ESAB N7500 Gouging System User manual

Brand: ESAB

Model: N7500 Gouging System

Category: Welding System

Type: User manual

This manual is also suitable for

N7500 Arcair-Matic® Gouging System

ART# A-10837_AC

English

Revision: AF Issue Date: 06.15.2016 Manual No.: 89250890

Arcair-Matic

Gouging System

N7500

Operating Man-

ual

www.esab.com/arcair

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Arcair

product. We are proud to have you as our customer and will strive to provide you with

the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get

the job done.

For more than 60 years Arcair has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

ARCAIR, an ESAB Brand is a manufacturer of cutting & metal removal products. We distinguish ourselves from our competition

through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, eciency and welding performance, enabling you to excel in your craft. We design products

with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its

safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety Precautions.

To locate your nearest distributor or service agency, visit us on the web at www.esab.eu.

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:

ESAB Group Inc. 940-566-2000

2800 Airport Rd. www.esab.com/arcair

Denton, TX. 76208 U.S. Customer Care: 800-426-1888

International Customer Care: 905-827-9777

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any

error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: 01.01.2012

Revision Date: 06.15.2016

Patent Pending

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Part Number Serial Number

Control Box: _______________________ _________________________

Pendant: _______________________ _________________________

Torch Head: _______________________ _________________________

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, RsRPrecautions and Safe Practices for Arc Welding, Cutting, and

Gouging,RsR Form 52-529. Do NOT permit untrained persons to install, operate, or main-

tain this equipment. Do NOT attempt to install or operate this equipment until you have

read and fully understand these instructions. If you do not fully understand these instruc-

tions, contact your supplier for further information. Be sure to read the Safety Precautions

before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when

installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunc-

tioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced

immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service

advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall

have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by

anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Declaration of Conformity

Manufacturer: Victor Technologies

Address: 2800 Airport Rd.

Denton, TX 76208

USA

Description of equipment: Gouging Equipment (GMAW, MMAW, GTAW, CAG and wirefeeders). Including, but not limited to Arcair-Matic

N7500 Gouging System and associated accessories.

Serial numbers are unique with each individual piece of equipment and details the description and parts that are used to manufacture a

unit and date of manufacture.

The equipment conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (Directive 73/23/EU, as recently changed

in Directive 93/68/EU and to the National legislation for the enforcement of the Directive.

National Standard and Technical Speciﬁcations

The product is designed and manufactured to a number of standards and technical requirements among them are:

• AS1966-1 applicable to welding equipment and associated accessories.

• AS/NZS 3652-(EMC Directive EN50199) applicable to arc welding equipment - generic emissions and regulations.

• EN60974-1 applicable to welding equipment and associated accessories.

• AS60974.1 applicable to welding equipment and associated accessories.

• IEC 60974-1 applicable to welding equipment and associated accessories

• 2002/95/EC RoHS directive

Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manufacturing process,

to ensure the product is safe and performs as speciﬁed. Rigorous testing is incorporated into the manufacturing process to ensure the

manufactured product meets or exceeds all design speciﬁcations.

Arcair has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and

world class quality for years and will continue to achieve excellence.

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ..................................................................................................................... 1-1

1.01 Notes, Cautions and Warnings ............................................................................................................. 1-1

1.02 Arc Welding Hazards ........................................................................................................................... 1-1

1.03 Principal Safety Standard Publications ................................................................................................ 1-4

1.04 Declaration of Conformity ................................................................................................................... 1-5

SECTION 2:

SPECIFICATIONS ................................................................................................................................. 2-1

2.01 Arcair-Matic N7500 Gouging System ................................................................................................... 2-1

2.02 N7500 Specications ........................................................................................................................... 2-2

SECTION 3:

SYSTEM COMPONENT DESCRIPTION ...................................................................................................... 3-1

3.01 Control Box .......................................................................................................................................... 3-1

3.02 Torch Head .......................................................................................................................................... 3-4

3.03 Remote Pendant ................................................................................................................................. 3-6

