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Hobart Welding Products 250ci Welder User Manual

1. 26 SECTION 7 ELECTRICAL 27 SECTIONS PARTS mine E eR edie hee Glee emer a en Seeman 28 OPTIONS AND ACCESSORIES PARTS LIST www HobartWelders com WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING pom _ 4 05 Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 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 Means Note not safety related 1 2 Plasma Arc Cutting Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safe ty Standards A Only qualified persons should install operate maintain and repair this unit 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
2. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e 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 equipment such as robots e To reduce possible interference keep cables as short as possible close together and down low such as on the floor e Locate cutting operation 100 meters from any sensitive electronic equipment e Be sure this cutting power source is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the machine using shielded cables using line filters or shielding the work area For Gasoline Engines 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 926 Page 3 1 5 Principal Safe
3. 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 0 Keep cutting power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the cut as possible About Pacemakers Pacemaker wearers consult your doctor before welding cutting or going near welding cutting operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION pom fre 4 05 Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives identifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit A EX Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des ris ques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVE MENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directi ves ci dessous afin de connaitre les mesures prendre pour viter tout dan ger 2 2 Dangers li s au coupage l arc au plasma Les symboles pr sent s ci apr s sont utili
4. CUP x SWITCH al cas 5 4 Lr Bu as NIS amp 21 Boost 42 ASA J l ACA 1 AA 5 A R R A K A AA 1 ES 59 95 foo Tas 51 LI BLK L1 RED Ct gi Te o T 2 Tiss Ti L2 BLK L2 RED 1 1 z WORK S 1 aK 9 ce oto on 5555 amp c c RCB 1 46 INPUT 2 4 AK POWER O ac2 es GND Rca 25 47 1 44 GND 3 nr RC8 35 m 45 GND 1 4 gt CONTROL RC1 PLG1 Res 142 LED POT 8 rea RC3 PLG3 P RC60 8 gt lt RC4 8 6 7 lt 7 RC5 PLGS 55 RC7 PLG7 6 gt gt lt lt BLUE OR BLK E RC8 PLGB RC5 2 gt gt 1 gt 54 lt 84 1 RC9 PLG9 RC807222 RC4 2 RC11 PLG11 30 lt 6 lt lt 9 10 lt lt Rc4 10 gt 2 lt 5 lt 212 926 it Diagram Ircul Figure 7 1 C OM 926 Page 27 SECTION 8 PARTS LIST 8 1 Recommended Spare Parts Item Dia Part No Mkgs No Description Quantity Recommended Spare Parts rm 227877 FILTER AIR ELEMENT 1 nee Ces dore 216447 CABLE WORK 25 FT 6 GA W CLAMP STRAIN RLF amp TERM 1 De ane 217891 CABLE WORK 50 FT 6 GA W CLAMP STRAIN RLF amp
5. Ne OM 926 211 123L ZN coal 2007 04 HOBART 2 Processes WELDERS i Plasma Cutting and Gouging Description Air Plasma Cutter AirForce 625 And ICE 40C Torch Online Forum www HobartWelders com OWNER S MANUAL File Plasma Cutters From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The parts list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular model are also provided IS0 9001 2000 QUALITY SYSTEM Hobart is registered to the ISO 9001 2000 Quality System Standard Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual spe
6. 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 jugementdu 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 926 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 porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder couper ou d approcher des op rations de soudage couper Si le m decin approuve il est recommand de suivre les proc dures pr c
7. 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 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 Use only well maintained equipment Repair or replace damaged parts at once e Wear a safety harness if working above floor level 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 Keep away from torch tip and pilot arc when trigger is pressed e Clamp work cable with good metal to metal contact to workpiece not piece that will fall away or worktable as near the cut as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e ELECTRIC SHOCK can kill SIGNIFICANT DC
8. Check ring and replace if side holes are plugged 7 O Ring Check O rings on torch If needed coat with thin film of silicone lubricant part no 169 231 Replace if damaged 8 Plunger Area Check this area for any debris or foreign material Clean out if necessary Carefully reassemble parts in reverse order OM 926 Page 24 A complete Parts List is available at www HobartWelders com 6 4 Troubleshooting Power Source EM 3 Ut Is Power switch S1 in the On position Place Power switch in the On position see Section 5 1 Is Power light flashing Reset Power switch S1 Is Cup Status light On or flashing Check torch consumables cup Reset Power switch S1 Check torch connec tions Check Control board PC1 Does pilot arc ignite Does pilot arc transfer to workpiece Yes 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 Check all connections Check main transformer T1 Check boost inductor L1 and output
9. Do not touch hot parts bare handed Allow cooling period before working on torch To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts FLYING METAL can injure eyes e Wear safety glasses with side shields or face shield MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before go ing near plasma arc cutting operations OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce amperage thickness or reduce duty cycle before starting to cut again EXPLODING HYDROGEN hazard e When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the work piece e See your cutting engineer and water table instructions for help 1 4 California Proposition 65 Warnings Welding or cutting equipme
