ESAB
/ esab.com
Arcair ® , an ESAB® brand, has made an improvement to the
Arcair-Matic N7500 gouging system by incorporating an
emergency stop switch (E-Stop) to the Remote Pendant,
Part No. 72-008-020. This E-Stop switch, when pressed in,
will take precedence over any other “stop” signal and will drop
out the engaged contactor in the power supply stopping the
fl ow of current to the carbon electrode.
The E-Stop switch will be found on any new system purchased
after September 2015.
For systems that are already in the fi eld, Arcair is offering an
E-Stop Button Functional Kit, Part No. 80659. This kit will
contain all the necessary component parts and wiring harnesses
required to upgrade the Remote Pendant, Part No. 72-008-020
and Control Box, Part No. 72-008-021.
A new Remote Pendant Cable will need to be ordered to replace
the five wire cable assembly with one having six wires. The same
part number ordered when the system was new should be used
since all cable assemblies will have six wires going forward.
E-Stop Button Functional Kit.
Arcair-Matic
®
N7500 Gouging System
Product Update
Remote Pendant Cable Assembly
Part No. Description
96-170-069 14 in. (0.36 m) Remote Pendant Cable Assembly
96-170-070 15 ft. (5 m) Remote Pendant Cable Assembly
96-170-071 25 ft. (8 m) Remote Pendant Cable Assembly
96-170-072 50 ft. (15 m) Remote Pendant Cable Assembly
E-Stop Button Functional Kit, Part No. 80659
Bumper Guard
Power Supply Harness
Pendant Cable to PCBA
Pendant Cable to Control Box
GOUGING SYSTEM PRODUCT UPDATE 2 89250970
N7500 GOUGING SYSTEM PRODUCT UPDATE
E-STOP BUTTON FUNCTIONAL KIT, PART NO. 80659
The following instruction steps refer to the Illustration on the back page.
Screws, nuts, bolts and washers are not supplied with this Kit. When removing please save for reuse.
Kit Contents Tools Required
Bumper Guard #1 Phillips Screwdriver
Power Supply Harness to PCBA #2 Phillips Screwdriver
Pendant Cable to PCBA 5.5 mm Wrench
Pendant Cable to Control Box 3 mm Hex Wrench
4 mm Hex Wrench
Prepare for Kit Installation
WARNING
Risk of ELECTRICAL SHOCK.
1. Power down the main welding power supply system connected to the Control Box. Use lockout/tagout safety procedures.
2. Place the Control Box ON/OFF switch (Item 1) in the “OFF” position.
Replace Pendant END CAP
1. Disconnect the Pendant cable from Pendant and remove the Bumper Guard.
2. Remove 4 Phillips head screws (save) from Pendant end plate and disconnect wiring from the circuit board. Discard old Pendant end
plate.
3. Using the new Pendant end plate, attach wiring connector to Pendant circuit board.
4. Attach new Pendant end plate to the Pendant housing using the saved screws.
5. Insert Pendant into new Bumper Guard.
6. Set Pendant aside until Control Box assembly steps call for it.
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89250970 1 GOUGING SYSTEM PRODUCT UPDATE
GOUGING SYSTEM PRODUCT UPDATE N7500
Disassembly and Replacing Control Box Parts
1. Remove the Cover Plate (Item 3) using a 3mm hex wrench to remove the 2 pan head socket screws.
2. Use an 8mm hex wrench to remove DC power connection bolts, washers, and spring lock washers (Item 6) and power supply cables
from the Control Box.
3. Disconnect Power Supply Communication cable from the Control Box. Disconnect the Remote Pendant cable from Control Box and
Pendant.
4. Using a 3mm hex wrench remove the 10 pan head socket screws (Item 7) from the Rear Panel Assembly (Item 4).
5. For ease of access remove the 2 Phillips head screws (Item 8) on the Control Box ON/OFF switch (Item 1) and set aside.
6. Using a 4mm hex wrench remove the 4 pan head socket screws (Item 9) located on the bottom of the Control Box (Item 5) that hold
the Electrical Plate Bracket Assembly (Item 10) in place. Disconnect the assembly from PCBA and set aside. (Note the location of this
connector on PCBA.)
7. Remove 4 Phillips head screws and hex nuts (Item 11) from Control Box securing the Power Supply Communication Connector (Item
12) and disconnect wiring from PCBA. Discard this Power Supply Communication Connector. (Note the location of this connector on PCBA.)
8. Fasten new Power Supply Communication Connector (Item 12) into place and plug wiring into the PCBA. Notice: The 2 loose wires
will connect to the Remote Pendant Connector (Item 14) after it is installed.
9. Remove 4 Phillips head screws and hex nuts (Item 13) securing Remote Pendant connector (Item 14) to the Control Box and discon-
nect Pendant connector wiring from PCBA. Discard this Remote Pendant connector. (Note the location of this PCBA connector.)
10. Fasten new Remote Pendant Connector (Item 14) into place and plug connector into the PCBA, then connect the 2 loose wires from
the Remote Pendant Connector to the 2 loose Power Supply Communication Connector wires from Step 5.
11. Plug new Electrical Plate Bracket Assembly wiring into PCBA. Use the 4 (4mm) pan head socket screws (Item 9 from Step 3) to fasten
the Bracket Assembly (Item 10) to the Control Box.
12. Take the Control Box ON/OFF switch (Item 1) and reattach with the 2 Phillips head screws (Item 8).
13. Remount the Rear Panel Assembly (Item 4) to the Control Box with the 10 pan head socket screws from Step 1.
14. Connect the new Remote Pendant cable to the Remote Pendant. Reconnect the Power Supply Communication cable and the new
Remote Pendant cable to their connectors on the Control Box (Item 5).
15. Using an 8mm hex wrench reconnect the Input and Output DC power supply cables using the bolts, washers, and spring lock washers
(Item 6).
16. Reattach Cover Plate to the Rear Panel.
17. Restore the main welding power supply and turn “ON” the ON/OFF switch (Item 1) to the Control Box (Item 5) to resume operations.
GOUGING SYSTEM PRODUCT UPDATE 2 89250970
N7500 GOUGING SYSTEM PRODUCT UPDATE
16
MAX 100 psi
1
3
4
5
6
2
7
8
11
12
9
10
11
13
14
CONTROL
BOX
FRONT
REAR
PANEL
ASSEMBLY
PCBA
15
(kit part)
(kit part)
to PCBA
to
PCBA
to
PCBA
(Purchased separately
Arcair-Matic N7500 Control Box
Item No. Description Qty
1 ON/OFF Switch 1
2 3mm Pan Head Socket Screws 2
3 Cover Plate 1
4 Rear Panel Assembly 1
5 Control Box 1
6 8mm Bolts Washers and Spring Lock Washers 2 ea
7 3mm Pan Head Socket Screws 10
8 Phillips Head Screws (reuse) 2
9 4mm Pan Head Socket Screws 4
10 Electrical Plate Bracket Assembly 1
11 Phillips Head Screws and Hex Nuts 4 ea
12 Power Supply Communication Connector 1
13 Phillips Head Screws and Hex Nuts 4 ea
14 Remote Pendant Connector 1
15 Remote Pendant Cable Assembly 1
16 Bumper Guard 1
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2
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3
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ESAB Arcair-Matic® N7500 Gouging System Product Update User manual
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