Hobart AIRFORCE 40I AND XT40R TORCH User guide

OM-272 182B 2015−07

Processes

Description

Air Plasma Cutter

™

AirForce 40i

Air Plasma Cutting

And XT40R Torch

www.HobartWelders.com

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. Additional Safety Symbols And Definitions 10..........................................

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

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

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

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

4-3. Duty Cycle And Overheating 12......................................................

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

4-5. Torch Dimensions And Weight 13....................................................

4-6. 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. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat,

5-8. Installing Alternative Plug 19.........................................................

SECTION 6 − OPERATION 20..................................................................

6-1. Controls 20

6-2. Mild Steel Recommended Cut 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............................................................

7-2. Checking Or Replacing Filter Element 26..............................................

7-3. Status/Trouble Lights 27............................................................

7-4. Checking Shield Cup Shutdown System 27............................................

7-5. Checking/Replacing Retaining Cup, Tip, And Electrode 28...............................

7-6. Torch And Work Cable Connections 29................................................

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

7-8. Troubleshooting Torch 31...........................................................

SECTION 8 − ELECTRICAL DIAGRAM 32........................................................

SECTION 9 − PARTS LIST 34...................................................................

WARRANTY

Trailblazer Or Champion 10,000 18...................................................

.......................................................................

Hobart is registered to
the ISO 9001 Quality
System Standard.

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 ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

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.

CUTTING can cause fire or explosion.

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.

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 Stan­dards).

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.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

ELECTRIC SHOCK can kill.

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

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.

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.

live when power is on. Plasma arc cutting requires

OM-272 182 Page 1

ELECTRIC SHOCK can kill.

FUMES AND GASES can be hazardous.

SIGNIFICANT DC VOLTAGE exists in
inverter power sources AFTER the re­moval 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.

EXPLODING PARTS can injure.

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.

FLYING SPARKS can injure.

Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.

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 can burn eyes and skin.

Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that 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 pro­vided 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

#4
#5
#6
#8

NOISE can damage hearing.

Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).

D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.

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.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of metalworking pro­cesses, be sure to treat them carefully.

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 as­sociated 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-272 182 Page 2

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 work­piece.

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 char­ging 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-272 182 Page 3

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.)

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: [phone], 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: [phone], 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: [phone], 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: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], 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: [phone], website:
www.cganet.com).

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.

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: [phone], 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: [phone], 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: [phone]) (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: [phone], 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 pro­cesses 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. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con­duct 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 weld­ing 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 recom­mended.

OM-272 182 Page 4

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.

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.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

. Indique des instructions spécifiques.

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

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 1-5. Veuillez lire et respecter
toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.

LE COUPAGE présente un risque de
feu ou d’explosion.

Des particules de métal chaud et des étincelles
peuvent jaillir de la pièce au moment du coupage.
Les étincelles et le métal chaud, la pièce à couper

feu ou des brûlures. Avant de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.

D Déplacez toute matière inflammable se trouvant à l’intérieur d’un

périmètre de 10,7 m (35 pi) de la pièce à couper. Si cela est
impossible, vous devez les couvrir avec des housses approuvées
et bien ajustées.

D Ne coupez pas dans un endroit où des étincelles pourraient

atteindre des matières inflammables.

D Protégez−vous, ainsi que toute autre personne travaillant sur les

lieux, contre les étincelles et le métal chaud.

D Assurez−vous qu’aucune étincelle ni particule de métal ne peut se

glisser dans de petites fissures ou tomber dans d’autres pièces.

D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours

un extincteur à la portée de la main.

D Si vous coupez sur un plafond, un plancher ou une cloison, soyez

conscient que cela peut entraîner un feu de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un

bidon.

D Fixez le câble de masse sur la pièce à couper, le plus près possible

de la zone à couper afin de prévenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une
décharge électrique, d’étincelles ou un feu.

D Ne pas utiliser le coupeur plasma pour dégeler des conduites

gelées.

chauffée et l’équipement chaud peuvent causer un

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

D Ne coupez jamais des contenants qui peuvent contenir des

matières inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.

D Ne coupez pas quand l’atmosphère peut contenir des poussières,

gaz ou vapeurs (comme l’essence) inflammables.

D Ne coupez pas dans un endroit où l’atmosphère risque de contenir

de la poussière ou des vapeurs explosives.

D Ne coupez pas de bouteilles, de tuyaux ou de contenants

pressurisés.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

D Ne placez pas le poste sur une surface combustible ou au−dessus

de celle−ci.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Avant le coupage, retirez tout combustible de vos poches, par

exemple un briquet au butane ou des allumettes.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures
graves. Le chalumeau et le circuit de masse sont
automatiquement actifs lorsque le poste est sous
tension. L’alimentation d’entrée et les circuits
internes de l’appareil le sont également. Le coupage
plasma nécessite des tensions plus importantes
que le soudage pour amorcer et maintenir l’arc (200
à 400VDC est typique), mais peut être utilisé avec
des torches équipées de systèmes de verrouillage
de sécurité qui arrêtent la machine en cas de buse
desserrée ou si l’électrode touche la tuyère. Un
poste incorrectement installé ou inadéquatement
mis à la terre constitue un danger.

