N7500 Arcair-Matic® Gouging System Operating Manual ART# A-10837_AB English Français Canadien Revision: AF Issue Date: Feb. 19, 2014 VictorTechnologies.com/Arcair ARCAIR ® Manual No.
WE APPRECIATE YOUR BUSINESS! Congratulations on receiving your new Victor® Arcair® product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network. We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Arcair-Matic® N7500 Gouging System Operating Manual Operating Manual Guide Number: 89250890 Published by: Victor Technologies, Inc. 2800 Airport Rd. Denton, TX. 76208 940-566-2000 www.victortechnologies.com/arcair U.S.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION.................................................................... 1-1 1.01 Notes, Cautions and Warnings......................................................................... 1-1 1.02 Arc Welding Hazards........................................................................................ 1-1 1.03 Principal Safety Standard Publications............................................................ 1-4 1.04 Declaration of Conformity.........................
TABLE OF CONTENTS SECTION 7: MAINTENANCE................................................................................ 7-1 7.01 Introduction..................................................................................................... 7-1 7.02 Remote Pendant ARCTIME.............................................................................. 7-2 SECTION 8: TROUBLESHOOTING GUIDE................................................................. 8-1 8.01 Arcair-Matic N7500 Gouging System..............
Figures and Tables SECTION 2: SPECIFICATIONS.............................................................................. 2-1 Table 2-1: N7500 Specifications............................................................................... 2-2 SECTION 3: SYSTEM COMPONENT DESCRIPTION..................................................... 3-1 Figure 3-1: Control Box............................................................................................ 3-1 Table 3-2: Control Box Features......................
SECTION 5: OPERATING THE N7500 SYSTEM........................................................... 5-1 Figure 5-1: Remote Pendant.................................................................................... 5-1 Table 5-2: Remote Pendant Controls........................................................................ 5-1 Figure 5-3: Torch Head Parts................................................................................... 5-2 Figure 5-4: Default Pendant Screen CC or CV mode.....................
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GENERAL INFORMATION SECTION 1: GENERAL INFORMATION N7500 1.01 Notes, Cautions and Warnings WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
N7500 GENERAL INFORMATION 8. Do not use worn, damaged, undersized, or poorly spliced cables. 9. Do not wrap cables around your body. 10. Ground the workpiece to a good electrical (earth) ground. 11. Do not touch electrode while in contact with the work (ground) circuit. 12. Use only well-maintained equipment. Repair or replace damaged parts at once. 13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output. 14.
GENERAL INFORMATION 3. Remove all flammables within 35 ft. (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. 4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. 5. Watch for fire, and keep a fire extinguisher nearby. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. 7. Do not weld on closed containers such as tanks or drums. 8.
N7500 GENERAL INFORMATION 1.03 Principal Safety Standard Publications 1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254, and 1000. U.S. Government Printing Office, Washington, DC 20402 http://www.osha.gov/pls/oshaweb/owasrch. search_form?p_doc_type=STANDARDS&p_toc_ level=1&p_keyvalue=1910 2. ANSI Z49.1 “Safety in Welding and Cutting” http://www.nssn.org/ 3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection” http://www.nssn.
GENERAL INFORMATION N7500 1.04 Declaration of Conformity Manufacturer: Victor Technologies Address: 2800 Airport Rd. Denton, TX 76208 USA Description of equipment: Gouging Equipment (GMAW, MMAW, GTAW, CAG and wirefeeders). Including, but not limited to Arcair-Matic N7500 Gouging System and associated accessories. Serial numbers are unique with each individual piece of equipment and details the description and parts that are used to manufacture a unit and date of manufacture.
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SPECIFICATIONS N7500 SECTION 2: SPECIFICATIONS 2.01 Arcair-Matic N7500 Gouging System The Arcair-Matic N7500 Gouging System adds new dimensions of flexibility and control in modern weld preparation. It’s the most advanced air carbon-arc gouging/grooving system in the world.
N7500 SPECIFICATIONS 2.02 N7500 Specifications Rated Output 400-1600 Output Current MAX.
