Thermal Arc EXCEL-ARC 750 CC, EXCEL-ARC 8065 CC/CV, EXCEL-ARC 8065 CV Owner's Manual

EXCEL-ARC®750 and 8065
Transformer-Rectifier DC

Welding Machine

For the Following Specs:

500016-1 750 CC, 60 Hz

•

500016-2 8065 CV, 60 Hz

•

500016-3 8065 CC/CV, 60 Hz

•

500016A-1 750 CC, 60 Hz

•

500016A-2 8065 CV, 60 Hz

•

500016A-3 8065 CC/CV, 60 Hz

•

OWNER’S MANUAL Number 430429-174

Revised December 1, 1997

IMPORTANT: Readtheseinstructionsbeforeinstalling,operating, or servicing this system.

THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

430429-174

Table of Contents

INTRODUCTION 1

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

Equipment Identification ..................................1-1

Receipt Of Equipment ...................................1-1

SAFETY INSTRUCTIONS AND WARNINGS 2
DESCRIPTION OF EQUIPMENT 3

General ...........................................3-1

Recommended Unit Applications ..............................3-1

Wire Feeder Compatibility .................................3-1

Controls and Outlets ....................................3-3

Duty Cycle .........................................3-5

INSTALLATION 4

Location ...........................................4-1

Grounding ..........................................4-1

Internal Wiring Check ....................................4-2

Connecting Welding Machine to Line Voltage .......................4-2

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

OPERATION 5

General ...........................................5-1

Preweld Operation .....................................5-1

SMAW (Stick) Welding, Carbon Arc Gouging .......................5-1

Welding, Semiautomatic or Automatic ...........................5-1

MAINTENANCE 6

Replacing SCRs ......................................6-1

Lubrication .........................................6-1

Inspection and Cleaning ..................................6-1

TROUBLESHOOTING 7

Detailed Troubleshooting Instructions ...........................7-5

PARTS LIST 8

Equipment Identification ..................................8-1

How To Use This Parts List .................................8-1

DIAGRAMS

December 1, 1997 Revised Page 1

INTRODUCTION

430429-174

INTRODUCTION

How To Use This Manual

This Owner’s Manual usually applies to just the
underlined specification or part numbers listed on
the cover. If none are underlined, they are all cov­ered by this manual.

To ensure safe operation, read the entire manual,
including the chapter on Safety Instructions and
Warnings.

Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotationsareeasily rec­ognized as follows:

WARNING gives information re­garding possible personal in­jury. Warnings will be enclosed
in a box such as this.

CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.

NOTEoffershelpfulinformationconcerning
certain operating procedures. Notes will be
shown in italics.

Equipment Identification

The unit’s identification number (specification or
part number), model, and serial number usually
appear on a nameplate attached to the control
panel. In some cases, the nameplate may be at­tached to the rear panel. Equipment whichdoes not
have a controlpanel such as gun and cable assem­blies are identified only by the specification or part
number printed on the shipping container. Record
these numbers for future reference.

Receipt Of Equipment

When you receivethe equipment, check it against
the invoice to make sure it is complete and inspect
theequipmentforpossibledamageduetoshipping.
If there is any damage, notify the carrier immedi­ately to file a claim. Furnish complete information
concerning damage claims or shipping errors to
Thermal Arc, Order Department, 2200 Corporate
Drive, Troy, Ohio 45373-1085. Include all equip­ment identification numbers as described above
along with a full description of the parts in error.

Move the equipment to the installation site before
uncratingtheunit.Aliftingeyeonthetopofthecase
has been provided so that the equipment may be
carried or lifted with a crane or hoist. Use care to
avoid damaging the equipment when using bars,
hammers, etc., to uncrate the unit.

WARNING: Falling machine due
to lifting eye failure may cause
death or serious injury.

• Lifting device may fail when overloaded.

• This lifting device is designed to lift the

power source ONLY. If the machine is
equipped with a trailer or accessories over
100 pounds, DO NOT LIFT by lifting eyes.

• Avoid sudden jerks, drops, or swinging.

• Check lifting device components visually

for looseness and signs of metal fatigue.

• Before changing any hardware, check
grade and size of bolts, and replace with
bolts of equal or higher size and grade.

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

December 1, 1997 Revised 1-1

430429-174
INTRODUCTION

This page intentionally left blank.

1-2 April 7, 1997 Revised

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERSKEEPAWAY UNTIL CONSULTINGYOUR DOCTOR. DONOT LOSE THESEINSTRUCTIONS. READOPERATING/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
trainingbeforeusingthis equipment. Anyone not havingextensivetraining in welding and cuttingpracticesshould 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:
other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill.

Touchingliveelectrical partscancause fatal shocks
or severe burns. The electrode and work circuit is
electricallylivewhenevertheoutputison. The input
power circuit and machine internal circuits are also
livewhen poweris on.In semiautomaticor automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

1. Do not touch live electrical parts.

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

3. Insulate yourselffromwork and ground using dryinsulatingmats
or covers.

4. Disconnect input power or stop engine before installing or serv­icing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.

SAFETY IN WELDING AND CUTTING. This publication and

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.Donot
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.

8. Do notuseworn, damaged,undersized,or poorly splicedcables.

9. Do not wrap cables around your body.

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

11. Do not touch electrode while in contact with the work (ground)
circuit.

12. Useonlywell-maintained equipment.Repairor replacedamaged
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.

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.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.

Welding or Cutting

Operation

Torch soldering
Torch brazing
Oxygen cutting

Light
Medium
Heavy

Gas welding

Light
Medium

Heavy
Shielded metal-arc welding
(stick) electrodes

Electrode Size

Metal Thickness

or Welding Current

—
—

Under 1 in., 25 mm

1 to 6 in., 25-150 mm

Over 6 in., 150 mm

Under 1/8 in., 3 mm

1/8 to 1/2 in., 3-12 mm

Over 1/2 in., 12 mm

Under 5/32 in., 4 mm

5/32 to 1/4 in., 4 to 6.4 mm

Over 1/4 in., 6.4 mm

Filter

Shade

No.

2

3or4
3or4

4or5
5or6

4or5
5or6
6or8

10
12
14

1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.

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

Welding or Cutting

Operation

Gas metal-arc welding (MIG)

Non-ferrous base metal

Ferrous base metal
Gastungstenarcwelding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging

Light

Heavy
Plasma arc cutting

Light

Medium

Heavy

Electrode Size

Metal Thickness

or Welding Current

All
All
All
All
All
All

Under 300 Amp

300 to 400 Amp

Over 400 Amp

May 8, 1996 2-1

Filter

Shade

No.

11
12
12
12
12
12

12
14

9
12
14

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

FUMES AND GASES can be hazardous
to your health.

Weldingproducesfumesandgases.Breathingthese
fumes and gases can be hazardous to your health.

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

2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.

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

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot work­piece, and hot equipment cancausefiresandburns.
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.

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.

6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and raysofthearccanreactwithvapors 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.

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

6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.

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

8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

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

11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.

FLYING SPARKS AND HOT METAL can
cause injury.

Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.

CYLINDERS can explode if damaged.

