Hobart Welding Products 400 Welder User Manual
Contents
1. Tools Needed 3 CP 1 4 in 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 Terminal PILOT Connect ring terminal on end of red leads to PILOT terminal 6 Ring Terminal And Terminal L2 RED Connect ring terminal on end of white leads to L2 RED terminal Tighten strain relief nut Tighten strain relief around cable Work Cable Connections Remove existing work cable from unit 7 Strain Relief Be sure to allow some work cable slack inside the unit Insert work clamp lead through strain relief and install strain relief into front panel 8 Work Lead Ring Terminal Connect ring terminal on end of work clamp lead to terminal labeled WORK on circuit board PC1 Route lead along torch lead bundle Ref 802 854 Ref 802 860 200 173 A OM 203 653 Page 20 6 4 Checking Replacing Retaining Cup Tip And Electrode EU T V e2. 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 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 entra ner des blessures La chaleur d gag e par le plasma d arc peut entra ner 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 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 gachette 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 c
3. IT UL oem dg yy iv p A GND E CE MODELS ONLY PC2 4 PRIMARY CHANGE OVER zur RC21 PLG21 REV REM RC21 2235 Oe RC21 1 Xen 170VAC 20VAC 20VAC 20VAC T1 TP1 LLY BLU Z 70 12 wl WHT 14 L2 D US BUCK TORCH u RED WHT ELECTRODE L2 BLK m PILOTO RED PILOT Up WORK AK WORK X lt RC3 1 RC1 3 gt wo a lt RC3 2 RC1 4 gt gt _ 9 pr 1 lt RC4 5 Rad LY l pc re 47 AU CUP POWER CONTROL SWITCH lt RC4 4 RC1 PLG1 i 19 AS amp RO4 10 gc2 pioa 09 7 Y RC3 PLG3 p RC4 PLG4 RC6 2 gt RC6 PLG6 lt RC4 9 RC7 PLG7 ar 3 Rc4 2 TPI TEST RC8 1 TP3 PROGRAM RCB PLGB uos gt MAT PC1 HS5 lt RC4 1 RC2 1 gt WHT RD LONE lt RC4 3 Rc2 2 9 77 L1 BLK O AK id L1 REDO MT BOOST 200 809 D ircuit Diagram Figure 7 1 C amp RC7 1 SECTION 7 ELECTRICAL DIAGRAM TNR GND THROUGH ALUMINUM PCB STANDOFF OM 2229 Page 24 Notes OM 203 653 Page 25 SECTION 8 PARTS LIST Hardware is common and not available unless listed 802 805 Figure 8 1 Main Assembly OM 203 653 Page 26 No Mkgs
4. Ref 802 877 4 5 Selecting A Location e EZ 8 1 2 in gt gt Gh A 216 mm Dimensions And Weight 12 5 16 in 49 Ib 22 2 kg 313 mm not including torch Add 13 16 in 21 mm for handle ue Ps 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 similar device to move unit 3 120 VAC Receptacle 4 230 VAC Receptacle Locate unit near correct input power supply A 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 802 784 802 785 802 786 203 892 OM 203 653 Page 11 4 6 Connecting Gas Air Supply FF Use only clean dry air with 70 to 150 psi 483 to 1034 kPa pressure 1 Gas Air Inlet Opening 2 Hose 3 Teflon Tape Obtain hose with 1 4 NPT right hand thread fitting Wrap threads with teflon tape optional or apply 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 Tools Needed IC 5 8 1 1 8 in 2 802 787 Ref 801 319 C Ref 802 784 OM 203 653 Page 12 4 7 Connecting Work Clamp 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free
5. Overtightening will strip threads Do not overtighten retaining cup during assembly Do not cross thread parts causing stripping Use care during torch assembly and parts replacement 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 E A good practice is to replace both the tip and electrode at the same time a Turn Off power source before checking torch parts Make sure this area is clean of any debris Make sure swirl ring is clean of any debris and no holes are obstructed Worn Turn Off power source 1 Shield Cup 2 O Ring Remove shield cup Check cup for cracks and replace if necessary Check O ring for cracks or worn spots re place shield cup if necessary 8 Tip 4 Opening Remove tip Check tip and replace if open ing is deformed or 50 oversize If inside of tip is not clean and bright clean with steel wool Be sure to remove any pieces of steel wool afterwards 5 Electrode Check electrode If center has a pit more than a 1 16 in 2 mm deep remove and re place electrode 6 Swirl Ring 802 465 7 O Ring Remove swirl ring Check ring and replace if side holes are plugged Check O ring for cracks or worn spots replace swirl ring if necessary 8 O Ring Check O ring for cracks or worn spots and re
6. 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 Compressed Gases in Cylinders 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 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 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
