Hobart AIRFORCE 750 User's Manual
Contents
1. Single Phase Three Phase Input Voltage 200 230 460 230 460 575 Input Amperes At Rated Output 42 3 36 8 18 4 18 4 9 2 7 4 Max Recommended Standard Fuse Rating In Amperes Time Delay 50 45 20 20 10 8 Normal Operating 3 60 60 25 25 15 10 Min Input Conductor Size In AWG Kcmil 8 10 14 14 14 14 Max Recommended Input Conductor Length In Feet Meters 35 ES E La e Gees Min Grounding Conductor Size In AWG Kcmil 10 10 14 14 14 14 Reference 1999 National Electrical Code NEC 1 Consult factory for circuit breaker applications 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 OM 279 Page 11 2 8 Placing Jumper Links Check input voltage available at site 1 Jumper Link Label Move jumper links to match input voltage and label on unit iia Do not overtighten Single Phase Models 200 VOLTS 230 VOLTS 460 VOLTS GR o o dn o Cm AR ooo o OL OL S 083 566 C Three Phase Models 230 Volts 460 Volts 575 Volts FAR MAA e MAA e offic oo offo o o ofA oo so o op o oo of o o o ofA L1 L2 L3 L1 L2 L3 L1 S 094 120 B Tools Needed Ee B CC Ak 3 8 in Ref 801 455 OM 279 Page 12 2 9 Connecting Input Power 1 Strain Relief Clamp Route input and grounding conduc tors through clamp to terminal board Three Phase Connections 22. Have Factory Authorized Service Agent check power switch S1 control relay CR1 CR5 and CR6 rectifi er SR1 and SR2 for single phase models safety control board PC1 power control boards PC2 and PC3 inductor L1 resistor R1 and check gas air system for leaks No cutting output Power light off Trouble lights off Ready light off fan mo tor FM does not run Place Power switch in On position Place line disconnect device in On position see Section 2 9 Check line fuse s and replace if needed or reset circuit breakers see Sections 2 7 and 2 9 Have Factory Authorized Service Agent check power switch 1 transformer T1 and fan motor No cutting output Power light on Ready light on Trouble lights off fan motor FM running Be sure work clamp is connected Clean or replace worn consumables as necessary see torch Owner s Manual Have Factory Authorized Service Agent check safety control board PC1 power control boards PC2 and PC3 and rectifier SR1 and SR2 for single phase models No cutting output Power light on Ready light on Trouble lights off fan motor FM running slowly Check position of input voltage jumper links see Section 2 8 Check input power and check for proper input connections see Sections 2 7 and 2 9 No control of output Have Factory Authorized Service Agent check safety control board PC1 and power control boards PC2 and PC3 No gas air flow
3. Dangers suppl mentaires en relation avec l installation le fonctionnement etla maintenance Principales normes de s curit Information sur les champs lectromagn tiques Duty Gycle And QOverbealrg a praet ta Ais oe te oe te boli paced td Cutting Speed Selecting A Location Connecting Gas Air Supply Electrical Service Guide Placing Jumper Links Connecting Input Power SECTION 3 OPERATION Front Panel Controls Setting Gas Air Pressure Sequence Of Operation SECTION 4 MAINTENANCE 8 TROUBLESHOOTING OO 4 1 Routine Maintenance 4 2 Trouble Lights 4 3 Checking Shield Cup Shutdown System 4 4 Troubleshooting SECTION 5 ELECTRICAL DIAGRAMS Lu SECTION 6 PARTS LIST OPTIONS AND ACCESSORIES WARRANTY E GO O1 O1 O1 oo NN SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage ih 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
4. WELDING PRODUCTS OM 279 180 060P August 2001 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter AirForce 750 OWNER S MANUAL 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 M 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 gt Z installation and operation quick and easy With Hobart you can count on years of reliable service with proper WARRANTY maintenance And if for some reason the unit Working as hard as you do every power source Hobart is registered to the needs repair there s a Troubleshooting section from Hobart is backed by ISO 9001 Quality System that will help you figure out what the problem the best warranty in the Standard business is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided REGISTEHED QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor Hobart offers a Technical Manual whic
5. coques lat rales sous votre casque ou cran facial e Ayez recours a des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements et les blouissements 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 et laine et des bottes de protection OM 279 Page 6 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 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 protege 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 2 tre dangereux AN Le coupage produit des vapeurs et des gaz Respirer N ces vapeurs et ces gaz peut tre dangereux pour la sant e Ne mettez 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