Shielding gas cylinderscontaingasunderhighpres­sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.

1. Protectcompressed gascylinders fromexcessiveheat,mechani­cal shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining
themtoa stationarysupport orequipment cylinderrack toprevent
falling or tipping.

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Wear approved face shield or safety goggles. Side shields rec­ommended.

2. Wear proper body protection to protect skin.

3. Keep cylindersawayfrom any welding orotherelectricalcircuits.

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 instructionsoncompressedgascylinders, asso­ciated equipment, and CGA publication P-1 listed in Safety
Standards.

ENGINES can be hazardous.

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.

2-2 May 8, 1996

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

Instruction 830001

ENGINE FUEL can cause fire or
explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

MOVING PARTS can cause injury.

Moving parts,suchasfans, rotors, and belts cancut
fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely
in place.

2. Stop engine before installing or connecting unit.

SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.

Batteriescontain acidandgenerateexplosivegases.

STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.

The coolantinthe radiator can beveryhotand under
pressure.

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known 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,
of Power 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 can 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.

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

2. Do not addfuelwhile smokingorif unitisnear anysparksor 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 spillfuel.Iffuelisspilled,clean up before starting engine.

3. Have only qualified people remove guards or covers for mainte­nance and troubleshooting as necessary.

4. To prevent accidentalstartingduring servicing, disconnectnega­tive (-) 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.

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.

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.

Biological Effects

3. Do not coil or drape cables 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.

Safety inWeldingandCutting,ANSIStandard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

SafetyandHealthStandards, OSHA 29 CFR1910,fromSuperinten­dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and
CuttingofContainersThatHaveHeldHazardousSubstances,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.

May 8, 1996 2-3

PRINCIPAL SAFETY STANDARDS

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson DavisHigh­way, Suite 501, Arlington, VA 22202.

Code forSafetyin Welding and Cutting,CSAStandard 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.

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

This page intentionally left blank.

2-4 May 8, 1996

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC

Instruction 830002

PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC

LE SOUDAGE A L′ARC EST DANGEREUX

PROTEGEZ-VOUS,AINSI QUE LES AUTRES, CONTRE LES BLESSURESGRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTSS’APPROCHER,NILES PORTEURSDE STIMULATEURCARDIAQUE(A MOINSQU’ILS N’AIENTCONSULTE UNMEDECIN).
CONSERVEZ CES INSTRUCTIONS.LISEZLEMANUELD’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER,UTILISEROU
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,sil’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’expériencepassée. Ces pratiques doivent être apprises
parétude ou entraînement avant d’utiliserl’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.

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. Ne touchez pas à des pièces sous tension.

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

3. Isolez-vous de lapièceà souderetde la miseà la terreaumoyen
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
commutateurencircuit ouvertouenlevez lesfusibles del’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.

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 indiquéeci-après)

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

7. N’utilisez quedes porte-électrodesbien isolés.Ne jamaisplonger
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 porte-électrodes 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.

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 espacesconfinésoumouillés,n’utilisezpasde 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.

pour vous protéger le visageetlesyeuxlorsquevoussoudezou
que vous observez l’exécution d’une soudure.

2. Portez des lunettesdesécurité approuvées.Desécrans latéraux
sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arcoudel’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.

8-V-96 2-1

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE

Opération

de

Coupage ou soudage

Brasage tendre au chalumeau
Brasage fort au chalumeau
Oxycoupage

mince
moyen
épais

Soudage aux gaz

mince
moyen

épais
Soudage à l’arc avec
electrode enrobées (SMAW)

Soudage à l’arc sous gaz
avec fil plein (GMAW)

métaux non-ferreux

métaux ferreux
Soudage à l’arc sous gaz
avec électrode de tungstène (GTAW)
Soudage à l’hydrogène
atomique (AHW)
Soudage à l’arc avec
électrode de carbone (CAW)
Soudage à l’arc Plasma (PAW)
Gougeage Air-Arc avec
électrode de carbone

mince

épais
Coupage à l’arc Plasma (PAC)

mince

moyen

épais

( selon AWS A 8.2-73 )

Dimension d’électrode ou

Epaisseur de métal ou

Intensité de courant

toutes conditions
toutes conditions

moins de 1 po. (25 mm)

de 1 à 6 po. (25 à 150 mm)

plus de 6 po. (150 mm)

moins de 1/8 po. (3 mm)

de 1/8 à 1/2 po. (3 à 12 mm)

plus de 1/2 po. (12 mm)

moins de 5/32 po. (4 mm)

de 5/32 à 1/4 po. (4 à 6.4 mm)

plus de 1/4 po. (6.4 mm)

toutes conditions
toutes conditions

toutes conditions
toutes conditions
toutes conditions

toutes dimensions

moins de 300 ampères

de 300 à 400 ampères

plus de 400 ampères

Nuance de

de filtre

oculaire

2

3 ou 4
2 ou 3

4 ou 5
5 ou 6

4 ou 5
5 ou 6
6 ou 8

10
12
14

11
12

12
12
12

12

12
14

12
14

9

LES VAPEURS ET LESFUMEES SONT
DANGEREUSES POUR LA SANTE.

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

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 adduc-
tion d’air approuvé.

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

2-2 8-V-96

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 sileszonesà souder ont été grattées à fond, que
si l’espace est bien ventilé;sinécessaire portez un respirateur
à adductiond’air.Car ces revêtementsettoutmétal qui contient
cesélémentspeuventdégagerdes fuméestoxiques aumoment
du soudage.

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC

Instruction 830002

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. 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.

LES ETINCELLES ET LES PROJEC­TIONS BRULANTES PEUVENT
CAUSER DES BLESSURES.

LES BOUTEILLES ENDOMMAGEES
PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs
sous haute pression.Desbouteillesendommagées
peuvent exploser. Comme les bouteilles font nor­malement partie du procédé de soudage, traitez­les 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. Méfiez-vous des projectionsbrulantesde soudage susceptibles
de pénétrerdansdesaires adjacentes pardepetitesouvertures
ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portéede
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 desoudageleplus près possibledelazone
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 coupezle filautube-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.

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.

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

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.

LES GAZ D’ECHAPPEMENT DES
MOTEURS PEUVENT ETRE MORTELS.

Les moteurs produisent des gaz d’échappement
nocifs.

LE CARBURANT PEUR CAUSER UN IN­CENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

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

8-V-96 2-3

LES MOTEURS PEUVENT ETRE DANGEREUX

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

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.

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. Faites attention de nepasrenverserde carburant. Nettoyeztout
carburant renversé avant de faire démarrer le moteur.

PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

DES PIECES EN MOUVEMENT PEU­VENT CAUSER DES BLESSURES.

Despiècesen mouvement,telsdes 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.

DESETINCELLESPEUVENT FAIREEX­PLOSER UN ACCUMULATEUR;
L’ELECTROLYTE D’UN ACCUMU­LATEUR PEUT BRULER LA PEAU ET
LES YEUX.

Les accumulateur s contiennent de l’électr oly te
acide et dégagent des vapeurs explosives.

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.

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

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.

1. Portez toujours un écran facial en travaillant sur un accumu­lateur.

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.