10. dentes A complete Parts List is available at www HobartWelders com SECTION 3 DEFINITIONS 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label A Be Plasma Arc Cutting Adjust Air Gas Low Air Pressure Inperes V PAC Pressure Light V Volts Increase SO Du mut Do E Temperature Protective Earth D Ground 1 Ny Single Phase K Constant Current lt Voltage Input Q Off 9 e Direct Current Rated No Load U Primary Voltage U Conventional Load DE Line Connection Voltage Average Voltage Single Phase Static Frequency Rated Maximum Rated Welding X N Duty Cycle KY HP ll Converter 1 Supply Current 2 Current Transformer Rectifier Degree Of H P Protection Le Loose Shield Cup 6 Input 2 Hertz Suitable for Some Power Rating of power factor IS Hazardous S Product Of Voltage upply Locations 1 And Current OM 926 Page 9 A complete Parts List is available at www HobartWelders com SECTION 4 INSTALLATION 4 1 Specifications D ted a Rated Maximum ated Loa Rated Type of Plasma 208 230V KVA KW Direct Single SC Current Air Or 0 5 in 33 30 6 8 6 7 Ene Du Straight Nitrogen 12 7 mm 260 Cie y Polarity Only At 16 IPM y DCEN 4 2 Specifications For Torch Air cooled torch for plasm
11. volatile liquids are present see NEC Article 511 or CEC Section 20 230 VAC 1 v 208 959 803 222 OM 926 Page 14 A complete Parts List is available at www HobartWelders com 4 10 Wiring Optional 240 Volt Plug 119 172 For Connection To Bobcat Trailblazer Or Champion 10 000 1 Input And Grounding ir Gs Conductors 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Brass Terminal And Prong Not Used 4 Load 1 Brass Terminal And Prong 5 Load2 Brass Terminal And Prong Tools Needed 6 Ground Brass Terminal And Prong 7 Black And White Input Conductors Plug Front View 8 Green Or Green Yellow Ground Conductor Always connect green or green yellow wire to ground terminal never to a load terminal Connect black L1 and white L2 wires to load terminals Green Or Green Yellow Engine Control Switch must be set at RUN Set generator Fine Adjustment Control to 10 position not RUN IDLE for maximum auxiliary power if applicable amy e 7 DE ar 8 stant y 29 2 ENGINE FINE ADJUST Ref 120 813 D Ref 803 222 OM 926 Page 15 A complete Parts List is available at www HobartWelders com 4 11 Installing Alternative Plug This procedure is necessary if the unit is to be connected to a 208 230 VAC 1 Supplied230 VAC Plug receptacle that
12. Do sparks come out of top of cut or cut is not clean Yes Torch travel speed too fast reduce travel speed see Section 5 5 Clean replace torch consumables as necessary see Section 6 3 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 1 Are Trouble lights On unit has no cutting output Check torch consumables Check for gas air flow at torch Check air supply con nection and pressure to unit and torch Reset unit Power switch Check torch and connections inside unit T Go to Section 6 4 Go to Section 6 4 Servicing procedure to be performed only by authorized Service Station OM 926 Page 26 SECTION 7 ELECTRICAL DIAGRAM Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit 4 WARNING ELECTRIC SHOCK HAZARD CONSISTS OF 4 PAIRS OF LEADS CONSISTS OF 1 PAIR OF LEADS WHT ELECTRODE TORCH RED PILOT WORK i AK x AED T1 FED gureur 42 E PRIMARY SECONDARY 2 TRIGGER ORG e 8 E
13. 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 926 Page 13 A complete Parts List is available at www HobartWelders com 4 9 Selecting A Location And Connecting Input Power D 18 in 457 mm of space for airflow Do not move or operate unit where it could tip GND PE Always connect grounding conductor first Green Yellow Install conductors into L1 Black L2 White a deenergized line disconnect device x Serial Number Rating Label located on rear panel of plasma cutter use label to determine input power for unit 1 Plug NEMA Type 6 50P 2 Receptacle NEMA Type 6 50R Connect plug to receptacle 3 Input And Grounding Conductors For single phase operation A Make input power connections to the machine before making connections into a deenergized line disconnect device In the line disconnect device always connect green or green yellow grounding conductor to supply grounding terminal first never to a line terminal Connect directly to line disconnect device if hard wiring is required 4 Line Disconnect Device See Section 4 7 Special installation may be required where gasoline or
14. VOLTAGE exists in inverter power sources AFTER the re moval of input power e Turn Off unit disconnect input power check voltage on input ca pacitors and be sure it is near zero 0 volts before touching any parts Check capacitors according to instructions in Mainte nance Section of Owner s Manual or Technical Manual before touching any parts OM 926 Page 1 EXPLODING PARTS can injure e On inverter power sources failed parts can ex plode or cause other parts to explode when power is applied Always wear a face shield and long sleeves when servicing inverters Ba FLYING SPARKS can cause injury Sparks and hot metal blow out from the cutting arc Chipping and grinding cause flying metal N 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 ARC RAYS can burn eyes and skin 4 9 Arc rays from the cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin e Wear face protection helmet or shield with a proper shade of filter lenses to protect your face and eyes when cutting or watching ANSI Z49 1 see Safety Standards suggests a No 9 shade with No 8 as minimum for all cutting currents less than 300 amperes Z49 1 adds that lighter filter shades may be used when the arc is hidden by the workpiece As this is nor
