HobartWelders AIRFORCE 27i AND XT30R TORCH Owner's manual

Brand: HobartWelders

Model: AIRFORCE 27i AND XT30R TORCH

Category: Welding System

Type: Owner's manual

www.HobartWelders.com

Description

OM-272 181B 2015−07

Processes

Air Plasma Cutting

Air Plasma Cutter

AirForce 27i

And XT30R Torch

™

File: Plasma Cutters

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1................................

1-1. Symbol Usage 1.................................................................

1-2. Plasma Arc Cutting Hazards 1......................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.......................

1-4. California Proposition 65 Warnings 4.................................................

1-5. Principal Safety Standards 4.......................................................

1-6. EMF Information 4................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5.........................

2-1. Signification des symboles 5.......................................................

2-2. Dangers liés au coupage à l’arc au plasma 5..........................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7

2-4. Proposition californienne 65 Avertissements 9.........................................

2-5. Principales normes de sécurité 9....................................................

2-6. Informations relatives aux CEM 9...................................................

SECTION 3 − DEFINITIONS 10..................................................................

3-1. Manufacturer’s Warning Label Definitions 10...........................................

3-2. Miscellaneous Symbols And Definitions 10............................................

SECTION 4 − SPECIFICATIONS 11..............................................................

4-1. Serial Number And Rating Label Location 11...........................................

4-2. Specifications 11..................................................................

4-4. Duty Cycle And Overheating 12......................................................

4-5. Power Source Dimensions And Weight 13.............................................

4-6. Torch Dimensions And Weight 13....................................................

4-7. Environmental Specifications 13.....................................................

SECTION 5 − INSTALLATION 14................................................................

5-1. Selecting A Location 14.............................................................

5-2. Connecting Gas/Air Supply 14.......................................................

5-3. Connecting Work Clamp 14.........................................................

5-4. Electrical Service Guide 15..........................................................

5-5. Extension Cord Data 15............................................................

5-6. Connecting 240 VAC 1-Phase Input Power 16..........................................

5-7. Multi−Voltage Plug (MVP) Connection 18..............................................

5-8. Connecting Unit To Input Power 19...................................................

5-9. Generator Or Inverter Requirements 19...............................................

SECTION 6 − OPERATION

20..................................................................

6-1. Controls 20.......................................................................

6-2. Cutting Speed 21..................................................................

6-3. Trigger Safety Lock 21.............................................................

6-4. Plasma Cutting System Practices 22.................................................

6-5. Sequence Of Cutting Operation 23...................................................

6-6. Sequence Of Piercing Operation 24..................................................

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 25.........................................

7-1. Routine Maintenance 25............................................................

7-3. Overload Protection 25.............................................................

7-4. Checking Or Replacing Filter Element 26..............................................

7-5. Status/Trouble Lights 27............................................................

7-6. Checking Shield Cup Shutdown System 27............................................

7-7. Checking/Replacing Retaining Cup, Tip, And Electrode 28...............................

7-8. Torch And Work Cable Connections 29................................................

7-9. Troubleshooting Power Source 30....................................................

7-10. Troubleshooting Torch 31...........................................................

SECTION 8 − ELECTRICAL DIAGRAM 33........................................................

SECTION 9 − PARTS LIST 35...................................................................

WARRANTY

Hobart is registered to

the ISO 9001 Quality

System Standard.

OM-272 181 Page 1

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. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Plasma Arc Cutting Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

Hot metal and sparks blow out from the cutting arc.

The flying sparks and hot metal, hot workpiece, and

hot equipment can cause fires and burns. Check

and be sure the area is safe before doing any cutting.

CUTTING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this

is not possible, tightly cover them with approved covers.

D Do not cut where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D Be alert that sparks and hot materials from cutting can easily go

through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that cutting on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not cut on containers that have held combustibles, or on closed

containers such as tanks, drums, or pipes unless they are properly

prepared according to AWS F4.1 and AWS A6.0 (see Safety Stan-

dards).