D Ne touchez pas aux pièces électriques sous tension.
D Portez des gants isolants et des vêtements de protection secs et

sans trous.

D Isolez−vous de la pièce à couper et du sol en utilisant des housses

ou des tapis assez grands afin d’éviter tout contact physique avec
la pièce à couper ou le sol.

D Ne touchez pas aux pièces du chalumeau si vous êtes en contact

avec la pièce à couper ou le sol.

D Mettez l’appareil hors tension avant d’effectuer la vérification, le

nettoyage ou le changement d’une pièce du chalumeau.

OM-272 182 Page 5

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 Assurez−vous que le fil de terre du cordon d’alimentation est

correctement relié à la borne de terre dans la boîte de coupure ou
que la fiche du cordon est branchée à une prise correctement mise
à la terre − vous devez toujours vérifier la mise à la terre.

D Avant d’effectuer les connexions d’alimentation, vous devez relier

le bon fil de terre.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé. Le
remplacer immédiatement s’il l’est . Un fil dénudé peut entraîner la
mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, sous dimensionnés

ou réparés.

D Vérifiez et remplacez les cosses du câble du chalumeau si elles

sont usées ou altérées.

D Le câble du chalumeau ne doit pas s’enrouler autour de votre

corps.

D Si les normes le stipulent, la pièce à couper doit être mise à la terre.
D Utilisez uniquement de l’équipement en bonne condition. Réparez

ou remplacez immédiatement toute pièce altérée.

D Portez un harnais de sécurité si vous devez travailler au−dessus

du sol.

D Assurez−vous que tous les panneaux et couvercles sont

correctement en place.

D N’essayez pas d’aller à l’encontre des systèmes de verrouillage de

sécurité ou de les contourner.

D Utilisez uniquement le ou les chalumeaux recommandés dans le

manuel de l’opérateur.

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 pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

DÉCHARGES ÉLECTRIQUES poten­tiellement mortelles.

Il reste une TENSION DC NON
NÉGLIGEABLE dans les sources de
soudage onduleur UNE FOIS
l’alimentation coupée.

D Mettre l’unité hors tension, mesurer la tension des

condensateurs d’entrée et s’assurer qu’elle est pratiquement
nulle avant de toucher à l’une quelconque des pièces. Mesurer
cette tension conformément aux directives énoncées à la
section Entretien du manuel de l’utilisateur ou du manuel
technique avant de toucher à l’une quelconque des pièces.

Risque de blessure en cas
D’EXPLOSION DES PIÈCES.

D Mise sous tension, toute pièce défectueuse

des sources d’alimentation de l’inverseur peut
exploser ou faire exploser d’autres pièces.
Pour entretenir les inverseurs, toujours porter
un masque protecteur et un vêtement à
manches longues.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

Le coupage plasma produit des étincelles et
projections de métal à très haute température.
Lorsque la pièce refroidit, du laitier peut se former.

D Portez une visière ou des lunettes de sécurité avec des écrans

latéraux approuvées.

D Portez des vêtements de protection adéquats afin de protéger

votre peau.

D Ayez recours à des protège−tympans ou à un serre−tête ignifuges

afin d’éviter que les étincelles n’entrent dans vos oreilles.

LES RAYONS D’ARC peuvent
entraîner des brûlures aux yeux et à la
peau.

Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner
des brûlures aux yeux et à la peau.

D Une protection faciale (casque ou masque) avec des lunettes

filtrantes de teinte adéquate est indispensable pour protéger le
visage et les yeux des rayonnements de l’arc et des étincelles
pendant la découpe ou en regardant simplement ANSI Z49.1
(reportez−vous aux Principales normes de sécurité) suggère
d’utiliser un filtre de teinte nd 9 (nd 8 étant le minimum) pour tout
travail de coupage faisant appel à un courant de moins de 300 A.
On mentionne également dans la norme Z49.1 qu’un filtre plus
faible peut être utilisé lorsque l’arc est caché par la pièce à couper.
Comme cela est habituellement le cas pour les travaux de coupage
à faible courant, les teintes énumérées au tableau 1 sont fournies à
titre d’information pour l’opérateur.

D Porter des lunettes de sécurité à coques latérales sous votre

casque ou écran facial.

D Ayez recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements, les étincelles et les
éblouissements; prévenez toute personne sur les lieux de ne pas
regarder l’arc.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

Tableau 1. Protection des yeux pour le coupage au plasma d’arc

Intensité de courant en ampères Filtre de teinte (minimum)

Moins de 20 no. 4

20 − 40 no. 5
40 − 60 no. 6

60 − 100 no. 8

LE BRUIT peut endommager l’ouïe.

Certaines applications de coupage produisent un
bruit constant, ce qui peut endommager l’ouïe si le
niveau sonore dépasse les limites permises par
l’OSHA (reportez−vous aux Principales normes de
sécurité).

