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Hobart Welders Champion 145 Manuel D'utilisation

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OM-250 200A
2011−07
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Champion 145
)
File: Engine Drive
www.HobartWelders.com

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  • Page 1 OM-250 200A 2011−07 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator Champion 145 File: Engine Drive www.HobartWelders.com...

  • Page 2: Table Des Matières

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . 1-1.

  • Page 3: Section 1 − Safety Precautions − Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−04 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
  • Page 4 D Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.

  • Page 5: Engine Hazards

    1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...

  • Page 6: Hydraulic Hazards

    1-4. Hydraulic Hazards D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics HYDRAULIC EQUIPMENT can injure near sparks or flames; do not smoke near hydraulic fluid. or kill. D Reinstall doors, panels, covers, or guards when servicing is D Incorrect installation or operation of this unit finished and before starting unit.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.

  • Page 8: California Proposition 65 Warnings

    WELDING WIRE can injure. H.F. RADIATION can cause interference. D Do not press gun trigger until instructed to do D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Do not point gun toward any part of the body, other people, or any metal when threading D Have only qualified persons familiar with welding wire.

  • Page 9: Principal Safety Standards

    1-8. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-...

  • Page 10: Signification Des Symboles

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−04 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 11 Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe.

  • Page 13: Dangers Liés À L'hydraulique

    D Mettre des lunettes de sécurité et des gants, placer un torchon sur LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur. peuvent provoquer un incendie. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. D Empêcher les étincelles d’échappement du moteur de provoquer un incendie.

  • Page 14: Dangers Liés À L'air Comprimé

    Les PIÈCES MOBILES peuvent causer LES PIÈCES ET LIQUIDES CHAUDS des blessures. peuvent provoquer des brûlures. D S’abstenir de toucher des parties mobiles telles D Ne pas toucher les pièces chaudes à main nue que des ventilateurs, courroies et rotors. ni laisser des liquides chauds entrer en contact avec la peau.

  • Page 15: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Remettre en place les portes, panneaux, recouvrements ou PRESSION D’AIR RÉSIDUELLE dispositifs de protection à la fin des travaux d’entretien et avant ET DES FLEXIBLES QUI FOUETTENT de mettre le moteur en marche. risquent de provoquer des blessures. D Détendre la pression pneumatique des outils et PIÈCES CHAUDES peuvent...

  • Page 16: Proposition Californienne 65 Avertissements

    D Demander seulement à des personnes qualifiées familiarisées LES CHARGES ÉLECTROSTATI- avec des équipements électroniques de faire fonctionner l’installa- QUES peuvent endommager les tion. circuits imprimés. D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.

  • Page 17: Principales Normes De Sécurité

    2-8. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-...
  • Page 18 Complete Parts List available at www.HobartWelders.com Notes OM-250 200 Page 16...

  • Page 19: Section 3 − Definitions

    Complete Parts List available at www.HobartWelders.com SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Read Operator’s Engine Choke Amperes Volts Manual Engine − Direct Current Generator − (DC) Rectifier Engine Oil Fuel Battery (Engine) Engine Alternating Current Positive Negative Output (AC) Protective Earth Hours Seconds...

  • Page 20: Dimensions, Weights, And Operating Angles

    Complete Parts List available at www.HobartWelders.com 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 26-17/64 in. (667 mm) Width 20-3/32 in. (510 mm) Depth 31-1/4 in. (794 mm) Do not exceed tilt angles or engine could 31-1/4 in. (794 mm) be damaged or unit could tip.

  • Page 21: Duty Cycle

    Complete Parts List available at www.HobartWelders.com 4-4. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. 30% Duty Cycle This unit is rated at 30% duty cycle (3 minutes welding, 7 minutes rest- ing) at 130 amperes.

  • Page 22: Volt-Ampere Curves

    Complete Parts List available at www.HobartWelders.com 4-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. DC AMPERES 250 193 OM-250 200 Page 20...

  • Page 23: Section 5 − Installation

    Complete Parts List available at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and the rating information for this product is located on the stator. Use rating label to determine input power requirements and/or rated output.

  • Page 24: Engine Prestart Checks

    Complete Parts List available at www.HobartWelders.com 5-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low. 1/2 in (13 mm) Fuel Valve Full...

  • Page 25: Weld Output Terminals

    Complete Parts List available at www.HobartWelders.com 5-5. Weld Output Terminals Negative (−) Weld Output Terminal Positive (+) Weld Output Terminal For Direct Current Electrode Posit- ive (DCEP), connect electrode holder to Positive (+) terminal and work cable to Negative (−) terminal. For Direct Current Electrode Neg- ative (DCEN), reverse cable con- nections.