3.04 Electrodes ........................................................................................................................................... 3-7

3.05 Gouging Operation Settings ................................................................................................................ 3-8

3.06 Selecting the Proper Electrode Diameter ............................................................................................. 3-9

3.07 Keeping Electrodes Dry ....................................................................................................................... 3-9

3.08 Secondary Power Cables (Welding Leads) ........................................................................................... 3-9

3.09 Compressed Air ................................................................................................................................. 3-10

3.10 Main Air Line ..................................................................................................................................... 3-10

SECTION 4:

ASSEMBLY AND INSTALLATION ............................................................................................................. 4-1

4.01 Receiving and Handling ...................................................................................................................... 4-1

4.02 Assembly ............................................................................................................................................ 4-3

4.03 Miscellaneous Cable/Plumbing Assemblies......................................................................................... 4-3

4.04 Control Box Installation ....................................................................................................................... 4-4

4.05 Torch Head Installation ........................................................................................................................ 4-7

4.06 Remote Pendant Installation ............................................................................................................... 4-8

4.07 Remote Pendant Storage .................................................................................................................... 4-9

SECTION 5: OPERATING THE N7500 SYSTEM .................................................................................................... 5-1

5.01 Remote Pendant Operation ................................................................................................................. 5-1

5.02 Position Torch Head ............................................................................................................................. 5-2

5.03 Insert the Electrode ............................................................................................................................. 5-2

5.04 Remote Pendant Programming ........................................................................................................... 5-3

TABLE OF CONTENTS

SECTION 6:

N7500 SYSTEM USES ........................................................................................................................... 6-1

6.01 SYSTEM USES ...................................................................................................................................... 6-1

6.02 Zero Force Rough Machining ............................................................................................................... 6-1

SECTION 7:

MAINTENANCE ................................................................................................................................... 7-1

7.01 Introduction ........................................................................................................................................ 7-1

7.02 Remote Pendant ARCTIME .................................................................................................................. 7-2

SECTION 8:

TROUBLESHOOTING GUIDE .................................................................................................................. 8-1

8.01 Arcair-Matic N7500 Gouging System ................................................................................................... 8-1

8.02 N7500 General .................................................................................................................................... 8-1

8.03 Torch Head .......................................................................................................................................... 8-2

8.04 Remote Pendant ................................................................................................................................. 8-4

8.05 Control Box .......................................................................................................................................... 8-5

SECTION 9:

REPLACEMENT PARTS ......................................................................................................................... 9-1

9.01 Control Box Replacement Parts ........................................................................................................... 9-1

9.02 Torch Head Replacement Parts ............................................................................................................ 9-2

9.03 Remote Pendant Replacement Parts ................................................................................................... 9-3

9.04 110V Power Supply Cable Assembly .................................................................................................... 9-4

9.05 220V Power Supply Cable Assembly .................................................................................................... 9-4

9.06 Pendant Cable Assembly ..................................................................................................................... 9-4

9.07 Motor Cable Assembly ......................................................................................................................... 9-4

9.08 Power Supply Communication Cable Assembly ................................................................................... 9-4

9.09 Power Cables ....................................................................................................................................... 9-4

9.10 Air Hose Assembly ............................................................................................................................... 9-4

SECTION 10:

APPENDIX ......................................................................................................................................... A-1

10.01 Wiring Schematic ................................................................................................................................. A-2

PUBLICATION HISTORY ................................................................................................................................. A-4

Statement of Warranty .................................................................................................................................. 1

FIGURES AND TABLES

SECTION 2:

SPECIFICATIONS ................................................................................................................................. 2-1

Table 2-1: N7500 Specications ..................................................................................................................... 2-2

SECTION 3:

SYSTEM COMPONENT DESCRIPTION ...................................................................................................... 3-1

Figure 3-1: Control Box .................................................................................................................................. 3-1

Table 3-2: Control Box Features ...................................................................................................................... 3-2

Figure 3-3: LEFT Side of Control Box ............................................................................................................... 3-3