7. demment font partie de celles desti n es aux personnes ayant recours a un stimulateur cardiaque Veuillez consulter votre m decin pour obtenir plus de d tails SECTION 3 DEFINITIONS 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label A LE Plasma Arc Cutting YN Adjust Air Gas Low Air Pressure mperes V PAC Pressure Light V Volts Increase SO Nos Pu Do E Temperature Protective Earth 1 D Ground 1 ING Single Phase N Constant Current Voltage Input On O off Percent Direct Current Rated No Load U Primary Voltage Conventional Load DE Line Connection Voltage Average U 2 Voltage Single Phase Rated Maximum Rated Welding X is a Static Frequency l imax Supply Current l Current Duty Cycle DPH Transformer Rectifier Converter Degree Of H P Protection Lee Loose Shield Cup Input Z Hertz s Suitable for Some Power Rating ear pf power factor IS Hazardous S Product Of Voltage leff ppy Locations 1 And Current KVA OM 203 653 Page 9 SECTION 4 INSTALLATION 4 1 Specifications NOTE gt 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 Amperes Input at Rated Output Rated 60 Hz Single Phase
8. 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 BU a 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 possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 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 par des symboles adjacents aux directives A ldentifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit APA pom fre 5 04 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 conna tre les mesures pren
9. 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 203 653 Page 1 EXPLODING PARTS can injure e Oninverter power sources failed parts can ex plode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing inverters Ba FLYING SPARKS can cause injury nd 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 Wear flame resistant ear plugs or ear muffs to prevent sparks from entering ears D 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 ENG e Wear face protection helmet or 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
10. clamp consisting of 1 MEE FER 203 988 CLAMP work 150A 1 AOT SUEDE ER 199 995 TIP contact work clamp copper 150A 2 anta coL Ne 200 517 KNOB pointer 1 st POS was S3 200876 GAUGE air w pressure switch amp fitting consisting of 1 TEE RAE TER 204 012 FITTING quick disconnect 1 sed sius T1 200871 TRANSFORMER toroid main 60HZ 115 230V 1 Bl de AAA REOR CR NAMEPLATE order by model and serial number 1 When ordering a component originally displaying a precautionary label the label should also be ordered Optional 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 203 653 Page 27 Item Part No No Description 183 427 171 248 203 120 203 119 185 833 190 220 169 231 195 014 Handle Assy complete 1 Push Button Switch 1 Leads 20ft 1 Main Body 1 Switch Assembly w spring 1 Spring trigger assembly Grease silicone 1 Torch replacement 20ft 1 See Figure 8 3 for additional consumable parts Figure 8 2 Torch ICE 27C Gonsumabl s 4 CAUTION FAILURE TO RE PLAC
11. de celle ci Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes UNE DECHARGE ELECTRIQUE peut entrainer la mort Le fait de toucher a 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 Lalimentation d entr e et les circuits internes de l appareil le sont galement Le coupage au plasma d arc exige des tensions plus lev es que le soudage pour amorcer et maintenir l arc souvent de 200 400 V CC c est pourquoi on fait appel des chalumeaux con us avec un syst me de verrouillage s curitaire qui met l appareil hors tension lorsque la capsule anti feu est desserr e ou si le tube touche l lectrode l int rieur de la buse Un poste incorrectementinstall ou inad quatement mis la terre constitue un danger e Ne touchez pas aux pi ces lectriques sous tension e Portez des gants isolants et des v tements de protection secs et sans trous e Isolez vous de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne touchez pas aux pi ces du chalumeau si vous tes en contact avec la pi ce couper ou le sol e Mettez l appareil hors tension avant d effectuer la v rification le nettoyage ou le changement
12. distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor or service agency call 1 877 Hobart1 6a RAN THO Hob_Thank 7 03 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Te Symbol USAGE ttes Renee anne AA AA YO UE ERU GET EUR 1 1 2 Plasma Arc Cutting Hazards ro e rr unten 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 4 1 6 EME Informiation 4 seite ee RE ex EE RT RR RUE RR E aly ce ERR E RT ERR P 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers li s au coupage l arc au plasma 5 2 8 Dangers suppl mentaires en relation avec l installation le fonctionnement et a maintenance a ep te Ree e ne ede ide ear REO n ACE ERE RE 7 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 22 22 42 I IR Le a
