use as a welder - Perfect Switch, LLC

use as a welder - Perfect Switch, LLC
2
TABLE OF CONTENTS
CONTENTS
PAGE
INTRODUCTION……………………………………
4
PACKING LIST / INSTALLATION TOOLS……..
5
CONTROL UNIT INSTALLATION……………….
6
INSTALLATION INSTRUCTIONS……………….
7
CONNECTIONS TO ALTERNATOR ……………
8
SECONDARY THROTTLE INSTALLATION……
9
POST INSTALLATION CHECK LIST……………
10
SAFE WELDING PRACTICES …………………..
12
USE AS A WELDER ………………………………
12
AUTOMATIC SWITCHING………………………..
15
PROPER OPERATING SPEED….…………….…
16
BATTERY BOOST-CHARGING / JUMP-STARTING…16
LED STATUS DISPLAY……………………………
17
BYPASS KIT………………………………………..
18
WARRANTY INFORMATION…………………….
19
WARRANTY REGISTRATION……………………
20
MOBI-POWER 3-PHASE OUTPUT ……………..
23
TECHNICAL SPECIFICATIONS………………….
24
TROUBLESHOOTING GUIDE…………………….
APPENDIX AND WIRING SCHEMATICS
25
3
INTRODUCTION
Congratulations on your purchase of the most technologically advanced alternator-actuated
welder and battery charger available. We use the highest quality components and cuttingedge technology to ensure that your MOBI-ARC Control Unit will be reliable for years to
come.
The star will indicate an item of special importance. Please read this manual in its entirety
before undertaking installation.
MOBI-ARC is a multi-function platform that provides the following functions when connected
to an alternator:
Ø Regulates the alternator during normal driving
Ø Provides a welding output equivalent to the amperage capability of the alternator
to which it is connected
Ø By using optional Mode Select Modules, the unit will provide accurate voltage
output at 100% of alternator’s current capability (based upon RPM) for vehicle
jump-starting and battery boost-charging applications
MOBI-ARC is designed to control most alternators. In most cases, no modifications are
required. However, in some cases, small modifications may be needed. For instance, an
alternator’s electrical components may not work with the MOBI-ARC Control Unit and must
be replaced. Alternators such as the Delco CS Series use avalanche diodes which are
designed to break down at approximately 20 volts. Because the MOBI-ARC open circuit
voltage is 42 volts, avalanche diodes would fail. In many cases, this issue can be overcome
by replacing the alternator’s diode plate with a rectifier which does not use avalanche diodes.
. Changing to a different alternator may be the most cost-effective way of working around the
avalanche diodes. In some cases, an internal regulator is present and must be disabled or
removed. Consult your MOBI-ARC reseller or contact the manufacturer for more information.
Due to the number of different alternators in use, for installation manual purposes, the
assumption is that the alternator connected to the MOBI-ARC Control Unit is “MOBI” ready.
Please refer to the APPENDIX at the end of this manual for information specific to your
alternator (as of printing). For current alternator information, please visit our website, contact
your MOBI-ARC reseller, or contact the manufacturer.
A basic understanding of your alternator and auto-electrics is required for installation. We
encourage those who don’t have a healthy auto-electrical background to have MOBI-ARC
professionally installed.
Installation instructions specific to your particular vehicle can be found in the APPENDIX at
the end of this manual, on our website at www.mobi-arc.com or can be supplied by your
MOBI-ARC reseller.
THIS PRODUCT CONTAINS ELECTRONICS AND HIGH-CURRENT CONNECTIONS. THE
STRICTEST CARE MUST BE TAKEN WHEN CONNECTING AND TERMINATING WIRES.
CONNECTIONS MUST BE CRIMPED AND SOLDERED IN ORDER FOR MOBI-ARC TO
WORK AT PEAK PERFORMANCE. POOR CRIMPS AND HIGH-RESISTANCE
CONNECTIONS WILL YIELD EXCESSIVE HEAT, DIMINISHED PERFORMANCE, AND
POSSIBLY FAILURE.
UNITS INSTALLED IMPROPERLY ARE NOT COVERED
UNDER THE MANUFACTURER’S WARRANTY
4
MOBI-ARC PACKING LIST
The following items make up the MOBI-ARC Kit:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
MOBI-ARC Control Unit
Stainless Steel Mounting Bracket
#4 AWG Cable Assembly
10-Pin Molex Wiring Harness Assembly
Ground Clamp
Electrode Holder
Welding Cable Connectors (2)
Secondary Throttle Assembly w/ hardware
Hardware Kit
Welding Receptacle Covers (2)
BYPASS Kit (Bypass Plug, insulation tape, bolt, instruction card)
#4 AWG welding cables are not included and can be purchased from your MOBI-ARC reseller, or
from a local welding supply store, and may be cut to whatever length you require. If welding
cables exceed 70 feet in length, drop to #2 AWG cable.
WHERE POSSIBLE, CABLES AND WIRES HAVE BEEN TERMINATED BY INDUSTRIAL
COMPRESSION MACHINERY USING UL APPROVED METHODS. WE STRONGLY
RECOMMEND NOT CUTTING AND SPLICING.
HIGH-CURRENT AND LOW-CURRENT CONNECTIONS MUST BE SOUND IN ORDER FOR
MOBI-ARC TO RUN AT PEAK PERFORMANCE. WHERE THE INSTALLER TERMINATES
CABLES AND WIRES, CRIMP AND SOLDER DILIGENTLY.