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

2. Mettez des gants et posez un torchonsurlebouchonpour l’ôter.

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

PRINCIPALES NORMES DE SECURITE

SafetyinWeldingandCutting, normeANSIZ49.1,AmericanWelding
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
CuttingofContainersThatHaveHeldHazardousSubstances,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 JeffersonDavisHighway,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.

2-4 8-V-96

DESCRIPTION OF EQUIPMENT

DESCRIPTION OF EQUIPMENT

430429-174

General

There are three basic units of the EXCEL-ARC®.
The EXCEL-ARC
1 & 500016A-1, 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
500016-2&500016A-2,isa constant-voltagetrans­former-rectifier type DC welding machine that pro­vides volt-ampere characteristic curves that are
basically flat.

The EXCEL-ARC
500016-3 & 500016A-3, is a combination constant­current and constant-voltage transformer-rectifier
typeDCweldingmachinethatprovidesvolt-ampere
characteristic curves for each mode of operation.

Table 3-1 gives input voltage and amperage data
for all part numbers covered by this manual.

ITEM

Rated Output Amperage
Rated Output Voltage
Rated Duty Cycle
Minimum Output
Maximum Output
Rated Input Voltage
Rated Input Amperage
Input kW
Input kVA
Input Frequency
Input Phase

Maximum Open Circuit Voltage
Auxiliary Power
No Load Input Voltage
No Load Input Amperage
No Load kW
No Load kVA
Power Factor
Efficiency

®

750 (CC), PartNumber 500016-

®

8065 (CV ), Part N umber

®

8065 (CC/CV), Part Number

PART NO. 500016-1
& 500016A-1
EXCEL-ARC

600 Amps
44 Volts
60% Duty
60 Amps
750 Amps
230/460/575
126/62.6/50
36 kW

50.1 kVA
60 Hz
3 Phase

86

1 kVA – 115V, 9A

230/460/575

4.4/2.4/2.0

1.2 kW

1.75 kVA
.72

72%

Recommended Unit Applications

APPLICATIONS
Gas metal arc welding (MIG)
Flux cored arc welding (with or

without gas shielding)
Submerged arc welding
Electro-slag welding
Carbon arc gouging
SMAW (Stick welding)
GTAW (TIG welding)

-1 -2 -3

XX
XX

XX

XX
X
X
X

Wire Feeder Compatibility

Some models of Thermal Arc wire feeders will
connect onto this unit with no special preparation.
In some cases, however,aninterface must be used
and in other instances, some rewiring must be
accomplished. Complete details for these excep­tionswillbefoundintheinstructionmanualsupplied
with the wire feeder.

PART NO. 500016-2

®

CC

& 500016A-2
EXCEL-ARC®CV

650 Amps
44 Volts
100% Duty
75 Amps @ 15 Volts
800 Amps @ 40 Volts
230/460/575
110/55/43
36 kW

43.8 kVA
60 Hz
3 Phase

62
1 kVA – 115V, 9 A
230/460/575
6/3/2.4

1.2 kW

2.4 kVA
.82
80%

PART NO. 500016-3
& 500016A-3
EXCEL-ARC®CC/CV

CC
600 Amps
44 Volts
60% Duty
75 Amps
750 Amps

230/460/575
110/55/43
36 kW

43.8 kVA
60 Hz
3 Phase

62
1 kVA – 115V, 9 A
230/460/575
6/3/2.4

1.2 kW

2.4 kVA
.82
80%

CV
650 Amps
44 Volts
100% Duty
75 Amps @ 15 Volts
800 Amps @ 40 Volts

December 1, 1997 Revised 3-1

Table 3-1 Input Voltage/Amperage Data

430429-174
DESCRIPTION OF EQUIPMENT

3-2 April 7, 1997 Revised

Figure 3-1 Front and Rear Panel

Controls and Outlets

See callouts on Figure 3-1.

430429-174

DESCRIPTION OF EQUIPMENT

5. CC/CV Selector Switch (CC/CV) (500016-3 &

500016A-3) — Selects the welding mode of opera-
tion.

1. Pilot Light (500016-1, -2, -3 & 500016A-1, -2,

-3) — When lighted, indicates that theinput contac­tor (power) is ON.

2. Input Contactor Control (500016-1, -2, -3 &
500016A-1, -2, -3) — This toggle switch is the
master power switch for the welding machine, and
must be in the ON position before any other section
will operate. The primary circuit of the control trans­formerisenergizedwheneverlinevoltageispresent
at the inputterminals. This switch closesthe secon­darycircuitofthecontroltransformer, energizingthe
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
SelectorSwitch(500016-1,-2,-3&500016A-1,-2,

-3) — Selects either the output control (Local) or
some remote control device (Remote) to control
welding output.

4. 115-V AC Receptacles (500016-1, -2, -3 &
500016A-1, -2, -3) — Provides auxiliary power for
lights, wire feeders, water pumps, etc. — 15 amps
maximum.

6. Feeder Control Receptacle Panel (Automat-

ic) (CV units) (500016-2, -3 & 500016A-2, -3) —

Amphenol (19-pin) connector for a remote voltage
control type wire feeder. (Semiautomatic) (5-pin)
connector for the control cable from semiautomatic
wire feeder only.

NOTE: Only one feeder control receptacle
is used at any one time.

7. Arc Force Control (CC/CV Units) (500016-1,

-3 & 500016A-1, -3) — This potentiometer controls
short circuit (welding) current to produce an in­creaseincurrentasthearclengthisshortened.The
control is present to provide the degree of “hard
start” required, and the additional dynamic change
for welding tight grooves, etc. Turn clockwise to
increase “hard start” characteristics, counterclock­wise to obtain a soft-start, smooth arc.

8. Welding Voltage/Am peres Control (CV

Units) (500016-2, -3 & 500016A-2, -3) — Adjusts

arc welding output and open circuit voltage. Open­circuit voltage is approximately 1.5 times the weld­ing voltage for constant voltage welding. On
500016-1, -3 & 500016A-1,-3(CC units) — Adjusts
the welding current.

December 1, 1997 Revised 3-3

Figure 3-2 EXCEL-ARC®8065

Dimensions and Weight

430429-174
DESCRIPTION OF EQUIPMENT

TO FEEDER

TO AUTOMATIC

EQUIPMENT

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

5-PIN

GUN SWITCH

RECEPTACLE

OVERLOAD

THERMOSTAT

PHASE SIGNAL

STABILIZER

FILTER

L1

AMPHENOL BOARD

OUTPUT

SCR

SCR1—SCR6

19-PIN

GUN SWITCH

RECEPTACLE

PC CONTROL

BOARD

BACKGROUND

REGULATOR

PC BOARD

CC MODE

STABILIZER

FILTER

L2

3-4 April 7, 1997 Revised

+

CV UNITS

+

CC UNITS

—

CC UNITS

Functional Block Diagram for EXCEL-ARC®8065

—

CV UNITS

9. Volt/Amp Meter and Switch (CV Units)

(500016-2, -3 & 500016A-2, -3) — A single meter
with switch that will read DC volts when in the V.
position or read DC amps in the A. position.

