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OM-926 Page 22

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1.

Routine Maintenance

Y

Disconnect power
before maintaining.

.

Maintain more often
during severe 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

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Summary of Contents for AirForce 625

Page 1: ...AirForce 625 And ICE 40C Torch OM 926 211 123C January 2003 Visit our website at www HobartWelders com Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter ...

Page 2: ... 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 then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular ...

Page 3: ...vice Guide 13 3 8 Extension Cord Data 13 3 9 Selecting A Location And Connecting Input Power 14 3 10 Wiring Optional 240 Volt Plug 119 172 For Connection To Bobcat Trailblazer Or Champion 10 000 15 3 11 Installing Alternative Plug 16 3 12 Setting Gas Air Pressure 16 SECTION 4 OPERATION 17 4 1 Controls 17 4 2 Cutting Speed 17 4 3 Trigger Safety Lock 18 4 4 Plasma Cutting System Practices 18 4 5 Seq...

Page 4: ......

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: ...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 computer...

Page 8: ...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 conc...

Page 9: ...ons 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 automatique...

Page 10: ...otection 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 endom...

Page 11: ...r 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 chariot ...

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: ...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 3 1 3 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: ... purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above Y Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard 3 8 Extension Cord Data When calculating max cord length remember to include conductor length from line disconnect device to input power receptacle NOTE Input Voltage I...

Page 18: ... line terminal Connect directly to line disconnect device if hard wiring is required 5 Line Disconnect Device See Section 3 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 grounding conduc...

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 3 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 4 1 Controls 4 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 5 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 3 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 5 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 4 5 Clean or replace torch consumables as necessary see Section 5 3 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 3 1 Are Trouble lights On unit has no cutting output Yes Check torch consumables C...

Page 31: ...OM 926 Page 27 SECTION 6 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram 212 926 A ...

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

Page 33: ...RAIN RELIEF TERM 1 203988 CLAMP WORK 150A 1 199995 CONTACT TIP WORK CLAMP 150A 2 19 S1 124511 SWITCH 1 20 FM 208240 FAN MUFFIN 24VDC 3000 RPM W 19 250 IN LEADS 1 21 179276 BUSHING SNAP IN NYL 1 000 ID X 1 375 MTG HOLE CENT 8 22 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 23 174991 KNOB POINTER 1 250 DIA X 250 ID W SPRI...

Page 34: ...trigger assembly 169 231 Grease silicone 1 Part No Item No Description See Figure 6 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 6 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 6 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: ...parately by the manufacturer Hobart s 5 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 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are cover...

Page 40: ...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...

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