6. 20 5 O 1 8 1 4 3 8 1 2 5 8 3 4 7 8 3 2 6 4 9 5 12 7 15 9 19 1 22 3 MATERIAL THICKNESS IN MM 180 909 2 5 Selecting A Location 1 Handle Use handle to roll unit short distances 2 Lifting Eye 3 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 4 Rating Label Under Access Door Use rating label to determine input power needs 5 Line Disconnect Device Location And Airflow Locate unit near correct input pow er supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC INPUT SERIAL NO Section 20 STOCK NO VOLTS AMPERES KW PHASE Do not block airflow around base of unit 800 402 Ref 801 454 C OM 279 Page 10 2 6 Connecting Gas Air Supply Unit Gas Fitting Female 1 4 NPT Quick Connect Gas Fitting Standard Gas Fitting Obtain and install desired fitting Use only clean and dry gas air with 70 to 150 psi 483 to 1034 kPa pressure 4 Hose Obtain suitable hose according to installed fitting and connect to fit ting Route hose to gas air supply Adjust gas air pressure according to Section 3 2 A Incorrect plasma gas can cause torch and power From Gas Air Supply source damage Use only air or nitrogen for the plasma gas Ref 801 455 2 7 Electrical Service Guide
7. 312 375 w post and lock 12 Pare aida 070 026 STAND OFF support No 6 32 x 437 lg 4 Pr MVP 162 818 DOOR access 1 icd cpi 044 426 CONNECTOR clamp cable 1 QU EE 176 159 ss PANEL Side HE EE 1 Ic ELE 095 094 WHEEL polyolefin 6 in dia x 1 375w 500 hub dia 2 iod iu deben 178163 AXLE running gear 500dia x 24 5 1 T 081 960 RING rtng ext 500 shaft x 035thk C style 2 44 AA AA AA A ane 1 OM 279 Page 25 Item Dia Part NO Mkgs NO Description Quantity Figure 6 1 Main Assembly Continued Mo er E PANEL TroDt CONSISTING ON e data ceca hat Coed RUPEE ESSE RE TIAS 1 Te 206 446 vasa PANEL on e iniecto nien tu acf tire ee T T LOL NAMEPLATE order by model and serial number 1 guess E S 204 326 CONSUMABLE STORAGE BOX w DOOR 7 METERTE EEEN 99 899 mawa LATCH SIG EE 206 303 LABEL ICE 50C consumables 1 Liliane PC1 192 790 CIRCUIT CARD ASSEMBLY safety control 1 POR awe eae t Kong 184 544 LINER polycarbonate lens 7 uocis te en 176 478 STAND OFF support PC card 4 CUT 92 155013 SWITCH rocker SP
8. cutting fumes and gases e lf ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufac turer 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 deple tion can alter air quality causing injury or death Be sure the breathing air is safe e Donot 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 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 if necessary 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 e Do not grip material near the cutting path The pilot arc can cause burns keep away from torch tip
9. Input And Grounding Conductors 3 Line Disconnect Device Select type and size of overcurrent protection using Section 2 7 Three Phase System i y A Always connect Single Phase System T grounding conductor first N WA D 2 GND PE TIZZZIZITT Na 5D 1 lt Tools Needed 7 16 in Co 1 2 in Ref 801 455 Ref 144 221 Ref 070 399 C Ref 801 454 C OM 279 Page 13 3 1 SECTION 3 OPERATION Front Panel Controls PRESSURE 1 EXPANDED BZ METAL KN OFF ON d _ amp TIP SAVER D PILOT 1 Pilot Arc Switch Use switch to control pilot arc Place switch in Expanded Metal position for continuous pilot arc Use while cutting ex panded metals only I7 The Expanded Metal position keeps the pilot arc in the circuit at all times Life of consumables will be significantly re duced while in Expanded Metal mode Place switch in Tip Saver position to provide pilot arc output for arc starting only Use Tip OM 279 Page 14 RES GAS AIR SET O O ga cup OUTPUT STATUS Saver position in most applications to length en the life of the torch and its consumables and to obtain maximum cutting performance Torch trigger must be reset after every cut while in Tip Saver mode 2 Gas Air Pressure Gauge 3 Output Control Use control to select cutting output in am peres Gas air aut