D Utilisez des protège−tympans ou un serre−tête antibruit si le

niveau sonore est élevé.

D Prévenez toute personne sur les lieux du danger relié au bruit.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le coupage produit des vapeurs et des gaz.
Respirer ces vapeurs et ces gaz peut être
dangereux pour la santé.

D Ne mettez pas votre tête au−dessus des vapeurs. Ne respirez pas

ces vapeurs.

OM-272 182 Page 6

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.

D Lire et comprendre les fiches de données de sécurité et les

instructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de
refroidissement, les dégraisseurs, les flux et les métaux.

D Travaillez dans un espace restreint uniquement s’il est bien ventilé

ou si vous portez un respirateur anti−vapeurs. Les vapeurs
causées par le coupage et l’épuisement de l’oxygène peuvent
altérer la qualité de l’air et entraîner des blessures ou la mort.
Assurez−vous que l’air ambiant est sain pour la santé.

D Ne coupez pas dans un endroit près d’opérations de décapage, de

nettoyage ou de vaporisation. La chaleur et les rayons d’arc
peuvent réagir avec les vapeurs et former des gaz hautement
toxiques et irritants.

D Ne coupez pas des métaux enrobés tels que des métaux

galvanisés, contenant du plomb ou de l’acier plaqué au cadmium, à
moins que l’enrobage ne soit ôté de la surface du métal à couper,
que l’endroit où vous travaillez ne soit bien ventilé, ou que vous ne
portiez un respirateur anti−vapeurs. Les enrobages ou tous
métaux qui contiennent ces éléments peuvent créer des vapeurs
toxiques s’ils sont coupés.

D Ne coupez pas de contenants qui renferment ou ont renfermés des

matières toxiques ou réactives − vous devez en premier lieu les
vider et les nettoyer convenablement.

L’ARC PLASMA peut provoquer des
blessures.

La chaleur dégagée par le plasma d’arc peut
entraîner de sérieuses brûlures. La force de l’arc est
un facteur qui s’ajoute au danger de brûlures. La

rapidement passer au travers de gants et de tissus.

D N’approchez pas le tube du chalumeau.
D Ne saisissez pas la pièce à couper près de la ligne de coupage.
D L’arc pilote peut causer des brûlures − n’approchez pas le tube du

chalumeau lorsque vous avez appuyé sur le gâchette.

D Porter un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.

chaleur intense et la puissance de l’arc peuvent

D Ne pointez pas le chalumeau en direction de votre corps ni de la

pièce à couper lorsque vous appuyez sur la gâchette − l’arc pilote
s’allume automatiquement.

D Mettez l’alimentation hors tension et débranchez le cordon

d’alimentation avant de démonter le chalumeau ou de changer une
pièce du chalumeau.

D Utilisez uniquement le ou les chalumeaux recommandés dans le

manuel de l’opérateur.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Puisque les

processus de travail des métaux, assurez−vous de les manipuler
correctement.

D Protégez les bouteilles de gaz comprimé contre la chaleur

excessive, les chocs mécaniques, des dommages physiques, le
laitier, la flamme, les étincelles et l’arc.

D Installez et attachez les bouteilles dans la position verticale à l’aide

d’une chaîne, sur un support stationnaire ou un châssis
porte−bouteille afin de prévenir qu’elles ne tombent ou ne
basculent.

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 gaz comprimé , des

détendeurs, des boyaux et des raccords conçus pour l’application
déterminée. Gardez−les, ainsi que toute autre pièce associée, en
bonne condition.

D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

vous utilisez la bouteille ou qu’elle est reliée pour usage ultérieur.

D Utiliser les équipements corrects, les bonnes procédures et

suffisamment de personnes pour soulever et déplacer les
bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de
sécurité.

bouteilles de gaz font habituellement partie d’un

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

maintenance

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher des parties chaudes à mains

nues.

D Prévoir une période de refroidissement avant

d’utiliser l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les

outils recommandés et porter des gants de
soudage et des vêtements épais pour éviter les
brûlures.

D Lorsque cela est nécessaire pour des travaux d’entretien et de

dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel
qualifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

Les PIÈCES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de
protection.

OM-272 182 Page 7

LIRE LES INSTRUCTIONS.

t

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.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

D Porter des lunettes de sécurité avec écrans

latéraux ou un écran facial.

Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants
médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur

médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement;

respecter le cycle opératoire nominal.

D Réduire l’ampérage (épaisseur) avant de

continuer à couper ou réduire le facteur de
marche.

Danger D’EXPLOSION
D’HYDROGÈNE.

D Lors du coupage d’aluminium partiellement ou

totalement immergé dans l’eau, de l’hydrogène
libre peut s’accumuler sous la pièce.

D Consultez votre ingénieur de coupage et les instructions de la

table de coupage.

L’EXPLOSION DE LA BATTERIE peu
provoquer des blessures.

