Tweco 6045 User Manual

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Page 1

6045

EXCEL ARC

CC/CV POWER SOURCE

Operating Manual

Revision: AA Issue Date: August 26, 2011 Manual No.: 0-5213 Operating Features:

Page 2

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.

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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

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 #: ____________________________________

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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

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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)

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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

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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.

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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

Page 9

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

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

Page 10

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

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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

Page 12

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

Page 13

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

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

IPM

MPM

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

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.

August 26, 2011 1-7 Manual 0-5213

Page 14

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

Page 15

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

Page 16

EXCEL ARC 6045 INTRODUCTION

VOLT-AMP CURVES FOR CV MODE

50%

MIN.

MAX.

DC VOLTS

DC AMPS

0 100 200 300 400 500 600 700 800 900

Art# A-10914

0 100 200 300 400 500 600 700

50%

VOLT-AMP CURVES FOR CC STICK MODE

DC VOLTS

DC AMPS

MIN. ARC FORCE

MAX.

2.04 Description

The Excel Arc® 6045 (CC/CV) is a combination constant-current and constant-voltage transformer-rectiﬁ er type conventional DC welding machine that provides excellent welding characteristic for STICK (SMAW), LIFT TIG (GTAW), submerged arc & GMAW/FCAW welding as well as carbon arc gouging (CAG).

Applications include Shipbuilding, Fabrication & Construction, Heavy Manufacturing, Rental Fleets, Pipe Welding, Reﬁ neries & Foundries, Railcar Manufacturing, Earth-Moving Equipment Manufacturing, Pressure Tank/Vessel Fabrication.

NOTE

Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source. Curves of other settings will fall between the curves shown.

Manual 0-5213 2-2 August 26, 2011

Figure 2-1: Excel Arc® 6045 Volt-Ampere Curves

Page 17

INTRODUCTION EXCEL ARC 6045

2.05 Features

1. Auxiliary power receptacles.

a. 1 x 19 pin (MS Compatible) with 115V 8-amp/42V 8-amp/24V 8-amp auxiliary power for wirefeeders, tractor

and SAW accessories.

b. 2 x 115V @ 20A.

2. Circuit breaker protection for 115V, 42V, 24V.

3. Simple, easy to operate front control panel.

4. Access to control PCB via the front panel control cover.

5. Front panel ON/OFF switch and pilot light.

6. Contactor ON switch for voltage sensing wire feeders.

7. Multi-process switch for GTAW, SMAW/CAG, GMAW/FCAW.

8. Large meter amps / volts + Memory holds for 20 seconds.

9. All user interfaces accessed from front of unit.

10. Line voltage compensation.

11. Fan turns ON when the arc is established and stays on for 10-15 minutes after it is extinguished.

12. Windings and rectiﬁ ers protected against moisture and corrosive environments.

13. Thermal overload protection / Temperature shutdown light.

14. Circuit protection - In the event of a mains power failure machine defaults to OFF.

15. Accessories:

a. Remote output control

b. Control cable adapters

c. Hour meter

August 26, 2011 2-3 Manual 0-5213

Page 18

EXCEL ARC 6045 INTRODUCTION

750

650

550

450

100

% Duty Cycle

Weld Amperes

Art# A-10881

2.06 Functional Block Diagram

Input

Main

Contactor

Aux. Power

Accessories /

Features

2.07 Duty Cycle

Main Power

Amplifier

(XFMR)

Cooling

Rectifier

System Controls

Measuring

User Controls

Figure 2-2: Functional Block Diagram for Excel Arc® 6045

Current

Device

Welding Output

Power

CC/CV

Welding

Performance

Control

Output

CC/CV/Neg

Connections

Output

Art# A-10882

Duty cycle is the percentage of each ten-minute period of time that the welding machine may be operated under rated load conditions. For example, a duty cycle of 60% means that the machine can be operated at rated load for an average of 6 minutes of each 10 minute period of operation. During the remaining 4 minutes, the machine must idle to permit proper cooling. Figure 2-3 enables the operator to determine the duty cycle at various welding amperages.

Figure 2-3: Duty Cycle Chart

Manual 0-5213 2-4 August 26, 2011

Page 19

INTRODUCTION EXCEL ARC 6045

2.08 Speciﬁ cations

Rated Output

Output Current

Duty Cycle

Open Circuit Voltage 68VAC maximum for all input voltages Arc Voltage in CV Mode 10-44V Output Current Range STICK (MMAW) 20-650A GMAW/FCAW 50-700A Operating Temperature Range 0 to 40° C (32 to 104° F) Maximum Temperature 50° C (120° F) Minimum Temperature -4° C (-40° F) Storage Temperature Range -4 to +80° C (-40 to +176° F)

Rated Input

Rated Input Voltage 400VAC - three phase - 50Hz

Rated Input Amperage

Input Frequency 50 Hz Input Phase 3 Phase Auxiliary Power 1 kVA –115V, 9A No Load Input Voltage 400VAC

Auxiliary Power Supplies

Remote Receptacle for Wire Feeder or Remote Control Device(s)

Auxiliary Power for tractor or SAW accessories 1 -15 A 115V Duplex

Front Panel Controls

115V auxiliary outlet 1 -10 A 115V

450 Amps at 38 Volts DC for all input voltages 600 Amps at 42 Volts DC for all input voltages

450A @ 100%

600A @ 60%

43A @ 100%

39A @ 60%

19 Pin MS socket

(2) 10A circuit breaker for 115V

1 off push-button circuit breaker for the 115V outlet8A circuit breaker for 115V wirefeeder circuit

8A circuit breaker for 42V

Multi-Pin Sockets 19 Pin MS socket

Thermal Arc/Cigweld: A2000, VA2000, VA4000, VS212, VA48, VS48, VA412

Circuit Interface to Wire feeders

Sub arc automatic and semi automatic wirefeeder

Lincoln: NA3, NA5, LN7, & LN9 (adapter required - see section

4.07 and Appendix 1)

Table 2-4: Speciﬁ cations

August 26, 2011 2-5 Manual 0-5213

Page 20

EXCEL ARC 6045 INTRODUCTION

2.09 Dimensions and Weight

[837]

32.9"

[402]

15.8"

[701]

27.6"

[301]

11.9”

[75]

3.0”

[602]

23.7"

[92]

3.6”

Art# A-10916

2.10 Excel Arc® 6045 Data Tag

ExcelArc 6045

Serial No:

U1=460V I

Figure 2-5: Dimensions and Weight

IDENTIFICATION

Part No: W1001703

IEC 60974-1

WELDING OUTPUT

MIG Output 50A/16.5V - 600A/44V

X 60% 100% I

=61.7V

44V 36.5V

MMAW Output 25A/21V - 600A/44V

X 60% 100% I

=61.7V

44V 38V

TIG Output 25A/11V - 600A/34V

X 60% 100% I

=61.7V

34V 28V

ENERGY INPUT

=45.4A I

1max

[510]

20.1"

Thermal Arc 82 Benning Street, West Lebanon, NH 03784 MADE IN USA

450A600A

=37.2A

1e

60Hz

IP23S

N1890

Art# A-10896

Figure 2-6: Data Tag

Manual 0-5213 2-6 August 26, 2011

Page 21

INSTALLATION EXCEL ARC 6045

SECTION 3:

INSTALLATION

3.01 Location

Be sure to locate the welder according to the following guidelines:

• Ambient temperature between 0 degrees C to 40 degrees C.

