 LT BL

C1

37

C2

29 RED

PRIMARY LEADS
A1 THRU A5 TO
CHANGEOVER BOARD

PRIMARY LEADS
B1 THRU B5 TO
CHANGEOVER BOARD

PRIMARY LEADS
C1 THRU C5 TO

CHANGEOVER BOARD

37

6

12

-

-

+

­C7 C8

C6C5C4

+

+

12

100

A

-

+

103

26 BLK

105

25 RED

MOUNTED ON REAR

OF BASE

30 BLU

15

31 ORN

30

X1 (A)

X3 (A)

15

X1 (B)

B

T1

C

X3 (B)

X1 (C)

X3 (C)

13

X2 (A)

X4
X5

X6
X7

30 BLU

18

7

18

X2 (B)

X2 (C)

TOP

7 BRN

8 WHT

BOT.

9 BLK

10 YEL

80 BLU

34

17
34

11 RED

12 ORN

TOP

R2

42

30

42

TOP

42

30
42

35

BOT.

13

42

30

42

7

C

S4

9

B

NOTE 1: COMPONENT IDENTITY NO. 9, 24 ARE

A

NOT USED ON THIS DRAWING.

Art # A-06077

12 11 10 9 8 7

A-14

8

BOT.

106

14

C3

L1

101

14

16

LOOKING DOWN ON BASE

MOUNTED ON REAR

OF BASE

25 RED

12

18

R3

26 BLK

12

17

90 WHT
91 WHT
92 WHT

X6

50 WHT

47 WHT

46 GRN-YEL

GROUND SCREW
ON REAR OF YOKE

31
43
46

15

26

33

33

August 22, 2005

DIAGRAM, CONNECTION & SCHEMATIC

EXCEL-ARC 6045 CC/CV, (60 HZ)

800001:

NONE

7

NONE

VOGEL

BESECKER

8-2-99

830700S7

7-23-03

BJV

8-2-99

140

8/99

456 123

EXCEL-ARC 500, 6045

19

J7

R9R5

R7

49 GRY

C13C9 C11

75 YEL

28

74 WHT

25

73 RED

22

CR1

J8

J9
J10

J11
J12

J5

J3 J1

J13

J2J4

J6

WT

WT

WT

SCR5 SCR6

25

22

73 RED

19

26

SCR3

74 WHT

19

28

SCR1

75 YEL

19

101

151515

A4B1A4

2

0

0

V

B1

A4

B2

B2

15

B2

15

15
15

38 BLK

10

15

6 5 4 3 2 1

460V

L1

B3

A5

230V

B3

B3

A5

367228-11

575V

2
00V

B4

151015

B4B4C1

15

5

C1

40 BLK

C5

V

5

7

C2

B5

August 22, 2005

FACING SUPPRESSOR BOARDS

FROM LEFT SIDE

C15

C16

BOTTOM

C17

30

27

23

6 YEL

4 WHT

2 RED

424242

OUTPUT RECTIFIER

ASSEMBLY

LOOKING FROM FRONT

OF UNIT

B1

50 WHT

17

16 RED

39

17 GRY

39

A3

A3

230V

L2

575V

200V

B5

230V

L

3

460V

C2

15

15

15

A3

15

A2

15

A2

15

A2

460V

A1

A1

15

C5

15

39 BLK

10

C4

15

C4

C4

15

C3

15

C3

15

C3

C2

15

76 BLK

77 BLU

78 BRN

7

WT

16 RED

WT

104

J7

R10

32

J8

J9
J10

J11

J12
J13

WT

17 GRY

J6 J4 J2

SCR4

SCR2

51 GRY

R6R8

C10C14 C12

J5 J3 J1

21

Art # A-06077

21

20

C18

C19

TOP

C20

1 BRN

5 BLK

3 BLU

424242

51 GRY

20

23

78 BRN

20

52 RED

S6

77 BLU

TOP

85 YEL

35 WHT

S5

72 BLK

76 BLK

31 ORN

X2 (A)

