TM-203 653 August 2003

Eff w/Serial Number LB101130

Processes
Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter


AirForce 400
And Ice-27C Torch

Visit our website at

www.HobartWelders.com
 TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WARNING
1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
This product, when used
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . 3
for welding or cutting,
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 produces fumes or
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gases which contain
SECTION 2 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 chemicals known to the
State of California to
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 cause birth defects and,
2-2. Specifications For Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 in some cases, cancer.
2-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 (California Health &
2-4. Torch Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety Code Section
25249.5 et seq.)
2-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-6. Connecting Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-7. Connecting Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-8. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-9. Installing Alternative Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-2. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-4. Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-2. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-4. Troubleshooting Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-5. Troubleshooting Changeover Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-6. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System . . . . . . . . . . . 25
SECTION 6 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2. Torch And Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

TM-203 653
 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Plasma Arc Cutting Hazards
Y 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 1-4. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y 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 Protect yourself and others from flying sparks and hot metal.
D Do not cut where flying sparks can strike flammable material.
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 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 closed containers such as tanks or drums.
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 and fire hazards.
D Never cut containers with potentially flammable materials inside −
they must be emptied and properly cleaned first.
D Do not cut in atmospheres containing explosive dust or vapors.
D Do not cut pressurized cylinders, pipes, or vessels.
D Do not cut containers that have held combustibles.
D Wear oil-free protective garments 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.
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
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 also uses 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.
AirForce 400
pom _nd_9/98
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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 and ground 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 Frequently inspect input power cord for damage or bare wiring − re-
place cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Inspect and replace any worn or damaged torch cable leads.
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.
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists on
internal parts of 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 Mainte-
nance Section of Owner’s Manual or Technical Manual before
touching any parts.
TM-203 653 Page 1

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 cause injury.
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 correct shade of filter to
protect your face and eyes when cutting or watching. ANSI Z49.1
(see Safety Standards) suggests a No. 9 shade (with No. 8 as mini-
mum) 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 conve-
nience.
D Wear approved safety glasses with side shields under your helmet
or shield.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
Table 1. Eye Protection For Plasma Arc Cutting
Current Level In Amperes Minimum Shade Number
Below 20 #4
20 − 40 #5
40 − 60 #6
60 − 80 #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.
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.
TM-203 653 Page 2
D If inside, ventilate the area and/or use exhaust at the arc to remove
cutting fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the manufac-
turer’s instruction for metals to be cut, coatings, and cleaners.
D Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Fumes from cutting and oxygen deple-
tion 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 if necessary, 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 cause injury.
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 proper flame-retardant clothing covering all exposed body ar-
eas.
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.
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylin-
ders are normally part of metalworking processes,
be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, 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 gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated
parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders, asso-
ciated equipment, and CGA publication P-1 listed in Safety
Standards.
AirForce 400
1-3. Additional Symbols For Installation, Operation, And Maintenance
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on torch.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before go-
ing near plasma arc cutting 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.
FALLING UNIT can cause injury.
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.
AirForce 400
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.
TM-203 653 Page 3
1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
Recommended Safe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.

1-5. EMF Information

Considerations About Welding Or Cutting And The Effects Of Low 1. Keep cables close together by twisting or taping them.
Frequency Electric And Magnetic Fields
Welding or cutting current, as it flows through the welding or cutting 2. Arrange cables to one side and away from the operator.
cables, will cause electromagnetic fields. There has been and still is
3. Do not coil or drape cables around your body.
some concern about such fields. However, after examining more than
500 studies spanning 17 years of research, a special blue ribbon 4. Keep cutting power source and cables as far away from operator
committee of the National Research Council concluded that: “The body
as practical.
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human- 5. Connect work clamp to workpiece as close to the cut as possi-
health hazard.” However, studies are still going forth and evidence ble.
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic About Pacemakers:
fields when welding or cutting. Pacemaker wearers consult your doctor first. If cleared by your doctor,
To reduce magnetic fields in the workplace, use the following proce- then following the above procedures is recommended.
dures:

TM-203 653 Page 4 AirForce 400

 SECTION 2 − INSTALLATION
2-1. Specifications

NOTE If the unit is operated from a 30 ampere, 115 volt circuit or a 15 ampere, 230 volt
circuit, a different input power plug must be installed on the power cord. See
Section 2-9 for instructions.

