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EXCEL-ARC 500, 6045
August 22, 2005
2-7
2.07 Controls and Outlets
Refer to callouts in Figure 2-2.
1. Overload Indicator
(100005A-1, -2, -3, -5, -6, -7):
Yellow L.E.D., when lighted, indicates that the machine
has shut down as a result of amperage overload or
rectifier overtemperature (S2).
2. Input Contactor Control
(100005A-1, -2, -3, -5, -6, -
7): This toggle switch is the master power switch for
the welding machine, and must be in the ON position
before any other section will operate. The primary
circuit of the control transformer is energized
whenever line voltage is present at the input terminals.
This switch closes the secondary circuit of the control
transformer, energizing the contactor, which energizes
the power transformer. Do not use this switch to start
or stop arc. Start arc with switch ON, break arc, then
turn switch OFF.
3. Local/Remote Output Control Volts/Amps
Selector
Switch
(100005A-1, -2, -3, -5, -6, -7): Selects either
the output control (Local) or some remote control
device (Remote) to control welding output.
4. 115-V AC Receptacles
(100005A-1, -2, -3, -5, -6, -
7): Provides auxiliary power for lights, wire feeders,
water pumps, etc. — 15 amps maximum.
5. CC/CV Selector Switch (CC/CV)
(100005A-3, -7):
Selects the welding mode of operation.
6. Feeder Control Receptacle Panel (Automatic)
(CV
units)
(100005A-2, -3, -6, -7): Amphenol (19-pin)
connector for a remote voltage control type wire
feeder.
7. Arc Force Control (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 of “hard start” required, and the additional
dynamic change for welding tight grooves, etc. Turn
clockwise to increase “hard start” characteristics,
counterclockwise to obtain a softstart, smooth arc.
8. Welding Voltage/Amperes Control (CV
Units)
(100005A-2, -3, -6, -7): Adjusts arc welding output
and open circuit voltage. On 100005A-1, -3, -5, -7
(CC units): Adjusts the welding current.
9. Volt/Amp Meter and Switch (CV Units)
(100005A-2,
-3, -6, -7): A single meter with switch that will readDC
volts when in the V. position or read DC amps in the
A. position.
10.Positive Terminal (+) (CV mode)
(100005A-2, -3, -6,
-7): Serves as a connection point for the lead to the
wire feeder when reverse polarity is desired.
11.Positive Terminal (+) (CC mode)
(100005A-1, -3, -5,
-7): Serves as a connection point for the lead to the
electrode holder lead for SMAW (stick) or arc gouging
mode of operation when reverse polarity is desired.
12.Negative Terminal
(—): Serves as a connection point
for the lead to the workpiece when reverse polarity is
desired.
13.Circuit Breaker
— Rated at 15 amps: provides
protection to the 115-volt circuit which includes the
fan and the 115-volt AC power receptacle.
14.Circuit Breaker
— Rated at 10 amps: provides
protection to the 24-volt circuit for the wire feeder
and automatic equipment.
NOTE
To obtain opposite welding polarity, simply
reverse the connections to the positive and
negative terminals.
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