Fabco Power HYDRO ARC-S-6500 JSBC User manual

Setting the Standard in Mobile Power
InstructionManualforModel
HYDRO ARC-S-6500 JSBC
Hydraulic Generator Welder
Manufacturing of: Vehicle Mounted Generators • Hydraulic Generators
P.O. Box 582 • Chester, NY 10918 • 845-469-9151 • Fax: [phone] •Web Site/E-mail: www.fabcopower.com
1

Caution
When used with customer supplied flow
regulator, use extreme caution on initial
setup. Over speed will cause physical
damage and is not covered under
manufacturer’s warranty.
2

General Information
The Hydro Arc-S-6500 JSBC welder/generatorare welders that
produce DC current welding power. The unit consists of three major
components: a DC welder, an AC generator and a jumpstart battery
charger to power 36 volt Dc wire feeders in CC and CV. The
amperage of the DC welder is controlled by selector switches. All JS
DC welders are operating at 3600 RPM. The AC generator section
produces 120/240Volt and 60 Hz sine wave output at 3600 RPM.
The welder generator is equipped with a high volume
internal fan for a maximum cooling effect.
3

GENERAL INFORMATION AND SPECIFICATIONS
HYDRO-ARC-S-6500 DC WELDER AC GENERATOR
GENERATOR DC / AC 60 HZ, SPEED = …3600 RPM
GENERATOR VOLTAGE……………..120 OR 120 / 240
MOTOR STARTING SURGE …= 300% OF CONTINUOUS
OUTPUT……..…5,000 WATTS CONTINUOUS AC OR DC
6,500 WATTS PEAK AC
AC AMPS @ 240 VOLT = 25
AC AMPS @ 120 VOLT = 50
DC WELDING AMPS = 300
HYDRAULIC MOTOR SPECIFICATIONS
AXIAL PISTON TYPE ……11 cc DISPLACEMENT
MOTOR SHAFT DIAMETER…………….ONE INCH
FLOW CONTROL (OPTIONAL)…CARTRIDGE TYPE
RATED FLOW = 11.6 GPM .…………. RATED PSI = 2,400
MOTOR SPEED = 3,600 RPM……. MAXIMUM = 4,200 RPM
INLET PORT SIZE = 1 & 1/16 –12 S.A.E
RETURN PORT SIZE = 1 & 1/16 –12 S.A.E
CASE DRAIN PORT SIZE = 1 & 1/16 –12 S.A.E
REV SH 7/2018
4

General Operating Instructions
This hydraulically-driven welder-generator consists of 3 main components:
a) Hydraulic drive
b) DC welder
c) AC generator
For the welder or generator to function properly the hydraulic drive must maintain
the proper speed (3600 –3720 for 60 Hz, 3000-3120 for 50 Hz) under all
conditions. Always allow the set to run for at least 2 minutes before operating the
welder or generator.
Operation
1) Connect welder leads (observe polarity).
2) Set Range Switch to the highest position for startup
3) Fine tune amp selector switch to desired amperage.
4) Start hydraulic system.
After waiting for a few minutes the welder is now ready for welding.
Increase amperage if necessary or decrease if amperage is too high.
Never operate any switches during welding.
The generator can be used during welding operation. A flicker and low Voltage in
the lights will occur every time you strike an arc, this cannot be avoided.
In order to obtain rated output of your generator section, the range switch must be
in the high position. The generator output is 120 VAC at 60
Hz and 230 V at 50 Hz. An optional 120/240 panel is available.
5

