Hobart Welding Products OM-474 Connecting To Weld Output Terminals, Selecting Weld Cable Sizes

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4-5. Connecting To Weld Output Terminals

Open left side door.

1 Bracket

Route cables through bracket.

2 Positive (+) Weld Output

Terminal

3

Negative (–) Weld Output Ter-

3

minal

For Stick welding Direct Current Electrode Positive (DCEP), con-

2 nect work cable to (–) terminal and electrode holder cable to (+) terminal.

For Direct Current Electrode Nega- tive (DCEN), reverse cable connections.

If equipped with optional polarity switch, connect electrode holder

Left Sidecable to Electrode (–) terminal and work cable to Work (+) terminal.

For MIG and FCAW welding with CV option, connect work cable to (–) terminal and wire feeder cable to

(+) terminal

Close door.

1

Tools Needed:

 

3/4 in

 

 

 

 

 

 

ST-800 162-A

 

 

 

 

 

 

 

 

 

 

 

4-6. Selecting Weld Cable Sizes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Total Cable (Copper) Length In Weld Circuit Not Exceeding

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Welding

 

100 ft (30 m) Or Less

150 ft

200 ft

250 ft

300 ft

350 ft

400 ft

 

 

(45 m)

(60 m)

(70 m)

(90 m)

(105 m)

(120 m)

 

Amperes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10 – 60%

60 – 100% Duty

 

 

10 – 100% Duty Cycle

 

 

 

 

 

Duty Cycle

Cycle

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100

 

4

4

4

3

2

1

1/0

1/0

 

 

 

 

 

 

 

 

 

 

 

 

150

 

3

3

2

1

1/0

2/0

3/0

3/0

 

 

 

 

 

 

 

 

 

 

 

 

200

 

3

2

1

1/0

2/0

3/0

4/0

4/0

 

 

 

 

 

 

 

 

 

 

 

 

250

 

2

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

 

 

 

 

 

 

 

 

 

 

 

 

300

 

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

 

 

 

 

 

 

 

 

 

 

 

 

350

 

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

 

 

 

 

 

 

 

 

 

 

 

 

400

 

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

 

 

 

 

 

 

 

 

 

 

 

 

500

 

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-3/0

 

 

 

 

 

 

 

 

 

 

 

 

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your dis-

tributor for the mm2 equivalent weld cable sizes.

S-0007-E

OM-474 Page 16

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Contents OM-474 ProcessesDescription JulyFrom Hobart to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill ARC Rays can burn eyes and skinEngine Hazards Battery Explosion can Blind Moving Parts can cause injuryEngine Exhaust Gases can kill Engine Heat can cause firePrincipal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interferenceSignification des symboles Consignes DE Sécurité Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie LA Chute DE L’APPAREIL peut blesserPrincipales normes de sécurité Information sur les champs électromagnétiquesLE Soudage À L’ARC risque de provoquer des interférences Consignes relatives aux stimulateurs cardiaquesSpecifications Symbols And DefinitionsWeld, Power, And Engine Specifications DefinitionsDimensions, Weights, And Operating Angles DimensionsWeight Fuel ConsumptionAC Auxiliary Power Duty Cycle And Overheating60% Duty Cycle At 350 Amperes Minutes Welding12.5 KVA/KW Three-Phase Auxiliary Power Plant No Weld Load Optional AC Power Plant Curves5 KVA/KW Single-Phase Auxiliary Power Plant No Weld Load Volt-Ampere Curves DC Volts CC/DC StandardAC Amperes CV/DC Models with Optional CV-3 Module 100 Ranges 190-Max 110-270Connecting The Battery InstallationInstalling Welding Generator Installing Muffler Temperatures below 0 F -18C 13 mm Full Diesel Valve OpenEngine Prestart Checks Do not use gasoline. Gasoline will damage engineConnecting To Weld Output Terminals Selecting Weld Cable Sizes100 ft 30 m Or Less 10 100% Duty CycleRemote 14 Receptacle RC3 Information Optional, See Section Terminal Strip 3T Connections OptionalSocket Information Stop engineOperating Welding Generator Front Panel Controls See SectionAmpere Range Switch Do not switch under loadDescription Of Front Panel Controls See Section Stop engine and fix trouble if either warning light goes onRemote Control Optional Example Combination remote amperage controlOperating Auxiliary Equipment Volt Duplex And Optional Gfci ReceptaclesVolt Duplex Receptacle Optional Open ContactFront Connecting Optional Auxiliary Power PlantSet Engine Control switch to Run when using auxiliary power Maintenance and Troubleshooting Maintenance Label Do not clean housing with air hose Servicing Air CleanerTo Clean air filter Servicing Fuel System Stop engine and let coolTo drain water from fuel system To replace fuel filterEngine Speed No Load Adjusting Engine SpeedIdle Speed Adjustment Changing Engine Oil And Filter Overload Protection If any fuse or circuit breakerInspecting And Cleaning Optional Spark Arrestor Muffler TroubleshootingWelding Trouble RemedyAuxiliary Power Coolant temperature gets too high see Section Check engine control switch, and replace if necessaryEngine See engine manualOM-474 Electrical Diagrams Circuit Diagram For Welding Generator For Standard ModelsOM-474 193 989-B RUN-IN Procedure WetstackingRun-In Procedure Using Load Bank Load BankRun-In Procedure Using Resistance Grid Do not touch hot exhaustBank/grid From flammablesGrounding Generator To Truck Or Trailer Frame Auxiliary Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Use ground device as stated in electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP xTypical Connections To Supply Standby Power Welding Generator Auxiliary Power output circuitItem 4 is not necessary if circuit Protection is already presentSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesParts List 101 102 105 104 10365 66 Includes Items Dia Part Description Mkgs Quantity PLG9,RC9 PC4 Control Box w/Components -4 Item Control Box w/ComponentsGenerator Generator -1 Item Panel, Front w/Components Panel, Front w/Components -1 Item Page Service SupportCall Contact your Distributor forHobart Welding Products