EXCEL-ARC® 750 and 8065

Transformer-Rectifier DC
Welding Machine

For the Following Specs:

• 500016-1 750 CC, 60 Hz
• 500016-2 8065 CV, 60 Hz
• 500016-3 8065 CC/CV, 60 Hz
• 500016A-1 750 CC, 60 Hz
• 500016A-2 8065 CV, 60 Hz
• 500016A-3 8065 CC/CV, 60 Hz

OWNER’S MANUAL Number 430429-174

Revised December 1, 1997

IMPORTANT: Read these instructions before installing, operating, or servicing this system.

THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.

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 430429-174
Table of Contents

INTRODUCTION 1
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SAFETY INSTRUCTIONS AND WARNINGS 2

DESCRIPTION OF EQUIPMENT 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Recommended Unit Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wire Feeder Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Controls and Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

INSTALLATION 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Internal Wiring Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Connecting Welding Machine to Line Voltage . . . . . . . . . . . . . . . . . . . . . . . 4-2
Welding Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

OPERATION 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Preweld Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SMAW (Stick) Welding, Carbon Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . 5-1
Welding, Semiautomatic or Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

MAINTENANCE 6
Replacing SCRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

TROUBLESHOOTING 7
Detailed Troubleshooting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

PARTS LIST 8
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

DIAGRAMS

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 430429-174
INTRODUCTION

INTRODUCTION

How To Use This Manual Receipt Of Equipment

This Owner’s Manual usually applies to just the When you receive the equipment, check it against
underlined specification or part numbers listed on the invoice to make sure it is complete and inspect
the cover. If none are underlined, they are all cov- the equipment for possible damage due to shipping.
ered by this manual. If there is any damage, notify the carrier immedi-
ately to file a claim. Furnish complete information
To ensure safe operation, read the entire manual,
concerning damage claims or shipping errors to
including the chapter on Safety Instructions and
Thermal Arc, Order Department, 2200 Corporate
Warnings.
Drive, Troy, Ohio 45373-1085. Include all equip-
Throughout this manual, the words WARNING, ment identification numbers as described above
CAUTION, and NOTE may appear. Pay particular along with a full description of the parts in error.
attention to the information provided under these
Move the equipment to the installation site before
headings. These special annotations are easily rec-
uncrating the unit. A lifting eye on the top of the case
ognized as follows:
has been provided so that the equipment may be
carried or lifted with a crane or hoist. Use care to
WARNING gives information re- avoid damaging the equipment when using bars,
garding possible personal in- hammers, etc., to uncrate the unit.
jury. Warnings will be enclosed
in a box such as this. WARNING: Falling machine due
to lifting eye failure may cause
CAUTION refers to possible equipment death or serious injury.
damage. Cautions will be shown in bold
type. • Lifting device may fail when overloaded.
• This lifting device is designed to lift the
NOTE offers helpful information concerning power source ONLY. If the machine is
certain operating procedures. Notes will be equipped with a trailer or accessories over
shown in italics. 100 pounds, DO NOT LIFT by lifting eyes.
• Avoid sudden jerks, drops, or swinging.
Equipment Identification • Check lifting device components visually
for looseness and signs of metal fatigue.
The unit’s identification number (specification or • Before changing any hardware, check
part number), model, and serial number usually grade and size of bolts, and replace with
appear on a nameplate attached to the control
bolts of equal or higher size and grade.
panel. In some cases, the nameplate may be at-
tached to the rear panel. Equipment which does not
have a control panel such as gun and cable assem- Additional copies of this manual may be pur-
blies are identified only by the specification or part chased by contacting Thermal Arc at the address
number printed on the shipping container. Record given above. Include the Owner’s Manual number
these numbers for future reference. and equipment identification numbers.

December 1, 1997 Revised 1-1

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 430429-174
INTRODUCTION

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 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS

ARC WELDING can be hazardous.

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/INSTRUC-
TION 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. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain
of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
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.
ELECTRIC SHOCK can kill. 6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
Touching live electrical parts can cause fatal shocks
7. Use fully insulated electrode holders. Never dip holder in water
or severe burns. The electrode and work circuit is
to cool it or lay it down on the ground or the work surface. Do not
electrically live whenever the output is on. The input
touch holders connected to two welding machines at the same
power circuit and machine internal circuits are also
time or touch other people with the holder or electrode.
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, 8. Do not use worn, damaged, undersized, or poorly spliced cables.
and all metal parts touching the welding wire are 9. Do not wrap cables around your body.
electrically live. Incorrectly installed or improperly 10. Ground the workpiece to a good electrical (earth) ground.
grounded equipment is a hazard.
11. Do not touch electrode while in contact with the work (ground)
1. Do not touch live electrical parts. circuit.
2. Wear dry, hole-free insulating gloves and body protection. 12. Use only well-maintained equipment. Repair or replace damaged
3. Insulate yourself from work and ground using dry insulating mats parts at once.
or covers. 13. In confined spaces or damp locations, do not use a welder with
4. Disconnect input power or stop engine before installing or serv- AC output unless it is equipped with a voltage reducer. Use
icing this equipment. Lock input power disconnect switch open, equipment with DC output.
or remove line fuses so power cannot be turned on accidentally. 14. Wear a safety harness to prevent falling if working above floor
5. Properly install and ground this equipment according to its level.
Owner’s Manual and national, state, and local codes. 15. Keep all panels and covers securely in place.

ARC RAYS can burn eyes and skin; 1. Wear a welding helmet fitted with a proper shade of filter (see
NOISE can damage hearing. 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.
Arc rays from the welding process produce intense 3. Use protective screens or barriers to protect others from flash
heat and strong ultraviolet rays that can burn eyes and glare; warn others not to watch the arc.
and skin. Noise from some processes can damage
4. Wear protective clothing made from durable, flame-resistant
hearing.
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.

Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Electrode Size Filter Electrode Size Filter
Welding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shade
Operation or Welding Current No. Operation or Welding Current No.
Torch soldering — 2 Gas metal-arc welding (MIG)
Torch brazing — 3 or 4 Non-ferrous base metal All 11
Oxygen cutting Ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding (TIG) All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 Atomic hydrogen welding All 12
Heavy Over 6 in., 150 mm 5 or 6 Carbon arc welding All 12
Gas welding Plasma arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Carbon arc air gouging
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Light 12
Heavy Over 1/2 in., 12 mm 6 or 8 Heavy 14
Shielded metal-arc welding Under 5/32 in., 4 mm 10 Plasma arc cutting
(stick) electrodes 5/32 to 1/4 in., 4 to 6.4 mm 12 Light Under 300 Amp 9
Over 1/4 in., 6.4 mm 14 Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14

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 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

FUMES AND GASES can be hazardous 4. Read the Material Safety Data Sheets (MSDSs) and the manu-
to your health. facturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
Welding produces fumes and gases. Breathing these wearing an air-supplied respirator. Shielding gases used for
fumes and gases can be hazardous to your health. 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
1. Keep your head out of the fumes. Do not breath the fumes.
form highly toxic and irritating gases.
2. If inside, ventilate the area and/or use exhaust at the arc to
7. Do not weld on coated metals, such as galvanized, lead, or
remove welding fumes and gases.
cadmium plated steel, unless the coating is removed from the
3. If ventilation is poor, use an approved air-supplied respirator. 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. 5. Watch for fire, and keep a fire extinguisher nearby.
Sparks and spatter fly off from the welding arc. The 6. Be aware that welding on a ceiling, floor, bulkhead, or partition
flying sparks and hot metal, weld spatter, hot work- can cause fire on the hidden side.
piece, and hot equipment can cause fires and burns.
7. Do not weld on closed containers such as tanks or drums.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire. 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.
1. Protect yourself and others from flying sparks and hot metal.
9. Do not use welder to thaw frozen pipes.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. 10. Remove stick electrode from holder or cut off welding wire at
If this is not possible, tightly cover them with approved covers. contact tip when not in use.
4. Be alert that welding sparks and hot materials from welding can 11. Wear oil-free protective garments such as leather gloves, heavy
easily go through small cracks and openings to adjacent areas. shirt, cuffless trousers, high shoes, and a cap.

FLYING SPARKS AND HOT METAL can 1. Wear approved face shield or safety goggles. Side shields rec-
cause injury. ommended.
2. Wear proper body protection to protect skin.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.

CYLINDERS can explode if damaged. 3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
Shielding gas cylinders contain gas under high pres- fittings designed for the specific application; maintain them and
sure. If damaged, a cylinder can explode. Since gas associated parts in good condition.
cylinders are normally part of the welding process,
6. Turn face away from valve outlet when opening cylinder valve.
be sure to treat them carefully.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
1. Protect compressed gas cylinders from excessive heat, mechani- 8. Read and follow instructions on compressed gas cylinders, asso-
cal shocks, and arcs. ciated equipment, and CGA publication P-1 listed in Safety
2. Install and secure cylinders in an upright position by chaining Standards.
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.