X2 (B)
X2 (C)

79 GRY

31

R4

90 WHT

C22

17

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

93 BLK

24

27

34

20

29

37

1

TWIST

43

20

13

30

15

15

15

43

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.
INCH

34

45 BLK

GOLD

83 BLK

REAR PANEL FACING FROM FRONT

PLOT DATE

FILE NAME

830700S7

7-23-03

ANGLES

±

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

27

33

52 RED

RV1

J10

SILVER

CB1

CB2

82 WHT

48 GRN-YEL

46 GRN-YEL

47 WHT

17

35

17

35

35

82 WHT

33

J8

AMPHENOL BOARD

35

J3

J6

J7

48 GRN-YEL

83 BLK

80 BLU

33

33

15

R

800001:

REPLACED BY REPLACES

QUANTITY-U.M.

BESECKER

BJV

R

D

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 6045 CC/CV, (60 HZ)

DESIGNED DRAWN DATE SCALE

VOGEL

CHECKED APPROVED RECORDS ITEM TYPE

TROY, OHIO 45373 , U.S.A.

DWG. NO.SIZE

J1

RIBBON

36

OUTSIDE DISTR.

8-2-99

8-2-99

15

33

X7

45 BLK

34

X5

15

CABLE

140

DISTRIBUTION TABLE

NONE

SHEET

830700

COMM. CLS.

H

G

F

E

D

C

8/99

B

NONE

A

7

A-15

EXCEL-ARC 500, 6045

APPENDIX 5: EXCEL-ARC 6045 CONNECTION DIAGRAM (2 OF 2)

(100005A-3, 100005A-7)

789101112

14

13

12

11

10

9

8
7

6

5

4

3

2

1

TO AMPENOL BOARD

35

CABLE

RIBBON

J1

36

39

J3

26 CONDUCTOR

4

32 LT BL

2

1

29 RED

3

6

81 BLK

81 BLK

7

4

6

5

J4

37

FRONT PANEL

MAIN CONTROL BOARD

TO METER

RIBBON

8

9

45

10 CONDUCTOR

CABLE

5

29

22 VLT

85 YEL

11

10

13

12

1

46

3346

70 GRY

21 VLT

14 BRN

71 RED

3

2

38

8

10

7

4

9

6

5

J7

41

H

G

27 WHT

5

23 LT BL

3

88 BLK

7

44 YEL

3

81 BLK

19 ORN

7

69 BRN

F

17 GRY

31

16 RED

31

46

17 GRY

16 RED

J8

40

E

42

J2

6

5 BLK

201920

7

36 BLK

1

8

11 RED

12 ORN

15

KEY

11

10

9

13

14

12

7 BRN

8 WHT

9 BLK

10 YEL

151515

15

15

3

4

5

2

1

D

1 BRN

3 BLU

6 YEL

4 WHT

2 RED

19

20

19

J6

43

KEY

3

4

5

2

1

C21

72 BLK

79 GRY

29

30

91 WHT

17

11

10

13

12

44

J9

8

9

3

7

4

6

5

2

1

20 ORN

81 BLK

81 BLK

7

C

B

NOTE 1: COMPONENT IDENTITY NO.S 41, AND 47 ARE

NOT USED ON THIS DRAWING.

A

Art # A-06078

12 11 10 9 8 7

A-16

August 22, 2005

FACING REAR OF INSERT PANEL

81 BLK

81 BLK

J1

1

2

3

45

4

5

6

J2

7

8

METER P.C. BOARD

456 123

40

CABLE

RIBBON

EXCEL-ARC 500, 6045

H

G

F

46

69 BRN

39

70 GRY

38

38

71 RED

R11

47

C23

92 WHT

17

140

OUTSIDE DISTR.

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of

Art # A-06078

6 5 4 3 2 1

Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

FILE NAME

830700S8 8-2-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 6045 CC/CV, (60 HZ)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

R

DISTRIBUTION TABLE

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

DWG. NO.SIZE

R

SHEET

D

830700

COMM. CLS.

