Hobart Welding Products AirForce 625, Owner'S Manual

Page 1: ...OM 926 211 123H 2006 01 Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter AirForce 625 And ICE 40C Torch File Plasma Cutters ...

Page 2: ...ducts 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 par...

Page 3: ...ating 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 13 4 8 Extension Cord Data 13 4 9 Selecting A Location And Connecting Input Power 14 4 10 Wiring Optional 240 Volt Plug 119 172 For Connection To Bobcat Trailblazer Or Champion 10 000 15 4 11 Installing Alternative Plug 16 4 12 Setting ...

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Page 5: ...ents 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 start a...

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

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

Page 8: ...ww 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 W...

Page 9: ...coupez pas de contenants qui ont déjà reçu des combustibles D 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 D Ne placez pas le poste sur une surface combustible ou au dessus de celle ci D Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes D ...

Page 10: ...curité LE BRUIT peut endommager l ouïe D Utilisez des protège tympans ou un serre tête antibruit si le niveau sonore est élevé D 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 D Ne mettez pas votre tête au dessus des vapeurs Ne res...

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

Page 12: ... 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 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...

Page 13: ...urrent 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 Single Phase Static Frequency Converter Transformer Rectifier IP Degree Of Protection Loose Shield Cup Input Hz Hertz I1eff Maximum Effective Supply Current pf power factor S Suit...

Page 14: ...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 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 Y Exceeding duty cycle can damage unit ...

Page 15: ... 96 Ref 803 219 803 220 1 Lifting Handles Use handles to lift unit 2 Hand Cart Use cart or similar device to move unit Movement Y Do not move or operate unit where it could tip Dimensions And Weight 57 lb 25 9 kg 17 1 4 in 438 mm 15 1 4 in 387 mm 10 1 4 in 260 mm ...

Page 16: ...inimum 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 Y Incorrect plasma gas can ca...

Page 17: ...ies 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 Y Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard 4 8 Extension Cord Data When c...

Page 18: ...never to a line terminal Connect directly to line disconnect device if hard wiring is required 4 Line Disconnect Device See Section 4 7 Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 L1 L2 230 VAC 1 18 in 457 mm of space for airflow L1 Black L2 White Y Do not move or operate unit where it could tip Y Always connect ground...

Page 19: ...al And Prong 6 Ground Brass Terminal And Prong 7 Black And White Input Conductors 8 Green Or Green Yellow Ground Conductor Y 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 Tools Needed 7 Green Or Green Yellow 2 3 4 5 6 240V 8 3 16 in 8 7 6 5 4 3 Plug Front View Y Engine Control Switch must be set at RUN po...

Page 20: ...C receptacle that requires a plug that is different from the supplied plug Tools Needed 1 6 7 2 3 4 5 1 Power Switch Place power switch in On position 2 Output Control Place output control in Gas Air position 3 Pressure Gauge 4 Gas Air Pressure Adjustment Knob Adjust pressure to 75 psi 517 kPa on pressure gauge by pulling and turning knob Push knob in to lock setting Select desired cutting output ...

Page 21: ... may be necessary see Section 4 12 Use only clean dry air with 90 to 150 psi 620 to 1035 kPa pressure Prevent moisture from entering air supply at extreme cold temperatures Ref 211 048 2 6 4 5 3 1 5 1 Controls 5 2 Cutting Speed The cutting speed curve shows the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness The best cut quality is a...

Page 22: ...e as close to cutting area as possible Set correct air pressure for process 75 PSI 517 kPa for cutting 55 PSI 379 kPa for gouging 90 DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle 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 either travel...

Page 23: ... approx 20 seconds after releasing trigger cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger The pilot arc starts immediately when trigger is pressed 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 Connect work clamp to a clean p...

Page 24: ... surface Release trigger Postflow continues for approx 20 seconds after releasing trigger arc can be instantly restarted during postflow by raising trigger lock and pressing trigger The pilot arc starts immediately when trigger is pressed Hold torch at approximately 45 angle to workpiece Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Set air pre...

Page 25: ...by raising trigger lock and pressing trigger The pilot arc starts immediately when trigger is pressed Hold torch at an angle to the workpiece Raise trigger lock and press trigger Pilot arc starts 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 90 90 Rotate torch to upright position approximately 90 t...

Page 26: ...re conditions Each Use Check Torch Tip Electrode And Shield Cup Check Gas Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service Air Filter Regulator Assembly Filter Replace Unreadable Labels Tape Torn Outer Covering Or Replace Cable Replace Cracked Parts Check Gas Air Hose Check Torch Body 6 Months Blow Out Or Vacuum Inside OR ...

Page 27: ...p 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 C 4 F see Section 4 3 Fan On Dema...

Page 28: ...ebris and no holes are obstructed New Worn New Worn 5 1 32 in 1 mm Pit 4 3 8 7 6 2 1 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 50 oversize If inside of tip is not clean and bright clean with steel wool Be sure to remove any pieces of ste...

Page 29: ...ps or transfers to workpiece Check work clamp connection Check Control board PC1 and connections and torch and its connections Yes No Does pilot arc transfer to workpiece Check all connections Check main transformer T1 Check boost inductor L1 and output inductor L2 Return to beginning of chart Servicing procedure to be performed only by authorized Service Station Is Cup Status light On or flashing...

Page 30: ...ction 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 5 Clean or 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 Yes Check torch consumables C...

Page 31: ...OM 926 Page 27 SECTION 7 ELECTRICAL DIAGRAM 212 926 A Figure 7 1 Circuit Diagram ...

Page 32: ... SECTION 8 PARTS LIST Hardware is common and not available unless listed Ref 803 223 C 25 28 10 16 17 14 11 12 13 9 8 5 7 6 1 4 2 34 35 33 32 30 26 27 29 22 21 20 19 18 23 24 5 31 3 5 15 5 36 Figure 8 1 Main Assembly ...

Page 33: ...M NI 1 20 208168 BAFFLE AIR WINDTUNNEL 1 21 L2 207298 INDUCTOR OUTPUT 1 22 L1 207297 INDUCTOR BOOST 1 23 T1 207296 XFMR MAIN SPECTRUM 625 1 24 173693 FOOT MTG UNIT 4 601965 SCREW 375 16X1 00 HEX HD PLN GR5 PLD 4 010909 NUT 375 16 56HEX 46H STL PLD ELASTIC STOP NUT 4 25 204324 BASE 1 26 PC2 192965 CIRCUIT CARD ASSY LED POT 1 27 174991 KNOB POINTER 1 250 DIA X 250 ID W SPRING CLIP 21 1 28 204331 PAN...

Page 34: ...trigger assembly 169 231 Grease silicone 1 Part No Item No Description See Figure 8 3 for additional consumable parts 1 5 3 4 2 6 Ref 195 092 Ref 803 224 NOTE The ICE 40C torch is specifically for use only with this plasma cutting unit Figure 8 2 Torch ICE 40C To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number ...

Page 35: ... Retaining Cup 192 050 Tip 204 325 Electrode 192 047 Swirl Ring 192 049 O Ring 169 232 Deflector 177 888 Retaining Cup 192 050 35A Tip 192 052 Electrode 192 048 Shield 192 203 Retaining Cup 192 050 Tip 204 332 Electrode 192 047 Standard Cutting Extended Cutting 1 8 3 mm standd off recommended Apply silicone grease 169 231 before installing Figure 8 3 Consumable Parts For ICE 40C To maintain the fa...

Page 36: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 37: ...Notes ...

Page 38: ...Notes ...

Page 39: ...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 ...

Page 40: ...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 Resources...