Hobart Welding Products OM-486 manual

Processes Description TIG (GT A W ) W elding Stick (SMA W) W elding MIG (GMA W) W elding Flux Cored (FCAW) Engine Driven Welding Generator Arcstar 251 NT OM-486 187 236H February 2000 Visit our website at www.HobartWelders.com[...]

Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

The following terms are used interchangeably throughout this manual: MIG = GMAW , Wire W elding TIG = GT AW Stick = SMAW The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USIN[...]

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OM-486 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_1 1/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “Note”; not safety related. This group of symbols means W arning! W[...]

OM-486 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks c a n fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and b e sure the a[...]

OM-486 Page 3 MOVING P ARTS can cause injury .  Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards closed and securely in place.  Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary .  T o prevent acci[...]

OM-486 Page 4 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  Th e user is responsible for having a qualified electrician prompt- ly cor[...]

OM-486 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION rom _nd_fre 1 1/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.  Identifie un message de s é curit é parti[...]

OM-486 Page 6 Le soudage ef fectu é sur des conteneurs ferm é s tels que des r é servoirs, tambours ou des conduites peut provoquer leur é clatement. Des é tincelles peuvent ê tre projet é es de l ’ arc de soudure. La projection d ’é tincelles, des pi è ces chaudes et des é quipements chauds peut provoquer des incendies et des br û l[...]

OM-486 Page 7 DES ORGANES MOBILES peuvent provoquer des blessures.  Ne pas approcher les mains des ventilateurs, cour- roies et autres pi è ces en mouvement.  Maintenir ferm é s et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.  Arr ê ter le moteur avant d ’ installer ou brancher l ’ appareil. ?[...]

OM-486 Page 8 LE RA YONNEMENT HAUTE FR É - QUENCE (H.F .) risque de provoquer des interf é rences.  Le rayonnement haute fr é quence (H.F .) peut provoquer des interf é rences avec les é quipements de radio – navigation et de communication, les services de s é curit é et les ordinateurs.  Demander seulement à des personnes qualifi ?[...]

OM-486 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Panel/Local T emperature Fuel Engine Oil On Check V alve Clearance Battery (Engine) Engine Read Operator ’ s Manual A Amperes V V olts MIG (GMAW), Wire Stick (SMAW) TIG (GT AW) Circuit Breaker Positive [...]

OM-486 Page 10 3-2. Dimensions, W eights, and Operating Angles Dimensions A Height 33 in (838 mm) B C Width 18-3/4 in (476 mm) C  Depth 45-1/2 in ( 1 156 mm) D  Do not exceed tilt angles or engine could be damaged or unit could tip. A 18 in (457 mm) G  Do not move or operate unit where it could tip. B 16-1/2 in (419 mm) 4 Holes tip. C 3/4 [...]

OM-486 Page 1 1 ST-189 268 The ac auxiliary power curve shows the auxiliary power available in amperes at the receptacles. 3-4. Auxiliary Power Curve 0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 0 120 80 40 200 160 280 240 AC POWER AMPERES A T 120V AC POWER AMPERES A T 240V 0 10 20 30 40 60 50 70 80 AC POWER VOL TS Duty cycle is the perc[...]

OM-486 Page 12 ST-189 266 / ST -189 267 / ST-189 265 The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding generator. Curves of other settings fall between the curves shown. A. CC/DC Mode B. CV/DC Mode C. CC/AC Mode 3-6. V olt-Ampere Curves 0 0 DC AMPERES DC VOL TS 50 100 150 200 250 300 350 20[...]

OM-486 Page 13 SECTION 4 – INST ALLA TION install1 12/99 – Ref. ST -800 652 / Ref. ST-800 477-A / ST -158 936-A / S-0854  Do not weld on base. W eld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- vided in base.  Always ground generator frame t o vehicle frame to pre- vent electric shock and static elec[...]

OM-486 Page 14 4-3. Activating The Dry Charge Battery (If Applicable) Remove b attery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai t ten minute[...]

OM-486 Page 15 4-4. Connecting The Battery Ref. ST-800 394-C / Ref. ST -189 925-A / Ref. S-0756-D + – 3/8, 1/2 in  Connect negative ( – ) cable last. T ools Needed: 4-5. Installing Exhaust Pipe ST-801 681 / Ref. ST -189 925-A  Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of t[...]

OM-486 Page 16 4-7. Selecting W eld Cable Sizes T otal Cable (Copper) Length In W eld Circuit Not Exceeding W elding Amperes 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2[...]

OM-486 Page 17 4-9. Adjusting MIG Weld Puddle Consistency ST-801 944-C / Ref. ST -189 925-A  Stop engine. Stabilizer DC-Z is factory connected to suit most MIG (Wire W elding) applications. T o change MIG weld puddle consis- tency , proceed as follows: Remove lower front panel and side panel. Starting from center of DC-Z, the three leads 79 will[...]

OM-486 Page 18 SECTION 5 – OPERA TING WELDING GENERA TOR 5-1. Front Panel Controls Ref. ST-189 925-A 1 DC Polarity/AC Switch  Do not switch under load. Us e switch to select AC weld output or polar- ity of DC weld output. 2 Process Select Switch  Do not switch under load. Us e switch to select output for weld process. 3 A/V Control Use cont[...]