D Connect work cable to the work as close to the cutting area as prac-

tical to prevent cutting current from traveling long, possibly unknown

paths and causing electric shock, sparks, and fire hazards.

D Do not use plasma cutter to thaw frozen pipes.

D Never cut containers with potentially flammable materials inside −

they must be emptied and properly cleaned first.

D Do not cut where the atmosphere may contain flammable dust, gas,

or liquid vapors (such as gasoline).

D Do not cut pressurized cylinders, pipes, or vessels.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

D Do not locate unit on or over combustible surfaces.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any cutting.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

Touching live electrical parts can cause fatal shocks

or severe burns. The torch and work circuit are

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. Plasma arc cutting requires

higher voltages than welding to start and maintain the arc (200 to 400

volts dc are common), but may also use torches designed with safety

interlock systems which turn off the machine when the shield cup is

loosened or if tip touches electrode inside the nozzle. Incorrectly

installed or improperly grounded equipment is a hazard.

ELECTRIC SHOCK can kill.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats or

covers big enough to prevent any physical contact with the work or

ground.

D Do not touch torch parts if in contact with the work or ground.

D Turn off power before checking, cleaning, or changing torch parts.

D Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA CFR

1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to its

Owner’s Manual and national, state, and local codes.

D Check and be sure that input power cord ground wire is properly

connected to ground terminal in disconnect box or that cord plug is

connected to a properly grounded receptacle outlet − always verify

the supply ground.

D When making input connections, attach proper grounding conduc-

tor first.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord and ground conductor for dam-

age or bare wiring – replace immediately if damaged – bare wiring

can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or repaired cables.

D Do not wrap torch cable around your body.

D Ground the workpiece to a good electrical (earth) ground if required

by codes.

D Use only well-maintained equipment. Repair or replace damaged

parts at once.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Do not bypass or try to defeat the safety interlock systems.

D Use only torch(es) specified in Owner’s Manual.

D Keep away from torch tip and pilot arc when trigger is pressed.

D Clamp work cable with good metal-to-metal contact to workpiece

(not piece that will fall away) or worktable as near the cut as

practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

OM-272 181 Page 2

ELECTRIC SHOCK can kill.

SIGNIFICANT DC VOLTAGE exists in

inverter power sources AFTER the re-

moval of input power.

D Turn Off unit, disconnect input power, check voltage on input ca-

pacitors, and be sure it is near zero (0) volts before touching any

parts. Check capacitors according to instructions in Maintenance

Section of Owner’s Manual or Technical Manual before touching

any parts.

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 PARTS can injure.

Sparks and hot metal blow out from the cutting arc.

Chipping and grinding cause flying metal.

FLYING SPARKS can injure.

D Wear approved face shield or safety goggles with side shields.

D Wear proper body protection to protect skin.

D Wear flame-resistant ear plugs or ear muffs to prevent sparks from

entering ears.

Arc rays from the cutting process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin.

ARC RAYS can burn eyes and skin.

D Wear face protection (helmet or shield) with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks when

cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a

No. 9 shade (with No. 8 as minimum) for all cutting currents less

than 300 amperes. Z49.1 adds that lighter filter shades may be used

when the arc is hidden by the workpiece. As this is normally the case

with low current cutting, the shades suggested in Table 1 are pro-

vided for the operator’s convenience.

D Wear approved safety glasses with side shields under your helmet

or shield.

D Use protective screens or barriers to protect others from flash, glare

and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes Minimum Shade Number

Below 20

20 − 40

40 − 60

60 − 100

Prolonged noise from some cutting applications can

damage hearing if levels exceed limits specified by

OSHA (see Safety Standards).

NOISE can damage hearing.

D Use approved ear plugs or ear muffs if noise level is high.

D Warn others nearby about noise hazard.

FUMES AND GASES can be hazardous.

Cutting produces fumes and gases. Breathing

these fumes and gases can be hazardous to

your health.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove cutting fumes and gases. The recommended way to

determine adequate ventilation is to sample for the composition and

quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.