SYSTEM COMPONENT DESCRIPTION N7500 SECTION 3: SYSTEM COMPONENT DESCRIPTION There are three (3) main components making up the Arcair-Matic N7500 Gouging System; Torch Head, Control Box, and Remote Pendant. 3.01 Control Box ART# A-10928_AC ART# A-10855_AC Figure 3-1: Control Box The Control Box controls the system’s operation before, during and after gouging. Under command of the Remote Pendant, the Control Box supplies DC power and compressed air to the Torch Head.
N7500 SYSTEM COMPONENT DESCRIPTION Item 1 2 Fitting Function Two (2) 4 amp AC power receptacles provide AC power for a travel system if needed, 110 VAC or 220 VAC. The Remote Pendant controls when these Travel System receptacles receive AC power through the Remote Pendant travel delay Power Connector circuitry. Only the AC power voltage (110V or 220V from the Input Power AC) that the Control Box is connected to will be delivered. Air Out Conn.
SYSTEM COMPONENT DESCRIPTION N7500 13 3 MAX 100 psi 6 (Rear panel assembly not shown for clarity) 8 2 9 1 (Rear panel assembly not shown for clarity) 4 7 10 12 ART# A-10851_AC 5 5 AMP 11 5 AMP 7 5 12 ART# A-10844_AB Figure 3-4: RIGHT Side of Control Box Figure 3-3: LEFT Side of Control Box 7 13 8 2 6 WARNING! AVERTISSEMENT! Protect yourself and others. Wear ear, eye, and body protection. Protégez-vous et d'autres. Portez l'oreille, l'oeil, et la protection de corps.
N7500 SYSTEM COMPONENT DESCRIPTION 3.02 Torch Head ART# A-10838_AB Figure 3-6: Torch Head The N7500 Torch Head feeds the jointed electrodes down to the work surface. The Control Box controls and signals the motor on the Torch Head to feed or retract the electrode. This action maintains arc voltage or current, set on the Remote Pendant. The Control Box (See “Figure 3-1: Control Box” on page 3-1) channels the DC current from the DC Welding Power Supply to the Torch Head using standard welding cables.
SYSTEM COMPONENT DESCRIPTION N7500 Item Fitting 1 Motor 2 Motor Cable 3 DC Power Cable Busbar This is the connection point on the Torch Head for the DC power cables from the Control Box. 4 Air Inlet Air is fed into a 3/8” NPT fitting on the Torch Head using an air supply line from the Control Box. 5 Air Plenum This housing circulates air around electrode housing before releasing in a directed spray to remove gouging slag.
N7500 SYSTEM COMPONENT DESCRIPTION 3.03 Remote Pendant Remote Pendant provides the welder/operator the ability to: • Start/stop the gouging operation, • Manually jog of the air carbon-arc electrode in the Torch Head prior to gouging, • Pre-set options to ensure proper operation of the system.
SYSTEM COMPONENT DESCRIPTION N7500 3.04 Electrodes The most important part of the N7500 System is the electrode. Since the N7500 system uses only DC power, the electrodes must be formulated and manufactured for use exclusively with Direct Current. The use of Victor Arcair Jointed Jetrods Copperclad DC Electrodes is highly recommended.
N7500 SYSTEM COMPONENT DESCRIPTION 3.05 Gouging Operation Settings “Table 3-12: Operating Parameters”” shows recommended operating amperage by electrode sizes. The travel speeds listed for each size carbon and gouge depth were derived in the laboratory using a 1500 amp Power Supply. Your results may vary depending on the arc current, voltage and other parameters you use. Electrode Diameter Inch mm 7.9 5/16 7.
SYSTEM COMPONENT DESCRIPTION N7500 3.06 Selecting the Proper Electrode Diameter CAUTION Power Supplies must be rated for 100% duty cycle at the amperage required for the size (diameter) electrode used. Contact the manufacturer of the Power Supply for paralleling procedures or with questions concerning amperage ratings and duty cycles. Your choice should be based on the depth and width of the gouge you need.
N7500 SYSTEM COMPONENT DESCRIPTION 3.09 Compressed Air Compressed air flows from an air nozzle in the N7500 Torch Head, travels parallel along the axis of the electrode, and is directed into the molten puddle. The air solenoid included in the N7500 Control Box accepts ordinary shop compressed air. An air regulator (supplied by user) should be mounted on the air line and adjacent to the Control Box. Use at least 60 psi, but not greater than 100 psi input of compressed air to the regulator.
