Tweco N7500 User Manual
N7500
Arcair-Matic® Gouging System
Operating
Manual
English
Français Canadien
Revision: AF Issue Date: Feb. 19, 2014 Manual No.: 89250890
VictorTechnologies.com/Arcair
ART# A-10837_AB
ARCAIR
®
Cutting and Gouging Systems
WE APPRECIATE YOUR BUSINESS!
Congratulations on receiving your new Victor® Arcair® product. We are proud to have you as our
customer and will strive to provide you with the best service and support in the industry. This product
is backed by our extensive warranty and world-wide service network.
We know you take pride in your work and we feel privileged to provide you with this high performance
product that will help you get the job done.
For more than 60 years Victor Arcair has provided quality products you can trust, when your reputation
is on the line.
YOU ARE IN GOOD COMPANY!
Victor Arcair is a global brand of cutting products for Victor Technologies™ Inc. We distinguish
ourselves from our competition through market-leading innovation and truly dependable products that
will stand the test of time.
We strive to enhance your productivity, efficiency and welding performance, enabling you to excel in
your craft. We design products with the welder in mind delivering- advanced features, durability, ease
of use and ergonomic comfort.
Above all, we are committed to a safer working environment within the welding industry. Your
satisfaction with this product and its safe operation is our ultimate concern. Please take the time to
read the entire manual, especially the Safety Precautions.
If you have any questions or concerns regarding your new Victor Arcair product, please contact our
friendly and knowledgeable Customer Service Team at:
1-800-462-2782 (USA) and 1-905-827-4515 (Canada),
or visit us on the web at www.victortechnologies.com/arcair
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.
Arcair-Matic® N7500 Gouging System
Operating Manual
Operating Manual Guide Number: 89250890
Published by:
Victor Technologies, Inc. 940-566-2000
2800 Airport Rd. www.victortechnologies.com/arcair
Denton, TX. 76208 U.S. Customer Care: 800-426-1888
International Customer Care: 905-827-9777
Copyright © 2012, 2013 Victor Technologies, 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: January, 2012
Revision Date: Feb. 19, 2014
Patent Pending
Record the following information for Warranty purposes:
Where Purchased:
Purchase Date:
Part Number Serial Number
Control Box: _____________________ ________________________
Pendant: _____________________ ________________________
Torch Head: _____________________ ________________________
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION ................................................................... 1-1
1.01 Notes, Cautions and Warnings ........................................................................ 1-1
1.02 Arc Welding Hazards ....................................................................................... 1-1
1.03 Principal Safety Standard Publications ........................................................... 1-4
1.04 Declaration of Conformity ............................................................................... 1-5
SECTION 2: SPECIFICATIONS ............................................................................. 2-1
2.01 Arcair-Matic N7500 Gouging System .............................................................. 2-1
2.02 N7500 Specifications ...................................................................................... 2-2
SECTION 3: SYSTEM COMPONENT DESCRIPTION .................................................... 3-1
3.01 Control Box ..................................................................................................... 3-1
3.02 Torch Head ...................................................................................................... 3-4
3.03 Remote Pendant ............................................................................................. 3-6
3.04 Electrodes ....................................................................................................... 3-7
3.05 Gouging Operation Settings ............................................................................ 3-8
3.06 Selecting the Proper Electrode Diameter ........................................................ 3-9
3.07 Keeping Electrodes Dry ................................................................................... 3-9
3.08 Secondary Power Cables (Welding Leads) ..................................................... 3-9
3.09 Compressed Air ............................................................................................ 3-10
3.10 Main Air Line ................................................................................................ 3-10
SECTION 4: ASSEMBLY AND INSTALLATION ........................................................... 4-1
4.01 Receiving and Handling .................................................................................. 4-1
4.02 Assembly ........................................................................................................ 4-3
4.03 Miscellaneous Cable/Plumbing Assemblies .................................................... 4-3
4.04 Control Box Installation .................................................................................. 4-4
4.05 Torch Head Installation ................................................................................... 4-7
4.06 Remote Pendant Installation ........................................................................... 4-8
4.07 Remote Pendant Storage ................................................................................ 4-9
SECTION 5: OPERATING THE N7500 SYSTEM .......................................................... 5-1
5.01 Remote Pendant Operation ............................................................................. 5-1
