AirForce 400 - Hobart Welders
Contents
1. 8 SECTION 3 DEFINITIONS 4 ua oda ES dt a M d e oen QR E SC a da b n ER 9 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 9 SECTION 4 INSTALLATION u c 0 Zan a sand a a dln a kn au a a ded ee 10 Z5 SDeCI CA OS usi Sa Hh e lal ee Ox x wee aes DR k eka xui o an dl ees xk 10 4 2 SpPechicalions FOr TOICD ss 3 xan dev tuer Ex xel n Hu EVE NEEDED 10 4 3 Duty Cycle And Overheating Hausse neutres kk KK KK KK KK KI he EU xd RES Sq ii 11 4 4 Torch Dimensions And Weight usas kid kk kk kk kk kk kk KK dE KK KK KK K KK hr KK KK kk kK kk kk lk kk kk kk 11 4 5 selecting A EoOOCallOD d o xus kan sil bal Bid stud omes cu L edu iem shed bd std qq Si B RUM 12 4 6 Connecting Gas Air Supply kk kk n kk kk kk ee ene kk kk kk kk kk kk kk eens 13 4 7 xConnecung WORK Clamp 249 eg su suk ka sais d edd Ku delk k aod acq Ale esl hind hed Re cicius 14 4 9 Connecting Mpul POWE uei deterruit der tena iras een 14 4 9 Installing Alternative Plug cena ttem ds oa KK KK KK PE KIR K KK KIR KIR KIR a ad kk d 15 SECTIONS OPERATION zus na y da mada a a DA ERA Rada du a an dd Ey dan 16 De XS Salo VD tiri t n alata Thurs duce MAR doi ators aha th coma di acad aie deed 16 9 2 AQUINO POE cu aoa e ES aba eb remis denied Sce GO abe Scd n wd pp pz 17 5 3 Higger SAM OCR es cose A De Pro TEES qe Ea 17 5 4 Sequence OR2. Does arc go on and off while cutting Torch travel speed too slow increase travel speed see Section 5 2 Clean or replace torch consumables __ Go to Section 6 5 as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece Be sure work clamp is securely attached to work Does arc go out piece Make sure tip is on or 1 16 in 1 1 while cutting in 32 a E 2 Go to Section 6 5 Section 5 4 Clean or replace torch consumables as necessary see Section 6 4 Torch travel speed too fast reduce travel speed see Section 4 1 Clean or Do sparks come replace torch consumables out of top of cut as necessary see Section or cut is not 6 4 Be sure work clamp is clean securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 1 Check torch shield cup see Section 6 2 reset unit Power switch Check torch j Go to Section 6 5 and connections inside unit Is Trouble light On unit has no cutting output Go to Section 6 5 Servicing procedure to be performed only by authorized Service Station OM 228 287 Page 24 SECTION 7 ELECTRICAL DIAGRAM os IN TE1 TE2 TES IRL IL del IX j 7 a INPUT POWER I 2 Q lll JT oL dl db 1 J 16 76 C 000904 0000040 TZ RGC4 2 ZOVAC E lt RC4 1 lt RC4 8 EN zZ
3. RC4 6 DEN i 2 PINK lt RC4 7 a I X Rc4 10 20VAC 10 RC4 5 PUR WHT nn 11 TP lt RC4 S Q WAT use or service this unit engine before servicing e Do not operate with covers removed e Have only qualified persons install 15 4L UN d a a T 9 da da o 2 co o X o o Em E o c o a e e Disconnect input power or stop VOLTAGE CHANGE OVER SWITCH 4 WARNING ELECTRIC SHOCK HAZARD L2 BLK S1 GAN 16 g J E PO RCS 1 fo df 170VAC POWER SWITCH a EC RO3 2 AIC o z SO gt gt m X Q S L2 REDO WAT ELECTRODE PILOTO AED PILOT WORK BLK WORK Ris RC1 4 gt no l RC1 1 Z7 HU POWER CONTROL RC1 PLG1 RC2 PLG2 RC3 PLG3 RC4 PLG4 RC6 PLG6 RC7 PLG7 TP 1 TEST TP3 PROGRAM RC8 PLG8 L1 BLK RC6 1 Zo RC6 2 gt perd da PC1 HS5 Re2 1 37 R2 mr E O RC2 2 gt AK BOOST CHASSIS GND THROUGH ALUMINUM PCB STANDGFF 227 893 A ircuit Diagram Figure 7 1 C OM 228 287 Page 25 SECTION 8 PARTS LIST 8 1 Recommended Spare Parts Item Diagram Part NO marking NO Description Quantity Recommended Spare Parts za 227877 FILTER air element kk kk kk KK KK RR ee KK RS SK KS I T 195 014 ICE 27C 20ft hand held including T o ral Se 227 036 CABLE work 20ft 12ga w clamp including 1 vr mm 213 619 CLAMP Work 90
4. travailler assurez vous que l endroit est s curitaire e D placez toute mati re inflammable se trouvant l int rieur d un p rim tre 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 o 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 t e Ne coupez pas sur un contenant ferm tel qu un r servoir ou un bi don e Fixez le 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
5. 1eff UPPI Ten Locations 1 And Current KVA OM 228 287 Page 9 r A complete Parts List is available at www HobartWelders com SECTION 4 INSTALLATION 4 1 Specifications If the unit is operated from a 30 ampere 115 volt circuit or a 15 ampere 230 volt circuit a different input power plug must be installed on the power cord See Section 4 9 for instructions A 30 ampere branch circuit is recommended for maximum performance Performance on a 20 ampere branch service may be limited due to the circuit breaker or line fuse Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse A 15 ampere branch circuit is recommended for maximum performance Performance on a 10 ampere branch service may be limited due to the circuit breaker or line fuse Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse Amperes Input at Rated Output Rated 60 Hz Single Phase z Plasma Cutting 115 V 230 V 115 V 230 V Plasma Gas Flow Capacity Max Rated Output 15 15 KVA KW KVA KW Gas Pressure at 10 IPM OCV Air Or 4 5 CFM 27 A at 92 Volts DC At 28 max 14 max 3 32 KVA 3 25 KVA Nitrogen 129 L min 3 8 in 288 Volts 35 Duty Cycle 0 30 0 13 3 25 KW 3 19 KW a At 60 PSI 10 mm DC y 414 kPa While idling 4 2 Specifications For Torch Air cooled torch for plasma arc cutting PAC 35 duty c
