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OM-203 653 Page 23

SECTION 5 – ELECTRICAL DIAGRAM

Figure 6-1. Circuit Diagram

200 809-D

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Summary of Contents for AirForce 400

Page 1: ...OM 203 653C February 2003 Visit our website at www HobartWelders com Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter AirForce 400 And Ice 27C Torch ...

Page 2: ...lue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller 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 With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit n...

Page 3: ... 5 Selecting A Location 10 2 6 Connecting Gas Air Supply 11 2 7 Connecting Work Clamp 12 2 8 Connecting Input Power 12 2 9 Installing Alternative Plug 13 SECTION 3 OPERATION 14 3 1 Controls 14 3 2 Cutting Speed 15 3 3 Trigger Safety Lock 15 3 4 Sequence Of Operation 16 SECTION 4 MAINTENANCE TROUBLESHOOTING 17 4 1 Routine Maintenance 17 4 2 Overload Protection Trouble Lights Checking Shield Cup Shu...

Page 4: ......

Page 5: ...an 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 mach...

Page 6: ...lied 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 coatin...

Page 7: ...o not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit STATIC ESD can damage PC boards D Put on grounded wrist 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 comput...

Page 8: ...Y 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 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 co...

Page 9: ...alons 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 automatiq...

Page 10: ...protection Tableau 1 Protection des yeux pour 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 end...

Page 11: ...per ou réduire le facteur de marche Danger D 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 chario...

Page 12: ...agnétiques 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 acc...

Page 13: ... idling 2 2 Specifications For Torch Air cooled torch for plasma arc cutting PAC 35 duty cycle Safety interlock devices shut down power source Safety trigger guard Cutting capacity see Section 2 1 2 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...

Page 14: ...rmine input power needs 4 120 VAC Receptacle 5 230 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 8 1 2 in 216 mm 12 5 16 in 313 mm Movement 1 2 Location And Airflow 3 Dimensions And Weight 49 lb 22 2 kg not including torch 10 in 254 mm 10 in 254 mm 4 5 Add 13 16 ...

Page 15: ...sure 1 Gas Air Inlet Opening 2 Hose 3 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 4 Air Filter Regulator Adjust gas air pressure according to Section 3 1 Tools Needed 5 8 1 1 8 in 3 1 4 2 From Gas Air Supply ...

Page 16: ... individual branch circuit capable of carrying the effective eff current for the output being used The unit must have a properly sized plug installed and the circuit must be protected by properly sized fuses or cir cuit breakers A 120 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required see Section 2 1 4 Plug From Unit Select extension cord of 12 AW...

Page 17: ...s Strip conduc tors enough to make good contact with plug terminals Make plug con nections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not overtighten Ref 801 305 A 801 611 This procedure is necessary if the unit is to be connected to a 230 VAC receptacle or to a 115 VAC receptacle that requires a plug that is different from the supplied plug Tools Needed 1 6 7 2 ...

Page 18: ...input power and the overload protection on the input power circuit fre quently opens either reduce the cutting out put and or the cut time or find more adequate power see Section 2 1 2 Trouble Lights See Section 4 2 3 Power Light 4 Power Switch Setting Gas Air Pressure 5 Air Filter Regulator 6 Pressure Adjustment Knob Place Output control in Gas Air position and turn on gas air supply Lift knob an...

Page 19: ...he recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness Cut at speeds below the lines shown to avoid poor cuts and torch wear wmdesign 3 3 Trigger Safety Lock Trigger Locked Trigger Unlocked 1 Trigger 802 877 1 ...

Page 20: ...tting Operation Raise trigger lock and press trigger Pilot arc starts Postflow continues for 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 Place tip on work for drag cutting or for maximum cutting speed and tip life use a standoff distance of 1 16 in 1 6...

Page 21: ...often during severe conditions Each Use Check Gas Air Pressure Check Torch Tip Electrode And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Unreadable Labels Service Air Filter Regulator Replace Cracked Parts Gas Air Hose Torch Body Cable Tape Torn Outer Covering 6 Months Blow Out Or Vacuum Inside ...

Page 22: ...ed A flashing Cup light indicates that the torch consumables are stuck or worn and should be inspected and or replaced see Section 4 4 Check shield cup shutdown system once a week 3 Temperature Light Lights if power source overheats or when ambient temperature is below 35 C 31 F see Section 2 3 4 Torch Shield Cup Turn Power On and loosen shield cup If shutdown system works properly Ready light goe...

Page 23: ...harness connected to circuit board PC1 5 Ring Terminal And Terminal PILOT Connect ring terminal on end of red leads to PILOT terminal 6 Ring Terminal And Terminal L2 RED Connect ring terminal on end of white leads to L2 RED terminal 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 cab...

Page 24: ... ring for cracks or worn spots re place 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 R...

Page 25: ...e Status light On or flashing Press torch trigger and check if pilot arc ignites Check torch consumables Check torch connections air filter pressure switch S3 valve AS1 air supply connection to unit torch and PC1 Yes No Does pilot arc ignite Place torch near workpiece and check if pilot arc jumps or transfers to workpiece Check work clamp connection Check Control board PC1 and connections and torc...

Page 26: ...lace torch consumables as necessary see Section 4 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 2 1 Clean or replace torch consumables as necessary see Section 4 4 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 2 1 Is Trouble light On unit has no cutt...

Page 27: ...OM 203 653 Page 23 SECTION 5 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram 200 809 D ...

Page 28: ...OM 203 653 Page 24 SECTION 6 PARTS LIST Figure 7 1 Main Assembly Hardware is common and not available unless listed 802 805 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 22 2 ...

Page 29: ...NG straight quick disconnect 1 8NPT 1 204 004 FITTING elbow quick disconnect 1 8NPT 1 16 200 728 BRACKET mtg air filter 1 17 200 875 REGULATOR air w fittings consisting of 1 204 004 FITTING elbow quick disconnect 1 8NPT 1 204 005 FITTING elbow quick disconnect 1 4NPT 2 18 PC1 213 150 CIRCUIT CARD ASSY control w pgm non CE 1 19 138 044 BUSHING strain relief 1 20 195 014 ICE 27C 20ft hand held consi...

Page 30: ...rease silicone 1 195 014 Torch replacement 20ft 1 Part No Item No Description See Figure 7 3 for additional consumable parts 1 1 2 3 4 5 Figure 7 2 Torch ICE 27C 202 108 A Figure 7 3 Consumable Parts For ICE 27C To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local dist...

Page 31: ...rols Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manu...

Page 32: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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