10. Positive Terminal (+) (CV mode) (500016-2,

-3&500016A-2,-3)—Servesasaconnectionpoint
for the lead to the wire feeder when reverse polarity
is desired.

11. Positive Terminal (+) (CC mode) (500016-1,

-3&500016A-1,-3)—Servesasaconnectionpoint
for the lead to the electrode holder lead for SMAW
(stick) or arc gouging mode of operation when re­verse polarity is desired.

NOTE: To obtain opposite weldingpolarity,
simply reverse the connections to the posi­tive and negative terminals.

12. Negative Terminal (—) —Serves as a connec-
tionpointfortheleadtotheworkpiecewhenreverse
polarity is desired.

13. Circuit Breaker — Rated at 15 amps — pro-
vides protection to the 115-volt circuit which in-

430429-174

DESCRIPTION OF EQUIPMENT

cludes the fan and the 115-volt AC power recepta­cle.

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

15. Stick/Tig Selector Switch (CC Units)

(500016-3 & 500016A-3) — Selects a reduced cur­rent start in the TIG mode.

Duty Cycle

(Figure 3-3)

Duty cycle is the percentage of each ten-minute
period of time that the welding machine may be
operated under rated loadconditions. For example,
a duty cycle of 60% means thatthe 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 op­eratortodeterminethedutycycle at variouswelding
amperages.

December 1, 1997 Revised 3-5

Figure 3-3 Duty Cycle Chart

430429-174
DESCRIPTION OF EQUIPMENT

Figure 3-4 Volt/Ampere Characteristic Curves

3-6 April 7, 1997 Revised

INSTALLATION

430429-174

INSTALLATION

Location

For best operatingcharacteristics and longest unit
life, take care in selecting an installation site. Avoid
locations exposed to high humidity, dust, high am­bienttemperature,orcorrosivefumes.Moisturecan
condense on electrical components, causing corro­sionorshortingofcircuits. Dirtoncomponentshelps
retain this moisture.

Adequate air circulation is needed at all times in
order to assure proper operation. Provide a mini­mumof 12 inches (305 mm) of freeairspaceatboth
front and rear of the unit. Make sure that the venti­lator openings are not obstructed.

Grounding

The frame of this welding machine should be
groundedforpersonnelsafety,andtoassureopera­tion of the overcurrent protection. The grounding

method, and the equipment grounding conductor
size and type shall conform to local and national
codes.

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

If flexible power cable isused, use a cableassem­bly 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 s hall 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 rubber­tire mounted equipment. This static charge can

Outside Ground

April 7, 1997 Revised 4-1

Inside Ground

Figure 4-1

430429-174
INSTALLATION

COPPER

RATED

LINE

VOLTS

230 110 150 No. 2 No. 1 No. 6
460 55 75 No. 6 No. 4 No. 8
575 43 50 No. 8 No. 6 No. 8

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

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

cause painful shock and lead to the erroneous
conclusionthatanelectricalfaultexistsinthe 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 morethan10 feet (30 meters)
from the machine.

LOAD
AMPS

Table 4-1 Recommended Wire and Fuse Size Table

APPROX.

LINE

FUSE SIZE

LINE WIRE SIZE*

FLEXIBLE

IN CONDUIT

CABLE

Connecting Welding Machine to
Line Voltage

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

COPPER

GROUNDING

CONDUCTOR

MIN. SIZE

The equipment grounding conductor size is listed
in Table 4-1 as a guide, if no local or national code
is applicable.

Attach the equipment grounding conductor to the
stud provided on the yoke. Determine that the
ground wire size is adequate before the machine is
operated.

CAUTION:Besuretoreplace the cabinet
top to assure adequate internal ventila­tion and prevent component failure.

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.

DANGER: 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.

CAUTION: The method of installation,
conductor size, and overcurrent protec­tion shall conform to the requirements
of the local electrical code, the National
ElectricalCode, or other national codes,
as applicable. All installation wiring and
machine reconnections shall be done
by qualified persons.

Table 4-1 provides minimal information for 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, avail-

4-2 April 7, 1997 Revised

able 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.

430429-174

INSTALLATION

Welding Leads

Use Table 4-2 for selection of the proper size

copper welding leads.

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

For 60% duty cycle

NOTE: Lead size shown isfor 90°C cable insulation, 30°C (86°F) ambient, and not over 4.5 volts lead

drop.

50 Feet

(15.2 M)

TOTAL LENGTH OF LEAD CIRCUIT IN FEET (AND METERS)

(ELECTRODE LEAD PLUS WORK LEAD)

100 Feet

(30.5 M)

Table 4-2

150 Feet

(45.7 M)

200 Feet

(61.0 M)

250 Feet

(76.2 M)

April 7, 1997 Revised 4-3

430429-174
INSTALLATION

Figure 4-2 Input Voltage Connection & Changeover

4-4 April 7, 1997 Revised

For 500016-1 & 500016A-1

430429-174

INSTALLATION

Figure 4-3 Input Voltage Connection & Changeover

April 7, 1997 Revised 4-5

For 500016-2, -3 & 500016A-2, -3

430429-174
INSTALLATION

4-6 April 7, 1997 Revised

Figure 4-4 Installation Diagram

OPERATION

430429-174

OPERATION

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
Consultoperating instructions for components used
with this system before operating.

A thermostatically controlled fan motoris standard
onthisunit.Thefanmotorstartsandstopsautomat­ically when a predetermined temperature has been
reached.

®

8065 welding machines.

Preweld Operation

1. Connect welding leads to terminals on front

panel.

WARNING: Disconnect line volt­age from the unit before making
any connec tions inside unit.
Turn off fused disconnect
switch that supplies power to
welding machine, and remove
its fuse.

7. Place the voltage sensing jumpers (500016-2
and-3&500016A-2and -3)onthemainP.C. control
board to the desired mode. Local (voltage sensing
from the power source which comes from the fac­tory), Jumper JP-2 (–) and JP-4 (+). For remote
voltage sensing, going out to the optional terminal
strip – Thermal Arc P/N 204248 Jumper JP-3 (–)
and JP-5 (+).

SMAW (Stick) Welding, Carbon
Arc Gouging

(500016-3 & 500016A-3)

Referto Figure 3-1 for controls (numbers in paren-

thesis refer to callouts on Figure 3-1).

1. On 500016-3 & 500016A-3 set the CC/CV
selector switch to CC position.

2. Hold electrode clear of work, and set Stick/Tig
Switch (15) to STICK position.Be sure the Remote­Local 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.Atthe conclusionof welding, break arc, and turn
Input Contactor Control Switch (2) to OFF position.

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 weldingmachine.Connectfeeder
receptacle to wire electrode feeder system.

3. Refer to other manuals for component connec­tions.

4. Set Output Control to desired value.

5.Settheremote/localcontrol switchinthedesired
mode.

6. Set the stick/Tig switch (500016-3 & 500016A-

3) in the desired mode.

December 1, 1997 Revised 5-1

Welding, Semiautomatic or
Automatic

Refer to Figure 3-1 for controls.