15. cir o cuits imprim s 2 55 La e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes PC LE RAYONNEMENT HAUTE FRE QUENCE H F risque de provoquer des interf rences e Le 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 r guli rement 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 utiliser une terre et et un blindage pour r duire les interf rences ventuelles OM 926 Page 7 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 e Pour r duire la possibilit d interf rence maintenir les cables aussi courts que po
16. des vapeurs et des gaz Respirer 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 Si vous tes l int rieur au moment du coupage ventilez la pi ce ou ayez recours une ventilation aspirante install e pr s de l arc pour vacuer les vapeurs et les gaz e Sila ventilation est m diocre utilisez un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travaillez dans un espace restreint uniquement s il est bien ventil ou Si vous portez un respirateur anti vapeurs Les vapeurs caus es par le coupage et l puisement de l oxyg ne peuvent alt rer la qualit de l air et entrainer des blessures ou la mort Assurez vous que l air am biant est sain pour la sant e Ne coupez pas dans un endroit pr s d op rations de d capage de nettoyage ou de vaporisation La chaleur et les rayons d arc peuvent r agir avec les vapeurs et former des gaz hautement toxiques et irri tants e Ne coupez pas des m taux enrob s tels que des m taux galvanis s contenant du plomb ou de l acier plaqu au cadmium moins que l enrobage ne soit t de la surface du m tal couper que l endroit o vous travaillez ne soit bien ventil ou que vous ne portiez un re
17. device to move unit loc 2 3 96 Ref 803 219 803 220 OM 926 Page 11 A complete Parts List is available at www HobartWelders com 4 6 Connecting Work Clamp and Gas Air Supply From Gas Air ic 3 AIR N2 90 120 psi Tools Needed 5 8 1 1 8in Rear of Unit 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Use only clean dry air with 90 lo 120 psi 621 to 827 kPa pressure Prevent moisture from entering air supply at extreme cold temperatures 3 Gas Air Inlet Opening 4 Hose x Hose must have a minimum inside diameter of 3 8 in 9 5 mm 5 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 Or Install supplied quick connect male 1 4 in NPT pipe fitting Connect female quick connect fitting to pipe fitting Route hose to gas air supply A Incorrect plasma gas can cause torch and power source damage Use only air or nitrogen for the plasma gas Ref 801 319 C Ref 803 221 OM 926 Page 12 A complete Parts List is available at www HobartWelders com 4 7 Electrical Service Guide 50 60 Hz Single Phase Input Voltage 208 230 Input Amperes At Rated Output 33 30 Max Recomme
18. e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby V 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 OPA This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not touch torch parts if in contact with the work or ground Turn off power before checking cleaning or changing torch parts e Disconnect input power before installing or servicing this equip ment Lockout tagout input power according to OSHA CFR
19. inductor L2 Return to beginning of chart NOTE The fan will normally run for approximately 5 seconds after power switch is placed in the Off position see Is Temp Status light On If unit is overheated wait while fan cools down unit temperature Is Pressure Status light On or flashing Turn Output control fully counterclockwise see Section 4 12 Check for gas air flow at torch Check Control board PC1 pressure switch air filter valve AS1 and air supply connection to unit and torch Section 5 1 Servicing procedure to be performed only by authorized Service Station OM 926 Page 25 A complete Parts List is available at www HobartWelders com 6 5 Troubleshooting Torch 3 gt t3 Sy Does arc go on and off while cutting Torch travel speed too slow increase travel speed see Section 5 5 Clean or replace torch consumables as necessary see Section 6 3 Be sure work clamp is securely attached to workpiece T Go to Section 6 4 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 workpiece see Section 5 5 Clean replace torch consumables as necessary see Section 6 3 T Go to Section 6 4
20. period of the product they are installed in or for a minimum of one year whichever is greater Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonabl
21. sure the area is safe before doing any cutting e Remove all flammables within 35 ft 10 7 m of the cutting arc If this is not possible tightly cover them with approved covers Do not cut where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that cutting on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not cut on closed containers such as tanks or drums e Connect work cable to the work as close to the cutting area as prac tical to prevent cutting current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use plasma cutter to thaw frozen pipes Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Do not cut in atmospheres containing explosive dust or vapors Do not cut pressurized cylinders pipes or vessels Do not cut containers that have held combustibles Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Do not locate unit on or over combustible surfaces e Remove any combustibles such as a butane lighter or matches from your person before doing any cutting
22. tal chaud Assurez vous qu aucune tincelle ni particule de m tal ne peut se glisser dans de petites fissures ou tomber dans d autres pi ces e Afin d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main e Si vous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entrainer un feu de l autre c t coupez pas sur un contenant ferm tel qu un r servoir ou un bi don e Fixezle c ble de masse sur la pi ce couper le plus 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 d tincelles ou un feu e Ne pas utiliser le coupeur plasma pour d geler des conduites gel es e Necoupez jamais des contenants qui peuvent contenir des mati res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement e coupez pas dans un endroit o l atmosph re risque de contenir de la poussi re ou des vapeurs explosives e Necoupez pas de bouteilles de tuyaux ou de contenants pressuri S s e Ne coupez pas de contenants qui ont d j re u des combustibles e Portez des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque placez pas le poste sur une surface combustible ou au dessus de celle ci e Avant le
