Hobart Welding Products OM-478 manual

Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Engine Driven Welding Generator

OM-478 120 240V

August 2000

TIG (GTAW) Welding

With Optional Equipment:

Battery Charging

PowerPak

Visit our website at

www.HobartWelders.com

Contents

Main PowerPak From Hobart to You CALIFORNIA Proposition 65 Warning TABLE OF CONTENTS WARNING Page SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters. 1-3. Engine Hazards FUEL can cause fire or explosion. STEAM AND HOT COOLANT can burn. MOVING PARTS can cause injury. BATTERY EXPLOSION can BLIND. 1-4. Additional Symbols For Installation, Operation, And Maintenance FALLING UNIT can cause injury. FLYING SPARKS can cause injury. OVERHEATING can damage motors. OVERUSE can cause OVERHEATING. 1-5. Principal Safety Standards 1-6. EMF Information OM-478 Page 5 SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 1-1. Signification des symboles 1-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation. 1-3. Dangers existant en relation avec le moteur LE CARBURANT MOTEUR peut pro- voquer un incendie ou une explosion. LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brlures. 1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance LE RAYONNEMENT HAUTE FR- QUENCE (H.F.) risque de provoquer des interfrences. LE SOUDAGE LARC risque de provoquer des interfrences. 1-5. Principales normes de scurit 1-6. Information sur les champs lectromagntiques SECTION 2 DEFINITIONS 2-1. Symbols And Definitions AAmperes VVolts Panel/Local 14 Remote 3 Three Phase 1 SECTION 3 SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications 3-2. Air Compressor Specifications 3-3. Dimensions, Weights, And Operating Angles 3-4. Fuel Consumption 3-5. Duty Cycle And Overheating WELD AMPERES % DUTY CYCLE 3-6. Air Compressor Output Curve 3-7. AC Auxiliary Power 3-8. Volt-Ampere Curves 3-9. Optional AC Power Plant Curves A. 10 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) B. 15 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) 3-10. Optional Battery Charging Output Curve SECTION 4 INSTALLATION 4-1. Installing Welding Generator + 4-2. Connecting The Battery 4-3. Installing Precleaners, Exhaust Pipe, And Rain Cap 4-4. Engine Prestart Checks 4-5. Connecting To Weld Output Terminals 4-6. Selecting Weld Cable Sizes A/V 4-7. Installing Ether Cylinder (Optional Ether Starting Aid) 4-8. Remote 14 Receptacle RC3 Information Socket* Socket Information A/V 4-9. Terminal Strip 3T Connections 4-10. Air Compressor Connections Page SECTION 5 OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls (See Section 5-2) 5-2. Description Of Standard Controls (See Section 5-1) 5-3. Example Of Remote Amperage Control SECTION 6 OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt GFCI Duplex Receptacles 6-2. Optional 230 Volt South African Receptacle 240V 13A 60 Hz 6-3. Optional 5 kVA/kW Power Plant Receptacles 240 VOLTS AC THREE PHASE POWER 6-4. Connecting Auxiliary Power Plant SECTION 7 OPERATING OPTIONAL BATTERY CHARGER 7-1. Jump Start/Battery Charge Cable Connections 7-2. Jump Start/Battery Charge Controls 7-3. Determining Battery Charging Current 7-4. Battery Charging Procedure 7-5. Jump Starting Procedure SECTION 8 MAINTENANCE & TROUBLESHOOTING 8-1. Routine Maintenance 8 h 50 h 100 h 200 h 1000 h 1200 h 3000 h 8-2. Servicing Air Cleaner -3. Maintenance Label DEUTZ F4L912 DIESEL ENGINE 8-4. Servicing Engine Fuel And Lubrication Systems 8-5. Adjusting Air Pressure 8-6. Adjusting Engine Speed 8-7. Overload Protection 8-8. Checking And Replacing Engine Belt 8-9. Servicing Optional Spark Arrestor 8-10. Troubleshooting A. Welding B. Auxiliary Power Trouble C. Engine D. Optional Battery Charging System E. Air Compressor Page Page Page Page Page Page SECTION 10 RUN-IN PROCEDURE 10-1. Wetstacking 10-2. Run-In Procedure Using Load Bank 10-3. Run-In Procedure Using Resistance Grid + SECTION 11 AIR COMPRESSOR T ABLES 11-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters 11-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.S.I.G. SECTION 12 AUXILIARY POWER GUIDELINES 12-1. Selecting Equipment OR 12-2. Grounding Generator To Truck Or Trailer Frame 12-3. Grounding When Supplying Building Systems 12-4. How Much Power Does Equipment Require? 12-5. Approximate Power Requirements For Industrial Motors 12-6. Approximate Power Requirements For Farm/Home Equipment 12-7. Approximate Power Requirements For Contractor Equipment 12-8. Power Required To Start Motor 12-9. How Much Power Can Generator Supply? 12-10.Typical Connections To Supply Standby Power 12-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 13 SELECTING AND PREPARING TUNGSTEN ELECTRODE 13-1. Selecting Tungsten Electrode 13-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding 13-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding SECTION 14 GUIDELINES FOR TIG WELDING (GTAW) 14-1. Positioning The Torch 14-2. Torch Movement During Welding 14-3. Positioning Torch Tungsten For Various Weld Joints SECTION 15 PARTS LIST Figure 15-1. Main Assembly (Part 1 Of 2) Page Page Page Figure 15-2. Main Assembly (Part 2 of 2) Page Figure 15-3. Panel, Front w/Components Page Page Page Figure 15-5. Control Box Page Figure 15-6. Compressor, Air Page Page Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. Effective January 1, 2000 (Equipment with a serial number preface of LA or newer) Please complete and retain with your personal records. Resources Available Always provide Model Name and Serial/Style Number. Owners Record