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Thermal Arc 6045 EXCEL-ARC, Operating Manual

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Thermal Arc 6045 EXCEL-ARC Operating Manual Download Page 45

EXCEL-ARC 500, 6045

August 22, 2005

6-3

Item 

No

Part 

Number

Description

Qty per 

Assy

Application 

Code

 

 100005A-1   Excel-Arc Welder® - 500 CC, 60 Hz  

 1  

 A  

 

 100005A-2   Excel-Arc Welder® - 6045 CV, 60 Hz  

 1  

 B  

 

 100005A-3   Excel-Arc Welder® - 6045 CC/CV, 60 Hz  

 1  

 C  

 

 100005A-5   Excel-Arc Welder® - 500 CC, 60 Hz  

 1  

 D  

 

 100005A-6   Excel-Arc Welder® - 6045 CV, 60 Hz  

 1  

 E  

 

 100005A-7   Excel-Arc Welder® - 6045 CC/CV, 60 Hz  

 1  

 F  

 1    830698-1    . Panel - Control  

 1  

 All  

 2    204212  

 . Board - PC, Digital Display  

 1  

 BCEF  

 3    204600-2    . Spacer  

 4  

 BCEF  

 4    409000-1    . Bezel - Meter  

 1  

 BCEF  

 5    204053-11   . Panel - Control Module  

 1  

 AD  

 

 204053-8    . Panel - Control Module  

 1  

 BE  

 

 830207  

 . Panel - Control Module  

 1  

 CF  

 6    406806-3    . Knob - Control  

 1  

 ACDF  

 7    401428-8    . Potentiometer - Volt/Amp Ctl, Arc Force  

 2  

 ACDF  

 

 401428-8    . Potentiometer - Volt/Amp Ctl, Arc Force  

 1  

 BE  

 8    405365-1    . Switch - Toggle, ON/OFF  

 2  

 All  

 9    408850-5    . Knob - Black  

 1  

 All  

 10    402682  

 . Switch - Toggle, RMT/LC1  

 1  

 All  

 11    830710-1    . Light - Indicator  

 1  

 All  

 12    204052-6    . Panel - Output, Blank  

 1  

 ABDE  

 13    204052-5    . Panel - Output, Terminal  

 2  

 ABDE  

 

 204052-5    . Panel - Output, Terminal  

 3  

 CF  

 14    400614-1    . Nut - 1/2-13, Hex, Flanged  

 2  

 ABDE  

 

 400614-1    . Nut - 1/2-13, Hex, Flanged  

 3  

 CF  

 15    5CW-974    . Bus - Cable Stud  

 2  

 ABDE  

 

 5CW-974    . Bus - Cable Stud  

 3  

 CF  

 16    5CW-975    . Bushing - Insulator  

 2  

 ABDE  

 

 5CW-975    . Bushing - Insulator  

 3  

 CF  

 17    No Number   . Screw -1/2-13 x 3/4, HHC, ST.  

 2  

 ABDE  

 

 No Number   . Screw -1/2-13 x 3/4, HHC, ST.  

 3  

 CF  

 18    No Number   . Washer - LK, Std, ST. 1/2  

 4  

 ABDE  

 

 No Number   . Washer - LK, Std, ST. 1/2  

 6  

 CF  

 19    5CW-976A    . Washer - Insulator Stud  

 4  

 ABDE  

 

 5CW-976A    . Washer - Insulator Stud  

 6  

 CF  

 20    No Number   . Washer - FL, ST. 1/2  

 4  

 ABDE  

 

 No Number   . Washer - FL, ST. 1/2  

 6  

 CF  

Table 6-1: Parts List for Figure 6-1

Summary of Contents for 6045 EXCEL-ARC

Page 1: ...EXCEL ARC Version No 1 Issue Date August 22 2005 Manual No 430429 451 Operating Features TRANSFORMER RECTIFIER DC WELDER Operating Manual Art A 06056 500 6045...

Page 2: ...y the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwi...

Page 3: ...Arc 6045 CC CV Spec Number 100005A 7 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2001 by Thermal Dynamics...

Page 4: ...03 Receipt Of Equipment 2 1 2 04 Symbol Chart 2 2 2 05 Description 2 3 2 06 Specifications 2 4 2 07 Controls and Outlets 2 7 2 08 Functional Block Diagram 2 8 2 09 Duty Cycle 2 9 2 10 Volt Amp Curves...

