OM-230 455C 2007-10 Processes Air Plasma Cutting Description Air Plasma Cutter ™ AirForce 250ci And HP-25 Torch 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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
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 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
EXPLODING PARTS can injure. On inverter power sources, failed parts can explode or cause other parts to explode when power is applied. Always wear a face shield and long sleeves when servicing inverters. FLYING SPARKS can cause injury. Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. Wear approved face shield or safety goggles with side shields. Wear proper body protection to protect skin.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can cause severe burns. 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. FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift unit.
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_fre 4/05 Avertissement : 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 sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité.
N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée. Le câble de masse doit être pincé correctement sur la pièce à couper, 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. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. LE BRUIT peut endommager l’ouïe.
Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique. Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille. Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait. Utilisez uniquement des bouteilles de gaz, des détendeurs, des boyaux et des raccords conçus pour l’application déterminée. Gardez−les, ainsi que toute autre pièce associée, en bonne condition.
LE COUPAGE Ã L’ARC peut causer des interférence. L’énergie électromagnétique peut gêner le fonctionnement d’appareils électroniques comme des ordinateurs et des robots. Veiller à couper à une distance de 100 mètres de tout équipement électronique sensible. S’assurer que la source de coupage est correctement branchée et mise à la terre.
A complete Parts List is available at www.HobartWelders.com SECTION 3 − DEFINITIONS 3-1.
A complete Parts List is available at www.HobartWelders.com SECTION 4 − INSTALLATION 4-1. Specifications For Power Source Primary Primary Volts Amperes 120 19 (0.25*) Duty Cycle Individual Branch Primary Service (Recommended) 35% 20A Secondary Secondary Volts (DC) Amperes 110 12 KW KVA 2.01 2.27 Mild Steel Rated Cutting Capacity 1/8 in (3.2 mm) At 10 IPM (4.2 mm/s) Power Factor Max** OCV (DC) 0.82 375 *While idling **10% High line condition 4-2.
A complete Parts List is available at www.HobartWelders.com 4-4. Torch Dimensions And Weight 8-3/8 in (213 mm) 1 in (25 mm) 3.0 lb (1.4 kg) 1-3/8 in (35 mm) Ref. 801 397-A 4-5. Selecting A Location 8-1/4 in (210 mm) Dimensions And Weight 10-1/4 in (260 mm) 27 lb (12.3 kg) 12-1/4 in (311 mm) 1 Lifting Handle Use handle to lift unit. Movement, Location And Airflow Serial Number/Rating Label located on rear panel of plasma cutter; use label to determine input power for unit.
A complete Parts List is available at www.HobartWelders.com 4-6. Connecting Work Clamp Do not connect work clamp to 1 the portion of the workpiece that will fall when cut. 1 2 Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 Ref 803 915-A 4-7.
A complete Parts List is available at www.HobartWelders.com 4-9. Connecting Input Power 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 4-7). 120 V 20 A Receptacle 2 Plug From Unit Connect plug to receptacle. For extension cord data, see Section 4-8.
A complete Parts List is available at www.HobartWelders.com 4-11. Cable Management Strap 1 Cable Management Strap Coil cables together and secure to unit using the cable management strap. 1 804 885-A 4-12. Electrode Wrench 1 2 Cable Management Strap Electrode Wrench The electrode wrench is fastened to the cable management strap. 1 2 Ref.
A complete Parts List is available at www.HobartWelders.com SECTION 5 − OPERATION 5-1. Controls 2 1 3 4 230 442-B 1 Power Switch The cooling fan will run for a few seconds after the power switch is placed in the OFF position in order to discharge internal circuitry. 2 Power Light Use light to tell if unit is energized and ready to operate. Light blinks if input power is not within specified range . 3 Cup Light 4 Light comes on if cup is removed from torch.
A complete Parts List is available at www.HobartWelders.com 5-3. Plasma Cutting System Practices The pilot arc starts immediately when trigger is pressed. Always connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. DO NOT start pilot arc without cutting as this shortens the life of the tip and electrode. Do not connect work clamp to the portion of the workpiece that will fall when cut.