Figure 3-4: RIGHT Side of Control Box ............................................................................................................ 3-3

Figure 3-5: BACK of Control Box ..................................................................................................................... 3-3

Figure 3-6: Torch Head ................................................................................................................................... 3-4

Figure 3-7: Torch Head Components .............................................................................................................. 3-4

Table 3-8: Torch Head Features....................................................................................................................... 3-5

Figure 3-9: Remote Pendant .......................................................................................................................... 3-6

Table 3-10: Remote Pendant Controls ............................................................................................................ 3-6

Chart 3-11: Electrode Selection ..................................................................................................................... 3-7

Table 3-12: Operating Parameters ................................................................................................................. 3-8

Table 3-13: Power Cable Requirements .......................................................................................................... 3-9

Table 3-14: Compressed Air Input Requirements ......................................................................................... 3-10

SECTION 4:

ASSEMBLY AND INSTALLATION ............................................................................................................. 4-1

Figure 4-1: Control Box ................................................................................................................................. 4-1

Figure 4-2: Torch Head ................................................................................................................................... 4-1

Figure 4-3: Remote Pendant .......................................................................................................................... 4-1

Figure 4-4: Control Box Nameplate ................................................................................................................ 4-2

Figure 4-5: Remote Pendant and Torch Head Nameplates.............................................................................. 4-2

Figure 4-6: Nameplate Locations ................................................................................................................... 4-2

Table 4-7: Cable Identication ....................................................................................................................... 4-3

Figure 4-8: Assembly Stage 1 ......................................................................................................................... 4-4

Figure 4-9: Power Supply Comm. Cable Pin Conguration ............................................................................. 4-5

Table 4-10: Standard Wiring Connections ...................................................................................................... 4-6

Figure 4-11: Assembly Stage 2 ....................................................................................................................... 4-7

Figure 4-12: Assembly Stage 3 ....................................................................................................................... 4-8

Figure 4-13: Pendant Mounting ..................................................................................................................... 4-9

Figure 4-14: Pendant Mounted ...................................................................................................................... 4-9

SECTION 5: OPERATING THE N7500 SYSTEM .................................................................................................... 5-1

Figure 5-1: Remote Pendant .......................................................................................................................... 5-1

Table 5-2: Remote Pendant Controls .............................................................................................................. 5-1

Figure 5-3: Torch Head Parts .......................................................................................................................... 5-2

Figure 5-4: Default Pendant Screen CC or CV mode ........................................................................................ 5-3

Table 5-5: Parameter Table ............................................................................................................................ 5-4

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

Figure 5-7: Parameter Guide Setting Examples .............................................................................................. 5-5

Figure 5-8: Current Setting Example .............................................................................................................. 5-5

Figure 5-9: Travel Delay Screen ...................................................................................................................... 5-6

Table 5-10: Travel Delay Setting ..................................................................................................................... 5-6

Figure 5-11: No Current Detect screens .......................................................................................................... 5-7

SECTION 6:

N7500 SYSTEM USES ........................................................................................................................... 6-1

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

SECTION 7:

MAINTENANCE ................................................................................................................................... 7-1

Figure 7-1: Maintenance ................................................................................................................................ 7-1

Figure 7-2: Arctime Screen ............................................................................................................................. 7-2

SECTION 8:

TROUBLESHOOTING GUIDE .................................................................................................................. 8-1

Table 8-1: General Troubleshooting ............................................................................................................... 8-2

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

Table 8-3: Torch Head Troubleshooting .......................................................................................................... 8-3

Table 8-4: Pendant Cable Pin Identication ................................................................................................... 8-4

Table 8-5: Remote Pendant Troubleshooting ................................................................................................. 8-4

Table 8-6: Control Box Troubleshooting .......................................................................................................... 8-5

Table 8-7: AC Power Supply Cable Pin Identication ...................................................................................... 8-5

SECTION 9:

REPLACEMENT PARTS ......................................................................................................................... 9-1

Figure 9-1: Control Box PARTS ........................................................................................................................ 9-1