10. Power light on Ready light on Trouble lights off fan motor FM running Have Factory Authorized Service Agent check for proper torch connections and check safety control board PC1 Check operation of gas valve GS1 and check gas air system for leaks Pressure Trouble light On Ready light off Check for correct gas air pressure adjustment see Section 3 2 Check for sufficient gas air supply pressure see Section 2 6 Check for dirty air filter regulator and clean if needed see manufacturer s instructions Check air lines for leaks Have Factory Authorized Service Agent check pressure switch S3 and safety control board PC1 Cup Trouble light On Ready light off Check torch shield cup see Section 4 3 Reset power switch Have Factory Authorized Service Agent check for proper torch connections and check safety control board PC1 Temperature Trouble light On Ready light off Main transformer or main rectifier overheating Allow fan to run the Trouble light goes out when the unit has cooled Have Factory Authorized Service Agent check safety control board PC1 OM 279 Page 19 Trouble Remedy Fan motor FM does not run Power light and Ready light both On Have Factory Authorized Service Agent check fan motor connections Check input power and check for proper input connections see Sections 2 7 and 2 9 Trouble lights not working Have F
11. Si la ventilation est m diocre utilisez un respirateur anti vapeurs approuv e Veuillez lire le Material Safety Data Sheets MSDS et les instructions du fabricant pour obtenir plus de renseignements sur les m taux couper les enrobages et les nettoyants 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 Necoupez 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 si n cessaire que vous ne por tiez un respirateur 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 L
12. distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors Rotors Stators and Brushes 2 3 Years Parts and Labor Drive Systems PC Boards Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems HE Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 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 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 in
13. o W N o o NT 1 lt RC12 1 T T d ig EUR ST E 7 4 d 440 lee O 5 O o o gt O lt O c Oo O Y Y c wv c cC Oo o S O O c c c lt KU Ng 56 ee 2 NE RC12 2 COMMAND WO POWER RC11 8 gt PC1 AEA 3 78 LERC12 5 w Beie SAFETY CONTROL AS1 e RC10 PLG10 24VAC DI PRESSURE RC11 PLG11 59 Kay RC12 PLG12 RC11 13 KEL aute RO OG MA cur TEMP 7 LERC11 14 194 148 For 230 460 575 Volt Models ircuit Diagram Figure 5 2 C OM 279 Page 22 Notes OM 279 Page 23 SECTION 6 PARTS LIST CS Hardware is common and not available unless listed 801 499 J Figure 6 1 Main Assembly OM 279 Page 24 Item Dia Par NO Mkgs NO Description Quantity Figure 6 1 Main Assembly bv COR 116 1590 22 PANEL Side BEI aue usen Naka ee ee Da Per ue 1 p mo 026 947 OTAND OFRE Lu E EE Patron ams id eite de dees EN 1 ini Ob Sti hedged 176 162 5 BAEELEZCSDIOE iwi hows Ei BUE Ee bc pete OS wide eb prete nee 1 4 ASI max 169020 5 SWITOH TOS serze nA eters Hein ed mir UR e ERR to aU De Aeneas 1 oe VH3 is 190 184 VARISTOR VRS 22s enr edet deed eie ete Ri dence eer es 1 6 CR5 006 393 RELAY end 24VAC DPDT 10A 120VAC 1 M Geert Paani ee 188852 BRACKET rectifier sero e eR em or Oden e one den 1 8 CH1 6 180270 CONTACTOR def prp 40A 3P 24VAC coil cover 2 NE MO L 1 179 543 INDUCTOR 50A
14. ou un bi don Fixez le c ble de masse sur la pi ce couper le plus pr s 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 ou un feu Ne coupez jamais des contenants qui peuvent contenir des mati res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement Ne coupez pas dans un endroit o l atmosph re risque de contenir de la poussi re ou des vapeurs explosives Ne coupez pas de bouteilles de tuyaux ou de contenants pressuri ses Ne coupez pas de contenants qui ont deja recu des combustibles 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 Ne placez pas le poste sur une surface combustible ou au dessus de celle ci Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes N C 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 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 po
15. over or near combustible surfaces e Donotinstall 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 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 electro
16. 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 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 wh
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 279 Page 4 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 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 1 Keep cables 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 pv O TIS Keep cutting power source and cables as far away from operator as p