A complete Parts List is available at www.HobartWelders.com 5-4. Sequence Of Cutting Operation The pilot arc starts immediately when trigger is pressed. Moisture from the compressor will form in the air line and at the torch. It will be normal to sometimes see moisture come out the end of the torch. EXAMPLE Of Cutting Operation Place tip near work. Keep tip 1/16 in. from Press trigger. Pilot arc starts. work for max cutting speed and tip life.
A complete Parts List is available at www.HobartWelders.com 5-5. Sequence Of Cutting Using Stand-off Guide The pilot arc starts immediately when trigger is pressed. Moisture from the compressor will form in the air line and at the torch. It will be normal to sometimes see moisture come out the end of the torch. EXAMPLE Of Cutting Using Stand-off Guide Stand-off Guide Installation Split section to bottom 1/16 in (1.6 mm) Place stand-off guide on work. Stand-off guide provides 1/16 in (1.
A complete Parts List is available at www.HobartWelders.com 5-6. Sequence Of Piercing Operation The pilot arc starts immediately when trigger is pressed. Connect work clamp to a clean, paint-free location on workpiece, as close 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.
A complete Parts List is available at www.HobartWelders.com SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining.
A complete Parts List is available at www.HobartWelders.com 6-2. Trouble Lights And Checking Shield Cup Shutdown System 1 1 2 3 Power Light Light is steady if input power is okay. Light flashes if input power is less than 92 volts ac or greater than 136 volts ac. Light stops flashing 15 seconds after condition is corrected or when torch trigger is pressed. If certain problems occur, the trouble light comes on, and output stops. 2 Cup Light Lights if shield cup is loose/off.
A complete Parts List is available at www.HobartWelders.com 6-3. Checking/Replacing Retaining Cup, Tip, 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 has been significantly reduced. Do not operate torch without a tip or electrode in place.
A complete Parts List is available at www.HobartWelders.com 6-4. Compressor Filter Cleaning And Replacement Turn Off power source, and disconnect input power. 1 2 Power Source Compressor Filter Remove wrapper from unit. Unscrew filter from compressor. Clean debris from filter surface or replace filter, if necessary. 1 Do not overtighten filter. Screw filter back into compressor. Tighten 1 full turn past hand tight. 2 Reinstall wrapper. Tools Needed: 5/16 in 5/8 in Ref.
A complete Parts List is available at www.HobartWelders.com 6-5. Torch And Work Cable Connections Turn Off power source, and disconnect input power. If torch or work cable needs to be removed or replaced, proceed as follows: 1 8 Power Source Remove wrapper from unit. Torch Connections Remove existing torch cable from unit. 5 9 7 6 4 1 2 Strain Relief 3 Torch Cable Insert strain relief on end of cable through front panel opening. Slide strain relief nut onto torch cable, but do not tighten.
A complete Parts List is available at www.HobartWelders.com 6-6. Troubleshooting Power Source Is input power connected to correct line voltage? No Connect unit to proper input voltage. (see Section 4-9). Are Power and Temp lights flashing? Yes * The compressor current limit was exceeded either above or below its operating range (see Section 6-2). Yes No Is Power switch in the On position? No Place Power switch in the On position. (see Section 5-1).
A complete Parts List is available at www.HobartWelders.com 6-7. Troubleshooting Torch Does arc go on and off while cutting? Yes No Does arc go out while cutting? Yes Torch travel speed too slow; increase travel speed (see Sections 5-3, 5-4, and 5-6). Clean or replace torch consumables as necessary (see Section 6-3). Be sure work clamp is securely attached to a clean (paint and rust free) workpiece. Reduce torch tip to workpiece stand-off distance.
SECTION 7 − ELECTRICAL DIAGRAM 230 449-B Figure 7-1.
SECTION 8 − PARTS LIST 8-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts ................... ................... ................... ................... ................... ................... ................... 232 647 208 820 770 496 770 497 232 015 230 445 233 321 .. .. .. .. .. .. .. TORCH, HP-25 16.4ft (5 m) hand held (replacement) . . . . . . . . . . . . . . . . CLAMP, work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
229895 Notes MATERIAL THICKNESS GAUGE
Notes
Effective January 1, 2007 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface LH or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST 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.
Owner’s Record Please complete and retain with your personal records. Protect Your Investment! Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Zip Resources Available Always provide Model Name and Serial/Style Number.
