Instruction/ maintenance manual of the product 652 Hobart
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Cyber Flex 652 Model Processes Description Multiprocess W elding Arc Welding Power Source OM-278 163 769N June 2000.
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.
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 . . . . . . . . . . .
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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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
OM-278 Page 1 1 2-5. Manufacturer ’ s Rating Label For CE Products S-174 343 . For label location see Section 3-4..
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.
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.
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.
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).
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 .
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 .
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.
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.
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.
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.
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.
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).
OM-278 Page 24 Notes.
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.
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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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: Call1-800-33.
An important point after buying a device Hobart 652 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart 652 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart 652 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart 652 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart 652 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart 652, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart 652.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart 652. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart 652 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