18. 279 Page 17 4 2 Trouble Lights Difficulty establishing pilot arc may indicate consumables need to be cleaned or replaced O PRESSURE 2 Q G cup PO E TEMP 4 3 Checking Shield Cup Shutdown System t7 Power must be reset whenever the cup shutdown system is activated Always turn Off power when changing or checking consumables OM 279 Page 18 1 Pressure Light Lights if gas air pressure is below 40 PSI 276 kPa Turn power Off and check for prop er gas air pressure see Section 3 2 2 CupLight 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 Check shield cup shutdown system once a week see Section 4 3 3 Temperature Light Lights if power source overheats see Section 2 3 1 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 immedi ately turn Off power and have Fac tory Authorized Service Agent check safety control board PC1 op eration If system works properly retighten cup and reset power Ref 801 300 A 4 4 Troubleshooting Trouble Remedy No pilot arc difficulty in establishing an arc Clean or replace worn consumables as necessary see torch Owner s Manual Check for damaged torch or torch cable see torch Owner s Manual
19. 70 micro henry 1 e AER 176147 ss HEAT SINK EE 1 11 VR1 2 178393 VARISTOR 1 phase model 2 12 SR1 2 179682 RECTIFIER integ 40A 800V 1 phase model 2 2193 TP2 198 358 THERMOSTAT NC open 165 F close 135 F 1 14 VR1 178393 VARISTOR 3 phase model 1 aD re SH1 179542 RECTIFIER integ 30A 800V 3 phase model 1 T T PEE 204 241 sx COVER 0D RNN 1 IPTE 182 520 LABEL warning electric shock 1 LV AP R1 189235 RESISTOR WW fxd 675W 3 ohm 1 MATA d d 189 443 WASHER flat 2 0 OD mica PA ANY PA Na aa dui ea 189 442 WASHER flat 1 0 OD mica vr Mors dbi e e EE tata 010 381 CONNECTOR rectifier 2 a beb de Pe RN 096 867 INSULATOR end resistor 2 sb a tus 170 647 BUSHING snap in nyl 1 312 ID x 1 500mtg hole 3 19 FM1 148808 MOTOR fan 230V 50 60Hz 1550rpm 312dia shaft 1 ADS de IECUR 150 783 BLADE fan 9 000 5wg 39deg 312dia bore 1 a T T1 179 779 TRANSFORMER pwr main 200 230 460 1 phase model consisting of 1 Kr nn T1 178 959 TRANSFORMER pwr main 230 460 575 3 phase model consis
20. 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 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 1 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 pr
21. D WARRANTY 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 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 hobart retail 4 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Available Always provide Model Name and Serial Style Number T
22. ENDIE 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 Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn et prot g avant de mettre l appareil en service LES CHARGES LECTROSTATI 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 Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer regulierement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sour ces de haute fr quence maintenir les clateurs une distance correcte et util
23. L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particulierement 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 Prot gez vous ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Ne coupez pas dans un endroit ou des tincelles pourraient attein dre des mati res inflammables D placez toute mati re inflammable se trouvant l int rieur d un perimetre de 10 7 m 35 pi de la piece couper Si cela est impos sible vous devez les couvrir avec des housses approuv es et bien ajust es 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 Afin d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main Si vous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entrainer un feu de l autre c t Ne coupez pas sur un contenant ferm tel qu un r servoir
24. ST 10A 2bO0VDC enn 1 HA TA 17 4 991 2 KNOB POINT ee KAKA A cee Hana eine T en A Aa ht Sistas S1 128 756 SWITCH toggle 3PST 40A 600VAC scr l m 191 7098 2 GASKET SWIC 4 oum xi Itm Remote Aenea eee aac Sees TYPE C1 2 3 129954 CAPACITOR 3 phase model 38 rm C1 2 129954 CAPACITOR 1 phase model 2 TEPORE 178 739 FITTING plstc Qdisc straight fem 1 8NPT 1 ovre 179 536 TUBING pneumatic 250 OD x 170 ID x 10 00 1 ENEE 179 537 TUBING pneumatic 250 OD x 170 ID x 17 00 1 DNS SU chk ur 190 585 GAUGE pressure air 0 160psi w fittings 1 E Mabe ee aces 188 962 HOSE PVC 312 ID x 437 OD x 29 500 1 sod BR indo n ed dins deis ted 168 343 HINGE cont polyolefin 2 00 L w 125H 2 Ruhe ate Maa iid gor 199 997 COVER safety control board 1 ME AN 136 156 LABEL general precautionary 1 47 Work 199020 CABLE work 20ft No 8 w strain relief and term 1 48 Work 199 995 CONTACT TIP work clamp II 2 Em PLG22 27 37 164 900 CONNECTOR amp SOCKETS 38 TE PLG10 164 899 CONNECTOR amp SOCKETS iii