• In areas, free from oil, steam and corrosive gases.

• In areas, not subjected to abnormal vibration or shock.

• In areas, not exposed to direct sunlight or rain.

• Place at a distance of 12" (304.79 mm) or more from walls or similar boundaries that could restrict natural airﬂ ow for cooling.

WARNING

Thermal Arc advises that this equipment be electrically connected by a qualiﬁ ed electrician.

3.02 Electrical Input Connections

WARNING

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal of input power.

DO NOT TOUCH live electrical parts.

SHUT DOWN welding power source, disconnect input power employing lockout/tagging procedures. Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting OFF and red-tagging circuit breaker or other disconnecting device.

August 26, 2011 3-1 Manual 0-5213

Page 22

EXCEL ARC 6045 INSTALLATION

3.03 Electrical Input Requirements

NOTE

The Excel Arc ground power cable that is connected at the welding power source for three phase electrical input power. For direct wiring installation have a qualiﬁ ed person install according to all applicable codes and instructions.

Operate the welding power source from a three-phase 60 Hz, AC power supply. The input voltage must match one of the electrical input voltages shown on the input data label on the unit nameplate. Contact the local electric utility for information about the type of electrical service available, how proper connections should be made, and any inspection required.

The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit.

Do not connect an input conductor to the ground terminal.

Do not connect the ground conductor to an input line terminal.

Refer to "Figure 3-1: Electrical Input Connections" and:

1. Connect end of ground conductor to a suitable ground. Use a grounding method that complies with all applicable electrical codes.

6045 comes equipped from the factory with a pre-connected three-conductor with earth

2. Connect ends of line 1 and line 2 and line 3 input conductors to a de-energized line disconnect switch.

3. Use "Figure 3-1: Electrical Input Connections" and "Table 3-3: Recommended Wire and Fuse Size" on page 3-3 as a guide to select line fuses for the disconnect switch. "Table 3-3: Recommended Wire and Fuse Size" provides minimal information for selection of line conductors, fuses, and the equipment grounding conductor. This information is from AS1966-1, AS/NZS 3652-(EMC Directive EN50199), EN60974-1 and AS60974.1.

Ground Conductor

Ground

Excel Arc 6045 Power Supply

Terminal

Art # A-10419

Primary Power Cable

Line Fuse

Line Disconnect Switch

Line Fuse

Figure 3-1: Electrical Input Connections

Manual 0-5213 3-2 August 26, 2011

Page 23

INSTALLATION EXCEL ARC 6045

3.04 Grounding

The frame of this welding machine should be grounded for personnel safety, and to assure operation of the overcurrent protection. The grounding method, and the equipment grounding conductor size and type shall conform to local and national codes. For the National Electrical Code, the equipment grounding conductor shall be green, green with a yellow stripe, or bare. If ﬂ exible power cable is used, use a cable assembly which includes the equipment grounding conductor. If metallic armored cable or conduit is used, the metal sheathing or conduit must be effectively grounded per local and national codes.

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

Grounding Conductor

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

Rubber-tire mounted equipment shall be grounded to conform to local and national codes. The grounding assists in providing protection against line voltage electrical shock and static shock. The grounding serves to discharge the static electric charge which tends to build up on rubber-tire mounted equipment. This static charge can cause painful shock and lead to the erroneous conclusion that an electrical fault exists in the equipment. If a system ground is not available, consult the electrical code enforcement body for instructions. The welding machine should be connected to an adequate driven ground rod, or to a water pipe that enters the ground not more than 30 meters (10 feet) from the machine.

Art # A-05234_AB

Removable Cover

Floor

457 mm

Approx. 305 mm (1 Ft.)

Not less than

24.4 cm (8 Ft.)

Ground Rod

(18 inches) Approx.

Soil Treating

Ground Rod

Not less than 24.4 cm (8 Ft.)

Material

152 mm (6 Inches) Approx.

Figure 3-2: Grounding Diagram

The equipment grounding conductor size is listed in "Table 3-3: Recommended Wire and Fuse Size" 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

Be sure to replace all covers to assure adequate internal ventilation and prevent component failure.

COPPER LINE WIRE SIZE* COPPER

LINE VOLTS

RATED LOAD

AMPS

APPROX. LINE

FUSE SIZE

IN CONDUIT FLEXIBLE CABLE

GROUNDING CONDUCTOR

MIN. SIZE

460 38 60 No. 8 No. 8 No. 8

*Conductor size shall be modiﬁ ed 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.

Table 3-3: Recommended Wire and Fuse Size

August 26, 2011 3-3 Manual 0-5213

Page 24

EXCEL ARC 6045 INSTALLATION

3.05 Replacing the Input Power Cable

The input power should be connected to the unit through a fused disconnect switch, or other suitable disconnecting means furnished by the user. A hole is provided in the rear panel of the machine, near to the input connections, for the entry of the input conductors. Refer to "Figure 3-1: Electrical Input Connections".

WARNING

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

CAUTION

The method of installation, conductor size, and overcurrent protection shall conform to the requirements of the local electrical code, the National Electrical Code, or other national codes, as applicable. All installation wiring and machine re-connections shall be done by qualiﬁ ed persons.

Mains Supply Lead Size

Minimum Mains Current

Circuit size

Mains Supply Voltage

Weld Current & Duty

Cycle

8 AWG 40A 460V 3 phase 600A@60%

Table 3-4: Mains Current Circuit Sizes

1. Open the disconnect switch, or breaker, and determine that no voltage is present, before disconnecting wires be-

tween the Excel Arc

2. Remove the left-side cover of the Excel Arc

6045 and the power supply.

6045.

3. Loosen the compression clamp nut on the rear panel where the existing power cable enters the unit. Refer to "Figure 3-5: Power Cable Compression Nut".

4. Disconnect the three-phase line leads from terminals L1, L2, and L3 on the line contactor inside the welding machine cabinet. Disconnect the ground wire from the ground terminal. Refer to "Figure 3-6: Input Power Cable Connection".