13. 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 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 4 20 40 5 40 60 6 60 80 8 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 203 653 Page 2 e If inside ventilate the area and or use exhaust at the arc to remove cutting fumes and gases e f 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 wh
14. s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sour ces de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE COUPAGE L ARC peut causer des interf rence e L nergie lectromagn tique peut g ner le fonction nement d appareils lectroniques comme des ordi nateurs et des robots e Pour r duire la possibilit d interf rence maintenir les c bles aussi courts que possible les grouper et les poser aussi bas que possible ex par terre 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 Sil nterf 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 203 653 Page 7 2 4 Principales normes de s
15. 5 FITTING elbow quick disconnect 1 4NPT 1 RE TT uae hoa 010 830 FITTING pipe adapter 1 4NPT x 1 ANPT 1 re ne a Y A ta EN 204 066 FITTING extension M5 thread w gasket 1 15 AS1 206257 VALVE air w fittings consisting of 1 ER EEE ef 206 000 VALVE 24VDC 3 way 1 8NPT 1 ouem sad ue e Len ds 204 003 FITTING straight quick disconnect 1 8NPT 1 gua pb aM E s 204 004 FITTING elbow quick disconnect 1 8NPT 1 RE R o E Set aits 200 728 BRACKET mig air filter 1 pee b x dae le eee ties 200 875 REGULATOR air w fittings consisting of 1 a Moe cide sb CUS CR 204 004 FITTING elbow quick disconnect 1 8NPT 1 aC APRI CEA PRORA E NGA 204 005 FITTING elbow quick disconnect 1 ANPT 2 18 PC1 222502 CIRCUIT CARD ASSY control w pgm non CE 1 ERU ES MEE atic st ak 138 044 BUSHING strain relief 1 A ete 195014 ICE 27C 20ft hand held consisting of 1 ee A oer 121 276 BUSHING strain relief 1 pee 2d sal eut 199 021 CABLE work 15ft 12ga w
16. 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 6 EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current as it flows through the welding or cutting cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following proce dures OM 203 653 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
17. E WORN TIP OR ELECTRODE OR OPERATION WITH OUT THEM will ruin torch e Turn off power before checking torch parts Check before each Tip use and hourly during Swirl Ring 202809 Retaining Cup c 202808 e 176656 operation 202 108 A Figure 8 3 Consumable Parts For ICE 27C 202 108 A 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 203 653 Page 28 Notes Notes Warranty Questions Call 1 877 HOBART1 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 HOBART S WELDERS HOBART EL WARRANTY Effective January 1 2004 5 3 1 WARRANTY applies to all Handler 125 135 and 175 models Airforce 250 250A 375 400 and 625 models and Champion 4500 and 10 000 models Beta Mig 1800 Champ 1435 2060 8500 models I
18. EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above 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 3 04 Owner s Record Please com
19. ING 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 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 ov
20. No Description Quantity Figure 8 1 Main Assembly i dor pee loaesentie 195 621 WRAPPER asus ro ced pu e bx ere Ed gue eR 1 ix P Auot vetu od 196 851 LABEL warning precautionary 1 USO audi ia ee iy 208 015 HANDLE carrying rubberized 1 M Nae atk ata deta TRES 202 108 LABEL ICE 27C consumables 1 Den L2 200816 INDUCTOR buck 12 crack L1 200815 INDUCTOR boost 1 7 PC2 212572 CIRCUIT CARD ASSY primary change over 1 SR pentose 200 726 BRACKET switch 1 Fine FM 195610 FAN muffin 115V 50 60HZ 1 104 443 ST u 124511 SWITCH power 44 4444ee nennen nenn 1 Sal ee ee 200724 BAFEEE Cehl6 r cio ae Da ge aca ere Mn 1 i NARS an giv Sate 202 674 CABLE power 10ft 14ga3c 1 sig sicuti 202 494 CASE SECTION base front rear 1 Rs de Ec 179190 LABEL warning cssc ne dai 1 xd crai os 204 255 FILTER air w fittings consisting of 1 Sata ne a 200 878 FILTER air 5 micron 1 4NPT ports 1 RP EE EI EST EN 204 00
21. OM 203 653G MVA ZN December 2004 C Processes Air Plasma Cutting H2 and Gouging Description WELDERS Air Plasma Cutter AirForce 400 And Ice 27C Torch m OWNER S MANUAL Visit our website at www HobartWelders com 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 i ET Eon A ine you may need to fix the problem Warranty and from Hobart is backed by uality ice i i i the best warranty in the System Standard service information for your particular model y business are also provided 150 9001 2000 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