25. SURE RC11 PLG11 59 de RC12 PLG12 RC11 13 gt MEP 4 lt RC12 6 AA cup Y TEMP 7 SERO11 14 KAN 193 215 For 200 230 460 Volt Models ircuit Diagram Figure 5 1 C OM 279 Page 21 C2 C3 T 2 lt lt RCA 6 RC4 3 gt 27 PC3 L AN POWER CONTROL RC4 1 gt Y a RC1 PLG31 2 RC4 PLG34 i Ro Eon TE1 Mov RC7 PLG37 N ad RC4 4 gt gt Ny EM 5 o gt E RC4 7 gt 8 ROM N Ng ei 29 O et lt ROA 8 Lou ul ak al RESET 29 gt m Oo Oo NM E CE NE E ou Naan LNG SPP al l 1 O CI EO E 22 RC4 6 T due c Mecum E TIP ELECT s N st D S N a a ME a ME ME AM e DUO ES 1 4 5 6 3 8 2 PC2 zo M REA ep POWER CONTROL RC4 1 gt Yes S S 3 3 O RC4 9 CR6 PILOT 4 NY ei A qj EB 2 PLG1 PLG2 RC1 PLG21 H H A o EL 1 40 lt RC2 1 RC2 PLG22 Ball o Ree ELECTRODE e RC5 PLG25 c 47 RC4 4 gt YY O 2 RC6 PLG26 ELECTRODE Hk RC7 PL627 RC4 7 gt gt L a nS O EECH d Poy T P Ree 1 gt LIB c b 2T WORK 4 p x p ex a 45 o 9 Q RC6 2 gt 29 BLK ed LM LUNA LUN NG SA VR3 3 TURNS EACH i ME oe d pe CONTACTOR ES S S A e N Na N N Q S S 3 3 Q e amp D A ya ki s AN NEINEI NENEI NENE NAN No NEN NCC ACTAE O EC PLG7 PLG8 44 N o 4 m o
26. a 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 piece couper pres 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 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 bouteiles 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 Prot gez les bouteilles de gaz comprim contre la chaleur excessive les chocs m caniques le laitier la flamme les tincelles et l arc Installez et attache
27. a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards A 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 Protect yourself and others from flying sparks and hot metal Do not cut where flying sparks can strike flammable material 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 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 and fire hazards e Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Do not cut in
28. actory Authorized Service Agent check safety control board PC1 OM 279 Page 20 SECTION 5 ELECTRICAL DIAGRAMS RC4 3 z PC3 Z7 lt lt RC4 6 POWER CONTROL RC4 1 TE1 RC1 PLG31 1 RC4 PLG34 EG x 0 T1 22 RC6 PLG36 RC7 PLG37 20 o RC4 4 c s RC4 7 gt s CR1 RC4 9 t 2 MM OT m Y P RC6 1 gt 6 29 et C S E g g g g ghe TORCH E EINER EN T a TRIGGER SH N wl D e S S N x Sn M S 25 lt lt RC4 6 TO ame Je TIP ELECT s S 5 21 iu c a e S amp g RC4 3 gt RI 1 eee ee Y Pc CHI POWER CONTROL RC4 1 SQ amp amp amp al 3 3 26 lt RC4 9 CRB X N N NA Na PILOT Vy ys PLG1 PLG2 i RC1 PLG21 H H YEL 1 40 lt RC2 1 RC2 PLG22 Reg eot T ELECTRODE RC5 PLG25 RC7 PLG27 RC4 7 gt 00000 db Reo QD L 2T WORK 4 Bo z 9 9 RC6 2 m NATI E NATIN ARN SZ VR3 3 TURNS EACH CONTACTOR M S oN M NX ED Xx EI SI 3 t e N S D on 8 x N S PA ROR ROAR BR AR ATA ma PLG7 PLG8 M 0 o Ww N o mot NT 1 lt RC12 1 i A sb sl Wo Og i I EN A d o o o X O eic ao O T O O 2 O oO D 18VAC DE ac ac ad RU VA 26 AK 2 8 nea COMMAND JG POWER RC11 8 gt PC1 AED se 46 E oy SAFETY CONTROL AST READY RC10 PLG10 24VAC Y PRES
29. 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 N 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 pom nd 9 98 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
30. dustry 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 Millers 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 IMPLIE
31. e ini RD EE E PLG5 167640 CONNECTOR amp SOCKETS 1 T PLG24 34 168 071 CONNECTOR 8 SOCKETS 2 ee PLG26 36 176 121 CONNECTOR rect univ 084 2 Sari Davee PEOT2 153501 4 CONNECTOR amp SOCKETS 145 2p cantons stone ne nG ET Ses ieee due PLG21 31 158 720 CONNECTOR 8 SOCKETS 2 eo PLG11 169 240 CONNECTOR A SOCKETS 1 DORA PLG2 8 170 888 CONNECTOR amp SOCKETS 7 Rd eure PEG25 s 191056 lt CONNECTOR 8 SOCKETS 135653 24zkpER EI E EC Ww c ICE 50C order separately Ep 176 924 ICE S0C 25m0 suc 50 2 BN Gnas pia heads Hew be CEs rene AA EA ques E 176020 we e Le aduentus pido Paare NN duci esie Due ios anre pdt cd A i 176 828 ICE 50CM 50ft machine mounted 1 Re 180 605 PENDANT CONTROL recommended for use w ICE 50CM 1 HOUR dass 192 893 DISCONNECT quick IGE 50 ERE es RE 1 MUERTE 201 817 FLANGE receptacle 1 D rS 204 290 SO RS Se 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacem
32. en 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 ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists on internal parts of inverter power sources AFTER the removal 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 279 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 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 o