5. Remove the old power cable from the Excel Arc

6045 and route the new cable in through the same access hole.

6. Connect the three-phase line leads to terminals L1, L2, and L3 on the line contactor inside the welding machine cabinet. Connect the ground wire to the ground terminal. Refer to "Figure 3-6: Input Power Cable Connection".

7. Tighten the compression nut on the rear panel where the new power cable enters the unit. Refer to "Figure 3-5: Power Cable Compression Nut".

8. Replace the left-side cover of the Excel Arc

9. Close the disconnect switch, or breaker, and reapply power to the Excel Arc

6045.

6045 and the power supply.

Compression Nut

Art# A-10902

Figure 3-5: Power Cable Compression Nut

Manual 0-5213 3-4 August 26, 2011

Page 25

INSTALLATION EXCEL ARC 6045

Ground Terminal

Green/Yellow Wire

CAUTION

Power is present if

this is illuminated.

Art# A-10897

Figure 3-6: Input Power Cable Connection

(Unrelated wiring not shown for clarity purposes)

3.06 Welding Leads

Use "Table 3-7: Electrode Lead and Work Lead Size" for selection of the proper size copper welding leads.

TOTAL LENGTH OF LEAD CIRCUIT IN (AND METERS)

Welding Current

Amperes

50 Feet

(15.2M)

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

Table 3-7: Electrode Lead and Work Lead Size

(ELECTRODE LEAD PLUS WORK LEAD)

100 Feet

(30.5M)

150 Feet

(45.7M)

(For 60% duty cycle)

200 Feet

(61.0M)

250 Feet

(76.2M)

NOTE

Lead size shown is for 90°C cable insulation, 30°C (86°F) ambient, and not over 4.5 volts lead drop.

August 26, 2011 3-5 Manual 0-5213

Page 26

EXCEL ARC 6045 INSTALLATION

3.07 Installation Diagram

Terminal Bolt

Professional

PROCESS

FCAW

CAG

ARC FORCE (STICK)

Negative Terminal

FORCE D'ARC

PROCESSUS

WARNING:

READ OPERATING MANUAL

AVERTISSEMENT : LIRE LE MANUEL D’OPERATING

VOLTS

V / A

ARC ON TIME (HRS)

ARC À L'HEURE

POWER

MARCHE

REMOTE

COMMANDE À DISTANCE

OUTPUT

CONTACTOR

RENDEMENT

CONJONCTEUR

PUISSANCE

MARCHE

OFF

ARRÊT

HOT START

DE DÉPART CHAUD

MARCHE

OFF

ARRÊT

AMPS

OUTPUT

REMOTE

COMMANDE À DISTANCE

LOCAL

COMMANDE LOCALE

CONTROL

COMMANDE

Positive Terminal to Wire Feeder—shown for reverse polarity—DCEP

Stick

NOTE

Base Metal

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

Art# A-10898

Work Piece—should be grounded

Figure 3-8: Installation Diagram

Manual 0-5213 3-6 August 26, 2011

Page 27

OPERATION EXCEL ARC 6045

ARC FORCE (STICK)

VOLTS

V / A

AMPS

Professional

MARCHEONMARCHE

OUTPUT

POWER

PUISSANCE

MARCHE

WARNING:

READ OPERATING MANUAL

AVERTISSEMENT : LIRE LE MANUEL D’OPERATING

PROCESS

PROCESSUS

FCAW

CAG

ARC ON TIME (HRS)

ARC À L'HEURE

REMOTE

COMMANDE À DISTANCE

REMOTE

COMMANDE À DISTANCE

LOCAL

COMMANDE LOCALE

CONTROL

COMMANDE

HOT START

DE DÉPART CHAUD

OUTPUT

CONTACTOR

RENDEMENT

CONJONCTEUR

OFF

ARRÊT

OFF

ARRÊT

(

)

CONJONCTEUR

115V 20AMPS

NEUTRAL BONDED TO FRAME

NUETRE COLLÉ SUR L'ARMATURE

8A 20A 20A

8A 8A

19P

13 10 11 12 18 15

14 1716

23 22

Art# A-10891

SECTION 4:

OPERATION

4.01 Front Panel

Figure 4-1: Excel Arc® 6045 Front Panel

1. MODE SELECTOR SWITCH (SW2)

Selects between the three (3) following operational modes:

a. MIG (GMAW / FCAW) - Constant Voltage (CV) mode for MIG welding with constant speed wire feeder.

b. STICK (SMAW / CAG) - Constant Current (CC) mode for Stick Electrode Welding and Carbon Arc Gouging.

c. TIG (GTAW) - Constant Current (CC) mode for TIG welding.

August 26, 2011 4-1 Manual 0-5213

Page 28

EXCEL ARC 6045 OPERATION

Art# A-10894

2. ARC FORCE CONTROL POTENTIOMETER (R2) (SMAW/CAG)

To prevent electrode "sticking" this potentiometer

controls the short circuit welding current to produce an increase in current as the arc length is shortened. Arc Force Current is continuously adjustable from 0 350 amps.

3. REMOTE OUTPUT CONTACTOR

Remote output control. NOTE: Welding will not

start in GTAW mode without a Remote OUTPUT ON (CONTACTOR ON) signal.

4. FUSE (F1)

1/4A 250V fuse protecting the 24 volt auxiliary

transformer.

8A 20A 20A

11. VOLTAGE / CURRENT CONTROL POTENTIOMETER (R1)

Adjusts the output voltage (CV modes) or output

current (CC modes). This potentiometer will set the maximum limit when REMOTE control is selected.

12. CURRENT LED DISPLAY

Three digit display for preview current prior to enabling

the output and actual output current when it is enabled. Display will "HOLD" actual output current when the arc was stopped for approximately. 20 seconds and then will revert to preview setting.

13. HOUR METER (OPTIONAL)

Displays the unit arc hours.

14. OVER-TEMPERATURE LED INDICATOR (YELLOW)

Yellow Over-temperature LED indicates that the unit is overheated and that the unit output has been disabled. If the transformer is overheated, the power is disconnected.

8A 8A

19P

Figure 4-2: Fuse Location

5. CIRCUIT BREAKER (CB4) 8A - For 42VAC to J1.

6. 2 CIRCUIT BREAKERS (CB3) 20A - For 115VAC to J1.

7. CIRCUIT BREAKER (CB4) 8A - For 42VAC to J1.

8. CIRCUIT BREAKER (CB5) 8A - For 24VAC to J1.

9. FEEDER / REMOTE INTERFACE CONNECTOR (J1).

19 Pin amphenol connector - for interface with Wire

Feeder, remote control devices and controllers.

10. VOLTAGE LED DISPLAY

Three digit display for preview voltage prior to enabling

the output and actual output voltage when it is enabled. Display will "HOLD" actual output voltage when the arc was stopped for approximately. 20 seconds and then will revert to preview setting.