22. ailler au dessus du Sol e Assurez vous que tous les panneaux et couvercles sont correcte ment en place e N essayez 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 N approchez pas le tube du chalumeau et l arc pilote lorsque la g chette est enfonc e e Le c ble de masse doit tre pinc correctement sur la pi ce cou per m tal contre m tal et non de telle sorte qu il puisse se d tacher ou sur la table de travail le plus pr s possible de la ligne de coupage OM 203 653 Page 5 e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l ali mentation lectrique 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 tou cher l une quelconque des pi ces Mes
23. d Protection Trouble Lights amp Checking Shield Cup Shutdown System 19 6 3 Torch And Work Cable Connections 20 6 4 Checking Replacing Retaining Cup Tip And Electrode 21 6 5 Troubleshooting Power Source 22 6 6 Troubleshooting Toreh 5 eroe ben nt ensem morer ner a Re deg lel 23 SECTION 7 ELECTRICAL DIAGRAM ococccccc III nnn 24 SECTION 8 PARTS LISTo 2 2 2222 dde 26 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage 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 EF Means Note not safety related 1 2 Plasma Arc Cutting Hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away CUTT
24. 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 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 entra ner la mort e L 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 Portez un harnais de s curit si vous devez trav
25. de coupage passant dans les c bles de puis sance cr e des causera des champs lectromagn tiques Il 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 L accumulation 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 pendant le soudage ou le coupage Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes OM 203 653 Page 8 1 Garder les c bles 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 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 consignes mentionn es pr c
26. dre pour viter tout dan ger 2 2 Dangers li s au coupage l arc au plasma 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 A L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particuli rement les enfants U f 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 peuvcnt 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 o des tincelles pourraient attein dre des mati res inflammables D placez toute mati re inflammable se trouvant l int rie
27. e eee en A 9 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 9 SECTION 4 INSTALLATION 2 5 a2 s em RR gene rrr RR Er nie ee aie en ge aan 10 4 1 Specifications ere A ne p E Rn D UR NOU EATON UI OA ep pa Ran Her 10 4 2 Specifications For Torch tere A EP A Va ON E RA EE I I 10 4 3 Duty Cycle And Overheating 10 4 4 Torch Dimensions And Weight 2 11 4 5 Selecting A Locations ure Ape waa Eee BEER name iT UU NEN AU 11 4 6 Connecting Gas Air Supply 12 4 7 Connecting Work Clamp matase naa enn ae a T s ana hes 18 4 8 Connecting Input Power 13 4 9 Installing Alternative Plug eee Rem hh IR Rr rm ne nee 14 SECTION 5 OPERATION oie lx A RR EET KREIS QUE NEMUS Ede AERE in ane caue 15 521 Controls visits en HU A A ENUPA UM E ROM ENG 15 5 2 Cut ng Speed coussin pb S es RAM ME ele et bL ER Pt dels 16 5 3 Trigger Safety LOCK icu pep he DR ARR ANRT A RAS A EUER OE NI eR eg 16 5 4 Sequence Of Operation 17 SECTION 6 MAINTENANCE amp TROUBLESHOOTING euus 18 6 1 Routine Maintenance u a x y emat ease ee ea A cnet eee mi E ee Epis 18 6 2 Overloa
28. emicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling FIRE OR EXPLOSION hazard e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit gt e STATIC ESD can damage PC boards 5 e Puton grounded wrist strap BEFORE handling boards or parts SI 25 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 If 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 equipme
29. er combustible surfaces e Remove any combustibles such as a butane lighter or matches from your person before doing any cutting M 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 5 04 e y gt a This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do nat 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 i
30. ers such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipmentthat has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement 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 Millers 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