ENGINES can be hazardous.

ENGINE EXHAUST GASES can kill. 1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
Engines produce harmful exhaust gases. from any building air intakes.

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 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

ENGINE FUEL can cause fire or 2. Do not add fuel while smoking or if unit is near any sparks or open
explosion. flames.
3. Allow engine to cool before fueling. If possible, check and add
Engine fuel is highly flammable.
fuel to cold engine before beginning job.
1. Stop engine before checking or adding fuel. 4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
MOVING PARTS can cause injury. 3. Have only qualified people remove guards or covers for mainte-
Moving parts, such as fans, rotors, and belts can cut nance and troubleshooting as necessary.
fingers and hands and catch loose clothing. 4. To prevent accidental starting during servicing, disconnect nega-
tive (-) battery cable from battery.
1. Keep all doors, panels, covers, and guards closed and securely 5. Keep hands, hair, loose clothing, and tools away from moving
in place. parts.
2. Stop engine before installing or connecting unit. 6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES 1. Always wear a face shield when working on a battery.
TO EXPLODE; BATTERY ACID can 2. Stop engine before disconnecting or connecting battery cables.
burn eyes and skin. 3. Do not allow tools to cause sparks when working on a battery.
Batteries contain acid and generate explosive gases. 4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.

STEAM AND PRESSURIZED HOT 1. Do not remove radiator cap when engine is hot. Allow engine to
COOLANT can burn face, eyes, and cool.
skin. 2. Wear gloves and put a rag over cap area when removing cap.
The coolant in the radiator can be very hot and under 3. Allow pressure to escape before completely removing cap.
pressure.

WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing 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 can 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. 3. Do not coil or drape cables around the body.
2. Arrange cables to one side and away from the operator. 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.

PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, Code for Safety in Welding and Cutting, CSA Standard W117.2, from
D.C. 20402. Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri- Safe Practices for Occupation and Educational Eye and Face Pro-
can Welding Society Standard AWS F4.1, from American Welding tection, ANSI Standard Z87.1, from American National Standards
Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Institute, 1430 Broadway, New York, NY 10018.

National Electrical Code, NFPA Standard 70, from National Fire Cutting and Welding Processes, NFPA Standard 51B, from National
Protection Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

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 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC

LE SOUDAGE A L′ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU
ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises
par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage
ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres
s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à
suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.

L’E LE C T R OC UTION P E UT ETRE 6. Arrêtez tout équipement après usage. Coupez l’alimentation de
MORTELLE. l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
Une décharge électrique peut tuer ou brûler grave-
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
ment. L’électrode et le circuit de soudage sont sous
laisser traîner par terre ou sur les pièces à souder. Ne touchez
tension dès la mise en circuit. Le circuit d’alimenta-
pas aux porte-électrodes raccordés à deux sources de courant
tion et les circuits internes de l’équipement sont
en même temps. Ne jamais toucher quelqu’un d’autre avec
aussi sous tension dès la mise en marche. En
l’électrode ou le porte-électrode.
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le 8. N’utilisez pas de câbles électriques usés, endommagés, mal
logement des galets d’entrainement et toutes les épissés ou de section trop petite.
pièces métalliques en contact avec le fil de soudage 9. N’enroulez pas de câbles électriques autour de votre corps.
sont sous tension. Un équipement inadéquatement 10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
installé ou inadéquatement mis à la terre est dangereux. de la pièce à souder.
1. Ne touchez pas à des pièces sous tension. 11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
2. Portez des gants et des vêtements isolants, secs et non troués. soudage (terre).
3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen 12. N’utilisez que des équipements en bon état. Réparez ou rem-
de tapis isolants ou autres. placez aussitôt les pièces endommagées.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez 13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le de courant alternatif, à moins qu’il soit muni d’un réducteur de
commutateur en circuit ouvert ou enlevez les fusibles de l’alimen- tension. Utilisez plutôt une source de courant continu.
tation afin d’éviter une mise en marche accidentelle. 14. Portez un harnais de sécurité si vous travaillez en hauteur.
5. Veuillez à installer cet équipement et à le mettre à la terre selon 15. Fermez solidement tous les panneaux et les capots.
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.

pour vous protéger le visage et les yeux lorsque vous soudez ou

que vous observez l’exécution d’une soudure.
LE RAYONNEMENT DE L′ARC PEUT 2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
BRÛLER LES YEUX ET LA PEAU; LE sont recommandés.
BRUIT PEUT ENDOMMAGER L′OUIE.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
L’arc de soudage produit une chaleur et des protéger les autres des coups d’arc ou de l’éblouissement;
rayons ultraviolets intenses, susceptibles de avertissez les observateurs de ne pas regarder l’arc.
brûler les yeux et la peau. Le bruit causé par 4. Portez des vêtements en matériaux ignifuges et durables (laine
certains procédés peut endommager l’ouïe. et cuir) et des chaussures de sécurité.
1. Portez une casque de soudeur avec filtre oculaire de nuance 5. Portez un casque antibruit ou des bouchons d’oreille approuvés
appropriée (consultez la norme ANSI Z49 indiquée ci-après) lorsque le niveau de bruit est élevé.

8-V-96 2-1

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 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE
( selon AWS A 8.2-73 )

Opération Dimension d’électrode ou Nuance de

de Epaisseur de métal ou de filtre
Coupage ou soudage Intensité de courant oculaire
Brasage tendre au chalumeau toutes conditions 2
Brasage fort au chalumeau toutes conditions 3 ou 4
Oxycoupage
mince moins de 1 po. (25 mm) 2 ou 3
moyen de 1 à 6 po. (25 à 150 mm) 4 ou 5
épais plus de 6 po. (150 mm) 5 ou 6
Soudage aux gaz
mince moins de 1/8 po. (3 mm) 4 ou 5
moyen de 1/8 à 1/2 po. (3 à 12 mm) 5 ou 6
épais plus de 1/2 po. (12 mm) 6 ou 8
Soudage à l’arc avec moins de 5/32 po. (4 mm) 10
electrode enrobées (SMAW) de 5/32 à 1/4 po. (4 à 6.4 mm) 12
plus de 1/4 po. (6.4 mm) 14
Soudage à l’arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux toutes conditions 11
métaux ferreux toutes conditions 12
Soudage à l’arc sous gaz
avec électrode de tungstène (GTAW) toutes conditions 12
Soudage à l’hydrogène
atomique (AHW) toutes conditions 12
Soudage à l’arc avec
électrode de carbone (CAW) toutes conditions 12
Soudage à l’arc Plasma (PAW) toutes dimensions 12
Gougeage Air-Arc avec
électrode de carbone
mince 12
épais 14
Coupage à l’arc Plasma (PAC)
mince moins de 300 ampères 9
moyen de 300 à 400 ampères 12
épais plus de 400 ampères 14

LES VAPEURS ET LES FUMEES SONT 5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
DANGEREUSES POUR LA SANTE. sinon, portez un respirateur à adduction d’air. Les gaz protec-
teurs de soudage peuvent déplacer l’oxygène de l’air et ainsi
Le soudage dégage des vapeurs et des fumées causer des malaises ou la mort. Assurez-vous que l’air est
dangereuses à respirer. propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
1. Eloignez la tête des fumées pour éviter de les respirer.
peuvent réagir avec des vapeurs et former des gaz hautement
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ven- toxiques et irritants.
tilée ou que les fumées et les vapeurs sont aspirées à l’arc.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
3. Si la ventilation est inadequate, portez un respirateur à adduc- cadmium que si les zones à souder ont été grattées à fond, que
tion d’air approuvé. si l’espace est bien ventilé; si nécessaire portez un respirateur
4. Lisez les fiches signalétiques et les consignes du fabricant à adduction d’air. Car ces revêtements et tout métal qui contient
relatives aux métaux, aux produits consummables, aux revête- ces éléments peuvent dégager des fumées toxiques au moment
ments et aux produits nettoyants. du soudage.

