AirForce 250ci - Pdfstream.manualsonline.com
Contents
1. 50 60 Hz Single Phase Input Voltage 120 Input Amperes At Rated Output 19 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 Time Delay 2 20 Normal Operating 30 Min Input Conductor Size In AWG 12 Max Recommended Input Conductor Length In Feet Meters o Min Grounding Conductor Size In AWG 4 12 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements A Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard These recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the power source 4 8 Extension Cord Data Input Power Input Voltage Phase Hertz Conductor Size Max Cord Length 120 V 1 50 60 12 AWG 50 ft 15 m OM 230 455 Page 12 7 A complete Parts List is availa2. me les tincelles et l arc e Installez et attachez les bouteilles dans la position verticale l aide d une chaine sur un support stationnaire ou un ch ssis porte bouteil le afin de pr venir qu elles ne tombent ou ne basculent e Les bouteilles ne doivent pas tre pr s de la zone de coupage ni de tout autre circuit lectrique e Un contact lectrique ne doit jamais se produire entre un chalumeau de plasma d arc et une bouteille e Necoupez jamais sur une bouteille pressuris e une explosion en r sulterait e Utilisez uniquement des bouteilles de gaz des d tendeurs des boyaux et des raccords con us pour l application d termin e Gar dez les ainsi que toute autre piece associ e en bonne condition e D tournez votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque vous utilisez la bouteille ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffisam ment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance DES PIECES CHAUDES peuven
3. closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power AJ READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts FLYING METAL can injure eyes e Wear safety glasses with side shields or face shield MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before go ing near plasma arc cutting operations OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce amperage thickness or reduce duty cycle before starting to cut again EXPLODING HYDROGEN hazard e When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the work piece e See your cutting engineer and water table instructions for help 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq A Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause c
4. tiques 8 SECTION 3 DEFINITIONS vidit ssa sd Aida ES dt ae A end a an SC a uc ER 9 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 9 SECTION INSTALEATION cuida e wid ORC a S a a dd M AAA AAA AAA 10 4 1 Specifications For Power SQUICS i ew iss esis vee PS Mew don FODE nat Now de See eee ee AB add 10 4 2 SpPechicalions FOr TOC san Any on are Se x ote Oey ete Ta Oe wo ee he eet ores Se ote A a 10 4 3 Duty Cycle And Overheating 4a sedan Rud usu REL EE End aa aa rU Bx RES SG Ried 10 4 4 Torch DIMENSIONS ANG Weight esas Rd sctcRS XR ERE Rand ERE Bled pias RES pis as po KE 11 debi Selecting A EOOSllOD as mess rasas Bid std omes sl a ede dead kis bid stud qq gui BRUM 11 4 6 Connecting Work Clamp sas 4 999 x25 Xd sued Eras da ERA weed he EE bd sm md mss BT 12 4 7 Electrical Service Guide For 120 VAC 12 4 9 Extension Gord Dala ud debet dried dr eod meae he Ta mai danse dd 12 4 9 COnMMECINGMPUL POW El iua dos TCU des Secondo Sco d uis de se do de e Eun ud due aoc eb Sce gai 13 4 10 Generator Or Inverter Requirements 13 4 11 Cable Management Strap 0 cece nen ene e ses 14 4 12 c Electrode Wren ioii sms dem es die TCU dune dons de Raho dw cuin u soudain diet 14 SECTION 5 OPERATION ctncrcaneysste dis VRS A SLINGS IER A PN eRe ete E
5. 909 73 Og e O e o0 6 9 0 6 6 1 Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Most replacement paris 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 distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART 331 WARRANTY Effective January 1 2007 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface LH or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts
6. OM 230 455 Page 15 7 A complete Parts List is available at www HobartWelders com 5 3 Plasma Cutting System Practices A The pilot arc starts immediately Nee 78 eer when trigger is pressed Sse i a DO NOT start pilot arc without cutting as this Always connect work clamp to a clean i shortens the life of the tip and electrode paint free location on workpiece as close to cutting area as possible EF Do not connect work clamp to the portion of the workpiece that will fall when cut ee Maintain approximately a 90 angle to the workpiece surface for proper cutting results If sparks flare back from surface this usually is an indication that travel speed is too fast Sparks should pass through the workpiece and out the bottom when cutting Pulling rather than pushing the torch makes cutting easier Use a proper guide or template for accurate cutting operations DO NOT put pressure on shield when drag cutting instead slide shield along the surface for proper cutting results Ref 803 915 A Ref 804 848 A OM 230 455 Page 16 7 A complete Parts List is available at www HobartWelders com 5 4 Sequence Of Cutting Operation EXAMPLE Of Cutting Operation cd Place tip near work Press trigger Pilot arc starts E Keep tip 1 16 in from work for max cutting speed and tip life 4 Adjust speed so sparks go thru metal and out bottom of cut Pause briefly at end of c
7. Off power source and disconnect input power If torch or work cable needs to be removed or replaced proceed as follows 1 Power Source Remove wrapper from unit Torch Connections Remove existing torch cable from unit 2 Strain Relief 3 Torch Cable Insert strain relief on end of cable through front panel opening Slide strain relief nut onto torch cable but do not tighten 4 Air Line Connector Install air line connector onto compressor fitting 5 Plug PLG4 Receptacle RC4 Connect PLG4 to receptacle RC4 on circuit board PC1 6 Female And Male Friction Less E Terminal RC1 ELECTRODE 3 E Connect female friction terminal E on end of black lead to RC1 ELECTRODE 7 Female And Male Friction Terminal RC2 TIP Connect female friction terminal on end of red lead to RC2 TIP Tighten strain relief nut Tighten strain relief around cable Work Cable Connections Remove existing work cable from unit 8 Strain Relief Be sure to allow some work cable slack inside the unit Insert strain relief on end of cable through front panel opening Slide strain relief nut onto work cable and secure strain relief to front panel 9 Work Lead Male Friction Terminal Connect work clamp lead to male friction terminal labeled WORK on circuit board PC1 Reinstall wrapper Tools Needed TF 5 16 in Ref 804 852 B 804 887 A OM 230 455 Page 24 7 A complete Parts List is available at w