INSTALLATION TOOLS (not provided)
You or your installer will need the following tools:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Wire cutters / strippers
Crimping device
Solder and flux
Torch or high-heat soldering iron
1/2” wrench or nut driver
Drill and assorted drill bits (for bracket installation)
Digital multi-meter (test light inadequate)
Phillips screwdriver
5/32 hex driver
5
MOBI-ARC CONTROL UNIT INSTALLATION
The MOBI-ARC Control Unit is designed for engine compartment installations. It is engineered to
withstand under-hood temperatures, vibration, dust, and moisture. Please keep the following
points in mind when selecting a mounting location:
Ø
Ø
Ø
Ø
Ø
Distance to the alternator (standard cable/wire assembly is six feet)
Distance to the battery
Easy access to both front and back of the MOBI-ARC
Footprint doesn’t conflict with other wires/cables/reservoirs etc…
Adequate distance from high-heat sources like exhaust manifold
Once a mounting location has been selected, mount the U-Shaped Mounting Bracket using the
provided self-piercing #10, ½” steel hex-head screws. U-Shaped Mounting Bracket can be used
as a hanging bracket, or an under-unit support bracket.
Once the U-Shaped Mounting Bracket is securely mounted, mount the MOBI-ARC Control Unit in
the bracket using the provided Rosette Thumb Screws (2) and nylon flat washers (4). Nylon flat
washers are placed between the bracket and the MOBI-ARC Control Unit, two on each side.
DO NOT OVERTIGHTEN PLASTIC THUMB SCREWS
DO NOT REPLACE PLASTIC THUMB SCREWS WITH LONGER SCREWS. LONGER
SCREWS MAY GROUND INTERNAL COMPONENTS.
THE MANUFACTURER IS NOT RESPONSIBLE FOR DAMAGE CAUSE BY IMPROPER
INSTALLATIONS
6
INSTALLATION INSTRUCTIONS
DISCONNECT POSITIVE TERMINAL ON
BATTERY(S)
Your MOBI-ARC Kit is equipped with the following wiring/cabling harness:
10-Pin
Harness
Length
#4 AWG Cable
Assembly
Length
MOBI-ARC 130
YES
6‘
YES
6’
MOBI-ARC 200X
YES
6’
YES
6’
MOBI-ARC 200X
Extension
YES
15’
YES, 2 sets
15’
MOBI-ARC 300 I-Series
YES
6’
YES, 2 sets
6’
The following requires a ½” wrench or nut driver and please refer to the wiring diagram:
1.
2.
3.
4.
Remove 5/16” nylon insert locking nuts and washers from their respective posts on the
MOBI-ARC Control Unit.
BLACK #4 AWG cable(s) with right -angle lug(s) attach to “GROUND” post. Replace
washer, nut, and tighten.
YELLOW #4 AWG cable(s) with right-angle lug(s) attach to “ALTERNATOR” post.
Replace washer, nut, and tighten. Those with two YELLOW #4 AWG cables utilize both
“ALTERNATOR” posts.
RED #4 AWG cable(s) with right-angle lug(s) attach to “BATTERY” post.
DO NOT OVERTIGHTEN NYLON INSERT LOCKING NUTS. IF MOUNTING STUDS SPIN,
INTERNAL CONNECTIONS MAY BE BROKEN.
MAKE SURE RIGHT-ANGLE LUGS ARE PROPERLY INSULATED AND CANNOT SHORT ON
EACH OTHER, OR THE MOBI-ARC CASING.
7
CONNECTIONS TO THE ALTERNATOR
REMOVE ORIGINAL ALTERNATOR OUTPUT
CABLE. IT WILL NOT BE USED. INSULATE AND
SECURE FROM ROTATING PARTS.
Please refer to the wiring diagram specific to your vehicle. The following is a general
overview and not all wires are used for every installation:
1.
2.
3.
4.
5.
6.
Disconnect all wires and cables attached to the original alternator. Insulate and secure
away from moving parts; they will not be used.
Original BATTERY OUTPUT CABLE will not be used. Insulate and secure out of the way
of moving parts.
BLACK #4 AWG cable connects to ground, preferably alternator. (ex. ground sandwiched
between the thru-bolt, alternator casing, or mounting bracket) If a solid alternator ground
is in question, connect to the BATTERY NEGATIVE terminal on the battery. It is critical
that the alternator is grounded properly.
YELLOW #4 AWG cable(s) connect to the large battery output post on the back of the
alternator.
RED #4 AWG cable(s) connect to the BATTERY POSITIVE post on the vehicle’s battery.
Refer to the diagram specific to your vehicle when connecting the wires from the 10-Pin
Wiring Harness.
DO NOT REMOVE 10-Pin HARNESS WHILE VEHICLE IS RUNNING
8
SECONDARY THROTTLE INSTALLATION
A secondary throttle has been provided and may be used to adjust the vehicle RPM up or
down. The faster the alternator spins, the greater the power output.
IMPROPER INSTALLATION OF A SECONDARY THROTTLE CAN BE VERY
DANGEROUS AND SHOULD ONLY BE UNDERTAKEN BY A PROFESSIONAL.