6. 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 c bles 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 r 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 Ted e gt PAC Pressure Light V Volts Increase N yee e o E Temperature Protective Earth l D Ground 1 ENG Single Phase N Constant Current Lv Voltage Input On O Off o6 Percent Direct Current Rated No Load U Primary Voltage U Conventional Load p Line Connection Voltage Average Voltage Single Phase Rated Maximum Rated Welding X E _ Static Frequency 1max Supply Current Current Duty Cycle LIA Transformer 2 Rectifier Converter Degree Of H D Prolecti ri Er Loose Shield Cup Input Z Hertz Suitable for Some Power Rating a pf power factor S Hazardous S Product Of Voltage
7. 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 o 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 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 g chette e Portez des v tements de protection ad quats qui recouvrent tout vo tre
8. see torch Owner s Manual If system works properly retighten cup and reset power Ref 200 808 Ref 802 877 r A complete Parts List is available at www HobartWelders com 6 3 Torch And Work Cable Connections If torch or work cable needs to be removed or replaced proceed as follows Turn power Off and disconnect input power plug from receptacle Remove wrapper from unit Torch Connections Remove existing torch cable from unit 1 Strain Relief 2 Torch Cable Insert cable through strain relief Slide strain relief nut onto torch cable but do not tighten 3 Air Line Connector Insert air line connector into solenoid fitting 4 Plug PLG1 Receptacle RC1 Connect PLG1 from torch to receptacle RC1 on end of wiring harness connected to circuit board PC1 5 Ring Terminal And TORCH RED Terminal Connect ring terminal on end of red leads to TORCH RED terminal 6 Ring Terminal And TORCH WHITE Terminal Connect ring terminal on end of white leads to TORCH WHITE terminal daa E mE cr 77g e s a E ids FERE E or 4 eee Biz CRT Ez i B fe FERE len TES Redi ue E o a Tighten strain relief nut Tighten strain relief around cable Pies PO El ge Work Cable Connections 8 HE Remove existing work cable from unit 7 Work Cable Be sure to allow some work cable slack inside the unit Insert work cable with strain relief into fro
9. tendeurs des boyaux et des raccords con us pour l application d termin e Gar dez les ainsi que toute autre pi ce 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 peuvent 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 K 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
10. 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 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 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 ds par des symboles adjacents aux directives ldentifie un mes
11. 60 80 no 8 OM 228 287 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 et les gaz e Sila 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
12. 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 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
13. 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 pi ce 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 contourner e Utilisez uniquement le ou les chalumeaux recommand s dans le manuel de l op rateur OM 228 287 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 piece 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 Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e D CHARGES LECTRIQUES poten
14. cutting arc starts slowly maximum cutting speed and tip life use a trigger Pilot arc starts start moving torch across metal standoff distance of 1 16 in 1 6 mm to 1 8 in 3 2 mm dragging tip will reduce tip life Adjust torch speed so Pause briefly at end of Postflow continues for 20 seconds after sparks go thru metal and cut before releasing trigger releasing trigger cutting arc can be instantly out bottom of cut restarted during postflow by raising trigger lock and pressing trigger Ref 802 878 OM 228 287 Page 18 r A complete Parts List is available at www HobartWelders com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance Disconnect power before maintaining r Maintain more often during severe conditions y Check Change Clean x Replace Reference To be done by Factory Authorized Service Agent Each x Section 4 6 Use 6 4 y Gas Air Pressure Y Torch Tip Electrode And Shield Cup Wee 5 Section 6 2 y Shield Cup Shutdown System 2 XA 7 iil Every gt Damaged Or Unreadable Air Filter Regulator Cracked Parts Y x Gas Air Hose 3 Labels Section 8 Months Every 6 Months Inside Unit OM 228 287 Page 19 7 A complete Parts List is available at www HobartWelders com 6 2 Overload Protection Trouble Lights amp Checking Shield Cup Shutdown System 7 e z 20 O lt PRESSURE O
