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Hobart Welding Products OM-230 455D manual

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Table of contents for the manual

  • Page 1

    AirForce 250ci A n d H P - 2 5 T o r c h Processes Description Air Plasma Cutting Air Plasma Cutter OM-230 455D 2008-07 ™ 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-230 455 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _4/05  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.  Marks a special safet[...]

  • Page 6

    OM-230 455 Page 2  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 [...]

  • Page 7

    OM-230 455 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance HOT P ARTS can cause severe burns.  Do not touch hot parts bare handed.  Allow cooling period before working on torch.  T o handle hot parts, use proper tools and/or wear heavy , insulated welding gloves and clothing to prevent burns. MOVING P ARTS can c[...]

  • Page 8

    OM-230 455 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 AWS C5.2, from Global Engineering Documents (phone: 1-877[...]

  • Page 9

    OM-230 455 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 4/05  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 ! Ce[...]

  • Page 10

    OM-230 455 Page 6  N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée.  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. [...]

  • Page 11

    OM-230 455 Page 7  Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique.  Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille.  Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait.  Utilisez uniquement des bo[...]

  • Page 12

    OM-230 455 Page 8 LE COUP AGE Ã L ’ARC peut causer des interférence.  L ’énergie électromagnétique peut gêner le fonction- nement d’appareils électroniques comme des ordi- nateurs et des robots.  Pour réduire la possibilité d’interférence, maintenir les câbles aussi courts que possible, les grouper , et les poser aussi bas [...]

  • Page 13

     A complete Parts List is available at www .HobartW elders.com OM-230 455 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) Sing[...]

  • Page 14

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications For Power Source Primary V olts Primary Amperes Duty Cycle Individual Branch Primary Service (Recommended) Secondary V olts (DC) Secondary Amperes KW KV A Mild Steel Rated Cutting Capacity Power Factor Max** OCV (DC)[...]

  • Page 15

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 1 1 4-4. T orch Dimensions And Weight Ref. 801 397-A 3.0 lb (1.4 kg) 1 in (25 mm) 8-3/8 in (213 mm) 1-3/8 in (35 mm) 12-1/4 in (31 1 mm) 4-5. Selecting A Location loc_2 3/96 - Ref. 804 852-A 1 Lifting Handle Use handle to lift unit. 2 120 V AC, 20 A Receptacle Locate [...]

  • Page 16

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 12 4-6. Connecting Work Clamp  Do not connect work clamp to the portion of the workpiece that will fall when cut. 1 W ork Clamp 2 W orkpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 1 2 Ref 803 915-A 4-7[...]

  • Page 17

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 13 4-9. Connecting Input Power Ref. 804 852-A / Ref. 803 766-B Check input voltage available at site. 1 Grounded Receptacle A 120 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required (see Section 4- 7 ). 2 Plug From Un[...]

  • Page 18

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 14 4-1 1. Cable Management Strap 804 885-A 1 Cable Management Strap Coil cables together and secure to unit using the cable management strap. 1 4-12. Electrode Wrench Ref. 804 885-A 1 Cable Management Strap 2 Electrode W rench Th e electrode wrench is fastened to the [...]

  • Page 19

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 15 SECTION 5 − OPERA TION 5-1. Controls 2 230 442-B 1 1 Power Switch The cooling fan will run for a f ew sec onds after the pow er switc h is plac ed in the OFF position in or der t o disc harge internal circ uitry . 2 Power Light Us e light to tell if unit is energ[...]

  • Page 20

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 16 Ref 803 915-A / Ref. 804 848-A 5-3. Plasma Cutting System Practices Pulling rather than pushing the torch makes cutting easier . Use a proper guide or template for accurate cutting operations. Maintain approximately a 90 ° angle to the workpiece surface for proper[...]

  • Page 21

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 17 804 848-A 5-4. Sequence Of Cutting Operation EXAMPLE Of Cutting Operation  Moisture from the compressor will form in the air line and at the torch. It will be normal to sometimes see moisture come out the end of the torch. Place tip near work.  Keep tip 1/16 [...]

  • Page 22

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 18 Ref. 804 848-A 5-5. Sequence Of Cutting Using Stand-off Guide EXAMPLE Of Cutting Using Stand-off Guide  Moisture from the compressor will form in the air line and at the torch. It will be normal to sometimes see moisture come out the end of the torch. Place stan[...]

  • Page 23

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 19 Ref. 803 640-A / 801 400-B 5-6. Sequence Of Piercing Operation Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. Hold torch at an angle to the workpiece. Press trigger . Pilot arc starts. Move torch to upright po[...]

  • Page 24

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 20 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance  Disconnect power before maintaining.  Maintain more often during severe conditions .  = Check  = Change  = Clean  = Replace * T o be done by Factory Authorized Service Agent[...]

  • Page 25

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 21 6-2. T rouble Lights And Checking Shield Cup Shutdown System 1 Power Light Light is steady if input power is okay . Light flashes if input power is less t h a n 9 2 v o l t s a c o r g r e ater than 136 volts ac. Light stops flashing 15 seconds after condition is c[...]

  • Page 26

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 22 6-3. Checking/Replacing Retaining Cup, Tip, And Electrode A good practice is to replace both the tip and electrode at the same time. Ref. 804 851-A T urn Of f power source. 1 Shield Cup Remove shield cup. Check cup for cracks, and replace if necessary . 2 O-Ring Ch[...]

  • Page 27

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 23 6-4. Compressor Filter Cleaning And Replacement  T urn Off power source, and disconnect input power . 1 Power Source 2 Compressor Filter Remove wrapper from unit. Unscrew filter from compressor . Clean debris from filter surface or replace filter , if necessary [...]

  • Page 28

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 24 6-5. T orch And Work Cable Connections  T urn Off power source, and disconnect input power . If torch or work cable needs to be removed or replaced, proceed as follows: 1 Power Source Remove wrapper from unit. T orch Connections Remove existing torch cable from [...]

  • Page 29

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 25 6-6. T roubleshooting Power Source Connect unit to proper input voltage. (see Section 4-9). Ye s No Is input power connected to correct line voltage? Is Power switch in the On position? Place Power switch in the On position. (see Section 5-1 ). No Ye s Is Power lig[...]

  • Page 30

     A complete Parts List is available at www .HobartW elders.com OM-230 455 Page 26 6-7. T roubleshooting T orch T orc h t ravel speed too slow ; incr ease travel s peed (see Sec tions 5-3, 5-4 , a nd 5-6) . Clean or r eplace torc h cons umables as nec essar y (see Section 6-3). Be sure work clamp is securely attac hed to a clean (paint and rus t [...]

  • Page 31

    OM-230 455 Page 27 SECTION 7 − ELECTRICAL DIAGRAM 230 449-C Figure 7-1. Circuit Diagram[...]

  • Page 32

    OM-230 455 Page 28 SECTION 8 − P ARTS LIST 8-1. Recommended Spare Parts Description Part No. Item No. Recommended Spare Parts Quanti ty Dia. Mkgs. 232 647 TORCH, HP-25 16.4ft (5 m) hand held (replacement) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 820 CLAMP , work 1 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 33

    Notes 229895 MA TERIAL THICKNESS GAUG E[...]

  • Page 34

    Notes[...]

  • Page 35

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2007−01 Service Y ou 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 Pr oduct s An I l li noi s T ool Works Company 600 W est Mai n S treet Troy , OH 45373 USA For T echnical Assi stance: 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[...]