D Ne pas utiliser le découpeur plasma pour charger

des batteries ou faire démarrer des véhicules à
l’aide de câbles de démarrage, sauf si l’appareil
dispose d’une fonctionnalité de charge de
batterie destinée à cet usage.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariot, les
bouteilles de gaz ou tout autre accessoire.

D Utiliser un engin d’une capacité appropriée pour soulever

l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

Risque D’INCENDIE OU
D’EXPLOSION.

D Ne pas installer l’appareil à proximité de

produits inflammables

D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces

infllammables.

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionné et protégé avant de
mettre l’appareil en service.

LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits im­primés.

D Etablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes PC.

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

D Le Rayonnement haute frequence (H.F.) peut

provoquer des interférences avec les
équipements de radio−navigation et de
communication, les services de sécurité et les
ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner
l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une
distance correcte et utiliser une terre et et un blindage pour réduire
les interférences éventuelles.

LE COUPAGE Ã L’ARC peut causer
des interférence.

D L’énergie électromagnétique peut gêner le

fonctionnement d’appareils électroniques
comme des ordinateurs 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
possible (ex. par terre).

D Veiller à couper à une distance de 100 mètres de tout équipement

électronique sensible.

D S’assurer que la source de coupage est correctement branchée et

mise à la terre.

D Si l’interférence persiste, l’utilisateur doit prendre des mesures

supplémentaires comme écarter la machine, utiliser des câbles
blindés de des filtres, ou boucler la zone de travail.

OM-272 182 Page 8

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)

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: [phone], 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: [phone], 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: [phone], 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: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Quincy, MA 02269 (phone: [phone],
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: [phone], website:
www.cganet.com).

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.

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: [phone], 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: [phone]) (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: [phone], 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-272 182 Page 9

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.

When power is applied failed parts can explode or cause other parts to explode.

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

Safe1 2012−05

Safe26 2012−05

A

V

U

I

1max

IP

I

1eff

0

Amperes

Volts Increase

Protective Earth

(Ground)

On Off Percent Direct Current

Rated No Load

Voltage (OCV) U

Rated Maximum

Supply Current

Degree Of
Protection

Maximum Effective

Supply Current

I

pf

Plasma Arc Cutting

1

2

(PAC)

Single Phase Constant Current Voltage Input

Primary Voltage

Rated Welding

Current

Loose Shield Cup Input

power factor

U

X

S

2

Adjust Air/Gas

Pressure

No − Do Not Do

This

Conventional Load

Voltage

Duty Cycle

Suitable for Some

Hazardous

Locations

Hz

S

1

Low Air Pressure

Light

Temperature

Line Connection

Single Phase

Static Frequency

Converter-

Transformer-

Rectifier

Hertz

Power Rating,
Product Of Voltage
And Current (KVA)

OM-272 182 Page 10

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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. 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 (U1) and rated Input
Current (I1) and I1 eff at rated output. I1 eff used
to determine power cord rating

Power Factor/KVA/KW at Rated Output

Peak KW at Arc Stretch 10.1 KW — — — —

Volts AC RMS − (U1) Amps RMS − (I1) I1 eff

208 Volts 33 23.3
240 Volts 30 21.2

Volts AC RMS − (U1) Power Factor KVA/KW

208 Volts 0.98 6.8/6.6
240 Volts 0.98 6.8/6.6

Output

Rated Open Circuit Voltage (U0) Type 400 Volts DC/Electrode Negative — — — —
Output Characteristic Constant Current — — — —
Output Current Range 20-40 A — — — —

Volts AC

RMS − (U1)

Volts AC

RMS − (U1)

Output Current and Voltage Rating at Rated
Input Voltage (I2 and U2 at U1)

Duty Cycle at 1045 F (405 C) at rated conditions
(U1, I1, U2, I2) based on a 10 minute period

Amps DC − (I2) Volts DC − (U2)

40 A 140 Volts DC 208 Volts
40 A 140 Volts DC 240 Volts

Duty Cycle % Amps DC − (I2)

50 40 A 208 Volts
50 40 A 240 Volts

General

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

2 − No ingress of foreign objects  12.5 mm

IP Code − Degree of protection provided by
enclosure

Toppling or tilting Up to 15° incline — — — —
Gas Type Air — — — —
Gas Quality Clean, moisture-free, oil-free — — — —

Gas Inlet Flow and Pressure 4.8 SCFM (85 L/min)

Gas Filtering Particulates to 5 microns — — — —

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 — — — —

(0.5 in.)

— — — —

— — — —

90 PSI (621 kPa)

Min

120 PSI (827

kPa) Max

OM-272 182 Page 11

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4-2. Unit Specifications (Continued)

Torch

Mild Steel capacities (see Section 6-2 for
cutting speeds vs material type and thickness)

Rated Capacity (edge start) 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) — — — —
*Travel speeds are approximately 80% of maximum.