5.02 Position Torch Head ........................................................................................ 5-2
5.03 Insert the Electrode ......................................................................................... 5-2
5.04 Remote Pendant Programming ...................................................................... 5-3
SECTION 6: N7500 SYSTEM USES ....................................................................... 6-1
6.01 SYSTEM USES ................................................................................................ 6-1
6.02 Zero Force Rough Machining .......................................................................... 6-1
TABLE OF CONTENTS
SECTION 7: MAINTENANCE ............................................................................... 7-1
7.01 Introduction .................................................................................................... 7-1
7.02 Remote Pendant ARCTIME ............................................................................. 7-2
SECTION 8: TROUBLESHOOTING GUIDE ................................................................ 8-1
8.01 Arcair-Matic N7500 Gouging System .............................................................. 8-1
8.02 N7500 General ................................................................................................ 8-1
8.03 Torch Head ...................................................................................................... 8-2
8.04 Remote Pendant ............................................................................................. 8-4
8.05 Control Box ..................................................................................................... 8-5
SECTION 9: REPLACEMENT PARTS ...................................................................... 9-1
9.01 Control Box Replacement Parts ...................................................................... 9-1
9.02 Torch Head Replacement Parts ....................................................................... 9-2
9.03 Remote Pendant Replacement Parts ............................................................... 9-3
9.04 110V Power Supply Cable Assembly .............................................................. 9-4
9.05 220V Power Supply Cable Assembly .............................................................. 9-4
9.06 Pendant Cable Assembly ................................................................................ 9-4
9.07 Motor Cable Assembly .................................................................................... 9-4
9.08 Power Supply Communication Cable Assembly .............................................. 9-4
9.09 Power Cables .................................................................................................. 9-4
9.10 Air Hose Assembly .......................................................................................... 9-4
SECTION 10: APPENDIX ................................................................................... A-1
10.01 Wiring Schematic ........................................................................................... A-2
PUBLICATION HISTORY ................................................................................... A-4
Statement of Warranty .................................................................. Inside Rear Cover
Figures and Tables
SECTION 2: SPECIFICATIONS ............................................................................. 2-1
Table 2-1: N7500 Specifications .............................................................................. 2-2
SECTION 3: SYSTEM COMPONENT DESCRIPTION .................................................... 3-1
Figure 3-1: Control Box ........................................................................................... 3-1
Table 3-2: Control Box Features .............................................................................. 3-2
Figure 3-3: LEFT Side of Control Box ...................................................................... 3-3
Figure 3-4: RIGHT Side of Control Box ................................................................... 3-3
Figure 3-5: BACK of Control Box ............................................................................. 3-3
Figure 3-6: Torch Head ............................................................................................ 3-4
Figure 3-7: Torch Head Components ....................................................................... 3-4
Table 3-8: Torch Head Features ............................................................................... 3-5
Figure 3-9: Remote Pendant ................................................................................... 3-6
Table 3-10: Remote Pendant Controls ..................................................................... 3-6
Chart 3-11: Electrode Selection ............................................................................... 3-7
Table 3-12: Operating Parameters ........................................................................... 3-8
Table 3-13: Power Cable Requirements ................................................................ 3-10
Table 3-14: Compressed Air Input Requirements .................................................. 3-10
SECTION 4: ASSEMBLY AND INSTALLATION ........................................................... 4-1
Figure 4-1: Control Box .......................................................................................... 4-1
Figure 4-2: Torch Head ............................................................................................ 4-1
Figure 4-3: Remote Pendant ................................................................................... 4-1
Figure 4-4: Control Box Nameplate ......................................................................... 4-2
Figure 4-5: Remote Pendant and Torch Head Nameplates ...................................... 4-2
