Tweco N7500 User Manual

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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

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

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:

• Higheryieldsofoptimumqualityendproduct

• Dramaticreductionsofman-hoursandprocesscost

• Expandedareasofapplicability

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

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

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

Torch Head Elec-

trode Motor

Remote Pendant

Connector

Circuit Breaker

w/reset

6 ON/OFF switch

Input and Output

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.

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

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

(Rear panel assembly not shown for clarity)

Figure 3-3: LEFT Side of Control Box

MAX 100 psi

ART# A-10851_AC

(Rear panel assembly not shown for clarity)

5 AMP

Figure 3-4: RIGHT Side of Control Box

5 AMP

ART# A-10844_AB

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

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

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.

ART# A-10833_AB

- 5/16 3/8

- 1/2

- 5/8

- 3/4

N7500

Figure 3-7: Torch Head Components

SYSTEM COMPONENT DESCRIPTION 3-4 Manual 89250890

SYSTEM COMPONENT DESCRIPTION N7500

Item Fitting Function

1 Motor

2 Motor Cable

DC Power Cable

4 Air Inlet

5 Air Plenum

7 Electrode Size

9 Air Plenum Shield

10 Torch Head Shield

Busbar

Electrode Release

Lever

Carriage Mounting

Fixture

This motor feeds the electrode away from and towards the work. The Motor’s action is controlled by the Pendant settings.

This Motor Cable end is connected to the Control Box via a cable assembly that comes in 3, 15, 25, or 50 foot lengths. See “9.07 Motor Cable Assembly” on page 9-4 for part numbers.

This is the connection point on the Torch Head for the DC power cables from the Control Box.

Air is fed into a 3/8” NPT ﬁtting on the Torch Head using an air supply line from the Control Box.

This housing circulates air around electrode housing before releasing in a directed spray to remove gouging slag.

This lever is used to open the Motor Feed assembly allowing the operator to manually remove or replace an Electrode.

The guide inside helps the insertion of the electrode through the Torch Head.

The mounting bracket that comes with the Torch Head allows it to fasten to a vertical adjustment assembly which is either mounted on a travel system or stationary ﬁxture.

This metal shield protects the Air Plenum housing from slag splash back.

This metal shield protects the motor and housing from slag splash back.

Table 3-8: Torch Head Features

Manual 89250890 3-5 SYSTEM COMPONENT DESCRIPTION

N7500 SYSTEM COMPONENT DESCRIPTION

3.03 Remote Pendant

Remote Pendant provides the welder/operator the ability to:

• Start/stop the gouging operation,

• Manually jog of the air carbon-arc electrode in the Torch Head prior to gouging,

• Pre-set options to ensure proper operation of the system.

ART# A-10856_AB

Figure 3-9: Remote Pendant

Item Feature Item Feature

1 Mode-indicator Display 7

Jog Up/Down Travel

START

Start Button

STOP

Stop Button

10 Connector

Mode Selector

OK Button

Rough (Machining)

11 Bumper

Rotary Dial

TRV

12 Grip Feet

Travel Button

Table 3-10: Remote Pendant Controls

For additional details on the operation of the Remote Pendant see “5.04 Remote Pendant Programming” on page 5-3. For storage information see “4.07 Remote Pendant Storage” on page 4-9.

SYSTEM COMPONENT DESCRIPTION 3-6 Manual 89250890

SYSTEM COMPONENT DESCRIPTION N7500

3.04 Electrodes

The most important part of the N7500 System is the electrode. Since the N7500 system uses only DC power, the electrodes must be formulated and manufactured for use exclusively with Direct Current.

The use of Victor Arcair Jointed Jetrods Copperclad DC Electrodes is highly recommended. These electrodes are manufactured to Victor Arcair speciﬁcations to provide the best electrical conductivity, to maintain proper electrode diameter at the point of the arc, and to minimize carbon sublimation. A male/female joint enables electrodes to be joined together while the gouging operation is taking place.

Electrode Diameter Gouge Width Amperage

Inch mm Inch mm Min Max

⁄

⅜ ½ ⅝ ¾

The formulation and design of the Jetrods Electrodes embody numerous laboratory-proven advantages under the user’s production conditions. Among these advantages are:

7.9

9.5

12.7

15.9

19.1 Chart 3-11: Electrode Selection

⁄

½ ⁄ ⁄

1⁄

11.1 400 450

12.7 450 600

20.7 800 1000

24.9 1000 1250

27.0 1250 1600

• Cooler operation due to a small incandescent area at the tip and joint

• Excellent arc stability

• High metal-removal rates

• Uniformity of diameter

• Clean grooves or cuts

Manual 89250890 3-7 SYSTEM COMPONENT DESCRIPTION

N7500 SYSTEM COMPONENT DESCRIPTION

3.05 Gouging Operation Settings

“Table 3-12: Operating Parameters”” shows recommended operating amperage by electrode sizes. The travel speeds listed for each size carbon and gouge depth were derived in the laboratory using a 1500 amp Power Supply. Your results may vary depending on the arc current, voltage and other parameters you use.

Automatic Gouging Operating Data

Electrode Diameter Desired Depth DC Current Travel Speed Per Min.

Inch mm Inch mm Amps Inch mm

⁄ ⁄ ⁄ ⁄ ⁄

⅜ ⅜ ⅜ ⅜ ⅜ ½ ½ ½ ½ ½ ⅝ ⅝ ⅝ ⅝ ⅝ ¾ ¾ ¾ ¾ ¾ ¾

7.9

9.5

12.7

15.9

19.1

⅛

⁄

¼ ⁄ ⁄

⅛ ⁄

⅜ ⁄

⅛

⅜

⅝

⁄

⅜

⅝

¾ 1⅛

Table 3-12: Operating Parameters

3.2 400 65 1651

4.8 400 45 1143

6.4 450 36 914

7.9 450 33 838

11.1 500 22.5 572

3.2 500 70 1778

4.8 500 44 1118

6.4 500 35 889

9.5 500 20 508

14.3 500 17.5 445

3.2 850 96 2438

6.4 850 57 1448

9.5 850 35 889

12.7 850 24 610

19.1 850 17.5 445

6.4 1250 72 1829

9.5 1250 48 1219

12.7 1250 37 940

15.9 1250 30 762

23.8 1250 19.5 495

6.4 1400 72 1829

9.5 1400 42 1068

12.7 1400 34 865

15.9 1400 27 687

19.1 1400 22 560

28.6 1400 13 330

NOTE

If you want a groove depth that is greater than 1-1/2 times the diameter of the electrode being used, make the groove in two or more passes.

SYSTEM COMPONENT DESCRIPTION 3-8 Manual 89250890

SYSTEM COMPONENT DESCRIPTION N7500

3.06 Selecting the Proper Electrode Diameter

Your choice should be based on the depth and width of the gouge you need. If you want a gouge 1-1/2 times greater than the diameter of the electrode being used, make the groove in two or more passes or oscillate the Torch Head.

3.07 Keeping Electrodes Dry

Keep electrodes dry. Damp electrodes should be dried before using. (Ten hours at 300°F [176.7°C]) Wet electrodes may shatter from internal steam pressure when an arc is struck.

POWER SUPPLY (SUPPLIED BY USER) FOR THE N7500 SYSTEM

WARNING

Direct current/electrode positive (reverse polarity) is required for the N7500 System. Use direct current/electrode negative (straight polarity) for special applications. DO NOT use alternating current with the system.

CAUTION

Power Supplies must be rated for 100% duty cycle at the amperage required for the size (diameter) electrode used. Contact the manufacturer of the Power Supply for paralleling procedures or with questions concerning amperage ratings and duty cycles.

NOTE

Recommendations are based on a 4 volt DC drop per 100 ft. (30.48 m) length given is onehalf the sum of lengths of electrode and ground leads. Inadequate grounding may cause cable overheating. There should be at least 1 square inch (6.45 cm2) of contact per 1000 amps.

DC Welding Power Supply with a minimum Open-Circuit Voltage (OCV) of 60 volts and 45 volts at rated load supply the DC current for the N7500 System. Use single Power Supplies rated at 1,000 or 1,500 amperes to get enough amperage for larger diameter electrodes. Power Supplies may be paralleled in combinations of two or more similar units.

