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OM-1581 137 532M
March 2001
Processes
MIG (GMAW) Welding
Description
Wire Feeder And Feeder Gun
Olympic XR A
And XR W
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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 – SPECIFICATIONS 2-1. Wire Feeder Specifications Specification Description Type Of Input Power 115 Volts AC, 3 Amperes At 50/60 Or 100 Hz Power Control Circuit Voltage Provided At Gun 30 Volts DC Wire Feed Speed Range 70-875 ipm (1.9-22.2 mpm) Overall Dimensions Length: 19 in (483 mm); Width: 9-1/4 in (235 mm); Height: 15-1/4 in (387 mm) Maximum Spool Capacity 12 in (305 mm) Cooling Method Air-Cooled (A Models) Or Water-Cooled (W Models) Weight (Feeder With Gun) Models With 15 ft (4.6
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SECTION 3 – INSTALLATION Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See NOTE Section 5 to change parts as needed. See Section 7 for list of other available contact tips. Review Section 3-1 through Section 3-4 to determine how equipment will be connected. Air-cooled models are shown in Section 3-1 through Section 3-4. For water-cooled models, supplied water hoses must be connected from wire feed- er to coolant supply. Read entire Section 3 before installi
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3-2. Connections With A CV Welding Power Source Having Separate 115 VAC And Contactor Control Receptacles 1 Constant Voltage (CV) Weld- 1 ing Power Source 2 Plug 2 Obtain matching plugs for connect- ing to power source receptacles. 8 3 Workpiece 4 Voltage Sensing Lead Do not connect to workpiece. 5 Gun 6 Wire Feeder 7 115 VAC/Contactor Control Cord 8 Gas Cylinder 3 4 7 5 6 151 775-C 3-3. Connections With A CC Welding Power Source Having A Contactor Control Receptacle 1 Constant Current (CC) Weld
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3-4. Connections With A CC Welding Power Source And A 115 VAC/12 VDC Secondary Contactor 1 Constant Current (CC) Weld- ing Power Source 2 Workpiece 3 Voltage Sensing Lead 1 4 Gun 5 Wire Feeder 6 3-Conductor 115 VAC Cord 7 3-Conductor Contactor Con- 10 trol Cord 8 5-Pin Plug 11 9 Secondary Contactor 10 Gas Cylinder 11 115 VAC Plug Obtain plug for wire feeder. 2 9 8 3 7 6 4 5 151 777-B 3-5. Removing Top Cover Of Gun 1 Top Cover Push back and lift off as shown. 1 To reinstall cover, set rear of cov
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3-6. Air-Cooled Gun Connections 1 Gun Control Cable Insert plug into Gun Control recep- tacle, and tighten threaded collar. 2 Gas Hose Connect to Gas fitting on feeder. 3 Weld Cable 4 Weld Cable Terminal In Feeder Connect gun weld cable to weld cable terminal in feeder. 5 Wire Conduit 6 Thumbscrew 7 Wire Conduit Block Loosen thumbscrew, and insert 6 5 conduit through Wire opening until it bottoms against block. Tighten thumbscrew. Close and latch door. 7 4 3 Left Side 5 2 3 1 Tools Needed: 5/8,
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3-7. Water-Cooled Gun Connections 1 Gas Hose Connect to Gas fitting on feeder. 2 Water Hose Connect to Water To Gun fitting on feeder (left-hand threads). 3 Wire Conduit 4 Thumbscrew 5 Wire Conduit Block Loosen thumbscrew, and insert conduit through Wire opening until it bottoms against block. Tighten thumbscrew. 6 Gun Control Cable Insert plug into Gun Control recep- tacle, and tighten threaded collar. 7 Strain Relief 43 Remove strain relief as shown. 8 Power/Water Cable Route cable through str
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3-8. Air-Cooled Feeder Connections 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear of Gas fitting in feeder. Connect remaining end of hose to regulator/flowmeter. 4 Weld Cable To Welding Power Source Select and prepare weld cable ac- cording to welding power source manual. 5 Weld Cable Grommet 6 Current Sensing (Reed) Relay 7 Weld Cable Terminal In Feeder Route one end of weld cable through grommet, through reed
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3-9. Water-Cooled Feeder Connections Obtain coolant supply. 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet, and connect hose to rear 5 of Gas fitting in feeder. Connect remaining end of hose to regulator/flowmeter. 6 4 Coolant Supply Hose Grommet 5 10 ft (3 m) Water Supply Hose With 5/8 in Adapter Fitting 6 Rear Of Water Fitting (Left- Hand Threads) Remove 5/8 in adapter fitting from hose. Route one end of a water hose through grommet, a