15. FAULT LED INDICATOR (RED)

Red Fault LED indicates a fault from the J1 Connector.

If any of the supply voltages (24VAC, 42VAC, 115VAC) are shorted to any of the signal wires connected to the J1 connector, this indicator will turn ON.

16. ON/OFF INDICATOR LED (GREEN)

Green ON/OFF LED indicates when the ON/OFF SWITCH

(SW1) is set in the ON position; Control circuits are active.

17. ON/OFF SWITCH (SW1)

Turns the control circuitry ON/OFF. In the OFF position,

the high power circuits and output terminals are disabled.

18. OUTPUT ON LED

Green LED indicates that an OUTPUT ENABLE (START)

signal is present.

NOTE

This will come ON immediately when either STICK (CC) or VS MIG (GMAW or FCAW) modes are selected.

19. LOCAL / REMOTE SWITCH (SW4)

Switches between front panel or remote voltage/

amperage control.

Manual 0-5213 4-2 August 26, 2011

Page 29

OPERATION EXCEL ARC 6045

to welding machine, and remove its fuse.

LOCAL position is used when the output

voltage/amperage is controlled by the OUTPUT VOLTAGE / AMPERAGE CONTROL POTENTIOMETER on the front panel.

20. HOT START SWITCH (SW3) – For STICK mode only

REMOTE position is selected when the output voltage/amperage is controlled through the 19 Pin Amphenol Receptacle. The maximum limit is set by the LOCAL (front panel) Voltage/Amperage Control Potentiometer.

(SMAW/CAG)

ELECTRIC SHOCK can kill! Do not touch live electrical parts, including the output terminals and electrode.

2. Plug remote control into 19-pin amphenol receptacle (J1).

3. Set Output Control to desired value.

4. Set the Local/Remote control switch in the desired mode.

5. Make any DIP switch and/or trim pot adjustments on or next to the control panel PCB (located behind the front panel) as deﬁ ned in the next ﬁ ve sections.

Allows a short duration pulse of higher current for ease

of starting an arc in SMAW mode only. The current level and duration are adjustable by trim pots on the Main PCB.

21. AC RECEPTACLE

Four (4) Circuit breakers protected auxiliary 115VAC

20 amp outlet.

22. POSITIVE OUTPUT RECEPTACLE CC/CV

Main positive output supply terminal for CC and CV

modes.

23. NEGATIVE OUTPUT TERMINAL

Main negative output supply terminal.

4.02 Machine Set-Up and 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 instructions for components used with this system before operating.

6045 welding machine. Consult operating

4.03 Adjustments Behind the Control

Panel

The Excel Arc® 6045 provides four different user adjustable settings behind the Control Panel to accommodate ﬁ xed installations and operator preferences. These user-deﬁ ned settings do not require continuous access and are normally for one-time, "set and forget" functions. Therefore, they are located on and next to the Control Panel PCB behind the front panel.

The adjustments behind the Control Panel are:

1. Hot Start Switch Enable/Disable.

2. Hot Start - Duration and amplitude adjustment on PCB. Refer to “Figure 4-3: Front Panel Access”.

In order to make any of these adjustments, the upper front panel section needs to be pulled down as follows:

A. Turn the two slotted screws 1/4 turn to release panel.

See “Figure 4-3: Front Panel Access”.

B. Pull down the front panel and locate the Control Panel

PCB behind it.

Preweld Operation

1. Connect welding leads to terminals on front panel.

WARNING

Disconnect line voltage from the unit before making any connections inside unit. Turn OFF fused disconnect switch that supplies power

August 26, 2011 4-3 Manual 0-5213

Page 30

EXCEL ARC 6045 OPERATION

ARC FORCE (STICK)

FORCE D'ARC

VOLTS

V / A

AMPS

Professional

MARCHE

M ARC

OUTPUT

POWER

PUISSANCE

MARCHE

WARNING:

READ OPERATING MANUAL

AVERTISSEMENT : LIRE LE MANUEL D’OPERATING

PROCESS

PROCESSUS

FCAW

CAG

ARC ON TIME (HRS)

ARC À L'HEURE

REMOTE

COMMANDE À DISTANCE

REMOTE

COMMANDE À DISTANCE

LOCAL

COMMANDE LOCALE

CONTROL

COMMANDE

HOT START

D ÉPA

T C H

AUD

OUTPUT

CONTACTOR

RENDEMENT

CONJONCTEUR

OFF

ARRÊT

OFF

ARRÊT

Art# A-10892

1/4 turn both Front Cover Screws to release

Pull Down Front Panel

Control Panel PCB

Hinge Pin

4.04 Hot Start Switch Enable/Disable

When activated, the HOT START SWITCH (Item “20. HOT START SWITCH (SW3) – For STICK mode only (SMAW/CAG)” on page 4-3) allows a short duration pulse of higher current for ease of starting an arc in SMAW/ CAG mode only. The level and duration of the hot start current are adjustable using two trim pots on the Control Panel PCB.

1. Pull down the front panel. Refer to Section “4.03 Adjustments Behind the Control Panel” and “Figure 4-3: Front Panel Access”.

2. Locate the HOT START two trim pots on the Control Panel PCB. R295 adjusts the hot start duration and R275 adjusts the hot start current level. Refer to “Figure 4-4: Hot Start Level and Duration Adjustments”.

3. Using a small ﬂ at-blade screwdriver, adjust the trim pots in accordance with the parameters deﬁ ned in “Figure 4-4: Hot Start Level and Duration Adjustments”.

Figure 4-3: Front Panel Access

Manual 0-5213 4-4 August 26, 2011

Page 31

OPERATION EXCEL ARC 6045

SW1

SW2 SW3

Art# A-10895

R295 HOT START DURATION- Continuously adjustable from 0.5 to 2 seconds.

R275 HOT START VALUE - Continuously adjustable between 0 - 100% of the LOCAL or REMOTE demand level up to 700 amps total.

Figure 4-4: Hot Start Level and Duration Adjustments

4.05 SMAW (Stick) Welding & Carbon Arc Gouging

1. Connect the work cable and electrode holder lead. The

positive lead should be connected to the POSITIVE OUTPUT RECEPTACLE.

2. Connect the work clamp to the work piece or work

table.

R295

R275

5. If HOT START feature is desired, turn HOT START SELECTOR SWITCH (SW3) to ON position.

5a. If required, to adjust HOT START current level and

duration.

6. Set ARC FORCE CONTROL POTENTIOMETER (R2) to the maximum level.

7. Set LOCAL / REMOTE SWITCH (SW4) to LOCAL.

3. Turn ON/OFF SWITCH (SW1) to ON position.

NOTE

The output enable LED (green) will be ON at this time.

