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Hobart 652 manual

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Table of contents for the manual

  • Page 1

    Cyber Flex 652 Model Processes Description Multiprocess W elding Arc Welding Power Source OM-278 163 769N June 2000[...]

  • 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

    The following terms are used interchangeably throughout this manual: MIG = GMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-278 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 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! Watch O[...]

  • Page 6

    OM-278 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 Z87[...]

  • Page 7

    OM-278 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 A[...]

  • Page 8

    OM-278 Page 4 1-5. EMF Information Considerations About W elding And The Ef fects Of Low Frequency Electric A n d M a g n e t i c F i e l d s 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 [...]

  • Page 9

    OM-278 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_Fre 4/97 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-278 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 le[...]

  • Page 11

    OM-278 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 l[...]

  • Page 12

    OM-278 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- 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-278 Page 9 SECTION 2 – DEFINITIONS 2-1. General Precautionary Label W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric sho[...]

  • Page 14

    OM-278 Page 10 2-2. Input Connection Label 1 W arning! Watch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Read the Owner ’ s Manual before working on this machine. 5 Consult rating label for input power requirements, and check power av[...]

  • Page 15

    OM-278 Page 1 1 2-5. Manufacturer ’ s Rating Label For CE Products S-174 343 . For label location see Section 3-4.[...]

  • Page 16

    OM-278 Page 12 2-6. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Amperage/V oltage Control – Panel Gas Tungsten Arc W elding (GT AW) Shielded Metal Arc W elding (SMA W) T emperature Wire Feeder Arc Force (DIG) Gas Metal Arc W elding (GMA W) Output Circuit Breaker Remote V V olts Positive High In- ductance Wel[...]

  • Page 17

    OM-278 Page 13 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 m in - utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit and v[...]

  • Page 18

    OM-278 Page 14 3-4. Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit. If using lifting forks, extend forks beyond opposite side of unit. 3 Rating Label (Non CE Models Only) Use rating label to determine input power needs. Label located under front access door . 4 Plate Label (CE Models Only) Label loc[...]

  • Page 19

    OM-278 Page 15 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 1 15 V AC Receptacle And Circuit Breakers 3 Ref. ST-800 166-C Y T urn Off power before connecting to receptacle. 1 1 15 V 15 A AC Receptacle RC9 Power i s shared between RC9 a n d Remote 14 receptacle RC8 or terminal strip 1T (see Section 3-10). 2 Circui[...]

  • Page 20

    OM-278 Page 16 3-8. W eld Output T erminals And Selecting Cable Sizes Y ARC WELDING can cause Electromagnetic Interference. T o reduce possible interference, keep weld cables as short as possible, close together , and down low , such as on the floor . Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding [...]

  • Page 21

    OM-278 Page 17 3-10. Connecting Remote Control Ref. ST-800 170-E / Ref. S-0004-A / S-0750 1 Remote 14 Receptacle RC8 Connect remote control to RC8. If plug does not fit, wire cord to terminal strip 1T . Y T urn Off power before open- ing terminal strip cover . 2 T erminal Strip 1T 3 Remote Control Cord 4 Strain Relief (Customer Supplied) Secure cor[...]

  • Page 22

    OM-278 Page 18 3-1 1. Electrical Service Guide 60 Hz Models 50 Hz Models Input V oltage 230 460 575 380 400 440 520 Input Amperes At Rated Output 126 63 50.4 77 73 66 54 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 150 70 60 90 90 80 60 Normal Operating 3 200 90 80 125 11 0 100 80 Min Input Conductor Size In A WG/Kcmil 1 6 6 4 4 4[...]

  • Page 23

    OM-278 Page 19 3-12. Placing Jumper Links And Connecting Input Power 1 230 VOL TS Ref. S-174 973-A 575 VOL TS 460 VOL TS ST-800 103-B / Ref. ST -801 1 16 Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input voltage. 3 Input And Grounding Conductors See Sectio[...]

  • Page 24

    OM-278 Page 20 SECTION 4 – OPERA TION 4-1. Controls (Non CE Models) 4 1 2 3 7 8 5 6 Ref. ST-184 939 1 Arc Force (Dig) Control Control increases SMAW short-circuit amperage which allows the operator to use a very short arc length without sticking the electrode. Set control at 0 for normal welding amper- age. T urn clockwise to increase short-circu[...]

  • Page 25

    OM-278 Page 21 4-2. Controls (CE Models) 4 Ref. ST-184 936 12 3 7 8 5 6 1 Arc Force (Dig) Control Control increases SMAW short-circuit amperage which allows the operator to use a very short arc length without sticking the electrode. Set control at 0 for normal welding amper- age. T urn clockwise to increase short-circuit amperage. 2 Process Selecto[...]

  • Page 26

    OM-278 Page 22 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . OR 5-2. Fuse F1 Ref. ST-800 101-C Y T urn[...]

  • Page 27

    OM-278 Page 23 5-3. T roubleshooting T rouble Remedy No weld output; unit completely inoperative; pilot light PL1 off. Place line disconnect device in On position (see Section 3-12). Check for open line fuse(s), and replace if open (see Section 3-12). Check for proper input power connections (see Section 3-12). Check for proper jumper link position[...]

  • Page 28

    OM-278 Page 24 Notes[...]

  • Page 29

    OM-278 Page 25 SECTION 6 – ELECTRICAL DIAGRAM SC-196 108-A For Primary Circuit Diagram Portion, refer to the Circuit Dia- gram located inside the wrapper of the welding power source. Figure 6-1. Circuit Diagram[...]

  • Page 30

    OM-278 Page 26 SECTION 7 – P ARTS LIST ST-800 703-D Figure 7-1. Main Assembly (652 Model Illustrated) . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 14 17 18 (Fig.7 – 4) 19 20 21 1 22 3 4 23 25 26 24 27 28 (Fig. 7-2) 22 29 (Fig. 7-3)[...]

  • Page 31

    OM-278 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (652 Model Illustrated) Quantity 1 +179 432 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 179 431 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM-278 Page 28 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 30) Quantity 1 159 863 ELECTRONICS BOX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PC1 187 834 CIRCUIT CARD, control (60Hz) 1 . . . . . . . . . . . . . . . . [...]

  • Page 33

    OM-278 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 30) (Continued) Quantity 14 174 937 PLA TE, control lower (60Hz) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 179 389 PLA TE, control lower (50Hz) 1 . . . . . . . . . . .[...]

  • Page 34

    OM-278 Page 30 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Rectifier , Si Diode (Fig 7-1 Item 31) Quantity 1 C7.12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 191 989 BAR, mtg rectifier 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 35

    OM-278 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 7-4. Panel, Rear w/Components (Fig 7-1 Item 18) Quantity 1 124 275 CHAMBER, plenum 14 in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 180 165 BLADE, fan 14 in 3wg 23deg .375 bore CCW 1 . . . . . . . . . . . . .[...]

  • Page 36

    Notes[...]

  • Page 37

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  • Page 38

    [...]

  • Page 39

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

  • Page 40

    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 Main St reet Troy , OH 45373 U SA 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 or[...]