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Hobart Welding Products 1025 manual

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Table of contents for the manual

  • Page 1

    And Non-CE Models Cybercut 1025 Processes Descrip tio n Air Plasma Cutting and Gouging Air Plasma Cutter OM -2210 176 876K March 1999 Visit our website at www.HobartWelders.com[...]

  • Page 2

    [...]

  • 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

    dec_con1 1/96 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Declares that the product: Cybercut 1025 conforms to the following Directives and Standards: Directives Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC Low V oltag[...]

  • Page 5

    OM-2210 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_5/97 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 message. . Means “Note”; not safety related. This group of symbols means W arning! W atch[...]

  • Page 6

    OM-2210 Page 2 Sparks and hot metal blow out from the cutting arc . Chipping and grinding cause flying metal. FL YING SP ARKS can cause injury . D W ear approved face shield or safety goggles with side shields. D W ear proper body protection to protect skin. D Wear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears. Arc ray[...]

  • Page 7

    OM-2210 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. MOVING P ARTS can cause injury . D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in [...]

  • Page 8

    OM-2210 Page 4 1-5. EMF Information Considerations About W elding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields W elding or cutting current, as it flows through the welding or cutting cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However , after examining more than [...]

  • Page 9

    OM-2210 Page 5 SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_nd_fre_5/97 1-1. 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. Y Identifie un message de sécurité particulier . . Signi[...]

  • Page 10

    OM-2210 Page 6 D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée. D 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. D Isoler la pi[...]

  • Page 11

    OM-2210 Page 7 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro- voquer des brûlures graves. D Ne pas toucher des parties chaudes à mains nues. D Laisser refroidir avant d’intervenir sur la torche. DES ORGANES MOBILES peuvent provoquer des blessures. D S’absten[...]

  • Page 12

    OM-2210 Page 8 1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les ef fets, pour l’organisme, des champs magnétiques 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 [...]

  • Page 13

    OM-2210 Page 9 SECTION 2 − DEFINITIONS 2-1. W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Cutting sparks can cause explosion or fire. 1.1 Keep flammables away from cutting. Do not cut near flammables. 1.2 Cutting sparks can cause fires. Have a fire extinguisher nearby , and have a watchperso[...]

  • Page 14

    OM-2210 Page 10 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Incorrect voltage will damage unit. 3 Read Owner ’ s Manual. 4 Look at input power receptacle and plug, and be sure they match. 5 Move switch to match input voltage. 4/96 S-176 481-A 1 15V 230V 1 2 3 4 5 2-2. Manufacturer ’ s Rating Label For CE Produc[...]

  • Page 15

    OM-2210 Page 1 1 SECTION 3 − INST ALLA TION 3-1. Specifications For Units Connected to a 20 Ampere, 1 15 V olt Circuit or a 10 Ampere, 230 V olt Circuit Amperes Input at Rated Output, 60 Hz, Single-Phase 1 15 V 230 V Plasma Plasma Gas Flow/ Rated Cutting Capacity Max Rated Output 1 15 V 230 V 1 15 V KV A/KW 230 V KV A/KW Plasma Gas Gas Flow/ Pres[...]

  • Page 16

    OM-2210 Page 12 3-4. Duty Cycle And Overheating For Non-CE Model Duty Cycle is percentage of 10 mi n- utes that unit can cut at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, T emperature trouble light goes On, and cooling fan runs. Wait fifteen minutes for unit to cool or temperature light to go off. Reduce a[...]

  • Page 17

    OM-2210 Page 13 18 in (457 mm) 3-6. Selecting A Location loc_2 3/96 - ST-801 303-B / ST -801 319-B 1 Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 Plate Label Use label to determine input power needs. 4 1 15 Or 230 V AC Receptacle Locate unit near correct input power supply . Y Special installation m[...]

  • Page 18

    OM-2210 Page 14 3-7. Connecting W ork Clamp And Gas/Air Supply Ref. ST-091 547-C / Ref. ST -801 306-B 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 70 to 150 psi (483 to 1034 kPa) pressure. 3 Air Filter/Regulator 4 Gas/Air Inlet Opening[...]