Figure 4-6: Nameplate Locations ............................................................................ 4-2
Table 4-7: Cable Identification ................................................................................. 4-3
Figure 4-8: Assembly Stage 1 ................................................................................. 4-4
Figure 4-9: Power Supply Comm. Cable Pin Configuration ..................................... 4-5
Table 4-10: Standard Wiring Connections ............................................................... 4-6
Figure 4-11: Assembly Stage 2 ............................................................................... 4-7
Figure 4-12: Assembly Stage 3 ............................................................................... 4-8
Figure 4-13: Pendant Mounting .............................................................................. 4-9
Figure 4-14: Pendant Mounted ................................................................................ 4-9
SECTION 5: OPERATING THE N7500 SYSTEM .......................................................... 5-1
Figure 5-1: Remote Pendant ................................................................................... 5-1
Table 5-2: Remote Pendant Controls ....................................................................... 5-1
Figure 5-3: Torch Head Parts .................................................................................. 5-2
Figure 5-4: Default Pendant Screen CC or CV mode ............................................... 5-3
Table 5-5: Parameter Table ...................................................................................... 5-4
Figure 5-6: Parameter Guide Screen ....................................................................... 5-5
Figure 5-7: Parameter Guide Setting Examples ....................................................... 5-5
Figure 5-8: Current Setting Example ....................................................................... 5-5
Figure 5-9: Travel Delay Screen ............................................................................... 5-6
Table 5-10: Travel Delay Setting .............................................................................. 5-6
Figure 5-11: No Current Detect screens .................................................................. 5-7
SECTION 6: N7500 SYSTEM USES ....................................................................... 6-1
Figure 6-1: N7500 DC Straight Polarity (DCEN) ...................................................... 6-1
SECTION 7: MAINTENANCE ............................................................................... 7-1
Figure 7-1: Maintenance ......................................................................................... 7-1
Figure 7-2: Arctime Screen ..................................................................................... 7-2
SECTION 8: TROUBLESHOOTING GUIDE ................................................................ 8-1
Table 8-1: General Troubleshooting ......................................................................... 8-2
Table 8-2: Torch Head Motor 6 PIN Wire Schedule ................................................. 8-2
Table 8-3: Torch Head Troubleshooting ................................................................... 8-2
Table 8-4: Pendant Cable Pin Identification ............................................................. 8-4
Table 8-5: Remote Pendant Troubleshooting .......................................................... 8-4
Table 8-6: Control Box Troubleshooting .................................................................. 8-5
Table 8-7: Power Supply Cable Pin Identification .................................................... 8-5
SECTION 9: REPLACEMENT PARTS ...................................................................... 9-1
Figure 9-1: Control Box PARTS ............................................................................... 9-1
Table 9-2: Control Box PARTS ................................................................................. 9-1
Figure 9-3: Torch Head PARTS ................................................................................ 9-2
Table 9-4: Torch Head PARTS ................................................................................. 9-2
Figure 9-5: Remote Pendant PARTS ....................................................................... 9-3
Table 9-6: Remote Pendant PARTS ......................................................................... 9-3
SECTION 10: APPENDIX ................................................................................... A-1
Figure 10-1: N7500 Wiring Schematic .................................................................... A-3
This Page Intentionally Blank
GENERAL INFORMATION N7500
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ
OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property,
if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned
through study and training before using this equipment. Some of these practices apply to equipment connected to
power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and
cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
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.
WARNING
SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly installed, used, and
maintained. Misuse of this equipment and other unsafe practices can be hazardous. The operator, supervisor, and helper must read and understand the following safety warnings and instructions before installing
or using any welding or cutting equipment, and be aware of the dangers of the welding or cutting process.
Training and proper supervision are important for a safe work place. Keep these instructions for future
use. Additional recommended safety and operating information is referenced in each section.