Amperes Input at
Rated Output,
60 Hz, Single-Phase Rated
Plasma Cutting
115 V 230 V 115 V 230 V Plasma Gas Flow/ Capacity Max
Rated Output (+15%) (+15%) KVA/KW KVA/KW Gas Pressure at 10 IPM OCV
4.5 CFM
Air Or
27 A at 92 Volts DC At 28 max; 14 max; 3.32 KVA 3.25 KVA (129 L/min) 3/8 in 288 Volts
Nitrogen
35% Duty Cycle 0.30* 0.13* 3.25 KW 3.19 KW At 60 PSI (10 mm) DC
Only
(414 kPa)
*While idling

2-2. Specifications For Torch

Air-cooled torch for plasma arc cutting (PAC)

35% duty cycle

Safety interlock devices shut down power source

Safety trigger guard

Cutting capacity: see Section 2-1

2-3. Duty Cycle And Overheating

For Units Connected to a 115 Volt Circuit Duty Cycle is percentage of 10 min-
or a 230 Volt Circuit: utes that unit can cut at rated load
without overheating.
35% Duty Cycle At 27 amperes, 92 volts dc
If unit overheats, thermostat(s)
opens, output stops, Temperature
35% duty cycle 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 or gouging.
Y Exceeding duty cycle can
damage unit and void
3-1/2 Minutes Cutting 6-1/2 Minutes Resting warranty.

Overheating
A

15
OR
Minutes Reduce Duty Cycle sduty1 5/95 / 802 784

AirForce 400 TM-203 653 Page 5

2-4. Torch Dimensions And Weight

8-3/8 in
1 in (213 mm)
(25 mm)

1-3/8 in
3.0 lb (1.4 kg) (35 mm) Ref. 802 877

2-5. Selecting A Location

8-1/2 in
(216 mm)

Dimensions And Weight 12-5/16 in*

49 lb (22.2 kg) (313 mm)
not including torch
*Add 13/16 in (21 mm) for handle.

16 in
(406 mm)

Movement 1
1 Lifting Handle
Use handle to lift unit.
2 2 Hand Cart
Use cart or similar device to move
unit.
3 Plate Label
Use label to determine input power
Location And Airflow INPUT needs.
SERIAL NO. 3
STOCK NO. 4 120 VAC Receptacle
VOLTS 5 230 VAC Receptacle
AMPERES
KW
Locate unit near correct input
PHASE HERTZ power supply.
LR5071
Y Special installation may be
NRTL/C EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY required where gasoline or
volatile liquids are present −
4 see NEC Article 511 or CEC
Section 20.

10 in
(254 mm)

10 in
loc_2 3/96 - Ref. 802 784 / 802 785 / 802 786 / 203 892
(254 mm)

TM-203 653 Page 6 AirForce 400

2-6. Connecting Gas/Air Supply
. Use only clean, dry air with 70
to 150 psi (483 to 1034 kPa)
pressure.
1 Gas/Air Inlet Opening
2 Hose
3 Teflon Tape
Obtain hose with 1/4 NPT right-
Tools Needed: hand thread fitting. Wrap threads
with teflon tape (optional) or apply
5/8, 1-1/8 in pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
4 Air Filter/Regulator
Adjust gas/air pressure according
1 to Section 3-1.
3

From Gas/Air
Supply 2
4

802 787 / Ref. 801 319-C / Ref. 802 784

AirForce 400 TM-203 653 Page 7

2-7. Connecting Work Clamp
1 Work Clamp
1
2 Workpiece
Connect work clamp to a clean,
paint-free location on workpiece, as
close to cutting area as possible.