23. 40C 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 926 Page 28 NOTE The ICE 40C torch is specifically for use Part only with this plasma cutting unit No No Description 195110 40 25ft Torch 195 111 ICE 40C 50ft Torch 183427 Handle Assy complete 1 192059 Main Bogy 1 209298 Leads 25ft 1 209299 Leads 50ft 1 185833 Switch Assembly w spring 1 171248 Push Button Switch 1 190220 Spring trigger assembly 169231 Grease silicone 1 X See Figure 8 1 for additional consumable parts Ref 195 092 Ref 803 224 Figure 8 2 Torch ICE 40C NOTE gt A complete Parts List is available on line at www HobartWelders com To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 926 Page 29 Notes Work like a Pro Pros weld and cut s
24. Cutting E below the line too slow will result 5 in excess dross Cutting above the 200 line too fast will cause blowback e and lack of penetration amp 150 5 6 100 50 0 16GA 1 8th 1 4th 3 8th 5 8th 0 060 Mild Steel Thickness inches OM 926 Page 17 A complete Parts List is available at www HobartWelders com 5 3 Trigger Safety Lock Trigger Locked Trigger Unlocked 1 Trigger 801 397 A 5 4 Plasma Cutting System Practices Always connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Maintain approximately a 90 angle to the workpiece surface for proper cutting results When doing extended non shielded cutting maintain approximately 1 8 in standoff between electrode and surface Set correct air pressure for process 75 PSI 517 kPa for cutting 55 PSI 379 kPa for gouging Sparks should pass through the workpiece and out the bottom when cutting DO NOT put pressure on shield when drag cutting instead slide shield along the surface for proper cutting results a The pilot arc starts immediately when trigger is pressed DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle and electrode If sparks flare back from surface this usually is an indication that either travel Speed is too fast or amperage is se
25. Les porteurs sont pri s de consulter leur m decin avant d approcher les op rations de coupage plasma L EMPLOI 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 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 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 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 gt LES CHARGES ELECTROSTATI QUES peuvent endommager les
26. TERM 1 C OUR 213619 CLAMP WORK 300A STL CHROME PLD W COPPER CONTACTS 1 ee S ADR RS 213620 CONTACT TIP WORK CLAMP 300AMP COPPER 2 Lender EUIS 195110 ICE 40C 25FT HAND HELD REPLACEMENT TORCH OR m 195111 ICE 40C 50FT HAND HELD REPLACEMENT TORCH 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 Replacement Parts Model and serial number required when ordering parts from your local distributor gt For extended tip use set Amperage control to 40 Drag Shield Retaining Cup Tip Electrode Swirl Ring O Ring 204 323 192 050 204 325 192 047 192 049 169 232 52 9 Cutting Apply silicone Deflector Retaining Cup 40A Tip Electrode grease 169 231 177 888 192 050 192 052 192 048 before installing Extended 6 cj Cutting 1 8 3 mm standd off recommended Shield Retaining Cup Electrode 192 203 192 050 192 047 Gouging 211 120 B NOTE Set air pressure to 75 PSI for cutting or 55 PSI for gouging FAILURE TO REPLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY Turn off power before checking torch parts ICE 40C CONSUMABLES Check before each use and hourly during operation 211 120 B Figure 8 1 Consumable Parts For ICE
27. a arc cutting PAC 50 duty cycle Safety interlock devices disable power source Safety trigger guard Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating For Units Connected to a 208 Volt Circuit or a 230 Volt Circuit 50 Duty Cycle At 40 amperes 140 volts dc typical cutting Duty Cycle is percentage of 10 minutes that unit can cut at rated TS 5 Minutes Cutting NJ 5 Minutes Resting load without overheating If unit overheats output stops temperature status light illuminates 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 Overheating LL E e CON Minutes x gt warranty A OR Reduce Duty Cycle sduty1 5 95 Ref 803 219 1 in 25 mm 3 5 lb 1 6 kg With 25 ft 7 6 m Cable Ref 801 397 A OM 926 Page 10 A complete Parts List is available at www HobartWelders com 4 5 Unit Dimensions Weight And Movement MS Dimensions And Weight 57 Ib 25 9 kg 24 15 1 4 387 mm 10 1 4 260 mm 1 Lifting Handles Movement Use handles to lift unit 2 Cart Do not move or operate unit where it could tip Use cart or similar
28. afely Read the safety rules at the beginning of this manual Warranty Questions Call 1 800 332 3281 7 AM 6PMEST Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor or call 1 800 332 3281 The expertise of the distributor and Hobart is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART 531 WARRANTY Effective January 1 2007 5 31 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface LH or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will
29. cat Trailblazer Or Champion 10 000 15 4 11 Installing Alternative 2 16 4 12 Setting Gas Air Pressure 16 SECTION 5 OPERATION 2 ga nian 17 5 1 Controls p nevis RAE EY PO RUNE US RAT URN E CHE RE MN IEEE s 17 5 2 Gutting Speed spere PR pu ai cote El Es LUE P EE s 17 5 3 Trigger Safety LOCK a2 fiesta eter dede Abe eric bp cals pide E dade dees doer ee 18 5 4 Plasma Cutting System 18 5 5 S quence Of Cutting Operation erre ee ee ASG ee EE ee ee 19 5 6 Sequence Of Gouging Operation 20 5 7 S quence Of Piercing Operation resero teresi e xx Ren SR ae Ye ee E or s 21 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 22 6 1 Routine Maintenance 1 2 22 6 2 Overload Protection Status Lights amp Checking Shield Cup Shutdown System 23 6 3 Checking Replacing Retaining Cup Tip And Electrode 24 6 4 Troubleshooting Power Source 25 6 5 Troubleshooting Torch