3.08 Secondary Power Cables (Welding Leads)

Recommended Number and Size of Secondary Cables

Amps

100 4 4 1 1 1/0 1 2/0 1 4/0 200 3 2 1 1/0 1 3/0 1 3/0 3 3/0 300 2 1 1 3/0 2 2/0 2 4/0 4 4/0 400 2 1 1/0 1 4/0 3 3/0 3 4/0 500 1 1 2/0 2 2/0 3 4/0 4 4/0 600 1 1 3/0 2 3/0 3 4/0

800 1 3/0 1 4/0 2 4/0 5 4/0 1000 1 4/0 2 2/0 3 3/0 1200 2 2/0 2 3/0 3 4/0 1400 2 4/0 2 4/0 4 3/0 1600 3 3/0 2 4/0 4 4/0 1800 2 4/0 3 3/0 2000 3 4/0 3 4/0

25 ft. (7.5 m) 50 ft. (15 m) 100 ft. (30 m) 150 ft. (46 m) 200 ft. (61 m) 250 ft. (76 m)

No. Size No. Size No. Size No. Size No. Size No. Size

Table 3-13: Power Cable Requirements

Choose the number and size of secondary power cables on the basis of the combined length of both the positive (Electrode) and negative (work piece/ground) cables to ensure greatest efﬁciency and safe operation in terms of 100% duty cycle.

Manual 89250890 3-9 SYSTEM COMPONENT DESCRIPTION

N7500 SYSTEM COMPONENT DESCRIPTION

3.09 Compressed Air

Compressed air ﬂows from an air nozzle in the N7500 Torch Head, travels parallel along the axis of the electrode, and is directed into the molten puddle. The air solenoid included in the N7500 Control Box accepts ordinary shop compressed air. An air regulator (supplied by user) should be mounted on the air line and adjacent to the Control Box. Use at least 60 psi, but not greater than 100 psi input of compressed air to the regulator. “Table 3-14: Compressed Air Input Requirements” shows recommended pressure and volume inputs:

Compressed Air Requirements

Air Pressure Air Volume

psi* kg/cm

60 4.2 46 1.3 80 5.6 63 1.8

100 7.0 81 2.3

Table 3-14: Compressed Air Input Requirements

*To convert psi to kpa (kilopascals), multiply by 6.895

3.10 Main Air Line

Up to the air regulator mounted (see “Figure 4-9: Assembly Stage 1” on page 4-4) on the N7500 system, the Primary Air Line may be either rigid or ﬂexible. The inside diameter of the Primary Air Line varies with the length of the line between compressor and regulator.

CFM m3/min.

Recommended Air Line Requirements

Line length up to 25’ (7.6 m): 1/2” (12.7 mm) inside diameter

Line length above 26’ (7.9 m): 5/8” (15.9 mm) inside diameter

SYSTEM COMPONENT DESCRIPTION 3-10 Manual 89250890

ASSEMBLY AND INSTALLATION N7500

SECTION 4:

ASSEMBLY AND INSTALLATION

CAUTION

Be sure to read this manual completely before trying to install or use this equipment. Call your Victor Arcair Representative or Distributor if you have any questions.

4.01 Receiving and Handling

Remove all components from the boxes. Using the packing lists, check to be sure you have all parts. Inspect each part for damage. Buyers may ﬁle claims for loss or damage with the carrier.

Unpacking Components

Write down the Part Number and Serial Number for the Control Box, Remote Pendant, and Torch Head on the Warranty page in the back of this book.

ART# A-10855_AC

ART# A-10838_AB

Figure 4-1: Control Box

ART# A-10865_AC

Figure 4-3: Remote Pendant

Manual 89250890 4-1 ASSEMBLY AND INSTALLATION

Figure 4-2: Torch Head

N7500 ASSEMBLY AND INSTALLATION

MAX 100 p

When asking about your equipment, be sure to give its full serial and model number(s) that appear on the nameplate of each component. The N7500 has name plates on each major component; Control Box, Torch Head, and Remote Pendant. The Torch Head and the Pendant have smaller nameplates than the Control Box. The Control Box nameplate is located on the rear plate. The nameplate for the Torch Head is located on the inside shield and the nameplate for the Pendant is on it’s back surface.

Art# A-10857_AB

Art# A-10845_AC

Figure 4-4: Control Box Nameplate

Art# A-10849_AB

Figure 4-5: Remote Pendant and Torch Head

Nameplates

Remote Pendant

Control Box

Torch Head

ART# A-10924_AC

Figure 4-6: Nameplate Locations

NOTE

When using the Arcair-Matic N7500 Gouging System with a travel system, the Control Box should be centrally placed.

Prior to installing the N7500 components please have the following components or items in place:

WARNING

Connections to ‘live’ or “hot” are inherently dangerous. DO NOT service or repair equipment with power ON. DO NOT operate equipment with protective insulators or covers removed.

• Conﬁrm that your Power Supply cable size is rated for the work and the cable ends have ﬁttings that will mount on the Control Box Power Supply buss poles (See Step 6). See "Table 3-13: Power Cable Requirements" on page 3-10.

• Conﬁrm that your air supply is rated for the work (See Step 6). See "Table 3-14: Compressed Air Input Requirements" on page 3-10.

ASSEMBLY AND INSTALLATION 4-2 Manual 89250890

ASSEMBLY AND INSTALLATION N7500

4.02 Assembly

The assembly instruction steps are divided into ﬁve groups; Miscellaneous Cable/Plumbing Assemblies, Control Box, Torch Head, Remote Pendant, and Final Connections. Remote Pendant Storage is located at the end of this section.

4.03 Miscellaneous Cable/Plumbing Assemblies

Cable assemblies required to operate the N7500 system come in various lengths and must be speciﬁed by the end user to meet their speciﬁc needs.

Cable

Description

Routing

AC Power Cable Assembly

Plug rated for 110VAC 60Hz or 220VAC 50Hz with 3 pin connector at opposite end.

Outside power to Control Box

ART# A-10858_AB

ART# A-10863_AB

ART# A-10854_AB

Remote Pendant Cable Assembly

Large 7 pin connector with male/female ends.

Pendant to Control Box

Motor Cable (on Torch Head) Assembly

6 pin connector with male/female connectors.

Control Box to Torch Head

Power Supply Communication Assembly

6 pin connector with female connector and a cut end.

Control Box to Power Supply

DC Power Cable Assembly

Based on customer requirements.

Control Box to Torch Head

Air Hose Assembly

ART# A-10862_AC

ART# A-10859_AB

ART# A-10839_AC

ART# A-10860_AC

Based on customer requirements.

Control Box to Torch Head

Table 4-7: Cable Identiﬁcation

Manual 89250890 4-3 ASSEMBLY AND INSTALLATION

N7500 ASSEMBLY AND INSTALLATION

4.04 Control Box Installation

Determine where the Control Box should be located in relationship to where the gouging will take place. It is not recommended to carry the Control Box on any travel system other than the Victor Arcair Titan® Machine Carriage due to the added weight of the Control Box and the weight of the power cables coming from the DC Power Supply.

The Control Box can be secured to a stationary surface with the mounting brackets on both sides. Refer to "Table 3-2: Control Box Features" on page 3-2 for the mounting brackets and "Figure 3-4: RIGHT Side of Control Box" and "Figure 3-5: BACK of Control Box" on page 3-3 for bracket locations.

NOTE

DO NOT force connections. All connectors should be fastened easily. Be sure to tighten connections as you go through each step. Avoid crimping hoses or wires.

WARNING

Select the receptacle voltage that correctly matches the plug and power requirements of the Carriage System.

WARNING

Conﬁrm that the Power Supply and Control Box Power In switches are OFF.

Make the following connections from Power Supply to Control Box and work piece. See "Figure 4-8: Assembly Stage 1".

POWER SUPPLY

POWER

SUPPLY

DC POWER CABLE (+) IN

GROUND CABLE (–)

CONTROL BOX INPUT

AC POWER CABLE

120V

220V

COMMUNICATION CABLE

(Rear panel assembly not shown for clarity)

MAX 100 psi

CONTROL BOX

AIR REGULATOR

SIGNAL WIRE

INCOMING

AIR LINE

(VIEWED FROM CABINET LEFT SIDE)

ART# A-10850_AC

GROUND CABLE (–)

WORK PIECE

Figure 4-8: Assembly Stage 1

1. Connect the air regulator to the side of the Control Box labeled “AIR IN”. Preset the regulator to the recommended operating pressure based on "Table 3-14: Compressed Air Input Requirements" on page 3-10. (The compressed air inlet and outlet ﬁttings on the Control Box are 1/2-14 NPT.)

2. Connect the incoming shop compressed air line to the air regulator. Charge the shop compressed air supply to the air regulator on the Control Box’s AIR IN side to conﬁrm air pressure is within recommended speciﬁcations. Refer to the speciﬁcations listed on the Control Box nameplate.

3. Attach the AC Power Cable to the connector labeled “POWER IN”.

4. Loosen the screws holding the Control Box rear cover plate. Re-position and tighten one screw.

ASSEMBLY AND INSTALLATION 4-4 Manual 89250890

ASSEMBLY AND INSTALLATION N7500

WARNING

Conﬁrm the DC Power Supply is OFF before beginning the next step.

5. Connect the positive (+) Power Supply cable(s) of the DC Power Supply to the busbar terminal on the back

side of the Control Box labeled “POWER SUPPLY IN”. This connection must be wrench tight to avoid over heating of the connection. Refer to "Table 3-13: Power Cable Requirements" on page 3-10 in this manual for proper amount and size Power Supply cabling that you plan to use.