4. Set MODE SELECTOR SWITCH (SW2) to STICK position (SMAW / CAG - CC).

8. Set VOLTAGE CURRENT CONTROL POTENTIOMETER (R1) to select desired current level.

9. If VRD protection is desired, set SW1-A located on the Main PCB to ON (DN) position. Factory setting is ON (Down) position.

10. Hold electrode clear of work.

11. Strike the arc.

12. When welding / gouging is ﬁ nished, turn the ON/OFF SWITCH (SW1) to OFF position.

August 26, 2011 4-5 Manual 0-5213

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EXCEL ARC 6045 OPERATION

4.06 GTAW (TIG) Welding

1. Connect the work lead to the POSITIVE OUTPUT RECEPTACLE.

2. Connect the TIG torch lead to the NEGATIVE OUTPUT RECEPTACLE.

3. Set MODE SELECTOR SWITCH (SW2) to TIG position (GTAW - CC).

4. Turn the ON/OFF SWITCH (SW1) to ON position.

a. Connect remote to J1 Connector.

5. When using a Remote Potentiometer to control the output current:

a. Set the VOLTAGE / CURRENT CONTROL

POTENTIOMETER (R1) to select the maximum current level for the remote.

b. Set LOCAL / REMOTE SWITCH (SW4) to REMOTE

position.

If no remote current control is to be used:

a. Set LOCAL / REMOTE SWITCH (SW4) to LOCAL

position.

4.07 GMAW / FCAW with Constant Speed Wire Feeder

1. Complete all Wire Feeder and MIG Gun connections.

2. Turn ON/OFF SWITCH to ON position.

3. Set MODE SELECTOR SWITCH (SW2) to MIG position

(CV GMAW / FCAW).

4. VOLTAGE CONTROL.

If using a wire feeder with remote voltage control:

a. Set the VOLTAGE / CURRENT CONTROL

POTENTIOMETER (R1) to set the maximum voltage level for the remote.

b. Set the LOCAL / REMOTE SWITCH (SW4) to

REMOTE position.

If using a wire feeder without remote voltage control:

a. Set LOCAL / REMOTE SWITCH (SW4) to LOCAL

position.

b. Set the VOLTAGE / CURRENT CONTROL

POTENTIOMETER (R1) to desired voltage level.

5. Position the MIG Gun for welding and close gun switch

and start welding.

b. Set the VOLTAGE / CURRENT CONTROL

POTENTIOMETER (R1) to select the desired welding current.

6. Position the torch for welding.

7. Touch the electrode to the work piece, activate the Remote OUTPUT ON (CONTACTOR ON) signal, then lift the electrode off from the plate and the welding arc will initiate.

8. When finished welding, deactivate OUTPUT ON (CONTACTOR ON) signal.

NOTE

Welding will not start in GTAW mode without a Remote OUTPUT ON (CONTACTOR ON) signal.

4.08 GMAW / FCAW with Voltage Sensing Wire Feeder with Contactor

1. Complete all Wire Feeder and MIG Gun connections.

2. Turn ON/OFF SWITCH (SW1) to ON position.

NOTE

The output enable LED (green) will be on at this time and there should be output at the (+) and (-) terminals.

3. VOLTAGE CONTROL.

If using a wire feeder

a. Set the LOCAL / REMOTE SWITCH (SW4) to

REMOTE position.

b. Set the VOLTAGE / CURRENT CONTROL

POTENTIOMETER (R1) to set the maximum voltage level for the remote.

If using a wire feeder

a. Set LOCAL / REMOTE SWITCH (SW4) to LOCAL

position.

with

remote voltage control:

without

remote voltage control:

b. Set the VOLTAGE / CURRENT CONTROL

POTENTIOMETER (R1) to desired voltage level.

4. Position the MIG Gun for welding and close gun switch

and start welding.

Manual 0-5213 4-6 August 26, 2011

Page 33

SERVICE EXCEL ARC 6045

SECTION 5:

SERVICE

5.01 General

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

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced, qualiﬁ ed person only. Any electrical work must be performed by an electrician or other person properly trained in servicing electrical equipment. Do not permit untrained persons to inspect, clean or repair this equipment. Use only recommended replacement parts when servicing this machine.

WARNING

HIGH VOLTAGE is present internally even with the control power switch in the OFF position. Before inspecting, cleaning, or servicing disconnect and lock out input power to the power source.

5.02 Maintenance

Periodically clean the inside of the welding power source by using a shop vacuum cleaner as normal preventive maintenance. At the time of cleaning, a full inspection of the welding machine and setup should be performed. Check warning labels on the machine for readability and replace if necessary. Check input and output connections as well as frame ground connections to the machine to insure that they are tight and that the wires are not frayed or overheated. Inspect the internal wiring of the machine for loose or frayed connections and tighten or repair as necessary. It would also be advisable to check connections to wire feeders, ﬁ xtures, etc., at this time. Any damaged cables or hoses should be replaced.

WARNING

ALL SERVICE SHOULD BE PERFORMED BY

TRAINED PERSONNEL ONLY.

August 26, 2011 5-1 Manual 0-5213

Page 34

EXCEL ARC 6045 SERVICE

Warning! Disconnect input power before maintaining.

Each Use

Visual check of regulator and pressure

Visual check of torch Consumable parts

Weekly

Visually inspect the torch body and consumables

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Visually check and use a vacuum to carefully clean the interior

Maintain more often if used under severe conditions

Gas and air lines

Art # A-10883

ARC FORCE (STICK)

FORCE D'ARC

VOLTS

V / A

AMPS

Professional

MARCHE

OUTPUT

POWER

PUISSANCE

MARCHE

WARNING:

READ OPERATING MANUAL

AVERTISSEM

ENT : LIRE LE MANUEL D’OPERATING

PROCESS

PROCESSUS

FCAW

CAG

ARC ON TIME (HRS)

ARC À L'HEURE

REMOTE

COMMANDE À DISTANCE

REMOTE

COMMANDE À DISTANCE

LOCAL

COMMANDE LOCALE

CONTROL

COMMANDE

HOT START

DE DÉPART CHAUD

OUTPUT

CONTACTOR

RENDEMENT CONJONCT

EUR

OFF

ARRÊT

OFF

ARRÊT

ARC FORCE (STICK)

FORCE D'ARC

VOLTS

V / A

AMPS

Professional

MARCHE

OUTPUT

POWER

PUISSANCE

MARCHE

WARNING:

READ OPERATING MANUAL

AV ERTISSEMENT : LIRE LE MANUEL D’OPERATING

PROCESS

PROCESSUS

FCAW

CAG

ARC ON TIME (HRS)

ARC À L'H

URE

REMOTE

COMMANDE À DISTANCE

REMOTE

COMMANDE À DISTANCE

LOCAL

C O MMANDE LOCALE

CONTROL

COMMANDE

HOT START

DE DÉPART CHAUD

OUTPUT

CONTACTOR

RENDEMENT

CONJONCTEUR

OFF

A RRÊT

OFF

ARRÊT

5.03 Maintenance Diagram

Manual 0-5213 5-2 August 26, 2011

Figure 5-1: Maintenance Diagram

Page 35

SERVICE EXCEL ARC 6045

5.04 Basic Troubleshooting Guide

A. Scope:

This Operator Troubleshooting guide is intended to correct unsatisfactory operation of the Excel Arc intended to be an electrical service troubleshooting or repair guide. Refer to “Figure A-1: System Schematic” on page A-2 to gain an overview of the interconnections of the electrical components that are cited in this guide.