15. 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 Whencutting 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 cancer 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 notlocate unit on over or near combustible surfaces e Donotinstall unit near flammables e Do not overload building wiring be
16. sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettre 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 i y 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 couper ou r 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 four
17. 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 correct 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 s
18. 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 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 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
19. 0A a a a REA a ak ERE a lana an ara XI Ew d E k ba 213 620 TIP contact work clamp copper 300A 2 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 Retaining Swirl Tip Electrode Ring 176 656 176 655 202 809 up 202 808 Drag Retain Cup Tip Drag Shield Drag Shield Shield 225 616 225 672 225 671 a ICE 27C T CONSUMABLES FAILURE TO RE PLACE 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 228 449 A Figure 8 1 Consumable Parts For ICE 27C T 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 228 287 Page 26 Part No Description 183427 Handle Assy complete 1 171248 Push Button Switch 1 203 120 Leads 20ft 1 203119 Main Body 1 185833 Switch Assembly w spring 1 190220 Spring trigger assembly 169231 Grease silicone 1 195014 Torch replacement 20ft 1 See Figure Figure 8 1 for additional consumable parts Figure 8 2 Torch ICE 27C A complete Parts List is available on line at www HobartWelders com To maintain the
20. 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 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
21. IES 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 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
22. OM 228 287C 2007 03 Ne ZIN EA Processes Air Pl Cutti W E L D E R S Description Air Plasma Cutter AirForce 400 And lce 27C Torch SHAT Online Forum www HobartWelders com OWNER S MANUAL File Plasma Cutters 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 to the 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
23. OPESA EG ee Edna RUE En 18 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 19 6 1 RoulineMainlenance aia TS Se AE ee he ke ER Partes Pe egg 19 6 2 Overload Protection Trouble Lights amp Checking Shield Cup Shutdown System 20 6 3 Torch And Work Cable OConnecons carcasas o S E que etx E quu aoe oa des MUS 21 6 4 Checking Replacing Retaining Cup Tip And Electrode 22 5 5 droubl shooling Power SOUC E aic a x qua E eee a Ri EUIS a eeu MUS 23 6563 dioubl sbooubdg TOL tao asad ears qbus indes SU qui tub seas oO dire us 24 SECTION 7 ELECTRICAL DIAGRAM u kx ooa cC EC SR c CC heed 25 SECTION PARIS LIST gu sc gu A E ino e ua uic a e d v AE e MR de a eee 26 OPTIONS AND ACCESSORIES PARTS LIST www HobartWelders com WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING pom 4 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage ds 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 r Means Note not safety related 1 2 Plasma Arc Cutting Hazards Thesymbols 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
24. Reset Power switch S1 Yes and verify line power RS ont voltage see Section 4 1 Check relay CR2 thermistor R1 on PC2 and Control board PC1 No Is Cup Status Yes Check torch consumables light On or Reset Power switch S1 flashing No Is Temp Status Yes If unit is overheated wait light On while fan cools down unit temperature No Turn Output control fully counterclockwise see Section 5 1 Check for gas air flow at torch Check Control board PC1 pressure switch S3 gauge air filter valve AS1 and air supply connection to unit and torch Is Pressure Status light On or flashing Press torch trigger and check if pilot arc ignites Check torch consumables Does pilot arc Check torch connections ignite air filter pressure switch S3 valve AS1 air supply connection to unit torch and PC1 Yes Place torch near workpiece and check if pilot arc jumps or transfers to workpiece Check WOrk clamp connection Check Control board PC1 and connections and torch and its connections Does pilot arc transfer to workpiece Yes Check all connections Check main transformer T1 Check boost inductor L1 and buck inductor L2 Return to beginning of chart Servicing procedure to be performed only by authorized Service Station OM 228 287 Page 23 r A complete Parts List is available at www HobartWelders com 6 6 Troubleshooting Torch A r PS
25. 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 limitation 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 Circ
26. ches 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 FR QUENCE H F risque de provoquer des interf rences e Le Rayonnement 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