NOTE

It is recommended to use a minimum of two Power Cable assemblies with the N7500. The cables should be connected at the same points on the Control Box. Refer to "Table 3-13: Power Cable Requirements" on page 3-10.

6. Connect the negative (-) cable(s) of the DC Power Supply to the work piece.

7. A signal wire (not supplied) must be attached to the work piece and the other end to the ground post on the left side of the Control Box labeled “SIGNAL WIRE”.

NOTE

Use standard #12 insulated copper wire as your signal wire. It must be long enough to prevent stress on the Control Box connection.

8. Connect the Power Supply Communication Cable Assembly (6 pin female connector) to the side of the Control Box labeled “POWER SUPPLY” and run it back to the Power Supply. Refer to "Table 4-7: Cable Identiﬁcation" on page 4-3 for cable identiﬁcation. "Figure 4-9: Power Supply Comm. Cable Pin Conﬁguration" below illustrates the pin arrangement for the Power Supply Communication Cable and "Table 4-10: Standard Wiring Connections" has the wire connection schedule for several common power supplies. If your Power Supply is not listed here please refer to the Owner’s manual of your Power Supply for correct wiring instructions.

PIN F BLACK #2

PIN A BLACK #1

CONTROL BOX POWER SUPPLY

COMMUNICATION CABLE PIN LAYOUT

ART# A-10832_AD

Figure 4-9: Power Supply Comm. Cable Pin Conﬁguration

Manual 89250890 4-5 ASSEMBLY AND INSTALLATION

N7500 ASSEMBLY AND INSTALLATION

Power Supply Control Connection Chart

N7500 Control Box Power Supply

Brand Model

Lincoln Idealarc® DC 600 2 4

Lincoln Idealarc DC 600 PRO 2 4

Lincoln Idealarc DC 650 PRO 2 4

Lincoln Idealarc DC 655 - EUROPE 2 4

Lincoln Idealarc DC 655 2 4

Lincoln Idealarc DC 750 2 4

Lincoln

Lincoln Idealarc DC 1000 (Prior to Nov 1991) 2 4

Lincoln Idealarc DC 1000 (for code numbers 9919 - 9925, 10293, 11305, 11330, 11331, 11332, 11333, 11334, 11681 thru 11684)

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5

2 4

Comm. Cable

Miller

ESAB

Lincoln Idealarc DC 1500 (Prior to May 1979) 2 4

Lincoln Idealarc 1500 (for Code Numbers 8294 and above) 2 4

Lincoln RED-D-ARC DC 600 2 4

Miller BIG BLUE 500D - 600X A or I B or J

Miller Deltaweld® 450-650 A or I B or J

Miller Deltaweld SERIES A or I B or J

Miller Dimension™ 650 A or I B or J

Miller Dimension 1000 A or I B or J

Miller Dimension SUBARC A or I B or J

Miller Dynasty® 700 - MAXSTAR 700 A B

Miller Gold Star® 300SS - 400SS - 600SS A B

ESAB 653 CVCC U V

ESAB MULTIPOWER 460 PULSE U V

Table 4-10: Standard Wiring Connections

ASSEMBLY AND INSTALLATION 4-6 Manual 89250890

ASSEMBLY AND INSTALLATION N7500

)

AIR LINE

POWER

SIGNAL

AC PO

4.05 Torch Head Installation

Make connections from Control Box to the Torch Head. See "Figure 4-11: Assembly Stage 2".

OWER SUPPLY

OMMUNICATION CABL

UPPL

AIR HOSE

MOTOR CABLE -

CONTROL BOX TO

TORCH HEAD

INCOMIN

AIR REGULATOR

DC POWER CABLE (+) IN

NTROL BOX INPUT

WER CABL

120V

220

ROUND CABLE (–

RT# A-10848_A

TORCH HEADPENDANTAIR OUT

5 AMP

ON OTHER SIDES

THESE CONNECTIONS

WIR

CONTROL BOX

(VIEWED FROM CABINET RIGHT SIDE)

ROUND CABLE (–)

DC POWER

CABLE (+) OUT

(Rear panel assembly not shown for clarity)

N7500

MOUNTING

FIXTURE

AIR INLET

TORCH HEAD

RK PIE

Figure 4-11: Assembly Stage 2

9. Mount the Torch Head to the vertical adjustment assembly located on the travel system or ﬁxed stationary ﬁxture using the mounting hardware supplied with the Torch Head. Further adjustments will be discussed in the operating section of this manual. See "5.02 Position Torch Head" and "5.03 Insert the Electrode" on page 5-2.

NOTE

Tuning the mounting position of the Torch Head or adjusting the traveler ﬁxture or carriage system may be required to achieve best gouging results.

10. Connect the DC power cable(s) to the Torch Head busbar and to the busbar terminal on the back side of the Control Box labeled “POWER SUPPLY OUT”. These connections must be wrench tight to avoid overheating the connection. Slide the cable boot over the busbar on the Torch Head. Use the 1/2”-13 hex head bolt

and nut supplied for the cable connection on the Torch Head busbar.

11. Return the Control Box Power Supply cover plate to its original position and tighten both screws.

12. Connect the Air Hose Assembly to the Torch Head and to the side of the Control Box labeled “AIR OUT”. Slide the rubber boot over the connection on the Torch Head.

13. Connect the Torch Head Motor Cable Assembly to the connector on the side of the Control Box labeled “TORCH HEAD” and the other end to the motor cable connection on the Torch Head. This cable has a 6 pin connector at each end. Refer to "Table 4-7: Cable Identiﬁcation" on page 4-3.

Manual 89250890 4-7 ASSEMBLY AND INSTALLATION

N7500 ASSEMBLY AND INSTALLATION

n for clarity

OSE

TORC

)

AIR LINE

POWER

SIGNAL

AC PO

4.06 Remote Pendant Installation

Make the following connections from the Pendant to the Control Box. See "Figure 4-12: Assembly Stage 3".

REMOTE PENDANT

N7500 Gouging System

TRV

JOG

START

Automatic Control

TUNE

ROUGH

STOP

UPPL

OWER SUPPLY

OMMUNICATION CABL

REMOTE PENDANT CABLE

IR H

TORCH HEADPENDANTAIR OUT

DC POWE

ABLE (+) OUT

MOTOR CABLE -

NTROL BOX T

TORCH HEAD

AIR INLET

INCOMIN

AIR REGULATOR

DC POWER CABLE (+) IN

NTROL BOX INPUT

WER CABL

120V

220

ROUND CABLE (–

RT# A-10854_A

ON OTHER SIDES

THESE CONNECTIONS

WIR

(VIEWED FROM CABINET RIGHT SIDE)

5 AMP

CONTROL BOX

(Rear panel assembly not shown for clarity)

ROUND CABLE (–)

MOUNTIN

FIXTURE

H HEAD

RK PIE

Figure 4-12: Assembly Stage 3

14. Connect the Remote Pendant Cable Assembly to the Remote Pendant and the Control Box. Cable has a large 7 pin connector at each end. Refer to "Table 4-7: Cable Identiﬁcation" on page 4-3.

15. Plug the travel system grounded power cord into the receptacle labeled “POWER OUTLET”.

WARNING

Select the receptacle voltage that correctly matches the plug and power requirements of the Carriage System.

ASSEMBLY AND INSTALLATION 4-8 Manual 89250890

ASSEMBLY AND INSTALLATION N7500

4.07 Remote Pendant Storage

Use safe storage practices when storing the Remote Pendant and cable. When not in use, mount the Remote Pendant to the top of the Control Box as shown below.

Automatic Control

TUNE

STOP

N7500 Gouging System

ROUGH

START

MAX 100 psi

ART# A-10831_AC

Figure 4-13: Pendant Mounting

Automatic Control

TUNE

STOP

ROUGH

START

ART# A-10830_AC

Figure 4-14: Pendant Mounted

N7500 Gouging System

MAX 100 psi

Manual 89250890 4-9 ASSEMBLY AND INSTALLATION

N7500 ASSEMBLY AND INSTALLATION

This Page Intentionally Blank

ASSEMBLY AND INSTALLATION 4-10 Manual 89250890

SYSTEM OPERATION N7500

SECTION 5: OPERATING THE N7500 SYSTEM

5.01 Remote Pendant Operation

ART# A-10856_AB

Figure 5-1: Remote Pendant

Item No. Feature Function

Mode-indicator

Display

START

Start Button

STOP

Stop Button

Rough

Digital display of current mode setting/adjustment value/rate.

Signals the Power Supply to close it’s internal contactor to supply current to the Torch Head and the electrode in the Torch Head feeds down to begin the gouging operation. Signals the Power Supply to open it’s internal contactor shutting OFF the current to the Torch Head and the electrode in the Torch Head will retract away from the work surface.