B. Safety:

To ensure safe operation and service, read this entire manual before attempting to service this machine.

WARNING

Disconnect the power source from the input power source before carrying out any service or repair work. Hazardous voltages can be present in the machine whenever input power is connected.

C. Troubleshooting Hints:

6045. It is not

5.05 General Thermal Conditions

The fan on the unit will turn ON whenever a welding arc is active and will remain on for approximately 10 minutes after welding is stopped. This will help to minimize the entry of dust and foreign material into the unit while at idle.

There are two types of thermal overload conditions. The thermal switch on the SCR heatsink protects the SCRs by shutting the gating signals OFF when the switch opens due to excessive heat. The output voltage / current will be disabled until the heatsink has cooled sufﬁ ciently. At that time in STICK (CC) or VS MIG (GMAW or FCAW) modes the output will come back on. In MIG (GMAW) or TIG (GTAW) mode, the operator will have to reapply the remote trigger switch.

The thermal switches in the Main Transformer will cause the system to shut down when excessive heat causes any of them to open. The contactors will turn OFF, disabling the output. The fan and all lights will turn OFF. This condition should alert the operator that a serious overheating condition has occurred and that the unit and primary power should be checked by a qualiﬁ ed technician before attempting to use the unit further.

Examine connections for proper assembly and contact before replacing a component. Wire lugs should be in tight contact with the lead's conductor and should be crimped to the lead's insulation. The mating surfaces of the connection should be clean and free of oxidation. Faulty connections or wiring problems are often the cause of an equipment malfunction.

Do not pull on wires to disassemble connections. Firmly grasp each lug or connector when disconnecting. Pulling on wires for disassembly can damage the integrity of the connection and cause future malfunctions.

Prior to disassembly or servicing of the machine, note the wiring and connections in the machine. Reassembling should place wires in the same location and routing as received from the factory. Keep wires and leads away from hot parts and sharp objects.

LIVE POWER WARNING

CC Mode Only

When the (SW1) ON/OFF is turned to the ON position, there will be output power. Therefore, when the unit is in STICK or VS MIG modes turn the ON/OFF switch to OFF when not in use.

VS MIG (VS GMAW) will also have output power when switched to that mode.

August 26, 2011 5-3 Manual 0-5213

Page 36

EXCEL ARC 6045 SERVICE

5.06 Operator Troubleshooting

The Excel Arc® 6045 is the power supply, one component in a welding system. Other system components may include a Wire Feeder, Remote Current Control Potentiometer, Remote Output Enable (START) switch, MIG Gun, TIG Torch, Electrode Holder and cables, Gas Control Valve and Gas Regulators. These components may each have a manual and may be required to solve the problem.

Before proceeding with this manual section, it is recommended to review the Machine Set-Up and Operation section and also verify that the correct polarity is observed for the particular welding operation being performed.

How to Use This Guide

The following information will help the Operator determine the most likely causes for various symptoms. Follow all instructions as listed and complete each section in the order presented.

This guide is set up in the following manner:

5.07 Troubleshooting All Modes of Operation

A. All indicator lights on the machine are OFF. Fan

does not turn.

1. ON / OFF SWITCH (SW1) is in the OFF position.

a. Turn SW1 to ON position.

2. Fuse F1 blown.

a. Check and replace if open.

3. Primary Power Problem.

a. Measure for correct voltage at the Primary

Power Receptacle.

4. Input Power Cable connected incorrectly.

a. See “3.05 Replacing the Input Power

Cable” on page 3-4 for correct installation.

5. Defective Input Power Cable.

a. Check continuity.

X. Symptom (Bold Type)

Any Special Instructions

1. Cause

a. Check / Remedy

Locate your symptom, check the causes (easiest listed ﬁ rst), then remedies. Repair as needed being sure to verify that unit operates properly after any repairs.

6. Unit is overheated and one of the T1 thermal switches TS1-TS3 has opened.

a. Unit should be inspected by authorized service

personnel prior to operating the machine.

B. OVER TEMPERATURE INDICATOR is on. No output

from the unit.

Allow the unit to cool. The output will come back on automatically in STICK (CC) or VS MIG modes when the OVERTEMP indicator goes OFF. In MIG or TIG modes, because this is a Latched Fault it requires that the remote OUTPUT ENABLE (START) signal be removed and be turned to OFF position before it will reset the machine. the OVER TEMPERATURE INDICATOR remains ON contact an authorized service facility.

1. Duty Cycle has been exceeded.

2. Ambient temperature is too high.

a. Operating duty cycle must be reduced at

elevated ambient temperature conditions exist.

3. Inadequate ventilation space around the unit.

a. Check air intake and exhaust openings.

Openings must be unobstructed.

C. Unit output is low or cannot be adjusted.

1. OUTPUT VOLTAGE /CURRENT CONTROL POTENTIOMETER (R1) is set too low.

a. Increase setting of R1.

Manual 0-5213 5-4 August 26, 2011

Page 37

SERVICE EXCEL ARC 6045

For LOCAL VOLTAGE or CURRENT control:

2. LOCAL / REMOTE SWITCH (SW4) is set in REMOTE position.

a. Switch SW4 to LOCAL position.

For REMOTE VOLTAGE or CURRENT control:

2. Remote potentiometer or cable is open.

a. Check continuity.

D. Welding Arc will not transfer.

1. Defective Positive or Negative output cables.

a. Check continuity.

2. Work cable not connected or poor connection to work.

a. Check / clean connections.

E. Poor weld performance.

1. Incorrect polarity.

a. Verify welding cable polarity is correct for the

welding mode and application requires.

5.08 Troubleshooting STICK (SMAW / CAG) Mode Problems

A. ON / OFF INDICATOR is ON. No arc can be

established. OUTPUT on INDICATOR is OFF.

1. Defective control board.

a. Replace control board.