8. consult your doctor before welding cutting or going near welding cutting operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION pom_fre 4 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s d par des symboles adjacents aux directives Identifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des ris ques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVE MENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directi ves ci dessous afin de connaitre les mesures prendre pour viter tout dan ger 2 2 Dangers li s au coupage l arc au plasma A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 2 4 Veuillez lire
9. contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets Register your product at To locate your nearest distributor or service agency call 1 877 Hobart1 or HobartWelders com visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 ORARI AS Hob Thank 2005 06 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Iis Symbol DS age oat obe cnt RS ma x CRUS E qud ee aR Oye Cm lacs ue 1 1 2 Rlasma Arc Coin Hazards aaron cee owe ances P Ec dba ture ip deir o a de hes 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings wea x eg xx RENI ROO EE OPEP E E Ref px e e dee bere Re 3 d Principal Satety Standards catia caba oa tbe ex said 4 ES EMP MTOR ON sul pda Sl das ass tad Gr Nan eat 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 2 suba cd etse Bota hen Sant Rd Rc os ee RES ded cod NES a 5 2 2 Dangers li s au coupage l arc au plasma 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement ena MAN NANCE SR bitu fedes ade 7 2 4 Principales normes de s curit sus a ki kan e x promere e movere REA oe dcn ep Uus 8 2 5 Information sur les champs lectromagn
10. des blessures La chaleur d gag e par le plasma d arc peut entrainer de s rieuses br lures La force de l arc est un facteur qui s ajoute au danger de br lures La chaleur intense et la puissance de l arc peuvent rapidement passer au travers de gants et de tissus e N approchez pas le tube du chalumeau e Ne saisissez pas la pi ce couper pr s de la ligne de coupage e Larc pilote peut causer des br lures n approchez pas le tube du cha lumeau lorsque vous avez appuy sur le gachette e Portez des v tements de protection ad quats qui recouvrent tout vo tre corps e Ne pointez pas le chalumeau en direction de votre corps ni de la pi ce couper lorsque vous appuyez sur la g chette l arc pilote s allume automatiquement e Mettez l alimentation hors tension et d branchez le cordon d alimen tation avant de d monter le chalumeau ou de changer une pi ce du chalumeau e Utilisez uniquement le ou les chalumeaux recommand s dans le ma nuel de l op rateur LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles de gaz contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Puisque les bouteilles de gaz font habituellement partie d un processus de travail des m taux assurez vous de les manipuler correctement e Prot gez les bouteilles de gaz comprim contre la chaleur excessive les chocs m caniques des dommages physiques le laitier la flam
11. duire le facteur de marche Danger D EXPLOSION D HYDROGENE e Lors du coupage d aluminium partiellement ou totale ment immerg dans l eau de l hydrog ne libre peut s accumuler sous la pi ce e Consultez votre ing nieur de coupage et les instruc tions de la table de coupage LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour sou lever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces infllammables e Ne pas installer l appareil proximit de produits in flammables e Ne pas surcharger l installation lectrique s assurer que l aliImentation est correctement dimensionn et prot g avant de mettre l appareil en service LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes PC LE RAYONNEMENT HAUTE FRE QUENCE H F risque de provoquer des interf rences e Le Ray
12. et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particuli rement les enfants LE COUPAGE pr sente un risque de feu ou d explosion Des particules de m tal chaud et des tincelles peuvent jaillir de la pi ce au moment du coupage Les tincelles et le m tal chaud la pi ce couper chauff e et l quipement chaud peuvent causer un feu ou des br lures Avant de commencer travailler assurez vous que l endroit est s curitaire e D placez toute mati re inflammable se trouvant l int rieur d un p rimetre de 10 7 m 35 pi de la pi ce couper Si cela est impos sible vous devez les couvrir avec des housses approuv es et bien ajust es e Ne coupez pas dans un endroit ou des tincelles pourraient attein dre des mati res inflammables e Prot gez vous ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud e Assurez vous qu aucune tincelle ni particule de m tal ne peut se glisser dans de petites fissures ou tomber dans d autres pi ces e Afin d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main e Si vous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entrainer un feu de l autre c
13. hot materials from cutting can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that cutting on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not cut on closed containers such as tanks or drums e Connect work cable to the work as close to the cutting area as prac tical to prevent cutting current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use plasma cutter to thaw frozen pipes Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Do not cut in atmospheres containing explosive dust or vapors Do not cut pressurized cylinders pipes or vessels Do not cut containers that have held combustibles Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Do not locate unit on or over combustible surfaces e Remove any combustibles such as a butane lighter or matches from your person before doing any cutting e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby C ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The torch and work circuit are electrically live whenever the output is on The input power circui