30. ce Sn ARE eae ala atc bt e A RA eU Mee ls 7 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 22 teri NIU RN DANN EE 9 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 9 SECTION 4 INSTALLATION 05 RR ED REIR 10 4 1 Specifications ss I ISIN RR DEN 10 4 2 Specifications FOr TOrchi es Ae vane DR ve a RENE EUREN De 10 4 3 Duty Cycle And Overheating 10 4 4 Torch Dimensions And Weight 10 4 5 Unit Dimensions Weight And Movement 11 4 6 Connecting Work Clamp and Gas Air Supply 12 4 7 Electrical Service Guide eod 13 4 8 Extension Cord Data ta SEES 13 4 9 Selecting A Location And Connecting Input 14 4 10 Wiring Optional 240 Volt Plug 119 172 For Connection To Bob
31. cification sheets To locate your nearest distributor or service agency call 1 877 Hobart1 or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob Thank 2005 06 5 31 WARRANTY Working as hard as you do every power source from Hobart is backed by the best warranty in the business Protect Your Investment Register your product at HobartWelders com Ga PAAS THO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 TES Symbol Gates cee etse Ys e e dina tir ee vin eub bae de 1 1 2 Plasma Arc Cutting Hazards ist zorro mer ER xe be xot rx vi text pr xr US 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 06 EME Informationes ss ne eme le am ed Ode a La Bel s e dM Ss dU s 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 3 Dangers suppl mentaires en relation avec l installation le fonctionnement otla maintenan
32. complete Parts List is available at www HobartWelders com SECTION 5 OPERATION 5 1 Controls 4 HOBART AirForce 625 DC Plasma Cutting System SOS Plasma Cutting System 1 4 a ON De S 3 O OFF QU 40 r4 A POWER PRESSURE 75 PSI OUTPUT 3 2 STATUS 6 Ref 211 048 1 Output Control 4 Power Switch At ambient temperatures below 5 C Use control to set cutting output Place control in Gas Air Set position to safely 23 F readjustment of gas air E7 The fan will normally run for pressure regulator may be necessary approximately 5 seconds after power see Section 4 12 Onl uit i iti m switch is placed in the Off position Use only clean dry air with 90 to 120 psi P 621 to 827 kPa pressure Prevent 2 Status Lights See Section 6 2 3 Pressure Gauge moisture from entering air supply at 3 Power Light 6 Pressure Adjustment Knob extreme cold temperatures 5 2 Cutting Speed 400 The cutting speed curve shows the recommended maximum cutting 350 speed capabilities of the power source and torch for mild steel of a 300 various thickness The best cut quality is achieved by 250 cutting near the chart line
33. coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes e Suivre les consignes de OSHA 1910 252 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un extincteur proximit i 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 pour amorcer et maintenir l arc souvent de 200 400 V CC c est pourquoi on fait appel des chalumeaux congus 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 Ne touchez pas aux pi ces lectriques sous tension Portez des gants isolants et des v tements de protection secs et sans trous lsolez 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
34. d or while wearing an air supplied respirator Fumes from cutting and oxygen depletion can alter air quality causing injury or death Be sure the breathing air is safe e Donotcutin locations near degreasing cleaning or spraying oper ations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not cut on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the cutting area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes when cut e Do not cut containers with toxic or reactive materials inside or containers that have held toxic or reactive materials they must be emptied and properly cleaned first PLASMA ARC can cause injury The heat from the plasma arc can cause serious burns The force of the arc adds greatly to the burn hazard The intensely hot and powerful arc can quickly cut through gloves and tissue Keep away from the torch tip Do not grip material near the cutting path e The pilot arc can cause burns keep away from torch tip when trig ger is pressed e Wear proper flame retardant clothing covering all exposed body ar eas 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 sembling
35. d 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 4 12 A flashing Pressure light indicates that gas air system may be set too low faulty leaking or has a flow restriction see Section 6 4 2 Cup Light Lights if shield cup is loose off Turn Power On and loosen shield cup If shutdown system works properly Cup light comes on If not turn power Off and have a factory authorized service agent check unit If system works properly retighten cup and reset power 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 3 Check shield cup shutdown system once a week 3 Temperature Light Lights if power source overheats or when ambient temperature is below 20 4 F see Section 4 3 Fan On Demand Cooling fan will operate during the following conditions a Unit is in an OVERTEMP condition TEMP indicator light will illuminate and fan will run until unit cools down b Unit gets hot during idle either from a change in ambientair temperature or after long periods of cutting c Unitis in cutting or postflow mode Ref 200 808 Ref 801 300 A OM 926 Page 23 A c
36. e cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY 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 cons