Page 5: ...XCEL ARC 500 CONNECTION DIAGRAM 2 OF 2 100005A 1 100005A 5 A 4 APPENDIX 3 EXCEL ARC 500 SCHEMATIC DIAGRAM 100005A 1 100005A 5 A 6 APPENDIX 4 EXCEL ARC 6045 CONNECTION DIAGRAM 1 OF 2 100005A 2 100005A...

Page 6: ......

Page 7: ...two welding machines at the same time or touch other people with the holder or electrode 8 Do not use worn damaged undersized or poorly spliced cables 9 Do not wrap cables around your body 10 Ground...

Page 8: ...ases 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 we...

Page 9: ...nnect 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 we...

Page 10: ...fore 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 ne...

Page 11: ...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 A...

Page 12: ...ge l arc AVERTISSEMENT L ELECTROCUTION PEUT ETRE MORTELLE Une d charge lectrique peut tuer ou br ler gravement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d...

Page 13: ...laine et cuir et des chaussures de s curit 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES...

Page 14: ...ode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie 1 Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud 2 Ne soudez pas d...

Page 15: ...S MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs 1 Utilisez l quipement l ext rieur dans des aires ouvertes et...

Page 16: ...peut tre br lant et sous pression 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s ch...

Page 17: ...t UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1...

Page 18: ...r representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USE...

Page 19: ...ed below and clicking on the Literature Library link http www thermalarc com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually...

Page 20: ...Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary P...

Page 21: ...t and constant voltage transformer rectifier type DC welding machine that provides volt ampere characteristic curves for each mode of operation Table 2 1 gives input voltage and amperage data for all...

Page 22: ...ge 200 230 460 575 200 230 460 575 Rated Input Amperage 78 67 33 27 70 60 30 24 Input kW 20 kW 22 5 kW Input kVA 26 3 kVA 30 1 kVA Input Frequency 60 Hz 60 Hz Input Phase 3 Phase 3 Phase Maximum Open...

Page 23: ...5 August 22 2005 2 5 Art A 06058 31 in 787 mm 21 1 4 in 540 mm 29 7 16 in 748 mm 26 1 2 in 673 mm Weight CC CV 510 Lbs 231 kg CC 460 Lbs 209 kg CV 455 Lbs 206 kg Figure 2 1 Excel Arc 500 and 6045 Dime...

Page 24: ...CEL ARC 500 6045 2 6 August 22 2005 10 7 5 9 8 1 2 3 11 12 6 14 13 4 Art A 06057 NOTE The rear panel rubber guard used on Spec 100005A 3 is not shown for clarity purposes Figure 2 2 Front and Rear Pan...

Page 25: ...trol CC CV Units 100005A 1 3 5 7 This potentiometer controls short circuit welding current to produce an increase in current as the arc length is shortened The control is present to provide the degree...

Page 26: ...R 24 V 10 AMP CV MODE OVERLOAD THERMOSTAT PC CONTROL BOARD PHASE SIGNAL WELDING TRANSFORMER T1 INPUT CONTACTOR INPUT POWER CONTROL TRANSFORMER INPUT CONTACTOR SWITCH CIRCUIT BREAKER 115 V 15 AMP OUTPU...

Page 27: ...3 enables the operator to determine the duty cycle at various welding amperages Art A 06060 750 650 550 450 40 50 60 80 100 DUTY CYCLE FOR EXCEL ARC 500 AND 6045 Duty Cycle Weld Amperes Figure 2 4 Du...

Page 28: ...EXCEL ARC 500 6045 2 10 August 22 2005...

Page 29: ...assists in providing protection against line voltage electrical shock and static shock The grounding serves to discharge the static electric charge which tends to build up on rubber tire mounted equi...

Page 30: ...Open the disconnect switch or breaker and determine that no voltage is present before connecting wires between welding machine and power supply CAUTION The method of installation conductor size and o...

Page 31: ...L 3 230V 460V 5 7 5 V 367228 11 Place links in proper position based on input voltage value GROUND CONNECTION ON LIFTING YOKE INPUT LINE CONTACTOR MOUNTED ON LIFTING YOKE L1 L2 L3 CUSTOMER S INPUT CAB...