802 463-A

2-8. Connecting Input Power

Check input voltage available at
site.
1 Changeover Switch
Switch is accessible through slot in
rear panel.
1 2 Changeover Switch Label
Look at label to find correct switch
position.
Y Be sure input power
connection meets all
applicable national,
regional, and local electrical
codes.
3 Grounded 120 VAC
2 Receptacle
Y To use rated output (see
specifications), connect the
3 unit to an individual branch
circuit capable of carrying
the effective (eff) current for
4 5 the output being used. The
unit must have a properly
sized plug installed and the
6 circuit must be protected by
properly sized fuses or cir-
cuit breakers.
A 120 volt, 20 ampere individual
branch circuit protected by
time-delay fuses or circuit breaker
is required (see Section 2-1).
4 Plug From Unit
Select extension cord of 12 AWG
for up to 53 ft (16 m).
5 Grounded 230 VAC
Receptacle
A 230 volt, 10 ampere individual
branch circuit protected by
time-delay fuses or circuit breaker
is required (see Section 2-1).
6 Plug From Unit (Customer
Supplied)
Select extension cord of 14 AWG
for up to 133 ft (41 m).
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

Ref. 802 787 / 802 786

TM-203 653 Page 8 AirForce 400

2-9. Installing Alternative Plug
This procedure is necessary if the unit is to be connected to a 230 1 Supplied 115 VAC Plug
VAC receptacle, or to a 115 VAC receptacle that requires a plug that
is different from the supplied plug. Cut cord close to plug.

See Section 2-8 for instructions on setting changeover switch for 2 Alternative PLug (230 VAC
proper voltage. Plug Shown)
2
3 Load 1 (Brass) Terminal
4 Load 2 (Brass) Terminal
3 5 Ground (Green) Terminal
6 Outer Shell
6
7 Cord Grip
1 7
Strip cord jacket back enough to
4 separate conductors. Strip conduc-
tors enough to make good contact
5 with plug terminals. Make plug con-
nections and reinstall outer shell and
cord grip. Tighten assembly screws
Tools Needed: onto shell. Do not overtighten.

Ref. 801 305-A / 801 611

AirForce 400 TM-203 653 Page 9

 SECTION 3 − OPERATION
3-1. Controls

4 2 3

ON

OFF
1
PRESSURE
60 PSI 6

20

16 24

27

Set To
Setting Gas/Air Pressure 60 PSI (414 kPa)

1
20 5 20

16 24 16 24
Requires
70-150 PSI 6
(483-1034 kPa)
Supply
27 27

1 Output Control
Use control to set cutting output.
Place control in Gas/Air Set position to safely
adjust gas/air pressure. Only gas/air circuit
is activated.
If 22-27 amperes of cutting output is used
with 115 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 2-1).
2 Trouble Lights (See Section NO TAG)
3 Power Light
4 Power Switch
Setting Gas/Air Pressure
5 Air Filter/Regulator
6 Pressure Adjustment Knob
Place Output control in Gas/Air position and
turn on gas/air supply. Lift knob and turn to
adjust pressure. Push knob down to lock in
setting.
Place Output control in desired cutting
output.
. At ambient temperatures below −55 C
(235 F), readjustment of gas/air
pressure regulator may be necessary.

Ref. 200 808 / Ref. 802 784

TM-203 653 Page 10 AirForce 400

3-2. Cutting Speed
The cutting speed curves show the
recommended maximum cutting
speed capabilities of the power
source and torch for mild steel of
various thickness.
Cut at speeds below the lines
shown to avoid poor cuts and torch
wear.

wmdesign

3-3. Trigger Safety Lock

1 Trigger

Trigger Locked Trigger Unlocked

802 877

AirForce 400 TM-203 653 Page 11

3-4. Sequence Of Operation

EXAMPLE Of Cutting Operation

The pilot arc starts immediately when trigger is pressed.

Place tip on work for drag cutting or for Raise trigger lock and press After cutting arc starts, slowly
maximum cutting speed and tip life, use a trigger. Pilot arc starts. start moving torch across metal.
standoff distance of 1/16 in (1.6 mm) to 1/8
in (3.2 mm) (dragging tip will reduce tip life).

