Tweco 6045 User Manual
6045
®
EXCEL ARC
CC/CV POWER SOURCE
Operating Manual
Revision: AA Issue Date: August 26, 2011 Manual No.: 0-5213
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.thermadyne.com/thermalarc.
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 market
leading, 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.
Operating Manual Number 0-5213 for:
Excel Arc® 6045 Welding Power Supply
Catalog Number W1001703
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, 03784
www.thermadyne.com/thermalarc
Copyright 2011 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: August 26, 2011
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________
i
TABLE OF CONTENTS
SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ............................. 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 Principal Safety Standards .............................................................................. 1-5
1.03 Product Lifting Safety ..................................................................................... 1-6
1.04 Welding Symbol Chart .................................................................................... 1-7
1.05 Declaration Of Conformity .............................................................................. 1-8
SECTION 2: INTRODUCTION ............................................................................. 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identifi cation ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Description ..................................................................................................... 2-2
2.05 Features .......................................................................................................... 2-3
2.06 Functional Block Diagram ............................................................................... 2-4
2.07 Duty Cycle ....................................................................................................... 2-4
2.08 Specifi cations ................................................................................................. 2-5
2.09 Dimensions and Weight .................................................................................. 2-6
2.10 Excel Arc
®
6045 Data Tag ............................................................................... 2-6
SECTION 3: INSTALLATION ............................................................................... 3-1
3.01 Location .......................................................................................................... 3-1
3.02 Electrical Input Connections ........................................................................... 3-1
3.03 Electrical Input Requirements ......................................................................... 3-2
3.04 Grounding ....................................................................................................... 3-3
3.05 Replacing the Input Power Cable .................................................................... 3-4
3.06 Welding Leads ................................................................................................ 3-5
3.07 Installation Diagram ........................................................................................ 3-6
SECTION 4: OPERATION ................................................................................... 4-1
4.01 Front Panel ..................................................................................................... 4-1
4.02 Machine Set-Up and Operation ....................................................................... 4-3
4.03 Adjustments Behind the Control Panel ............................................................ 4-3
4.04 Hot Start Switch Enable/Disable ..................................................................... 4-4
4.05 SMAW (Stick) Welding & Carbon Arc Gouging ............................................... 4-5
4.06 GTAW (TIG) Welding ....................................................................................... 4-6
4.07 GMAW / FCAW with Constant Speed Wire Feeder ........................................... 4-6
4.08 GMAW / FCAW with Voltage Sensing Wire Feeder with Contactor .................. 4-6
TABLE OF CONTENTS
SECTION 5: SERVICE....................................................................................... 5-1
5.01 General ........................................................................................................... 5-1
5.02 Maintenance ................................................................................................... 5-1
5.03 Maintenance Diagram ..................................................................................... 5-2
5.04 Basic Troubleshooting Guide .......................................................................... 5-3
5.05 General Thermal Conditions ............................................................................ 5-3
5.06 Operator Troubleshooting ............................................................................... 5-4
5.07 Troubleshooting All Modes of Operation ......................................................... 5-4
5.08 Troubleshooting STICK (SMAW / CAG) Mode Problems ................................. 5-5
5.09 Troubleshooting TIG (GTAW) Mode Problems ................................................ 5-5
5.10 Troubleshooting MIG (GMAW / FCAW) Mode Problems ................................. 5-5
APPENDIX 1: WIRING SCHEMATICS ..................................................................... A-1
Wiring Schematics .................................................................................................. A-2
LIMITED WARRANTY ................................................................. INSIDE BACK COVER
WARRANTY SCHEDULE .............................................................. INSIDE BACK COVER
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ........................ INSIDE BACK COVER
TABLE OF CONTENTS (continued)
Figures and Tables
SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ............................. 1-1
Table 1-1: Eye Protection Shade Chart .................................................................... 1-2
SECTION 2: INTRODUCTION ............................................................................. 2-1
®
Figure 2-1: Excel Arc
Figure 2-2: Functional Block Diagram for Excel Arc
Figure 2-3: Duty Cycle Chart ................................................................................... 2-4
Table 2-4: Specifi cations ......................................................................................... 2-5
Figure 2-5: Dimensions and Weight ........................................................................ 2-6
Figure 2-6: Data Tag ................................................................................................ 2-6
SECTION 3: INSTALLATION ............................................................................... 3-1
Figure 3-1: Electrical Input Connections ................................................................. 3-2
Figure 3-2: Grounding Diagram .............................................................................. 3-3
Table 3-3: Recommended Wire and Fuse Size ........................................................ 3-3
Table 3-4: Mains Current Circuit Sizes .................................................................... 3-4
Figure 3-5: Power Cable Compression Nut ............................................................. 3-4
Figure 3-6: Input Power Cable Connection .............................................................. 3-5
Table 3-7: Electrode Lead and Work Lead Size ........................................................ 3-5
Figure 3-8: Installation Diagram .............................................................................. 3-6
6045 Volt-Ampere Curves ................................................... 2-2
®
6045 ..................................... 2-4
SECTION 4: OPERATION ................................................................................... 4-1
Figure 4-1: Excel Arc
®
6045 Front Panel ................................................................ 4-1
Figure 4-2: Fuse Location ....................................................................................... 4-2
Figure 4-3: Front Panel Access ............................................................................... 4-4
Figure 4-4: Hot Start Level and Duration Adjustments ............................................ 4-5
SECTION 5: SERVICE....................................................................................... 5-1
Figure 5-1: Maintenance Diagram ........................................................................... 5-2
APPENDIX 1: WIRING SCHEMATICS ..................................................................... A-1
Figure A-1: System Schematic ................................................................................ A-2
SAFETY INSTRUCTIONS EXCEL ARC 6045
!