Page 32: ...1 1 0 200 2 2 1 1 0 2 0 250 1 1 1 0 2 0 3 0 300 1 0 1 0 2 0 3 0 4 0 350 1 0 1 0 3 0 4 0 4 0 400 2 0 2 0 3 0 4 0 2 2 0 450 2 0 2 0 4 0 2 2 0 2 3 0 500 3 0 3 0 4 0 2 2 0 2 3 0 TOTAL LENGTH OF LEAD CIRCU...

Page 33: ...ce Should Be Grounded Positive CC Terminal Positive CV Terminal To Wire Feeder Shown For Reverse Polarity DCEP Stick To Automatic Control NOTE To change polarity reverse connections on power output te...

Page 34: ...EXCEL ARC 500 6045 3 6 August 22 2005...

Page 35: ...le to wire electrode feeder system 3 Refer to other manuals for component connections 4 Set Output Control to desired value 5 Set the remote local control switch in the desired mode 4 03 SMAW Stick We...

Page 36: ...ack Table 4 1 Configuration Settings 4 06 Configuration Settings The following settings Table 4 1 can be made by jumper plug changes on the main control board Explanation of settings 1 Thewire sharpen...

Page 37: ...2 drops of 20W non detergent oil at each end of bearing 5 03 Inspection and Cleaning For uninterrupted satisfactory service from this welding machine it is necessary to keep the machine clean dry and...

Page 38: ...1 Check nameplate of welding machine for line voltage to use check line voltage B Links on voltage changeover board incorrectly connected 1 Check Voltage Changeover diagrams for link positions connec...

Page 39: ...loaded 9 Operator gets shock when welding machine case ground cable work or work table is touched A Case of welding machine not grounded 1 Ground welding machine case B Work table and work not grounde...

Page 40: ...ard remove the control panel from the front panel of the power source 1 Control Board 830267 All readings taken at nominal line voltage with maximum OCV on the machine Test Point Expected Reading Rema...

Page 41: ...ct terminal on the suppressor board Turn the voltage control pot to maximum Disconnect one lead to one SCR and observe the OCV If the OCV drops to a lower value this indicates that this particular SCR...

Page 42: ...s Friction will produce a false reading Always start from Step 1 Art A 06066 Figure 5 2 Adjusting Nuts to Correct Force Gauge To Calibrate Force Gauge If the gauge is suspected of being out of calibra...

Page 43: ...t into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently atta...

Page 44: ...EXCEL ARC 500 6045 6 2 August 22 2005 Art A 06068 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 39 18 20 8 7 Figure 6 1 Parts 1...

Page 45: ...Arc Force 2 ACDF 401428 8 Potentiometer Volt Amp Ctl Arc Force 1 BE 8 405365 1 Switch Toggle ON OFF 2 All 9 408850 5 Knob Black 1 All 10 402682 Switch Toggle RMT LC1 1 All 11 830710 1 Light Indicator...

Page 46: ...EXCEL ARC 500 6045 6 4 August 22 2005 Art A 06068 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 39 18 20 8 7 Figure 6 1 Parts 1 continued...

Page 47: ...Push on 1 CF 28 410602 1 Bracket 1 CF 29 410589 Contact Stationary 1 CF 30 12RT 238 Contact Movable 2 CF 31 410541 Spring 1 CF 32 910061 Guide 1 CF 33 W 9549 21 Rod Threaded 1 4 Dia 1 CF 34 No Number...

Page 48: ...EXCEL ARC 500 6045 6 6 August 22 2005 Art A 06069 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 33 Figure 6 2 Parts 2...

Page 49: ...All 13 204060 1 Yoke Lifting 1 All 14 402037 33 Grommet Rubber 2 All 15 402037 11 Grommet Rubber 3 All 16 Deleted 17 Deleted 18 830037 1 Panel Side Right 1 ABC 830037 5 Panel Side Right 1 DEF 204099...

Page 50: ...EXCEL ARC 500 6045 6 8 August 22 2005 Art A 06069 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 33 Figure 6 2 Parts 2 continued...

Page 51: ...cation Code 32 368705 36 Capacitor W Leads 2 ABDE 368705 36 Capacitor W Leads 3 CF Not Illustrated 33 830116 Label Frame Ground 2 All 34 408891 Label Warning 1 All Not Illustrated 204204 Label Voltage...

Page 52: ...EXCEL ARC 500 6045 6 10 August 22 2005 Art A 06070 24 4 Figure 6 3 Parts 3...