Adjust torch speed so Pause briefly at end of Postflow continues for 20 seconds after
sparks go thru metal and cut before releasing trigger. releasing trigger; cutting arc can be instantly
out bottom of cut. restarted during postflow by raising trigger
lock and pressing trigger.

Ref. 802 878

TM-203 653 Page 12 AirForce 400

Notes

AirForce 400 TM-203 653 Page 13

 SECTION 4 − THEORY OF OPERATION

1 Power Switch S1
Provides on/off control of power to
main transformer T1. 1 6
2 Capacitors C1 And C2 115 Or 230 VAC
Power Switch S1 Fan Motor
Single-Phase
C1 and C2 provide filtering to FM
Line Input
protect other equipment connected
Power
to same branch circuit from noise
generated by unit.
3 Changeover Switch S2 Changeover
2 Board PC2 7
Connects primary of main
transformer T1 for 115 or 230 volts Main
ac operation. Capacitors C1, C2 Transformer
5
T1
4 Resistor R1 (Thermistor) CR2
Limits amperage draw at power-up
to prevent nuisance tripping or 3 4
blowing of input power breaker or
fuse. Changeover Thermistor
5 Power-Up Delay Relay CR2 Switch S2 R1
Bypasses thermistor R1
approximately 2 seconds after
power switch S1 contacts close.
6 Fan Motor FM
Provides cooling of internal
components. Fan turns on when
unit is energized.
7 Main Transformer T1
Supplies power for cutting circuit
(170 VAC) and control circuitry
(three 20 VAC supplies) to control
board PC1.
8 Control Board PC1
Delivers 27 A of controlled output
current through L2 to the torch
(approximately 12 A for pilot arc),
and a regulated 24 VDC to the air
solenoid AS1 whenever the torch
trigger contacts close.
Controls all logic and timing
functions which include:
S Postflow − approximately 20
seconds
S Pilot Time-out − approximately
5 seconds
S Instantaneous detection of arc
outage at end of cut to maintain
a pilot arc.
Receives inputs from:
S Torch cup − safety protection to
ensure consumables are
correctly installed
S Transformer T1 supplies
cutting and control power
S Temperature feedback from
thermistor R2 and thermostat TP1
(transformer T1)
S Torch trigger signal allows
operator to begin and end
the cutting process.

TM-203 653 Page 14 AirForce 400

 9 Thermistor R2
AC Or DC Control Circuits Senses overheating and protects
IGBT on PC1.
1φ Power 10 Boost Inductor L1
L1 smooths/sustains amperage
from transformer T1.
Cutting And Pilot Current Circuits
11 Buck Inductor L2
Gas/Air Directly connected to torch
electrode. L2 sustains/smooths
8 output amperage.
170 VAC
12 Thermostat TP1
Power
Control Senses overheating and protects
Board PC1 main transformer T1.
20 VAC
13 Work Clamp/Workpiece
Connecting clamp to workpiece
provides closure of cutting circuit
20 VAC (clamp must be connected to work-
piece for unit to operate properly).
14 Torch

20 VAC Receives inputs from:

S PC1 − supplies 12 A for pilot arc
and 15-27 A for cutting
5 S Solenoid AS1 − supplies air for
Power-Up cutting, cooling and postflow.
Delay Provides outputs to PC1:
Relay CR2
9 S Torch cup − safety protection
to ensure consumables are
12
Thermistor correctly installed
Thermostat R2 S Torch trigger signal allows
TP1 operator to begin and end
the cutting process.
15 15 Gauge
16 Regulator
Gauge 10
17 Filter
Boost
Inductor L1 18 Solenoid AS1
16 18 19 Air Inlet
Regulator Solenoid
AS1 11
Buck
17 Inductor L2

Filter

Pilot (+)
19

Air Inlet Electrode (−)

Torch Trigger Circuit 14

Cup Safety Circuit

Work
Gas/Air 13 Clamp (+)

Workpiece (+)

AirForce 400 TM-203 653 Page 15

 SECTION 5 − TROUBLESHOOTING
5-1. Troubleshooting Power Source

WARNING
ELECTRIC SHOCK can kill. MOVING PARTS can cause injury.
• Do not touch live electrical parts. • Keep away from moving parts.
• Turn Off power source and remove input power plug
from receptacle.