14. lat rales sous votre casque ou cran facial e Ayez recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les tincelles et les blouisse ments pr venez toute personne sur les lieux de ne pas regarder l arc e Portez des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection Tableau 1 Protection des yeux pour le coupage au plasma d arc Intensit de courant en amp res Filtre de teinte minimum Moins de 20 no 4 20 40 no 5 40 60 no 6 60 80 no 8 OM 230 455 Page 6 LE BRUIT peut endommager l ouie Certaines applications de coupage produisent un bruit constant ce qui peut endommager l ouie si le niveau sonore d passe les limites permises par l OSHA repor tez vous aux Principales normes de s curit e Utilisez des prot ge tympans ou un serre t te antibruit si le niveau sonore est lev e Pr venez toute personne sur les lieux du danger reli au bruit LES FUM ES ET LES GAZ peuvent tre dangereux Le coupage produit des vapeurs et des gaz Respirer ces vapeurs et ces gaz peut tre dangereux pour la sant e Nemettez pas votre t te au dessus des vapeurs Ne respirez pas ces vapeurs e Si vous tes l int rieur au moment du coupage ventilez la pi ce ou ayez recours une ventilation aspirante install e pr s de l arc pour vacuer les vapeurs e
15. t e Ne coupez pas sur un contenant ferm tel qu un r servoir ou un bi don e Fixezle c ble de masse sur la pi ce couper le plus pres possible de la zone couper afin de pr venir que le courant de coupage ne prenne une trajectoire inconnue ou longue et ne cause ainsi une d charge lectrique d tincelles ou un feu e Ne pas utiliser le coupeur plasma pour d geler des conduites gel es e Ne coupez jamais des contenants qui peuvent contenir des mati res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement e Ne coupez pas dans un endroit ou l atmosph re risque de contenir de la poussi re ou des vapeurs explosives e Ne coupez pas de bouteilles de tuyaux ou de contenants pressuri S s e Ne coupez pas de contenants qui ont d j recu des combustibles e Portez des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque e Ne placez pas le poste sur une surface combustible ou au dessus de celle ci e Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un extincteur proximit d UNE D CHARGE LECTRIQUE peut entra ner la mort Le fait de toucher une pi ce lectrique sous tension p
16. American Welding Society Standard AWS C5 2 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Regles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 e Veiller couper une distance de 100 metres de tout quipement lectronique sensible e Sassurer que la source de coupage est correctement branch e et mise la terre e Silinterf rence persiste l utilisateur doit prendre des mesures sup pl mentaires comme carter la machine utiliser des c bles blind s de des filtres ou boucler la zone de travail Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Weld
17. FORE USING pom 4 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4h A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols 7 Means Note not safety related 1 2 Plasma Arc Cutting Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safe ty Standards Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away gt CUTTING can cause fire or explosion Hot metal and sparks blow out from the cutting arc The flying sparks and hot metal hot workpiece and hot equipment can cause fires and burns Check and be sure the area is safe before doing any cutting e Remove all flammables within 35 ft 10 7 m of the cutting arc If this is not possible tightly cover them with approved covers e Do not cut where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that sparks and
18. M 230 455 Page 4 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou levard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keepcables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body E ue IN Keep cutting power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the cut as possible About Pacemakers Pacemaker wearers
19. OM 230 455D 2008 07 Processes Air Plasma Cuttin i WELDERS Description Air Plasma Cutter AirForce 250ci And HP 25 Torch Online Forum www HobartWelders com OWNER S MANUAL File Plasma Cutters gt 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 With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts WARRANTY list will then help you to decide the exact part Working as hard as you do every power source Hobart is registered tothe you may need to fix the problem Warranty and from Hobart is backed by ISO 9001 2000 Quality Service information for your particular model the best warranty in the System Standard business are also provided 150 9001 2000 QUALITY SYSTEM Protect Your Investment Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products
20. SUMABLE KIT cup swirl ring O ring 1 re ne eee 232 015 FILTER air intake compressor 1 8 NPT 1 ee ee do 230 445 CABLE work 0 eee eee eee s 1 VS 233 321 STAND OFF GUIDE HP 25 PLASMA TORCH 1 FAILURE TO REPLACE WORN TIP OR ELECTRODE WILL DAMAGE TORCH AND VOID WARRANTY Turn off power before checking torch parts Check before each use and hourly during operation Torque electrode lightly w small wrench 15 20 in lbs HP 25 CONSUMABLE KITS 770 496 D0 Retaining Cup 770 497 230 446 B Figure 8 2 Consumable Parts For HP 25 A complete Parts List is available on line at www HobartWelders com To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 230 455 Page 28 Notes 24 GA 0239 22 GA 0299 20 GA 0359 18 GA 0478 116 GA 0598 14 GA 0747 1 8 125 10 GA 1345 229895 3 16 0 1875 1 4 250 5 16 0 3125 gt 024 030 gt 035 zl MATERIAL THICKNESS GAUGE Notes DECIMAL EQUIVALENTS 96 Oo 96 e 59 96 Oo o6 PE 96 eu 96 OO vo 9 0 MX E 96 9 9 Se 9 0 6o i 0660 3 96
21. U LEN 15 5 15 COMMONS S Scr Decent eee aout RL REL penam Mgr puma tte ar eS per ee us 15 5 2 Recommended Cutting Speed For Material Thickness 15 9 3 Plasma Cutting System Pracices as due corse d ie CEL eee eee SE Be eee See en 16 o4 Sequence OF CuUIING Operation 59 d aus Pace ha a bs bee eee a pt Se Se 17 5 5 Sequence Of Cutting Using Stand off Guide 18 5 6 Sequence Of Piercing OPeralion sene ues sina S us Oke E EE RI HO EE EG eae RS FEY 19 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 20 b ROUTING Mantena E ox wee site te xo e quina bs os we E ie ES ee Aes xD RE ea AU 20 6 2 Trouble Lights And Checking Shield Cup Shutdown System 21 6 3 Checking Replacing Retaining Cup Tip And Electrode 22 6 4 Compressor Filter Cleaning And Replacement 23 6 5 Torch And Work Cable Connections 24 6 6 Troubleshooting Power Source 0 eee hh ras 25 6 7 TROUBIGSMOOLING TOC tds ata canst a DO ths Gras RE Ren RS Gene dene A EE A 26 SECTION 7 ELECTRICAL DIAGRAM 0 00 cece cence eee eee eee 27 SECTION 8 PARTS LIST 22232 23 2 2m A EA stead see a a dd ee a od cl 28 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BE