ASSEMBLY AND INSTALLATION N7500 SECTION 4: ASSEMBLY AND INSTALLATION CAUTION Be sure to read this manual completely before trying to install or use this equipment. Call your Victor Arcair Representative or Distributor if you have any questions. 4.01 Receiving and Handling Remove all components from the boxes. Using the packing lists, check to be sure you have all parts. Inspect each part for damage. Buyers may file claims for loss or damage with the carrier.
N7500 ASSEMBLY AND INSTALLATION When asking about your equipment, be sure to give its full serial and model number(s) that appear on the nameplate of each component. The N7500 has name plates on each major component; Control Box, Torch Head, and Remote Pendant. The Torch Head and the Pendant have smaller nameplates than the Control Box. The Control Box nameplate is located on the rear plate.
ASSEMBLY AND INSTALLATION N7500 4.02 Assembly The assembly instruction steps are divided into five groups; Miscellaneous Cable/Plumbing Assemblies, Control Box, Torch Head, Remote Pendant, and Final Connections. Remote Pendant Storage is located at the end of this section. 4.03 Miscellaneous Cable/Plumbing Assemblies Cable assemblies required to operate the N7500 system come in various lengths and must be specified by the end user to meet their specific needs.
N7500 ASSEMBLY AND INSTALLATION 4.04 Control Box Installation Determine where the Control Box should be located in relationship to where the gouging will take place. It is not recommended to carry the Control Box on any travel system other than the Victor Arcair Titan® Machine Carriage due to the added weight of the Control Box and the weight of the power cables coming from the DC Power Supply. The Control Box can be secured to a stationary surface with the mounting brackets on both sides.
ASSEMBLY AND INSTALLATION N7500 WARNING Confirm the DC Power Supply is OFF before beginning the next step. 5. Connect the positive (+) Power Supply cable(s) of the DC Power Supply to the busbar terminal on the back side of the Control Box labeled “POWER SUPPLY IN”. This connection must be wrench tight to avoid over heating of the connection. Refer to "Table 3-13: Power Cable Requirements" on page 3-10 in this manual for proper amount and size Power Supply cabling that you plan to use.
N7500 ASSEMBLY AND INSTALLATION Power Supply Control Connection Chart Brand Lincoln N7500 Control Box Power Supply Comm.
ASSEMBLY AND INSTALLATION N7500 4.05 Torch Head Installation Make connections from Control Box to the Torch Head. See "Figure 4-11: Assembly Stage 2".
N7500 ASSEMBLY AND INSTALLATION 4.06 Remote Pendant Installation Make the following connections from the Pendant to the Control Box. See "Figure 4-12: Assembly Stage 3".
ASSEMBLY AND INSTALLATION N7500 4.07 Remote Pendant Storage Use safe storage practices when storing the Remote Pendant and cable. When not in use, mount the Remote Pendant to the top of the Control Box as shown below.
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SYSTEM OPERATION N7500 SECTION 5: OPERATING THE N7500 SYSTEM 5.01 Remote Pendant Operation 4 2 11 7 6 1 5 3 10 9 8 12 Item No. 1 2 3 4 Feature Mode-indicator Display S TA RT Start Button S T OP Stop Button Rough (Machining) 5 ART# A-10856_AB Figure 5-1: Remote Pendant Function Digital display of current mode setting/adjustment value/rate.
N7500 SYSTEM OPERATION 5.02 Position Torch Head 1. Position the Torch Head above the work piece you want to start gouging. 2. Using the Angle Gauge supplied with the N7500, adjust the Torch Head to the work piece. The angle gauge sets the torch angle, electrode stick-out and aligns the air nozzle. 3. The air should flow between the electrode and the work piece. Charts, graphs and other data in this manual are based on a 45° electrode angle, but you can use electrode angles from 45° to 60°.
SYSTEM OPERATION N7500 5.04 Remote Pendant Programming The first (default) menu setting option is “Power Mode”, see “Figure 5-4: Default Pendant Screen CC or CV mode”. This setting must match the DC Power Supply being used. 1. Select the CC or CV mode setting. To set the CC or CV mode; a. Press the “OK” OK b. Rotate the Rotary button on the Pendant. Once pressed, the CC or CV letters will begin blinking. Dial to switch between CC or CV modes.
