Hobart AirForce 250A, Owner'S Manual

Page 1: ...AirForce 250A And ICE 12C Torch Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM 928 198 842H 2007 01 ...

Page 2: ... 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...

Page 3: ... DEFINITIONS 9 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 9 SECTION 4 INSTALLATION 10 4 1 Specifications For Power Source 10 4 2 Specifications For Torch 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 Connecting Input Power 12 SECTION 5 OPERATION 13 5 1 Controls 13 5 2 Trigger Safety...

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Page 5: ... 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 machin...

Page 6: ...ed respirator Fumes from cutting and oxygen deple tion 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 ...

Page 7: ...es computers and communicationsequipment D Have only qualified persons familiar with elec tronic equipment perform this installation D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation D If notified by the FCC about interference stop using the equipment at once D Have the installation regularly checked and maintaine...

Page 8: ...10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current as it flows through the welding or cutting cables will cause electromagnetic fields There has been and still is some conc...

Page 9: ...ns 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 Le fait de toucher à une pièce électrique sous tension peut donner une décharge fatale ou entraî ner des brûlures graves Le chalumeau et le circuit de masse sont automatiquem...

Page 10: ... le coupage au plasma d arc Intensité de courant en ampères Filtre de teinte minimum Moins de 20 no 4 20 40 no 5 40 60 no 6 60 80 no 8 Certaines applications de coupage produisent un bruit constant ce qui peut endommager l ouïe si le niveau sonore dépasse les limites permises par l OSHA repor tez vous aux Principales normes de sécurité LE BRUIT peut endommager l ouïe D Utilisez des protège tympans...

Page 11: ...EXPLOSION D HYDROGÈNE D Lors du coupage d aluminium partiellement ou totale ment immergé dans l eau de l hydrogène libre peut s accumuler sous la pièce D Consultez votre ingénieur de coupage et les instruc tions de la table de coupage LA CHUTE DE L APPAREIL peut blesser D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariot les bouteilles de gaz ou tout autre accesso...

Page 12: ...nétiques basse fréquence Le courant de soudage ou de coupage passant dans les câbles de puis sance crée des causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du Natio nal Research Council a conclu L accum...

Page 13: ...nt 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 Supply Current pf power factor S ...

Page 14: ...re 1 SCFM 28 3 L min at 50 PSI 345 kPa Safety interlock devices shut down power source Safety trigger guard Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can cut at rated load without overheating If unit overheats thermostat s opens output stops Temperature trouble light goes On and cooling fan runs Wait fifteen minutes for unit t...

Page 15: ...r similar device to move unit 3 120 VAC Receptacle Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 6 3 4 in 171 mm 17 in 432 mm Movement 1 2 Location And Airflow 3 Dimensions And Weight 42 lb 19 1 kg 10 in 254 mm 10 in 254 mm Serial Number Rating Label located on rear panel of pl...

Page 16: ...A Check input voltage available at site 1 Grounded Receptacle A 120 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required see Section 4 1 2 Plug From Unit Select extension cord of 12 AWG for up to 75 ft 23 m or 10 AWG for up to 140 ft 46 m Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC...

Page 17: ...Trouble Light Trouble light comes on for the following conditions a If cup is removed from torch unit power must be turned off and back on again b If unit overheats c If input power is not within specification 93 to 137 vac If input power is outside of specified range cycle power by placing the power switch in the off position and back on again Check input power if problem continues 196 630 5 2 Tr...

Page 18: ...to sometimes see moisture come out the end of the torch As a convenience the torch can be set up with two cutting combinations either drag or non shielded cutting The torch comes standard with drag cutting Maximum performance on thicker materials can be obtained by using non shieldedcutting with a 1 16 1 8 in 1 6 3 2 mm standoff 197 567 196 929 Use retaining cup 197 567 and drag shield 196 929 to ...

Page 19: ...ere conditions Each Use Check Torch Tip Electrode And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Unreadable Labels Replace Cracked Parts Torch Body Cable Tape Torn Outer Covering 6 Months Blow Out Or Vacuum Inside Check Compressor Filter Clean With A Damp Cloth Or Replace If Necessary Compressor Model Only ...

Page 20: ...put power is not within specification 93 to 137 vac Power must be reset whenever the input voltage shutdown is activated 2 Torch Shield Cup Turn Power On and loosen shield cup If shutdown system works properly trouble light comes on If not turn power Off and check for loose shield cup Check consumables see Sections 6 4 and Parts List If system works properly retighten cup and reset power Ref 196 6...

Page 21: ...Male Friction Terminal RC11 ELECT WHITE Connect female friction terminal on end of white leads to RC11 ELECT WHITE 6 Female And Male Friction Terminal RC7 PILOT RED Connect female friction terminal on end red leads to RC7 PILOT RED Tighten strain relief nut Tighten strain relief around cable Work Cable Connections Remove existing work cable from unit 7 Strain Relief Be sure to allow some work cabl...

Page 22: ...e shield cup 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 steel wool afterwards 5 Electrode Check electrode If center has a pit more than a 1 16 in 2 mm deep remove and re place electrode 6 Swirl Ring 7 O Ring Remove swirl ring Check ring and replac...

Page 23: ...t temperature No Yes Momentarily press torch trigger and listen for gas air valve operation Check for Postflow air at torch Check Control board PC1 air filter and gas air connections to PC1 and torch Yes No Is compressor operating Press torch trigger and check if pilot arc ignites Check torch consumables Check torch connections relay CR1 gas air system and torch Yes No Does pilot arc ignite Place ...

Page 24: ...es as necessary see Section 6 4 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 4 2 Clean or replace torch consumables as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 1 Is Trouble light On unit has no cutting output Yes Check...

Page 25: ...OM 928 Page 21 SECTION 7 ELECTRICAL DIAGRAM 213 899 A Figure 7 1 Circuit Diagram ...

Page 26: ...e 22 SECTION 8 PARTS LIST Hardware is common and not available unless listed Ref 802 591 E 1 3 5 6 7 9 10 12 13 14 15 16 17 18 19 20 22 27 28 29 30 32 31 33 34 35 4 21 23 11 2 8 25 26 24 Figure 8 1 Main Assembly ...

Page 27: ...1 FILTER compressor 1 21 197 255 RUBBER MOUNT 4 22 602 205 WASHER tooth 195 ID x 381 OD x 025T stl pld 4 23 216 277 FTG brs elbow qdisc 1 8 NPT X 250 TBG 1 24 216 276 TUBING copper coil heat exchanger 1 25 216 296 CLAMP cable 1 4 ID stl galv 1 26 216 280 FTG brs straight qdisc 1 4 OD X 1 4 OD tubing 1 27 PC1 214 585 CIRCUIT CARD 1 28 TP2 197 892 THERMOSTAT 1 29 138 044 BUSHING strain relief 1 30 1...

Page 28: ...12C and CE markings only apply when the torch is used with shielded parts retaining cup 197 567 and drag shield 196 929 S Ref 197 336 A O Ring 196935 Swirl Ring 196927 Electrode 196925 Tip 196926 Retaining Cup 197567 Drag Shield 196929 Retaining Cup 196928 For best performance use 1 8 stand off with this part Figure 8 3 Consumable Parts For ICE 12C To maintain the factory original performance of y...

Page 29: ...Notes ...

Page 30: ...Notes ...

Page 31: ...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...

Page 32: ...r To locate a Distributor retail 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 th...