1. On 500016-2 and -3 & 500016A-2 and -3 set
Remote/Local Output Control Switch (3) and Volt­age Sensing Jumpers to LOCAL — JP-2 and JP-4.

NOTE: Set Output Control Switch (3) to
REMOTE when using a feeder which con­trols the voltage, and remote voltage con­trol is desired. Set Voltage Sensing
Jumpers to JP-3 and JP-5 to REMOTE
when using a feeder which provides volt­age sensing at the actual welding location.
If the Voltage Sensing Jumpers are placed
in the REMOTE position, and the voltage
sensing leads are not connected at the
welding location, the output of the welding
machine will go to maximum amperage.

430429-174
OPERATION

2. On 500016-3 & 500016A-3 set the CC/CV Se-

lector 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.

®

6. The Excel-Arc

weld termination sequence is
fully adjustable. Three simple jumper changes on
the main circuit board allow the following weld ter­mination treatments.

A.) Burnback Delay (JP-1)
B.) “Wire Sharpening”

TM

(JP-9)

C.) Inhibit (JP-1)

A. Burnback Delay — The burnback setting calls

the Excel-Arc

®

to maintain a contactor closure for
.25 seconds after thegun trigger has been released
and wire feeding hasstopped.The features primary
functionis the prevention of wire sticking totheweld
puddle upon completion of a weld. Another term
commonly used to describe burnback is the term
anti-stick.

The burnback option is preferred in the following

situations.

– WhenExcel-Arc

®

isusedwitholderwirefeeders
whichdonothavedynamicbrakingandwouldshow
a tendency to wire coasting.

– When Excel-Arc

®

is used on high cycle short
weld applications or if a great deal of tack welding
is done.

B. “Wire Sharpening”

TM

— Serves the same func­tion as burnback. However in addition to maintain­ing contactor closure for .25 seconds, Excel-Arc
also lowers weld voltage to a value too low to
maintain an arc but sufficient enoughto burn offthe
remainingwire.Theeffectofthis a significantreduc­tion in the ball size of the end of the wire.

CAUTION: In order for this circuit to
work properly, the MIG torch must re­main stationary for the complete wire
sharpening cycle.

“Wire Sharpening”

TM

is preferred in the following

situations.

– Automatic welding operations, Robotic applica-

tions.

C. Inhibit—Theinhibitselection disablesboththe
wire sharpening circuit and the burnback circuit.
This feature may be useful in situations where an
external control is used to control power source
functions with the burnback circuit mentioned ear­lier.

®

5-2 December 1, 1997 Revised

MAINTENANCE

430429-174

MAINTENANCE

Replacing SCRs

Replacing a 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.

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)
Moderate(7to 15 hrs./day)
Heavy (16 to 24 hrs./day)

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

Lubrication

Interval

Every 12 months
Every 6 months
Every 3 months

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
threemonths,ormoreoftenasnecessary,wipeand
blow out all dirt from the machine’s internal compo­nents,withairpressureofnotover25psi(172kPa).
Be sure to wipe the fan blades clean.

Check and tighten all electrical connections as
necessary to eliminate unnecessary losses and to
avoid subsequent troublefrom overheating or open
circuits. Check for broken wiring or damaged insu­lation on wiring.

CAUTION: The flow of air through the
weldingmachineiscarefullydirectedby
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.

December 1, 1997 Revised 6-1

430429-174
MAINTENANCE

This page intentionally left blank.

6-2 April 7, 1997 Revised

TROUBLESHOOTING

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

Troubleshooting Guide

Welding machine will not start.

Power switch OFF

Place power switch in ON position.

Power lines dead

Check voltage.

Broken power lead

Repair.

Wrong line voltage

430429-174

TROUBLESHOOTING

Check power supply.

Incorrect input power connections at welding machine

Check connections against wiring diagram.

Open circuit to power switch or control transformer

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

Fuse on control transformer blown

Remedy cause. Replace fuse.

Line contactor fails to close.

Defective NVR coil

Replace.

Mechanical obstruction on contactor

Remove.

Broken leads at line contactor

Repair.

Contactor chatters.

Line leads too small

Use larger leads.

Low line voltage

Check line voltage.

April 7, 1997 Revised 7-1

430429-174
TROUBLESHOOTING

Contactor operates and blows link fuses.

Wrong line voltage

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

Links on voltage changeover board incorrectly connected

Check Voltage Changeoverdiagrams for link positions; connect links correctly.See
Diagrams chapter.

Line fuse too small

Install proper size fuse.

SCR failure or shorted flyback diode

Refer to Detailed Troubleshooting Instructions.

Short circuit in primary connections

Remove short circuit.

Transformer failed

Repair or replace.

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

Welding machine overloaded

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

Duty cycle too high

Do not operate continually at overload currents.

Power leads too long or too small in cross section

Replace with larger diameter cable.

Ambient temperature too high

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

Ventilation blocked

Check air intake and exhaust openings to be unobstructed.

Fan not operating after machine is loaded down

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

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.

No ground connections at work

Make connections.

Welding cables not connected

Make connections.

7-2 April 7, 1997 Revised

430429-174

TROUBLESHOOTING

Voltage/amps dial does not control welding voltage.

Potentiometer burned out

Replace.

Loose connections in voltage control circuit

Check connections.

Control circuit board failure

Replace control board.

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

NOTE: Fan will not operate until rectifier heats up.
Motor failed

Replace or repair.

Broken lead or connection to fan motor

Repair wiring.

Blown circuit breaker on rear panel of welding machine

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

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

Case of welding machine not grounded

Ground welding machine case.

Work table and work not grounded

Ground work and work table to plant ground.

Abnormal current fluctuation, voltage nearly constant

Irregular wire feed speed

See welding head manual.

Inadequate shielding of arc by flux or gas

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

Wire feed rate too slow

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

Too much shielding gas

Decrease by trial and error. See welding head manual.

Loose cable connections

Check for overheated connections and tighten.

Welding contact tube (tip) on wire feeder makes poor contact with electrode

Check contact tube hole size and replace with proper tube.

April 7, 1997 Revised 7-3

430429-174
TROUBLESHOOTING

Contactor fails to open.

Contactor contacts sticking

Clean contacts.

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

Control circuit board failure

Replace Control P.C. Board.

Output of welding machines goes to maximum and there is no control.

Voltage sensing lead not connected

Connect lead.

Jumper JP-2 and JP-4 on Control P.C. Board not connected

Add jumpers JP-2 and JP-4 on Control P.C. Board.

7-4 April 7, 1997 Revised

Detailed Troubleshooting
Instructions

The EXCEL-ARC®8065 is a solid-state welding
machine.Themethodof troubleshootingisdifferent,
but is not more difficult than troubleshooting a con­ventional unit. Do not overlook the obvious. As in
the case of all electrical equipment, loose connec­tions are the primary cause of malfunction both
internalandexternaltotheweldingmachine.Donot
overlook bad grounds, worn contact tubes (tips),
dirty cable liners, shorted control cables, wrong
settings, blown fuses, worncontactors, misconnec­tions from feeding equipment, misapplication, etc.
To check the Control P.C. Board, take controlmod­ulepaneloffthefront panel. Check the controlboard
for loose connectors, brokenor loose wires. Inspect
the P.C. Board forbrokencomponents, scorched or
burnedcomponents.The onlyequipmentneededto
properly detect a problem on this welding machine
is a simple voltohmmeter, although an oscillo­scope is the best method to quickly “see” the prob­lem.

