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OM-186 165C
October 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
Olympic VS
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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 Welding Input Type of Wire Feed Wire Max. Wire Power Welding IP Overall Input Speed Diameter Spool Weight Source Circuit Rating Dimensions Power Range Range Capacity Type Rating 500 Amperes At 100% Length: 22-1/2 50 To 700 ipm Duty Cycle Constant in (572 mm) Open-Circuit/ (1.3 To 18 Voltage (CV) 330 Amperes Arc Voltage, mpm) .023 To 5/64 in 30 lb (13.6 kg), Width: 8-3/4 in 29 lb Or Constant 23 At 60% 15 To 100 Depending (0.6 To 2 mm) 12 in (304 mm) (2
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2-2. Installing And Aligning Wire Guide And Drive Roll When changing wire size or type, check drive roll and wire guide size (see Parts List). Installing Wire Guide And Drive Rolls: 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier. 3 Drive Roll Slide drive roll onto drive roll carrier. Turn nut one click. Repeat procedure for top drive roll. 4 Inlet Wire Guide Screw 5 Inlet Wire Guide Loosen securing screw. Install inlet guide s
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2-3. Typical Connections 1 CC Or CV Welding Power Source If using a CC welding power source without a weld output contactor, use optional secondary contactor. 2 Weld Cable 1 3 Work For GMAW, use optional gas valve. 2 3 2-4. Gun Recommendation Table Process Gun GMAW – Hard or Corded Wires Piecemaker 25A, or 40A Gun FCAW – Self-Shielding Wires Piecemaker 40A Gun 2-5. Connecting Welding Gun And Voltage Sensing Lead 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun end
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2-6. Connecting Shielding Gas (Optional) 1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) 2 Shielding Gas Cylinder 4 3 3 Valve 4 Flowmeter Close valve on cylinder when fin- ished welding. Rear View 2 1 Tools Needed: 5/8 in ST-801 155-A 2-7. Connecting Weld Cable 1 Weld Cable Standard Model Follow wire manufacturer’s recom- mendations for weld cable polarity. 2 Male Connector 3 Female Connector Close door, push female connector over male connector, and turn 1/4 turn clockwise
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2-8. Installing And Threading Welding Wire 1 Retaining Ring 2 Hub Tension Adjustment Nut Installing Wire And Adjusting Hub Tension: Remove retaining ring, and install spool so hub pin fits spool hole. Re- install retaining ring. Adjust tension nut so only a slight force is needed to turn spool. Threading Welding Wire: 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 tighten
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SECTION 3 – OPERATION 3-1. Controls 1 Wire Speed Meter (Optional) 2 Voltage Meter (Optional) Use meter to set and display rate of wire speed in inches per minute (ipm). 3 Power Control Switch 4 Wire Speed Range Switch 1 2 5 Wire Speed Control Use switch to select high or low wire speed range. High range is 100 to 700 ipm. Low range is 50 to 350 3 5 ipm. Use control to adjust wire speed within range selected by switch. 6 Purge Switch (Optional) 4 Press switch to momentarily ener- gize gas solenoi
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SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Clean And Replace Tighten Damaged Or Replace Damaged Weld Unreadable Gas Hose Terminals Labels Repair Or Replace Cracked Cables And Cords 6 Months Clean Blow Out Or Drive Vacuum Inside Rolls 4-2. Overload Protection Turn Off wire feeder and welding power source. Stop engine on welding generator. 1 Circuit Breaker CB1 Overload Protec
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4-3. Calibrating Optional IPM Meter Meter is factory calibrated, but may need recalibration after motor brushes are fully seated. To recali- brate, proceed as follows: 1 1 CV/CC Switch Set switch to CV. 2 2 Meter Board PC4 3 Resistor R53 Adjustment 3 Screw (High Range) 4 Resistor R54 Adjustment 4 Screw (Low Range) Calibrate Low range wire speed first. 5 Wire Speed Range Switch 6 Wire Speed Control A Set range switch to Low, and control to about 50%. Turn wire feeder and weld- ing power source On