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 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

LE SOUDAGE PEUT CAUSER UN IN- 4. Méfiez-vous des projections brulantes de soudage susceptibles
CENDIE OU UNE EXPLOSION de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
L’arc produit des étincellies et des projections. Les
5. Méfiez-vous des incendies et gardez un extincteur à portée de
particules volantes, le métal chaud, les projections
la main.
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact 6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
accidentel de l’électrode ou du fil-électrode avec un plancher, une cloison ou une paroi peut enflammer l’autre côté.
objet métallique peut provoquer des étincelles, un échauffement 7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
ou un incendie. 8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long par-
cours inconnu, et prévenir ainsi les risques d’électrocution et
1. Protégez-vous, ainsi que les autres, contre les étincelles et du d’incendie.
métal chaud.
9. Ne dégelez pas les tuyaux avec un source de courant.
2. Ne soudez pas dans un endroit où des particules volantes ou
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-con-
des projections peuvent atteindre des matériaux inflammables.
tact lorsqu’inutilisé après le soudage.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
11. Portez des vêtements protecteurs non huileux, tels des gants
mètres autour de l’arc, ou couvrez-les soigneusement avec des
en cuir, une chemise épaisse, un pantalon revers, des bottines
bâches approuvées.
de sécurité et un casque.

Le piquage et le meulage produisent des particules métalliques

volantes. En refroidissant, la soudure peut projeter du éclats de
LES ETINCELLES ET LES PROJEC- laitier.
TIO N S BRU LA NTES PEU V EN T
1. Portez un écran facial ou des lunettes protectrices approuvées.
CAUSER DES BLESSURES.
Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.

LES BOUTEILLES ENDOMMAGEES 4. Empêchez tout contact entre une bouteille et une électrode de
PEUVENT EXPLOSER soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
Les bouteilles contiennent des gaz protecteurs
des boyauxs et des raccords conçus pour chaque application
sous haute pression. Des bouteilles endommagées
spécifique; ces équipements et les pièces connexes doivent
peuvent exploser. Comme les bouteilles font nor-
être maintenus en bon état.
malement partie du procédé de soudage, traitez-
les avec soin. 6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
1. Protégez les bouteilles de gaz comprimé contre les sources de
7. Laissez en place le chapeau de bouteille sauf si en utilisation
chaleur intense, les chocs et les arcs de soudage.
ou lorsque raccordé pour utilisation.
2. Enchainez verticalement les bouteilles à un support ou à un
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
cadre fixe pour les empêcher de tomber ou d’être renversées.
comprimé et aux équipements connexes, ainsi que la publica-
3. Eloignez les bouteilles de tout circuit électrique ou de tout tion P-1 de la CGA, identifiée dans la liste de documents
soudage. ci-dessous.

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES 1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et
MOTEURS PEUVENT ETRE MORTELS. bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
Les moteurs produisent des gaz d’échappement
fumées d’échappement doivent être envoyées à l’extérieur, loin
nocifs.
des prises d’air du bâtiment.

2. Ne faites pas le plein en fumant ou proche d’une source

d’étincelles ou d’une flamme nue.
LE CARBURANT PEUR CAUSER UN IN- 3. Si c’est possible, laissez le moteur refroidir avant de faire le
CENDIE OU UNE EXPLOSION. plein de carburant ou d’en vérifier le niveau au début du
Le carburant est hautement inflammable. soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
1. Arrêtez le moteur avant de vérifier le niveau de
l’espace pour son expansion.
carburant ou de faire le plein.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.

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 PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002

DES PIECES EN MOUVEMENT PEU- 3. Seules des personnes qualifiées doivent démonter des protec-
VENT CAUSER DES BLESSURES. teurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.
Des pièces en mouvement, tels des ventilateurs, des
4. Pour empêcher un démarrage accidentel pendant l’entretien,
rotors et des courroies peuvent couper doigts et
débranchez le câble d’accumulateur à la borne négative.
mains, ou accrocher des vêtements amples.
5. N’approchez pas les mains ou les cheveux de pièces en mou-
vement; elles peuvent aussi accrocher des vêtements amples
1. Assurez-vous que les portes, les panneaux, les capots et les et des outils.
protecteurs soient bien fermés. 6. Réinstallez les capots ou les protecteurs et fermez les portes
2. Avant d’installer ou de connecter un système, arrêtez le moteur. après des travaux d’entretien et avant de faire démarrer le
moteur.

DES ETINCELLES PEUVENT FAIRE EX- 1. Portez toujours un écran facial en travaillant sur un accumu-
P LOSER UN ACC UMU LATEUR; lateur.
L’ELECTROLYTE D’UN ACCUMU- 2. Arrêtez le moteur avant de connecter ou de déconnecter des
LATEUR PEUT BRULER LA PEAU ET câbles d’accumulateur.
LES YEUX. 3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
Les accumulateurs contiennent de l’électrolyte un accumulateur ou survolter momentanément un véhicule.
acide et dégagent des vapeurs explosives.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

LA VAPEUR ET LE LIQUIDE DE RE- 1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
FROIDISSEMENT BRULANT SOUS refroidi.
PRESSION PEUVENT BRULER LA 2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
PEAU ET LES YEUX. 3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
Le liquide de refroidissement d’un radiateur peut
être brûlant et sous pression.

PRINCIPALES NORMES DE SECURITE

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Safe Handling of Compressed Gases in Cylinders, document P-1,
Society, 550 N.W. LeJeune Rd., Miami, FL 33128. Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. Code for Safety in Welding and Cutting, norme CSA W117.2 Asso-
20402. ciation canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme Safe Practices for Occupation and Educational Eye and Face Pro-
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., tection, norme ANSI Z87.1, American National Standards Institute,
Miami, FL 33128. 1430 Broadway, New York, NY 10018.

National Electrical Code, norme 70 NFPA, National Fire Protection Cutting and Welding Processes, norme 51B NFPA, National Fire
Association, Batterymarch Park, Quincy, MA 02269. Protection Association, Batterymarch Park, Quincy, MA 02269.

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 430429-174
DESCRIPTION OF EQUIPMENT

DESCRIPTION OF EQUIPMENT

General Recommended Unit Applications

There are three basic units of the EXCEL-ARC®.
The EXCEL-ARC® 750 (CC), Part Number 500016- APPLICATIONS -1 -2 -3
1 & 500016A-1, is a constant-current transformer- X X
Gas metal arc welding (MIG)
rectifier type DC welding machine that provides
volt-ampere characteristic curves that are basically Flux cored arc welding (with or X X
drooping with a slight slope. without gas shielding)
Submerged arc welding X X
®
The EXCEL-ARC 8065 (CV), Part Number Electro-slag welding X X
500016-2 & 500016A-2, is a constant-voltage trans- Carbon arc gouging X
former-rectifier type DC welding machine that pro-
SMAW (Stick welding) X
vides volt-ampere characteristic curves that are
basically flat. GTAW (TIG welding) X

The EXCEL-ARC® 8065 (CC/CV), Part Number Wire Feeder Compatibility

500016-3 & 500016A-3, is a combination constant- Some models of Thermal Arc wire feeders will
current and constant-voltage transformer-rectifier connect onto this unit with no special preparation.
type DC welding machine that provides volt-ampere In some cases, however, an interface must be used
characteristic curves for each mode of operation. and in other instances, some rewiring must be
accomplished. Complete details for these excep-
Table 3-1 gives input voltage and amperage data tions will be found in the instruction manual supplied
for all part numbers covered by this manual. with the wire feeder.
PART NO. 500016-1 PART NO. 500016-2 PART NO. 500016-3
ITEM & 500016A-1 & 500016A-2 & 500016A-3
EXCEL-ARC® CC EXCEL-ARC® CV EXCEL-ARC® CC/CV
CC CV
Rated Output Amperage 600 Amps 650 Amps 600 Amps 650 Amps
Rated Output Voltage 44 Volts 44 Volts 44 Volts 44 Volts
Rated Duty Cycle 60% Duty 100% Duty 60% Duty 100% Duty
Minimum Output 60 Amps 75 Amps @ 15 Volts 75 Amps 75 Amps @ 15 Volts
Maximum Output 750 Amps 800 Amps @ 40 Volts 750 Amps 800 Amps @ 40 Volts
Rated Input Voltage 230/460/575 230/460/575 230/460/575
Rated Input Amperage 126/62.6/50 110/55/43 110/55/43
Input kW 36 kW 36 kW 36 kW
Input kVA 50.1 kVA 43.8 kVA 43.8 kVA
Input Frequency 60 Hz 60 Hz 60 Hz
Input Phase 3 Phase 3 Phase 3 Phase
Maximum Open Circuit Voltage 86 62 62
Auxiliary Power 1 kVA – 115V, 9A 1 kVA – 115V, 9 A 1 kVA – 115V, 9 A
No Load Input Voltage 230/460/575 230/460/575 230/460/575
No Load Input Amperage 4.4/2.4/2.0 6/3/2.4 6/3/2.4
No Load kW 1.2 kW 1.2 kW 1.2 kW
No Load kVA 1.75 kVA 2.4 kVA 2.4 kVA
Power Factor .72 .82 .82
Efficiency 72% 80% 80%

Table 3-1 Input Voltage/Amperage Data

December 1, 1997 Revised 3-1

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 430429-174
DESCRIPTION OF EQUIPMENT

Figure 3-1 Front and Rear Panel

3-2 April 7, 1997 Revised

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 430429-174
DESCRIPTION OF EQUIPMENT
Controls and Outlets 5. CC/CV Selector Switch (CC/CV) (500016-3 &
500016A-3) — Selects the welding mode of opera-
See callouts on Figure 3-1. tion.

