Thermal Arc 6045 EXCEL-ARC, 4030 FABSTAR, Fabricator 281, ARCMASTER 400 TIG HF, VA 2000 Operating Manual

6045

®

EXCEL-ARC

TRANSFORMER-RECTIFIER
DC WELDER

Operating Manual

Version No: AA.01 Issue Date: November 30, 2006 Manual No.: 0-4934
Operating Features:

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 a Global Brand of Arc Welding Products for
Thermadyne Industries Inc. We manufacture and supply to major
welding industry sectors worldwide including; Manufacturing,
Construction, Mining, Automotive, Aerospace, Engineering, Rural
and DIY/Hobbyist.

We distinguish ourselves from our competition through market­leading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically
advanced products to achieve a safer working environment within
the welding industry.

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 6045 (CV and CC/CV) Transformer-Rectifier DC Welder
Instruction Manual Number 0-4934 for:

Excel-Arc 6045 (CC/CV) System Part Number W1001700

Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermalarc.com

Copyright 2006 by
Thermadyne Industries, Inc.

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: November 30, 2006

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

1.03 Precautions de Securite en Soudage à l’Arc ................................................... 1-5

1.04 Dangers Relatifs au Soudage à l’Arc ............................................................... 1-5

1.05 Principales Normes de Securite ..................................................................... 1-8

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

LIMITED WARRANTY

WARRANTY SCHEDULE

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .......................... Inside Rear Cover

EXCEL ARC 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. Some of these practices apply to equipment connected to power lines; other practices apply to engine
driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled:
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.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine internal circuits are also live when power
is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.

SAFETY IN WELDING AND CUTTING. This publication and other

7. Use fully insulated electrode holders. Never dip holder in water to
cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.

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

9. Do not wrap cables around your body.

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

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.

1. Do not touch live electrical parts.

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

3. Insulate yourself from work and ground using dry insulating mats
or covers.

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

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

6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.

November 30, 2006

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.

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

2. Wear approved safety glasses. Side shields recommended.

1-1

EXCEL ARC 6045

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

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

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

WARNING

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying
sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.

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

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

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

4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.

5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.

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.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.

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

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

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

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

9. Do not use welder to thaw frozen pipes.

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

Eye protection filter shade selector for welding or cutting

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

Torch soldering 2 Gas metal-arc

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

Oxygen C utting Ferrous base metal All 12

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

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

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

Gas welding Carbon arc welding All 12

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

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

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

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

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

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

1-2

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

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

November 30, 2006