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OM-478 120 240V
August 2000
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
TIG (GTAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
With Optional Equipment:
Battery Charging
Description
Engine Driven Welding Generator
PowerPak
Visit our website at
www.HobartWelders.com
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From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Weldi
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when working on a hot engine. can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and Do not touch hot engine parts or just-welded burns. Accidental contact of electrode to metal objects can cause par
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BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. Keep away from fans, belts, and rotors. Do not tip battery. Keep all doors, panels, covers, and guards closed and securely in place. Replace damaged battery. Flush eyes and skin immediately with water. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect n
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de Rincer immédiatement les yeux et la peau à l’eau. protection. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio–navigation et de communication, les Veiller à ce que tout l’équi
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SECTION 2 – DEFINITIONS 2-1. Symbols And Definitions Fast (Run, Weld/ Stop Engine Slow (Idle) Start Engine Power) Check engine belt Check Air Cleaner Ether Starting Aid Engine Jump start/Battery Battery (Engine) Battery Charge Jump Start Charge OPT Do Not Switch Read Operator’s Certified/Trained Engine Oil Under Load Manual Mechanic Check Injectors/ Check Valve Engine Coolant Fuel Pump Clearance Temperature Circulating Hourmeter (HM) Air Pressure Temperature Compressor Positive Negative Wire Fee
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SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Maximum 5 kVA/kW Weld Rated Auxiliary 15 kVA/kW Fuel Welding Open-Circuit Auxiliary Output Welding Power Auxiliary Engine Tank Mode Voltage Power Plant Range Output Rating Power Plant Capacity (Nominal) (Optional) 400 A, 36 Volts DC, CC/DC 50 – 500 A 95 (88) Single Phase, 100% Duty 10 kVA/kW , Cycle 42 A, 42 A, Deutz Single-Phase, Three-Phase, 120/240 V AC, 300 A, F4L-912 3 kVA/kW, 5 kVA/kW, 60 Hz; 32 Volts DC, Air-Cooled, 1
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3-4. Fuel Consumption The curve shows typical fuel use under weld or auxiliary power loads. 7.57 1.67 2.00 28 CFM @ 90 PSI 6.81 1.50 1.80 AIR DELIVERY 6.06 1.33 1.60 5.30 1.17 1.40 4.54 1.00 1.20 W/O AIR DELIVERY 3.79 0.83 1.00 1800 R.P.M. (NO LOAD) 3.03 0.67 0.80 2.27 0.50 0.60 1.51 0.33 0.40 IDLE 0.76 0.17 0.20 1150 R.P.M. 0.00 0.00 0.00 0 50 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE ST-188 312 3-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 100
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3-6. Air Compressor Output Curve The air output curve shows the vol- ume and pressure of air available from the air compressor. 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 P.S.I.G. SB-121 490-A 3-7. AC Auxiliary Power The ac power curve shows the aux- iliary power in amperes available at the 120 and 240 volt receptacles. 150 300 125 250 3 KW 100 200 75 150 50 100 25 50 0 0 0 5 10 15 20 25 AC AMPERES IN 240V MODE 0 10 20304050 AC AMPERES IN 120V MODE ST-109 3
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3-8. Volt-Ampere Curves The volt-ampere curve shows the A. For AC Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. B. For Constant Current (CC) DC Mode C. For Constant Voltage (CV) DC Mode ST-188 211 / ST-188 212 / ST-188 220 OM-478 Page 13
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3-9. Optional AC Power Plant Curves The ac power curves show the aux- iliary power in amperes available at the single-phase 120/240 volt or A. 10 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load) three-phase 240 volt terminals. 260 250 240 230 220 210 200 190 180 0 10 20 30 40 50 60 70 80 90 100 AC AMPERES B. 15 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) 260 250 240 230 220 210 200 190 180 0 10 20 30 40 50 60 70 80 90 100 AC AMPERES ST-188 214 / ST-188 213 OM-478 Page 14 AC V
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3-10. Optional Battery Charging Output Curve The battery charging curves show the charging amperage and voltage output of the welding generator. As battery voltage nears the charg- ing voltage, charging current de- 50 creases. 40 30 MAX 20 MIN 10 0 0 100 200 300 400 500 600 700 DC AMPERES ST-188 221 OM-478 Page 15 DC VOLTS
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance Location 18 in Do Not Lift Unit From End (460 mm) 18 in (460 mm) 18 in (460 mm) OR OR 18 in 18 in (460 mm) (460 mm) Grounding Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. 3 1 4 1 Generator Base GND/PE 2 Metal Vehicle Frame 3 Equipment Grounding OR Terminal 4 Grounding Cable Use #10 AWG or larger insulated copper wire. Electrically bond generator