Table 9-2: Control Box PARTS ......................................................................................................................... 9-1

Figure 9-3: Torch Head PARTS ......................................................................................................................... 9-2

Table 9-4: Torch Head PARTS .......................................................................................................................... 9-2

Figure 9-5: Remote Pendant PARTS ............................................................................................................... 9-3

Table 9-6: Remote Pendant PARTS ................................................................................................................. 9-3

SECTION 10:

APPENDIX ......................................................................................................................................... A-1

Figure 10-1: N7500 Wiring Schematic ............................................................................................................A-3

This Page Intentionally Blank

GENERAL INFORMATION N7500

89250890 1-1 GENERAL INFORMATION

SECTION 1: GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL

CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING

OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly

observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training

before using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment.

Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to

what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERA-

TION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

WARNING

SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not properly installed, used, and maintained. Misuse of this

equipment and other unsafe practices can be hazardous. The operator, supervisor, and helper must read and understand the following safety

warnings and instructions before installing or using any welding or cutting equipment, and be aware of the dangers of the welding or cutting

process. Training and proper supervision are important for a safe work place. Keep these instructions for future use. Additional recommended

safety and operating information is referenced in each section.

5. Properly install and ground this equipment according to its Owner’s

Manual and national, state, and local codes.

6. Turn o all equipment when not in use. Disconnect power to equip-

ment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to

cool it or lay it down on the ground or the work surface. Do not touch

holders connected to two welding machines at the same time or touch

other people with the holder or electrode.

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 conned spaces or damp locations, do not use a welder with AC

output unless it is equipped with a voltage reducer. Use equipment

with DC output.

14. Wear a safety harness to prevent falling if working above oor level.

15. Keep all panels and covers securely in place.

1.02 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is electrically

live whenever the output is on. The input power circuit and

machine internal circuits are also live when power is on. In

semi-automatic or automatic wire welding, the wire, wire reel,

drive roll housing, and all metal parts touching the welding

wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or

covers.

4. Disconnect input power or stop engine before installing or servicing

this equipment. Lock input power disconnect switch open, or remove

line fuses so power cannot be turned on accidentally.

N7500 GENERAL INFORMATION

GENERAL INFORMATION 1-2 89250890

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing.

Arc rays from the welding process produce intense heat and

strong ultraviolet rays that can burn eyes and skin. Noise from

some processes can damage hearing.

1. Wear a welding helmet tted with a proper shade of lter (see ANSI

Z49.1 listed in Safety Standards) to protect your face and eyes when

welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from ash and

glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, ame-resistant material

(wool and leather) and foot protection.

5. Use approved ear plugs or ear mus if noise level is high.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes

and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s

instruction for metals, consumables, coatings, and cleaners.

5. Work in a conned space only if it is well ventilated, or while wear-

ing an air-supplied respirator. Shielding gases used for welding can

displace air causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying opera-

tions. The heat and rays of the arc can react with vapors to form highly

toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium

plated steel, unless the coating is removed from the weld area, the

area is well ventilated, and if necessary, while wearing an air-supplied

respirator. The coatings and any metals containing these elements can

give o toxic fumes if welded.

WARNING

WELDING can cause re or explosion.

Sparks and spatter y o from the welding arc. The ying

sparks and hot metal, weld spatter, hot workpiece, and hot

equipment can cause res and burns. Accidental contact of

electrode or welding wire to metal objects can cause sparks,

overheating, or re.

1. Protect yourself and others from ying sparks and hot metal.

2. Do not weld where ying sparks can strike ammable material.

3. Remove all ammables 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 re, and keep a re extinguisher nearby.

6. Be aware that welding on a ceiling, oor, bulkhead, or partition can

cause re on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical

to prevent welding current from traveling long, possibly unknown

paths and causing electric shock and re hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut o welding wire at contact

tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause ying metal. As welds cool, they

can throw o slag.

1. Wear approved face shield or safety goggles. Side shields recom-

mended.