Page 53: ...Fan 2 All 12 12TW 595 1 Motor Fan 1 All 13 369641 Insulator Mtg 2 All 14 369639 Heat Sink Rectifier 1 All 15 369642 Heat Sink SCR 6 All 16 405139 Rectifier Silicon 6 All 17 16DA 954 1 Pin Spring 6 All...

Page 54: ...EXCEL ARC 500 6045 6 12 August 22 2005...

Page 55: ...cification number columns below Use only those diagrams and instructions that are applicable MODEL NO PART NUMBER CONNECTION DIAGRAM SCHEMATIC DIAGRAM VOLTAGE CHANGEOVER DIAGRAM 100005A 1 100005A 5 10...

Page 56: ...L1 REAR PANEL YOKE CONTACTOR CONTROL TRANSFORMER WIRING 400 V 46 GRN YEL 33 37 BLU 11 101 C3 7 BRN 42 8 WHT 10 YEL 9 BLK 11 RED 12 ORN 30 BLU 13 PRIMARY LEADS A1 THRU A5 TO CHANGEOVER BOARD CHANGEOVE...

Page 57: ...E 76 BLK 30 77 BLU 27 78 BRN 23 J9 J11 J13 J9 J11 J13 C22 17 90 WHT TWIST 10 39 BLK B3 C3 C3 C4 C4 10 38 BLK 15 A5 15 15 B3 B5 40 BLK C2 C2 B4 B4 C1 15 15 15 10 15 15 15 15 15 15 15 C5 A2 A2 A3 A3 15...

Page 58: ...T 7 BRN 19 20 19 20 15 15 15 15 15 15 J5 46 3 3 71 RED 14 BRN 21 VLT J7 J4 1 2 3 4 5 6 7 8 9 10 J9 46 70 GRY 1 2 3 4 5 3 81 BLK 16 RED 17 GRY 31 31 3 3 88 BLK 16 RED 17 GRY 23 LT BL 19 ORN 46 69 BRN 1...

Page 59: ...EET FILE NAME DISTRIBUTION TABLE OUTSIDE DISTR 6 5 4 3 2 1 4 5 6 1 2 3 H G F E D C B A CONFIDENTIAL This drawing including all information contained thereon is the exclusive and confidential property...

Page 60: ...TEMP OVERCURRENT INDICATOR YELLOW REACTOR FILTER CC CONTACTOR RECEPTACLE 14 PIN CONTROL BOARD CIRCUIT BREAKER 10 AMP 115V FUSE CONTROL TRANSFORMER 1 2 AMP POTENTIOMETER VOLT AMPS 5K OHMS 2 WATTS RESIS...

Page 61: ...D RECORDS ITEM TYPE DESIGNED DRAWN DATE SCALE COMM CLS DESCRIPTIVE DATA TITLE MATERIAL SPEC MATERIAL NO ACTIVITY FINISH CODE PER REPLACED BY REPLACES QUANTITY U M DWG NO SIZE D FRACT INCH SHEET FILE N...

Page 62: ...0V REAR PANEL YOKE CONTACTOR CONTROL TRANSFORMER WIRING 400 V 46 GRN YEL 33 LOOKING FROM FRONT OF MACHINE L2 OF BASE MOUNTED ON REAR 26 BLK 25 RED 12 12 R3 31 102 18 LIFTING YOKE C7 C8 15 103 18 C6 C5...

Page 63: ...7 BLU 78 BRN 30 27 23 J8 J10 J7 J6 J4 J2 J8 J10 J12 J2 J4 J6 J7 42 42 42 2 RED 42 42 42 6 YEL 4 WHT J8 85 YEL 37 TWIST 15 B2 38 BLK 15 10 A5 15 15 15 B3 B3 B2 15 C1 15 15 B4 B4 40 BLK 15 10 15 15 B5 C...

Page 64: ...NOTE 1 J6 MAIN CONTROL BOARD J2 FRONT PANEL J3 15 15 15 15 15 15 20 19 20 19 7 BRN 8 WHT 9 BLK 10 YEL 11 RED 12 ORN 5 BLK 6 YEL 3 BLU 4 WHT 20 1 BRN 19 2 RED 81 BLK 81 BLK 8 29 RED 4 32 LT BL 13 12 1...