22. ancer and birth defects or other reproductive harm Wash hands after handling Operation And Maintenance BEBE FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift unit e f using lift forks to move unit be sure forks are long enough to ex tend beyond opposite side of unit FIRE OR EXPLOSION hazard e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with elec tronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at c
23. aris OM 230 455 Page 1 EXPLODING PARTS can injure e On inverter power sources failed parts can ex plode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing inverters Ba FLYING SPARKS can cause injury Sparks and hot metal blow out from the cutting arc a Chipping and grinding cause flying metal Wear approved face shield or safety goggles with side shields Wear proper body protection to protect skin e Wear flame resistant ear plugs or ear muffs to prevent sparks from entering ears ARC RAYS can burn eyes and skin Arc rays from the cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin e Wear face protection helmet or shield with a proper shade of filter lenses to protect your face and eyes when cutting or watching ANSI Z49 1 see Safety Standards suggests a No 9 shade with No 8 as minimum for all cutting currents less than 300 amperes 749 1 adds that lighter filter shades may be used when the arc is hidden by the workpiece As this is normally the case with low current cutting the shades suggested in Table 1 are provided for the operator s conve nience e Wear approved safety glasses with side shields under your helmet or shield e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protect
24. artWelders com 6 2 Trouble Lights And Checking Shield Cup Shutdown System de PANA Aa 1 2 JO POWER NO cup d o E TEMP Checking Torch Shield Cup Shutdown System Power switch must be reset whenever cup shutdown system is activated Always turn Off power source when changing or checking consumables 1 Power Light Light is steady if input power is okay Light flashes if input power is less than 92 volts ac or greater than 136 volts ac Light stops flashing 15 seconds after condition is corrected or when torch trigger is pressed If certain problems occur the trouble light comes on and output stops 2 Cup Light Lights if shield cup is loose off Check shield cup shutdown system as follows Turn power On and loosen shield cup If shutdown system works properly Cup light comes on If not turn power Off and have a factory authorized service agent check unit If system works properly retighten cup Power must be reset whenever the cup shutdown is activated Check shield cup shutdown system once a week A flashing Cup light indicates that the torch consumables are stuck or worn and should be inspected and or replaced see Section 6 3 3 Temp Light Lights if power source overheais or when ambient temperature is below 40 C 40 F If unit overheats allow fan to cool unit for 15 minutes see Sections 4 3 4 Power Temp Lights When both lights flash the com pre
25. at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limit
26. ation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province WELDERS hobart warr 2007 01 A 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 otate 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 com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact y
27. ble at www HobartWelders com 4 9 Connecting Input Power Check input voltage available at site 1 Grounded Receptacle A 120 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker 120 V 20 A Ui is required see Section 4 7 Receptacle 2 Plug From Unit Connect plug to receptacle For ex tension cord data see Section 4 8 Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 804 852 A Ref 803 766 B Generator or inverter operation varies by manufacturer The power light on the cutter will flash and the unit will not provide output if input voltage drops below 92 volts ac see Section 6 2 Minimum auxiliary power require ment at rated cutting capacity 1 8 in 3 2 mm mild steel is 4 KW con tinuous 4 5 KW peak at 120 volts Generator settings if applicable ac Engine Control Switch must be set at RUN A Set generator Fine Adjustment Control gt The 115 volts ac output of a position not RUN IDLE to 10 for maximum auxiliary power brushless generator will momen tarily droop when loaded This may result in arc outages at the cutter Connecting a load such as a 500 watt halogen light bulb RUN IDLE to the 115 volts ac generator circuit will pre load the circuit and a may result in less generator RUN output droop and better cutting y performance e EF For inver
28. d without overheating If unit overheats output stops Temperature trouble light goes On and cooling fan runs Wait fifteen minutes for unit to cool or temperature light to go off Reduce duty cycle before cutting A Exceeding duty cycle can damage unit and void warranty 3 1 2 Minutes Cutting 6 1 2 Minutes Resting Overheating Minutes duty1 4 95 804 852 A OM 230 455 Page 10 7 A complete Parts List is available at www HobartWelders com 4 4 Torch Dimensions And Weight 8 3 8 in an 213 mm Ref 801 397 A Dimensions And Weight 27 lb 12 3 kg 12 1 4 in d 311 mm 1 Lifting Handle Use handle to lift unit 2 120 VAC 20 A Receptacle 7 Serial Number Rating Label located on Locate unit near correct input rear panel of plasma cutter use label to power supply determine input power for unit Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 loc_2 3 96 Ref 804 852 A OM 230 455 Page 11 7 A complete Parts List is available at www HobartWelders com 4 6 Connecting Work Clamp EF Do not connect work clamp to the portion of the workpiece that will fall when cut 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Ref 803 915 A 4 7 Electrical Service Guide For 120 VAC
29. e Protective Earth l D Ground 1 ENG Single Phase DE Constant Current Lv Voltage Input On O Off o6 Percent Direct Current Rated No Load U Primary Voltage U Conventional Load Line Connection Voltage Average Voltage Single Phase Rated Maximum Rated Welding X Static Frequency 1max Supply Current Current Duty Cycle pie Transformer 2 Rectifier Converter Degree Of H D Protection Er Loose Shield Cup Input Z Hertz Suitable for Some Power Rating UNS of power factor S Hazardous S Product Of Voltage teff UPPI UNEN Locations 1 AndCurrent KVA OM 230 455 Page 9 7 A complete Parts List is available at www HobartWelders com SECTION 4 INSTALLATION 4 1 Specifications For Power Source Individual Mild Steel Branch Primary Rated Max Primary Primary Service Secondary Secondary Cutting Power OCV Amperes Recommended Volts DC Amperes KW KVA Capacity Factor DC 1 8 in 3 2 mm 120 19 0 25 3596 20A 110 12 2 01 2 27 At 10 IPM 4 2 0 82 375 mm s While idling 10 High line condition 4 2 Specifications For Torch Air cooled torch for plasma arc cutting PAC Gas flow pressure 1 1 SCFM 31 1 L min at 40 PSI 275 kPa Safety interlock devices shut down power source Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated loa