  • Page 26: Selecting Weld Cable Sizes

    Complete Parts List available at www.HobartWelders.com 5-7. Selecting Weld Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
  • Page 27 Complete Parts List available at www.HobartWelders.com Notes OM-250 200 Page 25...

  • Page 28: Section 6 − Operating The Welding Generator

    Complete Parts List available at www.HobartWelders.com SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Controls (See Section 6-2) 251 051 / 251 052 / 250 186-A OM-250 200 Page 26...

  • Page 29: Description Of Controls (See Section 6-1)

    Complete Parts List available at www.HobartWelders.com 6-2. Description Of Controls (See Section 6-1) Engine Switch D Pull starter handle until engine starts. Amperage Control Use control to select weld amperage. Control Use switch to control ignition circuit, and to D Move Choke control to the left (Run) as may be adjusted while welding.
  • Page 30 Notes OM-250 200 Page 28...

  • Page 31: Section 7 − Operating Auxiliary Equipment

    Complete Parts List available at www.HobartWelders.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT The welding generator provides power while welding and with the Amperage control in any position. However, under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered under these conditions.
  • Page 32 Complete Parts List available at www.HobartWelders.com Notes OM-250 200 Page 30...

  • Page 33: Section 8 − Maintenance

    Complete Parts List available at www.HobartWelders.com SECTION 8 − MAINTENANCE 8-1. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean...

  • Page 34: Servicing Air Cleaner

    Complete Parts List available at www.HobartWelders.com 8-2. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine with- out air cleaner or with dirty element. 1. Cover 2. Precleaner Remove air cleaner cover. Wash precleaner with soap and water so- lution.

  • Page 35: Section 9 − Troubleshooting

    Complete Parts List available at www.HobartWelders.com SECTION 9 − TROUBLESHOOTING 9-1. Troubleshooting A. Welding Trouble Remedy No weld output; no generator power Be sure all equipment is disconnected from receptacles when starting unit. output at ac receptacles. Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, integrated rectifier SR1, and capacitor C1.

  • Page 36: Section 10 − Parts List

    Complete Parts List available at www.HobartWelders.com Trouble Remedy Erratic output at generator power ac Check fuel level. receptacles. Check Amperage control setting. Set Amperage control at Max for generator power. Check receptacle wiring and connections. Check governor linkage for smooth, non-binding operation. Service air cleaner according to engine manual.

  • Page 37: Section 11 − Electrical Diagrams

    Complete Parts List available at www.HobartWelders.com SECTION 11 − ELECTRICAL DIAGRAMS 250 189-A Figure 10-1. Circuit Diagram For Welding Generator OM-250 200 Page 35...
  • Page 38 Notes OM-250 200 Page 36...

  • Page 39: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
  • Page 40 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 41 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 42 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 43 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage AC MOTOR To find starting amperage: VOLTS AMPS Step 1: Find code and use table to CODE find kVA/HP.
  • Page 44 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Properly install and ground Welding Utility Disconnect this equipment according to Electrical Generator Transfer Switch Switch its Owner’s Manual and na- Output Service (If Required)

  • Page 45: Selecting Extension Cord (Use Shortest Cord Possible)

    12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68) 137 (42)
  • Page 46 Notes OM-250 200 Page 44...

  • Page 47: Section 13 − Stick Welding (Smaw) Guidelines

    SECTION 13 − STICK WELDING (SMAW) GUIDELINES 13-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Equipment Needed: Tools Needed: Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 48: Electrode And Amperage Selection Chart

    13-2. Electrode and Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN HORIZ...
  • Page 49 13-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle ° ° ° ° Groove Welds ° ° ° ° Fillet Welds S-0060 13-5. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A...
  • Page 50 13-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected electrode angle, length, travel speed, and thick- ness of base metal. Correct Angle Angle Too Large ° - ° Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short...
  • Page 51 13-9. Groove (Butt) Joints Tack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before final weld. Square Groove Weld Good for materials up to 3/16 in. (5 mm) thick. Single V-Groove Weld Good for materials 3/16 −...
  • Page 52 13-12. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in. (51-76 mm) 2 To 3 in. (51-76 mm) 1/4 in. (6.4 mm) S-0057-B 13-13. Troubleshooting Porosity −...
  • Page 53 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.
  • Page 55 Effective January 1, 2011 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of MB or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
  • Page 56 Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, op- eration, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number. To locate a Service Center: Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy For Technical Assistance: Call 1-800-332-3281...

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