Voltages of Interest — Refer to Connection Dia-
gram.

1. Across the secondary on all three phases —

92.0 V AC ± 10%.

2. From the center bus bar on secondaries to the

top or bottom ofthe secondary — 46.0V AC ± 10%.

NOTE: The ± 10% refers to the possibility
of having a high or low input line voltage.

3. 115 V Receptacles — 115 V AC ± 10%.

4. AC Input Voltage — Test Points R206 to R207
–36V AC voltage reading – AC voltage input to P.C.
Board; Test Points R208 to R209 – 36V AC voltage
reading – AC voltage input to P.C. Board; Test
Points R210 to R211 – 36V AC voltage reading –
AC voltage input to P.C. Board.

5. Power Supply Checks — Test Points TP16 to
TP18 – +22V DC meter reading – power supply
reading; Test Points TP16 to TP17 – +15V DC
meter reading – power supply reading; Test Points
TP16 to TP19 ––15V DC meter reading – power
supply reading.

6. Output ContactorChecks — Test Point TP16to
Anode L9 – +16V DC meter reading (CC Mode);
TestPointTP16toL8–+16VDCmeterreading(CV
Mode) – output switch to local pins A and B on
Amphenolshortedtogether;TestPointTP16toR22
– +16V DC meter reading (Tig position).

430429-174

TROUBLESHOOTING

7. Output Reference Circuits — Test Point TP16
to TP9 – +10V DC meter reading – reference
voltage supply; TestPoint TP16 toL10 ––10V DC
(CC and 8065 models) – voltage reference supply
to output pots.

8. SCR Firing Circuits — Test Point TP16 to TPE
– 4.3V DC – checks ramp circuits; Test Point TP16
to TPD – 4.3V DC – all readings should be very
close for balance; Test Point TP16 to TPB – 4.3V
DC – all readings should be very close for balance;
Test Point TP16 to +C69 – 17-19V DC – checks
SCR gate; Test Point TP16 to +C70 – 17-19V DC
– generator circuits; Test Point TP16 to +C71 –
17-19V DC – all should be equal.

Control Circuit Board Malfunction — If a board
malfunction occurs, the following situations will
probably result:

1. Loss of arc completely.

2. Very noticeable, rough, sputtering arc.

3. Loss of control and burnback.

4. Minor starting problems.

SCR Malfunction — If one or more SCRs mal-
function,thefollowingsituationswillprobablyresult:

1. Blown line fuses as the result of a shorted SCR
(similar to a shorteddiode). A shortedflyback diode
will also produce this situation.

2. If one SCR does not turn on [either it is open or
the gate signal is not being received by the SCR
(gate circuit open)], a very small change will occur
atthearcandwill bedifficulttonoticeby theaverage
operator. Generally when this happens, it will be
necessary to adjust the voltage control on the front
of the welding machine (turn it up) to obtain the
samearcthatwasbeingproducedbeforethedefect
occurred.

3. If two SCRs do not turn on, the arc becomes
more erratic and unstable.

Component Testing

1. In the case of a severe malfunction, such as a
shorted SCR or diode, do not turn on the unit.
Disconnect the leads from the transformer to the
heat sink assembly and check with a VOM for
shorted SCRs or a shorted flyback diode.

2. If the welding machine is suspected, a very
simple test can tell you a great deal about it. Simu­late gun switch closing andobserve the open circuit
voltage. This can be done by putting the Process
SelectionSwitch(Fig.3-1,item5) in the CV position

April 7, 1997 Revised 7-5

430429-174
TROUBLESHOOTING

andshortingterminalsAandBtogetheronthe5-pin
connector on the rear panel. This voltage should
vary from 19V DC to 59V DC ± 10%, as the voltage
control is rotated from min. to max. slowly. If this
voltage varies smoothly, there is a strong possibility
that nothing has malfunctioned in the welding ma­chine. If the voltage varies erratically and does not
come close to the values listed, you probably have
a control circuit board problem. If the voltage vari­ation is somewhat smooth, but does not reach the
maximum value (remember the ± 10% refers to a
highor low line voltage), youprobablyhave an SCR
problem.

3. The next step is to go inside the unit and check
the control circuit board. See the instructions pro­vided for this test. It is important to run through the
tests in the order they are listed. If an interface box
is being used, it will be necessary to switch the
welding machine local-remote switch to the local
position.

4. If nothing is found defective on the board, the
next step is to go to the SCRs. First of all an open
gate or an open SCR cannot be checked with a
VOM. If an SCR isnotfiring,the open circuit voltage
(OCV) will shift down. Check the following table for
typical values:

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
rectifiertherearegate leadscomingoffofthe SCRs.
Each of these leads are connected to a quick-dis­connect terminal on thesuppressor 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 par­ticularSCRisworkingproperly.Reconnect this lead
anddothe same thing with the remaining leads until
you discover which disconnection does not cause
the OCV to drop to a lower level. This is the mal­functioning SCR. See Mounting Procedures for
SCRs which follows.

Mounting Procedure for SCRs

1. Thoroughly clean heat sink surface to eliminate

any dirt or contamination.

2. Apply a thin coat of Alcoa #2 compound to
cleanedsurface.Alcoa#2isavailablefromThermal
Arc, part number 903870.

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

Disconnect cable #103 from the capacitor bank
assembly. Insulate the lug end of cable #103 to
prevent it from touching chassis or any other sur­face.

500016-1 &

500016A-1

All SCRs firing properly
max. OCV = 85V DC.

1 SCR not firing
max. OCV = 77V DC.

2 SCRs not firing
max. OCV = 69V DC.

3 SCRs not firing
max. OCV = 61V DC.

500016-2, -3 &

500016A-2, -3

All SCRs firing properly
max. OCV = 57V DC.

1 SCR not firing
max. OCV = 51V DC.

2 SCRs not firing
max. OCV = 45V DC.

3 SCRs not firing
max. OCV = 39V DC.

NOTE: These voltages were recorded at
nominal line voltage with voltage control
adjustment at MAXIMUM setting (unit ad­justed for high open-circuit voltage).

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.PlacetheForceIndicator 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.

7-6 April 7, 1997 Revised

Examples:

430429-174

TROUBLESHOOTING

Less than
rated force.
Tightennutsal­ternately 1/4
turn at a time
until points co­incide.

Correct rated
force.

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

Figure 7-1

Figure 7-2

To Calibrate Force Gauge:
If the gauge is suspected of being out of calibration due to wear or damage, check it on a flat surface as

shown below.

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

April 7, 1997 Revised 7-7

Figure 7-3

430429-174
TROUBLESHOOTING

This page intentionally left blank.

7-8 April 7, 1997 Revised

PARTS LIST

430429-174

PARTS LIST

Equipment Identification

All identification numbers as described in the In­troductionchaptermustbefurnishedwhenordering
partsormakinginquiries.Thisinformationisusually
found on the nameplate attached to theequipment.
Be sure to include any dash numbers following the
Specification or Assembly numbers.