8

E

D

C

8/99

B

NONEVOGEL BESECKER 8-2-99

A

August 22, 2005

A-17

EXCEL-ARC 500, 6045

APPENDIX 5: EXCEL-ARC 6045 SCHEMATIC DIAGRAM

INPUT

FRAME

GROUND

COM.

CABLE

K1

L1

L2

PE

L3

T2

200

230

395

460

500

575

120V

K1

F1
1/2 A

L3

S1

OFF

ON

H

G

F

E

(100005A-3, 100005A-7)

789101112

T1

POWER

460

1

4

575

TRANSFORMER

230

200

5

L1

TOP

BOT.

J2-12

J2-13

J2-14

J2-6

J2-5

J6-3

J2-4

J2-3

J2-2

J2-1

X3

16-18VAC

X2

16-18VAC

C

X1

TOP

BOT.

X3

16-18VAC

X2

16-18VAC

X1

B

X5

24V

X4

X7

115V

X6

TOP

BOT.

X3

16-18VAC

A

X2

16-18VAC

X1

J2-8

J2-9

J2-11

L2

575

200

230

460

575

2

1

5

4

3

C

1

2

3

A

T1

B

5

4

200

3

230

2

460

D

B1

C1-C3,
C9-C14

C15-C20

CB1
CB2

CR1

DS1

F1

C

J1
J2
J3

J5 RECEPTACLE, 8 PIN CONTROL BOARD
J6 RECEPTACLE, 5 PIN CONTROL BOARD

J8
J9
J10 RECEPTACLE, 115 VOLT
K1
L1

B

R1
R2

R4
R5-R10
R11

RV1

S1
S2

S4

S5

S6

A

SCR 1-6 RECTIFIER SILICON CONTROL

T1
T2

FAN MOTOR

CAPACITOR, SUPPRESSION, .47 MFD, 400 WVDC
CAPACITOR, SUPPRESSION, .047 MFD, 400 WVDC
CAPACITOR, 23,000 MFD. 50 WVDCC4-C8
CAPACITOR, H.F. SUPPRESSION, .047, 400 WVDC

CIRCUIT BREAKER 10 AMP 115V
CIRCUIT BREAKER 10 AMP 24V

DIODE, SILICON POSITIVE BASE

OVERTEMP./OVERCURRENT INDICATOR (YELLOW)

FUSE, CONTROL TRANSFORMER, 1/2 AMP

RECEPTACLE, 26 PIN RIBBON CABLE
RECEPTACLE, 14 PIN CONTROL BOARD
RECEPTACLE, 14 PIN CONTROL BOARD
RECEPTACLE, 13 PIN CONTROL BOARDJ4

RECEPTACLE, 10 PIN CONTROL BOARDJ7
RECEPTACLE, 10 PIN RIBBON CABLE
RECEPTACLE, 13 PIN (TO OPTIONAL TERMINAL BLOCK)

CONTACTOR
REACTOR, FILTER, CC
REACTOR, FILTER, CvL2

POTENTIOMETER, VOLT/AMPS 5K OHMS, 2 WATTS
RESISTOR, 25 OHMS, 175 WATTS
RESISTOR, 10 OHMS, 300 WATTSR3
SHUNT 600 AMPS 100MV FEEDBACK
RESISTOR, SUPPRESSION, 50 OHMS, 5 WATTS
POTENTIOMETER, ARC FORCE 5K OHMS, 2 WATT