OM-486 Page 19 5-2. Remote Amperage/V oltage Control 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 (see Section 4-8). 2 Remote Hand Control (Optional) 3 Remote Foot Control (Optional)  Engine runs at weld/power speed whenever a device con- nected to the remote 14 recep- tacle is running. ST-801 943-B / ST -189 925-A / S-0769 [...]

OM-486 Page 20 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT 6-1. Auxiliary Power Receptacles And Circuit Breakers Ref. ST-189 925-A 1 4 2 5 3  If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord.  Auxiliary power decreases as weld current increases. 1 240 V 50 A AC Receptacle RC1 RC1 supplies 60 Hz single-phase power[...]

OM-486 Page 21 6-2. Optional Auxiliary Power Receptacles  If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord.  Auxiliary power decreases as weld current increases. Combined output of all receptacles limited to 8 kV A/kW rating of the generator . GFCI Receptacle Option 1 120 V 15 A AC GFCI Recep- tacles GFCI2 and GFCI[...]

OM-486 Page 22 SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  Se e Engine Manual and Maintenance Label. Ser- vice more often if used in severe conditions. * T o be done by Factory Authorized Service Agent. 8 h Wipe up spills. Check fluid levels. See Section 4-2. [...]

OM-486 Page 23 7-2. Maintenance Label Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE[...]

OM-486 Page 24 7-3. Servicing Air Cleaner aircleaner3 1/97 – ST-156 852 / Ref. ST -185 095-A / S-0759  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into wrapper . Squ[...]

OM-486 Page 25 7-5. Changing Engine Oil, Oil Filter , And Fuel Filter Ref. ST-801 942-C / ST -800 395-B / Ref. ST-189 925-A / S-0842  Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 12 in Hose 3 Oil Filter Change engine oil and filter accord- ing to engine manual.  Close valve and valve cap before adding oil and run- ning engine. Fill[...]

OM-486 Page 26 7-6. Adjusting Engine Speed Ref. ST-801 942-C / ST -800 397-A After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. T urn A/V control to max. Idle Speed Adjustment 1 Throttle Solenoid 2 Mounting Screw Loosen two mounting screws. 3 Governor Arm[...]

OM-486 Page 27  Stop engine.  When a circuit breaker or fuse opens, it usually indicates a more serious problem exists. Contact a Factory Authorized Service Agent. 1 Circuit Breaker CB5 CB5 protects the 24 volt ac output to Remote 14 receptacle RC1. If CB5 opens, 24 volt ac output to RC1 stops. 2 Circuit Breaker CB6 CB6 protects the 1 15 volt[...]

OM-486 Page 28 T rouble Remedy Low weld output. Check control settings. Place Remote Amperage/V oltage switch in Panel position, or move switch to Remote 14 position and connect remote amperage/voltage control to Remote 14 receptacle RC1. Check and clean air cleaner as necessary (see Section 7-3). Check and adjust engine speed (see Section 7-6). Ha[...]

OM-486 Page 29 B. Auxiliary Power T rouble Remedy No power output. Reset circuit breakers CB1, CB2, CB3 and/or CB4 (see Section 6-1). Check fuse F1, and replace if necessary (see Section 7-7). Have Factory Authorized Service Agent check brushes, slip rings, and field current control board PC2. Low power output. Check and clean air cleaner as necess[...]

OM-486 Page 30 SECTION 8 – ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Welding Generator[...]

OM-486 Page 31 ST-190 578-B[...]

OM-486 Page 32 SECTION 9 – AUXILIAR Y POWER GUIDELINES 9-1. Selecting Equipment aux_pwr 2/99 – Ref. ST-159 730 / ST -800 577 1 Auxiliary Power Receptacles – Neutral Bonded T o Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment OR 2 Be sure equipment has this symbol and/or wording. 3 1 9-2. Groundi[...]

OM-486 Page 33 9-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electrica[...]

OM-486 Page 34 9-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850 3 [...]

OM-486 Page 35 9-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 390[...]

OM-486 Page 36 9-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting amp[...]

OM-486 Page 37 9-10. T ypical Connections T o Supply Standby Power S-0405-A 1 Power Company Service Meter 2 Main and Branch Overcurrent Protection 3 Double-Pole, Double-Throw T ransfer Switch Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection. 4 Circuit Breakers or Fused Disconnect Swi[...]

OM-486 Page 38 9-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840[...]

OM-486 Page 39 SECTION 10 – P ARTS LIST ST-802 048-D  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 20 21 22 23 24 – Fig 10 – 3 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 46 47 48 49 50 47 51 46 45 53 54 – Fig. 10-2 52 55 41 Figure 10-1. Main Assembly[...]

OM-486 Page 40 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quantity 1 182 367 P ANEL, right side 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 185 352 P ANEL, right side stainless 1 . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-486 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly (Continued) Quantity RC1 174 824 CONNECTOR & PINS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG1 174 823 CONNECTOR & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-486 Page 42 Description Part No. Dia. Mkgs. Item No. Figure 10-2. Panel, Front w/Components (Fig 10-1 Item 54) Quantity 1 187 593 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 R3,VR1 046 819 SUPPRESSOR 1 . . . . . . . . . . . . . . . . .[...]

OM-486 Page 43 Description Part No. Item No. Figure 10-3. Generator (Fig 10-1 Item 24) Quantity 1 +186 238 ST A TOR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 013 367 LABEL, warning moving parts can cause serious injury 1 . . . . . . . . . . . .[...]

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Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distrib[...]

PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , O H 45373 US A For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]