30. ers to workpiece Check work clamp connec tion Check Control board PC1 and connections and torch and its connections Does pilot arc transfer to workpiece Yes Check all connections Servicing procedure to be performed only by authorized Service Station OM 230 455 Page 25 7 A complete Parts List is available at www HobartWelders com 6 7 Troubleshooting Torch Torch travel speed too slow S we y 4 FP 3 D increase travel speed see Does arc go Sections 5 3 5 4 and 5 6 on and off Clean or replace torch Go to Section 6 6 while cutting consumables as necessary see Section 6 3 Be sure work clamp is securely attached to a clean paint and rust free workpiece Reduce torch tip to workpiece stand off distance Be sure work clamp is securely attached to a clean Does arc go out paint and rust free l workpiece Make sure torch while cutting tip is within 1 16 in 1 6 mm Go to Section 6 6 of workpiece while cutting Clean or replace torch consumables as necessary see Section 6 3 Torch travel speed too fast reduce travel speed see Section 5 3 5 4 and 5 6 Do sparks come Clean or replace torch out of top of cut consumables as necessary or cut Is not see Section 6 3 Be sure clean work clamp is securely attached to workpiece Unit not capable of cutting met als thicker than rating see Section 5 2 Go to Section 6 6 Servicing pr
31. eut donner une d charge fatale ou entrai ner des br lures graves Le chalumeau et le circuit de masse sont automatiquement actifs lorsque le poste est sous tension L alimentation d entr e et les circuits internes de l appareil le sont galement Le coupage au plasma d arc exige des tensions plus lev es que le soudage pour amorcer et maintenir l arc souvent de 200 400 V CC c est pourquoi on fait appel des chalumeaux con us avec un syst me de verrouillage s curitaire qui met l appareil hors tension lorsque la capsule anti feu est desserr e ou si le tube touche l lectrode l int rieur de la buse Un poste incorrectementinstall ou inad quatement mis la terre constitue un danger e Ne touchez pas aux pi ces lectriques sous tension e Portez des gants isolants et des v tements de protection secs et sans trous e Isolez vous de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne touchez pas aux pi ces du chalumeau si vous tes en contact avec la pi ce couper ou le sol e Mettez l appareil hors tension avant d effectuer la v rification le nettoyage ou le changement d une pi ce du chalumeau e Coupez l alimentation d entr e avant d installer l appareil ou d ef fectuer l entretien Verrouillez ou tiquetez la sortie d alimentation selon la norme OSHA 29 CFR 1910 147 reportez vous aux Pri
32. in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement
33. ing Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage ou de coupage passant dans les c bles de puis sance cr e des causera des champs lectromagn tiques ll y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du Natio nal Research Council a conclu Laccumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs ma gn tiques et champs lectriques haute fr
34. ive clothing made from durable flame resistant material leather heavy cotton or wool and foot protection Table 1 Eye Protection For Plasma Arc Cutting Current Level In Amperes Minimum Shade Number Below 20 20 40 40 60 60 80 n NOISE can damage hearing Prolonged noise from some cutting applications can damage hearing if levels exceed limits specified by OSHA see Safety Standards e Use approved ear plugs or ear muffs if noise level is high e Warn others nearby about noise hazard FUMES AND GASES can be hazardous Cutting produces fumes and gases Breathing these fumes and gases can be hazardous to your health e Keep your head out of the fumes Do not breathe the fumes e lf inside ventilate the area and or use local forced ventilation at the arc to remove cutting fumes and gases OM 230 455 Page 2 If ventilation is poor wear an approved air supplied respirator e Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals to be cut coatings and cleaners e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Fumes from cutting and oxygen depletion can alter air quality causing injury or death Be sure the breathing air is safe e Do noi cut in locations near degreasing cleaning or spraying oper ations The heat and rays of the arc can react with vapors to form highly toxic and ir
35. mm maximum pit depth depending on acceptable cut quality EF Lightly tighten electrode using electrode wrench 15 20 in Ib 1 7 2 3 N m 4 Opening Remove tip Check tip and replace if open ing is deformed or 50 oversize If inside of tip is not clean and bright clean with steel wool Be sure to remove any pieces of steel wool afterwards 5 Electrode Check electrode If center has a pit more than a 1 16 in 2 mm deep remove and re place electrode Ref 804 851 A 6 Swirl Ring Remove swirl ring Check ring and replace if side holes are plugged Carefully reassemble parts in reverse order 7 Stand off Guide Placing the stand off guide on the end of the torch provides an optional method of maintaining a 1 16 in 1 6 mm gap between tip and workpiece 7 A complete Parts List is available at www HobartWelders com 6 4 Compressor Filter Cleaning And Replacement A Turn Off power source and disconnect input power 1 Power Source 2 Compressor Filter Remove wrapper from unit Unscrew filter ffom compressor Clean debris from filter surface or replace filter if necessary EF Do not overtighten filter Screw filter back into compressor Tighten 1 full turn past hand tight Reinstall wrapper Tools Needed CRA 516 in Y 58in Ref 804 887 A OM 230 455 Page 23 7 A complete Parts List is available at www HobartWelders com 6 5 Torch And Work Cable Connections NAW of B A Turn
36. nci pales normes de s curit e Installez le poste correctement et mettez le la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Assurez vous que le fil de terre du cordon d alimentation est cor rectement reli la borne de terre dans la boite de coupure ou que la fiche du cordon est branch e une prise correctement mise la terre vous devez toujours v rifier la mise la terre e Avant d effectuer les connexions d alimentation vous devez relier le bon fil de terre e V rifiez fr quemment le cordon d alimentation afin de vous assurer qu il n est pas alt r ou nu remplacez le imm diatement s il l est Un fil nu peut entrainer la mort e quipement doit tre hors tension lorsqu il n est pas utilis e V rifiez et remplacez les cosses du c ble du chalumeau si elles sont us es ou alt r es e Le c ble du chalumeau ne doit pas s enrouler autour de votre corps e Siles normes le stipulent la piece couper doit tre mise la terre e Utilisez uniquement de l quipement en bonne condition R parez ou remplacez imm diatement toute pi ce alt r e e Portezun harnais de s curit si vous devez travailler au dessus du sol e Assurez vous que tous les panneaux et couvercles sont correcte ment en place e Nessayez pas d aller l encontre des syst mes de verrrouillage de s curit ou de les conto