33. ent Parts Model and serial number required when ordering parts from your local distributor x Shield 2 053 Shield 192 058 Retaining Cup Tip 192 050 Electrode Swirl Ring O Ring 177 890 192 047 177 886 169 232 1 Standard e Cutting Apply silicone Machine ei Cutting Deflector 177 888 Retaining Cup Tip 192 050 grease 169 231 before installing Electrode 177 876 192 048 Extended Shield 192 203 ee a c Gouging Figure 6 2 Consumable Parts For ICE 50C OM 279 Page 26 Retaining Cup Ti 192 050 p 177 878 Cutting 1 8 3mm stand off Electrode recommended 192047 Ref 206 303 Warranty Questions Call 1 877 HOBART 1 for your local Hobart distributor 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 WELDERS HOBART 3 31 WARRANTY Effective October 1 1999 5 3 1 WARRANTY applies to all Handler 135 and 175 models Airforce 250 250A and 375 models and Champion 10 000 models This warranty also applies to the Beta Mig 1800 Champ 1435 2060 8500 models Ironman 250 Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Ser
34. euves 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 279 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 consignes mentionn es pr c demment font partie de celles desti n es aux personnes ayant recours un stimulateur cardiaque Veuillez consulter votre m decin pour obtenir plus de d tails SECTION 2 INSTALLATION 2 1 Specifications Amperes Input at Rated Load Rated gone Output 60 Hz Model E TYPE or iip asma Raled Cutting Circuit Output Gas Output Capacit Voltage 200V 230V 460V 575V KVA KW HU C Single 42 30 36 80 18 40 m 8 49 6 55 Direct 50A Phase 3 40 2 95 1 50 0 68 0 207 Current Air Or 110 Volts 0 7 in Tm Dn ZU n Ges Strai
35. ght Nitrogen DC 60 18 mm 280 I Polarit Onl At 10 IPM SSC E 2 13 107 0 85 0 85 0 32 DCEN 7 Duty Cycle While idling 2 2 Dimensions And Weight Dimensions A 36 3 4 in 934 mm B 24 1 2 in 622 mm C 21 in 533 mm Weight Single Phase Models 147 Ib 66 kg Three Phase Models 168 Ib 76 kg Without Torch Ref 801 454 C Duty Cycle is percentage of 10 min utes that unit can cut at rated load without overheating If unit overheats thermostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before cutting A Exceeding duty cycle can damage unit and void war ranty 60 Duty Cycle 6 Minutes Cutting 4 Minutes Resting Overheating SEN 0 A SET E Minutes Reduce Duty Cycle duty1 4 95 OM 279 Page 9 2 4 Cutting Speed The cutting speed curve shows the recommended maximum cutting speed capabilities of the power source and torch for mild steel of RECOMMENDED PRODUCTION CUTTING various thickness SPEED vs MATERIAL THICKNESS A Exceeding recommended 180 4 5 cutting speeds will cause 160 4 0 rapid erosion of the tip and electrode 140 3 5 120 3 0 MATERIAL MILD STEEL p Cutting speed is approximately 100 2 5 10 inches per minute at 0 7 in 80 2 0 mild steel thickness at max set ting tip saver mode 60 1 5 40 1 0 CUTTING SPEED IN MIN MM MIN
36. h provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local to receive the latest full line catalog or p distributor Your distributor TP can also supply you with individual catalog sheets To locate your nearest Welding Process Manuals such as SMAW GTAW distributor or service agency call 1 877 Hobart1 GMAW and GMAW P WELDING PRODUCTS 44 WARNING This product when used for welding or cutting 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 OM 279 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING ee 142 1 3 1 4 1 5 Symbol Usage Plasma Are Cuming Hazards a dd paste ea En ar dd cw tuni a dites ela et ada aa t Additional Symbols For Installation Operation And Maintenance Principal Safety Standards EMF Information SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 1 1 2 1 3 1 4 1 5 SECTION 2 INSTALLATION Specifications Dimensions And Weight 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 1 3 2 3 3 Signification des symboles Dangers li s au coupage a l arc au plasma
37. ial No KK200262 and 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 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International
38. iser une terre et et un blindage pour r duire les interf rences ventuelles LE COUPAGE A 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 Pour r 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 Veiller couper une distance de 100 m tres de tout quipement lectronique sensible S assurer que la source de coupage est correctement branch e et mise la terre Si l 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 OM 279 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 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 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of
39. 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 L quipement doit tre hors tension lorsqu il n est pas utilis e V rifiez et remplacez les cosses du cable 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 Si les normes le stipulent la pi ce couper doit tre mise a la terre Utilisez uniquement de l quipement en bonne condition R parez ou remplacez imm diatement toute pi ce alt r e e Portez un 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 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 p