SECONDARY THROTTLE CABLE SHOULD BE MOUNTED SO THE CONNECTION TO
THE VEHICLE’S THROTTLE IS EASILY REMOVABLE DURING DAILY DRIVING.
SECONDARY THROTTLE MUST NOT INTERFERE WITH NORMAL VEHICLE
OPERATION.
Refer to the complete wiring diagram and double-check that all connections are sound.
Thoroughly check installation integrity keeping in mind that the Manufacturer’s warranty does not
cover damage caused by improper installations.
INSTALLATION IS COMPLETE
BEFORE YOU RECONNECT THE BATTERY AND
FIRE EVERYTHING UP, CONTINUE TO
POST INSTALLATION CHECKLIST…
9
POST INSTALLATION CHECK-LIST
Most failed installations occur when installers are careless, don’t follow the instructions precisely,
or try to run MOBI-ARC when due diligence has not been executed. Before the vehicle is fired up
and welding is attempted, please follow this step-by-step procedure. Should any of these steps
not respond as indicated, STOP, double-check your work, or contact your MOBI-ARC reseller or
the manufacturer for assistance. It’s easier to ask a quick question, than to repair a damaged
product.
Check the Yellow, Red, and Black cables on the back of the MOBI-ARC. Be sure they
are properly insulated, oriented, and cannot short. Once completed, reconnect the
battery. Make sure there is no Mode Select Module Inserted.
With ignition off, use a digital multi-meter (not analog or a test light) and read voltage
between the ALTERNATOR POST and the GROUND POST on the back of the MOBIARC Control unit. The reading should be between .4v and 1v less than battery voltage.
Battery Voltage
_________volts
Alternator Voltage
_________volts
Subtract the two readings
_________volt
The difference should be between .4 and 1.0 volts. If it’s
not,
, you may have a configuration problem.
Double-check your work and call for support.
Switch vehicle’s ignition on. DO NOT START THE VEHICLE. The CHARGE and
IGNITION lights should be illuminated. Feel the control unit, wires, cables, and
alternator. If anything starts to get hot, then
and call for support. If the LED lights
fail to illuminate, then stop and call for support.
Using your digital multi-meter, connect the test leads between the GROUND POST and
ALTERNATOR POST on the back of the control unit. While watching the digital multimeter, start engine. With engine running, meter should read between 14.0 and 15.0
volts. If not,
. Shut off engine and call for support. If okay, move to next step.
Engine is running. With your digital multi-meter connected between ALTERNATOR
POST and BATTERY POST on the back of the control unit, reading should be no more
that 3/10 of a volt less than the alternator voltage reading above. As the battery accepts
a charge, this reading should slowly diminish. If your reading is greater than 3/10 of a
volt, or is increasing,
SHUT OFF ENGINE. Call for support.
Insert welding cables. Electrode holder (stinger) in the positive position, ground clamp in
the negative position. We are not going to weld, but you will need an electrode inserted
in the electrode holder. We are going to test the switching mechanism with the following
process:
1. Digital multi-meter connected to the ALTERNATOR POST and the GROUND
POST on the back of the control unit. We are reading the alternator’s output.
2. Start the vehicle and set the idle at 1200 rpm’s. With vehicle running, the meter
should read between 14.0 15.0 volts and the LED’s on the control unit should
reflect CHARGE and IGNITION illuminated.
10
3.
While reading the multi-meter, take your electrode and strike the tip against the
ground clamp, hard enough to create a quick arc or spark. The following will
occur:
Alternator’s output will instantly jump to +/- 37v to 42v
CHARGE LED will extinguish
WELD LED will illuminate.
If the alternator’s voltage does not instantly increase to +/- 40v, or the LED’s do
not behave as indicated above,
. Shut off engine. Call for support.
4.
The control unit will stay in the “Weld” mode for fifty (50) seconds, at which point
it will switch back to the “Charge” mode. While the unit is in the “Weld” mode,
although the alternator is at +/- 40 volts, the battery will read static battery voltage
of +/- 12.5 volts. If, during the “Weld” cycle, the battery rises to more than 15v,
then
. SHUT OFF ENGINE. Call for support.
If the above steps have been checked-off, then continue to “Safe Welding Practices” on the
following page.
If your control unit doesn’t behave exactly as indicated above, you may have an alternator
configuration problem, a wiring problem, or a control unit problem. Disconnect the battery
and double-check the installation diagram specific to your vehicle. If you cannot identify a
problem, follow the Troubleshooting Guide on page 25 of this manual, and then call for
support.
11
SAFE WELDING PRACTICES
Safe welding practices must be adhered to when using MOBI-ARC. Please abide by the
following guidelines:
Ø
ARC RAYS, HOT SLAG and SPARKS CAN INJURE EYES and BURN SKIN
The welding process produces extreme localized heat and strong ultraviolet rays.
Never attempt to weld without a welding helmet with the proper lens. A number 12 to
14 shade filter lens provides the best protection against arc radiation. Make sure
others are protected by approved shielding curtains. Make sure children and animals
are clear of the welding area. Skin should also be protected from arc rays, heat, and
molten metal by wearing gloves and clothing that will not allow skin exposure.
