Hobart Welding Products AirForce 250ci, Owner'S Manual

Page 1: ...AirForce 250ci And HP 25 Torch Processes Description Air Plasma Cutting Air Plasma Cutter OM 230 455C 2007 07 File Plasma Cutters ...

Page 2: ...ucts 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 part...

Page 3: ...rch 10 4 3 Duty Cycle And Overheating 10 4 4 Torch Dimensions And Weight 11 4 5 Selecting A Location 11 4 6 Connecting Work Clamp 12 4 7 Electrical Service Guide For 120 VAC 12 4 8 Extension Cord Data 12 4 9 Connecting Input Power 13 4 10 Generator Or Inverter Requirements 13 4 11 Cable Management Strap 14 4 12 Electrode Wrench 14 SECTION 5 OPERATION 15 5 1 Controls 15 5 2 Recommended Cutting Spee...

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Page 5: ...rements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby 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 star...

Page 6: ...g and oxygen depletion can alter air quality causing injury or death Be sure the breathing air is safe 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 Do not cut on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the cutting area the...

Page 7: ...ap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards H F RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communicationsequipment Have only qualified persons familiar with elec tronic equipment perform this installation The user is responsible for having a qualified electrician...

Page 8: ... www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About...

Page 9: ...sés Ne coupez pas de contenants qui ont déjà reçu des combustibles Portez des vêtements de protection exempts d huile tels que des gants en cuir une veste résistante des pantalons sans revers des bottes et un casque Ne placez pas le poste sur une surface combustible ou au dessus de celle ci Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes S...

Page 10: ...es de sécurité LE BRUIT peut endommager l ouïe Utilisez des protège tympans ou un serre tête antibruit si le niveau sonore est élevé Prévenez toute personne sur les lieux du danger relié au bruit LES FUMÉES ET LES GAZ peuvent être dangereux Le coupage produit des vapeurs et des gaz Respirer ces vapeurs et ces gaz peut être dangereux pour la santé Ne mettez pas votre tête au dessus des vapeurs Ne r...

Page 11: ...urs sont priés de consulter leur médecin avant d approcher les opérations de coupage plasma L EMPLOI EXCESSIF peut SURCHAUFFER L ÉQUIPEMENT Prévoir une période de refroidissement respecter le cycle opératoire nominal Réduire l ampérage épaisseur avant de continuer à couper ou réduire le facteur de marche Danger D EXPLOSION D HYDROGÈNE Lors du coupage d aluminium partiellement ou totale ment immerg...

Page 12: ...ring 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 téléphone 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 te...

Page 13: ...round Single Phase Constant Current Voltage Input On Off Percent Direct Current U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage Line Connection I1max Rated Maximum Supply Current I2 Rated Welding Current X Duty Cycle 1 f1 f2 Single Phase Static Frequency Transformer Rectifier Converter IP Degree Of Protection Loose Shield Cup Input Hz Hertz I1eff Maximum Effective ...

Page 14: ...fications For Torch Air cooled torch for plasma arc cutting PAC Gas flow pressure 1 1 SCFM 31 1 L min at 40 PSI 275 kPa Safety interlock devices shut down power source Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating If unit overheats output stops Temperaturetrouble light goes On and cooling f...

Page 15: ...Handle Use handle to lift unit 2 120 VAC 20 A Receptacle Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 8 1 4 in 210 mm 10 1 4 in 260 mm Movement Location And Airflow Dimensions And Weight 26 lb 11 8 kg 10 in 254 mm 10 in 254 mm Serial Number Rating Label located on rear panel of ...

Page 16: ...ncluding 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 ...

Page 17: ...on the cutter will flash and the unit will not provide output if input voltage drops below 92 volts ac see Section 6 2 NOTE Minimum auxiliary power require ment at rated cutting capacity 1 8 in 3 2 mm mild steel is 4 KW con tinuous 4 5 KW peak at 120 volts ac The 115 volts ac output of a brushless generator will momen tarily droop when loaded This may result in arc outages at the cutter Connecting...

Page 18: ... 11 Cable Management Strap 804 885 A 1 Cable Management Strap Coil cables together and secure to unit using the cable management strap 1 4 12 Electrode Wrench Ref 804 885 A 1 Cable Management Strap 2 Electrode Wrench The electrode wrench is fastened to the cable management strap 1 2 ...

Page 19: ...t blinks if input power is not within specified range 3 Cup Light Light comes on if cup is removed from torch Once cup is reinstalled on torch unit power must be turned off and back on again 4 Temp Light Light comes on if unit overheats 3 4 5 2 Recommended Cutting Speed For Material Thickness Material Material Thickness Recommended Cut Speed inches mm ipm mm min 18 ga 1 0 22 558 Mild Steel 16 ga 1...

Page 20: ...an paint free location on workpiece as close to cutting area as possible 90 DO NOT start pilot arc without cutting as this shortens the life of the tip and electrode Sparks should pass through the workpiece and out the bottom when cutting If sparks flare back from surface this usually is an indication that travel speed is too fast DO NOT put pressure on shield when drag cutting instead slide shiel...