Page 65: ...INCH SHEET FILE NAME DISTRIBUTION TABLE OUTSIDE DISTR 6 5 4 3 2 1 4 5 6 1 2 3 H G F E D C B A CONFIDENTIAL This drawing including all information contained thereon is the exclusive and confidential pr...

Page 66: ...BOARD CIRCUIT BREAKER 10 AMP 24V CIRCUIT BREAKER 10 AMP 115V FUSE CONTROL TRANSFORMER 1 2 AMP POTENTIOMETER VOLT AMPS 5K OHMS 2 WATTS RESISTOR 25 OHMS 175 WATTS SHUNT 600 AMP 100MV FEEDBACK RESISTOR...

Page 67: ...9 6 J9 5 J9 4 J9 3 J9 2 J9 1 RMT VS RMT VS 22 CIRCUIT COM 22 R1 5K LOCAL J9 13 J3 13 115 VAC HOT OPEN J3 14 J8 ON 4 ONLY L2 CHANGE RECORD E C No DATE PLOT DATE CHECKED APPROVED RECORDS ITEM TYPE DESIG...

Page 68: ...SFORMER WIRING 400 V 46 GRN YEL 33 C2 LOOKING FROM FRONT OF MACHINE OF BASE MOUNTED ON REAR 26 BLK 25 RED 12 12 R3 105 12 104 31 S4 7 105 18 LIFTING YOKE C7 C8 15 103 18 C6 C5 C4 26 BLK 25 RED 37 BLU...

Page 69: ...C13 C9 C11 R9 R5 C17 C16 R7 21 51 GRY 5 BLK 3 BLU 1 BRN C20 C19 C18 C10 C14 C12 R6 R8 R10 J7 J6 J4 J2 J2 J4 J6 J7 42 42 42 WT WT WT 42 42 42 6 YEL 4 WHT 2 RED WT WT WT J9 J11 J13 J9 J11 J8 C22 17 90 W...

Page 70: ...7 8 9 10 11 12 13 J2 FRONT PANEL J3 69 BRN 46 19 ORN 23 LT BL 17 GRY 16 RED 88 BLK 7 3 31 31 7 15 15 15 15 15 15 20 19 20 19 7 BRN 8 WHT 9 BLK 10 YEL 11 RED 12 ORN 5 BLK 6 YEL 3 BLU 4 WHT 20 1 BRN 19...

Page 71: ...TITY U M DWG NO SIZE D FRACT INCH SHEET FILE NAME DISTRIBUTION TABLE OUTSIDE DISTR 6 5 4 3 2 1 4 5 6 1 2 3 H G F E D C B A CONFIDENTIAL This drawing including all information contained thereon is the...

Page 72: ...AKER 10 AMP 24V CIRCUIT BREAKER 10 AMP 115V FUSE CONTROL TRANSFORMER 1 2 AMP POTENTIOMETER VOLT AMPS 5K OHMS 2 WATTS RESISTOR 25 OHMS 175 WATTS SHUNT 600 AMPS 100MV FEEDBACK RESISTOR SUPPRESSION 50 OH...

Page 73: ...10 J9 9 J9 8 J9 7 J9 6 J9 5 J9 4 J9 3 J9 2 J9 1 CIRCUIT COMM 22V RMT VS RMT VS 22 R1 5K LOCAL OPEN 115 VAC HOT J9 13 J3 14 J8 C22 L2 L1 CHANGE RECORD E C No DATE PLOT DATE CHECKED APPROVED RECORDS IT...

Page 74: ...2 FIG 1 230 VOLT CONNECTION 200 VOLT CONNECTION 575 VOLT CONNECTION 460 VOLT CONNECTION 460V 5 7 5 V 230V 575V 460V 460V 230V 5 7 5 V 230V A3 A2 C5 A4 B1 B2 L1 B3 B4 C1 C2 C3 C4 A1 B5 A5 L 2 L 3 38 BL...

Page 75: ...ANY CHANGES TO THIS DRAWING MUST BE REFLECTED ON DRAWING 204204 1 AA3597 7 24 92 A 1422 5 20 97 AA 5 27 99 CHANGE RECORD E C No DATE PLOT DATE CHECKED APPROVED RECORDS ITEM TYPE DESIGNED DRAWN DATE SC...

Page 76: ...EXCEL ARC 500 6045 A 22 August 22 2005...

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