1.02 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 semi-automatic 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.
3. Insulate yourself from work and ground using dry
insulating mats or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power
disconnect switch open, or remove line fuses so power
cannot be turned on accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
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.
Manual 89250890 1-1 GENERAL INFORMATION
N7500 GENERAL INFORMATION
8. Do not use worn, damaged, undersized, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or replace
damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.
14. Wear a safety harness to prevent falling if working
above floor level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can
damage hearing. Arc rays from the welding
process produce intense heat and strong
ultraviolet rays that can burn eyes and skin.
Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of
filter (see ANSI Z49.1 listed in Safety Standards) to
protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flameresistant material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is
high.
FUMES AND GASES can be hazardous to your
health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
1. Keep your head out of the fumes. Do not breath the
fumes.
2. If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables,
coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied respirator. Shielding
gases used for welding can displace air causing injury
or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can
react with vapors to form highly toxic and irritating
gases.
7. Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated,
and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if welded.
WELDING can cause fire or explosion.
WARNING
WARNING
Sparks and spatter fly off from the welding arc.
The flying sparks and hot metal, weld spatter,
hot workpiece, and hot equipment can cause
fires and burns. Accidental contact of electrode
or welding wire to metal objects can cause
sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot
metal.
2. Do not weld where flying sparks can strike flammable
material.
GENERAL INFORMATION 1-2 Manual 89250890
GENERAL INFORMATION N7500
3. Remove all flammables within 35 ft. (10.7 m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.
4. Be alert that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or
drums.
8. Connect work cable to the work as close to the welding
area as practical to prevent welding current from
traveling long, possibly unknown paths and causing
electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding
wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause
injury.
Chipping and grinding cause flying metal. As
welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
MOVING PARTS can cause injury.
NOTE
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 Office, May
1989): “...there is now a very large volume of scientific
findings based on experiments at the cellular level and from
studies with animals and people which clearly establish
that low frequency magnetic fields interact with, and
produce changes in, biological systems. While most of
this work is of very high quality, the results are complex.
Current scientific understanding does not yet allow us to
interpret the evidence in a single coherent framework.
Even more frustrating, it does not yet allow us to draw
definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize
or avoid potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.
1. Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
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.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers
for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from
moving parts.
6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.
Manual 89250890 1-3 GENERAL INFORMATION
N7500 GENERAL INFORMATION
1.03 Principal Safety Standard Publications
1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139,
251, 252, 253, 254, and 1000. U.S. Government Printing Office, Washington, DC 20402
http://www.osha.gov/pls/oshaweb/owasrch.
search_form?p_doc_type=STANDARDS&p_toc_
level=1&p_keyvalue=1910
2. ANSI Z49.1 “Safety in Welding and Cutting”
http://www.nssn.org/
3. ANSI Z87.1 “Practice for Occupational
and Educational Eye and Face Protection”
http://www.nssn.org/
4. ANSI Z88.2. “Standard Practice for Respiratory Protection.” American National Standards
Institute, 1430 Broadway, New York, NY 10018
http://www.nssn.org/
5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”
http://www.aws.org/w/a/technical/index.html
6. AWS C5.3. “Recommended Practices for
Air Carbon-Arc Gouging and Cutting.” The
American Welding Society, 550 NW Lejeune
Rd., P.O. Box 351040, Miami, FL 33135
http://www.aws.org/w/a/technical/index.html
7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes.”
http://www.nfpa.org/aboutthecodes/list_of_
codes_and_standards.asp
8. NFPA-7. “National Electrical Code” National Fire Protection Association, Battery Park, Quincy, MA 02269
http://www.nfpa.org/aboutthecodes/list_of_
codes_and_standards.asp
9. CSA W117.2. “Safety in Welding, Cutting and Allied
Processes”. Canadian Standards Association, 178
Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3
http://ccinfoweb.ccohs.ca/
10. ANSI Z535 Safety Alerting Standards
http://www.nssn.org/
11. Refer to your local codes.
GENERAL INFORMATION 1-4 Manual 89250890
GENERAL INFORMATION N7500
1.04 Declaration of Conformity
Manufacturer: Victor Technologies
Address: 2800 Airport Rd.