Stalls the Torch Head feed motor while maintaining current to the electrode to avoid gouging to irregular surface defects.

(Machining)

Potentiometer to adjust settings based on operation mode.

Rotary Dial

TRV

Travel Button

Jog Up/Down

When pressed, supplies AC voltage to the travel system that is plugged into the Control Box. Used when adjustments are required to locate the electrode to the start point of gouging.

Feeds or retracts the electrode in the Torch Head

Travel

Mode Selector

10 Connector Cable connection running from the Remote Pendant to Control Box

OK Button

Shifts mode (program display) selection in digital display to access a setting or adjustment.

Enters and Accepts data adjustments for the mode of operation.

11 Bumper Protective housing. 12 Grip Feet Plastic snap on feet to fasten Remote Pendant to Control Box.

Table 5-2: Remote Pendant Controls

Determine whether you will use a Constant Current (CC) or Constant Voltage (CV) Power Supply. A menu option on the Remote Pendant LED will prompt you to choose CC or CV to match your Power Supply.

Manual 89250890 5-1 SYSTEM OPERATION

N7500 SYSTEM OPERATION

3/8” NPT AIR INLET

WARNING! AVERTISSEMENT!

Insure good ground from power supply to workpiece. Poor ground may cause

damage to any or all components.

gg p

ppyp g

ppyp g See manual.

Smoke, fumes, and gases can be dangerous to your health.

ventilation. Keep your head out of the smoke.

,,gg

L les rayons de l’arc,

5.02 Position Torch Head

1. Position the Torch Head above the work piece you want to start gouging.

2. Using the Angle Gauge supplied with the N7500, adjust the Torch Head to the work piece. The angle gauge sets the torch angle, electrode stick-out and aligns the air nozzle.

3. The air should ﬂow between the electrode and the work piece.

Charts, graphs and other data in this manual are based on a 45° electrode angle, but you can use electrode angles from 45° to 60°. Users should develop their own standards based on shop conditions and application.

5.03 Insert the Electrode

1. Adjust the Electrode Guide Block for the electrode diameter being used. Loosen thumbscrew, adjust, and then tighten the thumbscrew again (See “Figure 5-3: Torch Head Parts”).

2. Push the Electrode Release (clamping) Lever down and insert the electrode FEMALE END FIRST into the rear of the Torch Head until it protrudes through the nozzle. The two-legged spring and protective shield should rest squarely on top of the electrode. To check their positions, look down the rear of the torch. If the spring and shield are pushed to either side, withdraw the electrode and insert it again. Release the clamping lever.

ELECTRODE

TORCH HEAD

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.

se only with compressed air.

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 manue

Noise can damage hearing.

Le bruit peut endommager l’ouïe.

Use adequate

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.

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

- 5/16 3/8

- 1/2

- 5/8

- 3/4

MOTOR CABLE

DC POWER

CABLE

BUSBAR

N7500

RELEASE LEVER

AIR PLENUM HOUSING

MOUNTING FIXTURE

ART# A-10834_AB

ELECTRODE GUIDE BLOCK

MOTOR

Figure 5-3: Torch Head Parts

3. Flip the power switch located on the side of the Control Box labeled “POWER OFF” & “POWER ON” to the “ON” position.

4. The electrode will retract for several seconds and stop.

5. The Mode Indicator Display on the Remote Pendant will light up showing the various menu options preprogrammed in the unit.

“Menu Setting” is the default display whenever the unit is powered up.

SYSTEM OPERATION 5-2 Manual 89250890

SYSTEM OPERATION N7500

5.04 Remote Pendant Programming

The ﬁrst (default) menu setting option is “Power Mode”, see “Figure 5-4: Default Pendant Screen CC or CV mode”. This setting must match the DC Power Supply being used.

1. Select the CC or CV mode setting. To set the CC or CV mode;

a. Press the “OK” OK button on the Pendant. Once pressed, the CC or CV letters will begin blinking.

b. Rotate the Rotary Dial to switch between CC or CV modes. The screen displays as follows:

Menu Setting Power Mode CV Parameter Guide

Current1400A

ART# A-10825_AC

Figure 5-4: Default Pendant Screen CC or CV mode

c. Press the “OK” OK button on the Pendant. The CC or CV choice displayed on the screen is entered.

If the “OK” button is not pressed within one minute, the blinking will stop and the mode will be whatever is shown.

2. Using the down “Mode Selector” button move the cursor to highlight “Parameter Guide” and press

the “OK” OK button. See “Figure 5-6: Parameter Guide Screen”.

3. There are 2 Parameter Guide settings based on the work performed. Use the “Mode Selector” or

buttons to scroll up or down the choices. Press the “OK” OK button and use the dial to select a value for any of these settings. Use the “Mode Selector” button again to exit a setting choice. The displayed setting value is accepted when you move to another setting.

NOTE

Menu Setting

Power Mode CC

Parameter Guide

Voltag

ART# A-10826_AC

2.0V

Unit - (of measurement) Inches or Millimeters

Diameter - Electrode diameter. Available settings are listed in the Parameter Table.

Depth - Gouging depth. Available settings (based on the electrode diameter) are listed in the Parameter Table.

Current - Defaults based on the recommended operating current.

Manual 89250890 5-3 SYSTEM OPERATION

N7500 SYSTEM OPERATION

Travel Speed - Travel Speed output provides a starting point to set the travel speed to obtain the gouge depth selected. Adjust by resetting parameter variables accordingly once the gouging process is started as needed.

Remember that the slower the travel speed the deeper the gouge and vice versa.

Electrode Diameter Gouge Depth Current Travel speed/min

INCH MM INCH MM AMPS INCH MM

5/16 7.9 1/8 3.2 400 65.0 1651

5/16 7.9 3/16 4.8 400 45.0 1143

5/16 7.9 1/4 6.4 450 36.0 914

5/16 7.9 5/16 7.9 450 33.0 838

5/16 7.9 7/16 11.1 450 22.5 572

3/8 9.5 1/8 3.2 500 70.0 1778

3/8 9.5 3/16 4.8 500 44.0 1118

3/8 9.5 1/4 6.4 500 35.0 889

3/8 9.5 3/8 9.5 500 20.0 508

3/8 9.5 9/16 14.3 500 17.5 445

1/2 12.7 1/8 3.2 850 96.0 2438

1/2 12.7 1/4 6.4 850 57.0 1448

1/2 12.7 3/8 9.5 850 35.0 889

1/2 12.7 1/2 12.7 850 24.0 610

1/2 12.7 3/4 19.1 850 17.5 445

5/8 15.9 1/4 6.4 1250 72.0 1829

5/8 15.9 3/8 9.5 1250 48.0 1219

5/8 15.9 1/2 12.7 1250 37.0 940

5/8 15.9 5/8 15.9 1250 30.0 762

5/8 15.9 15/16 23.8 1250 19.5 495

3/4 19.1 1/4 6.4 1400 72.0 1829

3/4 19.1 3/8 9.5 1400 42.0 1067

3/4 19.1 1/2 12.7 1400 34.0 864

3/4 19.1 5/8 15.9 1400 27.0 686

3/4 19.1 3/4 19.1 1400 22.0 559

3/4 19.1 1 1/8 28.6 1400 13.0 330

Table 5-5: Parameter Table

SYSTEM OPERATION 5-4 Manual 89250890

SYSTEM OPERATION N7500

Menu Setting Power Mode CV Parameter Guide

Curren

ART# A-10824_AC

Figure 5-6: Parameter Guide Screen (using CV mode)

Back Unit Inch Diameter

Depth

ART# A-10841_AB

Figure 5-7: Parameter Guide Setting Examples

4. Press the “OK” OK button to exit the Parameter Guide choices.

5. Set the DC Power Supply to obtain the recommended current as noted in the Parameter Guide. Set the travel speed to the recommended speed per the Parameter Guide.

6. Use the up or down “Mode Selector” or buttons to scroll to “<- Back” and press the “OK” OK button. You are returned to the main screen highlighting “Parameter Guide”.

7. Use the up or down “Mode Selector” or buttons to scroll to Current and press the “OK” OK button. See “Figure 5-8: Current Setting Examples”.

3/8

9/16

Curren Travel Speed

ART# A-10842_AB

50A

Back

00A

17.5 Inch/Min

When operating in the “CC” mode, set “Voltage” at any point between 40 - 44 Volts. The Remote Pendant

is set at 42 Volts from the factory.

When working in the “CV” mode, set the “Current”.

CV EXAMPLE:

Electrode Diameter = 1/2” (12.7 mm)

Amperage Required = 850

“OUTPUT LEVEL” setting = 850

Menu Setting Power Mode CV Parameter Guide

Curren

ART# A-10829_AB

Figure 5-8: Current Setting Example

8. Use the potentiometer dial to obtain the correct “Current” setting required when using CV mode.

Press the “OK” OK button to set the Current value.