SUPPRESSOR, 115 VOLT CIRCUIT

SWITCH, INPUT CONTACTOR CONTROL, 0N-OFF
SWITCH, CONTROL V/A, REMOTE/LOCAL

SWITCH, CC/CV
THERMOSTAT, OVER-TEMP.
THERMOSTAT, FAN TURN ON

TRANSFORMER, POWER
TRANSFORMER, CONTROL

LEGEND

Art # A-06079

12 11 10 9 8 7

J2-1

J2-2

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

J2-9
J2-11

J2-12

J2-13

J2-14

J6-2
J6-3

J6-5

DS1

S5

Y

OVER-TEMP.
OVER-CURRENT

J1

P.C. METER BOARD

C21

J2-2

J2-4

J2-6

J2-7

J8

P.C. CONTROL BOARD

J7-2

J7-3

J7-1

J7-4

CIRCUIT COMMON

J7-10

J7-9

J7-8

J7-7

J7-6

J7-5

ARC

FORCE
R11 5K

MAX

C23

A-18

August 22, 2005

456 123

EXCEL-ARC 500, 6045

C14

R10

SCR2

SCR1

R5

R2

C16

CR1

C9

C19

C12

R8

SCR4

C20

C11

R7

SCR3

R4

S4

CV

+++++

C4 C5 C6 C7 C8

C17

C22

L2

L1

C3

C2

H

G

R3

C1

CB2

F

CB1

C10

SCR6

R6

C13

R9

C18

SCR5

J10

RV1

S6

B1

E

C15

J8

AMPHENOL PC BOARD

J9-12

J9-11

J9-10

J9-9

J9-8

J9-7

J9-6

J9-5

J9-4

J9-3

J9-2

J9-1

+22V

RMT VS

RMT VS

+22

J4-1

J4-2

J4-3

J4-4

J4-5

J4-6

J4-7

J4-8

6 5 4 3 2 1

J9-13

J1

J3-1

J3-2

CIRCUIT COMM.

J3-3

J3-4

J3-5

J3-6

J3-7

J3-8

J3-9

J3-10

J3-11

J3-12

J3-13

J3-14

J4-9

J4-10

J4-11

J4-12

J4-13

CC

MAX

R1 5K

S4

VOLT/AMP
CONTROL

S2

REMOTE

Art # A-06079

LOCAL

LOCAL

LOCAL

REMOTE

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

J1

FILE NAME

830700S9 8-2-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

J3J7J6

19 PIN

REMOTE

RECEPTACLE

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

J4-A
J4-B
J4-C
J4-D
J4-E
J4-F
J4-G
J4-H
J4-J
J4-K
J4-L
J4-M
J4-N
J4-P
J4-R
J4-S
J4-T
J4-U
J4-V

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

EXCEL-ARC 6045 CC/CV, 60 HZ

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

R

GUN SWITCH

V METER +
24 VAC HOT
115 VAC HOT
115 VAC NEUT
CHASSIS GND
REMOTE MAX
REMOTE CT(VREF)
REMOTE MIN
CONTROL COMM
ARC ESTB

OPEN
24 VAC HOT
115 VAC NEUT
OPEN

OPEN
IFB (1V/100A)
V/A COMM

OUTSIDE DISTR.

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

BJV 8-2-99

DWG. NO.SIZE

R

D

156
S01

DISTRIBUTION TABLE

SHEET

830700

COMM. CLS.

9

D

C

2/98
2/98

B

NONEVOGEL BESECKER 8-2-99

A

August 22, 2005

A-19

EXCEL-ARC 500, 6045

APPENDIX 6: EXCEL-ARC 500 & 6045 VOLTAGE CHANGEOVER

DIAGRAM (ALL)

78 56 4

200 VOLT CONNECTION

F

A3

230V

L2

A2

39 BLK

40 BLK

575V

460V

575V

C5

A1

L3

460V

C2

42 BK
41 WT

C4

230V

C3

367228-11

TO CONTACTOR

B5

CONTROL TRANSFORMER BELOW CONTACTOR

B1

575V

A5

460V
500V

575V

38 BLK

B4

A4

C1

395V
230V
200V

COM.

1

B2

460V

L1

E

D

230V

B3

367228-11

CONTROL TRANSFORMER BELOW CONTACTOR

FIG:1

460 VOLT CONNECTION

230 VOLT CONNECTION

B1

B2

460V

575V

200V

B3

575 VOLT CONNECTION

A5

L1

460V
500V

575V

38 BLK

B4

A3

A2

L2

39 BLK

40 BLK

B5

C5

L3

460V

C2

42 BK

41 WT

575V

460V

200V

A1

C4

C3

TO CONTACTOR

200V

A4

575V

C1

395V
230V
200V

COM.