Ø
WELDING SPARKS CAN CAUSE FIRES and EXPLOSIONS
Causes of fire and explosion are; combustibles reached by the arc, flame, flying
sparks, hot slag or heated materials. Remove combustibles from the work area
and/or provide a fire watch with a suitable fire extinguisher and/or sufficient water and
tools. Avoid oily or greasy clothing as a spark may ignite them. Be alert to the
danger of conduction or radiation. All hollow spaces, cavities and containers should
be vented prior to welding to permit the escape of air or gases. Purging with inert
gas is recommended. Arcing against any compressed gas cylinder can cause
cylinder damage or explosion.
Ø
SMOKE, FUMES, and GASES CAN BE DANGEROUS TO YOUR HEALTH
Keep smoke, fumes, and gases from the breathing area. Fumes from the welding
process are of various types and strengths, depending on the kind of base metal
being worked on and can cause discomfort and physical harm if inhaled over an
extended period of time. To ensure your safety, do not breathe these fumes.
Ventilation must be adequate to remove smoke, fumes, and gases. Vapors of
chlorinated solvents can form the toxic gas “Phosgene” when exposed to ultraviolet
radiation from an electric arc. All solvents, degreasers and potential sources of these
vapors must be removed from the operating area.
Ø
DELICATE ELECTRONIC EQUIPMENT
Welding equipment can damage and/or interfere with the operation of delicate
electronic equipment. Welding equipment should not be used by individuals who use
pace-makers or other life-sustaining electronic medical implants or devices.
For more information:
Ø
Ø
Ø
Ø
US Government Printing Office, Washington, DC 20402 Code of Federal
Regulations (OSHA), Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253,
and 1000.
American National Standards Institute, 1430 Broadway, NY, NY 10018 ANSI Z49.1
“Safety in Welding and Cutting”; ANSI Z87.1 “Practice for Occupational and
Educational Eye and Face Protection”; ANSI Z88.2 “Standard Practice for
Respiratory Protection”
American Welding Society, 550 NW Lejune Road, POB 351040, Miami, FL 33135
AWS C5.3 “Recommended Practices for Air Carbon Arc Gouging and Cutting”; AWS
F4.1 “Recommended Safe Welding Practices for Welding and Cutting Containers”
National Fire Protection Association, Battery Park, Quincy, MA 02269 NFPA 51B
“Fire Prevention in Cutting and Welding Processes”
12
USE AS A WELDER
The MOBI-ARC Control Unit is completely automatic. During daily driving conditions, the Control
Unit will pulse-width modulate (PWM) the alternator output to create an automotive-friendly
14.7 volts (+/-). Should welding be required, simply insert welding cables, idle up the vehicle, and
strike an arc. The MOBI-ARC Control Unit is voltage-sensing meaning that when an arc is struck,
the Unit senses the strike, instantly isolates and protects the vehicle’s battery and electrical
system. The MOBI-ARC then pulse-width modulates the alternator very efficiently to create
higher voltage and maximum current (based upon alternator RPM) for welding and battery
boost/jump-starting applications (see “BATTERY-BOOST / JUMP-STARTING”).
The following instructions can be carried out either with, or without the vehicle running. Keep in
mind that the MOBI-ARC generates constant current and constant voltage; when connected to
the welding receptacles, the welding cables are live.
1.
Plug the welding cables into the welding sockets on the face of the MOBI-ARC Control
Unit; stinger positive, ground negative. Twist connector until firmly seated. To change
the polarity, simply switch the cables.
WHEN WELDING ON MY VEHICLE
When Welding on one’s own vehicle, ONLY weld with the STINGER in the
POSITIVE POSITION
2.
3.
4.
5.
Connect the ground clamp close to the intended welding target area.
Throttle up the vehicle to increase the alternator’s output.
Using the appropriate electrode, strike arc and weld. If weld is too cold, throttle vehicle
higher. If weld is too hot, throttle down vehicle. Refer to “DETERMINING PROPER
OPERATING SPEED” on the following page.
After welding, throttle down vehicle; disconnect cables and store for later use.
INTENTIONALLY LEFT BLANK
13
14
AUTOMATIC SWITCHING
A sophisticated timing circuit has been engineered into the MOBI-ARC Control Unit. This circuit
will automatically switch the Control Unit from the “Welding” mode back to the “Charging” mode
with no user intervention. The timer is set for a eleven (50) second delay. If there is any lapse in
welding, after 50 seconds of non-use, the MOBI-ARC Control Unit will automatically switch
modes and charge the vehicle’s battery at 14.7 volts (+/-).
PROPER OPERATING SPEED
The MOBI-ARC Control Unit is engineered for constant current and constant voltage. Voltage
and current will be present even when the vehicle’s engine is at idle and spinning slowly. Varying
alternator RPM will create higher or lower levels of voltage and current. Most alternators will
provide maximum output capability when rotating at approximately 6,000 alternator RPM.
Spinning slower will simply yield less output at a given RPM. To determine the approximate
engine operating speed for welding at best alternator capability, measure the diameter of the
engine’s crank pulley and refer to the chart below:
NOTE: Chart assumes 2” alternator pulley
CRANK PULLEY DIAMETER
4.5”
5“
5.5”
6”
6.5”
7”
7.5”
8”
8.5”
9”
9.5”
ENGINE RPM RANGE
2,700
2,400
2,200
2,000
1,800
1,700
1,600
1,500
1,400
1,300
1,300
to
to
to
to
to
to
to
to
to
to
to
3,100
2,800
2,500
2,300
2,200
2,000
1,900
1,800
1,600
1,600
1,500
Direct Current welding is considerably easier than welding with Alternating Current. By selecting
the appropriate welding electrode, excellent welds on numerous types of metals can be achieved.