Denton, TX 76208
USA
Description of equipment: Gouging Equipment (GMAW, MMAW, GTAW, CAG and wirefeeders). Including, but not
limited to Arcair-Matic N7500 Gouging System 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 Specifications
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.
• IEC 60974-1 applicable to welding equipment and associated accessories
• 2002/95/EC RoHS directive
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into
the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Victor Arcair has been manufacturing and merchandising an extensive equipment range with superior performance,
ultra safe operation and world class quality for years and will continue to achieve excellence.
Manual 89250890 1-5 GENERAL INFORMATION
N7500 GENERAL INFORMATION
This Page Intentionally Blank
GENERAL INFORMATION 1-6 Manual 89250890
SPECIFICATIONS N7500
SECTION 2:
SPECIFICATIONS
2.01 Arcair-Matic N7500 Gouging System
The Arcair-Matic N7500 Gouging System adds new dimensions of flexibility and control in modern weld preparation. It’s the most advanced air carbon-arc gouging/grooving system in the world. The N7500 System assures
improved productivity in the following ways:
• Higheryieldsofoptimumqualityendproduct
• Dramaticreductionsofman-hoursandprocesscost
• Expandedareasofapplicability
FEATURES
Remote Pendant providing complete control of the gouging operation where it needs to be .... in the welder/
operator hands.
All functions from determining gouge parameters, start/stop function, travel delay, and the capability to manually
feed or retract the electrode in the Torch Head. The welder/operator can view the amperage and voltage during
gouging sequence easily while maintaining the electrode on the weld seam that’s being back gouged.
A single electrode contact shoe assembly accepts the entire range of Victor Arcair gouging electrodes from
5/16” (7.9 mm) through 3/4” (19.1 mm).
The N7500 Torch Head eliminates the necessity of stocking or changing contact shoe assemblies when changing electrode sizes.
The gouging system uses the Power Supply “contactor” to ensure that the gouging current is only present
when the welder/operator presses the “start” button on the Remote Pendant.
System is easily connected to the various power supplies available in the industry.
Ensures conformity to pre-determined, pre-selected groove depth and width specifications.
Welder/Operator can use the “Parameter Guide” option on the Remote Pendant to view the recommended
amperage and travel speed once the electrode and gouge depth is chosen.
A unique “travel delay” function assures excellent groove geometry at the very beginning of the groove.
This function eliminates a sloped groove at the beginning of the gouge, eliminating the need for a starting pad.
No current detect and low voltage functions shut down the system when these conditions are sensed.
These functions ensure optimum groove quality and prevent damage to the equipment and work.
Redesigned Torch Head
Redesigned Torch Head with extended front end to give the welder/operator better range of viewing during the
gouging operation ensuring the electrode is maintained in the correct position to the weld seam.
Manual 89250890 2-1 SPECIFICATIONS
N7500 SPECIFICATIONS
2.02 N7500 Specifications
Rated Output
Output Current
Duty Cycle
Open Circuit Voltage Minimum of 60VDC
Rated Input
Rated Input Voltage 110V - 220V
Rated Input Amperage
Input Frequency 50/60 Hz
Control Box Controls
5A Circuit Breaker ON/OFF Switch w/reset ON/OFF Switch w/reset
110V/220V Control Box Power Input 3-Pin Socket
110V Auxiliary Outlet 4A, 110V
220V Auxiliary Outlet 4A, 220V
(2) 5A Circuit Breaker
Circuit Interface to Remote Pendant 7-Pin Socket
1 off push-button circuit breaker for the 110V outlet
1 off push-button circuit breaker for the 220V outlet
MAX. 1600A/42V @ 100%
400-1600
5A
Circuit Interface to Torch Head 6-Pin Socket
Circuit Interface to Power Supply 6-Pin Socket
Signal Interface to Work Piece 1-Pin Socket
Table 2-1: N7500 Specifications
N7500 SYSTEM
The N7500 System produces in a single pass uniform “U” or “J” grooves of various depths up to 1-1/8” (28.6
mm). Two or more passes produce grooves of greater depth. Through continuous control of arc voltage or amperage and a constant travel speed, the groove is held within 0.025” (0.635 mm) target depth. Victor Arcair Jointed
Jetrods® Electrodes, with tapered male and female ends, make it possible to produce grooves of unlimited length.
