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Hobart OM-1581 manual

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Table of contents for the manual

  • Page 1

    Olympic XR A And XR W Processes Description MIG (GMA W) W elding Wire Feeder And Feeder Gun OM-1581 137 532M March 2001[...]

  • 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-1581 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-1581 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-1581 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-1581 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-1581 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-1581 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-1581 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-1581 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-1581 Page 9 SECTION 2 – SPECIFICA TIONS 2-1. Wire Feeder Specifications Specification Description T ype Of Input Power 1 15 V olts AC, 3 Amperes At 50/60 Or 100 Hz Power Control Circuit V oltage Provided At Gun 30 V olts 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); Heig[...]

  • Page 14

    OM-1581 Page 10 SECTION 3 – INST ALLA TION Be sure that contact tip, liner , and drive rolls are correct for wire size and type. See Section 5 to change parts as needed. See Section 7 for list of other available contact tips. NOTE Review Section 3-1 through Section 3-4 to determine how equipment will be connected. Air-cooled models are shown in S[...]

  • Page 15

    OM-1581 Page 1 1 3-2. Connections With A CV Welding Power Source Having Separate 1 15 V AC And Contactor Control Receptacles 1 Constant V oltage (CV) W eld- ing Power Source 2 Plug Obtain matching plugs for connect- ing to power source receptacles. 3 W orkpiece 4 V oltage Sensing Lead Do not connect to workpiece. 5 Gun 6 Wire Feeder 7 1 15 V AC/Con[...]

  • Page 16

    OM-1581 Page 12 3-4. Connections With A CC Welding Power Source And A 1 15 V AC/12 VDC Secondary Contactor 1 Constant Current (CC) W eld- ing Power Source 2 W orkpiece 3 V oltage Sensing Lead 4 Gun 5 Wire Feeder 6 3-Conductor 1 15 V AC Cord 7 3-Conductor Contactor Con- trol Cord 8 5-Pin Plug 9 Secondary Contactor 10 Gas Cylinder 1 1 1 15 V AC Plug [...]

  • Page 17

    OM-1581 Page 13 3-6. Air-Cooled Gun Connections 3 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 T erminal In Feeder Connect gun weld cable to weld cable terminal in feeder . 5 Wire Conduit 6 Thumbscrew 7 Wire Conduit Block Loosen t[...]

  • Page 18

    OM-1581 Page 14 3-7. W ater-Cooled Gun Connections 1 Gas Hose Connect to Gas fitting on feeder . 2 W ater Hose Connect to Water T o 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. T ighten thumbscrew . 6 Gun Contro[...]

  • Page 19

    OM-1581 Page 15 3-8. Air-Cooled Feeder Connections 1 Gas Hose Grommet 2 10 ft (3 m) Gas Hose 3 Rear Of Gas Fitting Route on e e n d o f 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 T o Welding Power Source Select and prepare weld cable ac- cording t[...]

  • Page 20

    OM-1581 Page 16 3-9. W ater-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 of Gas fitting in feeder . Connect remaining end of hose to regulator/flowmeter . 4 Coolant Supply Hose Grommet 5 10 ft (3 m) Water Supply H[...]

  • Page 21

    OM-1581 Page 17 3-10. Adjusting Contact Tip Position 1 3 2 4 1 Contact T ip 2 Nozzle Adjusting barrel changes contact tip location from 1/16 in (1.6 mm) out beyond end of nozzle to 1/4 in (6.3 mm) inside nozzle. 3 Jam Nut 4 Barrel T o change contact tip location, loosen jam nut, and turn barrel. T ighten jam nut. 150 434 / Ref. 150 431 1 2 4 3 Air-[...]

  • Page 22

    OM-1581 Page 18 3-12. 1 15 V AC/Contactor Control Plug Information 1 Interconnecting Cord 2 1 15 V AC/Contactor Control Plug PLG5 If CC or CC/CV welding power source is equipped with matching 14-socket receptacle, insert plug, and tighten threaded collar . Proceed to Section 3-14. If plug PLG5 will not connect to CC welding power source receptacle,[...]

  • Page 23

    OM-1581 Page 19 3-13. Replacing 1 15 V AC/Contactor Control Plug With Customer-Supplied 5-Pin Or T wistlock Plug 1 1 15 V AC/Contactor Control Plug PLG5 2 Contactor Control Cord 3 1 15 V AC Cord Find and label cords by following leads to back of PLG5: Contactor control cord connects to pins A & B of PLG5 1 15 V AC cord connects to pin J of PLG5[...]

  • Page 24

    OM-1581 Page 20 3-14. Installing Wire Spool T urn Off wire feeder and welding power source. 1 Wire Spool 2 T op Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced, open pressure roll assembly in gun, and cut welding wire off at contact tip. For welding power sources without contactor , retract wire onto spool. For weld[...]