31. et To 60 PSI 414 kPa put and or the cut time or find more adequate power see Section 4 1 2 Trouble Lights See Section 6 2 3 Power Light 4 Power Switch Setting Gas Air Pressure 5 Air Filter Regulator 6 Pressure Adjustment Knob 27 OUTPUT Place Output control in Gas Air position and turn on gas air supply Lift knob and turn to adjust pressure Push knob down to lock in setting Place Output control in desired cutting output At ambient temperatures below 5 C 23 F readjustment of gas air pressure regulator may be necessary Ref 200 808 Ref 802 784 OM 203 653 Page 15 5 2 Cutting Speed The cutting speed curves show the recommended maximum cutting speed capabilities of the power Source and torch for mild steel of various thickness Cut at speeds below the lines shown to avoid poor cuts and torch wear 70 60 50 40 30 1 16 in Standoff 20 CUT SPEED IN MIN 10 0 0 064 0 187 0 25 0 312 0 375 0 437 0 5 0 625 MATERIAL THICKNESS wmdesign 5 3 Trigger Safety Lock 1 Trigger Trigger Locked Trigger Unlocked 802 877 OM 203 653 Page 16 5 4 Sequence Of Operation EXAMPLE Of Cutting Operation Place tip on work for drag cutting or for maximum cutting speed and tip life use a standof distance of 1 16 in 1 6 mm to 1 8 in 3 2 mm drag
32. g ne libre peut s accumuler sous la pi ce e Consultez votre ing nieur de coupage et les instruc tions de la table de coupage LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour sou lever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces infllammables e Ne pas installer l appareil proximit de produits in flammables e Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn et prot g avant de mettre l appareil en service P9 LES CHARGES LECTROSTATI QUES peuvent endommager les cir o cuits imprim s SIS So 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 LeRayonnement haute frequence H F peut provo quer des interf rences avec les quipements de ra dio navigation et de communication les services de
33. ging tip will reduce tip life Adjust torch speed so sparks go thru metal and out bottom of cut Raise trigger lock and press trigger Pilot arc starts Y ee HN THUAN LIINA A VA Pause briefly at end of cut before releasing trigger a The pilot arc starts immediately when trigger is pressed After cutting arc starts slowly start moving torch across metal ce Postflow continues for 20 seconds after releasing trigger cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger Ref 802 878 OM 203 653 Page 17 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance 3 ar y ca Y A Disconnect power Maintain more often T NC SD before maintaining during severe conditions 5 Each Use Check Check Torch Tip Gas Air Electrode Pressure And Shield Cup m EX Every Week NS Check V Shield Cup Shutdown SS System Li 3 Months WARNIN A IE Replace Service SEL Damaged Or Air Filter A uni aaoi e Regulator abels W exa Replace KY Cracked alll Parts 4 Gas Air Hose Torch Body Cable Tape Torn 2 Outer CDS N Covering E 6 Months Blow Out Or Vacuum Inside OM 203 653 Page 18 6 2 Overload Protection Trouble Lights am
34. gt g 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 3596 Duty Cycle 0 30 0 13 3 25 KW 3 19 KW 9 At 60 PSI 10 mm DC Only 414 KPa While idling 4 2 Specifications For Torch Air cooled torch for plasma arc cutting PAC 35 duty cycle Safety interlock devices shut down power source Safety trigger guard Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating For Units Connected to a 115 Volt Circuit or a 230 Volt Circuit 35 Duty Cycle At 27 amperes 92 volts dc zy 3596 duty cycle AS X20 3 1 2 Minutes Cutting 6 1 2 Minutes Resting 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 Temperature trouble light goes On and cooling fan runs Wait fifteen minutes for unit to cool or temperature light to go off Reduce amperage or duty cycle before cutting or gouging A Exceeding duty cycle can damage unit and void warranty Overheating SO Minutes Reduce Duty Cycle OR sduty1 5 95 802 784 OM 203 653 Page 10 4 4 Torch Dimensions And Weight 3 0 Ib 1 4kg 85 mm
35. halumeaux 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 le laitier la flamme 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 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
36. i 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 N 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 Sila 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 entra ner des blessures ou la mort Assurez vous que l air am biant est sain pour la sant e Ne coupez pas dans un endroit pr s d op rations de d capage de nettoyage ou de vaporisation La chaleur et les rayons d arc peuvent r agir avec les vapeurs et former des gaz hautement toxiques et irri tants e Ne coupez pas des m taux enrob s tels que des m taux galvanis s contenant du plomb ou de l acier plaqu au cadmium