How To Use This Parts List

The Parts List is a combination of an illustration
(Figure Number) and a corresponding list of parts
which contains a breakdown of the equipment into
assemblies, subassemblies, and detail parts. All
partsoftheequipmentare listedexceptforcommer­cially available hardware, bulk items such as wire,
cable, sleeving, tubing, etc., and permanently at­tached items which aresoldered,riveted, or welded

to another part. The part descriptions may be
indented to show part relationships.

Todeterminethepartnumber,description, quan­tity,orapplicationofanitem,simplylocate theitem
in question from the illustration and refer to that
item number in the corresponding Parts List.

An“ApplicationCode”isusedtodistinguishparts
that are applicable only to certain Specifications
and/or Assemblies. Thiscode is foundin the right­mostcolumnoftheParts List.Ifaniteminthe Parts
ListappliestoallSpecificationsorAssemblies,the
word “ALL” will be intheApplication Code column.
Refer to the following list to determine the appro­priate Application Codes for the Specifications or
Assemblies covered by this manual. If only the
assemblyor specification number is listed, the use
of an Application Code does not apply to this
manual.

PART NUMBER APPLICATION CODE

500016-1 A
500016-2 B

500016-3 C
500016A-1 D
500016A-2 E
500016A-3 F

April 1, 1997 Revised 8-1

430429-174
PARTS LIST

Figure 8-1 EXCEL-ARC®Control Panel Group

8-2 April 7, 1997 Revised

430429-174

PARTS LIST

Parts List for Figure 8-1

Item Part Description Qty Application

No Number per Code

Assy

500016-1 Excel-Arc®Welder - 750 CC 1 A

®

500016-2 Excel-Arc
500016-3 Excel-Arc
500016A-1 Excel-Arc
500016A-2 Excel-Arc
500016A-3 Excel-Arc

Welder - 8065 CV 1 B

®

Welder - 8065 CC/CV 1 C

®

Welder - 750 CC 1 D

®

Welder - 8065 CV 1 E

®

Welder - 8065 CC/CV 1 F

1 204281-7 . Panel - Control 1 ABC

204281A-1 . Panel - Control 1 DEF
2 204212 . Board - PC, Digital Display 1 BCEF
3 204600-2 . Spacer 4 BCEF
4 409000-1 . Bezel - Meter 1 BCEF
5 204053-5 . Panel - Control Module 1 A

204053-11 . Panel - Control Module 1 D

204053-2 . Panel - Control Module 1 B

204053-8 . Panel - Control Module 1 E

204053-3 . Panel - Control Module 1 C

204053-9 . Panel - Control Module 1 F
6 406806-1 . Knob - Control 1 AC

406806-3 . Knob - Control 1 DF
7 401428-8 . Potentiometer - Volt/Amp Ctl, Arc Force 1 All

401428-8 . Potentiometer - Volt/Amp Ctl, Arc Force 2 ACDF
8 405365-1 . Switch - Toggle, ON/OFF, Tig Stick 1 ABDE

405365-1 . Switch - Toggle, ON/OFF, Tig Stick 2 CF
9 408850-2 . Knob - Block 1 ABC

408850-5 . Knob - Block 1 DEF
10 402682 . Switch - Toggle, RMT/LC1 1 All
11 402421-2 . Light - Indicator 1 All
12 204052-2 . Panel - Output, Blank 1 AB

204052-6 . Panel - Output, Blank 1 DE
13 204052-1 . Panel - Output, Terminal 2 AB

204052-5 . Panel - Output, Terminal 2 DE

204052-1 . Panel - Output, Terminal 3 C

204052-5 . Panel - Output, Terminal 3 F
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

April 1, 1997 Revised 8-3

430429-174
PARTS LIST

This page intentionally left blank.

8-4 April 7, 1997 Revised

430429-174

PARTS LIST

Parts List for Figure 8-1

Item Part Description Qty Application

No Number per Code

Assy

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

No Number . Screw - 1/2-13 x 1, 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
21 204207B . 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 . Switch - Range 1 C

367260-1 . Switch - Range 1 F
26 405478 . . Rivet 1 CF
27 W-11291-3 . . Nut - Speed, Push on 1 CF
28 410602 . . Bracket 1 C

410602-1 . . Bracket 1 F
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 204055-7 . Box - Control Board 1 ABC

204055A-7 . Box - Control Board 1 DEF
— 204247-1 . Cable - Ribbon, Meter 1 BCEF
36 351505 . Screw - 1/2-13 x 1-3/4, HHC, ST.

(threaded for item 39) 2 ABDE

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

(threaded for item 39) 3 CF

37 No Number . Screw - #6-32 x 1/4 Rd. Hd. MH. ST. 2 ABDE

No Number . Screw - #6-32 x 1/4 Rd. Hd. MH. ST. 3 CF
38 405362-3 . Bushing - Snap 2 All

— Not Illustrated

April 1, 1997 Revised 8-5

430429-174
PARTS LIST

8-6 April 7, 1997 Revised

Figure 8-2 Base and Lifting Yoke Group

430429-174

PARTS LIST

Parts List for Figure 8-2

Item Part Description Qty Application

No Number per Code

Assy

1 204306 . Transformer - Power 1 BCEF

204595 . Transformer - Power 1 AD
2 367228-13 . . Board - Voltage Changeover 1 All
3 204318 . . Bracket - Voltage Changeover 1 ABC

204318-1 . . Bracket - Voltage Changeover 1 DEF
4 CW-811 . Link - Voltage Changeover 3 All
5 204301 . Bracket - Mtg. 1 ABC

204301-1 . Bracket - Mtg. 1 DEF
6 204326 . Choke - Filter, CC 1 CF

368084-6 . Transformer - Interface 1 AD
7 204304 . Choke - Filter, CV 1 BCEF
7A 367718-6 . Reactor - Filter, CC 1 AD
8 204772 . Door 1 ABC

204772-1 . Door 1 DEF
9 203453 . Hinge - Door 2 All
10 204281-5 . Panel - Side, Left 1 ABC

204281A-5 . Panel - Side, Left 1 DEF
11 406358-4 . Resistor - Fixed, 175 W 1 BCEF
12 406358-1 . Resistor - 25 Ohm, 175 W 1 BCEF

406358-2 . Resistor - 50 Ohm, 175 W 1 AD
13 204285 . Yoke - Lifting 1 ABC

204285-1 . Yoke - Lifting 1 DEF
14 402037-33 . Grommet - Rubber 3 All
15 402037-11 . Grommet - Rubber 2 All
— 402037-15 . Grommet - Rubber 1 All
16 375426-4 . Standoff 5 CF
17 204182 . Board - Current Booster 1 CF
18 204281-4 . Panel - Side, Right 1 ABC

204281A-4 . Panel - Side, Right 1 DEF

204099 . Capacitor - Assembly 1 BC

204099-1 . Capacitor - Assembly 1 EF
19 204152 . . Bus - Capacitor 2 BCEF
20 405278-15 . . Capacitor 5 BCEF
21 204301 . . Bracket - Mtg. 2 BC

204301-1 . . Bracket - Mtg. 2 EF
22 409870 . . Washer - Insulating 4 BCEF
23 409869 . . Bushing - Insulating 4 BCEF
24 204281-6 . Box - Contactor 1 ABC

204281A-6 . Box - Contactor 1 DEF
25 404132-1 . Contactor 1 All

April 1, 1997 Revised 8-7

430429-174
PARTS LIST

This page intentionally left blank.

