OM-186 165C October 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Wire Feeder Olympic VS
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.
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) OM-186 165 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
ARC RAYS can burn eyes and skin. 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. 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 Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. 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. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
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. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Rester à l’écart des organes mobiles comme le ventilateur. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding 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 Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – INSTALLATION 2-1. Specifications Type of Input Power Open-Circuit/ Arc Voltage, 15 To 100 Volts DC Welding Power Source Type Constant Voltage (CV) Or Constant Current (CC) DC Wire Feed Speed Range 50 To 700 ipm (1.3 To 18 mpm) Depending On Arc Voltage Wire Diameter Range Input Welding Circuit Rating IP Rating Max. Wire Spool Capacity 500 Amperes At 100% Duty Cycle .023 To 5/64 in (0.
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 2 Drive Roll Nut 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 5 Inlet Wire Guide Screw Inlet Wire Guide Loosen securing screw.
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 3 1 Weld Cable 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.
2-6. Connecting Shielding Gas (Optional) 1 2 3 4 4 3 Gas Hose With 5/8-18 Right-hand Thread Fittings (Customer Supplied) Shielding Gas Cylinder Valve Flowmeter Close valve on cylinder when finished welding. Rear View 2 1 Tools Needed: 5/8 in ST-801 155-A 2-7. Connecting Weld Cable 1 Standard Model Weld Cable Follow wire manufacturer’s recommendations for weld cable polarity. 2 3 Male Connector Female Connector Close door, push female connector over male connector, and turn 1/4 turn clockwise.
2-8. Installing And Threading Welding Wire 1 2 Retaining Ring Hub Tension Adjustment Nut Installing Wire And Adjusting Hub Tension: Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall 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. 2 1 3 A B C D A Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun.
SECTION 3 – OPERATION 3-1. Controls 1 2 Wire Speed Meter (Optional) Voltage Meter (Optional) Use meter to set and display rate of wire speed in inches per minute (ipm). 1 2 3 5 3 4 5 Power Control Switch Wire Speed Range Switch 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 ipm. Use control to adjust wire speed within range selected by switch.
SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance . Maintain more often Y Disconnect power before maintaining. during severe conditions. 3 Months Clean And Tighten Weld Terminals Replace Damaged Or Unreadable Labels Replace Damaged Gas Hose Repair Or Replace Cracked Cables And Cords 6 Months Clean Drive Rolls Blow Out Or Vacuum Inside 4-2. Overload Protection Y Turn Off wire feeder and welding power source. Stop engine on welding generator.
4-3. Calibrating Optional IPM Meter Meter is factory calibrated, but may need recalibration after motor brushes are fully seated. To recalibrate, proceed as follows: 1 1 CV/CC Switch Set switch to CV. 2 2 3 3 4 4 Meter Board PC4 Resistor R53 Adjustment Screw (High Range) Resistor R54 Adjustment Screw (Low Range) Calibrate Low range wire speed first. 5 6 Nonconductive Wire Speed Range Switch Wire Speed Control A Set range switch to Low, and control to about 50%.
4-4. Troubleshooting Trouble Remedy Wire does not feed; open-circuit voltage Check circuit breaker CB1 and fuse F1. Reset CB1 or replace F1 if necessary (see Section 4-2). available. Check sensing lead connection. Check gun trigger plug connection. Check gun trigger. See gun Owner’s Manual. Have Factory Authorized Service Agent check drive motor and control board PC1. Wire feeds erratically. Readjust hub tension (see Section 2-8). Readjust drive roll pressure (see Section 2-8).
SECTION 5 – ELECTRICAL DIAGRAM SC-176 218 Figure 5-1.
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. Hardware is common and OM-186 165 Page 20 42 18 43 47 37 17 48 46 41 45 9 7 15 8 14 6 Figure 6-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly . . 1 . . . . . . . . . . . . . . 058 427 . . 2 . . . . . . . . . . . . . . 601 965 . . 3 . . . . . . . . . . . . . . 602 243 . . 4 . . . . . . . . . . . . . . 010 233 . . 5 . . . . . . . . . . . . . . 057 971 . . 6 . . . . . . . . . . . . . . 010 191 . . 7 . . . . . . . . . . . . . . 058 628 . . 8 . . . . . . . . . . . . . . 058 428 . . 9 . . . . . . . . . . . . . . 058 424 . . 10 . . . . . . . . . . . . . 134 222 . . 11 .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly (Continued) . . 36 . . . . S4 . . . . . . 118 681 . . . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG60 . . . 131 056 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG62 . . . 131 055 . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly (Continued) . . 79 . . . . . . . . . . . . . 604 538 . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . 80 . . . . . . . . . . . . . 124 778 . . KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . 1 . . 81 . . . . . . . . . . . . . 151 828 . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 6-1. Drive Roll & Wire Guide Kits (2 Drive Roll) NOTE 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 wires. 5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
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Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, retail or service location: Contact your Distributor for: Welding Supplies and Consumables Call 1-877-Hobart1 or visit our website at www.HobartWelders.