STATIC ELECTRICITY can damage

parts on circuit boards.
HOT PARTS can cause severe burns. • Put on grounded wrist strap BEFORE handling
• Allow cooling period before servicing unit. boards or parts.
• Use proper static-proof bags.

Have only qualified persons familiar with and

following standard safety practices perform
troubleshooting procedures.
smwarn1.1 2/93

NOTE Use Testing Booklet (Part No. 150 853) when checking solid-state parts. Opened
or installed parts cannot be returned for credit as new items.

Is input power
No Connect unit to proper input
connected to Does the breaker Yes
voltage (see Section 2-8). Turn down output current.
correct line trip when unit is set
(see Section 3-1).
voltage? on 115V?

Yes No

Is Changeover
switch S2 in
the correct No Place Changeover switch in Is Power switch
position for proper position for input No Place Power switch in the
S1 in the On
supply line voltage, 115 or 230 V (see On position. (see Section
position?
voltage? Section 2-8). 3-1).

Yes
Yes

Continued On
Next Page

TM-203 653 Page 16 AirForce 400

 *
On indicates pressure
switch not activated; Flash-
ing indicates intermittent
From Previous loss of pressure while
Page cutting. Turn Output control
fully counterclockwise to
Is Pressure Status Yes
“gas set” position (see
Yes light On or flashing? Section 3-1). Check for
gas/air flow at torch. Check
pressure switch S3 (gauge),
air filter, valve AS1, and air
supply connection to unit
* No and torch.
Is the cooling No Check Power switch S1 and
fan running? relay CR2 and thermistor R1
on PC2. Replace PC2 if R1
or CR2 are not functioning
correctly.
Press torch trigger and
Yes No check if pilot arc ignites.
Does pilot arc
Check torch consumables.
ignite?
*Check torch connections,
torch, and PC1.
*
This indicates an over or
Is Power light Yes under voltage condition.
flashing? Reset Power switch S1
and verify line power Yes
voltage (see Section 2-1).
Check relay CR2,
thermistor R1 on PC2, Place torch near workpiece
No and Control board PC1. and check if pilot arc “jumps”
or transfers to workpiece.
Does pilot arc No
Check work clamp
transfer to
connection. *Check Control
workpiece?
On indicates cup circuit board PC1 and connections,
open; Flashing indicates and torch and its connections.
Is Cup Status Yes consumables not making
light On or good contact. Check torch
flashing? consumables. Reset Power Yes
switch S1. If problem
persists, take ohm reading
on blue cup leads on torch.
No
Is output No
adjustable from Check Control board PC1,
16 to 27 torch, and connections.
amperes?
If unit is overheated, wait
Is Temp Status Yes while fan cools down unit
light On? temperature, and Temp
Status light turns off. Yes

Go to Section 5-2.
No

*Servicing procedure to be
performed only by authorized
Service Station.

AirForce 400 TM-203 653 Page 17

5-2. Troubleshooting Torch

Torch travel speed too slow;

increase travel speed (see
Does arc go Section 3-2). Clean or
Yes replace torch consumables
on and off Go to Section 5-1.
while cutting? as necessary (see Section
6-3). Be sure work clamp is
securely attached to
workpiece.

No

Be sure work clamp is

securely attached to work-
Yes piece. Make sure tip is on or
Does arc go out near, 1/16 in (1.6 mm) to 1/8
while cutting? Go to Section 5-1.
in (3.2 mm) workpiece (see
Section 3-4). Clean or
replace torch consumables
as necessary (see Section
6-3).