— — — — — —

4-3. Duty Cycle And Overheating

Overheating

Notes

For Units Connected to a 208 Volt Circuit
or a 240 Volt Circuit:

50% Duty Cycle At 40 amperes, 140 volts DC

50%dutycycle

5 Minutes Cutting 5 Minutes Resting

0

15

Minutes

Duty Cycle is percentage of 10 min­utes 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.

A

OR

Reduce Duty Cycle

sduty1 5/95 / Ref. 244 405-A

OM-272 182 Page 12

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4-4. Power Source Dimensions And Weight

Dimensions And Weight

31.4 lb (14.2 kg)
including torch

8-1/4 in.

(210 mm)

11-1/4 in.

(286 mm)

14-1/4 in.
(362 mm)

4-5. Torch Dimensions And Weight

Dimensions And Weight

2.2 lb (1.0 kg)

1-3/16 in.

(30 mm)

loc_2 3/96 - Ref. 244 405-A

8-3/4 in.

(222 mm)

1-1/2 in.
(38 mm)

4-6. 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.

OM-272 182 Page 13

Ref. 253 554-A

IP23CS 2014−09

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SECTION 5 − INSTALLATION

5-1. Selecting A Location

! Do not move or operate unit

where it could tip.

18 in.

(460 mm)

5-2. Connecting Gas/Air Supply

18 in.

(460 mm)

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

loc_2 3/96 - Ref. 244 405-A

. Use only clean, dry air with 90

to 120 psi (621 to 827 kPa)
pressure.

1 Gas/Air Inlet Opening
2 Hose

1

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:

9/16 in.

5-3. Connecting Work Clamp

2

2

3

From

Gas/Air

Supply

Ref. 244 423-A

. Do not connect work clamp to

1

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

OM-272 182 Page 14

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5-4. Electrical Service Guide

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.
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.

Input Voltage (V) 208 240
Input Amperes (A) At Rated Output 33 30
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)

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.

4

4

1

2

3

Elec Serv 2014−11

60 Hz Single

Phase

40 35
50 45

3 10

80

(24)

10 10

98

(30)

5-5. Extension Cord Data

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

Input Power

Input Voltage

208 V 1 60 10 AWG 80 ft (24 m)

240 V 1 60 10 AWG 98 ft (30 m)

Phase

Hertz Conductor Size Max. Cord Length

OM-272 182 Page 15

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

1

3

7

2

4

L1

L2

6

1

=GND/PE Earth Ground

5

Tools Needed:

OM-272 182 Page 16

8

L2

L1

240 VAC, 1

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

. 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.

! Disconnect and lockout/tagout input

power before connecting input con­ductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.

! Always connect green or green/yellow

conductor to supply grounding termi­nal first, and never to a line terminal.

See rating label on unit and check input volt­age 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 dis­connect device line terminals.

7 Over-Current Protection
Select type and size of over-current protec-

tion using Section 5-4 (fused disconnect
switch shown).

Close and secure door on disconnect device.
Follow established lockout/tagout proced­ures to put unit in service.

8 Receptacle (NEMA 6-50R)

Customer Supplied

Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.

input4 2012−05

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-272 182 Page 17

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5-7. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat,

Trailblazer Or Champion 10,000

1 Input And Grounding

Conductors

2 Plug Wired for 240 V, 2-Wire

Load

Tools Needed:

3/16 in.

240V

2

3

4

7

5

5

6

8

6

3

Plug Front

View

3 Neutral (Brass) Terminal And

4

Prong (Not Used)

4 Load 1 (Brass)Terminal And

Prong

5 Load 2 (Brass) Terminal And

Prong

6 Ground (Brass) Terminal And

Prong

7 Black And White Input

Conductors

8 Green Or Green/Yellow

Ground Conductor

! Always connect green or

green/yellow wire to ground
terminal, never to a load
terminal. Connect black (L1)
and white (L2) wires to load
terminals.

1

! Engine Control Switch must be set at “RUN”

position − not “RUN/IDLE”.

7

8

Green Or

Green/Yellow

! Set generator Fine Adjustment Control to 10

for maximum auxiliary power, if applicable.

OM-272 182 Page 18

Ref. 120 813-D / Ref. 244 405-A

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

5-8. Installing Alternative Plug

Tools Needed:

. 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.
2 Alternative Plug (240 VAC

Plug Shown)

3 Input (Black Lead)

(Brass) Terminal

4 Input (White Lead)

(Brass) Terminal
5 Ground (Green) Terminal
6 Outer Shell
7 Cord Grip
Strip cord jacket back enough to

separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip. Tighten
assembly screws onto shell. Do not
overtighten.

Notes

Ref. 801 305-A / 801 611

OM-272 182 Page 19

6-1. Controls

2

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

SECTION 6 − OPERATION

1

3

1 Output Control
Use control to set cutting output.

2 Power Light
3 Trouble Lights (See Section 7-4)

4

4 Power Switch
Use switch to turn unit On or Off.

OM-272 182 Page 20

269 710-A

. 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. Cutting below the value
(too slow) will result in excess dross. Cutting above the value (too fast) will cause blowback and lack of penetration.