27. 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 Tl Symbol DS age oat obe oa Eme pu tire Sinatra Oye Cm lacs ue 1 1 2 Rlasma Arc Coin Hazards aaron aka lteren 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings ae 3 1 5 Brincipaksafely Slandards sk cay xl a kal ahh dc tbe ex d aee ad sex ehe tea helene 4 126z EFIE D on SH ae sept d oe Anti eating morte tesa ete on Se NTI tee 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 2 suba cd etse Bota hen Sant KK Rc os KK KK RES ded kk kk 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 etlamainlenance essen bitu fedes ade 7 2 4 Principales normes de s curit sus a ki kan e x promere KK KK KK a dcn ep Uus 8 2 5 Information sur les champs lectromagn tiques
28. 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 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 Ne coupez jamais sur une bouteille pressuris e une explosion en r sulterait e Utilisez uniquement des bouteilles de gaz des d
29. cur O E Temp i STATUS Checking Torch Shield Cup Shutdown System Power must be reset whenever the cup shutdown system is activated Always turn Off power when changing or checking consumables Do NOT overtighten torch shield cup Gently finger tighten cup onto torch OM 228 287 Page 20 If certain problems occur the Ready light goes off a trouble light comes on and output stops 1 Pressure Light Lights if gas air pressure is below 40 PSI 276 kPa Turn power Off and check for proper gas air pressure see Section 5 1 A flashing Pressure light indicates that gas air system may be set too low faulty leaking or has a flow re striction see Section 6 5 2 Cup Light Lights if shield cup is loose Turn power Off and check shield cup connection see torch Owner s Manual Power must be reset whenever the cup shutdown is activated A flashing Cup light indicates that the torch consumables are stuck or worn and should be inspected and or replaced see Section 6 4 Check shield cup shutdown system once a week 3 Temperature Light Lights if power source overheats or when ambient temperature is below 35 C 31 F see Section 4 3 4 Torch Shield Cup Turn Power On and loosen shield cup If shutdown system works properly Ready light goes off and Cup light comes on If not turn power Off and check for proper gas air pressure see Section 4 1 blocked or leaking hose or loose shield cup
30. 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 circuit 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 instructio
31. dans un endroit o 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 UNE D CHARGE LECTRIQUE peut entrainer la mort Le fait de toucher une pi ce lectrique sous tension peut donner une d charge fatale ou entra 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
32. e 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 compressed 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 t
33. elding 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 OM 228 287 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
34. endent 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 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 228 287 Page 8 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif
35. f Remove swirl ring Check ring and replace gt O Rin tip is not clean and bright clean with steel if side holes are plugged g wool Be sure to remove any pieces of steel Remove shield cup Check cup for cracks wool afterwards Check O ring for cracks or worn spots and replace if necessary 5 Electrode replace swirl ring if necessary Check O ring for cracks or worn spots re Check electrode If center has a pit more 8 O Ring place shield cup if necessary than a 1 16 in 2 mm deep remove and re Check O ring for cracks or worn spots and 3 Tip place electrode replace if necessary 4 Opening 6 Swirl Ring Carefully reassemble parts in reverse order OM 228 287 Page 22 r A complete Parts List is available at www HobartWelders com 6 5 Troubleshooting Power Source de Ww of B Is input power connected to correct line voltage Connect unit to proper input voltage see Section 4 8 Is Changeover switch S2 in the 115V or 230V position Place Changeover switch in proper position for input voltage see Section 4 8 Does the breaker trip when unit is set on 115V Turn down output current see Section 5 1 pak Is Power switch Place Power switch in the S1 in the On On position see Section position 5 1 Yes Is the cooling fan running Check Power switch S1 and relay CR2 and thermistor R1 on PC2 Replace PC2 if R1 or CR2 are not functioning correctly Yes
36. 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 228 287 Page 27 Notes Notes Notes Warranty Questions Call 1 800 332 3281 7 AM 6 PM EST Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the 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 WARRANT
37. hem 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 parts bare handed e Allow cooling period before working on torch e To handle hot parts 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 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 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
38. 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 solez 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 Princi 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