40. nic 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 OM 279 Page 3 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 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 American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 1 5 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
41. o locate a Distributor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com For technical assistance Call 1 800 332 3281 Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment O 2000 Hobart Welding Products 1 00 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 WELDING PRODUCTS
42. omatically flows at the set pressure POWER READY TEMP A 50 C E 4 7 d or PRESSURE F lt POWER Ref 190 676 Use Gas Air Set area of control range for set ting gas air pressure see Section 3 2 4 Trouble Lights see Section 4 2 5 Ready Light Ready light comes On when unit is On to indi cate that all safety shutdown systems are okay If Ready light does not come On check trouble lights 6 Power Light 7 Power Switch 3 2 Setting Gas Air Pressure Place controls in positions shown to adjust air pressure Only gas air cir cuit is activated when the Power switch is turned On with Output Control in Gas Air Set position 1 Pressure Gauge 2 Pressure Adjustment Knob Lift knob and turn to adjust pres sure Push knob down to lock in set ting Place output control in desired cutting output Set pressure to 70 PSI 483 kPa 22 d GAS AIR SET KN Requires 70 150 PSI 483 1034 kPa Supply Select Desired Set Controls Turn On Gas Air Supply Adjust Pressure Amperage To Begin Cutting Ref 190 676 Ref 801 454 C OM 279 Page 15 3 3 st Of Operation Do not clean torch by hitting it against a Inspect shield cup tip and electrode for hard surface Hitting hard surfaces can wear before cutting or whenever cutting Sn torch parts and stop proper opera speed has been significantly reduced see torch Owner s Manual Do not operate torch withou
43. 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 SH 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 protege tympans ou un serre t te ignifuges afin d viter que les tincelles n entrent dans vos oreilles LES RAYONS D ARC peuvent en trainer 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 mas que ou un cran facial avec le filtre appropri La norme ANSI Z49 1 reportez vous aux Principales normes de s curit sugg re d utiliser un filtre de teinte no 9 no 8 tant le minimum pour tout travail de cou page 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 habi tuellement le cas pour les travaux de coupage a 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
44. r shield with correct shade of filter 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 mini mum 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 and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather and 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 OM 279 Page 2 e lf inside ventilate the area and or use exhaust at the arc to remove
45. ractical 5 Connect work clamp to workpiece as close to the cut as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 1 1 ih Signification des symboles Signifie Mise en garde Soyez vigilant Cette procedure presente des risques de danger Ceux ci sont identifies par des symboles adjacents aux directives Identifie un message de s curit particulier Signifie NOTA n est pas relatif a la s curit pom nd fre 9 98 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 1 2 Dangers li s au coupage l arc au plasma A Les symboles pr sent s ci apres 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 apres ne font que r sumer l information contenue dans les normes de s cu rite num r es la section 1 5 Veuillez lire et respecter toutes ces normes de s curit A
46. t a tip or electrode in place Install amp Put On Personal Check Torch Tip Check Gas Air Set Turn On Connect Safety Electrode And Pressure Controls Power Source Equipment Equipment Retaining Cup Begin Cutting EXAMPLE Of Cutting Operation 4 The pilot arc starts immediately when trigger is pressed c gt on m Place drag shield on edge of metal Press trigger Pilot arc starts After cutting arc starts slowly or allow correct standoff distance start moving torch across metal approximately 1 8 in 3 mm o f EN E d wm Adjust torch speed so Pause briefly at end of Postflow continues for approx 20 to sparks go thru metal and cut before releasing trigger 30 seconds after releasing trigger out bottom of cut cutting arc can be instantly restarted during postflow by pressing trigger 801 400 A OM 279 Page 16 SECTION 4 MAINTENANCE amp TROUBLESHOOTING 4 1 Routine Maintenance A Disconnect power before maintaining Maintain more often during severe conditions Each Use SEE ONCN Check Gas Air Tip Electrode Press ro And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Service Air Unreadable D Labels d ssembly Filter Replace Cracked Tape Torn Outer Parts Covering Or Replace Cable Check Wy b P Check Torch Gas Air Hose Body 6 Months Blow Out Or Vacuum Inside OM