37. e 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 Nressayez pas d aller l encontre des syst mes de verrrouillage de s curit ou de les contourner e Utilisez uniquement le ou les chalumeaux recommand s dans le manuel de l op rateur OM 926 Page 5 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 e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e D CHARGES LECTRIQUES poten tiellement mortelles Il y a DES CHARGES DC SIGNIFICATI VES dans le poste de soudage inver seur m me APRES coupure du cou rant d alimentation e Mettre l unit hors tension mesurer la tension des condensateurs d entr e et s assurer qu elle est pratiquement nulle avant de tou cher l une quelconque des pi ces Mesurer cette tension confor m ment aux directives nonc es la section Entretien du manuel de l utilisateur ou du manuel technique avant de toucher l une quelconque des pi ces Risque de blessure e
38. e les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues Laisser refroidir avant d intervenir sur la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour vi ter les br lures x 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 e Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l ali mentation lectrique DES PARTICULES VOLANTES peuvent blesser les yeux LA e Porter des lunettes de s curit avec protections lat rales ou frontales LES CHAMPS MAGNETIQUES peu vent affecter les stimulateurs cardia ques Porteurs de stimulateur cardiaque restez distance e
39. en contact avec la pi ce couper ou le sol e Mettez l appareil hors tension avant d effectuer la v rification le nettoyage ou le changement d une pi ce du chalumeau e Coupez l alimentation d entr e avant d installer l appareil ou d ef fectuer l entretien Verrouillez ou tiquetez la sortie d alimentation selon la norme OSHA 29 CFR 1910 147 reportez vous aux Princi pales normes de s curit e Installez le poste correctement et mettez le la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales Assurez vous que le fil de terre du cordon d alimentation est cor rectement reli la borne de terre dans la boite de coupure ou que la fiche du cordon est branch e une prise correctement mise la terre vous devez toujours v rifier la mise la terre e Avant d effectuer les connexions d alimentation vous devez relier le bon fil de terre e V rifiez fr quemment le cordon d alimentation afin de vous assurer qu il n est pas alt r ou nu remplacez le imm diatement s il l est Un fil nu peut entrainer la mort e 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 Siles normes le stipulent la pi ce couper doit tre mise la terre e Utilisez uniquement d
40. equential 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 45 hobart_warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City 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
41. mally the case with low current cutting the shades suggested in Table 1 are provided for the operator s conve nience e Wear approved safety glasses with side shields under your helmet or shield e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection Table 1 Eye Protection For Plasma Arc Cutting Current Level In Amperes Minimum Shade Number Below 20 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 Use approved ear plugs or ear muffs if noise level is high e Warn others nearby about noise hazard FUMES AND GASES can be hazardous Cutting produces fumes and gases Breathing these fumes and gases can be hazardous to your health e Keep your head out of the fumes Do not breathe the fumes e f inside ventilate the area and or use local forced ventilation at the arc to remove cutting fumes and gases OM 926 Page 2 If ventilation is poor wear an approved air supplied respirator e Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals to be cut coatings and cleaners e Work in a confined space only if it is well ventilate
42. n 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 N 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 ner des br lures aux yeux et la peau Les rayons d arc provenant du proc d de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entra ner des br lures aux yeux et ala peau Lorsque vous coupez ou regardez quelqu un couper portez un cas que de soudage approuv muni de verres filtrants appropri La norme ANSI Z49 1 reportez vous aux Principales normes de s curi t sugg re d utiliser un filtre de teinte no 9 no 8 tant le minimum pour tout travail de coupage faisant appel un courant de moins de 300 A On men
43. nded Standard Fuse Rating In Amperes Cricuit Breaker Time Delay 40 35 Normal Operating 50 45 Min Input Conductor Size In AWG 4 10 10 Max Recommended Input Conductor Length In Feet Meters 24 an Min Grounding Conductor Size In AWG 4 10 10 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard 4 8 Extension Cord Data NOTE ae When calculating max cord length remember to include conductor length from line disconnect device to inout power receptacle Input Power Fuse Size Or Input Voltage Phase Circuit Breaker Rating Conductor Size Max Cord Length Time Delay 2 40A 208 V 50 60 Normal Operating 50 10 AWG 80 ft 24 m Time Delay 35A 230 V Es 50 60 Normal Operating 45 10 AWG 98 ft 30 m 2
44. nt 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 Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift unit e f using lift forks to move unit be sure forks are long enough to ex tend beyond opposite side of unit FIRE OR EXPLOSION hazard e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit STATIC ESD can damage PC boards e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards gt K on 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