2. Defective remote OUTPUT ENABLE (START) switch or cable.

5.09 Troubleshooting TIG (GTAW) Mode Problems

A. ON /OFF INDICATOR is ON. OUTPUT ON

INDICATOR is OFF. No output.

USING REMOTE CONTROL SWITCH FOR OUTPUT

ENABLE CONTROL:

1. Defective remote OUTPUT ON (CONTACTOR ON) switch.

a. Check switch continuity.

2. Remote control cable is open.

a. Check for continuity between J1 plug pins A &

B with remote switch closed.

B. OUTPUT ON INDICATOR is ON but there is no

output voltage from the unit.

1. Take unit to an Authorized Service Facility.

5.10 Troubleshooting MIG (GMAW / FCAW) Mode Problems

A. ON /OFF INDICATOR is ON. OUTPUT ON

INDICATOR is OFF. No output.

1. No remote OUTPUT ENABLE (CONTACTOR ON) signal.

a. Verify Start signal to J1 plug from feeder. (1 of

four possible signals.)

i) Contact closure between pins A & B.

a. Check continuity.

B. OUTPUT ON INDICATOR is ON but there is no

output voltage from the unit.

1. Take unit to Authorized Service Facility.

C. Hard or intermittent starting of the arc.

1. Insufﬁ cient output current.

a. Increase OUTPUT VOLTAGE /CURRENT

POTENTIOMETER (R1) to higher setting.

2. HOT START SWITCH (SW3) is in OFF position.

a. Switch SW3 to ON position.

3. Insufﬁ cient HOT START amperage or duration.

a. Adjust HOT START current level and/or duration

trimpots.

4. Electrodes sticking to work piece. ARC FORCE CONTROL POTENTIOMETER (R2) is set too low.

a. Increase R2 setting.

ii) Contact Closure between pins R & S.

iii) Contact closure between pins D & E.

iv) Contact closure between pins P & R.

2. Circuit Breaker Tripped.

a. Check/Reset CB3,CB4,CB5.

B. OUTPUT ON INDICATOR is ON but there is no

output voltage from the unit.

1. Take unit to an Authorized Service Facility.

August 26, 2011 5-5 Manual 0-5213

Page 38

EXCEL ARC 6045 SERVICE

THIS PAGE IS INTENTIONALLY BLANK

Manual 0-5213 5-6 August 26, 2011

Page 39

APPENDIX EXCEL ARC 6045

APPENDIX 1:

WIRING SCHEMATICS

THIS PAGE IS INTENTIONALLY BLANK

August 26, 2011 A-1 Manual 0-5213

Page 40

EXCEL ARC 6045 APPENDIX

1/4A 600V

SCR 4

8A CB

SCR 6

SCR 3

SCR 1

SCR 5

20A CB

SW2

115 VAC

8A CB

AC POWER

NEON

SCR 2

8A CB

400 VAC

3 PHASE

50 HZ INPUT

T1 MAIN TRANSFORMER

T2 AU X TR ANSFORM ER

24VAC

F G H J K

L M N P R

A B C D E

HEATSINK

HEATSINK OT SWITCH

115VAC

42VAC

24VAC

575 460

230 208

COM

S T U

380

400

415

SUPPRESSOR

BOARD

54A

WHITE

BLACK

ORANGE

FNQ-R-1/4

AMPHENOL

CONNECTOR

J15

J14

BROWN

RED

YELLOW

BLUE

VIOLET

115 VAC

20A CB

55B

12345678

Art# A-10877

Wiring Schematics

Figure A-1: System Schematic

Manual 0-5213 A-2 August 26, 2011

Page 41

APPENDIX EXCEL ARC 6045

111213

567

234

SHUNT RESISTOR

22000MFD 63V

ARC FO RCE POT

25 OHM

OUTPUT CONTACTOR

7 4 1

SW16

22000MFD 63V

10R

AC PO WE R

CR1

DIODE

22000MFD 63V

LOCAL/REMOTE

HOT START

22000 MFD 63V

SW1

LOCAL POT

22000MFD 63V

33V COM

L1 OUTPUT INDUCTOR

FAN1

CONSTANT CURRENT

PHASE_A1 PHASE_A2 PHASE_B1 PHASE_B2 PHASE_C1 PHASE_C2 TRANSFORMER OT SW.

CONTROL BOARD

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

6 7

9 10 11 12 13 14 15 16

CONTACTOR +15

24V/42V/120V RTN

REMOTE MAX REMOTE WIPER

CONTACTOR ON 2

IFB

CONTACT OR ON 1

VOUT+

VOUT-

GATE1

GATE2

GATE3

GATE4

GATE5

GATE6

HEATSINK OT SW

HEATSINK OT SW RET

VOUT+

VOUT-

SHUNT R1

SHUNT R2

6 7 8

9 10 11 12 13 14 15 16

1 2 3 4 5

SMAW/CAG

GTAW

GMAW

ARC FORC E WIPER

POWER ON

POWER OF F

+33V

SMAW / CAG

GTAW / TIG

GMAW / MIG

MAIN

CONTACTOR

24 VAC AUX

24 VAC AUX RETW2FAN POWER

FAN RTN

ARC EST = 1

+15V

TRANSFORMER OT SWITCH

+15V

REMOTE / LOCAL

OUTPUT ON = 1 5V

HOT START

MAX REF

MIN REF

REF IN

REMOTE WIPER

ARC FORC E POT

678

12345

678

12345

V OUT (-)

ARC ESTABLISHED

REMOTE MIN

24V/42V/120V RTN

VFB

CONTACTOR

818

212

CV MODE

CONTACTOR

(+)

(-)

55A

175W

OPTIONAL HOUR METER

17 18 19 20

5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20

19A

71 72 73

69 13 70

78 79

567

234

555655A

525354

495051

464748

REMOTE MAX

VSWF

MODE SWITCH

VSWF

81 82 83

WIRE 42 NOT USED ON 60Hz MODEL

50R

10W

10u 400V

u47 400V

54B

57A

55C

54A

J10

19B

August 26, 2011 A-3 Manual 0-5213

Page 42

EXCEL ARC 6045 APPENDIX

THIS PAGE IS INTENTIONALLY BLANK

Manual 0-5213 A-4 August 26, 2011

Page 43

WARRANTY

THIS PAGE IS INTENTIONALLY BLANK

August 26, 2011 A-3 Manual 0-5213

Page 44

LIMITED WARRANTY

This information applies to Thermal Arc products that were purchased in the USA and Canada.

November 2007

LIMITED WARRANTY: Thermal Arc

, Inc., A Thermadyne Company (“Thermal Arc”), warrants to customers of authorized distributors (“Purchaser”) that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the warranty period stated below, Thermal Arc shall, upon notiﬁ cation thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s speciﬁ cations, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or damage, 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.