6-3. Trigger Safety Lock

1 Trigger

Trigger Locked

1

Trigger Unlocked

Ref. 253 554-A

OM-272 182 Page 21

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6-4. Plasma Cutting System Practices

! The pilot arc starts immediately

when trigger is pressed.

Always connect work clamp to a clean,

paint-free location on workpiece, as close to

90°

Maintain approximately a 90

workpiece surface for proper cutting results.

cutting area as possible.

° angle to the

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.

1/16 in.

(1.6 mm)

When doing extended (non-shielded)

cutting, maintain approximately 1/16 in.

standoff between electrode and surface.

OM-272 182 Page 22

Wt

DO NOT put pressure on shield when

drag cutting; instead, slide shield along

the surface for proper cutting results.

Pulling rather than pushing the torch

makes cutting easier. Use a proper guide

or template for accurate cutting operations.

Ref. 254 087-A

. 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.

For standard (shielded) cutting, place drag shield on edge

of metal. For extended (non-shielded) cutting, use 1/8 in.

(3.2 mm) standoff distance (dragging tip will reduce tip life).

After cutting arc starts, slowly

start moving torch across metal.

Adjust torch speed so

sparks go thru metal and

out bottom of cut.

Pause briefly at end of

cut before releasing trigger.

Postflow continues for approx. 20 seconds

after releasing trigger; cutting arc can be

instantly restarted during postflow by raising

trigger lock and pressing trigger.

Ref. 254 087-A

OM-272 182 Page 23

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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

Rotate torch to upright position

approximately 90° to surface.

When arc has pierced through

workpiece, start cutting.

area as possible.

90°

Hold torch at approximately 45°

to the workpiece. Raise trigger

lock and press trigger. Pilot arc

90°

Maintain approximately 90° torch

position to surface, and continue

cutting.

starts.

Release trigger. Postflow continues for

approx. 20 seconds after releasing trigger;

arc can be instantly restarted during postflow

by raising trigger lock and pressing trigger.

Ref. 254 087-A

Notes

OM-272 182 Page 24

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

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

Each
Use

Every
Week

Every
3
Months

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

n Gas/Air Pressure n Torch Tip, Electrode,

n Shield Cup Shutdown

System

l Damaged Or Unreadable
Labels

And Shield Cup

~ Air Filter/Regulator l Cracked Parts n l Gas/Air Hose

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

Section 4-2,
7-6

Section 7-2

Section 7-3,
8

Every
6
Months

n l Torch Body, Cable

OR

~ Inside Unit

OM-272 182 Page 25

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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.
Check filter element for dirt and

moisture, and replace if necessary.
Be sure that all parts are clean and

dry.
Reinstall filter element, and secure

filter cup.
Reinstall wrapper.

Tools Needed:

1

2

3

5/16 in.

244 408-A / Ref. 805 211-A

OM-272 182 Page 26

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7-4. Status/Trouble Lights

. Difficulty establishing a pilot arc may indicate consumables need to be cleaned or replaced.

V

REWOP

ERUSSERP

PUC

PMET

Light Condition Status/Possible Cause

Power On Input power is okay.

Pressure/Cup/Temp

Power

Power

Pressure On No or low [below 40 psi (276 kPa)] input pressure.

Pressure

Pressure

Cup

Cup

Cup

Cup

Temperature

Temperature

Temperature

For system troubleshooting see Section 7-8 and Section 7-9.

Off When Power light is on, system is normal if these lights

Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of two quick cycles, then a one
second pause.

Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of two quick cycles, then a one
second pause for a 15 second period.

On Torch cup is loose or off. Once cup is tightened, unit

Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of two quick cycles, then a one
second pause for a 15 second period or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of three quick cycles, then a one
second pause for a 15 second period or until torch trigger
is pressed again, whichever comes first.

On Power source overheated (see Section 4-3). Stop cutting

On (indefinitely) Power source temperature sensors may have failed or

Flashing rate is steady (indefinitely). Power source temperature sensor provided inaccurate

are off.
Input power below 156 volts AC, but has returned to

normal.
Input power is below 156 volts AC.

Regulated pressure in the unit is low. Check torch for
leaks. Check input pressure to unit is between 90 to 120
psi (621 to 827 kPa).

Regulated pressure in the unit is high. Check input pressure
to unit is between 90 to 120 psi (621 to 827 kPa).

power must be cycled off and back on again.
No arc was established. Check consumables or torch.

No pilot arc established possibly due to a loss of current.
Check consumables.

Consumables in torch failed to separate during pilot arc
possibly due to being stuck. Check consumables.

and allow unit to cool down.

ambient temperature is below -22° F (-30° C).

readings, but returned to normal. Unit power must be
cycled off and back on again.

7-5. Checking Shield Cup Shutdown System

. Power must be reset whenever the cup

shutdown system is activated. Always
turn Off power when changing or
checking consumables. Do NOT
overtighten torch shield cup. Gently
finger tighten cup onto torch.