For general repairs on mild steel, we suggest the following:
Smaller alternators
Larger Alternators
Industrial Alternators
6010/6011/6013 or 7018
6010/6011/6013 or 7018
6010/6011/6013 or 7018
3/32” or 1/8" electrode 3.25mm
up to 5/32” electrode 4.00mm
up to ¼” electrode 6.35mm
15
BATTERY BOOST-CHARGING / JUMP-STARTING
When optional MODE SELECT Modules are purchased, the MOBI-ARC Control Unit can provide
regulated voltage at 100% of the alternator’s current capability for safe and efficient BATTERY
BOOST-CHARGING and vehicle JUMP-STARTING applications.
The 16-Pin Receptacle denoted as “MODE SELECT” is located on the back of the Control Unit.
MODE SELECT Modules can be inserted which program the MOBI-ARC Control Unit to create
specific voltage from the welding receptacles at 100% of the alternator’s current capability.
Standard MODE SELECT Modules are programmed for 14 volts, 28 volts, 36 volts, and 42 volts.
Any voltage requirement between 12 and 42 volts can be custom engineered. Please contact the
manufacturer.
When Jump-Starting, please adhere to the following safety conditions:
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Wear protective eyewear and clothing and remove all jewelry.
No smoking, open flames or sparks should be allowed near the battery.
Never attempt to jump-start a car if gasoline fumes are present either around the source vehicle (good battery)
or the dead vehicle.
Check the water level in the dead vehicle's battery and fill if needed.
Use extreme caution with jumper cables!
Avoid connecting cables in reverse polarity.
Do not let the vehicle bumpers touch.
Turn the source vehicle off before making any jumper cable connections between the two batteries.
Clean the battery terminal surfaces of corrosion to ensure clean and quick connections.
To jump-start a vehicle with a 12 volt negative ground, the jump-starting voltage should not
exceed 14.7 volts. Insert a 14 volt MODE SELECT Module and the Unit’s output voltage will not
exceed 14.7 volts, regardless of RPM.
1.
2.
3.
4.
5.
6.
Connect welding leads into welding sockets on the front of the MOBI-ARC Control Unit;
adhere to polarity: stinger positive, ground negative.
Insert 14 volt MODE SELECT Module in 16-Pin receptacle.
Adhering to correct polarity, connect stinger positive to the positive terminal of the
dead battery.
Adhering to correct polarity, connect ground clamp to the negative terminal of the dead
battery.
Start the source vehicle, increase RPM to about 2,000 and allow two to five minutes for
the dead battery to charge.
Start the dead vehicle and remove the cables in reverse order.
IMPORTANT
Do not Jump-Start or Boost-Charge without the proper MODE SELECT Module inserted.
Damage to vehicle, battery, or the MOBI-ARC may occur.
The chart below illustrates the MOBI-ARC Control Unit’s output levels:
MODE SELECT MODULE
VOLTAGE OUTPUT
IDEAL CHARGING SYSTEM
CURRENT LEVEL
NOT INSERTED
42v
DO NOT JUMP
100% of ALT. CAPABILITY
14v Module
14.7v
12v
100% of ALT. CAPABILITY
28v Module
28.7v
24v
100% of ALT. CAPABILITY
42v Module
42v
42v
100% of ALT. CAPABILITY
16
LED STATUS DISPLAY
The MOBI-ARC Control Unit is equipped with four indicator lights. These indicator lights provide
basic feedback as to the condition of the printed circuit board. For instance, when the green
CHARGE light is illuminated, the MOBI-ARC Control Unit is in the “CHARGE” mode. However, if
the battery is not correctly wired to the Control Unit, the battery will not be charging.
LIGHT
WELD
IGNITION
CHARGE
OVERTEMP
FUNCTION
Light illuminated when the Control Unit is triggered into the “WELDING” or “BATTERY
BOOST” modes. Control Unit disconnects battery and electrical system from the
alternator.
Light illuminates when ignition is keyed-on.
Light illuminates when the alternator is connected to the vehicle’s battery and
electrical system. Control Unit regulates the voltage to 14.5 volts (+/-)
Light illuminates when the temperature within the Control Unit exceeds specified
safety levels. When the temperature falls, the Control Unit will automatically reset.
Under normal conditions, MOBI-ARC will run cool. The illumination of the
OVERTEMP light is an indication of excessive heat either triggered by excessive
ambient engine temperature, or an internal MOBI-ARC component failure. Seek
assistance from the manufacturer or your MOBI-ARC representative.
17
BYPASS KIT
Utilizing the MOBI-ARC BYPASS Kit, the MOBI-ARC Control Unit can be removed from the
vehicle and the alternator’s original regulator can be re-enabled. This is beneficial in the following
circumstances:
1.
2.
Some customers have several vehicles and would like to utilize MOBI-ARC from several
different platforms. By purchasing additional installation kits, a customer can quickly
move the MOBI-ARC Control Unit from vehicle-t o-vehicle, avoiding the additional
expense of a second and third Control Unit.