D Read and understand the Safety Data Sheets (SDSs) and the man-

ufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

D Work in a confined space only if it is well ventilated, or while wearing

an air-supplied respirator. Fumes from cutting and oxygen depletion

can alter air quality causing injury or death. Be sure the breathing air

is safe.

D Do not cut in locations near degreasing, cleaning, or spraying oper-

ations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not cut on coated metals, such as galvanized, lead, or cadmium

plated steel, unless the coating is removed from the cutting area, the

area is well ventilated, and while wearing an air-supplied respirator.

The coatings and any metals containing these elements can give off

toxic fumes when cut.

D Do not cut containers with toxic or reactive materials inside or

containers that have held toxic or reactive materials − they must be

emptied and properly cleaned first.

PLASMA ARC can injure.

The heat from the plasma arc can cause serious

burns. The force of the arc adds greatly to the burn

hazard. The intensely hot and powerful arc can

quickly cut through gloves and tissue.

D Keep away from the torch tip.

D Do not grip material near the cutting path.

D The pilot arc can cause burns − keep away from torch tip when trig-

ger is pressed.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

D Point torch away from your body and toward work when pressing

the torch trigger − pilot arc comes on immediately.

D Turn off power source and disconnect input power before disas-

sembling torch or changing torch parts.

D Use only torch(es) specified in the Owner’s Manual.

Compressed gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of metalworking pro-

cesses, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flame, sparks, and arcs.

D Install and secure cylinders in an upright position by chaining them

to a stationary support or equipment cylinder rack to prevent falling

or tipping.

D Keep cylinders away from any cutting or other electrical circuits.

D Never allow electrical contact between a plasma arc torch and a

cylinder.

D Never cut on a pressurized cylinder − explosion will result.

D Use only correct compressed gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and as-

sociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient number

of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-272 181 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

HOT PARTS can burn.

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.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or wear

face shield.

ELECTRIC AND MAGNETIC FIELDS (EMF)

can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating

operations.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.

D Reduce amperage (thickness) or reduce duty

cycle before starting to cut again.

EXPLODING HYDROGEN hazard.

D When cutting aluminum underwater or with the

water touching the underside of the aluminum,

free hydrogen gas may collect under the work-

piece.

D See your cutting engineer and water table instructions for help.

BATTERY EXPLOSION can injure.

D Do not use plasma cutter to charge batteries or

jump start vehicles unless it has a battery char-

ging feature designed for this purpose.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift unit.

D If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manually

lifting heavy parts or equipment.

FIRE OR EXPLOSION hazard.

D Do not locate unit on, over, or near combustible

surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

H.F. RADIATION can cause interference.

D High frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with elec-

tronic equipment perform this installation.

D The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the equipment

at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC CUTTING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D To reduce possible interference, keep cables as short as possible,

close together, and down low, such as on the floor.

D Locate cutting operation 100 meters from any sensitive electronic

equipment.

D Be sure this cutting power source is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures such

as moving the machine, using shielded cables, using line filters, or

shielding the work area.

OM-272 181 Page 4

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. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents

(phone: 1-877-413-5184, website: www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting and Gouging, Ameri-

can Welding Society Standard AWS C5.2, from Global Engineering

Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com-

bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184,

website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 14501 George Carter Way, Suite

103, Chantilly, VA 20151 (phone: 703-788-2700, website:

www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, from U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone

for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). The current from arc welding (and allied pro-

cesses including spot welding, gouging, plasma arc cutting, and

induction heating operations) creates an EMF field around the welding

circuit. EMF fields may interfere with some medical implants, e.g. pace-

makers. Protective measures for persons wearing medical implants

have to be taken. For example, restrict access for passers−by or con-

duct individual risk assessment for welders. All welders should use the

following procedures in order to minimize exposure to EMF fields from

the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the weld-

ing circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

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OM-272 181 Page 9

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

25249.5 et suivants)