37. nded Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from Global Engineering Docu ments phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 1 6 EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current as it flows through the welding or cutting cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following proce dures O
38. ocedure to be performed only by authorized Service Station OM 230 455 Page 26 SECTION 7 ELECTRICAL DIAGRAM o i a E o 2 o o Z o 3 o o c a e A WARNING e Disconnect input power or stop engine before servicing e Do not operate with covers removed a D E 44 E o D a 5 D a DE 38 o gt 5 so o w TS e a tr EN Lh or Y Z 92M uo NEO PUNO T LET L 92M 19313 SOY MOSS3HdNWNO2 1531 10 MIV lt 1831 92M Z SoM 9OMd 42M XIR 9919 92 sdoy e ujos 11 O 6G91d S2y t ci v91d v2M ATY AYOM SON 10d Z2M IME HOLIMS lt 1531 198 3 dnd Z7 VOM ZA jOMINOO NIMOd Xm lt 1 v08 LOd Aug vtt LHM c 4359lML B C yOM lt aau z O OT VE gem on dIDLOTd LT 118 17 10d Z7 GLOM ATT AO booms lt KLON MIP 17 Gu 17 ZH 47 O O li J Z 72 LT L1 e SYY MATE TA ZU INTG is NYP LAMIE Ju IVAOZ 1 YIMO4 INdNI OTAN E MIG 1 Q5 M Li 230 449 C Figure 7 1 Circuit Diagram OM 230 455 Page 27 SECTION 8 PARTS LIST 8 1 Recommended Spare Parts Item Dia Part NO Mkgs NO Description Quantity Recommended Spare Parts pier du E ca ade oe 232 647 TORCH HP 25 16 4ft 5 m hand held replacement 1 Ene ae qt dd ea a ee 208 820 CLAMP work eeee eee eee eee eee eee 1 PL 770 496 CONSUMABLE KIT tip electrode 2 770 497 CON
39. onnement haute frequence H F peut provo quer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sour ces de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles OM 230 455 Page 7 LE COUPAGE L ARC peut causer des interf rence e L nergie lectromagn tique peut g ner le fonction nement d appareils lectroniques comme des ordi nateurs et des robots e Pour r duire la possibilit d interf rence maintenir les cables aussi courts que possible les grouper et les poser aussi bas que possible ex par terre 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ihs com Recommended Practices for Plasma Arc Cutting
40. or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 3 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed
41. orrect setting and use grounding and shielding to minimize the possibility of interference ARC CUTTING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e To reduce possible interference keep cables as short as possible close together and down low such as on the floor e Locate cutting operation 100 meters from any sensitive electronic equipment e Be sure this cutting power source is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 230 455 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recomme
42. our distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 Hobart Welding Products 2007 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 HOBART 0 WELDERS
43. quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait sou haitable de r duire votre exposition aux champs lectromagn tiques pendantle soudage ou le coupage Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes OM 230 455 Page 8 1 Garder les cables ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de vous 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder couper ou d approcher des op rations de soudage couper Si le m decin approuve il est recommand de suivre les proc dures pr c dentes 3 1 7 A complete Parts List is available at www HobartWelders com SECTION 3 DEFINITIONS Symbols And Definitions For Nameplate And Serial Number Rating Label A LE Plasma Arc Cutting S N Adjust Air Gas Low Air Pressure Petes V PAC Pressure Light V Volts Increase N nor e o E Temperatur
44. r will restart pilot arc Ref 804 848 A 7 A complete Parts List is available at www HobartWelders com 5 6 Sequence Of Piercing Operation A The pilot arc starts immediately when trigger is pressed Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Hold torch at an angle to the workpiece Press trigger Pilot arc starts a A Move torch to upright Maintain torch position Release trigger Postflow cooling position 90 to surface and continue cutting continues after releasing trigger Start cutting when arc Postflow must finish before pierces workpiece trigger will restart pilot arc Ref 803 640 A 801 400 B OM 230 455 Page 19 7 A complete Parts List is available at www HobartWelders com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance pec A Disconnect power Maintain more often before maintaining during severe conditions y Check Change Clean x Replace Reference To be done by Factory Authorized Service Agent Each PS Use Y Torch Tip Electrode And Shield Cup Every Week 1 Shield Cup Shutdown System Every X Damaged Or Unreadable x Cracked Parts 3 Labels Months Every 6 Months A N LO Inside Unit x Compressor Filter OM 230 455 Page 20 7 A complete Parts List is available at www Hob
45. ritating gases e Do not cut on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the cutting area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes when cut e Do not cut containers with toxic or reactive materials inside or containers that have held toxic or reactive materials they must be emptied and properly cleaned first PLASMA ARC can cause injury The heat from the plasma arc can cause serious burns The force of the arc adds greatly to the burn hazard The intensely hot and powerful arc can quickly cut through gloves and tissue Keep away from the torch tip Do not grip material near the cutting path e The pilot arc can cause burns keep away from torch tip when trig ger is pressed e Wear proper flame retardant clothing covering all exposed body ar eas e Pointtorch away from your body and toward work when pressing the torch trigger pilot arc comes on immediately e Turn off power source and disconnect input power before disas sembling torch or changing torch parts e Use only torch es specified in the Owner s Manual CYLINDERS can explode if damaged Gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylin ders are normally part of metalworking processes be sure to treat them carefully e Protect compre
