Instruction/ maintenance manual of the product 652 Hobart Welding Products
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Processes 302, 452, And 652 Models OM-222 164 850T January 2002 Cyber Arc TIG (GT A W ) W elding Stick (SMA W) W elding Air Plasma Cutting and Gouging Air Carbon Arc (CAC-A) Cutting and Gouging Flux C.
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: TIG = GT AW Stick = SMAW T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1.
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OM-222 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.
OM-222 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 of f 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-222 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-222 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.
OM-222 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.
OM-222 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-222 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-222 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 e l- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-222 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 W ear dry insulating gloves. Do not touch electrode with bare hand.
OM-222 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-222 Page 1 1 2-5. Manufacturer ’ s Rating Labels For CE Products . Match label to one on unit. See Section 3-4..
OM-222 Page 12 2-6. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes Amperage Control/ Panel Gas Tungsten Arc W elding (GT AW) Shielded Metal Arc W elding (SMA W ) T .
OM-222 Page 13 SECTION 3 – INST ALLA TION 3-1. Specifications Model Rated W elding Amp Maximum Open- IP Amperes Input at Rated Load Output, 50 or 60 Hz, Three-Phase Model W elding Output Range DC Circuit V oltage DC Rating 200 V 230 V 380 V 400 V 440 V 460 V 575 V KV A KW 300 Amp 300 A @ 32 V olts DC, 60% Duty Cycle 15 – 395 72 (70) 21M 70 4.
OM-222 Page 14 3-3. V olt-Ampere Curves V olt-ampere curves show mini- mum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall be- tween curves shown.
OM-222 Page 15 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-222 Page 16 3-6. Tipping Y Be careful when placing or moving unit over uneven surfaces. 3-7. 1 15 V AC Receptacle And Circuit Breakers Ref. ST-800 101-D 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 (see Section 3-10).
OM-222 Page 17 3-8. W eld Output T erminals And Selecting Cable Sizes T otal Cable (Copper) Length In W eld Circuit Not Exceeding 100 ft (30 m) Or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft.
OM-222 Page 18 3-10. Connecting Remote Control Ref. ST-800 101-D 1 Remote 14 Receptacle RC8 Connect remote control to RC8. OR OR AJ B K I C L NH D M G E F 1.
OM-222 Page 19 3-1 1. Electrical Service Guide 60 Hertz Models 300 Amp Model 450 Amp Model 650 Amp Model Input V oltage 200 230 460 575 200 230 460 575 230 460 575 Input Amperes At Rated Output 70 61 .
OM-222 Page 20 3-12. Placing Jumper Links Ref. ST-800 103-A Y Disconnect and lockout/tag- out input power before installing or moving jumper links. 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-222 Page 21 3-13. Connecting Input Power ST-800 103-B / Ref. ST -801 1 16 3/8 in 3/8 in T ools Nee d e d : IMPORT ANT GND/ 3 PE Connect Green Or Green/Y ellow GND/PE Conductor First.
OM-222 Page 22 SECTION 4 – OPERA TION 4-1. Controls (Non CE Models) 1 Polarity Selector Switch (Optional On 50 Hz Models) T o change polarity on models not equipped with a Polarity Selector switch, reverse work and electrode cables at the weld output termi- nals (see Section 3-8).
OM-222 Page 23 4-2. Controls (CE Models) 1 Polarity Selector Switch (Optional On 50 Hz Models) T o change polarity on models not equipped with a Polarity Selector switch, reverse work an d electrode cables at the weld output termi- nals (see Section 3-8).
OM-222 Page 24 5-2. Fuse F1 Ref. ST-800 101-C Y T ur n Off power before open- ing rear access door . 1 Fuse F1 (See Parts List For Rating) Fuse F 1 protects control transform- er from overload. If F1 opens, weld output and fan motor stops. Re- place F1.
OM-222 Page 25 SECTION 6 – ELECTRICAL DIAGRAM For Primary Circuit Diagram Portion, refer to Circuit Diagram located inside wrapper of welding power source.
OM-222 Page 26 SECTION 7 – P ARTS LIST ST-800 875-E . 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 – 5) 19 20 21 22 3 4 23 25 26 24 27 28 (Fig.7 – 2) 29 (Fig.7 – 3 & 4) 22 Figure 7-1.
OM-222 Page 27 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly Quantity Model 302 452 652 1 +179 430 P ANEL, side 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-222 Page 28 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Main Assembly (Continued) Quantity Model 302 452 652 24 T1 189 855 TRANSFORMER, pwr main 380/400/440 (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . 25 172 410 COIL, pri/sec (center & RH) 2 .
OM-222 Page 29 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 28) Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 652 1S 5 ♦ 169 331 SWITCH, mode polarity (single deck) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-222 Page 30 Figure 7-2. Panel, Front w/Components (Fig 7-1 Item 28) (Continued) Description Part No. Dia. Mkgs. Item No. Quantity Model 302 452 652 9 POS 181 245 TERMINAL, pwr output red 1 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-222 Page 31 Description Part No. Dia. Mkgs. SR1 Item No. Figure 7-3. Rectifier , Si Diode (302 Model) (Fig 7-1 Item 29) Quantity 175 070 1 C7-12 048 420 CAP ACITOR, cer disc .01uf 1000VDC 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-222 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 7-5. Panel, Rear w/Components (Fig 7-1 Item 18) Quantity 1 173 283 CHAMBER, plenum 14 in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 10/01 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.
PRINTED IN USA 2002 Hobart Welding Products. 1/02 Hoba rt We lding Product s An I l li noi s T ool Works Com pany 600 W es t Main St reet Troy , OH 45373 USA For T ech nical Assistance: Call1-800-.
An important point after buying a device Hobart Welding Products 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 Welding Products 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 Welding Products 652 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products 652 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products 652 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products 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 Welding Products 652.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products 652. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products 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