Hydro Arc 6500
Welder
General
Installation
The Arc 6500 is a hydraulically-driven AC welder/generator that will deliver rated amperage when the
proper flow is delivered to its hydraulic drive. Oil temperature should be between 100-140˚F. A
10-micron filter is also recommended to maintain the drive at its maximum performance. Depending on
the size of the reservoir, an oil cooler must be used; the smaller the reservoir; the larger the cooler.
* The tank should NEVER be smaller than 2 times the required GPM.
When starting a new hydraulic system, we strongly recommend that you connect the pressure line to the
return, bypassing the hydraulic welder drive. You should operate the system for 10 minutes that way.
This will clean the system; otherwise, all kinds of problems will occur. After connecting the pressure
and return line to the welder’s hydraulic drive, state your system at a low speed, slowly increasing the
speed until you reached the proper operating speed. While setting up a hydraulically-driven welder or
generator, it is necessary to check the speed setting of the hydraulic drive, since most systems will vary
in many ways (temperature –flow –viscosity / type of oil –etc.) from our test set up.
NEVER allow the welder to exceed 3900 RPM.
The return line pressure, under no circumstances, should reach 100 PSI or seal failure will occur.
The case drain must be connected directly to the tank (do NOT connect to the return line). We strongly
recommend that the case drain be connected to the upper portion of the tank. Making it easier for the
case drain oil to return to the tank.
Return line must be ¾ or larger
*This does not apply if using FABCO POWER’S high efficiency Super V Tank & Cooler
6

Important Hydraulic
Circuit Installation
Information
If the hydraulically-drivenwelder/generatoror
generator is mounted below the system tank, it is highly
recommended that a check valve with a very low cracking
pressure is installed in the case drain line (free flow motor
to tank, blocking tank to motor). This will eliminate seal
leakage during non-use time. It is also recommended that
the case drain be connected directly to the top of the tank
and not through a cooler or filter.
7

Operating Instructions
This welder is a hydraulicallydriven welder and it is extremely important that
the hydraulic system can supply the proper flow and pressure to maintain a
welder speed of 3,600 RPM under load. If the welder drops below 3600 RPM,
it cannot perform properly.
‰Start Hydraulic system
‰Turn welder hydraulic system on
‰Allow welder 2-3 minutes for warm-up
‰Be sure the red light between the 2 AC receptacles is lit
‰This will show you that the welder is close to the proper RPM and that
you have AC generator output
‰Insert welding leads into welding receptacles
CAUTION –Be sure that the positive cable is in the positive receptacle and
the negative cable in the negative receptive.
Set Range Selector switch to the position that is in the amperage range you
need for your welding job. Then set the Amp Selector switch to the amperage
that is nearest your desired amperage. Begin to weld. You may have to
switch one position up or down to get the desired amperage.
NEVER MOVE ANY SWITCHES DURING
WELDING
8

Welder-Generator Operations
1. Start Hydraulic System.
2. Allow system to operate for about 5 minutes before engaging welder-generator.
3. Engage welder-generator
3a. The red light between the receptacle must be lit bright indicating that the welder rotates
at the proper speed.
4. Set the range switch to the setting that covers the amperage you wish to weld at.
5. Set the amperage selector switch to the amperage that is closest to the amperage you want to weld at.
6. If the amperage is to high set the -10 amp switch to -10 amp side. This will lower the amperage by
10 amps from the amperage selector switch setting.
In order to maintain the set amperage welder must maintain its speed (3600 rpm). The max diameter rod
you can use on this welder is ¼” rod.
Do not change any switch settings during welding. The generator can be used during welding. To get the
6Kw at 120 volts from the generator the range switch must be in the 235-300 position.
The welder and generator are working as soon as the welder reaches the proper RPM (3600).
The generator can be used during welding operation.
9

Hydro ARC S-6500 JSBC
Welder Specifications
The ARC DC Welder/Generatorsare a combination Unit the will include
DC Welding , AC Power at 60 Hertz pure Sine Wave with less than 4 %
Distortion, Jump Starting of Vehicles in both 12 and 24 Volt , Batteries’
Charging for 12 and 24 Volt and will provide 36 Volt DC in CC and CV
to power Wire Feeders ( Mig ).
All the Functions can be performed at the same time with some
limitations.
The compact size of this Unit will save valuable space on Vehicles.
When compared to conventional Welders with some of the Features of
this Unit the Weight is reduced by around 70 %.
MODEL
WELDING
DC AMP
AC POWER
WATT
JUMP
STARTING
BATTERY
CHARGING
CC and CV
36 VDC
ARC-S-6500
300
6000
400
400
YES
10