46. s Le coupage plasma produit des tincelles et projections de m tal tr s haute temp rature Lorsque la piece refroidit du laitier peut se former S e Portez une visi re ou des lunettes de s curit avec des crans lat raux approuv es e Portez des v tements de protection ad quats afin de prot ger votre peau e Ayez recours des prot ge tympans ou un serre t te ignifuges afin d viter que les tincelles n entrent dans vos oreilles LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Les rayons d arc provenant du proc d de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entrainer des br lures aux yeux et la peau e Lorsque vous coupez ou regardez quelqu un couper portez un cas que de soudage approuv muni de verres filtrants appropri La norme ANSI Z49 1 reportez vous aux Principales normes de s curi t sugg re d utiliser un filtre de teinte no 9 no 8 tant le minimum pour tout travail de coupage faisant appel un courant de moins de 300 A On mentionne galement dans la norme Z49 1 qu un filtre plus faible peut tre utilis lorsque l arc est cach par la pi ce couper Comme cela est habituellement le cas pour les travaux de coupage faible courant les teintes num r es au tableau 1 sont fournies titre d information pour l op rateur e Porter des lunettes de s curit coques
47. ssed gas cylinders from excessive heat mechani cal shocks physical damage slag open flame sparks and arcs e Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any cutting or other electrical circuits Never allow electrical contact between a plasma arc torch and a cylinder Never cut on a pressurized cylinder explosion will result Use only correct gas cylinders regulators hoses and fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use e Use the right equipment correct procedures and sufficient number of persons to lift and move cylinders e Read and follow instructions on compressed gas cylinders asso ciated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation HOT PARTS can cause severe burns Do not touch hot paris bare handed e Allow cooling period before working on torch e To handle hot paris use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards
48. ssor current limit was exceeded either above or below its operating range The lights flash for 15 sec onds before the torch can be retrig gered If this condition continues during unit operation have a facto ry authorized service agent check unit Ref 230 442 B Ref 801 300 A OM 230 455 Page 21 7 A complete Parts List is available at www HobartWelders com 6 3 Checking Replacing Retaining Cup Tip And Electrode Ure Inspect shield cup tip and electrode for wear before cutting or whenever cutting speed has been significantly reduced Do not operate torch without a tip or electrode in place Be sure to use genuine replacement parts Overtightening will strip threads Do not overtighten retaining cup during assembly Do not cross thread parts causing stripping Use care during torch assembly and parts replacement e A good practice is to replace both the tip and electrode at the same time A Turn Off power source before checking torch parts Make sure this area is clean of any debris Make sure swirl ring is clean of any holes debris and no obstructed Replace tip if opening is deformed or 5096 oversized Turn Off power source 1 Shield Cup Remove shield cup Check cup for cracks and replace if necessary 2 O Ring Check O ring for cracks or worn spots and replace if necessary 3 Tip OM 230 455 Page 22 are ja Electrode Wrench 1 32 in 1 mm 1 16 in 2
49. t and machine internal circuits are also live when power is on Plasma arc cutting requires higher voltages than welding to start and maintain the arc 200 to 400 volts dc are common but also uses torches designed with safety interlock systems which turn off the machine when the shield cup is loosened or if tip touches electrode inside the nozzle Incorrectly installed or improperly grounded equipment is a hazard 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 e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not touch torch parts if in contact with the work or ground Turn off power before checking cleaning or changing torch parts e Disconnect input power before installing or servicing this equip ment Lockout tagout input power according to OSHA CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet always
50. t les gaz e Si la ventilation est m diocre utilisez un respirateur anti vapeurs approuv e lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travaillez dans un espace restreint uniquement s il est bien ventil ou Si VOUS portez un respirateur anti vapeurs Les vapeurs caus es par le coupage et l puisement de l oxyg ne peuvent alt rer la qualit de l air et entrainer des blessures ou la mort Assurez vous que l air am biant est sain pour la sant e Ne coupez pas dans un endroit pr s d op rations de d capage de nettoyage ou de vaporisation La chaleur et les rayons d arc peuvent r agir avec les vapeurs et former des gaz hautement toxiques et irri tants e Ne coupez pas des m taux enrob s tels que des m taux galvanis s contenant du plomb ou de l acier plaqu au cadmium moins que l enrobage ne soit t de la surface du m tal couper que l endroit ou vous travaillez ne soit bien ventil ou que vous ne portiez un respira teur anti vapeurs Les enrobages ou tous m taux qui contiennent ces l ments peuvent cr er des vapeurs toxiques s ils sont coup s e Ne coupez pas de contenants qui renferment ou ont renferm s des mati res toxiques ou r actives vous devez en premier lieu les vider et les nettoyer convenablement LE PLASMA D ARC peut entrainer
51. t pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Laisser refroidir avant d intervenir sur la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour vi ter les br lures 7 DES ORGANES MOBILES peuvent provoquer des blessures AJ e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour l entretien e Remetire les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l ali mentation lectrique DES PARTICULES VOLANTES peuvent blesser les yeux e Porter des lunettes de s curit avec protections lat rales ou frontales LES CHAMPS MAGN TIQUES peu vent affecter les stimulateurs cardia ques e Porteurs de stimulateur cardiaque restez distance e Les porteurs sont pri s de consulter leur m decin avant d approcher les op rations de coupage plasma 51 313 L EMPLOI EXCESSIF peut T SURCHAUFFER L QUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire l amp rage paisseur avant de continuer a couper ou r
