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Hobart Welding Products S-62 manual

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Table of contents for the manual

  • Page 1

    Processes Description MIG (GMA W) W elding Flux Cored (FCA W) W elding (Gas- and Self-Shielding) Submerged (SAW) W elding Wire Feeder (Use with CV Power Sources) OM-1579 133 566U October 2000 Olympic S-62 & S-64[...]

  • 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-1579 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 atch[...]

  • Page 6

    OM-1579 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 Z8[...]

  • Page 7

    OM-1579 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. F [...]

  • Page 8

    OM-1579 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 years [...]

  • Page 9

    OM-1579 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 particulier .[...]

  • Page 10

    OM-1579 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 dans l[...]

  • Page 11

    OM-1579 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 surcharger [...]

  • Page 12

    OM-1579 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 the[...]

  • Page 13

    OM-1579 Page 9 SECTION 2 – DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear . 1 Electric shoc[...]

  • Page 14

    OM-1579 Page 10 ST-178 794-A 50/60 S/N: 24 10.0 Hz 50/60 IP 21 V 100 A 750 X 100 % V U 1 = A I 1 = 1 U 2 = I 2 = 2-2. Rating Label For CE Products For label location see Section 4-4. 2-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circ[...]

  • Page 15

    OM-1579 Page 1 1 SECTION 3 – INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating IP Rating Overall Dimensions W eight 24 V olts AC Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC With 14-Pin And Contactor Control Standard: 50 T o 780 ipm [...]

  • Page 16

    OM-1579 Page 12 4-2. Gun Recommendation T able Process Gun GMA W – Hard or Cored Wires M25, M40, GA-50C, GW-500, Or GW -600 FCA W – Self-Shielding Wires GA-40GL Or GA-50GL 4-3. Equipment Connection Diagrams 152 319-B / 152 320-C 1 W elding Power Source 2 Contactor Control/Power Cord 3 Positive (+) Weld Cable 4 Negative ( – ) W eld Cable 5 W o[...]

  • Page 17

    OM-1579 Page 13 4-4. Rear Panel Connections And Rotating Drive Assembly Ref. ST-152 462-C / ST -156 930-A 1 2 7 3 5 6 1 Customer Supplied Gas Hose 2 Shielding Gas V alve Fitting Requires fitting with 5/8-18 right- hand threads. 3 Optional Current Sensor Connection 4 Power Switch 5 14-Pin Cord 6 Weld Cable 7 Weld Cable T erminal 8 Drive Assembly T o[...]

  • Page 18

    OM-1579 Page 14 4-5. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. A J G Circuit common for 24 volts AC circuit. A J B K I C +10 volts dc output to remote control with respect to socket D. C L N H D M G D Remote control circuit common. D M[...]

  • Page 19

    OM-1579 Page 15 4-8. Installing And Threading Welding Wire . Be sure that outlet cable has proper size liner for the welding wire size. When installing gun, position liner extending from outlet wire guide as close as pos- sible to drive rolls without touching. Install gun. Lay gun cable out straight. Cut off end of wire. Push wire through guides up[...]

  • Page 20

    OM-1579 Page 16 802 479 / Ref. SA-146 866-B / Ref. SA-148 666-E / Ref. SA-150 588-D T ools Nee d e d : . If wire feeder is equipped with a voltage sensing lead, set DIP switch S3 to the OFF position (up). If wire feeder is NOT equipped with a voltage sensing lead, set DIP switch S3 to the ON position (down). 12 OFF 1 2 OFF 12 OFF 12 Or Long Spot T [...]

  • Page 21

    OM-1579 Page 17 SECTION 5 – OPERA TION 5-1. Front Panel Controls ST-151 845-B 1 V oltmeter (Optional) (See Section NO T AG) 2 Wire Speed Meter (Optional) Factory set to display inches per minute. If display of meters per minute is desired, see Section 4-9. 3 Schedule A Wire Speed Control The scale is calibrated in inches per minute x 100 and mete[...]

  • Page 22

    OM-1579 Page 18 5-2. Overload Protection And Optional Side Panel Controls 802 418-A 1 Circuit Breaker CB1 CB1 protects wire feed motor from overload. Press to reset. 2 Preflow Control Control sets time gas flows before welding wire is energized. 3 Spot Time Control Factory set for 0 to 5 seconds of spot time. If 0 to 2.5 seconds is de- sired, see S[...]

  • Page 23

    OM-1579 Page 19 6-2. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but electrode wire is not energized. Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see Sections 4-3 and 4-4). Wire feeder is on, meter(s) do not light up, motor does n[...]

  • Page 24

    OM-1579 Page 20 SECTION 7 – ELECTRICAL DIAGRAM Figure 7-1.Circuit Diagram[...]

  • Page 25

    OM-1579 Page 21 196 503[...]

  • Page 26

    OM-1579 Page 22 SECTION 8 – P ARTS LIST Fig 8-4 Fig 8-2 1 2 3 4 5 7 8 9 6 7 10 11 12 18 14 19 22 23 24 25 26 27 6 20 21 ST-136 987-K 13 15 16 17 18 . Hardware is common and not available unless listed. Figure 8-1. Main Assembly[...]

  • Page 27

    OM-1579 Page 23 Description Part No. Item No. Figure 8-1. Main Assembly Quantity 1 141 753 HUB & SPINDLE ASSEMBL Y , (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 28

    OM-1579 Page 24 Ref. ST-142 438-G *See option that is applicable 1 2 4 3 * 5 6 7 Fig 8-3 8 9 11 12 13 14 15 20 19 18 17 16 21 22 23 24 25 9 26 10 29 30 * 28 31 27 . Hardware is common and not available unless listed. Figure 8-2. Control Box[...]

  • Page 29

    OM-1579 Page 25 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Control Box (Fig 8-1 Item 14) Quantity 1 RC6 048 282 CONNECTOR w/SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 S31 ♦ 134 847 SWITCH, tgl SPDT 15A 125V AC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 30

    OM-1579 Page 26 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Control Box (Fig 8-1 Item 14) Quantity ♦♦ 173 750 DIGIT AL DUAL SCHEDULE, (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 134 209 NUT , .250 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 31

    OM-1579 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Control Panel (Fig 8-2 Item 7) Quantity 1 S32 ♦ 01 1 770 SWITCH, tgl SPDT 6A 125V AC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PC70 +150 591 CIRCUIT CARD, interface 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM-1579 Page 28 See T able 8-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. 802 458 Figure 8-4. Drive Assembly , Wire[...]

  • Page 33

    OM-1579 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Drive Assembly , Wire (Fig 8-1 Item 23) Quantity 2 Drive Roll 4 Drive Roll 1 010 668 SCREW , cap stl sch .250-20 x 1.500 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/components 2 4 . . . . . . .[...]

  • Page 34

    OM-1579 Page 30 .023-.025 in. 0.6 mm 151 030 151 024 087 130 .030 in. 0.8 mm 151 031 151 025 053 695 .035 in. 0.9 mm 151 032 151 026 053 700 151 044 151 036 072 000 151 061 151 052 132 958 .045 in. 1.1/1.2 mm 151 033 151 027 053 697 151 045 151 037 053 701 151 062 151 053 132 957 151 077 151 070 083 489 .052 in. 1.3/1.4 mm 151 034 151 028 053 698 1[...]

  • Page 35

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 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 distrib[...]

  • Page 36

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt W elding 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 [...]