Ce produit contient des éléments chimiques, dont le plomb,

reconnus par l’État de Californie pour leur caractère

cancérogène ainsi que provoquant des malformations

congénitales ou autres problèmes de procréation. Se laver les

mains après toute manipulation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents

(phone: 1-877-413-5184, website: www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting and Gouging,

American Welding Society Standard AWS C5.2, from Global

Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from

Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held

Combustibles, American Welding Society Standard AWS A6.0, from

Global Engineering Documents (phone: 1-877-413-5184,

website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555,

website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 14501 George Carter Way, Suite

103, Chantilly, VA 20151 (phone: 703-788-2700, website:

www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 25 West 43rd Street, New York, NY 10036 (phone:

212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, from U.S. Government Printing Office,

Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA

15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional

Offices—phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The

National Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs

électromagnétiques (CEM) à certains endroits. Le courant issu d’un

soudage à l’arc (et de procédés connexes, y compris le soudage par

points, le gougeage, le découpage plasma et les opérations de

chauffage par induction) crée un champ électromagnétique (CEM)

autour du circuit de soudage. Les CEM peuvent créer des interférences

avec certains implants médicaux comme des stimulateurs cardiaques.

Des mesures de protection pour les porteurs d’implants médicaux

doivent être prises: Limiter par exemple tout accès aux passants ou

procéder à une évaluation des risques individuels pour les soudeurs.

Tous les soudeurs doivent appliquer les procédures suivantes pour

minimiser l’exposition aux CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec

du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre

corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni

s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le

dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de

s’approcher des opérations de soudage à l’arc, de soudage par points,

de gougeage, du coupage plasma ou de chauffage par induction. Si le

médecin approuve, il est recommandé de suivre les procédures

précédentes.

OM-272 181 Page 10

SECTION 3 − DEFINITIONS

3-1. Manufacturer’s Warning Label Definitions

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

Amperes

Plasma Arc Cutting

(PAC)

Adjust Air/Gas

Pressure

Low Air Pressure

Light

Volts Increase

No − Do Not Do

This

Temperature

Protective Earth

(Ground)

Single Phase Constant Current Voltage Input

On Off Percent Direct Current

Rated No Load

Voltage (OCV) U

Primary Voltage

Conventional Load

Voltage

Line Connection

1max

Rated Maximum

Supply Current

Rated Welding

Current

Duty Cycle

Single Phase

Static Frequency

Converter-

Transformer-

Rectifier

Degree Of

Protection

Loose Shield Cup Input

Hertz

1eff

Maximum Effective

Supply Current

power factor

Suitable for Some

Hazardous

Locations

Power Rating,

Product Of Voltage

And Current (KVA)

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 11

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. Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-4 and 5-6 for information on con-

necting input power.

Power Supply

Input

Rated AC phase (PH) and line frequency (Hz) 1 PH 60 Hz — —

Rated Input Voltage (U

) and rated Input Current (I

)

and I

eff at rated output. I

eff used to determine

power cord rating

Volts AC RMS − (U

) Amps RMS − (I

) I

eff

120 (20 A) at 20% Duty Cycle 28.8 12.9

120 (15 A) at 35% Duty Cycle 20.6 12.2

240 at 35% Duty Cycle 13.9 8.3

Power Factor/KVA/KW at Rated Output

Volts AC RMS − (U

) Power Factor KVA/KW

120 Volts (20 A) 0.93 3.4/3.2

120 Volts (15 A) 0.92 2.5/2.3

240 Volts 0.91 3.3/3.0

Peak KW at Arc Stretch 5.4 kW at U1 = 240 Volts — —

Output

Rated Open Circuit Voltage (U0) Type 400 Volts DC/Electrode Negative — — — —

Output Characteristic Constant Current — — — —

Output Current Range 14-27 A — — — —

Output Current and Voltage Rating at Rated Input

Voltage (I

and U

at U

)