45. omplete Parts List is available at www HobartWelders com 6 3 Checking Replacing Retaining Cup Tip And Electrode EY T V 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 as 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 holes obstructed Turn Off power source 1 Drag Shield 2 Retaining Cup Remove retaining cup Check retaining cup for cracks and replace if necessary 3 Tip 4 Opening Remove tip Check tip and replace if open ing is deformed or 5096 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 32 in 0 8 mm deep remove and replace electrode 6 Swirl Ring 1 32 in 1 mm to 1 16 in 2 mm maximum pit depth depending on acceptable cut quality Ref 803 224 Remove swirl ring
46. or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 9 2007 Hobart Welding Products 2007 01 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se ZN HOBART tHe
47. r doit prendre des mesures sup pl mentaires comme carter la machine utiliser des c bles blind s de des filtres ou boucler la zone de travail Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage ou de coupage passant dans les c bles de puis sance cr e des causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant
48. repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original retail purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 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 Units Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor 90 days Accessories Field Options NOTE Field options are covered for the remaining warranty
49. requires a plug that is different from the supplied plug p 4 Cut cord close to plug 2 Alternative Plug 230 VAC Plug Shown 2 3 Input Black Lead gt Brass Terminal m 4 Neutral White Lead 3 Brass Terminal D m 5 Ground Green Terminal 1 6 Outer Shell 4 7 Cord Grip Strip cord jacket back enough to 5 separate conductors Strip conductors enough to make good contact with plug terminals Make plug connections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not 2 LR overtighten _ Tools Needed Ref 801 305 A 801 611 4 12 Setting Gas Air Pressure lt 3 90 120 psi Rear of Unit Ref 803 219 Ref 803 221 Setting Gas Air Pressure Place Output Control in Gas Air Set Position Requires Power Switch On 90 120 PSI Supply Set To 75 PSI 517 kPa For Cutting 621 827 kPa Or 55 PSI 379 kPa For Gouging Select Desired Set Controls Turn On Gas Air Supply Adjust Pressure Amperage To On Unit Begin Cutting 1 Power Switch 2 Output Control 4 Gas Air Pressure Adjustment Knob Place power switch in On position Place output control in Gas Air position Adjust pressure to 75 psi 517 kPa on 3 Pressure Gauge pressure gauge by pulling and turning knob Push knob in to lock setting Select desired cutting output with Output Control OM 926 Page 16 A
50. ression Si une bouteille est endommag e elle peut exploser Puisque les bouteilles de gaz font habituellement partie d un processus de travail des m taux assurez vous de les manipuler correctement e Prot gez les bouteilles de gaz comprim contre la chaleur excessive les chocs m caniques des dommages physiques le laitier la flam me les tincelles et l arc Installez et attachez les bouteilles dans la position verticale l aide d une cha ne sur un support stationnaire ou un ch ssis 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 con us 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 Utiliser les quipements corrects les bonnes proc dures et suffisam ment de personnes pour soulever et d placer les bouteilles Lire et suivr
51. s 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 rit num r es la section 2 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus 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 peuvcnt causer un feu ou des br lures Avant de commencer travailler assurez vous que l endroit est s curitaire e D placez toute mati re inflammable se trouvant l int rieur d un p 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 Ne coupez pas dans un endroit o des tincelles pourraient attein dre des mati res inflammables e Prot gez vous ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m
52. spira teur anti vapeurs Les enrobages ou tous m taux qui contiennent ces l ments peuvent cr er des vapeurs toxiques s ils sont coup s e Ne coupez pas de contenants qui renferment ou ont renferm s des mati res toxiques ou r actives vous devez en premier lieu les vider et les nettoyer convenablement LE PLASMA D ARC peut entrainer des blessures La chaleur d gag e par le plasma d arc peut entrainer de s rieuses br lures La force de l arc est un facteur qui s ajoute au danger de br lures La chaleur intense et la puissance de l arc peuvent rapidement passer au travers de gants et de tissus e N approchez pas le tube du chalumeau e Ne saisissez pas la pi ce couper pr s de la ligne de coupage e Larc pilote peut causer des br lures n approchez pas le tube du cha lumeau lorsque vous avez appuy sur le gachette Portez des v tements de protection ad quats qui recouvrent tout vo tre corps e Ne pointez pas le chalumeau en direction de votre corps ni de la pi ce couper lorsque vous appuyez sur la g chette l arc pilote s allume automatiquement e Mettez l alimentation hors tension et d branchez le cordon d alimen tation avant de d monter le chalumeau ou de changer une pi ce du chalumeau e Utilisez uniquement le ou les chalumeaux recommand s dans le ma nuel de l op rateur LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles de gaz contiennent du gaz sous haute p
53. ssible les grouper et les poser aussi bas que possible ex par terre 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ins com Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de American Welding Society de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in 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 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 interf rence persiste l utilisateu