47. ted equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on torch 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 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 P d LV 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 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 Operation And Maintenance FIRE OR EXPLOSION hazard e Do not locate unit on
48. tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection DES PARTICULES VOLANTES peuvent blesser les yeux e Porter des lunettes de s curit avec protections lat rales ou frontales LES CHAMPS MAGN TIQUES peuv ent 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 f LEMPLOI EXCESSIF peut 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 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 INC
49. ting of 1 T TP1 166063 THERMOSTAT NC open 135C 1 22 2202 TET 098198 TERMINAL ASSEMBLY 0n SON SV escis se ame rine ur a ERE Y Ri pu 1 22 sas TEA 181214 TERMINAL ASSEMBLY pri 1 phase 3V model 1 cr 038 Gto ele UMPC vets a apad die ded aU IT rapa E whe Cu aos Ver US e Pb aoa dates 0 NA daa D 190 998 55 PANEL EE 1 24 PC2 3 193691 CIRCUIT CARD ASSEMBLY power control 2 JOD ASA 176 123 FITTING plstc Qdisc elbow 1 8NPT x 1 4 OD tubing 2 Uo TTE 175 827 VALVE 24VAC 3 way 1 8NPT 5 32 orf 100psi 1 RD ere 602 946 FITTING pipe brs tee B 1 8NPT 1 HOO REDE PEE 174 670 SWITCH pressure air 40psi fixed 1 pu oria E 204 237 REGULATOR FILTER 145psig in 120psig max out 1 4P 1 MEC EE PNE 602 938 FITTING pipe galv plug schhd 1 8NPT 1 m PT 181 693 GASKET neoprene 1 500 OD x 688 thick 1 De DUOC E 204 235 BRACKET mtg regulator 1 Too MT 602 963 FITTING pipe brs coupling 1 4NPT 1 NOM ee nes 015 733 FITTING pipe brs nipple L 1 4NPT x 2 00 1 OUR EIL Bane 073 655 FITTING pipe brs nipple hex 1 8NPT 1 Enc PE ES cS MIR T 1 DOTE D ao LPO 14O e MANDLE EE 1 nO de core 134 201 STAND OFF support PC card
50. uisse se d tacher ou sur la table de travail le plus pr s possible de la ligne de coupage OM 279 Page 5 e lsoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique ll y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l ali mentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces e D CHARGES LECTRIQUES poten tiellement mortelles Les pi ces internes des sources d ali mentation de l inverseur ont DES CHARGES C C SIGNIFICATIVES m me APRES coupure du courant 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 touch er l une quelconque des pi ces Mesurer cette tension conform ment aux directives nonc es la section Entretien du manuel de l utilisateur ou du manuel technique avant de toucher l une quel conque 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
51. ur amorcer et maintenir l arc souvent de 200 400 V CC c est pourquoi on fait appel des chalumeaux concus 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 incorrectement install 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 det 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
52. 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 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 e 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 e Keep protective cap in place over valve except when oylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders asso cia
53. z les bouteilles dans la position verticale l aide d une chaine sur un support stationnaire ou un chassis porte bouteil le afin de pr venir qu elles ne tombent ou ne basculent Les bouteilles ne doivent pas tre pr s de la zone de coupage ni de tout autre circuit lectrique Un contact lectrique ne doit jamais se produire entre un chalumeau de plasma d arc et une bouteille Ne coupez jamais sur une bouteille pressuris e une explosion en r sulterait Utilisez uniquement des bouteilles de gaz des d tendeurs des boyaux et des raccords concus pour l application d termin e Gar dez les ainsi que toute autre pi ce associ e en bonne condition D tournez votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille 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 Lisez et suivez les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA mentionn dans les Principales normes de s curit 1 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 DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles
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