2. Wear proper body protection to protect skin.

GENERAL INFORMATION N7500

89250890 1-3 GENERAL INFORMATION

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut ngers and hands and

catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualied people remove guards or covers for maintenance

and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative

(-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is nished

and before starting engine.

NOTE

The following is a quotation from the General Conclusions Section of the

U.S. Congress, Oce of Technology Assessment, Biological Eects of Power

Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63

(Washington, DC: U.S. Government Printing Oce, May 1989): RsR...there

is now a very large volume of scientic ndings based on experiments at

the cellular level and from studies with animals and people which clearly

establish that low frequency magnetic elds interact with, and produce

changes in, biological systems. While most of this work is of very high

quality, the results are complex. Current scientic 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 denite conclusions

about questions of possible risk or to oer clear science-based advice on

strategies to minimize or avoid potential risks.RsR

To reduce magnetic elds in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as

practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor

for complete information.

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. Govern-

ment Printing Oce, Washington, DC 20402

2. ANSI Z49.1 RsRSafety in Welding and CuttingRsR

3. ANSI Z87.1 RsRPractice for Occupational and Educational Eye

and Face ProtectionRsR

4. ANSI Z88.2. RsRStandard Practice for Respiratory Protection.

RsR American National Standards Institute, 1430 Broadway,

New York, NY 10018

5. AWS F4.1. RsRRecommended Safe Practices for Welding and

Cutting ContainersRsR

6. AWS C5.3. RsRRecommended Practices for Air Carbon-Arc

Gouging and Cutting.RsR The American Welding Society, 550

NW Lejeune Rd., P.O. Box 351040, Miami, FL 33135

7. NFPA 51B. RsRFire Prevention in Cutting and Welding Pro-

cesses.RsR

8. NFPA-7. RsRNational Electrical CodeRsR National Fire Protection

Association, Battery Park, Quincy, MA 02269

9. CSA W117.2. RsRSafety in Welding, Cutting and Allied Pro-

cessesRsR. Canadian Standards Association, 178 Rexdale Blvd.,

Rexdale, Ontario, Canada M9W 1R3

10. ANSI Z535 Safety Alerting Standards

11. Refer to your local codes.

N7500 GENERAL INFORMATION

GENERAL INFORMATION 1-4 89250890

This Page Intentionally Blank

89250890 2-1 SPECIFICATIONS

SPECIFICATIONS N7500

2.01 Arcair-Matic N7500 Gouging System

The Arcair-Matic N7500 Gouging System adds new dimensions of exibility and control in modern weld preparation. It’s the most advanced air

carbon-arc gouging/grooving system in the world. The N7500 System assures improved productivity in the following ways:

• Higher yields of optimum quality end product

• Dramatic reductions of man-hours and process cost

• Expanded areas of applicability

FEATURES

Remote Pendant providing complete control of the gouging operation where it needs to be .... in the

welder/operator hands.

All functions from determining gouge parameters, start/stop function, travel delay, and the capability to manually feed or retract the electrode in

the Torch Head. The welder/operator can view the amperage and voltage during gouging sequence easily while maintaining the electrode on the

weld seam that’s being back gouged.

Remote Pendant incorporates an Emergency Stop Switch that takes precedence over any other signals and will drop out the engaged contactor in

the power supply stopping the gouge current to the carbon rod.

A single electrode contact shoe assembly accepts the entire range of Arcair gouging electrodes from

5/16RsR (7.9 mm) through 3/4RsR (19.1 mm).

The N7500 Torch Head eliminates the necessity of stocking or changing contact shoe assemblies when changing electrode sizes.

The gouging system uses the Power Supply RsRcontactorRsR to ensure that the gouging current is

only present when the welder/operator presses the RsRstartRsR button on the Remote Pendant.

System is easily connected to the various power supplies available in the industry.

Ensures conformity to pre-determined, pre-selected groove depth and width specications.

Welder/Operator can use the RsRParameter GuideRsR option on the Remote Pendant to view the recommended amperage and travel speed

once the electrode and gouge depth is chosen.

