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Hobart Welding Products AirForce 625 And ICE-40C Torch manual

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Table of contents for the manual

  • Page 1

    OM-926 21 1 123H 2006 − 01 Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter AirForce 625 And ICE-40C T orch File: Plasma Cutters[...]

  • Page 2

    Hobart W elders 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 specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards 1 . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-926 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _4/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety messag[...]

  • Page 6

    OM-926 Page 2 D 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. EXPLODING P ARTS can injure. Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. FL YING SP ARKS can cause injury [...]

  • Page 7

    OM-926 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance HOT P ARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. D T o handle hot parts, use proper tools and/or wear heavy , insulated welding gloves and clothing to prevent burns. MOVING P ARTS can cause injur[...]

  • Page 8

    OM-926 Page 4 1-5. Principal Safety Standards Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Practices for Plasma Arc Cutting , American Welding Society Standard A WS C5.2, from Global Engineering Documents (phone: 1-877-413[...]

  • Page 9

    OM-926 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 4/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci [...]

  • Page 10

    OM-926 Page 6 D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée. D Le câble de masse doit être pincé correctement sur la pièce à cou- per , métal contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table de travail le plus près possible de la ligne de coupage. D Isoler la[...]

  • Page 11

    OM-926 Page 7 D Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique. D Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille. D Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait. D Utilisez uniquement des bouteilles de [...]

  • Page 12

    OM-926 Page 8 LE COUP AGE Ã L ’ARC peut causer des interférence. D L ’énergie électromagnétique pe ut gêner le fonction- nement d’appareils électroniques comme des ordi- nateurs et des robots. D Pour réduire la possibilité d’interférence, maintenir les câbles aussi courts que possible, les grouper , et les poser aussi bas que pos[...]

  • Page 13

    OM-926 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label A Amperes Plasma Arc Cutting (P AC) Adjust Air/Gas Pressure Low Air Pressure Light V V olts Increase No − Do Not Do This T emperature Protective Earth (Ground) Single Phase Constant Current Voltage Input On Of f Percent Direct Current[...]

  • Page 14

    OM-926 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications 50/60 Hz Amperes Input at Rated Load Output 50/60 Hz Rated Output T ype of Output Plasma Gas Rated Cutting Capacity Maximum Open-Circuit V oltage DC 208 V 230 V KV A KW Output Output Gas C apac it y V o lt age DC Single- Phase 33 30 6.8 6.7 40 A @ 140 V olts DC, 50% Duty Cycle Direct C[...]

  • Page 15

    OM-926 Page 1 1 4-5. Unit Dimensions, Weight, And Movement loc_2 3/96 - 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 W eight 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

    OM-926 Page 12 4-6. Connecting W ork Clamp and Gas/Air Supply 1 Work Clamp 2 W orkpiece 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 to 150 psi (620 to 1035 kPa) pressure. Prevent moisture from entering air supply at extreme cold temperatures. 3 Gas/Air Inle[...]

  • Page 17

    OM-926 Page 13 4-7. Electrical Service Guide 50/60 Hz Single Phase Input V oltage 208 230 Input Amperes At Rated Output 33 30 Max Recommended Standard Fuse Rating In Amperes Cricuit Breaker 1 , Time-Delay 2 40 35 Normal Operating 3 50 45 Min Input Conductor Size In A WG 4 10 10 Max Recommended Input Conductor Length In Feet (Meters) 80 (24) 98 (30)[...]

  • Page 18

    OM-926 Page 14 4-9. Selecting A Location And Connecting Input Power 1 Plug (NEMA T ype 6-50P) 2 Receptacle (NEMA T ype 6-50R) Connect plug to receptacle. 3 Input And Grounding Conductors For single-phase operation: Y Make input power connections to the machine before making connections into a deenergized line disconnect device. In the line disconne[...]

  • Page 19

    OM-926 Page 15 4-10. Wiring Optional 240 V olt Plug (1 19 172) For Connection T o Bobcat, T railblazer Or Champion 10,000 Ref. 120 813-D / Ref. 803 222 1 Input And Grounding Conductors 2 Plug Wired for 240 V , 2-Wire Load 3 Neutral (Brass) T erminal And Prong (Not Used) 4 Load 1 (Brass)T erminal And Prong 5 Load 2 (Bras s) T erminal And Prong 6 Gro[...]

  • Page 20

    OM-926 Page 16 4-1 1. Installing Alternative Plug 1 Supplied 23 0 V AC Plug Cut cord close to plug. 2 Alternative Plug (230 V AC Plug Shown) 3 Input (Black Lead) (Brass) T erminal 4 Neutral (White Lead) (Brass) T erminal 5 Ground (Green) T erminal 6 Outer Shell 7 Cord Grip Strip cord jacket back enough to separate conductors. Strip conductors enoug[...]