  • Page 19

    OM-2210 Page 15 3-8. Setting Input V oltage Selector Switch And Connecting Input Power ST-801 304-B / ST -801 319-B Check input voltage available at site. 1 Input V oltage Selector Switch Switch is accessible through slot in rear panel. 2 Changeover Switch Label Look at label to find correct switch position. Move switch to match input voltage. 3 Su[...]

  • Page 20

    OM-2210 Page 16 SECTION 4 − OPERA TION 4-1. Controls Ref. ST-801 306-B / Ref. SC-192 492 1 Output Control Use control to set cutting output. Th e yellow zone is for use on 20 A or greater primary circuits. Place control in Gas/Air Set position to safely adjust gas/air pressure. Only gas/air circuit is activated. If 20-25 amperes of cutting output[...]

  • Page 21

    OM-2210 Page 17 4-2. Cutting Speed The cutting speed curves show the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness. Cut at speeds below the lines shown t o avoid poor cuts and torch wear . ST-179 507 Recommended production cutting speed vs. material thickness is approximately 10 imp[...]

  • Page 22

    OM-2210 Page 18 4-3. Sequence Of Operation Press trigger . Pilot arc starts. After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and out bottom of cut. Pause briefly at end of cut before releasing trigger . Install & Connect Equipment Check T orch (See T orch Owner’ s Manual) Check Gas/[...]

  • Page 23

    OM-2210 Page 19 SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check Gas/Air Pressure Check T orch Tip, Electrode, And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Unreadable Labels Service [...]

  • Page 24

    OM-2210 Page 20 5-2. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System If certain problems occur , the Ready light goes off, a trouble light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). Tur n power Of f, and check for prop- er gas/air pressure (see Section 4-1 ). 2 C[...]

  • Page 25

    OM-2210 Page 21 5-3. T orch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: T urn power Of f, and disconnect in- pu t power plug from receptacle. Re- move top and screws holding front panel in place. Without disconnect- ing any plugs, move front panel to allow access. T orch Connections 1 Strai[...]

  • Page 26

    OM-2210 Page 22 5-4. T roubleshooting T rouble Remedy No pilot arc; dif ficulty in establishing an arc. Clean or replace worn consumables as necessary (see torch Owner ’ s Manual). arc. Check for damaged torch or torch cable (see torch Owner’s Manual). Have Factory Authorized Service Agent check control relay CR6, power control board PC1, safet[...]

  • Page 27

    OM-2210 Page 23 SECTION 6 − ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Power Source SC-189 005[...]

  • Page 28

    OM-2210 Page 24 SECTION 7 − P ARTS LIST Figure 7-1. Main Assembly . Hardware is common and not available unless listed. ST-801 412-E 1 2 4 5 6 7 8 9 10 11 3 12 13 14 16 17 18 19 20 21 22 23 15 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 29 40[...]

  • Page 29

    OM-2210 Page 25 Description Part No. Item No. Figure 7-1. Main Assembly Quanti ty Dia. Mkgs. 1 183 161 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 175 145 HANDLE, lifting 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 30

    OM-2210 Page 26 Description Part No. Item No. Figure 7-1. Main Assembly (Continued) Quanti ty Dia. Mkgs. 38 FRONT P ANEL, (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +181 717 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 31

    Effective January 1, 1997 This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expre ssed or implied. LIMITED W ARRANTY − Subject to the terms and conditions below , warrants to its original retail purchaser that new equipment sold after the ef fe ctive date of this limited[...]

  • Page 32

    PRINTED IN USA Mod el Name Seri al/Style Number Purc ha se Dat e (Date whic h equipment was deli v ered to original customer.) Distributor Address City Sta te Z ip Pleas e complete and retain with your personal records . Always provide Model Name and Seria l/Style Number. Contact your Distri butor for: Welding Supplies and Consumables Options and A[...]