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Summary of Contents for Fabco Power HYDRO ARC-S-6500 JSBC
- Page 1 Setting the Standard in Mobile Power Instruction Manual for Model 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: 845-469-7871 • Web Site/E-mail: www.fabcopower.com...
- Page 2 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.
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Page 3: General Information
General Information The Hydro Arc-S-6500 JSBC welder/generator are 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. - Page 4 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...
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Page 5: General Operating Instructions
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. - Page 6 Making it easier for the case drain oil to return to the tank. Retur n line must be ¾ or l a rge r *This does not apply if using FABCO POWER’S high efficiency Super V Tank & Cooler...
- Page 7 Important Hydraulic Circuit Installation Information If the hydraulically-driven welder/generator or 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).
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Page 8: Operating Instructions
Operating Instructions This welder is a hydraulically driven 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. - Page 9 Welder-Generator Operations Start Hydraulic System. Allow system to operate for about 5 minutes before engaging welder-generator. Engage welder-generator The red light between the receptacle must be lit bright indicating that the welder rotates at the proper speed. Set the range switch to the setting that covers the amperage you wish to weld at. Set the amperage selector switch to the amperage that is closest to the amperage you want to weld at.
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Page 10: Welder Specifications
Hydro ARC S-6500 JSBC Welder Specifications The ARC DC Welder/Generators are 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 ). - Page 11 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 Battery Charging 12 VDC Connect Battery Cables to lower left and lower right Terminals Set Range Switch to Center (BC)Position...
- Page 12 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.
- Page 13 FINE 300 A BC + JS Weld 12V BC + JS 36V BC + JS + CV FABCO ARC-S-6500-JSBC...
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Page 14: Troubleshooting
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. - Page 15 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 b o t t o m right, pull off the red and black wire coming from the brushes on the left bridge and red wire which is jumped over to the right bottom bridge.
- Page 16 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.
- Page 17 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 are 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.
- Page 18 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.
- Page 19 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.
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Page 20: Rotor Replacement
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. - Page 21 REPLACE BRUSHES Remove receptacle panel Cut tie raps holding brush holder wires, red & black Unplug red & black from rectifier bridges. Install wires in same way with new brush holder – red to red and black to black Remove old brush holder by removing one screw holding brush holder Do not lose plastic insulator located behind the brush holder Check slip rings Clean and polish with very fine sandpaper...
- Page 22 ARC-S-6500-JSBC DC Welder Parts 572723 300 AMP DC WELDER 572311 11 CC MOTOR PISTON TYPE 572617 MR2-A MOTOR MOUNT 572281 COUPLING 28 MM LO99 572282 HYTREL SPIDER LO99 572476 COUPLING 1” LO99 572341 240 V TWIST LOCK RECEPTACLE...
- Page 23 WARRANTY TERMS EACH FABCO POWER GENERATOR WARRANTED ORIGINAL OWNER FREE FROM DEFECTS IN MATERIAL OR WORKMANSHIP UNDER NORMAL SERVICE FOR ONE YEAR FROM DATE PURCHASE. OBLIGATION UNDER THIS WARRANTY LIMITED REPLACING OR REPAIRING, AT OUR OPTION, ANY PART PARTS PROVED TO...
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