OM-272 182B 2015−07 Processes Air Plasma Cutting Description Air Plasma Cutter AirForce 40i ™ And XT40R Torch File: Plasma Cutters www.HobartWelders.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom_2013−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
ELECTRIC SHOCK can kill. FUMES AND GASES can be hazardous. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input power. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any parts.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can burn. BATTERY EXPLOSION can injure. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. D Do not use plasma cutter to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose. FALLING EQUIPMENT can injure.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_2013−09fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
D Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation selon la norme OSHA 29 CFR 1910.147 (reportez−vous aux Principales normes de sécurité). D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, départementales et locales.
D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce ou ayez recours à une ventilation aspirante installée près de l’arc pour évacuer les vapeurs et les gaz. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquels est exposé le personnel. D Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs approuvé.
LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.
2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.
SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions . Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 3-2. Miscellaneous Symbols And Definitions . Some symbols are found only on CE products.
. A complete Parts List is available at www.HobartWelders.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2. Unit Specifications . Do not use information in unit specifications table to determine electrical service requirements.
. A complete Parts List is available at www.HobartWelders.com 4-2. Unit Specifications (Continued) Torch Mild Steel capacities (see Section 6-2 for cutting speeds vs material type and thickness) —— —— —— 5/8 in. at 9 ipm (229 mm/min)* —— —— Sever Cut Capacity (edge start) 7/8 in. (22 mm) —— —— Pierce Capacity 5/16 in. (8 mm) —— —— Rated Capacity (edge start) *Travel speeds are approximately 80% of maximum. 4-3.
. A complete Parts List is available at www.HobartWelders.com 4-4. Power Source Dimensions And Weight Dimensions And Weight 8-1/4 in. (210 mm) 31.4 lb (14.2 kg) including torch 11-1/4 in. (286 mm) 14-1/4 in. (362 mm) loc_2 3/96 - Ref. 244 405-A 4-5. Torch Dimensions And Weight Dimensions And Weight 2.2 lb (1.0 kg) 8-3/4 in. (222 mm) 1-3/16 in. (30 mm) 1-1/2 in. (38 mm) Ref. 253 554-A 4-6. Environmental Specifications IP Rating IP23CS This equipment is designed for outdoor use.
. A complete Parts List is available at www.HobartWelders.com SECTION 5 − INSTALLATION 5-1. Selecting A Location 18 in. (460 mm) ! ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Do not move or operate unit where it could tip. 18 in. (460 mm) loc_2 3/96 - Ref. 244 405-A 5-2. Connecting Gas/Air Supply . Use only clean, dry air with 90 to 120 psi (621 to 827 kPa) pressure.
. A complete Parts List is available at www.HobartWelders.com 5-4. Electrical Service Guide Elec Serv 2014−11 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
. A complete Parts List is available at www.HobartWelders.com 5-6. Connecting 240 VAC 1-Phase Input Power 1 =GND/PE Earth Ground 3 7 2 4 L1 L2 5 6 1 8 L1 L2 240 VAC, 1 Tools Needed: input4 2012−05 − 803 766-C / Ref.
. A complete Parts List is available at www.HobartWelders.com 5-6. Connecting 240 VAC 1-Phase Input Power (Continued) ! ! Installation must meet all National and Local Codes − have only qualified persons make this installation. 1 Input Power Cord 2 Disconnect Device (switch shown in the OFF position) Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.
. A complete Parts List is available at www.HobartWelders.com 5-7. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or Champion 10,000 Tools Needed: 2 3 3 4 4 7 240V 3/16 in.
. A complete Parts List is available at www.HobartWelders.com 5-8. Installing Alternative Plug . This procedure is necessary if the unit is to be connected to a 208/240 VAC receptacle that requires a plug that is different from the supplied plug. 2 3 1 6 7 4 5 1 Supplied 240 VAC Plug Cut cord close to plug.
. A complete Parts List is available at www.HobartWelders.com SECTION 6 − OPERATION 6-1. Controls 1 2 4 3 1 Output Control Use control to set cutting output. 2 Power Light 4 3 Trouble Lights (See Section 7-4) Use switch to turn unit On or Off.