Amps DC − (I

) Volts DC − (U

) Volts AC − (U

)

27 A 91 Volts DC 240 Volts

27 A 91 Volts DC 120 Volts (20 A)

20 A 88 Volts DC 120 Volts (15 A)

Duty Cycle at 1045 F (405 C) at rated conditions (U

, I

) based on a 10 minute period

Duty Cycle % Amps DC − (I

) Volts AC RMS − (U

)

35 27 A 240 Volts

20 27 A 120 Volts (20 A)

35 20 A 120 Volts (15 A)

General

Operating Temperature 5° to 104° F (−15° to 40° C) — — — —

IP Code − Degree of protection provided by enclosure

IP23CS** — — — —

IP − International Protection — — — —

2 − No ingress of foreign objects  12.5 mm (0.5 in.)

— — — —

3 − No harmful ingress spraying water — — — —

C − AC line circuits protected against ingress of tool

2.5 mm dia x 100 mm long (0.1 in. x 4 in.)

— — — —

S − Fan stationary during water test — — — —

Toppling or tilting Up to 15° incline — — — —

Gas Type Air — — — —

Gas Quality Clean, moisture-free, oil-free — — — —

Gas Inlet Pressure and Flow 3.0 SCFM (85 L/min)

90 PSI (621 kPa)

Min

120 PSI (827 kPa)

Max

Gas Filtering Particulates to 5 microns — — — —

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 12

4-3. Unit Specifications (Continued)

Torch

Mild Steel capacities (see Section 6-2 for cutting

speeds vs material type and thickness)

— — — — — —

Rated Capacity (edge start) 3/8 in. at 14 ipm (356 mm/min)* 27 Amps — —

Sever Cut Capacity (edge start) 5/8 in. 27 Amps — —

Pierce Capacity 3/16 in. 27 Amps — —

Pierce Capacity 1/8 in. 20 Amps

*Travel speeds are approximately 80% of maximum.

4-4. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can cut at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, Temperature

trouble light goes On, and cooling

fan runs. Wait fifteen minutes for

unit to cool or temperature light to

go off. Reduce amperage or duty

cycle before cutting.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

Overheating

sduty1 5/95 / Ref. 244 405-A

3-1/2 Minutes Cutting 6-1/2 Minutes Resting

35% duty cycle

For Units Connected to a 120 Volt Circuit

or a 240 Volt Circuit:

35% Duty Cycle At 27 amperes, 92 volts DC

Minutes

Reduce Duty Cycle

Notes

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 13

14-1/4 in.

(362 mm)

4-5. Power Source Dimensions And Weight

loc_2 3/96 - Ref. 244 405-A

8-1/4 in.

(210 mm)

11-1/4 in.

(286 mm)

Dimensions And Weight

29 lb (13.2 kg)

including torch

4-6. Torch Dimensions And Weight

Ref. 253 554-A

2.2 lb (1.0 kg)

1-3/16 in.

(30 mm)

8-3/4 in.

(222 mm)

1-1/2 in.

(38 mm)

Dimensions And Weight

4-7. Environmental Specifications

IP Rating

IP23CS

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for cutting outside during precipitation unless

sheltered.

IP23CS 2014−09

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 14

SECTION 5 − INSTALLATION

5-1. Selecting A Location

loc_2 3/96 - Ref. 244 405-A

! Do not move or operate unit

where it could tip.

18 in.

(460 mm)

18 in.

(460 mm)

! Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

5-2. Connecting Gas/Air Supply

Ref. 244 423-A

. Use only clean, dry air with 90

to 120 psi (621 to 827 kPa)

pressure.

1 Gas/Air Inlet Opening

2 Hose

3 Teflon Tape

Obtain hose with 1/4 NPT right-

hand thread fitting. Wrap threads

with teflon tape (optional) or apply

pipe sealant, and install fitting in

opening. Route hose to gas/air

supply.

Tools Needed:

From

Gas/Air

Supply

9/16 in.