1

1 Torch Shield Cup
Turn Power On and loosen shield

cup. If shutdown system works
properly, Cup light comes on. If not,
immediately turn Off power and
have Factory Authorized Service
Agent check unit.

If system works properly, retighten
cup and reset power.

Ref. 253 554-A

OM-272 182 Page 27

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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 signifi-

cantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement
parts.

! Turn Off power source before checking torch

parts.

Make sure this area is
clean of any debris.

8

6

Make sure swirl ring is clean of any
debris and no holes are obstructed.

5

4

New

Worn

Turn Off power source.

1 Drag Shield

The drag shield is rested on workpiece to
maintain a consistent tip to work distance
while cutting.

2 Deflector

The deflector helps protect the threads and
cup from being damaged while extended
cutting.

7

3

2

1

3 Shield Cup
Remove shield cup. Check cup for cracks,

and replace if necessary.
4Tip
5 Opening
Remove tip. Check tip, and replace if open-

ing is deformed or 50% oversize. If inside of
tip is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards.

New

1/32 in. (1 mm) to 1/16
in. (2 mm) maximum pit
depth depending on
acceptable cut quality

Worn

Ref. 253554-A

6 Electrode
Check electrode. If center has a pit more

than a 1/16 in. (2 mm) deep, remove and re­place electrode.

7 Swirl Ring
Remove swirl ring. Check ring, and replace

if side holes are plugged.
8 O-Ring
Check O-ring for cracks or worn spots, and

replace if necessary.
Carefully reassemble parts in reverse order.

OM-272 182 Page 28

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7-7. Torch And Work Cable Connections

6 7

2

5

79

5 6

3

Tools Needed:

2

4

8

3/8 in.

! 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 Power Source
Remove wrapper from unit.

Torch Connections

Remove existing torch cable from
unit.

2 Strain Relief
3 Torch Cable

1

Insert strain relief on end of cable
through front panel opening. Slide
strain relief nut onto torch cable, but
do not tighten.

4 Air Line Connector
Insert air line into solenoid fitting.
5 Plug PLG4/Receptacle RC4
Connect PLG4 from torch to

receptacle RC4 on end of wiring
harness connected to circuit board
PC1.

Route torch white and red leads
and work black lead through
sleeving the same way as the unit
was originally.

6 Ring Terminal And TORCH

WHITE Terminal
Connect ring terminal on end of

torch white lead to TORCH WHITE
terminal.

7 Ring Terminal And TORCH

RED Terminal
Connect ring terminal on end of

torch red lead to TORCH RED
terminal.

Tighten strain relief screw.

Work Cable Connections

Remove existing work cable from
unit.

8 Strain Relief
Loosen strain relief screw.

. Be sure to allow some work

cable slack inside the unit.

Insert strain relief on end of cable
through front panel opening. Slide
strain relief nut onto work cable and
secure strain relief to front panel.

9 Work Lead Ring Terminal And

WORK BLACK Terminal
Connect ring terminal on end of

work clamp lead to terminal labeled
WORK BLACK. Route lead along
torch lead bundle.

Reinstall wrapper.

Ref. 804 887-A / 244 409-A / Ref. 244 405-A

OM-272 182 Page 29

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7-8. Troubleshooting Power Source

Trouble Remedy

No pilot arc; difficulty in establishing an
arc.

No cutting output; Power light off; status
lights off; fan motor FM does not run.

Pilot arc working; no cutting output;
Power light on; status lights off; fan
motor running.

No gas/air flow; Power light on; status
lights off; fan motor running.

Pressure status light On. Check for sufficient gas/air supply pressure (see Section 4-2).

Cup status light On. Check torch shield cup (see Section 7-5). Reset power switch.

Temperature status light On. Unit overheating. Allow fan to run; the Trouble light goes out when the unit has cooled.

Clean or replace worn consumables as necessary (see torch Owner’s Manual).

Check for damaged torch or torch cable (see torch Owner’s Manual).

Place Power switch in On position.

Place line disconnect device in On position (see Section 5-6).

Check line fuse(s) and replace if needed or reset circuit breakers (see Section 5-6).

Be sure work clamp is connected.

Clean or replace worn consumables as necessary (see torch Owner’s Manual).

Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas
valve AS1, and check gas/air system for leaks. Check filter element (see Section 7-3).

Check for dirty air filter and replace, if necessary (see manufacturer’s instructions).

Check air lines for leaks.

Have Factory Authorized Service Agent check pressure switch and control board.

Have Factory Authorized Service Agent check torch.

Have Factory Authorized Service Agent check control board.

Status lights not working. Have Factory Authorized Service Agent check unit.

Power light flashing, status lights off. Reset power switch. Have qualified technician check input line power.

Pressure status light flashes. Unit lost pressure (momentarily) while cutting. Check air line for leaks.

Cup status light flashes. Unit lost output while attempting to cut or pilot. Check consumables and torch for wear.

Short tip life.

Check and clean drag shield of any slag, particles, and debris.