1

FIG:2

C

B

A

Art # A-06080

TO CONTACTOR

38 BLK

B4

200V

L2

39 BLK

40 BLK

B5

575V

C1

395V
230V
200V

COM.

1

B2

42 BK

B3

230V

B1

200V

575V

A5

575V

L1

460V
500V

CONTROL TRANSFORMER BELOW CONTACTOR

78

230V

C5

L3

C2

41 WT

A3

575V

200V

230V

A2

A1

C4

C3

TO CONTACTOR

A3

230V

L2

A2

C5

39 BLK

40 BLK

B5

L3

41 WT

460V

200V

230V

460V

C2

A1

C4

C3

TO CONTACTOR

A

TO CONTACTOR

38 BLK

B4

200V

A4

C1

395V
230V
200V

COM.

1

B1

B2

460V

L1

A5

200V

230V

B3

367228-11367228-11

460V

42 BK

500V

575V

CONTROL TRANSFORMER BELOW CONTACTOR

FIG:4FIG:3

654

A-20

August 22, 2005

EXCEL-ARC 500, 6045

3 2 1

INPUT CABLE DIAGRAM

SEE NOTE 3

INPUT CABLE

K1

L1

38 BK

F

K1

L2

39 BK

K1

L3

40 BK

GND SCREW

ON YOKE

FIG:5

INSTRUCTIONS FOR VOLTAGE CHANGEOVER

1. CHECK NAME PLATE OF MACHINE
FOR PROPER LINE VOLTAGE.

2. CONNECT CONTROL TRANSFORMER
JUMPERS AS SHOWN IN APPROPRIATE
FIG: FOR PROPER INPUT VOLTAGE.

3. CHECK YOUR LOCAL ELECTRICAL
CODES FOR PROPER INPUT WIRE SIZE
FOR LINE CURRENT SHOWN ON
NAMEPLATE. IF NO CODE EXISTS THEN
USE THE CHART IN THE "INSTALLATION"
SECTION OF OWNER'S MANUAL.

CONNECT INPUT LINES TO MAIN POWER
SWITCH AS SHOWN IN FIG:5.
( CAUTION - BE CERTAIN INPUT CIRCUIT
IS OPEN BEFORE HANDLING LINE. )

5. CONNECT THE "POWER SYSTEM"
GROUND TO THE SCREW MARKED FRAME
GROUND ON THE YOKE.

NOTE:
!. ANY CHANGES TO THIS DRAWING MUST BE REFLECTED ON DRAWING 204204.

140

140 TEST

3/92
3/95

E

D

C

B

Art # A-06080

August 22, 2005

CHANGE RECORD

E.C. No. DATE

1) AA3597 7-24-92
A) 1422 5-20-97
AA 5-27-99

CONFIDENTIAL: This drawing, including all information
contained thereon, is the exclusive and confidential property of
Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is
not to be copied, reproduced, delivered or disclosed to others,
in whole or in part, except with express written permission.

FILE NAME

204203 5-27-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS
TOLERANCES BELOW APPLY EXCEPT FOR
VENDOR DESIGNED PARTS AND ITEMS.
PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

±

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

FINISH CODE PER

PLOT DATE

MATERIAL SPEC.

ANGLES

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

TITLE

± 3˚

DESCRIPTIVE DATA

A THERMADYNE Company

TROY, OHIO 45373, U.S.A.

OUTSIDE DISTR.

DISTRIBUTION TABLE

ACTIVITY

MATERIAL NO.

800001: NONE

REPLACED BY REPLACES

QUANTITY-U.M.

COMM. CLS.

DIAGRAM, VOLTAGE, CONNECTION

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

RWS 3-13-92

R

R

C

DWG. NO.SIZE

SHEET

204203

123

A

FULLRGS BAJ 3-3-92

A-21

EXCEL-ARC 500, 6045

A-22

August 22, 2005