1. Pilot Light (500016-1, -2, -3 & 500016A-1, -2, 6. Feeder Control Receptacle Panel (Automat-
-3) — When lighted, indicates that the input contac- ic) (CV units) (500016-2, -3 & 500016A-2, -3) —
tor (power) is ON. Amphenol (19-pin) connector for a remote voltage
control type wire feeder. (Semiautomatic) (5-pin)
2. Input Contactor Control (500016-1, -2, -3 & connector for the control cable from semiautomatic
500016A-1, -2, -3) — This toggle switch is the wire feeder only.
master power switch for the welding machine, and
NOTE: Only one feeder control receptacle
must be in the ON position before any other section
is used at any one time.
will operate. The primary circuit of the control trans-
former is energized whenever line voltage is present 7. Arc Force Control (CC/CV Units) (500016-1,
at the input terminals. This switch closes the secon- -3 & 500016A-1, -3) — This potentiometer controls
dary circuit of the control transformer, energizing the short circuit (welding) current to produce an in-
contactor, which energizes the power transformer. crease in current as the arc length is shortened. The
Do not use this switch to start or stop arc. Start arc control is present to provide the degree of “hard
with switch ON, break arc, then turn switch OFF. start” required, and the additional dynamic change
for welding tight grooves, etc. Turn clockwise to
3. Local/Remote Output Control Volts/Amps increase “hard start” characteristics, counterclock-
Selector Switch (500016-1, -2, -3 & 500016A-1, -2, wise to obtain a soft-start, smooth arc.
-3) — Selects either the output control (Local) or
some remote control device (Remote) to control 8. Welding Voltage/Amperes Control (CV
welding output. Units) (500016-2, -3 & 500016A-2, -3) — Adjusts
arc welding output and open circuit voltage. Open-
4. 115-V AC Receptacles (500016-1, -2, -3 & circuit voltage is approximately 1.5 times the weld-
500016A-1, -2, -3) — Provides auxiliary power for ing voltage for constant voltage welding. On
lights, wire feeders, water pumps, etc. — 15 amps 500016-1, -3 & 500016A-1, -3 (CC units) — Adjusts
maximum. the welding current.

Figure 3-2 EXCEL-ARC® 8065

Dimensions and Weight

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 430429-174
DESCRIPTION OF EQUIPMENT
TO AUTOMATIC
TO FEEDER EQUIPMENT

5-PIN 19-PIN
GUN SWITCH GUN SWITCH
RECEPTACLE RECEPTACLE
CIRCUIT
BREAKER
24 V - 10 AMP
CV MODE AMPHENOL BOARD

OVERLOAD
INPUT THERMOSTAT
INPUT WELDING
POWER CONTACTOR TRANSFORMER PHASE SIGNAL
T1
PC CONTROL
BOARD

CONTROL BACKGROUND
TRANSFORMER CIRCUIT REGULATOR
BREAKER OUTPUT PC BOARD
115 V 15 AMP SCR CC MODE
SCR1—SCR6
INPUT
CONTACTOR RECEPTACLE
SWITCH 115 V
STABILIZER STABILIZER
FILTER FILTER
L1 L2

+ + — —
CV UNITS CC UNITS CC UNITS CV UNITS

Functional Block Diagram for EXCEL-ARC® 8065

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 430429-174
DESCRIPTION OF EQUIPMENT
9. Volt/Amp Meter and Switch (CV Units) cludes the fan and the 115-volt AC power recepta-
(500016-2, -3 & 500016A-2, -3) — A single meter cle.
with switch that will read DC volts when in the V.
14. Circuit Breaker — Rated at 10 amps — pro-
position or read DC amps in the A. position.
vides protection to the 24-volt circuit for the wire
10. Positive Terminal (+) (CV mode) (500016-2, feeder and automatic equipment.
-3 & 500016A-2, -3) — Serves as a connection point 15. Stick/Tig Selector Switch (CC Units)
for the lead to the wire feeder when reverse polarity (500016-3 & 500016A-3) — Selects a reduced cur-
is desired. rent start in the TIG mode.
11. Positive Terminal (+) (CC mode) (500016-1,
-3 & 500016A-1, -3) — Serves as a connection point Duty Cycle
for the lead to the electrode holder lead for SMAW
(stick) or arc gouging mode of operation when re-
verse polarity is desired. (Figure 3-3)

NOTE: To obtain opposite welding polarity, Duty cycle is the percentage of each ten-minute
period of time that the welding machine may be
simply reverse the connections to the posi-
operated under rated load conditions. For example,
tive and negative terminals.
a duty cycle of 60% means that the machine can be
12. Negative Terminal (—) — Serves as a connec- operated at rated load for an average of 6 minutes
tion point for the lead to the workpiece when reverse of each 10 minute period of operation. During the
polarity is desired. remaining 4 minutes, the machine must idle to
permit proper cooling. Figure 3-3 enables the op-
13. Circuit Breaker — Rated at 15 amps — pro- erator to determine the duty cycle at various welding
vides protection to the 115-volt circuit which in- amperages.

Figure 3-3 Duty Cycle Chart

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 430429-174
DESCRIPTION OF EQUIPMENT

Figure 3-4 Volt/Ampere Characteristic Curves

3-6 April 7, 1997 Revised

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 430429-174
INSTALLATION

INSTALLATION

Location method, and the equipment grounding conductor

size and type shall conform to local and national
For best operating characteristics and longest unit
codes.
life, take care in selecting an installation site. Avoid
locations exposed to high humidity, dust, high am- For the National Electrical Code, the equipment
bient temperature, or corrosive fumes. Moisture can grounding conductor shall be green, green with a
condense on electrical components, causing corro- yellow stripe, or bare.
sion or shorting of circuits. Dirt on components helps
If flexible power cable is used, use a cable assem-
retain this moisture.
bly which includes the equipment grounding con-
Adequate air circulation is needed at all times in ductor. If metallic armored cable or conduit is used,
order to assure proper operation. Provide a mini- the metal sheathing or conduit must be effectively
mum of 12 inches (305 mm) of free air space at both grounded per local and national codes.
front and rear of the unit. Make sure that the venti-
lator openings are not obstructed. Rubber-tire mounted equipment shall be
grounded to conform to local and national codes.
The grounding assists in providing protection
Grounding against line voltage electrical shock and static
The frame of this welding machine should be shock. The grounding serves to discharge the static
grounded for personnel safety, and to assure opera- electric charge which tends to build up on rubber-
tion of the overcurrent protection. The grounding tire mounted equipment. This static charge can

Outside Ground Inside Ground

Figure 4-1

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 430429-174
INSTALLATION

COPPER COPPER
RATED APPROX. LINE WIRE SIZE* GROUNDING
LINE LOAD LINE FLEXIBLE CONDUCTOR
VOLTS AMPS FUSE SIZE IN CONDUIT CABLE MIN. SIZE

230 110 150 No. 2 No. 1 No. 6

460 55 75 No. 6 No. 4 No. 8
575 43 50 No. 8 No. 6 No. 8

*Conductor size shall be modified as required for line voltage drop and ambient temperature. Sizes
listed for conduit installation are based on 90° C conductor insulation, designated as FEP, FEPB,
RHH, and THHN.

Table 4-1 Recommended Wire and Fuse Size Table

cause painful shock and lead to the erroneous Connecting Welding Machine to
conclusion that an electrical fault exists in the equip-
ment.
Line Voltage
The input power should be connected to the unit
If a system ground is not available, consult the
through a fused disconnect switch, or other suitable
electrical code enforcement body for instructions.
disconnecting means furnished by the user. A hole
The welding machine should be connected to an
is provided in the rear panel of the machine, near to
adequate driven ground rod, or to a water pipe that
the input connections, for the entry of the input
enters the ground not more than 10 feet (30 meters)
conductors.
from the machine.

