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Hobart Welding Products 400 manual

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Table of contents for the manual

  • Page 1

    OM-203 653G December 2004 Visit our website at www.HobartWelders.com Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter AirForce 400 And Ice-27C T orch [...]

  • 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 catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

  • 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-203 653 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_5/04 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 a[...]

  • Page 6

    OM-203 653 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 inj[...]

  • Page 7

    OM-203 653 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 [...]

  • Page 8

    OM-203 653 Page 4 1-5. Principal Safety Standards Safety in W elding and Cutting , ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 Safety and Health Standards , OSHA 29 CFR 1910, from Superinten- dent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Practices for Plasma A[...]

  • Page 9

    OM-203 653 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 5/04 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. Y Identifie un message de sécurité particulier . . Signi[...]

  • Page 10

    OM-203 653 Page 6 D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Il y a DU COURANT CONTINU IMPORT ANT dans les convertisseurs après la suppression de l’ali- mentation électrique. D Arrêter les convertisseurs, débrancher le courant électrique, et dé- charger les condensateurs d’al[...]

  • Page 11

    OM-203 653 Page 7 Les bouteilles de gaz contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser . Puisque les bouteilles de gaz font habituellement partie d’un processus de travail des métaux, assurez − vous de les manipuler correctement. LES BOUTEILLES peuvent exploser si elles sont endommagées. D Protég[...]

  • Page 12

    OM-203 653 Page 8 2-4. Principales normes de sécurité Safety in W elding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, W ashington, D.C. 20402. Recommended Safe Practice for the [...]

  • Page 13

    OM-203 653 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 Cur[...]

  • Page 14

    OM-203 653 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications If the unit is operated from a 30 ampere, 1 15 volt circuit or a 15 ampere, 230 volt circuit, a different input power plug must be installed on the power cord. See Section 4-9 for instructions. NOTE Amperes Input at Rated Output, 60 Hz, Single-Phase Plasma Rated Cutting Rated Outpu[...]

  • Page 15

    OM-203 653 Page 1 1 4-4. T orch Dimensions And W eight Ref. 802 877 3.0 lb (1.4 kg) 1 in (25 mm) 8-3/8 in (213 mm) 1-3/8 in (35 mm) 16 in (406 mm) 4-5. Selecting A Location loc_2 3/96 - Ref. 802 784 / 802 785 / 802 786 / 203 892 1 Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 120 V AC Receptacle 4 23[...]

  • Page 16

    OM-203 653 Page 12 4-6. Connecting Gas/Air Supply 802 787 / Ref. 801 319-C / Ref. 802 784 . Use only clean, dry air with 70 to 150 psi (483 to 1034 kPa) pressure. 1 Gas/Air Inlet Opening 2 Hose 3 T eflon T ape Obtain hose with 1/4 NPT right- hand thread fitting. Wrap threads with teflon tape (optional) or apply pipe sealant, and install fitting in [...]

  • Page 17

    OM-203 653 Page 13 4-7. Connecting Work Clamp 802 463-A 1 Work Clamp 2 W orkpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 1 2 4-8. Connecting Input Power Ref. 802 787 / 802 786 Check input voltage available at site. 1 Changeover Switch Switch is accessible through slot in rear panel. 2 [...]

  • Page 18

    OM-203 653 Page 14 4-9. Installing Alternative Plug 1 Supplied 1 15 V AC Plug Cut cord close to plug. 2 Alternative PLug (230 V A C Plug Shown) 3 Load 1 (Brass) T erminal 4 Load 2 (Brass) T erminal 5 Ground (Green) T erminal 6 Outer Shell 7 Cord Grip Strip cord jacket back enough to separate conductors. Strip conduc- tors enough to make good contac[...]

  • Page 19

    OM-203 653 Page 15 SECTION 5 − OPERA TION 5-1. Controls 1 42 3 5 ON OFF PRESSURE 60 PSI 5 6 24 27 6 Set T o 60 PSI (414 kPa) 20 16 24 27 20 16 1 24 27 20 16 Requires 70-150 PSI (483-1034 kPa) Supply Setting Gas/Air Pressure 1 Output Control Use control to set cutting output. Place control in Gas/Air Set position to safely adjust gas/air pressure.[...]

  • Page 20

    OM-203 653 Page 16 5-2. 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 to avoid poor cuts and torch wear . wmdesign 5-3. T rigger Safety Lock T rigger Locked T rigger Unlocked 1 T rigger 802 877 1[...]

  • Page 21

    OM-203 653 Page 17 out bottom of cut. Ref. 802 878 5-4. Sequence Of 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 . EXAMPLE Of Cutting Operation Raise trigger lock and press trigger . Pilot arc starts. Postflow continues[...]

  • Page 22

    OM-203 653 Page 18 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check Gas/Air Pressure Check T orch T ip, Electrode, And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Unreadable Labels Serv[...]

  • Page 23

    OM-203 653 Page 19 6-2. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System If certain problems occur , the Ready light goes of f, a trouble light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). T urn power Of f, and check for proper gas/air pressure (see Section 5-1). A [...]

  • Page 24

    OM-203 653 Page 20 6-3. T orch And W ork Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: T urn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. T orch Connections Remove existing torch cable from unit. 1 Strain Relief 2 T orch Cable Insert cable through strain relief[...]

  • Page 25

    OM-203 653 Page 21 6-4. 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[...]

  • Page 26

    OM-203 653 Page 22 6-5. T roubleshooting Power Source Connect unit to proper input voltage (see Section 4-8). Ye s No Is input power connected to correct line voltage? Is Changeover switch S2 in the 1 15V or 230V position? Place Changeover switch in proper position for input voltage (see Section 4-8). No Ye s Is the cooling fan running? Check Power[...]

  • Page 27

    OM-203 653 Page 23 6-6. T roubleshooting T orch T orch travel speed too slow; increase travel speed (see Section 5-2). Clean or replace torch consumables as necessary (see Section 6-4 ). Be sure work clamp is securely attached to workpiece. Ye s No Does arc go on and off while cutting? Does arc go ou t while cutting? No Ye s Be sure work clamp is s[...]

  • Page 28

    OM-2229 Page 24 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram 200 809-D[...]

  • Page 29

    OM-203 653 Page 25 Notes[...]

  • Page 30

    OM-203 653 Page 26 SECTION 8 − P ARTS LIST Figure 8-1. 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 31

    OM-203 653 Page 27 Description Part No. Item No. Figure 8-1. Main Assembly Quantity Dia. Mkgs. 1 +195 621 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 851 LABEL, warning precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    OM-203 653 Page 28 1 183 427 Handle Assy , complete (1) 2 171 248 Push Button Switch (1) 3 203 120 Leads, 20ft (1) 4 203 1 19 Main Body (1) 5 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 195 014 T orch, replacement 20ft (1) Part No. Item No. Description See Figure 8-3 for additional consumable p[...]

  • Page 33

    Notes[...]

  • Page 34

    Notes[...]

  • Page 35

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 3/04 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 distribut[...]

  • Page 36

    PRINTED IN USA  2004 Hobart Welding Products. 1/04 Hoba rt We lding P roduc ts An Illinois T ool W orks Compa ny 600 W est Main Street Tr oy , OH 45373 USA For T echnical Assi stance: Call1-800-332-3281 Fo r Liter atu r e Or Nea re st Deal er : Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to[...]