A unique RsRtravel delayRsR function assures excellent groove geometry at the very beginning of

the groove.

This function eliminates a sloped groove at the beginning of the gouge, eliminating the need for a starting pad.

No current detect and low voltage functions shut down the system when these conditions are sensed.

These functions ensure optimum groove quality and prevent damage to the equipment and work.

Redesigned Torch Head

Redesigned Torch Head with extended front end to give the welder/operator better range of viewing during the gouging operation ensuring

the electrode is maintained in the correct position to the weld seam.

SECTION 2: SPECIFICATIONS

SPECIFICATIONS 2-2 89250890

N7500 SPECIFICATIONS

2.02 N7500 Specications

Rated Output

Output Current

400-1600

Duty Cycle

MAX. 1600A/42V @ 100%

Open Circuit Voltage Minimum of 60VDC

Rated Input

Rated Input Voltage 110V - 220V

Rated Input Amperage

Input Frequency 50/60 Hz

Control Box Controls

5A Circuit Breaker ON/OFF Switch w/reset ON/OFF Switch w/reset

110V/220V Control Box Power Input 3-Pin Socket

110V Auxiliary Outlet 4A, 110V

220V Auxiliary Outlet 4A, 220V

(2) 5A Circuit Breaker

1 o push-button circuit breaker for the 110V outlet

1 o push-button circuit breaker for the 220V outlet

Circuit Interface to Remote Pendant 7-Pin Socket

Circuit Interface to Torch Head 6-Pin Socket

Circuit Interface to Power Supply 6-Pin Socket

Signal Interface to Work Piece 1-Pin Socket

Table 2-1: N7500 Specications

N7500 SYSTEM

The N7500 System produces in a single pass uniform RsRURsR or RsRJRsR grooves of various depths up to 1-1/8RsR (28.6 mm). Two or more passes

produce grooves of greater depth. Through continuous control of arc voltage or amperage and a constant travel speed, the groove is held within

0.025RsR (0.635 mm) target depth. Arcair Jointed Jetrods

Electrodes, with tapered male and female ends, make it possible to produce grooves

of unlimited length.

Control elements and circuitry for the N7500 System are housed in a Control Box and a splash-proof Pendant. Gouging operations are managed

remotely using the Remote Pendant with a multi-function LCD display and touch pad controls.

Groove depth and width are controlled in two ways:

• By changing the travel carriage’s forward speed or by changing the work piece rotational speed.

• By changing the electrode’s diameter and increasing or decreasing amperage.

NOTE

Remote Pendant is NOT submersible.

This manual has been structured to provide the user with all the information required for assembly, operation and troubleshooting of the N7500

System. Illustrations, charts and other supporting data are provided to bridge the gap between theory and practice.

In addition, the N7500 System can be integrated with any mechanized travel system that provides forward travel over a steel plate while in the

at, vertical, or over-head positions. The N7500 Torch Head can also be mounted in a stationary position for work on rotating shafts, round steel, or

a vessel. In a stationary set up the work-piece rotates in a

counter-clockwise direction

and the Torch Head is generally located at the work-piece’s

4 o’clock position.

Refer to Form No. 89-250-894 for further clarication. For additional information, contact your local Arcair Distributor.

89250890 3-1 SYSTEM COMPONENT DESCRIPTION

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. The unit has a power cord for required AC voltage, clamping xtures, and handles for secure lifting.

See RsRTable 3-2: Control Box FeaturesRsR for each of the Control Box’s connectors/ttings and the function of each component.

Item Fitting Function

Travel System Power

Connector

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 receptacles receive AC power through

the Remote Pendant travel delay circuitry. Only the AC power voltage (110V or 220V

from the Input Power AC) that the Control Box is connected to will be delivered.

2 Air Out Conn.

Delivers compressed shop air to the Torch Head when the START RsRStartRsR button is

pressed on the Remote Pendant.

START

SYSTEM COMPONENT DESCRIPTION 3-2 89250890

N7500 SYSTEM COMPONENT DESCRIPTION

Item Fitting Function

Connector to Torch

Head Electrode Motor

Delivers the signal from the Control Box to the Torch Head to either feed or retract the

electrode to maintain the preset arc voltage.