For WELDING
Connect Welding Leads to Pos and Neg Welding Terminals
Set Range Switch to desired Welding Range
Set rotary Switch to desired Amperage
With the Min 10 Switch you can lower the Amperage 10
Amps
For BatteryCharging 12 VDC
Connect Battery Cables to lower left and lower right
Terminals
Set Range Switch to Center (BC)Position
Connect Cables to Battery. Select Charging Amps w.rotary
Sw. For Battery Charging24 VDC
Repeat 12 VDC Steps except connect cables to lower
Center and lower right Terminals.
Jumpstarting 12 V Batteries
Connect Cables to lower left and right Terminals
Set Range Switch to left or right Position (right is higher charging) Set
Rotary Switch to highest Position
Crank Engine 11

For Jumpstarting 24 V Batteries
Connect Cables to lower right and Center Terminals
Repeat above Switch Settings
For wire
Feeders
Connect Wire feeder to lower left and POS Weld Terminal
Set Switches to desired Amperage.
12

Weld
C
ompound
FINE
24V
BC + JS
12V
BC + JS
300 A
Weld
36V BC + JS + CV
FABCO ARC-S-6500-JSBC

Troubleshooting
Welder Completely Dead –No AC or
Weld
Power
Make sure welder is at proper speed=3600RPM. Unplug all external connections. A
shorted weld cable or generator accessory plugged in can cause the welder not to build
up. Several components can cause the welder to stop functioning completely. This is
mainly in the excitation circuit. Consisting of armature (rotor), Excitations Bridge (left
bottom corner) and auxiliary winding. Check the resistance of the auxiliary winding
by removing the two purple wires from the Excitation Bridge located at the left bottom
corner. The reading should be about 1.5ohms. Check the resistance of the armature
between the two slip rings –this should be 22ohms. Remove all wires for the left
bottom Rectifier Bridge and test for continuity between the terminals. Again, you
should get a high and low reading. If those three main components test out ok, try to
flash the armature with a 24volt circuit. A p p l y 1 2 v o l t s t o t h e s l i p r i n g
f o r a b ou t 2 0 s e c o n d s .
14

Troubleshooting
No Output on Weld Receptacles or
AC
Receptacles
This problem can be caused by many different factors. At rare occasions
a
welder/generator could lose its residual magnetism, which will cause the welder to be
completely dead. To Re-energize the magnetism remove the receptacle panel. Locate
the 2 exciter bridges on bottom left and bottom right, pull off the red and black wi re
coming from the brushes on the left bridge and red wire which is jumped over to the
right bottom bridge. With an OHM meter check the resistance between the red and
black wire which will check the resistance of the rotor, this should be about 25 ohms, try
to rotate the rotor while you take the reading to be sure the brushes are receded –if the
reading is intermitted check the resistance right on the slip rings. If necessary, remove
the brush holder. (See brush holder replacement). Apply 12Volts to the terminals on the
red and black wire coming from the brush holder. Apply 12 Volts for about 5 seconds.
Re-install wires –reinstall receptacle panel and louvered end cover and start welding.
15

Troubleshooting
No Output on Weld Receptacles but AC
Receptacle Output OK
If you have no welding power at all but the AC (120volts) is fully operational, this could
be caused by three components
The welding impedance (
transformer)
The stator windings
The main welding rectifier bridge
Using the electrical diagram check for continuity of the welding impedance. By
disconnecting the three heavy lead wires from the main welding bridge rectifier, you
can check continuity between those three wires. In any combination, the resistance
should be between one and 2 ohms. All three readings should be the same. If you have
readings that determines that the stator winding and impedance winding are in good
condition. With the three wires removed, you can now check the resistance of the main
Rectifier Bridge. By measuring resistance between the three terminals forward and
reverse you always should get a high and a low reading, for example; if you measure
between one and two, if the first reading is very high the reverse reading should be
very low. You also can check the bridge by taking a resistance reading on the main
welding terminals. Again, you should have a high and low reading by reversing the
leads.
16