54. t too low Pulling rather than pushing the torch makes cutting easier Use a proper guide or template for accurate cutting operations 801 400 B Ref 802 878 OM 926 Page 18 A complete Parts List is available at www HobartWelders com 5 5 Sequence Of Cutting Operation Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Set air pressure to 75 PSI 517 kPa for cutting a The pilot arc starts immediately when trigger is pressed um 90 E For standard shielded cutting place drag shield on edge of metal For extended non shielded cutting use 1 8 in 3 2 mm standoff distance dragging tip will reduce tip life _ IN Adjust torch speed so sparks go thru metal and out bottom of cut Raise trigger lock and press trigger Pilot arc starts Pause briefly at end of cut before releasing trigger After cutting arc starts slowly start moving torch across metal F Postflow continues for approx 20 seconds after releasing trigger cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger 801 400 B OM 926 Page 19 A complete Parts List is available at www HobartWelders com 5 6 Sequence Of Gouging Operation Connect work clamp to a clean paint free Set air pressure
55. tionne galement dans la norme 249 1 qu un filtre plus faible peut tre utilis lorsque l arc est cach par la pi ce couper Comme cela est habituellement le cas pour les travaux de coupage faible courant les teintes num r es au tableau 1 sont fournies titre d information pour l op rateur e Porter des lunettes de s curit coques lat rales sous votre casque ou cran facial e Ayez recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les tincelles et les blouisse ments pr venez toute personne sur les lieux de ne pas regarder l arc Portez des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection Tableau 1 Protection des yeux pour le coupage au plasma d arc Intensit de courant en amp res Filtre de teinte minimum Moins de 20 no 4 20 40 5 40 60 no 6 60 80 no 8 OM 926 Page 6 LE BRUIT peut endommager l ouie Certaines applications de coupage produisent un bruit constant ce qui peut endommager l ouie si le niveau sonore d passe les limites permises par l OSHA repor tez vous aux Principales normes de s curit e Utilisez des prot ge tympans ou un serre t te antibruit si le niveau sonore est lev Pr venez toute personne sur les lieux du danger reli au bruit LES FUM ES ET LES GAZ peuvent tre dangereux Le coupage produit
56. to 55 PSI 379 kPa for gouging location on workpiece as close to cutting a The pilot arc starts immediately when trigger is pressed 45 5 5 5 Hold torch at approximately Raise trigger lock and press trigger Pilot Release trigger Postflow continues for 45 angle to workpiece arc starts Move tip to within approxi approx 20 seconds after releasing trigger mately 3 16 in 4 8 mm Start gouging arc can be instantly restarted during postflow across workpiece surface Maintain by raising trigger lock and pressing trigger approximately a 45 angle to surface 801 400 B OM 926 Page 20 A complete Parts List is available at www HobartWelders com 5 7 Sequence Of Piercing Operation a The pilot arc starts immediately Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Rotate torch to upright position approximately 90 to surface When arc has pierced through workpiece start cutting when trigger is pressed x Set air pressure to 75 PSI 517 kPa for cutting Hold torch at an angle to the workpiece Raise trigger lock and press trigger Pilot arc starts Maintain approximately 90 torch Release trigger Postflow continues for position to surface and continue approx 20 seconds after releasing trigger cutting arc can be instantly restarted during postflow by raising
57. 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 Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flame sparks and arcs e Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any cutting or other electrical circuits Never allow electrical contact between a plasma arc torch and a cylinder Never cut on a pressurized cylinder explosion will result Use only correct gas cylinders regulators hoses and fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use e Use the right equipment correct procedures and sufficient number of persons to lift and move cylinders e Read and follow instructions on compressed gas cylinders asso ciated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation HOT PARTS can cause severe burns
58. trigger lock and pressing trigger 801 400 B OM 926 Page 21 complete Parts List is available at www HobartWelders com SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance NS 3 9 pec Disconnect power 5 Maintain more often ES before maintaining during severe conditions t3 Vo 17 Check Change Clean Replace Reference A To be done by Factory Authorized Service Agent D Each K Use Torch Tip Electrode Gas Air Pressure And Shield Cup Every Week 7 Shield Cup Shutdown System Neu F gt W 26 m xA KG Gi M Every X Damaged Or Unreadable Cracked Parts Air Filter Regulator Gas Air Hose 3 Labels Assembly Filter Months Every 6 Months Q Inside Unit OM 926 Page 22 A complete Parts List is available at www HobartWelders com 6 2 Overload Protection Status Lights amp Checking Shield Cup Shutdown System Te PRESSURE lt 2 _ 2 cup E e STATUS Checking Torch Shield Cup Shutdown System Power must be reset whenever the cup shutdown system is activated Always turn Off power when changing or checking consumables Do NOT overtighten torch shield cup Gently finger tighten cup onto torch Shield If certain problems occur a status light comes on an
59. ty Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from Global Engineering Docu ments phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 1 6 EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current as it flows through the welding or cutting cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequenc
60. y 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 926 Page 4 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou levard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov

Hobart Welding Products 250ci Welder User Manual

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