No

Torch travel speed too fast;

reduce travel speed (see
Section 2-1). Clean or
Do sparks come replace torch consumables
out of top of cut; Yes as necessary (see Section
or cut is not 6-3). Be sure work clamp is
clean? securely attached to
workpiece. Unit not capable
of cutting metals thicker
than rating (see Section
2-1).
No

Is Cup trouble Check torch shield cup (see

light On; unit Yes Section 5-6); reset unit
has no cutting Power switch. *Check torch Go to Section 5-1.
output? and connections inside unit.

No

Go to Section 5-1.

*Servicing procedure to be performed

only by authorized Service Station.

TM-203 653 Page 18 AirForce 400

Notes

AirForce 400 TM-203 653 Page 19

5-3. Troubleshooting Circuit Diagram

WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage
• Do not touch live electrical parts. parts on circuit boards.
• Turn Off power source and remove input power plug • Put on grounded wrist strap BEFORE handling
from receptacle. boards or parts.
• Use proper static-proof bags.

Have only qualified persons familiar with and

following standard safety practices perform
troubleshooting procedures. smwarn2.1 2/93

R2

R1
V1

V3

V4

V2 V4

V4

V5

Test Equipment Needed:

Figure 5-1. Troubleshooting Circuit Diagram For Power Source

TM-203 653 Page 20 AirForce 400
 Voltage Readings
a) Tolerance − ±10% unless specified
b) Voltages are based on a nominal 115 V
line voltage
c) Reference − to circuit common (TP3-4)
unless noted
d) Wiring Diagram − see Section 7

V1 115 volts ac (line voltage)

V2 115 or 230 volts ac (line voltage)
V3 170 volts ac
R3
See Section 5-4 V4 20 volts ac
R5
for PC1 data V5 24 volts dc approximately 2 seconds
after power up of unit
V7
V6 0 volts if IGBT temperature normal;
5 volts dc if IGBT temperature high
V7 0 volts with trigger switch open;
approximately 120 volts dc with pilot arc;
288 volts dc (OCV) momentarily with
electrode lead disconnected and trigger
closed (must use peak detect to read)
V8 approximately 90 volts dc while cutting
V8 V9
V9,V10 0 volts with trigger/cup closed;
24 volts dc with trigger/cup open
V11 24 volts dc with solenoid AS1 on;
0 volts with AS1 off
V12 24 volts dc with switch S3 open;
V10 0 volts with S3 closed
V13 Voltage across resistor R85 or R86
(located above large electrolytic
V11 capacitors, see Figure 5-2) on Control
board PC1 is buss voltage of
285 volts dc

V12

R85
R6 Resistance Values
a) Tolerance − ±10% unless specified
b) Turn Off unit, and remove input power
plug from receptacle before checking
resistance
V6 R1 All values for T1 are less than 1 ohm
R4
R2 10 ohms at ambient temperature.
R3-R4 Less than 1 ohm
V13
R5 0 ohms with solenoid AS1 off;
∞ ohms with AS1 on
R6 About 30 k ohms at 25° C (77° F), as
temperature increases or decreases from
25° C (77° F) R6 resistance decreases or
increases respectively.

200 809-D

AirForce 400 TM-203 653 Page 21

5-4. Troubleshooting Control Board PC1

WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage
• Do not touch live electrical parts. parts on circuit boards.
• Turn Off power source and remove input power plug • Put on grounded wrist strap BEFORE handling
from receptacle. boards or parts.
• Use proper static-proof bags.

Have only qualified persons familiar with and

following standard safety practices perform
troubleshooting procedures.
smwarn2.1 2/93

Check Power Control Board by using an ohmmeter to measure Be sure plugs are secure before
resistances to determine if IGBTs are shorted as follows: testing. Use Table 5-1 for specific
values during testing.
S Remove Power Control Board from unit.
1 Control Board PC1
S On back side of circuit board, measure resistance between
pairs of legs on IGBTs (3 combinations). If any value is 2 Receptacle RC1
below 1 K ohm, IGBT may be bad and requires replacing 3 Receptacle RC2
circuit board.
4 Receptacle RC3
S While circuit board is out of unit, visually inspect for other
possible problems such as blackened (burnt) components, 5 Receptacle RC4
broken legs on components, bad solder joints, etc. Replace 6 Receptacle RC6
circuit board as necessary.
7 Receptacle RC7
If circuit board is okay, reinstall it back into unit.
8 Receptacle RC8
9 Resistors R85 And R86