Troubleshooting
No AC Output but Weld
Output
If the welder section functions properly but you have no AC output remove
the
receptacle panel and make sure the white plugs are plugged solid. If there a re
connected all the way, disconnect and make a resistance reading as follows
Blue to Brown (1.2ohm)
Black to White (1.2ohms)
If either one of those two readings are open the AC windings are defective. If they both
check out ok, check the receptacle and the wires going to the receptacles. To be certain
that is in the receptacle panel wiring, very carefully startup the welder and check for
120 volts between Blue and Brown and again 120 Volts between Black and White. If
you have 120 Volts pressing at those two readings, you must have a defective receptacle
or receptacle wiring.
17

Troubleshooting
Low Welding
Amps
Low welding amps can be caused by three
components
A defective Excitation Bridge located on the bottom right hand corner
B an open fine control (Optional). Resistance should be 6 ohms.
C Thermal trip in the windings. Disconnect the two AC wires off the bottom right
hand Excitation Bridge (white&orange) and make a resistance reading. With the
seven-step selector switch in the lowest position and the range switch and in the high
position you should get about 2 ohms. Move the seven-step switch while observing the
ohmmeter all the way to its highest position. The resistance should increase slightly
with every step. You should end up with about 3 ohms. If you do not start off with 2
ohms and the circuit shows open move your ohm meter 1 lead to the center terminal on
the range switch, the other ohm meter lead onto the terminal RL1 on the seven position
switch. If you have a reading, there about 2ohms the transformer is ok. To test for the
terminal trip in a windings take a reading between the center post of the range sw itch
and the white wire you remove from the Excitation Bridge. You should get 0ohms.
Any other readings on the trip are defective. To check the fine control put one-ohm
meter lead on the seven-step switch terminal RL1, the other lead on the orange wi re
you removed from the Excitation Bridge. You should be able by moving the fine
control up and down adjust the ohmmeter reading between 0 and 6 ohms. To check the
Excitation Bridge, remove all wires from it and measure forward and backw a rd
going around clockwise. In any position and in any combination between terminals
you should get a high and low reading. If any of the readings come out the same, the
bridge is defective.
18

Troubleshooting
Intermitting Welder Operation
Welder works properly for a few minutes and then stop operating but
returns to full
welding power after several minutes of cooling off.
This will occur when the welder is operated past its duty cycle or in extreme
high
ambient temperatures or if welder-cooling circuit is blocked. Be sure air intake is free
welder cooling might be affected by engine heat. Allow fresh air to enter louvered end
cover on welder. A cooling off period is 4-5 times longer if welder is turned off and
sitting still. Running it at its RPM will speed up the cooling and reset the internal
thermaltrip.
19

Rotor
Replacement
Remove two each fan grids. Remove receptacle panel Remove brush holder
held with one screw. Remove four plastic stop nuts holding front shield (fan
housing)
With gear puller push out rotor from slip ring side. Remove rotor assembly
from stator. Remove snap ring from shaft end which had the Pulley on it. Push
rotor out of front shield. Examine bearing and front shield to be sure it does not
need to be replaced. Push new rotor into front shield. Re-install small snap
ring. Be sure snap ring is in grove. Carefully re-install rotor into stator. Use
rubber mallet to tap into place. Re-install four elastic stop nuts. Tighten elastic
stop nuts in a criss/cross manner. Turn rotor by hand to make sure it turns
freely. If rotor seems not to run freely, tap the casting with a small metal
hammer on the slip ring end casting. This will seat the bearing. Apply 12Volts
to the slip ring for about 20 seconds. This will make sure that the residual
magnetism is energized. Re-install the brush holder. Be sure to have the
insulator behind the brush holder. Check for brush alignment to slip ring. Re-
install the two fan grids. re-install receptacle panel or louvered panel on slip
ring end.
20