SECTION 1:
ARC WELDING 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 Australian Standard AS1674.2-2003 entitled: Safety in welding and allied processes
Part 2: Electrical. This publication and other guides to what you should learn before operating this equipment are listed
at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK
PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever the
output is on. The input power circuit and
machine internal circuits are also live when
power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the
welding wire are electrically live. Incorrectly
installed or improperly grounded equipment
is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body
protection.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn OFF all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two
welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
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.
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.
August 26, 2011 1-1 Manual 0-5213
13. In confi ned 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 fl oor level.
15. Keep all panels and covers securely in place.
EXCEL ARC 6045 SAFETY INSTRUCTIONS
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 fi tted with a proper shade of
fi lter (See ANSI Z49.1 in “1.02 Principal Safety
Standards” on page 1-5) 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 fl ash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable,
fl ame-resistant material (wool and leather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level is
high.
WARNING
FUMES AND GASES can be hazardous to your
health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breath the
fumes.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confi ned 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.
Eye protection fi lter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering 2
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Non-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
welding
(stick) electrodes
Electrode Size
Metal Thickness
or Welding Current
Under 5/32 in., 4 mm 10 Heavy 14
Filter
Shade
No.
Welding or Cutting
Operation
Gas metal-arc
welding (MIG)
Electrode Size
Metal Thickness
or Welding Current
Table 1-1: Eye Protection Shade Chart
Filter
Shade
No.
Manual 0-5213 1-2 August 26, 2011
SAFETY INSTRUCTIONS EXCEL ARC 6045
!
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.
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause fl ying metal. As
welds cool, they can throw off slag.
WARNING
WARNING
WELDING can cause fi re or explosion.
Sparks and spatter fl y off from the welding arc.
The fl ying sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause
fi res and burns. Accidental contact of electrode
or welding wire to metal objects can cause
sparks, overheating, or fi re.
1. Protect yourself and others from fl ying sparks and hot
metal.
2. Do not weld where fl ying sparks can strike fl ammable
material.
3. Remove all fl ammables within 35 ft. (10.7M) 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 fi re, and keep a fi re extinguisher nearby.
6. Be aware that welding on a ceiling, fl oor, bulkhead, or
partition can cause fi re 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 fi re 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.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally part
of the welding process, be sure to treat them
carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators,
hoses, and fi ttings designed for the specifi c application;
maintain them and associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder
valve.
7. Keep protective cap in place over valve except when
cylinder is in use or connected for use.
8. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed in Safety Standards.
WARNING
Engines can be dangerous.
August 26, 2011 1-3 Manual 0-5213
EXCEL ARC 6045 SAFETY INSTRUCTIONS
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
WARNING
ENGINE FUEL can cause fi re or explosion.
Engine fuel is highly fl ammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any
sparks or open fl ames.
3. Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.
4. Do not overfi ll tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before
starting engine.
WARNING
SPARKS can cause BATTERY GASES TO
EXPLODE; BATTERY ACID can burn eyes and
skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting
battery cables.
3. Do not allow tools to cause sparks when working on
a battery.
4. Do not use welder to charge batteries or jump start
vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
STEAM AND PRESSURIZED HOT COOLANT
can burn face, eyes, and skin.
The coolant in the radiator can be very hot and
under pressure.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fi ngers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed
and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is fi nished and before starting engine.
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.