N7500 SYSTEM OPERATION Travel Speed - Travel Speed output provides a starting point to set the travel speed to obtain the gouge depth selected. Adjust by resetting parameter variables accordingly once the gouging process is started as needed. Remember that the slower the travel speed the deeper the gouge and vice versa. Electrode Diameter Gouge Depth Current Travel speed/min INCH MM INCH MM AMPS INCH MM 5/16 7.9 1/8 3.2 400 65.0 1651 5/16 7.9 3/16 4.8 400 45.0 1143 5/16 7.
SYSTEM OPERATION N7500 Menu Setting Power Mode CV Parameter Guide 850A Current ART# A-10824_AC Figure 5-6: Parameter Guide Screen (using CV mode) Back Unit Diameter Depth Back 500A Current Travel Speed 17.5 Inch/Min Inch 3/8 9/16 ART# A-10841_AB ART# A-10842_AB Figure 5-7: Parameter Guide Setting Examples 4. Press the “OK” OK button to exit the Parameter Guide choices. 5. Set the DC Power Supply to obtain the recommended current as noted in the Parameter Guide.
N7500 SYSTEM OPERATION 9. Use the up or down “Mode Selector” Delay Screen.” or buttons to scroll to “Travel Delay.” See “Figure 5-9: Travel OK Press the “OK” button and rotate the potentiometer dial length between 0 and 6.0 seconds. Press the “OK” OK to adjust the time delay for any time button to set the Travel Delay time setting. Menu Setting Parameter Guide 42.
SYSTEM OPERATION N7500 Set the “No Current Detect” option as needed. To change the setting press the “OK” the Potentiometer OK button and using knob select the setting that meets your needs. Menu Setting 0.2 Sec NoCurrent Detect Nor mal Menu Setting 0.2 Sec NoCurrent Detect Special Menu Setting 0.2 Sec NoCurrent Detect OFF ART# A-10823_AB ART# A-10827_AB ART# A-10822_AB Figure 5-11: No Current Detect screens Press the “OK” OK button again to retain the setting chosen. 11.
N7500 SYSTEM OPERATION Gouging operations can be stopped using the Remote Pendant controls. STOP 15. Press the “STOP” button and the electrode will retract, compressed air stops flowing through to the Torch Head, and the DC power supply contactor opens. If you press the “Start” tings. STA RT button again the N7500 will resume operations again in the same mode setNOTE LOW VOLTAGE SHUTDOWN can occur when the DC voltage supplied to the N7500 System drop below 28 volts.
SYSTEM USES N7500 SECTION 6: N7500 SYSTEM USES 6.01 SYSTEM USES This section briefly describes some uses for the N7500 System. If you have any questions concerning a specific application for this system contact Victor Technologies Technical Services Department at 800-426-1888 or 940566-2000. GOUGING NON-FERROUS METALS The N7500 System can be connected to DC Straight Polarity (DCEN) to gouge non-ferrous metals, such as nickel, copper alloys, etc.
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MAINTENANCE N7500 SECTION 7: MAINTENANCE 7.01 Introduction If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced, qualified person only. Any electrical work must be performed by an electrician or other person properly trained in servicing electrical equipment. Do not permit untrained persons to inspect, clean or repair this equipment.
N7500 MAINTENANCE The following checklist can be used as a guide for routine maintenance. • • • • • • • • • Check warning labels for readability. Check sheet metal panels, plates, and covers on the Control Box, Remote Pendant, and Torch Head. All screws, fasteners, and connectors should be firmly secured. Heavily corroded or damaged panels, damaged fasteners or connectors should be replaced. Check all wiring and hoses to the Control Box, Remote Pendant, and Torch Head.
TROUBLESHOOTING GUIDE N7500 SECTION 8: TROUBLESHOOTING GUIDE 8.01 Arcair-Matic N7500 Gouging System In all troubleshooting cases turn power OFF before performing work on the system unless otherwise directed to do so. CAUTION Use appropriate Lock OUT and tag OUT measures when working with electrical equipment or electrical components. 8.02 N7500 General General Problem Possible Cause Torch Head Low air pressure at nozzle nozzle melting Possible Remedy Increase air regulator pressure.