Check input air pressure.

OM-272 182 Page 30

. 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

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

Sparks come out top of cut or cut is not
clean.

Trouble lights are on; unit has no cutting
output.

as necessary (see Section 7-6). Be sure work clamp is securely attached to workpiece.

1/8 in. (3.2 mm)] workpiece (see Section 6-4). Clean or replace torch consumables as necessary (see
Section 7-6).

Torch travel speed too fast; reduce 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. Unit not capable
of cutting metals thicker than rating (see Section 6-2).

Check torch consumables. Check for gas/air flow at torch. Check air supply connection and pressure to
unit and torch. Reset unit Power switch. Have Factory Authorized Service Agent check torch and
connections inside unit.

OM-272 182 Page 31

SECTION 8 − ELECTRICAL DIAGRAM

OM-272 182 Page 32

Figure 8-1. Circuit Diagram

272 274-A

OM-272 182 Page 33

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.

S * When using 30 amp consumables amperage must be 30 amps or less.

Dia.

Mkgs.

Part

No.

268 923 XT40R, 12ft Hand Held Torch (Replacement) 1................. .... ........................

227 877 Filter, air element 1................. .... .................................................

272 527 Cable, Work 12 Ft 12 Ga W/Clamp & Term 1................. .... ..........................

262 557 Clamp, Work 1................. ....... ..................................................

770 793 Kit, Cup, Swirl Ring, O−Ring, Deflector− XT30R/40R Torch 1................. .... ............

770 791 Kit, Electrodes (2) For XT Torches 1................. .... ..................................

770 798 Kit, Drag Shield For XT40R Torches (40 Amps) 1................. .... .......................

770 797 Kit, Tips (2) For XT40R Torches (40 Amps) 1................. .... ..........................

*770 796 Kit, Tips (2) For XT30R Torches (30 Amps) 1................ .... ..........................

*770 799 Kit, Drag Shield For XT12R Torches (30 Amps) 1................ .... .......................

Description

Recommended Spare Parts

Quantity

. A complete Parts List is available on-line at www.HobartWelders.com

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-272 182 Page 34

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Notes

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. The
expertise of the distributor
and Hobart is there to
help you, every step of
the way.

Assistance

Visit the Hobart website:
www.HobartWelders.com

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.

This limited warranty supersedes all previous Hobart warranties and is exclusive with

Hobart products are serviced by Hobart or Miller Authorized Service Agencies.

LIMITED WARRANTY − Subject to the terms and conditions
below, Hobart Brothers Co., Troy, Ohio, and Miller Electric Mfg.
Co., Appleton, Wisconsin, warrants to its original retail purchaser
that new Hobart equipment sold after the effective date of this
limited warranty is free of defects in material and workmanship at
the time it is shipped by Hobart. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart/Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Hobart/Miller must be notified
in writing within thirty (30) days of such defect or failure, at which
time Hobart/Miller will provide instructions on the warranty claim
procedures to be followed. If notification is submitted as an online
warranty claim, the claim must include a detailed description of the
fault and the troubleshooting steps taken to identify failed
components and the cause of their failure.

Hobart/Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original retail purchaser, and not to exceed twelve
months after the equipment is shipped to a North American
distributor or twelve months after the equipment is shipped to an
International distributor.

1. 5 Years — Parts and Labor
* Original Main Power Rectifiers only to include SCRs,

diodes, and discrete rectifier modules
* Reactors
* Stabilizers
* Transformers

2. 3 Years — Parts and Labor
* Drive Systems
* Idle Module
* PC Boards
* Rotors, Stators and Brushes
* Solenoid Valves
* Spot Welder Transformer
* Switches and Controls

3. 1 Year — Parts and Labor Unless Specified
(90 days for industrial use)

* Accessories
* Batteries (Trek 180 Only)
* Contactors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* MIG Guns/TIG Torches
* Motor-Driven Guns
* Plasma Cutting Torches
* Regulators
* Relays
* Remote Controls
* Replacement Parts (No labor) − 90 days
* Running Gear/Trailers
* Water Coolant Systems
* Spoolguns

4. 6 Months — Parts
* Batteries

5. Engines and tires are warranted separately by the
manufacturer.

no other guarantees or warranties expressed or implied.

Hobart’s 5/3/1 Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Hobart/Miller, but manufactured by
others, such as engines or trade accessories. These
items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Hobart/Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Hobart’s/Miller’s option: (1) repair;
or (2) replacement; or, where authorized in writing by Hobart/Miller
in appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Hobart/Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Hobart’s/Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Hobart/Miller authorized service facility as determined
by Hobart/Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL HOBART/MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY HOBART/MILLER
IS EXCLUDED AND DISCLAIMED BY Hobart/Miller.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

hobart_warr 2015-01

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.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2015 Hobart Brothers Co.. 2015-01

Hobart Brothers Co.

An Illinois Tool Works Company
2200 Corporate Drive
Troy, OH 45373 USA

For Assistance:

Call1-800-332-3281