The MOBI-ARC Control Unit may require service. Because the Control Unit houses the
regulation system for the alternator, should the Control Unit be removed, the stock
regulator must be re-enabled so the vehicle may resume activity.
The BYPASS Kit is contained in the zip-lock baggie and is part of the accessory kit. The baggie
has a hole and is designed to be zip-tied to the Control Unit mounting bracket where it can be
easily accessed should a BYPASS be required. An extra hole in the mounting bracket has been
provided for this purpose.
In most cases, the BYPASS plug is housed in the zip-lock baggie for easy access. On some
installations, the BYPASS plug has been incorporated into an alternator’s modification harness.
DISCONNECT NEGATIVE TERMINAL ON
BATTERY(S)
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect Battery negative.
Detach 10-Pin wiring harness connector from the Control Unit.
Connect molded BYPASS plug to the wiring harness.
Remove yellow ALTERNATOR cable and red BATTERY cable from their respective
posts on the back of the Control Unit.
Attach yellow ALTERNATOR cable to red BATTERY cable with provided 5/16” steel
bolt.
Secure with nut and washer from the Control Unit and insulate with provided
electrical tape.
Be sure of proper insulation and secure cables from moving parts.
Reconnect BATTERY, start vehicle, and verify normal charging.
18
WARRANTY INFORMATION
Mobile Welding & Power, Inc. warrants the MOBI-ARC and MOBI-POWER against all defects in
materials and workmanship for a period of one year from the date of the original purchase,
subject to the following terms and conditions:
This warranty does not apply if the serial number or housing of the product has been removed, or
if the product has been subjected to physical abuse, improper installation, water damage,
corrosion due to road salts or de-icing chemicals, or modification.
To obtain warranty service, please contact the manufacturer for a Return Materials Authorization
(RMA) number. The product must be ret urned, insured and shipping prepaid, to Mobile Welding
& Power, Inc., at the address below, in its original packaging or a suitable equivalent, along with a
written description of the problem.
Mobile Welding & Power, Inc.'s responsibility under this warranty is limited to repair or
replacement of the product or refund of its purchase price, at the sole discretion of Mobile
Welding & Power, Inc.
Mobile Welding & Power, Inc. disclaims all other warranties, expressed or implied, including
warranties of merchantability and fitness for any particular purposes whatsoever, and no other
remedy shall be available including without limitation, incidental or consequential damages. In no
event shall Mobile Welding & Power, Inc.'s liability exceed the purchase price of the product in
question.
Some states do not allow the exclusion or limitation of incidental or consequential damages of
how long an implied warranty lasts, so the above limitations or exclusions may not apply to you.
This warranty gives you specific rights. You may have other legal rights which may vary from
state to state.
Mobile Welding & Power, Inc. wants you to be satisfied with its products. Should you have any
difficulties with the operation or performance of your MOBI-ARC and MOBI-POWER, please
contact:
Mobile Welding & Power, Inc.
Customer Service
11526 Sorrento Valley Road, Suite B
San Diego, California 92121
(858) 720-1339 (858) 720-8556 fax
www.mobi-arc.com
FOR YOUR PROTECTION, PLEASE FILL OUT THE WARRANTY / REGISTRATION CARD ON
THE FOLLOWING PAGE or REGISTER ON-LINE AT www.mobi-arc.com/register.htm
FILL IN AND KEEP FOR YOUR RECORDS:
MODEL
_____________________________
SERIAL NUMBER
_____________________________
PURCHASE DATE
_____________________________
PURCHASED FROM
____________________________
19
20
MOBI-ARC ** MOBI-POWER
11526 Sorrento Valley Road, Suite B
San Diego, CA 92121
TEAR HERE
ATTN: Registration Department
TAPE DOCUMENT CLOSED WITH THIS SIDE FACING OUT
NAME
____________________________
STREET
____________________________
CITY
____________________________
STATE
______________ ZIP__________
COUNTRY
____________________________
E-MAIL ADDRESS _________________________
MODEL
SERIAL No.
____________________________
____________________________
PURCHASE DATE
______________________
PURCHASED FROM
______________________
CITY / STATE ____________________________
PURCHASE PRICE (excluding tax) _______________
DATE OF BIRTH __________________________
WELDING LEVEL
q
q
q
Novice
Recreational
Professional
Turf Utility
Farm / Agriculture
Fire / Rescue
Off-Road
Racing
Industrial Fleet
General Maintenance
Construction
Other – Please explain below:
DO YOU OWN A COMPUTER?
YES
q
q
Self
Gift
WHAT INFLUENCED YOUR PURCHASE OF THIS
PRODUCT?
q
q
q
q
q
q
q
Friend’s Recommendation
Dealer Recommendation
Magazine Article
Magazine Advertisement
Reputation of Manufacturer
Infomercial
Other ________________________________________
WHERE HAVE SEEN ADVERTISING?
q
q
q
q
q
q
q
q
q
q
Offroad.com
Television
Four Wheeler
Sport Truck
Truck’n
JP
Off-Road
General Interest Publication ____________________
Specialty Trade Publication ____________________
Other:
HOW LONG DID YOU OWN YOUR PREVIOUS ON-BOARD
WELDER?
q
q
q
q
q
q
No previous welder
1 year or less
2 years
3 years
4 years
5 or more years
WHAT BRAND(S)
WHERE DO YOU PLAN TO USE YOUR MOBI PRODUCT?
q
q
q
q
q
q
q
q
q
DID YOU PURCHASE THIS PRODUCT FOR YOURSELF OR
DID YOU RECEIVE IT AS A GIFT?
q
q
q
q
q
q
q
q
q
q
q
Mobi-Weld
Ready Welder
Resco
Zena
Link-Arc
Hehr Power Arc II
Premier Power Welder
Thunderbolt
Canadarc
Stellarc
Other _________________________________________
We value your feedback and constantly strive to provide products and
applications that meet our customer's needs. Please use the space
below for comments, criticism, ideas, etc..
