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Hobart Welding Products OM-193 472F manual

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Table of contents for the manual

  • Page 1

    O l y m p i c 2 2 A Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding Wire Feeder OM-193 472F January 2002[...]

  • Page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 4

    [...]

  • Page 5

    OM-193 472 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! W a[...]

  • Page 6

    OM-193 472 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D 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[...]

  • Page 7

    OM-193 472 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

  • Page 8

    OM-193 472 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding 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 yea[...]

  • Page 9

    OM-193 472 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulie[...]

  • Page 10

    OM-193 472 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dan[...]

  • Page 11

    OM-193 472 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharg[...]

  • Page 12

    OM-193 472 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for [...]

  • Page 13

    OM-193 472 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 24 V olts AC Single Phase 7 Amperes 50/60 Hz Constant V oltage (CV) DC With 14-Pin And Contactor Control 75 to 750 ipm (1.9 T o 19 mpm) .023 [...]

  • Page 14

    OM-193 472 Page 10 2-3. Gun Recommendation T able Process Gun GMA W – Hard or Corded Wires M25 Or M40 FCA W – Self-Shielding Wires GA-40GL 1 CV Welding Power Source With 24 V AC Power 2 CV Welding Power Source Without 24 V AC Power 3 1 15 V olts AC /24 V olts AC Power Adapter 4 14-Pin Control Cord 5 Weld Cable (Required) 6 W ork 2-4. Equipment [...]

  • Page 15

    OM-193 472 Page 1 1 2-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to pin G. J B Contact closure to A completes 24 volts ac contactor control circuit. A J B K I G Circuit common for 24 volts AC circuit. B C L N H C +10 volts dc output to remote control with respect to pin D. D M G D Remote control circuit common. E F E[...]

  • Page 16

    OM-193 472 Page 12 2-8. Optional Meter Circuit Board Settings Ref. 802 357 / Ref. 186 266 T ools Nee d e d : 1/4 in 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 . 12 3 45 12 3 4 5 12 3 45 123 45 Or Or Meters/Minute Inches/Minute Di[...]

  • Page 17

    OM-193 472 Page 13 2-9. Motor Start/Burnback Control Ref. 802 357 / 192 653 T o change wire feed starting speed proceed as follows: T urn Off unit and welding power 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 no[...]

  • Page 18

    OM-193 472 Page 14 2-10. Installing Wire Guide And Drive Roll Ref. 802 357-A 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 i n drive roll lines up with wire guide as shown. During maintenance intervals, remove drive rolls, and c[...]

  • Page 19

    OM-193 472 Page 15 2-1 1. Installing And Threading Welding Wire T ools Nee d e d : 1 Retaining Ring 2 Hub T ension Adjustment Nut If nec essary, move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed st[...]

  • Page 20

    OM-193 472 Page 16 SECTION 3 – OPERA TION 3-1. Front Panel Controls 1 Optional V oltage/Wire Speed Meter 2 Optional V oltage/Wire Speed Switch Use to choose volts or wire feed speed display . 3 Optional Remote V oltage Control Use to set welding power source voltage a t the wire feeder . Num bers are for reference only . 4 Wire Speed Control 5 Jo[...]

  • Page 21

    OM-193 472 Page 17 3-2. Optional Side Panel Controls Ref. 802 357-A / Ref. 186 589 1 Preflow Control Control sets time gas flows before welding wire is energized. Time range is 0 to 5 seconds. 2 Postflow Control Control sets time gas flows after completion of burnback. T ime range is 0 to 5 seconds. 3 Spot Time Control Factory set for 0.25 to 5 sec[...]

  • Page 22

    OM-193 472 Page 18 4-2. Overload Protection Y T urn Off wire feeder and welding power source. Stop engine on welding generator . 1 Circuit Breaker CB1 CB 1 protects wire feeder from over- load. Correct problem and manually reset breaker . 802 349-A 1 4-3. T roubleshooting T rouble Remedy Wire does not feed, unit completely inop- erative. T urn Powe[...]

  • Page 23

    OM-193 472 Page 19 SECTION 5 – ELECTRICAL DIAGRAM 192 960-C Figure 5-1. Circuit Diagram For Wire Feeder With Optional Equipment[...]

  • Page 24

    OM-193 472 Page 20 SECTION 6 – P ARTS LIST Figure 6-1. Main Assembly 802 358-C . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 10 9 12 13 14 34 35 36 38 39 40 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 37 41 43 44 42[...]

  • Page 25

    OM-193 472 Page 21 Description Part No. Dia. Mkgs. Item No. Figure 6-1. Main Assembly Quantity 1 089 899 LA TCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +198 650 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 26

    OM-193 472 Page 22 Description Part No. Dia. Mkgs. Item No. Figure 6-1. Main Assembly (Continued) Quantity 35 097 924 KNOB, pointer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 ♦ 097 924 KNOB, pointer 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 27

    OM-193 472 Page 23 Description Part No. Dia. Mkgs. Item No. Figure 6-2. Drive Assembly , Wire (Fig 6-1 Item 40) Quantity 1 602 009 SCREW, .250-20 x 1.250 soc hd hex gr 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/component 24 pitch 1 . . . . . . . . . . . . . . . . .[...]

  • Page 28

    OM-193 472 Page 24 T able 6-1. Drive Roll And Wire Guide Kits Base selection of drive rolls upon the following recommended usages: 1. V -Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V -Knurled rolls for hard shelled cored [...]

  • Page 29

    Notes[...]

  • Page 30

    Notes[...]

  • Page 31

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 10/01 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distri[...]

  • Page 32

    PRINTED IN USA  2002 Hobart Welding Products. 1/02 Hoba rt We lding Produc ts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , O H 45373 US A For Technical A ssistan ce: Call1-800-332-3281 For Li terat ure Or Neares t Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to [...]