50A

Manual 89250890 5-5 SYSTEM OPERATION

N7500 SYSTEM OPERATION

9. Use the up or down “Mode Selector” or buttons to scroll to “Travel Delay.” See “Figure 5-9: Travel Delay Screen.”

Press the “OK” OK button and rotate the potentiometer dial to adjust the time delay for any time

length between 0 and 6.0 seconds.

Press the “OK” OK button to set the Travel Delay time setting.

Menu Setting

Parameter Guide

Voltag

Travel Delay

ART# A-10828_AB

Figure 5-9: Travel Delay Screen

Travel Delay Setting

Approximate

Setting

0.0

0.5

1.0

1.5

2.0

2.5

3.0 3/4” (19.05 mm)

3.5 3/4” (19.05 mm)

4.0 3/4” (19.05 mm)

5/16” (7.9 mm) through 3/4” (19.05 mm)

3/8” (9.53 mm) through 3/4” (19.05 mm)

1/2” (12.7 mm), 5/8” (15.88 mm), 3/4” (19.05 mm)

5/8” (15.88 mm), 3/4” (19.05 mm)

Electrode Size

Table 5-10: Travel Delay Setting

2.0V

Target Depth

Inches mm

⅛

⁄

⅜

⅝

⁄

⅞

3.2

6.4

7.9

9.5

12.7

15.9

17.5

19.0

22.2

10. Use the up or down “Mode Selector” or buttons to scroll to “No Current Detect”. See “Figure 5-11: No Current Detect screens“.

The N7500 System contains a “No-Current Detect” circuit. This circuit monitors Arc Current. Should the

arc increase or decrease outside set limits or the arc stop, the “No-Current Detect” circuit will shut down the gouging sequence. “Normal” mode is preset from the factory.

This program can be set for one of three response levels:

NORMAL - Setting provides 0.4 second System shutdown delay.

SPECIAL - Setting provides 0.8 second System shutdown delay.

OFF - System continues to operate regardless of Arc Current level. System shutdown is manually

controlled.

SYSTEM OPERATION 5-6 Manual 89250890

SYSTEM OPERATION N7500

Set the “No Current Detect” option as needed. To change the setting press the “OK” OK button and using

the Potentiometer knob select the setting that meets your needs.

Menu Setting

0.2 Sec

NoCurrent Detect

ART# A-10823_AB

Normal

Menu Setting

0.2 Sec

NoCurrent Detect

ART# A-10827_AB

Special

Menu Setting

0.2 Sec

NoCurrent Detect

ART# A-10822_AB

OFF

Figure 5-11: No Current Detect screens

Press the “OK” OK button again to retain the setting chosen.

11. Turn ON the compressed air.

12. Turn ON the Power Supply.

13. Press the “Start”

START

button.

The DC Power Supply contactor closes and the electrode will feed down to the work piece. The air solenoid

inside the Control Box will open to release compressed air to the Torch Head air nozzle. An arc will be struck as soon as the tip of the electrode reaches the work piece. The proper arc gap will be maintained, even while the electrode feeds downward. Once the electrode reaches the target depth, the travel system will be energized.

NOTE

If a short out interrupts the operation; check the air nozzle and the electrode guide block in the Torch Head for signs of arcing. If arcing is evident make appropriate repairs. If NO signs of arcing are present, retry starting the gouge procedure by pressing the “Start” button on the Pendant.

WARNING

Wear protective gear and be sure the work area is clear. The system is ready to begin gouging. If the unit is attached to a travel system, be sure the travel system is ready to operate. Stand clear of the Torch Head.

CAUTION

If the unit doesn’t respond, turn OFF the Power Supply and Control Box power. Refer to the Troubleshooting Guide.

14. To adjust arc voltage while operating in “CC” mode, push down on the rotary dial while turning clockwise to increase or counterclockwise to decrease the arc voltage under load. Range of adjustment is +/- 5 volts

from initial arc voltage value shown on the Remote Pendant before pressing the “Start”

START

button. If the gouging is stopped for any reason, the arc voltage value displayed at that point will be the new value that can be increased or decreased by 5 volts.

To adjust current while operating in “CV” mode, push down on the potentiometer dial while turning

clockwise to increase or counterclockwise to decrease the current under load. Range of adjustment is +/100 amperes from initial current value shown on the Remote Pendant before pressing the “Start” button. If the gouging is stopped for any reason, the current value displayed at that point will become the new value that can be increased or decreased by 100 amperes.

Manual 89250890 5-7 SYSTEM OPERATION

N7500 SYSTEM OPERATION

Gouging operations can be stopped using the Remote Pendant controls.

15. Press the “STOP”

STOP

button and the electrode will retract, compressed air stops ﬂowing through to the

Torch Head, and the DC power supply contactor opens.

If you press the “Start”

START

button again the N7500 will resume operations again in the same mode set-

tings.

NOTE

LOW VOLTAGE SHUTDOWN can occur when the DC voltage supplied to the N7500 System drop below 28 volts. This feature protects the system from serious damage. If this occurs determine the cause of the voltage drop, take corrective action and restart the system.

SYSTEM OPERATION 5-8 Manual 89250890

SYSTEM USES N7500

SECTION 6:

N7500 SYSTEM USES

6.01 SYSTEM USES

This section brieﬂy describes some uses for the N7500 System. If you have any questions concerning a speciﬁc application for this system contact Victor Technologies Technical Services Department at 800-426-1888 or 940- 566-2000.

GOUGING NON-FERROUS METALS

The N7500 System can be connected to DC Straight Polarity (DCEN) to gouge non-ferrous metals, such as nickel, copper alloys, etc. “Figure 6-1: N7500 DC Straight Polarity (DCEN)” shows the proper connections for the system to run on DC Straight Polarity.

REMOTE PENDANT

Automatic Control

DC POWER

CABLE (+) OUT

(Rear panel assembly not shown for clarity)

TRV

JOG

TUNE

MOUNTING

N7500 Gouging System

START

ROUGH

STOP

AIR HOSE

TORCH HEAD CABLE

FIXTURE

CONTROL BOX

AIR INLET

N7500

TORCH HEAD

WORK PIECE

POWER

SUPPLY

INCOMING

AIR LINE

DC POWER CABLE (-) IN

CONTROLLER INPUT

AC POWER CABLE

120V

220V

GROUND CABLE (–)

ART# A-10852_AC

POWER SUPPLY

COMMUNICATION CABLE

AIR REGULATOR

(VIEWED FROM CABINET RIGHT SIDE)

SIGNAL

WIRE

PENDANT CONTROL BOX CABLE

5 AMP

ON OTHER SIDES

THESE CONNECTIONS

CONTROL BOX

TORCH HEADPENDANTAIR OUT

5 AMP

GROUND CABLE (+)

Figure 6-1: N7500 DC Straight Polarity (DCEN)

NOTE

Use standard #12 insulated copper wire as your signal wire. It must be long enough to prevent stress on the Contactor connection.

6.02 Zero Force Rough Machining

The N7500 system can work with an automated travel system to remove hardsurfacing material from steel mill rolls; kiln rolls and shafts which needs re-working. Remove as much as 1-1/2” (3.81 cm) of old material from the outside diameter in a single pass and as little as 1/8” (3.18 cm) for the ﬁnish pass.

OSCILLATION GOUGING TO REMOVE MATERIAL

The N7500 can be mounted on a welding oscillator to remove material. Normal uses for an oscillated gouge would be to remove cladded material from plates requiring a beveled edge and to remove backup bars and excessive weld crowns.

Manual 89250890 6-1 SYSTEM USES

N7500 SYSTEM USES

This Page Intentionally Blank

SYSTEM USES 6-2 Manual 89250890

MAINTENANCE N7500

Maintain more often

SECTION 7:

MAINTENANCE

7.01 Introduction

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, qualiﬁed 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

Danger: HIGH VOLTAGE may be present internally even with the Control Box power switch in the OFF position. Before inspecting, cleaning, or servicing, disconnect and lock out the input power from the Mains.

Warning! Disconnect input power before maintaining.

Each Use

Visual check of regulator and pressure

Air lines

Replace all broken parts

Visually check and use a vacuum to carefully clean the interior

Visual check of Remote Pendant

- 5/16 3/8

- 1/2

- 5/8

- 3/4

3 Months

Clean exterior of Torch Head

6 Months

Visual check of Torch Head

Use only with compressed air. See manual.

Use adequate

énergie à l'objet. La terre pauvre peut endommager

WARNING! AVERTISSEMENT!

yez seulement avec l'air comprimé. Voir le manuel.

yons de l’arc,

Le bruit peut endommager l’ouïe.

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.

L les ra

Insure good ground from power supply to workpiece. Poor ground may cause damage to any or all components.

Assurez la bonne terre de l'alimentation d' quelques des ou tous composants. Emplo

Noise can damage hearing.