5-3. Connecting Work Clamp

. Do not connect work clamp to

the portion of the workpiece

that will fall when cut.

1 Work Clamp

2 Workpiece

Connect work clamp to a clean,

paint-free location on workpiece, as

close to cutting area as possible.

Ref 803 640-A

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 15

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 recommenda-

tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating

of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

60 Hz Single Phase

Input Voltage (V) 120 240

Input Amperes (A) At Rated Output

A 15 or 20

ampere individual

circuit protected

by time-delay

fuses or circuit

breaker is re-

quired.

See Sections 4-2

and 5-8

13.9

Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

(28)

Min Grounding Conductor Size In AWG

Reference: 2014 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.

2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).

4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

5-5. Extension Cord Data

. When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.

Input Voltage

Input Power

Phase

Hertz Conductor Size Max. Cord Length

120 V 1 60 14 AWG 22 ft (7 m)

240 V 1 60 14 AWG 92 ft (28 m)

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 16

5-6. Connecting 240 VAC 1-Phase Input Power

input4 2012−05 − 803 766-C / Ref. 802 443-A

=GND/PE Earth Ground

Tools Needed:

240 VAC, 1

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 17

input4 2012−05

! Installation must meet all National and

Local Codes − have only qualified per-

sons make this installation.

! Disconnect and lockout/tagout input

power before connecting input con-

ductors from unit. Follow established

procedures regarding the installation

and removal of lockout/tagout

devices.

! Always connect green or green/yellow

conductor to supply grounding termi-

nal first, and never to a line terminal.

See rating label on unit and check input volt-

age available at site.

1 Input Power Cord

2 Disconnect Device (switch shown in the

OFF position)

3 Disconnect Device Grounding Terminal

4 Disconnect Device Line Terminals

5 Black And White Input Conductor (L1

And L2)

6 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding

conductor to disconnect device grounding

terminal first.

Connect input conductors L1 and L2 to dis-

connect device line terminals.

7 Over-Current Protection

Select type and size of over-current protec-

tion using Section 5-4 (fused disconnect

switch shown).

8 Receptacle (NEMA 6-50R)

Customer Supplied

Close and secure door on disconnect device.

Follow established lockout/tagout proced-

ures to put unit in service.

5-6. Connecting 240 VAC 1-Phase Input Power (Continued)

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 18

5-7. Multi−Voltage Plug (MVP) Connection

Selecting Plug

1 Power Cord Connector From

Welding Power Source

Select plug for power supply receptacle

available at site. Not all plugs shown are

provided as standard with unit.

2 Plug − NEMA Type 5−15P

3 Receptacle − NEMA Type 5−15R

(Customer Supplied)

4 Plug − NEMA Type 5−20P (Optional)

5 Receptacle − NEMA Type 5−20R

(Customer Supplied)

6 Plug − NEMA Type 6−50P

7 Receptacle − NEMA Type 6−50R

(Customer Supplied)

! Follow electrical service guide for

230 VAC in Section 5-4. Do not use

plug rating to size branch circuit

protection.

Connecting Plug To Power Cord

Align arrow on plug with arrow on power

cord connector. Push together.

Tighten threaded collar. As threaded collar

is tightened, push plug onto adapter until

collar is completely tight.

Connect plug to receptacle.

MVP Plug1 2012−03 / Ref. 803 812-C

! Do not cut off power cord con-

nector and rewire. The power

cord connector and plugs will

work with standard NEMA re-

ceptacles. Modifying power

cord, connector, and plugs will

void product warranty.

Selecting Plug

Connecting Plug To Power Cord

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 19

5-8. Connecting Unit To Input Power

! Installation must meet all National

and Local Codes − have only

qualified persons make this

installation.

! Special installation may be required

where gasoline or volatile liquids

are present − see NEC Article 511 or

CEC Section 20.

NOTICE − The Auto-Line circuitry in this

unit automatically adapts the power source

to the primary voltage being applied, either

120 or 240 VAC.