37. iece see Section 5 4 Clean or replace torch consumables as necessary see Section 6 4 T Go to Section 6 5 Do sparks come out of top of cut or cut is not clean Yes Torch travel speed too fast reduce travel speed see Section 4 1 Clean or replace torch consumables as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 1 Is Trouble light On unit has no cutting output Check torch shield cup see Section 6 2 reset unit Power switch Check torch and connections inside unit T Go to Section 6 5 Go to Section 6 5 Servicing procedure to be performed only by authorized Service Station OM 203 653 Page 23 e Do not touch live electrical parts e Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit WARNING ELECTRIC SHOCK HAZARD INPUT POWER COLORS FOR CE MODELS ONLY 2 BLK zur 1 es R1 o SOUS i ER2 Bo 2 v7 a CR2 amp eur BROWN 4 a c2 E E AY 7 3 low CN q ERA ELI lt rer 7 L RC22 1 5 ON m T E 115V S if oi RC22 2 6 C4 230v_
38. ield cup see torch Owner s Manual If system works properly retighten cup and reset power Ref 200 808 Ref 802 877 OM 203 653 Page 19 6 3 Torch And Work Cable Connections DRE Oe CS Og ee o re Fan ass BL E E 127 Fes as n e m m Ea x lava ps E SEHEN q H E uL eL De WE S an a Tus RS Mill TO au BER BIT ot en a eet SoS SS Z O qa di 3 Ls LM LX itii ERI EX fu 2 per Le SB SS See aor best ud t LE Os Le a E s s 5 c LND m HT CH Ma Em T FE m md 1 Dui my Kea O mi oo Bye 11 Um DRE Ux Z ar ID DOE oe er FO R gt LL Li o r Fr o je ol lo Oo zm Er dun ax ue gd Cor uam uar 8 wm AN IU gl o5 z 3 slo b oe Oo
39. ile 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 Do not 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 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 when trig ger is pressed e Wear proper flame retardant clothing covering all exposed body ar eas e Point torch 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 se
40. ir supply connection to unit and torch Press torch trigger and check if pilot arc ignites Check torch consumables Check torch connections air filter pressure switch S3 valve AS1 air supply connection to unit torch and PC1 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 Is Power light flashing Reset Power switch S1 and verify line power voltage see Section 4 1 Check relay CR2 thermistor R1 on PC2 and Control board PC1 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 203 653 Page 22 6 6 Troubleshooting Torch EU T y 7 y SA 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 as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece T Go to Section 6 5 Does arc go out while cutting Be sure work clamp is securely attached to work piece Make sure tip is on or near 1 16 in 1 6 mm to 1 8 in 3 2 mm workp
41. 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 to find correct switch position A Be sure input power connection meets all applicable national regional and local electrical codes 3 Grounded 120 VAC Receptacle A 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 Select extension cord of 12 AWG for up to 53 ft 16 m 5 Grounded 230 VAC Receptacle A 230 volt 10 ampere individual branch circuit protected by time delay fuses or circuit breaker is required see Section 4 1 6 Plug From Unit Customer Supplied Select extension 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 802 787 802 786 OM 203 653 Page 13 4 9 Installing Alternative Plug This procedure is necessary if the uni
42. mbling 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 cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders asso ciated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance 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 i
43. njury 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 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 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 If using lift forks to move unit be sure forks are long enough to ex tend beyond opposite side of unit 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 ch
44. nput 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 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
45. nt such as robots e To reduce possible interference keep cables as short as possible close together and down low such as on the floor e Locate cutting operation 100 meters from any sensitive electronic equipment e Be sure this cutting power source is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the machine using shielded cables using line filters or shielding the work area For Gasoline Engines 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 203 653 Page 3 1 5 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