Smoke, fumes, and gases can be dangerous to your health. 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.

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.

Clean exterior of Control Box

if used under severe conditions

avec l'air comprimé. Voir le manuel.

Use only with compressed air. See manual.

Use adequate

'énergie à l'objet. La terre pauvre peut endommag

WARNING! AVERTISSEMENT!

yez seulement

ayons de l’arc,

Le bruit peut endommager l’ouïe.

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.

L les r

Insure good ground from power supply to workpiece. Poor ground may cause damage to any or all components.

Assurez la bonne terre de l'alimentation d quelques des ou tous composants. Emplo

Noise can damage hearing.

Smoke, fumes, and gases can be dangerous to your health. 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.

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.

Clean interior of Nozzle and

MAX 100 psi

Torch Head

Art # A-10847_AB

Figure 7-1: Maintenance

Manual 89250890 7-1 MAINTENANCE

N7500 MAINTENANCE

The following checklist can be used as a guide for routine maintenance.

• Check warning labels for readability.

• Check sheet metal panels, plates, and covers on the Control Box, Remote Pendant, and Torch Head. All screws,

fasteners, and connectors should be ﬁrmly secured. Heavily corroded or damaged panels, damaged fasteners or connectors should be replaced.

• Check all wiring and hoses to the Control Box, Remote Pendant, and Torch Head. Repair or replace any wires, cables, or hoses that have cracked or damaged insulation or frayed connections.

• Check Control Box internal connections including circuit board connectors. Any loose or corroded connections should be repaired.

• Check any connections to travelers, ﬁxtures, etc.

• Check all Control Box switches and controls. Damaged or broken switches or controls should be replaced.

• Check Remote Pendant control panel surface, bumper, connector, and controls. Cracked, torn, or peeling Remote

Pendant control panel surface should be replaced. If any of the control buttons or rotary dial are inoperable the Remote Pendant should be replaced. If the rotary dial knob is broken, missing, or malfunctioning the rotary dial knob should be replaced.

• Check Torch Head nozzle, air plenum housing, shield, motor, busbar connection, and motor cable. Heavily corroded or damaged nozzle, air plenum housing, or shield should be replaced.

• Check and log N7500 Arctime hours using the Remote Pendant.

7.02 Remote Pendant ARCTIME

Arctime will show the N7500 arctime when the unit is turned ON. This display will update as the N7500 is used.

1. Position the power switch located on the side of the Control Box labeled “POWER OFF” & “POWER ON” to the “ON” position. Notice the electrode will retract for several seconds and stop.

2. The Mode Indicator Display on the Remote Pendant will light up on the “Menu Setting” (Default display whenever the unit is powered up).

3. Using the down “Mode Selector” button move the cursor to highlight “Arctime” and press the “OK” OK button.

0.2 Sec

NoCurrent Detect

Normal

ART# A-10840_AB

Figure 7-2: Arctime Screen

4. Log the Arctime hours and the date the reading was taken onto a log sheet for your maintenance record.

0.0HRArctime

MAINTENANCE 7-2 Manual 89250890

TROUBLESHOOTING GUIDE N7500

SECTION 8:

TROUBLESHOOTING GUIDE

8.01 Arcair-Matic N7500 Gouging System

In all troubleshooting cases turn power OFF before performing work on the system unless otherwise directed to do so.

CAUTION

Use appropriate Lock OUT and tag OUT measures when working with electrical equipment or electrical components.

8.02 N7500 General

General

Problem Possible Cause Possible Remedy

Torch Head nozzle melting

No power

No operation with power supplied to Remote Pendant

N7500 starts operation but Torch Head does not begin traveling or delays start of travel

Low air pressure at nozzle

Power Supply not turned ON Turn ON Power Supply. AC Power Cable not connected to N7500 N7500 Control Box ON/OFF switch not turned ON

Power Supply wiring not correct

DC Power Cables not connected or improperly connected

DC Power Cable size too small

No low current

No ground

Incorrect control wiring to Power Supply or from AC Power

Programming on Remote Pendant incomplete Incomplete, loose, or broken connector Signal Wire not connected Connect Signal Wire.

Travel Delay improperly set

Traveler controls improperly set

Increase air regulator pressure. Dismantle Torch Head nozzle, clean and reassemble. Check Air Solenoid Valve.

Check AC Power Cable connection.

Turn ON N7500.

Check wiring connections to Power Supply. Refer to "Figure 4-10: Power Supply Comm. Cable Pin Conﬁguration" on page 4-5 for recommended control wiring. Check DC Power Cable connections. NOTE: Connections must be wrench tight. Refer to "Table 3-13: Power Cable Requirements" on page 3-10

Check ground wire, ground wire connections, work piece clamp, Power Supply DC Power Cables and wiring connections to Power Supply. Review "Table 4-11: Standard Wiring Connections" on page 4-6. Review "4.04 Control Box Installation" on page 4-4. Complete Pendant programming. Refer to "5.04 Remote Pendant Programming" on page 5-3.

Check all N7500 connections. Repair or replace.

Review "Table 5-10: Travel Delay Setting" on page 5-6 and reprogram as necessary. Review connections from Control Box to Traveler.

Conﬁrm Traveler is ON. Review the Traveler’s Owner / Operation manual and correct.

Manual 89250890 8-1 TROUBLESHOOTING GUIDE

N7500 TROUBLESHOOTING GUIDE

General

Problem Possible Cause Possible Remedy

N7500 starts operation but Torch Head stops Electrical Arc at Power supply, Control Box or Torch Head Buss Bar

Low voltage shutdown

Improper wiring connections

8.03 Torch Head

Table 8-1: General Troubleshooting

PIN # WIRE COLOR

Table 8-2: Torch Head Motor 6 PIN Wire Schedule

DC voltage has dropped below 28 volts. Determine cause of voltage drop, take corrective action, and restart the system.

Conﬁrm proper wiring, check for damage to components, repair or replace.

A EMPTY B RED C BLACK D EMPTY E GREEN F BLUE

Torch Head

Problem Possible Cause Possible Remedy

See "No air ﬂow through Control Box when system is activated" in Control Box Troubleshooting

No air or little air from Torch Head nozzle

Electrode does not feed through Torch Head

Shop air issue Check Shop air. Control Box to Torch Head air line kinked Ports in Torch Head nozzle are clogged White nozzle insulator ring on air nozzle missing or destroyed

Torch Head motor not operating

Joint separated or Electrode stub jammed inside housing

Electrode release lever jammed open

Remove kink in air line.

Clean slag from Torch Head nozzle.

Replace with new nozzle insulator ring. See Item number "27" in "Table 9-4: Torch Head PARTS" on page 9-2. See "8.04 Remote Pendant" Troubleshooting section. Check Motor cable connectors. Repair or replace cable. See "SYSTEM CABLES" on page 9-4. Check Motor. See "Figure 9-3: Torch Head PARTS" on page 9-2. Realign electrodes or replace damaged electrode. Shut N7500 down, disconnect Torch Head from Control Box, open housing cover plate and remove electrode. See "Figure 9-3: Torch Head PARTS" on page 9-2. Remove electrode(s) from Torch Head, inspect release lever, repair or replace. See "Figure 9-3: Torch Head PARTS" on page 9-2.

TROUBLESHOOTING GUIDE 8-2 Manual 89250890

TROUBLESHOOTING GUIDE N7500

Torch Head

Problem Possible Cause Possible Remedy

Air leaking from Air Plenum Housing

Busbar corrosion, arcing, overheating, or screws loose inside head

Electrode short out

Electrode retracts during normal operation

Electrode does not retract

Electrode does not retract and reposition itself at start up

Electrode does not arc

O-rings on Air Plenum supply tube worn Top assembly of Air Plenum Housing not fastened securely to lower Air Plenum Housing Top assembly of Air Plenum Housing is distorted from excessive heat

Cable connections are NOT wrench tight

DC Voltage setting is incorrect Adjust DC voltage to 40 to 44 DC Volts. Current set too low for electrode being used

Arc out on air nozzle or the electrode guide block

Power supply and N7500 not on same CC/CV setting DC Voltage setting is incorrect Adjust DC voltage to 40 to 44 volts. STOP button pushed Press START button. Torch Head motor not working Check Torch Head motor and cable. Repair or replace.

Joint separated or Electrode stub jammed inside housing

Torch Head Motor Cable not attached or improperly attached

No or low current

Table 8-3: Torch Head Troubleshooting

Check air tube o-rings, replace if necessary.

Tighten screws on Plenum.

Replace.

Tighten busbar leads connection wrench tight.

Adjust DC current.

If NO signs of arcing are present, retry starting the gouge procedure by pressing the “Start” button on the Pendant.

If signs of arcing are present, repair or replace components. See "Figure 9-3: Torch Head PARTS" on page 9-2.

Reset both to the same CC or CV setting.