  • Page 25

    OM-1581 Page 21 3-15. Threading Welding Wire Through Feeder 1 Wire Spool Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire of f spool. 2 T ension Arm 3 Mounting Arm T o open pressure roll assembly , open tension arm and lift mounting arm. 4 Wire Inlet Guide 5 Drive Roll 6 Wire Conduit Fitting Thread wire through wire inlet g[...]

  • Page 26

    OM-1581 Page 22 3-16. Threading Welding Wire Through Gun 1 Pressure Roll Assembly Lift arm and open pressure roll assembly . 2 Wire Co nduit Lay wire conduit out straight. 3 Jog Switch Push Jog switch up to feed wire through wire conduit. 4 Drive Roll Fo r wire sizes .035 in (0.9 mm) and smaller use small groove, and .047 in (1.2 mm) and 1/16 in (1[...]

  • Page 27

    OM-1581 Page 23 3-18. Adjusting Wire Feed Starting Speed 1 2 T op Of PC1 Ref. 151 772-A / Ref. 142 054-B T o adjust wire feed starting speed, proceed as follows: T urn Of f wire feeder and welding power source. Open right side panel. 1 Motor Speed Control Board PC1 2 Motor Start Control Potentiometer R70 T urn potentiometer clockwise to increase ti[...]

  • Page 28

    OM-1581 Page 24 SECTION 4 – OPERA TION 4-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown) 1 V oltage/Wire Speed Meter (Optional) 2 V oltage/Wire Speed Switch (Optional) 3 Run-In Speed Control 4 Jog Switch 5 Burnback Time Control (Optional) 6 Spot/Continuous Switch (Optional) 7 Remote V oltage Control (Optional) 8 Power Switch 9 Time Ran[...]

  • Page 29

    OM-1581 Page 25 4-4. Run-In Speed Control 1 Run-In Speed Control Use control to set wire feed speed before arc initiation. After arc initiation, wire feed speed is controlled by the Wire Speed Control on the welding gun (see Section 4-12). Th e scale around the control is per- cent of full range, not wire speed. As a general rule, set run-in speed [...]

  • Page 30

    OM-1581 Page 26 4-7. Spot Controls (Optional) 1 Spot/Continuous Switch Use switch to select either an un- timed continuous weld cycle or a timed spot weld cycle. Both weld cycles consist of the following steps: run-in, weld (untimed or spot time), and burnback. 2 Time Range Switch Use switch to select spot weld time range. 3 Spot Time Control Use c[...]

  • Page 31

    OM-1581 Page 27 4-10. Flowmeter (Optional) CAUTION Wire feeding system is designed for maximum of 50 psi (345 kPa) gas pressure. • Be sure that regulator/flowmeter has preset conditions of no more than 50 psi (345 kPa) gas pressure. 1 Flowmeter 2 V alve Use flowmeter to control shielding ga s flow at the feeder . The scale o n the flowmeter is in[...]

  • Page 32

    OM-1581 Page 28 4-12. Gun Controls 1 T rigger Press trigger to energize welding power source contactor (if applica- ble), start shielding gas flow , and begin wire feed. Fo r shielding gas preflow and post- flow , partially press trigger before and partially release after welding. 2 Wire Speed Control Use control to adjust wire feed speed. The numb[...]

  • Page 33

    OM-1581 Page 29 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance T urn Off all power before maintaining. 3 Months OR Blow O u t Or V acuum Inside Replace Unreadable Labels 6 Months Clean Drive Rolls 5-2 Clean And T ighten W eld T erminals 3-8 3 Months – – See Section 7 T ape Or Replace Cracked W eld Cable – – 14-Pin [...]

  • Page 34

    OM-1581 Page 30 5-2. Changing Or Cleaning Gun Drive Roll T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly Cut of f wire where it enters pressure roll assembly area. 3 Setscrew 4 Current Pick-Up T ab This tab helps prevent burnback caused by welding arcs inside the contact tip. This tab may be re- moved to provid[...]

  • Page 35

    OM-1581 Page 31 5-3. Changing Feeder Drive Roll And Wire Inlet Guide T urn Off wire feeder and welding power source. Lay wire conduit o u t straight. Open gun pressure roll assembly , and cut welding wire off at contact tip. 1 Pressure Roll Assembly 2 Wire Spool For welding power sources without contactor , retract wire onto spool. For welding powe[...]

  • Page 36

    OM-1581 Page 32 5-4. Replacing Or Cleaning Gun Drive Roll Bearing T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly 3 Screw 4 Pressure Roll Remove as shown. Use a wire brush to clean bearing. Reinstall with washers, and tighten screw . Close pressure roll assembly . Reinstall top cover . Ref. 151 599 – C 1 2 3 [...]

  • Page 37

    OM-1581 Page 33 5-6. Changing Gun Contact Tip And Liner T urn Off wire feeder and welding power source. Remove top cover and open pres- sure roll assembly as shown in Section 5-4. 1 Contact T i p W rench Insert wrench into nozzle over contact tip. 2 Compression Nut Loosen nut. Pull out contact tip. 3 Contact Tip 4 Nozzle Pull wire out nozzle and li[...]