NO
21
22
MOBI-POWER 3-Phase Output
MOBI-POWER™ is an optional accessory
designed to compliment any
MOBIARC™ Control Unit. Incorporating dual UL
approved splash-proof 120 volt DC power
outlets, MOBI-POWER™ can drive halogen
lighting, universal power-tools like grinders,
sanders, saws, etc, and comes in two
performance levels: 1,500-2,500 watts and
4,500-5,500 watts (alternator dependant). Foreign outlets providing 220 volts DC
are also available.
In order for the transformers to work correctly, AC current directly from the
alternator’s stator must be accessible. Some alternators provide AC taps on the
casing where it’s easy to reach, however most don’t. The idea is to provide
easy-to-access AC taps by adding three (or four) strands of 16-gauge wire and
routing the wires to the outside of the alternator where they can be easily tapped.
Alternators generally utilize two types of stator configurations:
• Wye (four stator wires)
• Delta (three stator wires)
Where each stator wire connects to the rectifier, diligently solder a strand of 16gauge wire. With a Wye configured stator, four wires will be added. With a Delta
configured stator, three wires will be added.
Being sure that the additional wires do not conflict with any rotating parts, secure
the wires with silicon and cable ties to ensure a gentle tug won’t pull the wires
free.
DELTA STATOR
THREE WIRES
WYE STATOR
FOUR WIRES
23
TECHNICAL SPECIFICATIONS
ALTERNATOR:
User supplied or purchased through select manufacturers
Delta Wound Stator Preferable
Removed or disconnected Excitation Diodes (diode trio)
Rectifier utilizing non-Avalanche Diodes
12 volt or 24 volt Compatible (pre-set at factory)
MOBI-ARC CONTROL UNIT:
Dimensions (W x H x D):
4.6" x 2.5" x 4.5"
Weight:
24 oz.
Pulse-Width Modulation Regulation
Solid-State Switch-mode technology
Automatic Mode Switching
Option Mode Select Modules
Fail-Safe Mode
LED Indicator Lights
Welding Cable Sockets
Diagnostic Output
Maximum Switchable Charging Current:
MOBI-ARC 130
MOBI-ARC 200x
MOBI-ARC 300 I-Series
up to 130 amps
up to 200 amps
up to 300 amps
Thermal / Amperage Overload Protection
Water Resistant / Dust Resistant
Welding: (Specifications Vary between Alternators)
Power produced:
Welding Amperage:
Duty Cycle: 100%
Open Circuit Voltage (OCV):
Closed Circuit ARC-voltage:
Electrode sizes:
Direct Current (DC).
Up to 300 amps
42 volts
18 to 28 volts
up to 5/32 (4.0mm)
Battery Jump/Boost Charging:
12-48 Volt Batteries
Regulated Direct Current
Optional Mode Select Modules
(14v, 28v, 36v, 42v)
We reserve the right to change technical specification.
24
TROUBLESHOOTING
The purchase of your MOBI -ARC Control Unit includes one 15 minute phone call. You
must have a serial number to access the service department. Subsequent calls will be
billed at $1.00/minute with a $15.00 minimum. Please have your Mastercard or Visa ready.
Before you call for technical support, please be sure installation instructions have been executed
as stipulated in the installation diagram pertaining to your vehicle. Most complications are due to
poor crimps, bad connections, or simply not following the directions.
To verify the MOBI-ARC Control Unit is working correctly, the 16-PIN “MODE SELECT”
receptacle also serves as a diagnostic output. Utilizing a digital multi-meter (not a test light), set
the DC reading to four places (ex. 12.52).
Switch vehicle ignition to the “ON” position. With the negative meter probe connected to
Ground, insert the positive probe into each of the sixteen points as viewed in the diagram below.
The sixteen holes are insulated from each other so don’t worry about shorting anything out. As
you probe each hole, write down the voltage reading in the empty box provided in the diagram.
If the voltage readings fall within the specified parameters, the control unit is working correctly.
Any problem will be external to the control unit (alternator, wiring/cabling, connections, or battery).
If the voltage readings fall outside the specified parameters, this may indicate a problem with the
control unit; please contact the manufacturer or your MOBI-ARC reseller.
(BELOW---16-PIN RECEPTACLE AS VIEWED FROM REAR OF
CONTROL UNIT)
BATTERY _______volts
BATTERY POST ________volts
ALTERNATOR POST _______volts
25
TYPE OF
PROBLEM
PROBABLE
CAUSE
RECOMMENDED FIX
Make sure 10- pin harness is inserted in HARNESS receptacle.
Battery connection has been restored.
NO LIGHTS ON CONTROL UNIT.