The equipment grounding conductor size is listed

in Table 4-1 as a guide, if no local or national code DANGER: ELECTRIC SHOCK
is applicable. CAN KILL. Open the discon-
Attach the equipment grounding conductor to the
nect switch, or breaker, and
stud provided on the yoke. Determine that the determine that no voltage is
ground wire size is adequate before the machine is present, before connecting
operated. wires between welding ma-
CAUTION: Be sure to replace the cabinet chine and power supply.
top to assure adequate internal ventila-
tion and prevent component failure.
CAUTION: The method of installation,
conductor size, and overcurrent protec-
tion shall conform to the requirements
Internal Wiring Check of the local electrical code, the National
Refer to the product identification plate (name- Electrical Code, or other national codes,
plate) on the welding machine’s rear panel to deter- as applicable. All installation wiring and
mine the power input voltages and frequency at machine reconnections shall be done
which it will be operated. by qualified persons.

Remove left side panel for access to Line Voltage Table 4-1 provides minimal information for selec-
Changeover circuitry. Check line voltage connec- tion of line conductors, fuses, and the equipment
tions against instructions on Voltage Changeover grounding conductor. This information is from the
Diagram supplied with this manual. If necessary, National Electrical Code NFPA 70-1981 Edition.
rearrange internal wiring and/or link connections. Install this equipment per the latest edition, avail-
4-2 April 7, 1997 Revised

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 430429-174
INSTALLATION
able from the National Fire Protection Association, Welding Leads
470 Atlantic Avenue, Boston, MA 02210.
Use Table 4-2 for selection of the proper size
Connect the three-phase line leads to terminals
copper welding leads.
L1, L2, and L3 on the line contactor inside the
welding machine cabinet.

TOTAL LENGTH OF LEAD CIRCUIT IN FEET (AND METERS)

Welding (ELECTRODE LEAD PLUS WORK LEAD)
Current 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet
Amperes (15.2 M) (30.5 M) (45.7 M) (61.0 M) (76.2 M)
100 #4 #4 #4 #3 #2
150 #3 #3 #2 #1 #1/0
200 #2 #2 #1 #1/0 #2/0
250 #1 #1 #1/0 #2/0 #3/0
300 #1/0 #1/0 #2/0 #3/0 #4/0
350 #1/0 #1/0 #3/0 #4/0 #4/0
400 #2/0 #2/0 #3/0 #4/0 2 — #2/0
450 #2/0 #2/0 #4/0 2 — #2/0 2 — #3/0
500 #3/0 #3/0 #4/0 2 — #2/0 2 — #3/0

For 60% duty cycle

NOTE: Lead size shown is for 90°C cable insulation, 30°C (86°F) ambient, and not over 4.5 volts lead
drop.
Table 4-2

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INSTALLATION

Figure 4-2 Input Voltage Connection & Changeover

For 500016-1 & 500016A-1

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 430429-174
INSTALLATION

Figure 4-3 Input Voltage Connection & Changeover

For 500016-2, -3 & 500016A-2, -3

April 7, 1997 Revised 4-5

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 430429-174
INSTALLATION

Figure 4-4 Installation Diagram

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 430429-174
OPERATION

OPERATION

General 7. Place the voltage sensing jumpers (500016-2

and -3 & 500016A-2 and -3) on the main P.C. control
Before operating this system, be sure that all in- board to the desired mode. Local (voltage sensing
stallation instructions have been accomplished. from the power source which comes from the fac-
When operating this system, observe all applicable tory), Jumper JP-2 (–) and JP-4 (+). For remote
Safety Warnings listed in this and related system voltage sensing, going out to the optional terminal
manuals. strip – Thermal Arc P/N 204248 Jumper JP-3 (–)
The operating instructions in this manual pertain and JP-5 (+).
only to the EXCEL-ARC® 8065 welding machines.
Consult operating instructions for components used SMAW (Stick) Welding, Carbon
with this system before operating.
Arc Gouging
A thermostatically controlled fan motor is standard (500016-3 & 500016A-3)
on this unit. The fan motor starts and stops automat-
ically when a predetermined temperature has been Refer to Figure 3-1 for controls (numbers in paren-
reached. thesis refer to callouts on Figure 3-1).
1. On 500016-3 & 500016A-3 set the CC/CV
selector switch to CC position.
Preweld Operation
2. Hold electrode clear of work, and set Stick/Tig
1. Connect welding leads to terminals on front Switch (15) to STICK position. Be sure the Remote-
panel. Local Switch (3) is set to LOCAL position.
3. Turn Input Contactor Control Switch (2) to ON
WARNING: Disconnect line volt- position.
age from the unit before making
4. Strike arc. Adjust Welding Output Control (8) if
any connections inside unit. required. Adjust Arc Force Control (7) to desired
T urn off f use d disconnect level.
switch that supplies power to 5. At the conclusion of welding, break arc, and turn
welding machine, and remove Input Contactor Control Switch (2) to OFF position.
its fuse.
Welding, Semiautomatic or
ELECTRIC SHOCK can kill! Automatic
• Do not touch live electrical Refer to Figure 3-1 for controls.
parts, including the output
1. On 500016-2 and -3 & 500016A-2 and -3 set
terminals and electrode. Remote/Local Output Control Switch (3) and Volt-
age Sensing Jumpers to LOCAL — JP-2 and JP-4.
2. If used, connect remote control wire assembly
and gun switch to welding machine. Connect feeder NOTE: Set Output Control Switch (3) to
receptacle to wire electrode feeder system. REMOTE when using a feeder which con-
trols the voltage, and remote voltage con-
3. Refer to other manuals for component connec- trol is desired. Set Voltage Sensing
tions. Jumpers to JP-3 and JP-5 to REMOTE
when using a feeder which provides volt-
4. Set Output Control to desired value. age sensing at the actual welding location.
5. Set the remote/local control switch in the desired If the Voltage Sensing Jumpers are placed
mode. in the REMOTE position, and the voltage
sensing leads are not connected at the
6. Set the stick/Tig switch (500016-3 & 500016A- welding location, the output of the welding
3) in the desired mode. machine will go to maximum amperage.
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OPERATION
2. On 500016-3 & 500016A-3 set the CC/CV Se- – When Excel-Arc® is used on high cycle short
lector Switch to CV position. weld applications or if a great deal of tack welding
3. Place Input Contactor Control Switch (2) in ON is done.
position (Power ON).
4. Inch wire electrode to position over work; see B. “Wire Sharpening”TM — Serves the same func-
related owner’s manuals. tion as burnback. However in addition to maintain-
ing contactor closure for .25 seconds, Excel-Arc®
5. Depress gun switch trigger and strike arc. also lowers weld voltage to a value too low to
maintain an arc but sufficient enough to burn off the
6. The Excel-Arc® weld termination sequence is
remaining wire. The effect of this a significant reduc-
fully adjustable. Three simple jumper changes on
tion in the ball size of the end of the wire.
the main circuit board allow the following weld ter-
mination treatments.
CAUTION: In order for this circuit to
A.) Burnback Delay (JP-1)
work properly, the MIG torch must re-
B.) “Wire Sharpening”TM (JP-9)
main stationary for the complete wire
C.) Inhibit (JP-1)
sharpening cycle.
A. Burnback Delay — The burnback setting calls
the Excel-Arc® to maintain a contactor closure for
“Wire Sharpening”TM is preferred in the following
.25 seconds after the gun trigger has been released
situations.
and wire feeding has stopped. The features primary
function is the prevention of wire sticking to the weld
puddle upon completion of a weld. Another term – Automatic welding operations, Robotic applica-
commonly used to describe burnback is the term tions.
anti-stick.
C. Inhibit — The inhibit selection disables both the
The burnback option is preferred in the following
wire sharpening circuit and the burnback circuit.
situations.
This feature may be useful in situations where an
– When Excel-Arc® is used with older wire feeders external control is used to control power source
which do not have dynamic braking and would show functions with the burnback circuit mentioned ear-
a tendency to wire coasting. lier.

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MAINTENANCE

MAINTENANCE

Replacing SCRs Inspection and Cleaning

Replacing a SCR is a critical task but it can be For uninterrupted, satisfactory service from this
accomplished in the field by following the instruc- welding machine, it is necessary to keep the ma-
tions in the Detailed Troubleshooting section of the chine clean, dry, and well ventilated. At least every
Troubleshooting chapter of this manual. three months, or more often as necessary, wipe and
blow out all dirt from the machine’s internal compo-
Lubrication nents, with air pressure of not over 25 psi (172 kPa).
Be sure to wipe the fan blades clean.
The fan motor incorporates a sleeve bearing and
therefore will need periodic lubrication. The follow- Check and tighten all electrical connections as
ing table will furnish a recommended guide to the necessary to eliminate unnecessary losses and to
frequency of this lubrication. avoid subsequent trouble from overheating or open
circuits. Check for broken wiring or damaged insu-
Lubrication lation on wiring.
Type of Duty Interval
Light (up to 6 hrs./day) Every 12 months CAUTION: The flow of air through the
Moderate (7 to 15 hrs./day) Every 6 months welding machine is carefully directed by
baffles. Never operate the welding ma-
Heavy (16 to 24 hrs./day) Every 3 months chine with any of the side or top panels
removed or open, as serious damage to
NOTE: Apply 1-12 drops of 20W non-deter- the rectifiers might result.
gent oil at each end of bearing.