Remote Pendant Con-

nector

Links the Remote Pendant to the Control Box to initiate start/stop of the gouging operation.

5 Circuit Breaker w/reset

Circuit breaker reset push button for 110 VAC and 220 VAC AC Travel System Power Connector

receptacles.

6 ON/OFF switch Control Box ON/OFF control switch with built in 5 amp circuit breaker and reset.

Input and Output DC

Power Conn.

Output and Input DC (+) positive power buss connections.

8 Air In Conn. This port accepts compressed shop air to the Control Box.

Power Supply Con-

nector

Links the Control Box to the Power Supply. On demand from the Remote Pendant the

internal contactor of the Power Supply can be closed and opened to deliver the current to

the Torch Head.

10 Input Power (AC) Delivers AC voltage to the Control Box from a standard wall receptacle.

11 Signal Wire Conn.

Allows the Control Box to detect open circuit voltage when the Power Supply contactor is

closed.

Control Box Hold Down

Fixture

Hold down xtures located on both sides of the Control Box to allow fastening to a base.

Remote Pendant

Cradle

Secure holding xture for Remote Pendant.

Table 3-2: Control Box Features

NOTE

The 110V and 220V power supply receptacles may be used to run any device that has the same line-voltage requirements and that require

RsRONOFFRsR or RsRStart-StopRsR control. However, any such device must be rated with a maximum current draw of 4 amperes.

89250890 3-3 SYSTEM COMPONENT DESCRIPTION

SYSTEM COMPONENT DESCRIPTION N7500

MAX 100 psi

ART# A-10851_AC

(Rear panel assembly

not shown for clarity)

Figure 3-3: LEFT Side of Control Box

ART# A-10844_AB

(Rear panel assembly

not shown for clarity)

5 AMP

Figure 3-4: RIGHT Side of Control Box

WARNING! AVERTISSEMENT!

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

damage to any or all components. Use only with compressed air. See manual.

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

ventilation. Keep your head out of the smoke.

Protect yourself and others. Wear ear, eye, and body protection.

Noise can damage hearing.

Electric shock can cause injury or death. Disconnect power before servicing.

Arc rays, hot slag, and sparks can injure eyes and burn skin.

Welding sparks can cause res and explosions.

Assurez la bonne terre de l'alimentation d'énergie à l'objet. La terre pauvre peut endommager

quelques des ou tous composants. Employez seulement avec l'air comprimé. Voir le manuel.

La fumée, les émanations et les gaz peuvent être dangereux pour votre santé.

Employez à ventilation proportionnée. Gardez votre tête hors de la fumée.

Protégez-vous et d'autres. Portez l'oreille, l'oeil, et la protection de corps.

Le bruit peut endommager l’ouïe.

Un choc électrique peut causer des blessures ou la mort. Déconnectez la puissance

avant l'entretien.

L les rayons de l’arc,

es scories et les étincelles chauds peuvent blesser les yeux et brûler la peau.

Les étincelles de soudage peuvent causer des incendies et des explosions.

POWER

SUPPLY IN

POWER

SUPPLY OUT

ART# A-10853_AB

(rear cover plate not shown for clarity)

Figure 3-5: BACK of Control Box

SYSTEM COMPONENT DESCRIPTION 3-4 89250890

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 RsRFigure 3-1: Control

BoxRsR on page 3-1) channels the DC current from the DC Welding Power Supply to the Torch Head using standard welding cables. Compressed

air coming from the Control Box connects at the Torch Head with a 3/8RsR NPT female pipe elbow.

- 5/16 3/8

- 1/2

- 5/8

- 3/4

N7500

ART# A-10833_AC

Figure 3-7: Torch Head Components

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ESAB N7500 Gouging System User manual

Brand: ESAB

Model: N7500 Gouging System

Category: Welding System

Type: User manual

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N7500 Arcair-Matic® Gouging System

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