8-8 April 7, 1997 Revised

430429-174

PARTS LIST

Parts List for Figure 8-2

Item Part Description Qty Application

No Number per Code

Assy

26 406392-2 . Transformer - Control 1 All
27 W-11166-11 . Fuse - 1/2 Amp 1 All
28 204281-3 . Panel - Top 1 ABC

204281A-3 . 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
32 368705-36 . Capacitor - W/Leads 2 ABDE

368705-36 . Capacitor - W/Leads 3 CF
33 830116 . Label - Frame Ground 1 All
34 408891 . Label - Ground 1 All

— 204698 . Label - Voltage Changeover 1 AD
— 204323 . Label - Voltage Changeover 1 BCEF
— 406484 . Label - Fuse 1 All

35 204280 . Base - Welder 1 ABC

204280-1 . Base - Welder 1 DEF
36 364042 . Resistor 1 BCEF

— Not Illustrated

April 1, 1997 Revised 8-9

430429-174
PARTS LIST

8-10 April 7, 1997 Revised

Figure 8-3 Rear Panel Group

430429-174

PARTS LIST

Parts List for Figure 8-3

Item Part Description Qty Application

No Number per Code

Assy

1 204109-2 . Panel - Amphenol, Blank 1 A

204109-4 . Panel - Amphenol, Blank 1 D
2 204109-1 . Panel - Amphenol 1 BC

204109-3 . Panel - Amphenol 1 EF
3 204184 . Board - P.C. Amphenol 1 BCEF
4 203627-7 . Breaker - Circuit, 10 A 2 BCEF

203627-7 . Breaker - Circuit, 10 A 1 AD
5 170919-2 . Plug - Hole 1 AD
6 402670 . Receptacle - 115 V. 1 All
7 366826-1 . Suppressor - Assembly 1 All
8 204281-2 . Panel - Rear 1 ABC

204281A-2 . Panel - Rear 1 DEF
9 406991 . Blade - Fan 1 BCEF

8RT-609 . Blade - Fan 1 AD
10 201016 . Shroud - Fan 1 BC

201016-1 . Shroud - Fan 1 EF

204055-8 . Shroud - Fan 1 A

369650-1 . Shroud - Fan 1 D
11 201015 . Bracket - Mtg. Fan 2 BC

201015-1 . Bracket - Mtg. Fan 2 EF

369640 . Bracket - Mtg. Fan 2 A

369640-1 . Bracket - Mtg. Fan 2 D
12 406992-1 . Motor - Fan 1 BCEF

12TW-595-1 . Motor - Fan 1 AD
13 369641 . Insulator - Mtg. 2 All
14 204302 . Heat Sink - Rectifier 1 BCEF

369639 . Heat Sink - Rectifier 1 AD
15 204303 . Heat Sink - SCR 6 BCEF

369642 . Heat Sink - SCR 6 AD
16 409639 . Rectifier - Silicon 6 BCEF

405139 . Rectifier - Silicon 6 AD
17 16DA-954-12 . Pin - Spring 6 All
18 405140-4 . Clamp - Mtg. 6 BCEF

405140-1 . Clamp - Mtg. 6 AD
19 204210 . Board - Suppressor 2 All
20 W-10931-3 . Diode - Flyback 1 BCEF
21 404044-6 . Thermostat - Fan 1 All
22 404044-3 . Thermostat - Overload 1 All
23 204575 . Shunt 1 All

April 1, 1997 Revised 8-11

430429-174
PARTS LIST

Parts List for Figure 8-3

Item Part Description Qty Application

No Number per Code

Assy

— 204038-6 . Cable - Ribbon, Amphenol 1 BCEF
— 903914-1 . Cap - Protective 1 BCEF
— 903914-2 . Cap - Protective 1 BCEF
— 403091-14 . Plug - Hole 1 All

— Not Illustrated

8-12 April 7, 1997 Revised

DIAGRAMS

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

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

• Use only those diagrams and instructions that are applicable.

MODEL

NO.

PART

NUMBER

500016-2 204321 Sheet 4 & 5 204321 Sheet 6 204322

CONNECTION

DIAGRAM

SCHEMATIC

DIAGRAM

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DIAGRAMS

VOLTAGE

CHANGEOVER

DIAGRAM

EXCEL-ARC®8065

EXCEL-ARC

®

750

500016-3 204321 Sheet 7 & 8 204321 Sheet 9 204322

500016A-2 204321 Sheet 4 & 5 204321 Sheet 6 204322

500016A-3 204321 Sheet 7 & 8 204321 Sheet 9 204322

500016-1 204321 Sheet 1 & 2 204321 Sheet 3 204697

500016A-1 204321 Sheet 1 & 2 204321 Sheet 3 204697

December 1, 1997 Revised

STATEMENT OF WARRANTY

LIMITED WARRANTY:ThermalArc®, Inc., AThermadyneCompany,warrantsthat its products will be free of defectsinworkmanship
ormaterial.Shouldany failuretoconformto this warrantyappearwithin the timeperiodapplicable to the ThermalArcproducts as stated
below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordancewithThermal 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 circumstancesbe liable for special or consequential damages, such as,

but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”)
for service interruption.TheremediesofthePurchaserset forth herein are exclusive and the liability of Thermal Arc with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strike tort, or under
any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is
based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other
warranty.

PURCHASER’SRIGHTS UNDERTHISWARRANTY AREVOID IFREPLACEMENTPARTSOR ACCESSORIESARE USEDWHICH
IN THERMAL ARC’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY
NON-AUTHORIZED PERSONS.

Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Arc’s
authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Arc delivers the
product to the authorized distributor.

Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below
beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the
authorized distributor.

ALL OTHER P-WEE, PRO-LITE

POWER SUPPLIES POWERSUPPLIES PRO-PLUS, PRO-WAVE LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 2 YEARS 1 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR
CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR
ALLOTHERCIRCUITSAND COMPONENTSINCLUDING 1 YEAR 1 YEAR 1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOID, PUMPS, POWER SWITCHING SEMI-CONDUCTORS

ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE
MANUFACTURER. SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS
CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR

EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS
REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS

Warranty repairsorreplacementclaims under thislimitedwarrantymust besubmittedto Thermal Arc by an authorizedThermalArc®repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to
sendproductsto anauthorizedwarranty repairfacility shallbethe responsibilityof thecustomer.All returnedgoodsshall beat the customer’s
risk and expense. This warranty supersedes all previous Thermal Arc warranties.

.

Thermal Arc®is a Registered Trademark of Thermadyne Industries Inc.

Thermal Arc Inc. Effective January 4, 1999
Troy, Ohio 45373 830538