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MAINTENANCE

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TROUBLESHOOTING

TROUBLESHOOTING

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

Troubleshooting Guide
Welding machine will not start.
Power switch OFF
Place power switch in ON position.
Power lines dead
Check voltage.
Broken power lead
Repair.
Wrong line voltage
Check power supply.
Incorrect input power connections at welding machine
Check connections against wiring diagram.
Open circuit to power switch or control transformer
Repair. Check for broken wire or loose connections at terminals.
Fuse on control transformer blown
Remedy cause. Replace fuse.

Line contactor fails to close.

Defective NVR coil
Replace.
Mechanical obstruction on contactor
Remove.
Broken leads at line contactor
Repair.

Contactor chatters.
Line leads too small
Use larger leads.
Low line voltage
Check line voltage.

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TROUBLESHOOTING

Contactor operates and blows link fuses.

Wrong line voltage
Check nameplate of welding machine for line voltage to use; check line voltage.
Links on voltage changeover board incorrectly connected
Check Voltage Changeover diagrams for link positions; connect links correctly. See
Diagrams chapter.
Line fuse too small
Install proper size fuse.
SCR failure or shorted flyback diode
Refer to Detailed Troubleshooting Instructions.
Short circuit in primary connections
Remove short circuit.
Transformer failed
Repair or replace.

Unit delivers welding current but soon shuts down (Thermal overload trips)
Welding machine overloaded
Reduce load, overload can be carried only for a short time.
Duty cycle too high
Do not operate continually at overload currents.
Power leads too long or too small in cross section
Replace with larger diameter cable.
Ambient temperature too high
Operate at reduced loads when temperature exceeds 104° F (40° C).
Ventilation blocked
Check air intake and exhaust openings to be unobstructed.
Fan not operating after machine is loaded down
Check fan thermostat. Check bearings, disconnect leads and apply motor name-
plate voltage to test.

Solid-state contactor operates, but welding machine will not deliver welding cur-
rent, and open circuit voltage is present at the output when gun switch is de-
pressed.
No ground connections at work
Make connections.
Welding cables not connected
Make connections.

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TROUBLESHOOTING

Voltage/amps dial does not control welding voltage.

Potentiometer burned out
Replace.
Loose connections in voltage control circuit
Check connections.
Control circuit board failure
Replace control board.

Fan not operating (also see causes and remedies under “Welding machine will
not start”)
NOTE: Fan will not operate until rectifier heats up.
Motor failed
Replace or repair.
Broken lead or connection to fan motor
Repair wiring.
Blown circuit breaker on rear panel of welding machine
Reset circuit breaker. 115-volt receptacle may be overloaded.

Operator gets shock when welding machine case, ground cable, work, or work ta-
ble is touched.
Case of welding machine not grounded
Ground welding machine case.
Work table and work not grounded
Ground work and work table to plant ground.

Abnormal current fluctuation, voltage nearly constant

Irregular wire feed speed
See welding head manual.
Inadequate shielding of arc by flux or gas
Increase shielding by trial and error. See welding head manual.
Wire feed rate too slow
Increase wire feed. See wire burn-off rate charts.
Too much shielding gas
Decrease by trial and error. See welding head manual.
Loose cable connections
Check for overheated connections and tighten.
Welding contact tube (tip) on wire feeder makes poor contact with electrode
Check contact tube hole size and replace with proper tube.
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TROUBLESHOOTING

Contactor fails to open.

Contactor contacts sticking
Clean contacts.

Very noticeable, rough, sputtering arc. Loss of control and burnback. Minor start-
ing problems.
Control circuit board failure
Replace Control P.C. Board.

Output of welding machines goes to maximum and there is no control.

Voltage sensing lead not connected
Connect lead.
Jumper JP-2 and JP-4 on Control P.C. Board not connected
Add jumpers JP-2 and JP-4 on Control P.C. Board.

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TROUBLESHOOTING
Detailed Troubleshooting 7. Output Reference Circuits — Test Point TP16
to TP9 – +10V DC meter reading – reference
Instructions voltage supply; Test Point TP16 to L10 – –10V DC
The EXCEL-ARC® 8065 is a solid-state welding (CC and 8065 models) – voltage reference supply
machine. The method of troubleshooting is different, to output pots.
but is not more difficult than troubleshooting a con-
ventional unit. Do not overlook the obvious. As in 8. SCR Firing Circuits — Test Point TP16 to TPE
the case of all electrical equipment, loose connec- – 4.3V DC – checks ramp circuits; Test Point TP16
tions are the primary cause of malfunction both to TPD – 4.3V DC – all readings should be very
internal and external to the welding machine. Do not close for balance; Test Point TP16 to TPB – 4.3V
overlook bad grounds, worn contact tubes (tips), DC – all readings should be very close for balance;
dirty cable liners, shorted control cables, wrong Test Point TP16 to +C69 – 17-19V DC – checks
settings, blown fuses, worn contactors, misconnec- SCR gate; Test Point TP16 to +C70 – 17-19V DC
tions from feeding equipment, misapplication, etc. – generator circuits; Test Point TP16 to +C71 –
To check the Control P.C. Board, take control mod- 17-19V DC – all should be equal.
ule panel off the front panel. Check the control board Control Circuit Board Malfunction — If a board
for loose connectors, broken or loose wires. Inspect malfunction occurs, the following situations will
the P.C. Board for broken components, scorched or probably result:
burned components. The only equipment needed to
properly detect a problem on this welding machine 1. Loss of arc completely.
is a simple voltohmmeter, although an oscillo- 2. Very noticeable, rough, sputtering arc.
scope is the best method to quickly “see” the prob-
lem. 3. Loss of control and burnback.

Voltages of Interest — Refer to Connection Dia- 4. Minor starting problems.

gram. SCR Malfunction — If one or more SCRs mal-
1. Across the secondary on all three phases — function, the following situations will probably result:
92.0 V AC ± 10%. 1. Blown line fuses as the result of a shorted SCR
2. From the center bus bar on secondaries to the (similar to a shorted diode). A shorted flyback diode
top or bottom of the secondary — 46.0 V AC ± 10%. will also produce this situation.
2. If one SCR does not turn on [either it is open or
NOTE: The ± 10% refers to the possibility
the gate signal is not being received by the SCR
of having a high or low input line voltage.
(gate circuit open)], a very small change will occur
3. 115 V Receptacles — 115 V AC ± 10%. at the arc and will be difficult to notice by the average
operator. Generally when this happens, it will be
4. AC Input Voltage — Test Points R206 to R207 necessary to adjust the voltage control on the front
– 36V AC voltage reading – AC voltage input to P.C. of the welding machine (turn it up) to obtain the
Board; Test Points R208 to R209 – 36V AC voltage same arc that was being produced before the defect
reading – AC voltage input to P.C. Board; Test occurred.
Points R210 to R211 – 36V AC voltage reading –
AC voltage input to P.C. Board. 3. If two SCRs do not turn on, the arc becomes
more erratic and unstable.
5. Power Supply Checks — Test Points TP16 to
TP18 – +22V DC meter reading – power supply Component Testing
reading; Test Points TP16 to TP17 – +15V DC 1. In the case of a severe malfunction, such as a
meter reading – power supply reading; Test Points shorted SCR or diode, do not turn on the unit.
TP16 to TP19 – –15V DC meter reading – power Disconnect the leads from the transformer to the
supply reading. heat sink assembly and check with a VOM for
6. Output Contactor Checks — Test Point TP16 to shorted SCRs or a shorted flyback diode.
Anode L9 – +16V DC meter reading (CC Mode); 2. If the welding machine is suspected, a very
Test Point TP16 to L8 – +16V DC meter reading (CV simple test can tell you a great deal about it. Simu-
Mode) – output switch to local pins A and B on late gun switch closing and observe the open circuit
Amphenol shorted together; Test Point TP16 to R22 voltage. This can be done by putting the Process
– +16V DC meter reading (Tig position). Selection Switch (Fig. 3-1, item 5) in the CV position

