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OM-193 472F
January 2002
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
Olympic 22A
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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. Additional Symbols For Installation, Operation, And Maintenance . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 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 au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Wire Type of Input Welding Power Wire Feed Welding Overall Diameter Weight Power Source Type Speed Range Circuit Rating Dimensions Range Length: 23-1/2 in 100 Volts, .023 To 5/64 in (597 mm) 24 Volts AC Single Constant Voltage 500 Amperes, (0.6 To 2 mm) 75 to 750 ipm Width: 10-3/4 in Phase (CV) DC With 100% 35 lb (15.9 kg) (1.9 To 19 mpm) (273 mm) 7 Amperes 50/60 14-Pin And Duty Cycle Max Spool Weight: Hz Contactor Control Height: 11 in 60 lb (27 kg)
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2-3. Gun Recommendation Table Process Gun GMAW – Hard or Corded Wires M25 Or M40 FCAW – Self-Shielding Wires GA-40GL 2-4. Equipment Connection Diagrams 1 CV Welding Power Source With 24 VAC Power 2 CV Welding Power Source Without 24 VAC Power 3 115 Volts AC /24 Volts AC Power Adapter 4 14-Pin Control Cord 5 Weld Cable (Required) 1 6 Work 4 6 3 5 2 115VAC 4 Contactor 6 5 2-5. 14-Pin Plug, Shielding Gas And Optional Volt Sense Lead 1 Gas Hose With 5/8-18 Right- hand Thread Fittings (Customer Suppl
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2-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to pin G. B Contact closure to A completes 24 volts ac contactor control circuit. J J A K I G Circuit common for 24 volts AC circuit. B B N L C C +10 volts dc output to remote control with respect to pin D. H M D G D Remote control circuit common. E F E 0 to +10 volts dc input command signal from remote control with respect to pin D. F Current feedback; 0 to 10 volts dc, 1 V/100 A H Voltage feedback; 0 to 10 volts dc, 1
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2-8. Optional Meter Circuit Board Settings 1 Meter Circuit Board 2 DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed display (see illustration). Reinstall wrapper. 1 2 12 X Means switch position does not affect specified function. . Means switch must be in this position. Voltage Sensing Function Digital Meter Display Arc Voltage Sensing Using Voltage Sensing Lead For Welding Power Source That Does Meters/Minute Not Support Pins F And H 12 3 4 5 12 3
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2-9. Motor Start/Burnback Control To change wire feed starting speed proceed as follows: Turn Off unit and welding power 1 source. Remove wrapper. 1 Motor Board PC1 2 Motor Start Control Potentiometer R73 Remove protective white rubber cap before making adjustment. Adjust potentiometer R73 using a small nonconductive screwdriver. Rotate potentiometer clockwise to increase time it takes the motor to ramp up to speed. 3 Burnback Potentiometer R42 Remove protective white rubber cap before making ad
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2-10. Installing Wire Guide And Drive Roll Install and secure inlet wire guide. Install drive rolls and turn drive roll nut one click. Only drive gear is adjustable. Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown. During maintenance intervals, remove drive rolls, and clean grooves using a wire brush. Check groove of drive roll for pitting or increase in the depth of the groove indicating drive roll is worn out. Installation Alignment Tools Needed: 3/
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2-11. Installing And Threading Welding Wire 1 Retaining Ring 2 Hub Tension Adjustment Nut If necessary, move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. 1 2 3 Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops. 3 Pressure Assembly Adjustment Knob Lay gun cable out straight. A Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun. B Close and tight
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SECTION 3 – OPERATION 3-1. Front Panel Controls 1 Optional Voltage/Wire Speed Meter 1 2 Optional Voltage/Wire Speed Switch Use to choose volts or wire feed 2 speed display. 3 Optional Remote Voltage Control 3 Use to set welding power source voltage at the wire feeder. Numbers are for reference only. 4 Wire Speed Control 4 5 Jog/Purge Switch Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without ener- gizing welding circuit or shielding gas valve. Use Purge p
