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Hobart Welding Products OM-928 manual

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Table of contents for the manual

  • Page 1

    AirForce 250A And Ice-12C T orch Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM-928 198 842F January 2003 Specifications Covered by this Manual: 500 436 and 500 437 [...]

  • 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-928 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_9/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n 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-928 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-928 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 p[...]

  • Page 8

    OM-928 Page 4 1-4. 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 o f Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Practices for Plasma Arc [...]

  • Page 9

    OM-928 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 . . Signif[...]

  • Page 10

    OM-928 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 pin[...]

  • Page 11

    OM-928 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’absteni[...]

  • Page 12

    OM-928 Page 8 1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, 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 so[...]

  • Page 13

    OM-928 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications For Power Source Primary V olts Primary Amperes Primary Service (Recommended) Secondary V olts (DC) Secondary Amperes KW KV A Power Factor Max** OCV (DC) 120 20.32 (0.25*) 20A 11 0 12 2.01 2.44 0.82 353 *While idling **10% High line condition 2-2. Specifications For T orch Air-cooled to[...]

  • Page 14

    OM-928 Page 10 2-4. 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) 18 in (457 mm) 2-5. Selecting A Location loc_2 3/96 - Ref. 802 588-A / 802 589-A 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 pow[...]

  • Page 15

    OM-928 Page 1 1 2-6. 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 2-7. Connecting Input Power 802 589-A Check input voltage available at site. 1 Grounded Receptacle A 120 volt, 20 ampere individual branch circuit protected by time[...]

  • Page 16

    OM-928 Page 12 SECTION 3 – OPERA TION 3-1. Controls 2 3 1 OFF ON POWER CUP TEMP INPUT VOL T AGE 1 Power Switch 2 Power Light Us e light to tell if unit is energized and ready to operate. Light goes of f if input power is not with specified range (see trouble light infor- mation). 3 Trouble Light T rouble light comes on for the following condition[...]

  • Page 17

    OM-928 Page 13 3-3. T rigger Safety Lock T rigger Locked T rigger Unlocked 1 T rigger 801 545-A 1 out bottom of cut. 801 400-A 3-4. 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[...]

  • Page 18

    OM-928 Page 14 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check T orch T ip, Electrode, And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Unreadable Labels Replace Cracked Parts T orch Bo[...]

  • Page 19

    OM-928 Page 15 4-2. T rouble Light And Checking Shield Cup Shutdown System If certain problems occur , the trouble light comes on, and output stops. 1 T rouble Light a Lights if shield cup is loose. Turn power Off, and check shield cup connection (see Item 2 below). Power must be reset whenever the cup shutdown is activated. Check shield cup shutdo[...]

  • Page 20

    OM-928 Page 16 4-3. 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 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. Sl[...]

  • Page 21

    OM-928 Page 17 4-4. 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 has[...]

  • Page 22

    OM-928 Page 18 4-5. T roubleshooting Power Source Connect unit to proper input voltage. (see Section 2-7). 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 3-1). No Ye s Is the cooling fan running? Check Power switch S1, relay CR2, and thermistor R1. No[...]

  • Page 23

    OM-928 Page 19 4-6. T roubleshooting T orch T orch travel speed too slow; increase travel speed (see Section 3-2). Clean or replace torch consumables as necessary (see Section 4-4). Be sure work clamp is securely attached to workpiece. Ye s No Does arc go on and of f while cutting? Does arc go out while cutting? No Ye s Be sure work clamp is secure[...]

  • Page 24

    OM-928 Page 20 SECTION 5 – ELECTRICAL DIAGRAM Figure 5-1. Circuit Diagram 202 707[...]

  • Page 25

    OM-928 Page 21 SECTION 6 – P ARTS LIST Figure 6-1. Main Assembly . Hardware is common and not available unless listed. 802 591-D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 25 24 26 27 28 29 30 17 18 31[...]

  • Page 26

    OM-928 Page 22 Description Part No. Item No. Figure 6-1. Main Assembly Quanti ty Dia. Mkgs. 1 +195 621 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 208 015 HANDLE, carrying 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 27

    OM-928 Page 23 1 183 427 Handle Assy , left and right w/screws (1) 2 171 248 Pushbutton Switch (1) 3 196 931 Leads, 20ft (1) 4 196 930 Label, ICE-12C (1) 5 196 932 Main Body (1) 6 185 833 Switch A ssy w/Spring (1) 190 220 Spring, trigger assy (1) 169 231 Grease, silicone (1) 196 923 T orch, replacement (1) Part No. Item No. Description 1 2 3 1 5 6 [...]

  • Page 28

    Notes[...]

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    Notes[...]

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    Notes[...]

  • Page 31

    Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 6/02 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 32

    PRINTED IN USA  2003 Hobart Welding Products. 1/03 Hoba rt We lding Product s An I l li noi s T ool Works Com pany 600 W es t Main St reet Troy , OH 45373 USA For T ech nical Assistance: 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 to or[...]