39. 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 228 287 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 Pourr duire la possibilit d interf rence maintenir les c bles 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 t l phone 1 877 413 5184 site Internet www global ihs com Recommended Practices for Plasma Arc Cutting 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 t l phone 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 Cy
40. linders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles 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 m tres de tout quipement lectronique sensible e S assurer que la source de coupage est correctement branch e et mise la terre e GSil interf 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 Welding 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 t
41. milar device to move unit 3 120 VAC Receptacle To connect unit to 230 VAC input power a customer supplied plug is necessary see Section 4 9 Locate unit near correct input power supply 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 804 486 A Ref 804 487 A Ref 804 488 A OM 228 287 Page 12 r A complete Parts List is available at www HobartWelders com 4 6 Connecting Gas Air Supply r Use only clean dry air with 90 to 120 psi 621 to 827 kPa pressure Gas Air Inlet Opening 2 Hose 3 Teflon Tape 22227 Obtain hose with 1 4 NPT right Tools Needed m M hand thread fitting Wrap threads 4 with teflon tape optional or apply IL 5 8 1 1 8 in pipe sealant and install fitting in opening Route hose to gas air supply 4 Air Filter Regulator Adjust gas air pressure according to Section 5 1 From Gas Air Supply 802 787 Ref 801 319 C Ref 804 486 A OM 228 287 Page 13 r A complete Parts List is available at www HobartWelders com 4 7 Connecting Work Clamp OM 228 287 Page 14 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible 802 463 A Check input voltage available at site 1 Changeover Switch Switch is accessible through slot in rear panel 2 Changeover Switch Label Look at label
42. ns 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 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
43. nt panel Tighten strain relief nut Tighten O strain relief around cable 8 Work Cable Ring Terminal 5 Route cable under center baffle Connect ring terminal on end of work cable to terminal labeled WORK on circuit board PC1 Les L p N TORCH WHITE Tools Needed E C H 1 4 in 804 489 B Ref 802 860 226 678 C OM 228 287 Page 21 r A complete Parts List is available at www HobartWelders com 6 4 Checking Replacing Retaining Cup Tip And Electrode E V Overtightening will strip threads Do not overtighten retaining cup during c assembly Do not cross thread parts causing stripping Use care during torch assembly and parts replacement 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 A good practice is to replace both the tip and electrode at the same time Turn Off power source before checking torch parts NN ZA e Gun Make sure this area is clean of any debris Make sure swirl ring is clean of any debris and no holes are obstructed 4 x uw New 4 82 in 1 mm to 1 16 in m 2 mm maximum pit lt 4 depth depending on acceptable cut quality Worn 802 465 Turn Off power source Remove tip Check tip and replace if open 7 O Ring 1 Shield Cup ing is deformed or 50 oversize If inside o
44. ovenant 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 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
45. sage 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 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 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
46. tacle that requires a plug that is different from the supplied plug Cut cord close to plug See Section 4 8 for instructions on setting changeover switch for 2 Alternative PLug 230 VAC proper voltage Plug Shown Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Outer Shell Cord Grip Strip cord jacket back enough to separate conductors Strip conduc tors enough to make good contact with plug terminals Make plug con nections and reinstall outer shell and cord grip Tighten assembly screws Tools Needed onto shell Do not overtighten Ref 801 305 A 801 611 OM 228 287 Page 15 7 A complete Parts List is available at www HobartWelders com SECTION 5 OPERATION 5 1 Controls POWER O 3 PRESSURE STATUS 3 PRESSURE POWER 60 PSI O 24 16 GAS AIR 9 gt SET UN A 27 OUTPUT Set To 60 PSI 414 kPa Setting Gas Air Pressure 24 Requires 90 120 PSI GAS AIR Supply SET Al A 27 OUTPUT 1 Output Control put and or the cut time or find more adequate Place Output control in Gas Air position and power see Section 4 1 turn on gas air supply Lift knob and turn to Use control to set cutting ouput 2 Trouble Lights See Section 6 2 adjust pressure Push knob down to lock in Place control in Gas Air Set position to safely setting adjust gas air pressure Only gas air circuit 3 Power Light Place Output control in desired c
47. tering 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 Z49 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 protective 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 f
