Air Carbon Arc Gouging (CAC-A) is the fastest, most economical method for excavating defective welds, preparing thick plate joint bevels, and removing unwanted metal in shipyards, pressure vessel manufacturing, and structural steel plants. Engineered with proprietary IGBT full-bridge inverter topology, APS Genesis Series gouging machines deliver high continuous current while saving up to 60% energy compared to traditional transformer units.
Optimized for structural steel bays and medium-to-heavy fabricators requiring fast joint back-gouging and SMAW stick capability.
Engineered for pressure vessel manufacturers and shipyards needing high deposition rates and continuous thermal endurance.
Built for foundry casting riser removal, heavy steel mill maintenance, and ultra-thick plate preparation in critical infrastructure projects.
Compare key operational parameters across our heavy-duty Carbon Arc Gouging range to select the optimal model for your plant requirement.
| Model Specification | Genesis 800 | Genesis 1000 | Genesis 1200 |
|---|---|---|---|
| Primary Input Voltage | 3-Phase 415V ± 15%, 50/60 Hz | 3-Phase 415V ± 15%, 50/60 Hz | 3-Phase 415V ± 15%, 50/60 Hz |
| Output Current @ 60% Duty (40°C) | 800 Amps | 1000 Amps | 1200 Amps |
| Output Current @ 100% Duty (40°C) | 610 Amps | 770 Amps | 930 Amps |
| Operating Processes | Carbon Arc Gouging (CAG) + MMA | Carbon Arc Gouging (CAG) + MMA | Carbon Arc Gouging (CAG) + MMA |
| Inverter Architecture | IGBT Full-Bridge Module | IGBT Full-Bridge Module | IGBT Full-Bridge Module |
| Recommended Carbon Electrodes | 5 mm to 10 mm | 6 mm to 12 mm | 8 mm to 15 mm |
| Safety Features | VRD, OC, OT, Phase Loss Protection | VRD, OC, OT, Phase Loss Protection | complaint>VRD, OC, OT, Phase Loss Protection|
| Remote pendant control | Standard Current Remote Included | Standard Current Remote Included | Standard Current Remote Included |
| Protection & Insulation Class | IP23 / Class H | IP23 / Class H | IP23 / Class H |
Note: Specifications are tested according to IEC 60974-1 standards at 40°C ambient temperature. Custom input voltage options (e.g., 380V, 440V, 480V 60Hz) are available for international export orders.
Air Carbon Arc Gouging strikes an electric arc between a carbon/graphite electrode and the metallic workpiece, melting the metal instantly while a focused jet of compressed air blows the molten slag clean away.
Select gouging amperage via the remote pendant directly at the workstation. Connect an air line supplying clean, dry compressed air (5.5 to 7.0 bar) to the gouging torch.
Touch the carbon rod electrode to the workpiece and withdraw slightly. The Genesis IGBT inverter delivers an immediate, smooth high-current arc with built-in Hot Start support.
Align the torch air orifices directly behind the carbon electrode. The continuous air jet blows the molten puddle forward instantly, carving a smooth, clean U-groove channel.
Wire-brush the gouged surface to remove residual carbon particles. The clean groove is immediately ready for non-destructive examination (NDE) and high-quality re-welding.
Advanced IGBT full-bridge topology cuts line power draw drastically compared to old transformer gougers, lowering facility electricity bills.
Automatically adjusts voltage during arc shortening to prevent electrode stubbing and maintain a constant metal-removal rate.
Reduces open-circuit voltage during non-welding standby to safe levels, protecting operators working in humid, wet, or confined environments.
Allows operators to fine-tune current settings directly at the gouging site, eliminating frequent trips back to the power source.
Genesis CAG power sources are deployed across global industrial plants where high-speed metal removal is vital to production schedules.
Back-gouging hull plate butt joints, opening defective fillet welds, and removing temporary fitting lugs cleanly.
Preparing deep double-V grooves and excavating non-destructive test (NDT) identified weld defects on heavy shells.
Rapidly removing risers, gates, flashings, and surface defects from large steel and iron castings before machining.
Beveling thick structural plates, gouging crane girder seams, and repairing field-installed beam assemblies.
Excavating root pass defects and preparing pipe ends for repair re-welding on oil, gas, and water lines.
Removing hardfacing layers, worn excavator teeth adapters, and cracked crusher components for refurbishment.
Understanding how Air Carbon Arc Gouging compares against traditional mechanical grinding and plasma cutting assists engineering teams in selecting the right equipment.
| Selection Parameter | Air Carbon Arc Gouging (CAG) | Mechanical Angle Grinding | Air Plasma Gouging / Cutting |
|---|---|---|---|
| Metal Removal Velocity | Ultra Fast (Up to 5x faster than grinding) | Slow to Moderate | Fast on thin-to-medium plates |
| Maximum Plate Depth Capacity | Unlimited (Suitable for extreme section thickness) | Limited by wheel diameter & operator fatigue | Limited by plasma torch amperage |
| Consumable Operating Cost | Very Low (Carbon rods & compressed air) | High (Frequent grinding wheel replacement) | Moderate-to-High (Nozzles, electrodes, shields) |
| Primary Fabrication Role | Deep weld defect excavation & heavy back-gouging | Surface touch-up & light beveling | Precision sheet profiling & thin gouging |
| Recommended APS Solution | Genesis 800 / 1000 / 1200 CAG Series | Heavy-duty workshop grinding tools | Rhino Cut Heavy-Duty Plasma Range |
Every APS Genesis Carbon Arc Gouging machine is designed, assembled, and load-tested in-house at our ISO 9001:2015 certified plant in Valsad, Gujarat, India.
We manufacture our own main transformers, PCB control assemblies, and structural chassis. Every machine undergoes 100% full-load thermal burn-in testing prior to export packing, ensuring flawless operation upon arrival at overseas site bays.
We supply international buyers with complete technical dossiers, CE compliance certificates where specified, sea-worthy wooden crate packaging, and spare part packages tailored for remote project locations worldwide.
Air Carbon Arc Gouging (CAC-A) uses a carbon electrode arc to melt metal combined with high-velocity compressed air to blast molten metal away. It is primarily used for removing defective welds, back-gouging double-sided joints, joint bevel preparation, and removing risers/gates in steel foundries.
APS Genesis Series IGBT inverter gougers cut power consumption by up to 60% compared to traditional SCR or transformer machines. They feature precise arc dynamics, instant arc striking, lighter weight, and continuous duty stability under extreme workshop thermal loads.
Genesis 800 accepts carbon electrodes up to 10mm; Genesis 1000 handles up to 12mm; and Genesis 1200 supports continuous heavy gouging with carbon electrodes up to 15mm diameter, suitable for intense metal excavation.
Yes. All Genesis CAG machines feature dual-mode control allowing switching between Carbon Arc Gouging and heavy-duty Shielded Metal Arc Welding (SMAW / MMA), including pipe root electrodes and structural stick welding.
Yes. APS provides export-compliant documentation, international warranty support, comprehensive spare parts packages, and remote technical consultation for overseas procurement teams.
Speak directly with APS application engineers to select the exact power source configuration for your project.