Test Equipment Needed:

2 8 5 6 3 1

9
Ref. 802 854 / 200 173-C

Figure 5-2. Control Board PC1 Testing Information (Use With Table 5-1)
TM-203 653 Page 22 AirForce 400
 Table 5-1. Control Board PC1 Test Point Values (Use With Figure 5-1 And Figure 5-2)

Voltage Readings:

a) Tolerance − ±10% unless specified b) Reference − to circuit common

(RC4-8) unless noted

Receptacle Pin Value

RC1 1 Cup switch: +24 volts dc in reference to RC1-2 (with cup off; 0 volts with cup on)

2 Cup switch: return

3 Trigger switch: +24 volts dc in reference to RC1-4 (with trigger released; 0 volts with trigger pressed)

4 Trigger switch: return

RC2 1 Thermistor: 2.64 volts dc at 22° C (72° F), 0.5 volts dc at 75° C (167° F) in reference to RC2-2

2 Circuit common

RC3 1 Main power: 170 volts ac in reference to RC3-2

2 Main power: 170 volts ac in reference to RC3-1

RC4 1 20 volts ac control power in reference to RC4-2

2 20 volts ac control power in reference to RC4-1

3 0 volts dc in reference to RC1-8 (with thermostat TP1 closed); +5 volts dc in reference to RC1-8 if
transformer T1 overheats (with thermostat TP1 open)

4 20 volts ac pilot IGBT power in reference to RC4-5

5 20 volts ac pilot IGBT power in reference to RC4-4

6 Not used

7 Not used

8 Circuit common

9 20 volts ac safety circuitry power in reference to RC4-10

10 20 volts ac safety circuitry power in reference to RC4-9

RC6 1 +24 volts dc with solenoid AS1 off; 0 volts dc with solenoid AS1 on

2 Solenoid AS1 return

RC7 1 +24 volts dc in-rush relay in reference to RC7-3

2 Not used

3 In-rush relay return

RC8 1 0 volts dc in reference to RC8-2 (with pressure switch S3 closed); +24 volts dc in reference to RC8-2
(with pressure switch S3 open)

2 Pressure switch S3 return

AirForce 400 TM-203 653 Page 23

5-5. Troubleshooting Changeover Board PC2

WARNING
ELECTRIC SHOCK can kill. STATIC ELECTRICITY can damage
• Do not touch live electrical parts. parts on circuit boards.
• Turn Off power source and remove input power plug • Put on grounded wrist strap BEFORE handling
from receptacle. boards or parts.
• Use proper static-proof bags.

Have only qualified persons familiar with and

following standard safety practices perform
troubleshooting procedures.
smwarn2.1 2/93

3 1 2 Be sure plugs are secure before

testing. Use Table 5-2 for specific
values during testing.
1 Changeover Board PC2
2 Receptacle RC21
3 Receptacle RC22

Test Equipment Needed:

Ref. 802 854 / 200 669-B

Figure 5-3. Changeover Board PC2 Testing Information (Use With Table 5-1)

Table 5-2. Changeover Board PC2 Test Point Values (Use With Figure 5-1 And Figure 5-3)

Voltage Readings:

a) Tolerance − ±10% unless specified

Receptacle Pin Value

RC21 1 +24 volts dc relay CR2 power in reference to RC21-2, 2 seconds after power up of unit