Bad connection or wired incorrectly
Electrical configuration of Blue and/or Green
wires are incorrect in relation to the alternator’s
electrical configuration
ALL LIGHTS ON (except CHARGE) ,
BUT NO CHARGING CURRENT
GETTING TO THE BATTERY
Battery level is too low for the control unit to
function correctly
Gray wire is not connected to battery or is o n
the wrong side of a dual -battery isolation
device.
Red and Yellow #4 AWG cables are not
installed between the control unit, alternator,
and battery
Poor ground on alternator
Bad alternator
Mode Select Module left in 16- pin receptacle
STRIKE AN ARC TO WELD, BUT
ONLY LIGHT SPARKING TAKES
PLACE AT THE WORK-PIECE.
Control unit isn’t switchi ng into “weld” mode.
STRIKE AN ARC TO WELD,
WELDING BEGINS BUT THEN
FADES AWAY.
Drive belt is not tight enough and slipping as
alternator loads.
Make sure in-line fuse(s) have not been blown. If blown. Check for
short and contact manufacturer.
Place battery on shop charger and bring charge level up to 12.5 v
+/Connect Gray wire to Battery.
Be sure Yellow cable is installed between alternator and control unit.
Be sure Red cable is installed between the battery and the control
unit.
Double check ground connection.
Install BYPASS Configuration to make sure alternator functions
normally. If no charge output, contact manufacturer and/or have
alternator serviced or replaced.
Remove Mode Select Module and allow timer to reset.
If an arc is struck, and the CHARGE LED does not go out, do the
following:
ü
Yellow #4AWG cable is the only connection on the
main post on the bck of the alternator. The original
alternator output cable is not used and only the Yellow
cable should be present.
ü
Make sure the blue and/or green wires for conductivity
though the in-line fuse(s). Be sure the blue/green
wire(s) are making the connection(s) on the alternator
based upon the correct wiring diagram.
An arc is struck, CHARGE LED extinguishes, but WELD LED does
not go on:
ü
Make sure the blue and/or green wires for conductivity
though the in-line fuse(s). Be sure the blue/green
wire(s) are making the connection(s) on the alternator
based upon the correct wiring diagram.
ü
Make sure Gray wire is connect ed to keyed- on 12
volts.
ü
Be sure the alternator does not use avalanche diodes
in the rectifier. If not sure, contact manufacturer.
Old or wet electrodes (welding rod).
DIFFICULT TO STRIKE AN ARC
AND WELD.
Violet wire is connected to keyed-on 12 volts and should be no
less than 1/10th of a volt below the battery post (tested w/ digital
multi-meter, not a test light)
Double-check wiring schematic specific to your vehicle.
42 volts open-circuit not being generated by the
alternator after initial strike.
Tighten belt.
Purchase fresh electrodes
Make sure the blue and/or green wires for conductivity though the
in-line fuse(s). Be sure the blue/green wire(s) are making the
connection(s) on the alternator based upon the correct wiring
diagram.
Make sure Gray wire is connect ed to keyed- on 12 volts
WELDING ARC LOST AFTER 7-10
SECONDS OF CONTINUOS
WELDING
Avalanche diodes are present in th e rectifier
plate not allowing the voltage to increase to 42
volts
End of electrode is no t close enough to puddle
in order to maintain arc.
Timer is not resetting and extending as welding
is taking place. Unit is timing out and briefly
switching into “Charge” mode, then back to
“Weld” mode.
Be sure the alternator does not use avalanche diodes in the rectifier.
If not sure, contact manufacturer.
Tighten gapping by keeping end of electrode closer to puddle.
Call for support and return unit for service. Component on PCB
must be replaced.
26
27
28
OPTONAL ACCESSORIES
MOBI-POWER will be available with
Dual Direct Current outlets standard.
An optional AC output to drive nonfrequency sensitive products will also
be available. Dual circuit breakers
rated at 15 amps will be standard.
MOBI-POWER will be configured to
generate approximately 3kW or 5kW
respectively.
ACCESSORIES
RETAIL PRICE
Control Unit Extension Kit (between alternator and control unit)
NOTE: ONLY 200x AND 300 I-SERIES ARE EXTENSION COMPATIBLE
15 feet
30 feet
$40.00
$60.00
Delco Brush-holder/Wire Assembly
Bosch Regulator/Wire Assembly
Ford External Regulator and Wire Assembly
Ford 6-G Regulator Assembly
DR4200HD CS-130-D special non-avalanche rectifier
DR4400 AD series special non-avalanche rectifier
DR5173 non-avalanche rectifier
D1-1604 10/12SI Terminal Block Dummy Regulator
IX128 Land Rover Dummy Regulator/Brush-holder
Toyota Nippon-Denso Install Kit
Land Rover Kit, Magneti-Marelli '93-'98
$22.00
$18.00
$15.00
$35.00
$35.00
$35.00
$18.00
$ 4.50
$25.25
$35.00
$79.00
Secondary Install Kit
14 volt Mode Select Module Kit
28 volt Mode Select Module Kit
Custom volt Mode Select Module Kit
Welding Cable Quick Disconnects (male or female)
$75.00
$45.00
$45.00
$85.00
$ 5.00 per
™
MOBI-ARC Hat
Stickers Free upon Request
14v Mode Select Module Kit
$10.00
29
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