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TROUBLESHOOTING
and shorting terminals A and B together on the 5-pin The best way to isolate the particular SCR which
connector on the rear panel. This voltage should is malfunctioning is as follows. Refer to Connection
vary from 19V DC to 59V DC ± 10%, as the voltage Diagram while inspecting the unit. On the output
control is rotated from min. to max. slowly. If this rectifier there are gate leads coming off of the SCRs.
voltage varies smoothly, there is a strong possibility Each of these leads are connected to a quick-dis-
that nothing has malfunctioned in the welding ma- connect terminal on the suppressor board. Turn the
chine. If the voltage varies erratically and does not voltage control pot to maximum. Disconnect one
come close to the values listed, you probably have lead to one SCR and observe the OCV. If the OCV
a control circuit board problem. If the voltage vari- drops to a lower value, this indicates that this par-
ation is somewhat smooth, but does not reach the ticular SCR is working properly. Reconnect this lead
maximum value (remember the ± 10% refers to a and do the same thing with the remaining leads until
high or low line voltage), you probably have an SCR you discover which disconnection does not cause
problem. the OCV to drop to a lower level. This is the mal-
3. The next step is to go inside the unit and check functioning SCR. See Mounting Procedures for
the control circuit board. See the instructions pro- SCRs which follows.
vided for this test. It is important to run through the Mounting Procedure for SCRs
tests in the order they are listed. If an interface box
is being used, it will be necessary to switch the 1. Thoroughly clean heat sink surface to eliminate
welding machine local-remote switch to the local any dirt or contamination.
position.
2. Apply a thin coat of Alcoa #2 compound to
4. If nothing is found defective on the board, the cleaned surface. Alcoa #2 is available from Thermal
next step is to go to the SCRs. First of all an open Arc, part number 903870.
gate or an open SCR cannot be checked with a
VOM. If an SCR is not firing, the open circuit voltage 3. Positively locate the SCR in place in the heat
(OCV) will shift down. Check the following table for sink. A small spring pin in the extruded heat sink will
typical values: locate the SCR.
Disconnect cable #103 from the capacitor bank 4. Place the clamp in position with the bolts
assembly. Insulate the lug end of cable #103 to through the holes in the heat sink, and proceed in
prevent it from touching chassis or any other sur- following manner.
face.
5. Tighten the nuts evenly until finger tight.
500016-1 & 500016-2, -3 &
500016A-1 500016A-2, -3 6. Tighten each bolt in 1/4 turn increments using
All SCRs firing properly All SCRs firing properly correct size hex key.
max. OCV = 85V DC. max. OCV = 57V DC.
7. Place the Force Indicator Gauge (903878) firmly
1 SCR not firing 1 SCR not firing
max. OCV = 77V DC. max. OCV = 51V DC. against the springs as shown. Be sure both ends
and the center are in firm contact with the springs.
2 SCRs not firing 2 SCRs not firing The gauge notch location will indicate the spring
max. OCV = 69V DC. max. OCV = 45V DC. deflection or force. Correct mounting force is indi-
3 SCRs not firing 3 SCRs not firing cated as shown below.
max. OCV = 61V DC. max. OCV = 39V DC.
8. Spring deflection over 2-1/4 inches of spring is
NOTE: These voltages were recorded at .037" ± .002" for all clamps.
nominal line voltage with voltage control
adjustment at MAXIMUM setting (unit ad- 9. All clamps to be set at 4° mark. This corre-
justed for high open-circuit voltage). sponds to the VE3000-VE2500 section on the
gauge label.

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TROUBLESHOOTING

Examples:

Less t ha n Correct rated Excessive

r a te d f or c e . force. force. Loosen
Tighten nuts al- both nuts and
ternately 1/4 start over.
turn at a time Never adjust
until points co- f or c e by
incide.
b a c k in g off
the nuts. Fric-
tion will pro-
duce a false
reading. Al-
w a y s s ta r t
from Step 1.
Figure 7-1 Figure 7-2

To Calibrate Force Gauge:

If the gauge is suspected of being out of calibration due to wear or damage, check it on a flat surface as
shown below.

If the calibration edges do not line up, calibrate the

gauge by filing the bottom contact points.

Figure 7-3

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PARTS LIST

PARTS LIST
to another part. The part descriptions may be
Equipment Identification indented to show part relationships.
All identification numbers as described in the In-
troduction chapter must be furnished when ordering To determine the part number, description, quan-
parts or making inquiries. This information is usually tity, or application of an item, simply locate the item
found on the nameplate attached to the equipment. in question from the illustration and refer to that
Be sure to include any dash numbers following the item number in the corresponding Parts List.
Specification or Assembly numbers.
An “Application Code” is used to distinguish parts
that are applicable only to certain Specifications
How To Use This Parts List and/or Assemblies. This code is found in the right-
The Parts List is a combination of an illustration most column of the Parts List. If an item in the Parts
(Figure Number) and a corresponding list of parts List applies to all Specifications or Assemblies, the
which contains a breakdown of the equipment into word “ALL” will be in the Application Code column.
assemblies, subassemblies, and detail parts. All Refer to the following list to determine the appro-
parts of the equipment are listed except for commer- priate Application Codes for the Specifications or
cially available hardware, bulk items such as wire, Assemblies covered by this manual. If only the
cable, sleeving, tubing, etc., and permanently at- assembly or specification number is listed, the use
tached items which are soldered, riveted, or welded of an Application Code does not apply to this
manual.

PART NUMBER APPLICATION CODE

500016-1 A
500016-2 B
500016-3 C
500016A-1 D
500016A-2 E
500016A-3 F

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PARTS LIST

Figure 8-1 EXCEL-ARC® Control Panel Group

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PARTS LIST
Parts List for Figure 8-1

Item Part Description Qty Application

No Number per Code
Assy

500016-1 Excel-Arc® Welder - 750 CC 1 A

500016-2 Excel-Arc® Welder - 8065 CV 1 B
500016-3 Excel-Arc® Welder - 8065 CC/CV 1 C
500016A-1 Excel-Arc® Welder - 750 CC 1 D
500016A-2 Excel-Arc® Welder - 8065 CV 1 E
500016A-3 Excel-Arc® Welder - 8065 CC/CV 1 F
1 204281-7 . Panel - Control 1 ABC
204281A-1 . Panel - Control 1 DEF
2 204212 . Board - PC, Digital Display 1 BCEF
3 204600-2 . Spacer 4 BCEF
4 409000-1 . Bezel - Meter 1 BCEF
5 204053-5 . Panel - Control Module 1 A
204053-11 . Panel - Control Module 1 D
204053-2 . Panel - Control Module 1 B
204053-8 . Panel - Control Module 1 E
204053-3 . Panel - Control Module 1 C
204053-9 . Panel - Control Module 1 F
6 406806-1 . Knob - Control 1 AC
406806-3 . Knob - Control 1 DF
7 401428-8 . Potentiometer - Volt/Amp Ctl, Arc Force 1 All
401428-8 . Potentiometer - Volt/Amp Ctl, Arc Force 2 ACDF
8 405365-1 . Switch - Toggle, ON/OFF, Tig Stick 1 ABDE
405365-1 . Switch - Toggle, ON/OFF, Tig Stick 2 CF
9 408850-2 . Knob - Block 1 ABC
408850-5 . Knob - Block 1 DEF
10 402682 . Switch - Toggle, RMT/LC1 1 All
11 402421-2 . Light - Indicator 1 All
12 204052-2 . Panel - Output, Blank 1 AB
204052-6 . Panel - Output, Blank 1 DE
13 204052-1 . Panel - Output, Terminal 2 AB
204052-5 . Panel - Output, Terminal 2 DE
204052-1 . Panel - Output, Terminal 3 C
204052-5 . Panel - Output, Terminal 3 F
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

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PARTS LIST

Parts List for Figure 8-1

Item Part Description Qty Application

No Number per Code
Assy

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

No Number . Screw - 1/2-13 x 1, 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
21 204207B . Board - PC, Control 1 All
22 171086-1 . Stand-off - PC Board 8 All
23 W-9956 . Knob - Switch, Range 1 CF
24 367880 . Sleeve - Sw. 1 CF
25 400562-24 . Spring - Compression 1 CF
367260 . Switch - Range 1 C
367260-1 . Switch - Range 1 F
26 405478 . . Rivet 1 CF
27 W-11291-3 . . Nut - Speed, Push on 1 CF
28 410602 . . Bracket 1 C
410602-1 . . Bracket 1 F
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 . . Nut - 1/4-20 SCR, MH, Hex, ST. 1 CF
35 204055-7 . Box - Control Board 1 ABC
204055A-7 . Box - Control Board 1 DEF
— 204247-1 . Cable - Ribbon, Meter 1 BCEF
36 351505 . Screw - 1/2-13 x 1-3/4, HHC, ST.
(threaded for item 39) 2 ABDE
351505 . Screw - 1/2-13 x 1-3/4, HHC, ST.
(threaded for item 39) 3 CF
37 No Number . Screw - #6-32 x 1/4 Rd. Hd. MH. ST. 2 ABDE
No Number . Screw - #6-32 x 1/4 Rd. Hd. MH. ST. 3 CF
38 405362-3 . Bushing - Snap 2 All