This warranty is exclusive and in lieu of any warranty of merchantability, ﬁ tness for any particular purpose, or other warranty of quality, whether express, implied, or statutory.

Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect, incidental, or consequential damages, including but not limited to lost proﬁ ts and business interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whether arising out of contract, tort, including negligence or strict liability , or under any warranty, or otherwise, shall not 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 , and Thermal Arc shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulﬁ llment of thermal’s obligations to purchaser with respect to the product.

This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Thermal Arc’s sole judgment, impaired 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 unauthorized persons.

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

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s discovery of any defect. Thermal Arc shall pay no transportation costs of any kind under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s

risk and expense. This warranty dated July 1

warranties. Thermal Arc

is a Registered Trademark of Thermal Arc, Inc.

2007 supersedes all previous Thermal Arc

Manual 0-5213 A-4 August 26, 2011

Page 45

WARRANTY SCHEDULE

This information applies to Thermal Arc products that were purchased in the USA and Canada.

November 2007

SAFETY EQUIPMENT Warranty Period Labor

Auto-Darkening Welding Helmet (Electronic Lens) Harness Assembly

ENGINE DRIVEN WELDERS Warranty Period Labor

Scout, Raider, Explorer Original Main Power Stators and Inductors 3 years 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors Engines and associated components are NOT warranted by Thermal Arc, although most are warranted by the engine manufacturer

GMAW/FCAW (MIG) WELDING EQUIPMENT Warranty Period Labor

Fabricator 131, 181; 140; 180; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed Original Main Power Transformer and Inductor 5 years 3 years Original Main Power Rectifiers, Control PC Boards, power switch semi-conductors 3 years 3 years All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors.

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT Warranty Period Labor

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors.

PLASMA WELDING EQUIPMENT Warranty Period Labor

Ultima 150 Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors 3 years 3 years Welding Console, Weld Controller, Weld Timer 3 years 3 years All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors, Coolant Recirculator.

SMAW (Stick) WELDING EQUIPMENT Warranty Period Labor

Dragster 85 Original Main Power Magnetics 1 year 1 year Original Main Power Rectifiers, Control P.C. Boards 1 year 1 year All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors 160S, 300S, 400S Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers, Control P.C. Boards 3 years 3 years All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors

GENERAL ARC EQUIPMENT Warranty Period Labor

Water Recirculators 1 year 1 year Plasma Welding Torches 180 days 180 days Gas Regulators (Supplied with power sources) 180 days Nil MIG and TIG Torches (Supplied with power sources) 90 days Nil Replacement repair parts 90 days Nil MIG, TIG and Plasma welding torch consumable items Nil Nil

August 26, 2011 A-5 Manual 0-5213

2 year

1 month

1 year 1 year

See the Engine Manufactures’ Warranty for Details

1 year 1 year

1 year

1 year 1 year

2 year

1 month

1 year

Page 46

THIS PAGE IS INTENTIONALLY BLANK

Manual 0-5213 A-6 August 26, 2011

Page 47

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@ThermalArc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510

Thermadyne Italy

OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773

Thermadyne, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne,Utama Indonesia

Kawasan Industri Jababeka JI Jababeka VI Blok P No. 3 Cikarang - Bekasi, 17550 Indonesia Tel: +62 21 893 6071 Fax: +62 21 893 6067 / 6068 http://www.thermadyne.com/thermalarc

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Page 48

Printed in:

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 • Canada Customer Care: 905-827-4515 / FAX 800-588-1714

International Customer Care: 940-381-1212 /

FAX 940-483-8178

•

www.thermalarc.com

A Global Cutting & Welding Market Leader

WORLD HEADQUARTERS: 16052 Swingley Ridge Road, Suite 300 • St. Louis, Missouri 63017 U.S.A.

THE AMERICAS EUROPE ASIA/PACIFIC

Denton, TX USA U.S. Customer Care

Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph: 1-940-381-1212 Fax: 1-940-483-8178

Miami, FL USA Sales Office, Latin America

Ph: 1-954-727-8371 Fax: 1-954-727-8376

Oakville, Ontario, Canada Canada Customer Care

Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree)

Chorley, United Kingdom Customer Care

Ph: +44 1257-261755 Fax: +44 1257-224800

Milan, Italy Customer Care

Ph: +39 0236546801 Fax: +39 0236546840

Cikarang, Indonesia Customer Care

Ph: 6221-8990-6095 Fax: 6221-8990-6096

Rawang, Malaysia Customer Care

Ph: +603 6092-2988 Fax: +603 6092-1085

Melbourne, Australia Australia Customer Care

Ph: 1300-654-674 (tollfree) Ph: 61-3-9474-7400 Fax: 61-3-9474-7391

International

Ph: 61-3-9474-7508 Fax: 61-3-9474-7488

Shanghai, China Sales Office

Ph: +86 21-64072626 Fax: +86 21-64483032

Singapore Sales Office

Ph: +65 6832-8066 Fax: +65 6763-5812

™

Tweco 6045 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

EXCEL ARC

TABLE OF CONTENTS

Figures and Tables

1.01 Arc Welding Hazards

1.02 Principal Safety Standards

1.03 Product Lifting Safety

1.04 Welding Symbol Chart

1.05 Declaration Of Conformity

2.01 How To Use This Manual

2.03 Receipt Of Equipment

2.04 Description

2.05 Features

2.06 Functional Block Diagram

2.07 Duty Cycle

2.09 Dimensions and Weight

2.10 Excel Arc® 6045 Data Tag

3.01 Location

3.02 Electrical Input Connections

3.03 Electrical Input Requirements

3.04 Grounding

3.05 Replacing the Input Power Cable

3.06 Welding Leads

3.07 Installation Diagram

4.01 Front Panel

4.02 Machine Set-Up and Operation

4.04 Hot Start Switch Enable/Disable

4.05 SMAW (Stick) Welding & Carbon Arc Gouging

4.06 GTAW (TIG) Welding

4.07 GMAW / FCAW with Constant Speed Wire Feeder

4.08 GMAW / FCAW with Voltage Sensing Wire Feeder with Contactor

5.01 General

5.02 Maintenance

5.03 Maintenance Diagram

5.04 Basic Troubleshooting Guide

5.05 General Thermal Conditions

5.06 Operator Troubleshooting

5.07 Troubleshooting All Modes of Operation

5.08 Troubleshooting STICK (SMAW / CAG) Mode Problems

5.09 Troubleshooting TIG (GTAW) Mode Problems

5.10 Troubleshooting MIG (GMAW / FCAW) Mode Problems

Wiring Schematics

LIMITED WARRANTY

WARRANTY SCHEDULE