  • Page 38

    OM-1581 Page 34 5-8. Removing Contact Tip Adapter In W ater-Cooled Models W A TER IN GUN P ARTS can cause ELECTRIC SHOCK and can lower weld quality . • Turn Of f welding power source and water supply before working on gun. Stop engine on welding generators. • Always point gun downward when removing water-cooled barrel to keep water out of gun p[...]

  • Page 39

    OM-1581 Page 35 5-10. Adjusting Hub T ension Turn On welding power source and wire feeder to make this adjustment. 1 Wire Speed Control Adjust control to wire speed for welding. 2 Jog Switch Push up, and then release Jog switch. Hub tension is okay if wire unwinds freely , but wire does not backlash when Jog switch is released. 3 Cap Screw T urn ca[...]

  • Page 40

    OM-1581 Page 36 5-13. T roubleshooting A. Wire Feeder T rouble T rouble Remedy Pressing gun trigger does not energize feeder . Welding wire is not energized. Shielding gas flows. Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 3-6). Secure 1 15 V AC input plug connection (see Section 3-12). Check fuse F1 (see S[...]

  • Page 41

    OM-1581 Page 37 B. Gun Trouble T rouble Remedy No weld output; gun/feeder does not work. Secure 1 15 V AC input plug in 1 15 volts ac receptacle (see Section 3-12). Place Power switch on welding power source in the On position. Erratic weld output. Tighten and clean all connections. Pressing gun/feeder trigger does not en- ergize weld control; weld[...]

  • Page 42

    OM-1581 Page 38 SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Wire Feeder 156 399-C[...]

  • Page 43

    OM-1581 Page 39 195 712-A Figure 6-2. Circuit Diagram For Gun[...]

  • Page 44

    OM-1581 Page 40 SECTION 7 – P ARTS LIST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17 19 20 21 22 23 24 25 21 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 60 59 61 62 71 Fig 7-2 72 73 74 75 76 77 78 79 Figure 7-1. Main Assembly Fig 7-3 63 64 65 66 67 70 68 69 41 40 PC1 PC3 . Hardware is common and[...]

  • Page 45

    OM-1581 Page 41 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity 1 089 572 CA TCH, link-lock 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 12 167 INSULA TOR, door 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 46

    OM-1581 Page 42 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (Continued) Quantity 50 1 1 1 152 SKID, base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 +176 714 CABINET , control 1 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 47

    OM-1581 Page 43 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Motor & Wire Drive (Fig 7-1 Item 71) Quantity 1 1 15 191 DRIVE ASSEMBL Y , wire (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 058 968 RING, retainer E 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 48

    OM-1581 Page 44 1 2 3 4 5 6 7 8 See Fig 7-1 Item 59 10 12 13 14 15 16 17 18 19 20 21 22 23 9 11 PC2 PC4 . Hardware is common and not available unless listed. 145 127-B Figure 7-3. Panel, Front w/Components (W ater-Cooled Model Illustrated)[...]

  • Page 49

    OM-1581 Page 45 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Panel, Front w/Components (Fig 7-1 Item 59) Quantity 1 ♦ 1 1 1 569 METER, flow 6-60 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 1 1 1 633 GUARD, flow meter 1 . . . . . . . . . . . . . .[...]

  • Page 50

    OM-1581 Page 46 Figure 7-4. Exploded View Of Gun *Includes Items 24 & 37 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 6 8 9 10 11 57 13 12 58 14 14 59 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34 35 36 37 38(Fig. 7 – 5) 39* 40 41 42 43 44 45 46 47 48 49 50 51 52 53 143 1 17-E 31 32 33 30[...]

  • Page 51

    OM-1581 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 7-4. Exploded View Of Gun Quantity 1 133 479 COVER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 135 196 SPRING, closure cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 52

    OM-1581 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 7-4. Exploded View Of Gun (Continued) Quantity 35 602 066 SCREW , mach stl trh 6-32 x .250 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 164 592 TRIGGER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 53

    OM-1581 Page 49 Description Part No. Item No. Figure 7-5. Barrel Assembly (Fig 7-4 Item 40) Quantity 1 144 862 EXTENSION, nozzle (15A & 30A models) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 156 821 EXTENSION, barrel 2.875 lg (15A & 30A models) 1 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 54

    OM-1581 Page 50 Description Part No. Item No. Figure 7-5. Barrel Assembly (Fig 7-4 Item 40) (Continued) Quantity 17 137 042 BARREL ASSEMBL Y , water cooled (15W & 30W models) . . . . . . . . . . . . . . . . (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 134 800 O-RING[...]

  • Page 55

    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 56

    PRINTED IN USA  2000 Hobart Welding Products. 1/00 Hoba rt We lding Produc ts An I l li noi s T ool Works Company 600 West M ain S treet Troy , O H 45373 USA For Technical Assi stance: Call1-800-332-3281 For Lit erat ure Or Nearest Dealer: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to ori[...]