52. ter operation a 200 ampere alternator is recom 40 SETAT 10 FOR mended for adequate recharg BE AC BOE ing of the vehicle battery FINE ADJUST OM 230 455 Page 13 7 A complete Parts List is available at www HobartWelders com 4 11 Cable Management Strap 1 Cable Management Strap Coil cables together and secure to unit using the cable management strap 804 885 A 4 12 Electrode Wrench 1 Cable Management Strap 2 Electrode Wrench The electrode wrench is fastened to the cable management strap Ref 804 885 A OM 230 455 Page 14 7 A complete Parts List is available at www HobartWelders com SECTION 5 OPERATION 5 1 Controls E E 316 staniess 11 EX MO 1 8 BRASS mmm 1 16 COPPER Rated cut 1 8 steel 10 minute O OFF Max cut 1 4 steel 3 minute 1 Power Switch 3 Cup Light 4 Temp Light The cooling fan will run for a few seconds after Light comes on if cup is removed from torch Light comes on if unit overheats the power switch is placed in the OFF position Once cup is reinstalled on torch unit power 2 Power Light Use light to tell if unit is energized and ready to operate Light blinks if input power is not within specified range 230 442 B 5 2 Recommended Cutting Speed For Material Thickness teria Waters Thickness Recommended Cut Speed oom m m mw Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced by as much as 30
53. urner e Utilisez uniquement le ou les chalumeaux recommand s dans le manuel de l op rateur OM 230 455 Page 5 e Napprochez pas le tube du chalumeau et l arc pilote lorsque la g chette est enfonc e e Le c ble de masse doit tre pinc correctement sur la pi ce cou per m tal contre m tal et non de telle sorte qu il puisse se d tacher ou sur la table de travail le plus pr s possible de la ligne de coupage e Isolerla pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e D CHARGES LECTRIQUES poten tiellement mortelles Il y a DES CHARGES DC SIGNIFICATI VES dans le poste de soudage inver seur m me APRES coupure du cou rant d alimentation e Mettre l unit hors tension mesurer la tension des condensateurs d entr e et s assurer qu elle est pratiquement nulle avant de tou cher l une quelconque des pi ces Mesurer cette tension confor m ment aux directives nonc es la section Entretien du manuel de l utilisateur ou du manuel technique avant de toucher l une quelconque des pi ces Risque de blessure en cas D EXPLOSION DES PIECES e Mise sous tension toute pi ce d fectueuse des sources d alimentation de l inverseur peut explo ser ou faire exploser d autres pi ces Pour entre tenir les inverseurs toujours porter un masque protecteur et un v tement manches longues D LES TINCELLES VOLANTES ris quent de provoquer des blessure
54. ut before releasing trigger A The pilot arc starts immediately when trigger is pressed E Moisture from the compressor will form in the air line and at the torch It will be normal to sometimes see moisture come out the end of the torch After cutting arc starts slowly move torch across metal gt Torch air cooling postflow continues after releasing trigger Postflow must finish before trigger will restart pilot arc 804 848 A OM 230 455 Page 17 7 A complete Parts List is available at www HobartWelders com 5 5 Sequence Of Cutting Using Stand off Guide EXAMPLE Of Cutting Using Stand off Guide Stand off Guide Installation DT Split section to bottom E 1 16 in 1 6 mm gt d Place stand off guide on work Stand off guide provides 1 16 in 1 6 mm gap between tip and workpiece Press trigger Pilot arc starts Pause briefly at end of cut before releasing trigger Adjust speed so sparks go thru metal and out bottom of cut OM 230 455 Page 18 A The pilot arc starts immediately when trigger is pressed C7 Moisture from the compressor will form in the air line and at the torch It will be normal to sometimes see moisture come out the end of the torch After cutting arc starts slowly move torch across metal gt Torch air cooling postflow continues after releasing trigger Postflow must finish before trigge
55. verify the supply ground e When making input connections attach proper grounding conduc tor first e Frequently inspect input power cord for damage or bare wiring re place cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use e Inspect and replace any worn or damaged torch cable leads e Do not wrap torch cable around your body e Ground the workpiece to a good electrical earth ground if required by codes e Use only well maintained equipment Repair or replace damaged parts at once e Wear a safety harness if working above floor level e Keep all panels and covers securely in place e Do not bypass or try to defeat the safety interlock systems e Use only torch es specified in Owner s Manual e Keep away from torch tip and pilot arc when trigger is pressed e Clamp work cable with good metal to metal contact to workpiece not piece that will fall away or worktable as near the cut as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the re moval of input power e Turn Off unit disconnect input power check voltage on input ca pacitors and be sure it is near zero 0 volts before touching any parts Check capacitors according to instructions in Mainte nance Section of Owner s Manual or Technical Manual before touching any p
56. ww HobartWelders com 6 6 Troubleshooting Power Source NAW of B Is input power connected to correct line voltage Connect unit to proper input voltage see Section 4 9 Is Power Place Power switch in the switch in the On position see Section On position 5 1 Check Power switch S1 see Section 6 2 Check Control board PC1 Is Power light on Reset Power switch S1 and verify input line voltage during cutting see Section 6 2 Check Control board PC1 Is Power light flashing Check torch consumables see Sections 6 2 and 6 3 Is Cup light flashing NO Unit overheated or ambient temperature is below 40 C Yes 40 F see Section 6 2 Check function of cooling fan Is Temp light On No The compressor current lim it was exceeded either above or below its operating range see Section 6 2 Are Power and Temp lights flashing Momentarily press torch trigger and listen for com pressor operation Check for Postflow air at torch Check Control board PC1 compressor filter and com pressor connections to PC1 and torch Is compressor operating Press torch trigger and check if pilot arc ignites Does pilot arc No Check torch consumables ignite Check torch connections Control board PC1 com pressor and torch Yes Place torch near workpiece and check if pilot arc jumps or transf
Download Pdf Manuals
Related Search