Manual 0-5213 1-4 August 26, 2011
SAFETY INSTRUCTIONS EXCEL ARC 6045
1.02 Principal Safety Standards
LEAD WARNING
This product contains chemicals, including
lead, or otherwise produces chemicals known
to the State of California to cause cancer, birth
defects and other reproductive harm. Wash
hands after handling. (California Health &
Safety Code § 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, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing
Offi ce, May 1989): “...there is now a very large volume
of scientifi c fi ndings based on experiments at the cellular
level and from studies with animals and people which
clearly establish that low frequency magnetic fi elds and
interact with, and produce changes in, biological systems.
While most of this work is of very high quality, the results
are complex. Current scientifi c 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 defi nite 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.
Safety in Welding and Cutting, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from
Superintendent of Documents, U.S. Government Printing
Offi ce, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National
Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, from Compressed Gas Association, 1235
Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, from Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W 1R3.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York,
NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safety in welding and allied processes Part 2: Electrical,
AS1674.2-2003 from SAI Global Limited, www.saiglobal.
com
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away
from body as practical.
ABOUT PACEMAKERS:
The above procedures are among those
also normally recommended for pacemaker
wearers. Consult your doctor for complete
information.
August 26, 2011 1-5 Manual 0-5213
EXCEL ARC 6045 SAFETY INSTRUCTIONS
!
1.03 Product Lifting Safety
The Excel Arc® 6045 is equipped with a lifting eye that is located in the middle of the top panel. The lifting eye is positioned to allow for balanced weight distribution when hoisting the unit.
WARNING
Do not attempt to lift the Excel Arc
®
6045 with other components attached to it.
Manual 0-5213 1-6 August 26, 2011
SAFETY INSTRUCTIONS EXCEL ARC 6045
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle RatingAuxiliary Power
Art # A-04130_AB
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Meters Per Minute
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
See Note
See Note
Note: For environments with increased hazard of electrical shock, Power Supplier bearing the mark conform to EN50192
1.04 Welding Symbol Chart
Note that only some of these symbols will appear on your model.
S
S
August 26, 2011 1-7 Manual 0-5213
EXCEL ARC 6045 SAFETY INSTRUCTIONS
1.05 Declaration Of Conformity
Manufacturer: Thermal Arc for CIGWELD
Address: 82 Benning Street
West Lebanon, NH 03784
USA
Description of equipment: Welding Equipment (GMAW, SMAW, GTAW, CAG and wirefeeders). Including, but not limited
to Thermal Arc Excel Arc
400i , VS212 Stealth, TRANSARC 130, 160 and associated accessories.
Serial numbers are unique with each individual piece of equipment and details the description and parts that are used
to manufacture a unit and date of manufacture.
The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU,
as recently changed in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.
National Standard and Technical Specifi cations
The product is designed and manufactured to a number of standards and technical requirements among them are:
• AS1966-1 applicable to welding equipment and associated accessories.
• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and
regulations.
• EN60974-1 applicable to welding equipment and associated accessories.
• AS60974.1 applicable to welding equipment and associated accessories.
Extensive product design verifi cation is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe and performs as specifi ed. Rigorous testing is incorporated into
the manufacturing process to ensure the manufactured product meets or exceeds all design specifi cations.
Thermal Arc has been manufacturing and merchandising an extensive equipment range with superior performance,
ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.
®
6045 Powermaster 500SP, 400SP, 320SP, TRANSTIG 200Pi, 300Si, 200AC/DC, 300AC/DC,
Manual 0-5213 1-8 August 26, 2011
INTRODUCTION EXCEL ARC 6045
!
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
This manual applies to just specifi cation or part numbers
listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention
to the information provided under these headings. These
special annotations are easily recognized as follows:
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
2.02 Equipment Identifi cation
The unit’s identifi cation number (specifi cation or part
number), model, and serial number usually appear on a
nameplate attached to the control panel. In some cases, the
nameplate may be attached to the rear panel. Equipment
which does not have a control panel such as gun and cable
assemblies is identifi ed only by the specifi cation or part
number printed on the shipping container. Record these
numbers on the bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If there is
any damage, notify the carrier immediately to fi le a claim.
Furnish complete information concerning damage claims
or shipping errors to the location in your area listed in the
inside back cover of this manual.
Include all equipment identifi cation numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-crate
the unit.
Additional copies of this manual may be purchased
by contacting Thermal Arc at the address and phone
number for your location listed in the inside back cover
of this manual. Include the Owner’s Manual number and
equipment identifi cation numbers.
Electronic copies of this manual can also be downloaded at
no charge in Acrobat PDF format by going to the Thermal
Arc web site listed below and clicking on the Literature
Library link:
www.thermadyne.com/thermalarc
August 26, 2011 2-1 Manual 0-5213
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