Realign electrodes or replace damaged electrode. Shut N7500 down, disconnect Torch Head from Control Box, open housing cover plate and remove electrode. See "Figure 9-3: Torch Head PARTS" on page 9-2.

Attach motor cable.

Check the Power Supply current output. Adjust the Power Supply output current to match the rated current for the Electrode size. Refer to "Table 5-5: Parameter Table" on page 5-4.

Manual 89250890 8-3 TROUBLESHOOTING GUIDE

N7500 TROUBLESHOOTING GUIDE

8.04 Remote Pendant

PENDANT CABLE

PIN COLOR LOCATION

A WHT (#1) PIN A B BK (#1) PIN B

C BK (#2) PIN C D NOT USED PIN D E WHT (no #) PIN E

F WHT (#2) PIN F G NOT USED PIN G

Table 8-4: Pendant Cable Pin Identiﬁcation

Remote Pendant

Problem Possible Cause Possible Remedy

Pendant Cable not attached Attach Pendant Cable. Absence of appropriate power Check power to Control Box.

Remote Pendant has no power

No Remote Pendant display

Rotary Dial does not work

“No-Current Detect” shut down

Mode Selector button(s) on Pendant do not respond to touch

Tripped ON/OFF Switch circuit breaker

Break in cable which links Control Box to Remote Pendant

Defective Remote Pendant Replace Remote Pendant. Pendant Cable not attached Attach Pendant Cable.

Power to Remote Pendant is OFF

Defective Remote Pendant Replace Remote Pendant.

Power to Remote Pendant is OFF

Rotary Dial is loose Tighten set screw on Rotary Dial.

No Current Detect setting is OFF

Power supply and N7500 not on same CC/CV setting

Arc Current not reporting

Defective Remote Pendant Replace Remote Pendant.

Table 8-5: Remote Pendant Troubleshooting

Turn power OFF, check for and repair fault.

Check cable connections.

Repair/replace cable.

Check cable connections.

Repair/replace cable.

Check cable connections.

Repair/replace cable.

Change Remote Pendant No Current Detect programming to ‘Normal’ or ‘Special‘. See page 5-7 for instructions.

Reset both to the same CC or CV setting.

Check signal wire for continuity, min wire size, clamp and connections at work piece and Control Box.

TROUBLESHOOTING GUIDE 8-4 Manual 89250890

TROUBLESHOOTING GUIDE N7500

8.05 Control Box

Control Box

Problem Possible Cause Possible Remedy

No AC power to Control Box

No DC “+” power to Control Box

No output from Travel System Power Connection on Control Box

No air ﬂow through Control Box when system is activated

Power Supply In/Out Busbars corroded, arcing, overheating

110/220VAC power to Control Box NOT turned ON Disconnected AC Power Cable Connect AC Power cable

Defective AC Power cable

Tripped ON/OFF Switch circuit breaker

Power Supply Comm Cable not connected or improperly connected

Circuit breaker tripped

Defective power cable Check for fault. Repair or replace cable. Defective power outlet on Control Box

Shop compressed air is OFF, regulator is closed or improperly adjusted

Air solenoid is faulty

DC cable connection is NOT wrench tight

Table 8-6: Control Box Troubleshooting

Check connections and turn power ON. See "Table 3-2: Control Box Features" on page 3-2.

Repair/replace cable. See "9.04 110V Power Supply Cable Assembly" on page 9-4. Turn AC power OFF, check for and repair fault, then reset. Connect Power Supply Comm Cable to Power Supply. Review "Table 4-11: Standard Wiring Connections" on page 4-6 and "Figure 4-10: Power Supply Comm. Cable Pin Conﬁguration" on page 4-5 for proper wiring points. Check for and repair fault. Reset. See "Table 3-2: Control Box Features" on page 3-2.

Replace outlet. See "Figure 9-1: Control Box PARTS" on page 9-1. Check shop air, check regulator at Control Box Air In inlet. Turn shop air ON and adjust regulator to operating psi.

WARNING

Do not exceed N7500 system max air pressure.

Replace air solenoid. See "Figure 9-1: Control Box PARTS" on page 9-1.

Tighten busbar connection wrench tight.

AC POWER SUPPLY CABLE

PIN COLOR VOLTAGE

A WHT NEUTRAL B GN GROUND C BK LINE

Table 8-7: AC Power Supply Cable Pin Identiﬁcation

Manual 89250890 8-5 TROUBLESHOOTING GUIDE

N7500 TROUBLESHOOTING GUIDE

This Page Intentionally Blank

TROUBLESHOOTING GUIDE 8-6 Manual 89250890

REPLACEMENT PARTS N7500

POWER

PPLY IN

SUP

PLY OUT

SECTION 9:

REPLACEMENT PARTS

9.01 Control Box Replacement Parts

MAX 100 psi

ART# A-10846_AC

Figure 9-1: Control Box PARTS

Item

No.

Qty Part Number Description

1 1 96-881-091 Power Supply With Brackets 2 1 96-169-334 Torch Head Connector 3 1 96-169-069 AC Power Receptacle - 110 VAC 4 1 96-169-337 Remote Pendant Connector 5 1 96-169-070 AC Power Receptacle - 220VAC 6 1 96-921-005 Solenoid Valve 7 1 96-174-079 Control Box Base - w/Handles 8 1 96-110-007 Circuit Breaker

9 1 96-169-333 Power Supply Communication Connector 10 1 96-644-007 Signal Wire Connector 11 1 96-169-332 AC Power Supply Connector 12 1 96-698-038 Current Sensor 13 1 94-111-046 Electrical Plate Bracket Assy 14 2 94-013-092 Poles 15 1 96-162-738 Main PCBA w/Standoffs 16 1 96-174-069 Rear Panel Assembly w/Cover 17 2 96-110-010 Circuit Breaker - 5 Amp

Table 9-2: Control Box PARTS

Manual 89250890 9-1 REPLACEMENT PARTS

N7500 REPLACEMENT PARTS

9.02 Torch Head Replacement Parts

ART# A-10843_AC

Figure 9-3: Torch Head PARTS

Item Part Number Description Item Part Number Description

05-124-001 N7500 Torch Head

1 94-395-106 Torch Housing 94-079-008 Beam & Pin

94-949-053 Wheel Assembly

15 2 94-171-278 Cover 94-949-052 Wheel (2 Required) 3 94-565-092 Locknut 16 94-800-184 Shoe Spring 4 94-013-098 Electrode Tube Adapter 17 94-476-067 Clamping Lever 5 94-096-132 Vee Block 18 94-949-051 Drive Wheel 6 94-784-076 Nozzle Sleeve 19 94-433-184 Insulator 7 94-636-002 Extended Plenum 20 96-524-100 Drive Motor & Gear Housing 8 94-556-071 Air Nozzle w/Insulator 21 94-893-082 Electrode Holder Tube 9 94-395-107 Air Inlet Housing Assembly 22 94-105-016 Cable Boot

10 94-433-190 Extension Insulator 23 94-306-151 Air Inlet Fittings 11 96-070-029 Bus Bars 24 94-096-133 Guide Block 12 96-458-025 Tinned Flat Copper Braid 25 94-777-105 Shield 13 96-168-028 Jumper Clamp 26 94-079-013 Mounting Beam Components 14 96-774-095 Shoe 27 94-433-189 Nozzle Insulator

28 94-800-186 Nozzle Spring and Guard

Table 9-4: Torch Head PARTS

REPLACEMENT PARTS 9-2 Manual 89250890

REPLACEMENT PARTS N7500

9.03 Remote Pendant Replacement Parts

ART# A-10835_AB

Figure 9-5: Remote Pendant PARTS

Item No. Qty Part Number Description

1 1 72-008-020 Remote Pendant (with bumper guard) 2 1 94-105-030 Rubber Bumper Guard

Table 9-6: Remote Pendant PARTS

Manual 89250890 9-3 REPLACEMENT PARTS

N7500 REPLACEMENT PARTS

SYSTEM CABLES

9.04 110V Power Supply Cable Assembly

Part No. Description Application

96-130-304 10 ft. (3m) length For the Control Box Power Supply IN

9.05 220V Power Supply Cable Assembly

Part No. Description Application

96-130-305 10 ft. (3m) length For the Control Box Power Supply IN

9.06 Pendant Cable Assembly

Part No. Description Application

96-170-069

96-170-070 15 ft. (5m) length 96-170-071 25 ft. (8m) length 96-170-072 50 ft. (15m) length

14 inches (0.36m)

length

Connects the Control Box to the Pendant

9.07 Motor Cable Assembly

Part No. Description Application

96-130-335 3 ft. (0.9m) length 96-130-336 15 ft. (5m) length 96-130-337 25 ft. (8m) length 96-130-338 50 ft. (15m) length