. A complete Parts List is available at www.HobartWelders.com 6-2. Mild Steel Recommended Cut Speed . Aluminum and stainless steel cut speeds at these thicknesses may be reduced as much as 30%. Thickness Approximate Travel Speed* Inches Millimeters IPM mm/min 1/8 3.2 130 3292 1/4 6.4 52 1321 3/8 9.5 28 711 1/2 12.7 14 345 5/8 15.9 9 224 3/4 19.1 6 163 *Travel speeds are approximately 80% if maximum. The best cut quality is achieved by cutting near the table value.
. A complete Parts List is available at www.HobartWelders.com 6-4. Plasma Cutting System Practices ! Always connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. The pilot arc starts immediately when trigger is pressed. DO NOT start pilot arc without cutting as this shortens the service life of the nozzle and electrode. 90° Maintain approximately a 90° angle to the workpiece surface for proper cutting results.
. A complete Parts List is available at www.HobartWelders.com 6-5. Sequence Of Cutting Operation 90° Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. ! The pilot arc starts immediately when trigger is pressed. Raise trigger lock and press trigger. Pilot arc starts. Adjust torch speed so sparks go thru metal and out bottom of cut. For standard (shielded) cutting, place drag shield on edge of metal. For extended (non-shielded) cutting, use 1/8 in.
. A complete Parts List is available at www.HobartWelders.com 6-6. Sequence Of Piercing Operation ! The pilot arc starts immediately when trigger is pressed. 45° Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 90° Rotate torch to upright position approximately 90° to surface. When arc has pierced through workpiece, start cutting. Hold torch at approximately 45° to the workpiece. Raise trigger lock and press trigger. Pilot arc starts.
. A complete Parts List is available at www.HobartWelders.com SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. . Maintain more often during severe conditions.
. A complete Parts List is available at www.HobartWelders.com 7-3. Checking Or Replacing Filter Element ! Turn power Off, and disconnect input power plug from receptacle. Check to see that all diagnostic LED’s have stopped flashing before removing wrapper from unit. Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. 1 Filter Base 2 Filter 3 Filter Cup Unscrew filter cup from base. Remove cup. Unscrew filter element from base.
. A complete Parts List is available at www.HobartWelders.com 7-4. Status/Trouble Lights . Difficulty establishing a pilot arc may indicate consumables need to be cleaned or replaced. V POWER PRESSURE CUP TEMP Light Power Condition Status/Possible Cause On Input power is okay. Off When Power light is on, system is normal if these lights are off. Power Flashing rate is steady for 15 seconds or until torch trigger is pressed again, whichever comes first.
. A complete Parts List is available at www.HobartWelders.com 7-6. 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 been significantly reduced. Do not operate torch without a tip or electrode in place.
. A complete Parts List is available at www.HobartWelders.com 7-7. Torch And Work Cable Connections ! 6 7 Turn power Off, and disconnect input power plug from receptacle. Check to see that all diagnostic LED’s have stopped flashing before removing wrapper from unit. If torch or work cable needs to be removed or replaced, proceed as follows: 1 2 Power Source Remove wrapper from unit. Torch Connections 5 Remove existing torch cable from unit.
. A complete Parts List is available at www.HobartWelders.com 7-8. Troubleshooting Power Source Trouble Remedy No pilot arc; difficulty in establishing an 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). No cutting output; Power light off; status Place Power switch in On position. lights off; fan motor FM does not run. Place line disconnect device in On position (see Section 5-6).
. A complete Parts List is available at www.HobartWelders.com 7-9. Troubleshooting Torch Trouble Remedy Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 6-2). Clean or replace torch consumables as necessary (see Section 7-6). Be sure work clamp is securely attached to workpiece. Arc goes out while cutting. Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in. (1.6 mm) to 1/8 in. (3.
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1.
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SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts . For extended tip use, set Amperage control to 40. 271 907-A Figure 9-1. Consumable Parts For XT40R Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts . . . . . . . . . . . . . . . . . 268 923 . . . . . . . . . . . . . . . . . 227 877 . . . . . . . . . . . . . . . . . 272 527 . . . . . . . . . . . . . . . . . 262 557 . . . . . . . . . . . . . . . . . 770 793 . . . . . . . . . . . . . . . . . 770 791 . . . . . . . . . . . . .
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Notes
Effective January 1, 2015 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial number preface of MF or newer. Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST Service You 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.
Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, operation, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number. To locate a Service Center: Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy For Technical Assistance: Call 1-800-332-3281 7 AM to 5 PM EST − Monday through Friday Owner’s Record Please complete and retain with your personal records.