  • Page 21

    OM-926 Page 17 SECTION 5 − OPERA TION 1 Output Control Use control to set cutting output. Place control in Gas/Air Set position to safely adjust gas/air pressure. Only gas/air circuit is activated. 2 Status Lights (See Section 6-2) 3 Power Light 4 Power Switch . The fan will normally run for approximately 5 seconds after power switch is placed in[...]

  • Page 22

    OM-926 Page 18 5-3. T rigger Safety Lock 1 T rigger 801 397-A 1 T rigger Locked T rigger Unlocked 801 400-B / Ref. 802 878 5-4. Plasma Cutting System Practices Pulling rather than pushing the torch makes cutting easier . Use a proper guide or template for accurate cutting operations. The pilot arc starts immediately when trigger is pressed. Maintai[...]

  • Page 23

    OM-926 Page 19 out bottom of cut. 801 400-B 5-5. Sequence Of Cutting Operation After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and Pause briefly at end of cut before releasing trigger . Raise trigger lock and press trigger . Pilot arc starts. Postflow continues for approx. 20 seconds afte[...]

  • Page 24

    OM-926 Page 20 801 400-B 5-6. Sequence Of Gouging Operation Raise trigger lock and press trigger . Pilot arc starts. Move tip to within approxi- mately 3/16 in (4.8 mm). Start gouging across workpiece surface. Maintain approximately a 45 ° angle to surface. Release trigger . Postflow continues for approx. 20 seconds after releasing trigger; arc ca[...]

  • Page 25

    OM-926 Page 21 801 400-B 5-7. Sequence Of Piercing Operation Maintain approximately 90 ° torch position to surface, and continue cutting. 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[...]

  • Page 26

    OM-926 Page 22 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check T orch Tip, Electrode, And Shield Cup Check Gas/Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service Air Filter/Regulator Assembly Filter R[...]

  • Page 27

    OM-926 Page 23 6-2. Overload Protection: Status Lights & Checking Shield Cup Shutdown System If certain problems occur , a status light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). T urn power Off, and check for proper gas/air pressure (see Section 4-12 ). A flashing Pressure light indicates[...]

  • Page 28

    OM-926 Page 24 6-3. Checking/Replacing Retaining Cup, T ip, And Electrode 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 ha[...]

  • Page 29

    OM-926 Page 25 6-4. T roubleshooting Power Source No Ye s Is Power light flashing? Reset Power switch S1. No Ye s 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. No Ye s Is Pressure Status [...]

  • Page 30

    OM-926 Page 26 6-5. T roubleshooting T orch T orch 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. Ye s No Does arc go on and of f while cutting? Does arc go out while cutting? No Ye s Be sure work clamp is secu[...]

  • Page 31

    OM-926 Page 27 SECTION 7 − ELECTRICAL DIAGRAM 212 926-A Figure 7-1. Circuit Diagram[...]

  • Page 32

    OM-926 Page 28 SECTION 8 − P ARTS 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

    OM-926 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 +21 1 1 18 WRAPPER, 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 208015 HANDLE,RUBBERIZED CARRYING 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 34

    OM-926 Page 30 195 1 10 ICE-40C 25ft T orch 195 1 1 1 ICE-40C 50ft T orch 1 183 427 Handle Assy , complete (1) 2 192 059 Main Body (1) 3 209 298 Leads, 25ft (1) 3 209 299 Leads, 50ft (1) 4 185 833 Switch Assembly w/spring (1) 5 171 248 Push Button Switch (1) 6 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) Part No. Item No. Descripti[...]

  • Page 35

    OM-926 Page 31 21 1 120-A For extended tip use, set Amperage control to 35. Gouging F AILURE TO REPLACE WORN TIP OR ELECTRODE WILL RUIN T ORCH AND VOID W ARRANTY . S Turn of f power before checking torch parts. S Check before each use and hourly during operation. CAUTION ICE − 40C CONSUMABLES NOTE: Set air pressure to 75 PSI for cutting or 55 PSI[...]

  • Page 36

    Notes W o r k l i k e a P r o ! Pros wel d and cut safel y . Read the safety rules at the beginni ng of this manual .[...]

  • Page 37

    Notes[...]

  • Page 38

    Notes[...]

  • Page 39

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2/05 Service Y o u 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 t[...]

  • Page 40

    PRINTED IN USA © 2005 Hobart Welding Products. 6/05 Hoba rt W elding Produc ts An Illinois T ool W orks Compan y 600 W est Main Stree t Tr oy , OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Liter atur e Or Ne are st Deal er : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to o[...]