Control elements and circuitry for the N7500 System are housed in a Control Box and a splash-proof Pendant.
Gouging operations are managed remotely using the Remote Pendant with a multi-function LCD display and touch
pad controls.
Groove depth and width are controlled in two ways:
• By changing the travel carriage’s forward speed or by changing the work piece rotational speed.
• By changing the electrode’s diameter and increasing or decreasing amperage.
NOTE
Remote Pendant is NOT submersible.
This manual has been structured to provide the user with all the information required for assembly, operation and
troubleshooting of the N7500 System. Illustrations, charts and other supporting data are provided to bridge the
gap between theory and practice.
In addition, the N7500 System can be integrated with any mechanized travel system that provides forward travel
over a steel plate while in the flat, vertical, or over-head positions. The N7500 Torch Head can also be mounted
in a stationary position for work on rotating shafts, round steel, or a vessel. In a stationary set up the work-piece
rotates in a
For additional information, contact your local Victor Arcair Distributor or Victor Technologies.
SPECIFICATIONS 2-2 Manual 89250890
counter-clockwise direction
and the Torch Head is generally located at the work-piece’s 4 o’clock position.
SYSTEM COMPONENT DESCRIPTION N7500
ART# A-10928_AC
SECTION 3:
SYSTEM COMPONENT DESCRIPTION
There are three (3) main components making up the Arcair-Matic N7500 Gouging System; Torch Head, Control
Box, and Remote Pendant.
3.01 Control Box
ART# A-10855_AC
Figure 3-1: Control Box
The Control Box controls the system’s operation before, during and after gouging. Under command of the Remote
Pendant, the Control Box supplies DC power and compressed air to the Torch Head. The unit has a power cord
for required AC voltage, clamping fixtures, and handles for secure lifting. See “Table 3-2: Control Box Features”
for each of the Control Box’s connectors/fittings and the function of each component.
Manual 89250890 3-1 SYSTEM COMPONENT DESCRIPTION
N7500 SYSTEM COMPONENT DESCRIPTION
Item Fitting Function
Two (2) 4 amp AC power receptacles provide AC power for a travel system
1
Travel System
Power Connector
if needed, 110 VAC or 220 VAC. The Remote Pendant controls when these
receptacles receive AC power through the Remote Pendant travel delay
circuitry. Only the AC power voltage (110V or 220V from the Input Power
AC) that the Control Box is connected to will be delivered.
2 Air Out Conn.
Delivers compressed shop air to the Torch Head when the
START
“Start”
button is pressed on the Remote Pendant.
Connector to
3
Torch Head Elec-
trode Motor
Remote Pendant
4
5
Connector
Circuit Breaker
w/reset
6 ON/OFF switch
Input and Output
7
DC Power Conn.
Delivers the signal from the Control Box to the Torch Head to either
feed or retract the electrode to maintain the preset arc voltage.
Links the Remote Pendant to the Control Box to initiate start/stop of
the gouging operation.
Circuit breaker reset push button for 110 VAC and 220 VAC AC Travel
System Power Connector receptacles.
Control Box ON/OFF control switch with built in 5 amp circuit breaker
and reset.
Output and Input DC (+) positive power buss connections.