46. p Checking Shield Cup Shutdown System Te 1 SO 2 PRESSURE C amp cup 0 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 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 sh
47. place if necessary Carefully reassemble parts in reverse order OM 203 653 Page 21 6 5 Troubleshooting Power Source EM A IM J Ut Is input power connected to correct line voltage Connect unit to proper input voltage see Section 4 8 Yes 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 Yes Turn down output current see Section 5 1 Is Power switch S1 in the On position Place Power switch in the On position see Section 5 1 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 Is Cup Status light On or flashing Is Temp Status light On Is Pressure Status light On or flashing Does pilot arc ignite Does pilot arc transfer to workpiece Yes Check torch consumables Reset Power switch S1 If unit is overheated wait while fan cools down unit temperature 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 a
48. plete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2004 Hobart Welding Products 1 04 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 Se ZN HOBART HS
49. ronman 210 and 250 models Stickmate models Tigmate models and HSW 15 and HSW 25 spot welder models effective with Serial 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
50. rtez 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 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 et les blouissements pr venez toute personne sur les lieux de ne pas regarder l arc Portez des v tements confectionn s avec des mati res r sistantes et ignifuges cuir et laine et des bottes de protection OM 203 653 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 s
51. t is to be connected to a 230 VAC receptacle or to a 115 VAC receptacle that requires a plug that is different from the supplied plug See Section 4 8 for instructions on setting changeover switch for proper voltage Tools Needed J E lt A 1 Supplied 115 VAC Plug Cut cord close to plug 2 Alternative PLug 230 VAC 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 onto shell Do not overtighten NO Oo Ref 801 305 A 801 611 OM 203 653 Page 14 SECTION 5 OPERATION 5 1 Controls 4 2 3 X POWER 5 on 3 PRESSURE A OFF O g CUP O E Temp O oFF STATUS G PRESSURE POWER 60 PSI 6 24 GAS AIR NS SET yw A 27 OUTPUT Setting Gas Air Pressure Requires 70 150 PSI 483 1034 kPa Supply 27 OUTPUT 1 Output Control Use control to set cutting output Place control in Gas Air Set position to safely adjust gas air pressure Only gas air circuit is activated If 22 27 amperes of cutting output is used with 115 VAC input power and the overload protection on the input power circuit fre quently opens either reduce the cutting out S
52. the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 8 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and Flowmeter Regulators No Labor HF Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 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 oth
53. ult rieur e 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 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 DES ORGANES MOBILES peuvent provoquer des blessures 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 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 Porteurs de stimulateur cardiaque restez distance Les porteurs sont pri s de consulter leur m decin avant d approcher les op rations de coupage plasma jd L EMPLOI EXCESSIF peut 1 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 hydro
54. ur 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 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 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 s s Ne coupez pas de contenants qui ont d j re u 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
55. urer 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 Ra 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 e Portez une visi re ou des lunettes de s curit avec des crans lat raux approuv es 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 9 ner des br lures aux yeux et la peau ENG LAA Les rayons d arc provenant du proc d de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entra ner 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 repo
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