Page 21: ... the end of the torch Place tip near work Keep tip 1 16 in from work for max cutting speed and tip life Press trigger Pilot arc starts After cutting arc starts slowly move torch across metal Adjust speed so sparks go thru metal and out bottom of cut Pause briefly at end of cut before releasing trigger Torch air cooling postflow continues after releasing trigger Postflow must finish before trigger ...

Page 22: ...tand off guide on work Stand off guide provides 1 16 in 1 6 mm gap between tip and workpiece Press trigger Pilot arc starts After cutting arc starts slowly move torch across metal Adjust speed so sparks go thru metal and out bottom of cut Pause briefly at end of cut before releasing trigger Torch air cooling postflow continues after releasing trigger Postflow must finish before trigger will restar...

Page 23: ...to cutting area as possible Hold torch at an angle to the workpiece Press trigger Pilot arc starts Move torch to upright position 90 to surface Start cutting when arc pierces workpiece Maintain torch position and continue cutting Release trigger Postflow cooling continues after releasing trigger Postflow must finish before trigger will restart pilot arc The pilot arc starts immediately when trigge...

Page 24: ...re maintaining Maintain more often during severe conditions Check Change Clean Replace To be done by Factory Authorized Service Agent Reference Each Use Use Torch Tip Electrode And Shield Cup Every Week Week Shield Cup Shutdown System Every 3 Months Damaged Or Unreadable Labels Cracked Parts Months Torch Body Cable Every 6 Months OR Inside Unit Compressor Filter ...

Page 25: ...ghten cup Power must be reset whenever the cup shutdown is activated Check shield cup shutdown system once a week A flashing Cup light indicates that the torch consumables are stuck or worn and should be inspected and or replaced see Section 6 3 3 Temp Light Lights if power source overheats or when ambient temperature is below 40 C 40 F If unit overheats allow fan to cool unit for 15 minutes see S...

Page 26: ...e parts in reverse order 7 Stand off Guide Placing the stand off guide on the end of the torch provides an optional method of maintaining a 1 16 in 1 6 mm gap between tip and workpiece Make sure this area is clean of any debris Make sure swirl ring is clean of any debris and no holes are obstructed New Worn New Worn 1 32 in 1 mm 1 16 in 2 mm maximum pit depth depending on acceptable cut quality 4 ...

Page 27: ...urce and disconnect input power 1 Power Source 2 Compressor Filter Remove wrapper from unit Unscrew filter from compressor Clean debris from filter surface or replace filter if necessary Do not overtighten filter Screw filter back into compressor Tighten 1 full turn past hand tight Reinstall wrapper Tools Needed 5 16 in Ref 804 887 A 2 5 8 in 1 ...

Page 28: ...receptacle RC4 on circuit board PC1 6 Female And Male Friction Terminal RC1 ELECTRODE Connect female friction terminal on end of black lead to RC1 ELECTRODE 7 Female And Male Friction Terminal RC2 TIP Connect female friction terminal on end of red lead to RC2 TIP Tighten strain relief nut Tighten strain relief around cable Work Cable Connections Remove existing work cable from unit 8 Strain Relief...

Page 29: ...ng range see Section 6 2 Yes Yes Are Power and Temp lights flashing Press torch trigger and check if pilot arc ignites Check torch consumables Check torch connections Control board PC1 com pressor and torch Yes No Does pilot arc ignite Place torch near workpiece and check if pilot arc jumps or transfers to workpiece Check work clamp connec tion Check Control board PC1 and connections and torch and...

Page 30: ... sure work clamp is securely attached to a clean paint and rust free workpiece Make sure torch tip is within 1 16 in 1 6 mm of workpiece while cutting Clean or replace torch consumables as necessary see Section 6 3 Do sparks come out of top of cut or cut is not clean No Yes Torch travel speed too fast reduce travel speed see Section 5 3 5 4 and 5 6 Clean or replace torch consumables as necessary s...

Page 31: ...OM 230 455 Page 27 SECTION 7 ELECTRICAL DIAGRAM 230 449 B Figure 7 1 Circuit Diagram ...

Page 32: ...TION Turn off power before checking torch parts Check before each use and hourly during operation Torque electrode lightly w small wrench 15 20 in lbs FAILURE TO REPLACE WORN TIP OR ELECTRODE WILL DAMAGE TORCH AND VOID WARRANTY HP 25 CONSUMABLE KITS 230 446 B Retaining Cup Tip Electrode Swirl Ring O Ring 770 496 770 497 Figure 8 2 Consumable Parts For HP 25 A complete Parts List is available on li...

Page 33: ...Notes 229895 MATERIAL THICKNESS GAUGE ...

Page 34: ...Notes ...

Page 35: ...h 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...

Page 36: ... or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to Resource...