— Not Illustrated

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PARTS LIST

Figure 8-2 Base and Lifting Yoke Group

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PARTS LIST
Parts List for Figure 8-2

Item Part Description Qty Application

No Number per Code
Assy
1 204306 . Transformer - Power 1 BCEF
204595 . Transformer - Power 1 AD
2 367228-13 . . Board - Voltage Changeover 1 All
3 204318 . . Bracket - Voltage Changeover 1 ABC
204318-1 . . Bracket - Voltage Changeover 1 DEF
4 CW-811 . Link - Voltage Changeover 3 All
5 204301 . Bracket - Mtg. 1 ABC
204301-1 . Bracket - Mtg. 1 DEF
6 204326 . Choke - Filter, CC 1 CF
368084-6 . Transformer - Interface 1 AD
7 204304 . Choke - Filter, CV 1 BCEF
7A 367718-6 . Reactor - Filter, CC 1 AD
8 204772 . Door 1 ABC
204772-1 . Door 1 DEF
9 203453 . Hinge - Door 2 All
10 204281-5 . Panel - Side, Left 1 ABC
204281A-5 . Panel - Side, Left 1 DEF
11 406358-4 . Resistor - Fixed, 175 W 1 BCEF
12 406358-1 . Resistor - 25 Ohm, 175 W 1 BCEF
406358-2 . Resistor - 50 Ohm, 175 W 1 AD
13 204285 . Yoke - Lifting 1 ABC
204285-1 . Yoke - Lifting 1 DEF
14 402037-33 . Grommet - Rubber 3 All
15 402037-11 . Grommet - Rubber 2 All
— 402037-15 . Grommet - Rubber 1 All
16 375426-4 . Standoff 5 CF
17 204182 . Board - Current Booster 1 CF
18 204281-4 . Panel - Side, Right 1 ABC
204281A-4 . Panel - Side, Right 1 DEF
204099 . Capacitor - Assembly 1 BC
204099-1 . Capacitor - Assembly 1 EF
19 204152 . . Bus - Capacitor 2 BCEF
20 405278-15 . . Capacitor 5 BCEF
21 204301 . . Bracket - Mtg. 2 BC
204301-1 . . Bracket - Mtg. 2 EF
22 409870 . . Washer - Insulating 4 BCEF
23 409869 . . Bushing - Insulating 4 BCEF
24 204281-6 . Box - Contactor 1 ABC
204281A-6 . Box - Contactor 1 DEF
25 404132-1 . Contactor 1 All

April 1, 1997 Revised 8-7

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PARTS LIST

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8-8 April 7, 1997 Revised

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PARTS LIST
Parts List for Figure 8-2

Item Part Description Qty Application

No Number per Code
Assy
26 406392-2 . Transformer - Control 1 All
27 W-11166-11 . Fuse - 1/2 Amp 1 All
28 204281-3 . Panel - Top 1 ABC
204281A-3 . Panel - Top 1 DEF
29 12CW-2170 . Boot - Lifting Eye 1 All
30 204036 . Label - Precautionary 1 All
31 402900 . Terminal - Quick Connect 2 ABDE
402900 . Terminal - Quick Connect 3 CF
32 368705-36 . Capacitor - W/Leads 2 ABDE
368705-36 . Capacitor - W/Leads 3 CF
33 830116 . Label - Frame Ground 1 All
34 408891 . Label - Ground 1 All
— 204698 . Label - Voltage Changeover 1 AD
— 204323 . Label - Voltage Changeover 1 BCEF
— 406484 . Label - Fuse 1 All
35 204280 . Base - Welder 1 ABC
204280-1 . Base - Welder 1 DEF
36 364042 . Resistor 1 BCEF

— Not Illustrated

April 1, 1997 Revised 8-9

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PARTS LIST

Figure 8-3 Rear Panel Group

8-10 April 7, 1997 Revised

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PARTS LIST
Parts List for Figure 8-3

Item Part Description Qty Application

No Number per Code
Assy

1 204109-2 . Panel - Amphenol, Blank 1 A

204109-4 . Panel - Amphenol, Blank 1 D
2 204109-1 . Panel - Amphenol 1 BC
204109-3 . Panel - Amphenol 1 EF
3 204184 . Board - P.C. Amphenol 1 BCEF
4 203627-7 . Breaker - Circuit, 10 A 2 BCEF
203627-7 . Breaker - Circuit, 10 A 1 AD
5 170919-2 . Plug - Hole 1 AD
6 402670 . Receptacle - 115 V. 1 All
7 366826-1 . Suppressor - Assembly 1 All
8 204281-2 . Panel - Rear 1 ABC
204281A-2 . Panel - Rear 1 DEF
9 406991 . Blade - Fan 1 BCEF
8RT-609 . Blade - Fan 1 AD
10 201016 . Shroud - Fan 1 BC
201016-1 . Shroud - Fan 1 EF
204055-8 . Shroud - Fan 1 A
369650-1 . Shroud - Fan 1 D
11 201015 . Bracket - Mtg. Fan 2 BC
201015-1 . Bracket - Mtg. Fan 2 EF
369640 . Bracket - Mtg. Fan 2 A
369640-1 . Bracket - Mtg. Fan 2 D
12 406992-1 . Motor - Fan 1 BCEF
12TW-595-1 . Motor - Fan 1 AD
13 369641 . Insulator - Mtg. 2 All
14 204302 . Heat Sink - Rectifier 1 BCEF
369639 . Heat Sink - Rectifier 1 AD
15 204303 . Heat Sink - SCR 6 BCEF
369642 . Heat Sink - SCR 6 AD
16 409639 . Rectifier - Silicon 6 BCEF
405139 . Rectifier - Silicon 6 AD
17 16DA-954-12 . Pin - Spring 6 All
18 405140-4 . Clamp - Mtg. 6 BCEF
405140-1 . Clamp - Mtg. 6 AD
19 204210 . Board - Suppressor 2 All
20 W-10931-3 . Diode - Flyback 1 BCEF
21 404044-6 . Thermostat - Fan 1 All
22 404044-3 . Thermostat - Overload 1 All
23 204575 . Shunt 1 All

April 1, 1997 Revised 8-11

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PARTS LIST
Parts List for Figure 8-3

Item Part Description Qty Application

No Number per Code
Assy
— 204038-6 . Cable - Ribbon, Amphenol 1 BCEF
— 903914-1 . Cap - Protective 1 BCEF
— 903914-2 . Cap - Protective 1 BCEF
— 403091-14 . Plug - Hole 1 All

— Not Illustrated

8-12 April 7, 1997 Revised

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DIAGRAMS

DIAGRAMS
• Note the model and part number shown on the equipment nameplate.

• Locate these numbers in the model and part number columns below.

• Use only those diagrams and instructions that are applicable.

VOLTAGE
MODEL PART CONNECTION SCHEMATIC CHANGEOVER
NO. NUMBER DIAGRAM DIAGRAM DIAGRAM

500016-2 204321 Sheet 4 & 5 204321 Sheet 6 204322

EXCEL-ARC® 8065 500016-3 204321 Sheet 7 & 8 204321 Sheet 9 204322

500016A-2 204321 Sheet 4 & 5 204321 Sheet 6 204322

500016A-3 204321 Sheet 7 & 8 204321 Sheet 9 204322

500016-1 204321 Sheet 1 & 2 204321 Sheet 3 204697

EXCEL-ARC® 750

500016A-1 204321 Sheet 1 & 2 204321 Sheet 3 204697

December 1, 1997 Revised

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 STATEMENT OF WARRANTY
®
LIMITED WARRANTY: Thermal Arc , Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated
below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal
Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential damages, such as,
but not limited to, damage or loss of 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 Thermal Arc with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strike 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. No employee, agent, or 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 USED WHICH
IN THERMAL ARC’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY
NON-AUTHORIZED PERSONS.

Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Arc’s
authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Arc delivers the
product to the authorized distributor.

Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below
beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the
authorized distributor.
ALL OTHER P-WEE, PRO-LITE
POWER SUPPLIES POWER SUPPLIES PRO-PLUS, PRO-WAVE LABOR
MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 2 YEARS 1 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR
CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOID, PUMPS, POWER SWITCHING SEMI-CONDUCTORS

ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE
MANUFACTURER. SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS.
CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS
REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS
®
Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to
send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s
risk and expense. This warranty supersedes all previous Thermal Arc warranties.
®
Thermal Arc is a Registered Trademark of Thermadyne Industries Inc.

Thermal Arc Inc. Effective January 4, 1999

Troy, Ohio 45373 830538

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