48. 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 IN LES TINCELLES VOLANTES ris quent de provoquer des blessures Le coupage plasma produit des tincelles et projections de m tal tr s haute temp rature Lorsque la pi ce refroidit du laitier peut se former a 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 pr
49. till 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 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 228 287 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 Recommended 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 ihs 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 W
50. to find correct switch position Be sure input power connection meets all applicable national regional and local electrical codes 3 Grounded 120 VAC Receptacle To use rated output see specifications connect the unit to an individual branch circuit capable of carrying the effective eff current for the output being used The unit must have a properly sized plug installed and the circuit must be protected by properly sized fuses or cir cuit breakers A 120 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required see Section 4 1 4 Plug From Unit Connect plug to receptacle If an extension cord is necessary select a cord of 12 AWG for up to 53 ft 16 m To connect unit to 230 VAC input power a customer supplied plug is necessary see Section 4 9 A 230 volt 15 ampere minimum individual branch circuit protected by time delay fuses or circuit breaker is required see Section 4 1 If an extension cord is necessary select a cord of 14 AWG for up to 133 ft 41 m A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 802 787 Ref 804 488 A r A complete Parts List is available at www HobartWelders com 4 9 Installing Alternative Plug This procedure is necessary if the unit is to be connected to a 230 1 Supplied 115 VAC Plug VAC receptacle or to a 115 VAC recep
51. uit 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 your 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 WELDERS
52. umes 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 228 287 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 irritating 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 forc
53. utting Is activated 4 Power Switch output If 22 27 amperes of cutting output is used Setting Gas Air Pressure with 115 VAC input power and the overload 5 Air Filter Reaul r At ambient temperatures below 5 C protection on the input power circuit fre Ir Filter Regulator 23 F readjustment of gas air quently opens either reduce the cutting out 6 Pressure Adjustment Knob pressure regulator may be necessary Ref 227 835 A Ref 804 486 A OM 228 287 Page 16 r A complete Parts List is available at www HobartWelders com 5 2 Cutting Speed Recommended Cut Speeds At 27 Amperes Output mes mm m mmm eer TT TT TT Recommended Gut Speed is approximately 80 of maximum 7 Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20 Recommended Cut Speeds At 20 Amperes Output Thickness Recommended Cut Speeds mere ms me m min Lom C 8 Ta Tm BE Recommended Cut Speed is approximately 80 of maximum 7 Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20 5 3 Trigger Safety Lock 1 Trigger Trigger Locked Trigger Unlocked 802 877 OM 228 287 Page 17 r A complete Parts List is available at www HobartWelders com 5 4 Sequence Of Operation EXAMPLE Of Cutting Operation a The pilot arc starts immediately when trigger is pressed Place tip on work for drag cutting or for Raise trigger lock and press After
54. 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 parts OM 228 287 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 D 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 en
55. ycle Safety interlock devices shut down power source Safety trigger guard Cutting capacity see Section 4 1 OM 228 287 Page 10 r A complete Parts List is available at www HobartWelders com 4 3 Duty Cycle And Overheating For Units Connected to a 115 Volt Circuit Duty Cycle is percentage of 10 min or a 230 Volt Circuit utes that unit can cut at rated load 35 Duty Cycle At 27 amperes 92 volts dc without overheating If unit overheats thermostat s opens output stops Temperature 3596 duty cycle trouble light goes On and cooling my EN fan runs Wait fifteen minutes for unit to cool or temperature light to m go off Reduce amperage or duty cycle before cutting or gouging Exceeding duty cycle can damage unit and void 3 1 2 Minutes Cutting 6 1 2 Minutes Resting warranty Overheating OR Reduce Duty Cycle sduty1 5 95 Ref 804 486 A 8 3 8 in 213 mm 3 0 Ib 1 4 kg 35 mm Ref 802 877 OM 228 287 Page 11 r A complete Parts List is available at www HobartWelders com 4 5 Selecting A Location 8 1 2 in 216 mm Dimensions And Weight 12 5 16 in 49 lb 22 2 kg 313 mm not including torch Add 13 16 in 21 mm for handle P d gt m od Movement Location And Airflow E Serial Number Rating Label located on rear panel of plasma cutter use label to determine input power for unit 1 Lifting Handle Use handle to lift unit 2 Hand Cart Use cart or si
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