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OM-1594 181 715H
December 2000
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
Olympic XR Control
Olympic XR Air- And Water-Cooled
Guns
Visit our website at
www.HobartWelders.com
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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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TABLE OF CONTENTS 6-12. Replacing Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6-13. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6-14. Water Flow Switch (Optional For Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6-15. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 – DEFINITIONS 2-1. Warning Label Definitions A. Warning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. AB C C. Welding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself 1 1.1 1.2 1.3 from work
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1 Read the Owner’s Manual. 2 Do not overtighten wire spool brake pressure. Tighten only until wire does not overspool from wire supply spool. 3 Do not overtighten drive roll pressure. Tighten only until drive roll will not slip (motor will not stall) on a stationary wire. 2-2. Rating Label For CE Products S/N: 50/60 U = 24 V 1 50/60 Hz 1 IP 23 I = 5.0 A 1 I = U = 100 V 400 A X 100 % 2 2 ST-178 794-A OM-1594 Page 10
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2-3. Symbols And Definitions Some symbols are found only on CE products. Note Amperes Volts Alternating Current Duty Cycle A V X Degree Of Hertz Circuit Breaker Wire Feed Protection IP Hz Jog Output Trigger Gun Press To Set Increase Trigger Hold On Trigger Hold Off Purge Spot Weld Time Percent Run-In Burnback Time Primary Voltage Load Voltage Read Instructions U U 1 2 Water (Coolant) In- Primary Current Rated Current Line Connection I I put 1 2 Water (Coolant) Continuous Fuse Output Spot Welding
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3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. Air-Cooled Models 100% Duty Cycle At 200 Amperes Using Argon 60% Duty Cycle At 250 Amperes Using Argon Continuous Welding 6 Minutes Welding 4 Minutes Resting Water-Cooled Models 100% Duty Cycle At 400 Amperes Using Argon Continuous Welding sduty1 5/95 OM-1594 Page 12
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SECTION 4 – INSTALLATION Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See NOTE Parts List to change parts as needed. Many procedures apply to both guns covered in this manual. Where procedures NOTE differ, separate instructions are given. 4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle 1 CC, CV Or CC/CV Welding Power Source 2 24 VAC/Contacto
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4-2. Air-Cooled Feeder Connections 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter. 2 Weld Cable To Welding Power Source Select and prepare weld cable according to welding power source manual. 3 Weld Cable Grommet 4 Current Sensing (Reed) Relay 5 Weld Cable Terminal In Feeder Route one end of weld cable through grommet, through reed relay, and connect to weld cable ter- minal in fe
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4-3. Air-Cooled Gun Connections 1 Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar. 2 Gas Hose 3 Reed Relay 4 Weld Cable 2 5 Weld Cable Terminal In Feeder 7 Route weld cable from welding 6 power source through reed relay to weld cable terminal in feeder and connect to weld cable terminal. 6 Gun Connector 8 7 Gun Securing Knob 8 Gun Connector Block Loosen gun securing knob, and insert gun connector through Wire 3 opening until it bottoms against 4 5 block. Ti
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4-4. Water-Cooled Feeder Connections Obtain coolant supply. 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter. 2 Weld Cable To Welding Power Source Select and prepare weld cable according to welding power source manual. 3 Weld Cable Grommet 4 Current Sensing (Reed) Relay 5 Weld Cable Terminal In Feeder Route one end of weld cable through grommet, through reed 5 7 relay, and connect t
