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Hobart Welding Products 625 manual

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Table of contents for the manual

  • Page 1

    OM-926 21 1 123L 2007−04 Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter AirForce 625 And ICE-40C T orch File: Plasma Cutters[...]

  • 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 specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • 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-926 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _4/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 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 messag[...]

  • Page 6

    OM-926 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 injury[...]

  • Page 7

    OM-926 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. D T o handle hot parts, use proper tools and/or wear heavy , insulated welding gloves and clothing to prevent burns. MOVING P ARTS can cause injur[...]

  • Page 8

    OM-926 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Practices for Plasma Arc Cutting , American Welding Society Standard A WS C5.2, from Global Engineering Documents (phone: 1-877-41[...]

  • Page 9

    OM-926 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 4/05 Y A vertissement : 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 [...]

  • Page 10

    OM-926 Page 6 D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée. D Le câble de masse doit être pincé correctement sur la pièce à cou- per , 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[...]

  • Page 11

    OM-926 Page 7 D Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique. D Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille. D Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait. D Utilisez uniquement des bouteilles de [...]

  • Page 12

    OM-926 Page 8 LE COUP AGE Ã L ’ARC peut causer des interférence. D L ’énergie électromagnétique peut gêner le fonction- nement d’appareils électroniques comme des ordi- nateurs et des robots. D Pour réduire la possibilité d’interférence, maintenir les câbles aussi courts que possible, les grouper , et les poser aussi bas que po s[...]

  • Page 13

    . A complete Parts List is available at www .HobartW elders.com OM-926 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 Pha[...]

  • Page 14

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications 50/60 Hz Amperes Input at Rated Load Output 50/60 Hz Rated Output T ype of Output Plasma Gas Rated Cutting Capacity Maximum Open-Circui t V oltage DC 208 V 230 V KV A KW Output Output Gas Capacity V oltage DC Single- Phase[...]

  • Page 15

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 1 1 4-5. Unit Dimensions, Weight, And Movement loc_2 3/96 - 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 W eight 57 lb (25.9 [...]

  • Page 16

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 12 4-6. Connecting Work Clamp and Gas/Air Supply 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 90 to 120 psi (621 to 827 kPa) pressure. Prevent moisture from en[...]

  • Page 17

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 13 4-7. Electrical Service Guide 50/60 Hz Single Phase Input V oltage 208 230 Input Amperes At Rated Output 33 30 Max Recommended Standard Fuse Rating In Amperes Cricuit Breaker 1 , Time-Delay 2 40 35 Normal Operating 3 50 45 Min Input Conductor Size In A WG 4 10 10 Max Rec[...]

  • Page 18

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 14 4-9. Selecting A Location And Connecting Input Power 1 Plug (NEMA T ype 6-50P) 2 Receptacle (NEMA T ype 6-50R) Connect plug to receptacle. 3 Input And Grounding Conductors For single-phase operation: Y Make input power connections to the machine before making connections[...]

  • Page 19

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 15 4-10. Wiring Optional 240 V olt Plug (1 19 172) For Connection T o Bobcat, T railblazer Or Champion 10,000 Ref. 120 813-D / Ref. 803 222 1 Input And Grounding Conductors 2 Plug Wired for 240 V , 2-Wire Load 3 Neutral (Brass) T erminal And Prong (Not Used) 4 Load 1 (Brass[...]

  • Page 20

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 16 4-1 1. Installing Alternative Plug 1 Supplied 230 V AC Plug Cut cord close to plug. 2 Alternative Plug (230 V AC Plug Shown) 3 Input (Black Lead) (Brass) T erminal 4 Neutral (White Lead) (Brass) T erminal 5 Ground (Green) T erminal 6 Outer Shell 7 Cord Grip Strip cord ja[...]

  • Page 21

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 17 SECTION 5 − OPERA TION 1 Output Control Use control to set cutting output. Place control in Gas/Air Set position to safely adjust gas/air pressure. Only gas/air circuit is activated. 2 Status Lights (See Section 6-2) 3 Power Light 4 Power Switch . The fan will normally[...]

  • Page 22

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 18 5-3. T rigger Safety Lock 1 T rigger 801 397-A 1 T rigger Locked T rigger Unlocked 801 400-B / Ref. 802 878 5-4. Plasma Cutting System Practices Pulling rather than pushing the torch makes cutting easier . Use a proper guide or template for accurate cutting operations. T[...]

  • Page 23

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 19 out bottom of cut. 801 400-B 5-5. Sequence Of Cutting 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 . Raise trigger lock and press trigger . [...]

  • Page 24

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 20 801 400-B 5-6. Sequence Of Gouging Operation Raise trigger lock and press trigger . Pilot arc starts. Move tip to within approxi- mately 3/16 in (4.8 mm). Start gouging across workpiece surface. Maintain approximately a 45 ° angle to surface. Release trigger . Postflow [...]

  • Page 25

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 21 801 400-B 5-7. Sequence Of Piercing Operation Maintain approximately 90 ° torch position to surface, and continue cutting. Release trigger . Postflow continues for approx. 20 seconds after releasing trigger; arc can be instantly restarted during postflow by raising trig[...]

  • Page 26

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 22 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions . n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Each Us[...]

  • Page 27

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 23 6-2. Overload Protection: Status Lights & Checking Shield Cup Shutdown System If certain problems occur , a status light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). T urn power Off, and check for proper gas/air p[...]

  • Page 28

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 24 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[...]

  • Page 29

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 25 6-4. T roubleshooting Power Source No Ye s Is Power light flashing? Reset Power switch S1. No Ye s T urn Output control fully counterclockwise (see Section 4-12 ). Check for gas/air flow at torch. *Check Control board PC1, pressure switch, air filter , valve AS1, and air[...]

  • Page 30

    . A complete Parts List is available at www .HobartW elders.com OM-926 Page 26 6-5. T roubleshooting T orch T orch travel speed too slow; increase travel speed (see Section 5-5 ). Clean or replace torch consumables as necessary (see Section 6-3 ). Be sure work clamp is securely attached to workpiece. Ye s No Does arc go on and off while cutting? Do[...]

  • Page 31

    OM-926 Page 27 SECTION 7 − ELECTRICAL DIAGRAM 212 926-A Figure 7-1. Circuit Diagram[...]

  • Page 32

    OM-926 Page 28 SECTION 8 − P ARTS LIST 8-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Item No. Recommended Spare Parts Quanti ty 227877 FIL TER,AIR ELEMENT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216447 CABLE,WORK 25 FT 6 GA W/CLAMP STRAIN RLF [...]

  • Page 33

    OM-926 Page 29 195 1 10 ICE-40C 25ft T orch 195 1 1 1 ICE-40C 50ft T orch 1 183 427 Handle Assy , complete (1) 2 192 059 Main Body (1) 3 209 298 Leads, 25ft (1) 3 209 299 Leads, 50ft (1) 4 185 833 Switch Assembly w/spring (1) 5 171 248 Push Button Switch (1) 6 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) Part No. Item No. Descripti[...]

  • Page 34

    Notes W o r k l i ke a P r o! Pros wel d and cut safel y . Read t he safety rules at the beginning of this manual .[...]

  • Page 35

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2007−01 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 distributor and Hobart[...]

  • Page 36

    PRINTED IN USA © 2007 Hobart Welding Products. 2007−01 Hoba rt We lding Produc ts An I l li noi s T ool Works Company 600 W es t Main Street Troy , OH 45373 US A For T echni cal A ssistance: Call1-800-332-3281 For Literat ure Or Nearest Deal er: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered t[...]