For 120 volts AC input power, a 15 or 20

ampere individual branch circuit protected

by time-delay fuses or circuit breaker is

required. For 240 volts AC input power, see

Section 5-4.

1 Power Cord Connector

2 Plug − NEMA Type 5−15P

3 Receptacle − NEMA Type 5−15R

(Customer Supplied)

4 Plug − NEMA Type 6−50P

5 Receptacle − NEMA Type 6−50R

(Customer Supplied)

Select plug for power supply receptacle

available at site. Install plug onto power

cord adapter. As threaded collar is tight-

ened, push plug onto adapter until collar is

completely tight.

Connect plug to receptacle.

18 in.

(460 mm)

input 6 2011−03 − Ref. 244 423-A / Ref. 804 504-A

18 in.

(460 mm)

5-9. Generator Or Inverter Requirements

. Generator or inverter operation varies by manufacturer. The power light on the cutter will flash and the unit will not provide output if input voltage

drops below 92 volts AC (see Section 4-2).

Minimum auxiliary power

requirement at rated cutting

capacity [3/8 in. (9.5 mm) mild steel]

is 6 KW continuous/6.5 KW peak at

120 volts AC.

! Engine Control Switch must be set at “RUN”

position − not “RUN/IDLE”.

! Set generator Fine Adjustment Control

to 10 for maximum auxiliary power.

Generator settings, if applicable.

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 20

SECTION 6 − OPERATION

6-1. Controls

1 Output Control

Use control to set cutting output.

If 22-27 amperes of cutting output is used

with 120 VAC input power, and the overload

protection on the input power circuit fre-

quently opens, either reduce the cutting out-

put and/or the cut time or find more adequate

power (see Section 4-2).

2 Power Light

3 Trouble Lights (See Section 7-5)

4 Power Switch

Use switch to turn unit On or Off.

269 709-A

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 21

6-2. Cutting Speed

Recommended Cut Speeds At 27 Amperes Output

Mild Steel

Thickness Recommended Cut Speeds*

Inches mm ipm mm/min

16 ga 1.5 192 4,877

1/8 3.2 71 1,808

1/4 6.4 25 630

3/8 9.5 14 345

1/2 12.7 6 163

*Recommended Cut Speed is approximately 80% of maximum.

. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

Recommended Cut Speeds At 20 Amperes Output

Mild Steel

Thickness Recommended Cut Speeds*

Inches mm ipm mm/min

16 ga 1.5 134 3,414

1/8 3.2 44 1,118

1/4 6.4 16 406

3/8 9.5 8 203

*Recommended Cut Speed is approximately 80% of maximum.

. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

6-3. Trigger Safety Lock

1 Trigger

Trigger Locked

Trigger Unlocked

Ref. 253 554-A

. A complete Parts List is available at www.HobartWelders.com

OM-272 181 Page 22

Ref. 254 087-A

6-4. Plasma Cutting System Practices

Pulling rather than pushing the torch

makes cutting easier. Use a proper guide

or template for accurate cutting operations.

! The pilot arc starts immediately

when trigger is pressed.

Maintain approximately a 90

° angle to the

workpiece surface for proper cutting results.

Always connect work clamp to a clean,

paint-free location on workpiece, as close to

cutting area as possible.

90°

DO NOT start pilot arc without cutting

as this shortens the service life of the

nozzle and electrode.

Sparks should pass through the workpiece

and out the bottom when cutting.

If sparks flare back from surface, this

usually is an indication that either travel

speed is too fast or amperage is set too low.

When doing extended (non-shielded)

cutting, maintain approximately 1/16 in.

standoff between electrode and surface.

1/16 in.

(1.6 mm)

DO NOT put pressure on shield when

drag cutting; instead, slide shield along

the surface for proper cutting results.

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HobartWelders AIRFORCE 27i AND XT30R TORCH Owner's manual

Brand: HobartWelders

Model: AIRFORCE 27i AND XT30R TORCH

Category: Welding System

Type: Owner's manual

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