8 Air In Conn. This port accepts compressed shop air to the Control Box.
9
Power Supply
Connector
Links the Control Box to the Power Supply. On demand from the Remote Pendant the internal contactor of the Power Supply can be closed
and opened to deliver the current to the Torch Head.
10 Input Power (AC) Delivers AC voltage to the Control Box from a standard wall receptacle.
11 Signal Wire Conn.
Control Box Hold
12
13
Down Fixture
Remote Pendant
Cradle
Allows the Control Box to detect open circuit voltage when the Power
Supply contactor is closed.
Hold down fixtures located on both sides of the Control Box to allow
fastening to a base.
Secure holding fixture for Remote Pendant.
Table 3-2: Control Box Features
NOTE
The 110V and 220V power supply receptacles may be used to run any device that has the same linevoltage requirements and that require “ON-OFF” or “Start-Stop” control. However, any such device
must be rated with a maximum current draw of 4 amperes.
SYSTEM COMPONENT DESCRIPTION 3-2 Manual 89250890
SYSTEM COMPONENT DESCRIPTION N7500
13
7
6
(Rear panel assembly
not shown for clarity)
7
10
12
Figure 3-3: LEFT Side of Control Box
MAX 100 psi
8
9
11
ART# A-10851_AC
2
1
(Rear panel assembly
not shown for clarity)
3
4
7
5 AMP
5
12
Figure 3-4: RIGHT Side of Control Box
5 AMP
5
ART# A-10844_AB
13
8
2
WARNING! AVERTISSEMENT!
Protect yourself and others. Wear ear, eye, and body protection.
Protégez-vous et d'autres. Portez l'oreille, l'oeil, et la protection de corps.
Insure good ground from power supply to workpiece. Poor ground may cause
damage to any or all components. Use only with compressed air. See manual.
Assurez la bonne terre de l'alimentation d'énergie à l'objet. La terre pauvre peut endommager
quelques des ou tous composants. Employez seulement avec l'air comprimé. Voir le manuel.
Noise can damage hearing.
Le bruit peut endommager l’ouïe.
Smoke, fumes, and gases can be dangerous to your health. Use adequate
ventilation. Keep your head out of the smoke.
La fumée, les émanations et les gaz peuvent être dangereux pour votre santé.
Employez à ventilation proportionnée. Gardez votre tête hors de la fumée.
Arc rays, hot slag, and sparks can injure eyes and burn skin.
L les rayons de l’arc,
es scories et les étincelles chauds peuvent blesser les yeux et brûler la peau.
Welding sparks can cause res and explosions.
Les étincelles de soudage peuvent causer des incendies et des explosions.
Electric shock can cause injury or death. Disconnect power before servicing.
Un choc électrique peut causer des blessures ou la mort. Déconnectez la puissance
avant l'entretien.
POWER
SUPPLY OUT
POWER
SUPPLY IN
6
ART# A-10853_AB
(rear cover plate not shown for clarity)
Figure 3-5: BACK of Control Box
Manual 89250890 3-3 SYSTEM COMPONENT DESCRIPTION
N7500 SYSTEM COMPONENT DESCRIPTION
4
3.02 Torch Head
ART# A-10838_AB
Figure 3-6: Torch Head
The N7500 Torch Head feeds the jointed electrodes down to the work surface. The Control Box controls and signals the motor on the Torch Head to feed or retract the electrode. This action maintains arc voltage or current, set
on the Remote Pendant. The Control Box (See “Figure 3-1: Control Box” on page 3-1) channels the DC current
from the DC Welding Power Supply to the Torch Head using standard welding cables. Compressed air coming
from the Control Box connects at the Torch Head with a 3/8” NPT female pipe elbow.
9
ART# A-10833_AB
2
6
10
3
- 5/16 3/8
- 1/2
- 5/8
- 3/4
N7500
5
7
1
Figure 3-7: Torch Head Components
8
SYSTEM COMPONENT DESCRIPTION 3-4 Manual 89250890
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