N7500 TROUBLESHOOTING GUIDE General Problem Possible Cause Possible Remedy N7500 starts DC voltage has dropped below 28 volts. Determine cause operation but Low voltage shutdown of voltage drop, take corrective action, and restart the Torch Head system. stops Electrical Arc at Power supConfirm proper wiring, check for damage to components, ply, Control Improper wiring connections repair or replace. Box or Torch Head Buss Bar Table 8-1: General Troubleshooting 8.
TROUBLESHOOTING GUIDE N7500 Torch Head Possible Cause Possible Remedy O-rings on Air Plenum supply tube Check air tube o-rings, replace if necessary. worn Air leaking Top assembly of Air Plenum Housfrom Air Ple- ing not fastened securely to lower Tighten screws on Plenum. num Housing Air Plenum Housing Top assembly of Air Plenum HousReplace. ing is distorted from excessive heat Busbar corrosion, arcing, overheating, Cable connections are NOT wrench Tighten busbar leads connection wrench tight.
N7500 TROUBLESHOOTING GUIDE 8.04 Remote Pendant PENDANT CABLE PIN COLOR LOCATION A WHT (#1) PIN A B BK (#1) PIN B C BK (#2) PIN C D NOT USED PIN D E WHT (no #) PIN E F WHT (#2) PIN F G NOT USED PIN G Table 8-4: Pendant Cable Pin Identification Remote Pendant Problem Remote Pendant has no power No Remote Pendant display Possible Cause Pendant Cable not attached Absence of appropriate power Tripped ON/OFF Switch circuit breaker Possible Remedy Attach Pendant Cable. Check power to Control Box.
TROUBLESHOOTING GUIDE N7500 8.05 Control Box Control Box Problem No AC power to Control Box No DC “+” power to Control Box No output from Travel System Power Connection on Control Box No air flow through Control Box when system is activated Possible Cause Possible Remedy 110/220VAC power to Control Box Check connections and turn power ON. See "Table NOT turned ON 3-2: Control Box Features" on page 3-2. Disconnected AC Power Cable Connect AC Power cable Repair/replace cable. See "9.
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REPLACEMENT PARTS N7500 SECTION 9: REPLACEMENT PARTS 9.01 Control Box Replacement Parts 12 2 6 4 5 13 7 17 3 MAX 100 psi 8 17 14 9 10 15 11 SU POW PP ER LY OU T 1 P SU OW PP ER LY IN 16 ART# A-10846_AC Figure 9-1: Control Box PARTS Item No.
N7500 REPLACEMENT PARTS 9.
REPLACEMENT PARTS N7500 9.03 Remote Pendant Replacement Parts 1 2 ART# A-10835_AB Figure 9-5: Remote Pendant PARTS Item No.
N7500 REPLACEMENT PARTS SYSTEM CABLES 9.04 110V Power Supply Cable Assembly Part No. 96-130-304 Description 10 ft. (3m) length Application For the Control Box Power Supply IN 9.05 220V Power Supply Cable Assembly Part No. 96-130-305 Description 10 ft. (3m) length Application For the Control Box Power Supply IN 9.06 Pendant Cable Assembly Part No. 96-170-069 96-170-070 96-170-071 96-170-072 Description 14 inches (0.36m) length 15 ft. (5m) length 25 ft. (8m) length 50 ft.
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N7500 APPENDIX 10.
APPENDIX Manual 89250890 N7500 A-3 APPENDIX
N7500 APPENDIX PUBLICATION HISTORY Manual No. 89250890 Cover Date Jan, 2012 Mar, 2012 April, 2012 June, 2012 Aug, 2013 Feb. 2014 Rev Change(s) AA First issue AB Added UL logo, changed duty cycle rating from 1600A to 1500A, changed Motor Cable from 5 pin to 6 pin and Power Supply Communication cable from 7 pin to 6 pin. AC Updated wiring pin colors in Table 8-2: Torch Head Motor 6 PIN Wire Schedule, changed duty cycle rating from 1500A to 1600A, converted all images to greyscale.
Statement of Warranty Effective 08/01/2011 This warranty supersedes all previous Victor Technologies warranties. LIMITED WARRANTY: Victor Technologies warrants that its products will be free of defects in workmanship or material.
THE AMERICAS Denton, TX USA U.S.