Connects the Control Box to the Torch Head motor

9.08 Power Supply Communication Cable Assembly

Part No. Description Application

96-130-339 15ft. (5m) length

Connects the Control Box to the Power Supply96-130-340 25ft. (8m) length

96-130-341 50ft. (15m) length

9.09 Power Cables

Part No. Description Application

96-130-254 4ft. (1.22M) Length

Connects the Torch Head to the Control Box buss bar96-130-256 15ft. (5M) Length

96-130-300 25ft. (7.62M) Length

NOTE: Minimum 2 Power Cables Required

9.10 Air Hose Assembly

Part No. Description Application

94-396-051 4ft. (1.22M) Length 94-396-049 15ft. (5M) Length 94-396-048 25ft. (7.62M) Length

REPLACEMENT PARTS 9-4 Manual 89250890

Supplies compressed air from the Control Box to the Torch Head

APPENDIX N7500

SECTION 10:

APPENDIX

This Page Intentionally Blank

Manual 89250890 A-1 APPENDIX

N7500 APPENDIX

10.01 Wiring Schematic

ART# A-10836_AC

Figure 10-1: N7500 Wiring Schematic

Manual 89250890 A-2 APPENDIX

APPENDIX N7500

Manual 89250890 A-3 APPENDIX

N7500 APPENDIX

PUBLICATION HISTORY

Manual No. 89250890

Cover Date Rev Change(s)

Jan, 2012 AA First issue Mar, 2012 AB Added UL logo, changed duty cycle rating from 1600A to 1500A, changed Motor Cable

from 5 pin to 6 pin and Power Supply Communication cable from 7 pin to 6 pin.

April, 2012 AC Updated wiring pin colors in Table 8-2: Torch Head Motor 6 PIN Wire Schedule, changed

duty cycle rating from 1500A to 1600A, converted all images to greyscale.

June, 2012 AD Corrected text and drawings on pages 2-2, 3-6, 3-10, 5-3 and 5-5. Changed Thermadyne

to Victor Technologies International, Inc.

Aug, 2013 AE Updated photos on pages 3-1, 4-1, and 4-3. Changed Arcair to Victor Arcair. Corrected

text on page 4-4. Updated drawing on page 4-5. Updated tables in Section 8. Corrected drawing and table on page 9-2. Updated Wiring Schematic on page A-2. Updated text on page 2.

Feb. 2014 AF Rebranded. Added new step om page 5-7.

NOTE

*Victor Arcair uses the date on the manual cover to indicate the most recent revision of the manual.

Manual 89250890 A-4 APPENDIX

Statement of Warranty

This warranty supersedes all previous Victor Technologies warranties.

Effective 08/01/2011 Effective 08/01/2011

LIMITED WARRANTY:

the

time period applicable to the operated, and maintained in accordance with alteration, or accident, correct such defects by suitable repair or replacement, at be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Victor Technologies 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 negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY VICTOR TECHNOLOGIES PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED 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 1 year from the date Victor Technologies delivered the product to the authorized distributor.

1 year parts and Labor Unless specified 4 Years Parts and Labor

180 days parts / No Labor Water recirculators

90 days parts and Labor Unless specified180 days parts and Labor Unless specified

30 days parts / No Labor Replacement repair parts

5 Years Parts / No Labor * 5 years on the Original Main Power Transformer and Inductors not

3 Years Parts / No Labor 2 Years Parts and Labor Unless specified

2 Years Parts / No Labor

1 Years Parts / No Labor

90 days parts / No Labor Remote Controls

Consult your STOODY® representative for warranty information on this product MIG Torch for Fabricator 181i

Victor Technologies limited warranty shall not apply to: Consumable Parts for MIG, TIG, Plasma welding, Plasma cutting and Oxy fuel torches, O-rings, fuses, filters or other parts that fail due normal wear

* Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Victor Technologies repair facility within thirty (30) days of the repair. * No employee, agent, or representative of Victor Technologies is authorized to change this warranty in any way or grant any other warranty, and Victor Technologies shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of Victor Technologies ’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 Victor Technologies 's sole judgment, impaired the safety or performance of any Victor Technologies product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

Victor Technologies warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within

Victor Technologies

QRC-2000 Nozzle Cleaning Stations CutMaster TRUE TC and TCV Water Coolers (No Labor) TSC-96 Smoke Collector (No Labor) 2 Years Parts / 1 Year Labor ESG-1, EPG-CR1, CR2 Control DragGun Plus, PAK 200, PAK 45 Boxes for Spool & Pull Guns (No Labor) AutoCut and UltraCut Professional Eliminator® Spool Guns (No Labor) Arcair® N7500 (No Labor) 1 Year Parts and Labor Unless specified

Professional MIG Guns (i.e. PulseMaster™ MIG Guns & PullMaster™, Stand Off Controls, Remote Controls, other Consols

Spray Master™, Eliminator®, Supra, Professional No. #, SEFC, etc)

Robotic Deflection Mounts All other “Torch and Leads” Packages QRM-1 and QRM-2 Anti-Spatter Applicator

All other products including: Weldskill® MIG and Spool Guns (No Labor) (from the date sold by authorized distributor to purchaser)

Victor® Slimlite Medical mounted on PCBoards. Victor® Professional * 3 years on Power Supply Components

TurboTorch

CutSkill®, Oxygen Conservers, Victor® VSP, 1 Years Parts and Labor Unless specified HP&I Brass regulators/manifolds 95S, Water recirculators All other Victor® Medical product All Plasma Welding consols (i.e WC-1 Controller, WT Timer,

FirePower® 180 days parts and Labor Unless specified Steel Cylinders, Cutting Machine Motors (i.e. VCM 200) Plasma Welding Torch and leads packages HP&I Stainless regulators/manifolds Gas Regulators "Supplied with power sources" (No Labor) Parts in Rental Applications

HP&I Corrosive Gas Regulators/Manifolds MIG and TIG Torches (Supplied with power sources)

products as stated below,

Victor Technologies

shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of

(from the date sold by seller to authorized distributor)

specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect,

Victor Technologies

shall, upon notification thereof and substantiation that the product has been stored, installed,

’s sole option, of any components or parts of the product determined by

Victor Technologies

AirCut 15, CutSkill® units,

1Torch, Surelok, XT300 / XT301 and Maximizer torches

90 days parts / No Labor

5 Years Parts* / 3 Years Labor

ArcMaster, Excelarc, Fabricator, Fabstar, PowerMaster

Portafeed, Ultrafeed, Ultima 150, WC 100B

Auto-Darkening Welding Helmet (electronic Lens), ** Victor Regulator for Fabricator 181i (No labor)

WF-100 Capstain Feeder, etc)

90 days parts / No Labor

Replacement repair parts

30 days parts / No Labor

5-2-1 years Parts / No Labor

FirePower® Welders

Victor Technologies

whether arising out of contract,

1 Month Harness Assy

THE AMERICAS

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)

EUROPE

Chorley, United Kingdom Customer Care

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

Milan, Italy Customer Care

Ph +39 0236546801 Fax: +39 0236546840

ASIA/PACIFIC

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

INNOVATION TO SHAPE THE WORLD™

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

Tweco N7500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Arc Welding Hazards

1.03 Principal Safety Standard Publications

1.04 Declaration of Conformity

2.01 Arcair-Matic N7500 Gouging System

N7500 SPECIFICATIONS

3.01 Control Box

3.02 Torch Head

3.03 Remote Pendant

3.04 Electrodes

3.05 Gouging Operation Settings

3.06 Selecting the Proper Electrode Diameter

3.07 Keeping Electrodes Dry

3.08 Secondary Power Cables (Welding Leads)

3.09 Compressed Air

3.10 Main Air Line

4.01 Receiving and Handling

4.02 Assembly

4.03 Miscellaneous Cable/Plumbing Assemblies

4.04 Control Box Installation

4.05 Torch Head Installation

4.06 Remote Pendant Installation

4.07 Remote Pendant Storage

SECTION 5: OPERATING THE N7500 SYSTEM

5.01 Remote Pendant Operation

5.02 Position Torch Head

5.03 Insert the Electrode

5.04 Remote Pendant Programming

6.01 SYSTEM USES

6.02 Zero Force Rough Machining

7.01 Introduction

7.02 Remote Pendant ARCTIME

8.01 Arcair-Matic N7500 Gouging System

8.02 N7500 General

8.03 Torch Head

8.04 Remote Pendant

8.05 Control Box

9.01 Control Box Replacement Parts

9.02 Torch Head Replacement Parts

9.03 Remote Pendant Replacement Parts

9.04 110V Power Supply Cable Assembly

9.05 220V Power Supply Cable Assembly

9.06 Pendant Cable Assembly

9.07 Motor Cable Assembly

9.08 Power Supply Communication Cable Assembly

9.09 Power Cables

9.10 Air Hose Assembly

10.01 Wiring Schematic

PUBLICATION HISTORY

Statement of Warranty