2 Relay CR2 return

RC22 1 115 volts ac fan power in reference to RC22-2

2 115 volts ac fan power in reference to RC22-1

TM-203 653 Page 24 AirForce 400

5-6. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System
If certain problems occur, the
Ready light goes off, a trouble light
comes on, and output stops.
1 Power Light
1 Light is steady if input power is
okay. Light flashes if input power is
2 less than 92 vac or greater than 138
vac.
3
2 Pressure Light
Lights if gas/air pressure is below
40 PSI (276 kPa).
Turn power Off, and check for
proper gas/air pressure (see
Section 3-1).
5 A flashing Pressure light while
cutting indicates that gas/air
system may be set too low, faulty,
leaking or has a flow restriction (see
Section 5-1).
3 Cup Light

Checking Torch Shield Cup Shutdown System For Cup light, proceed as follows:
Lights if shield cup is loose.
Turn power Off, and check shield
cup connection (see torch
Power must be reset whenever the cup shutdown system is activated. Owner’s Manual). Power must be
Always turn Off power when changing or checking consumables. reset whenever the cup
shutdown is activated.

Y Do not overtighten torch shield cup. A flashing Cup light indicates that
the torch consumables are stuck
or worn and should be inspected
and/or replaced (see Section
6-3).
4 Torch Shield Cup
4 To test shield cup, proceed as
follows:
Check shield cup shutdown
system once a week.
Turn Power On and loosen shield
cup. If shutdown system works
properly, Cup light comes on.
If not, turn power Off and
check consumables for
proper assembly.
5 Temperature Light
Lights if power source overheats or
when ambient temperature is below
−35° C (−31° F) (see Section 2-3).
If system works properly, retighten
cup and reset power.

Ref. 200 808 / Ref. 802 877

AirForce 400 TM-203 653 Page 25

 SECTION 6 − MAINTENANCE

6-1. Routine Maintenance

Y Disconnect power . Maintain more often

before maintaining. during severe conditions.

Each Use
Check
Check Torch Tip,
Gas/Air Electrode,
Pressure And Shield
Cup

Every Week

Check
Shield Cup
Shutdown
System

3 Months

Replace Service
Damaged Or Air Filter/
Unreadable Regulator
Labels

Replace
Cracked
Parts
Gas/Air Hose Torch Body, Cable

Tape Torn
Outer
Covering

6 Months

Blow Out Or
Vacuum Inside

TM-203 653 Page 26 AirForce 400

6-2. Torch And Work Cable Connections

If torch or work cable needs to be

removed or replaced, proceed as
follows:
5 Turn power Off, and disconnect
8 input power plug from receptacle.
4 6 Remove wrapper from unit.
7 Torch Connections
Remove existing torch cable from
unit as follows:
Disconnect lead ring terminals and
plug PLG1 from Control board PC1.
1
Disconnect torch air connector by
pushing on solenoid fitting collar
and pulling connector out from
2 fitting.
5 6
1 Strain Relief
2 Torch Cable
Insert cable through strain relief.
2
Slide strain relief nut onto torch
cable, but do not tighten.
4
3 Air Line Connector
Insert air line connector into
solenoid fitting.
3
3
4 Plug PLG1/Receptacle RC1
Connect PLG1 from torch to
4 receptacle RC1 on end of wiring
harness connected to circuit board
PC1.
5 Ring Terminal And Terminal
PILOT
Connect ring terminal on end of red
leads to PILOT terminal.
6 Ring Terminal And Terminal
L2−RED
Connect ring terminal on end of
white leads to L2−RED terminal.
Tighten strain relief nut.
Tighten strain relief around cable.
Work Cable Connections
Remove existing work cable from
unit.
7 Strain Relief

. Be sure to allow some work

cable slack inside the unit.
5 8 6
Insert work clamp lead through
strain relief, and install strain relief
into front panel.
8 Work Lead Ring Terminal
Connect ring terminal on end of
work clamp lead to terminal labeled
WORK on circuit board PC1. Route
lead along torch lead bundle.

Tools Needed:

1/4 in Ref. 802 854 / Ref. 802 860 / 200 173-C

AirForce 400 TM-203 653 Page 27

6-3. Checking/Replacing Retaining Cup, Tip, And Electrode

Overtightening will strip threads. Do not overtighten retaining cup during

assembly. Do not cross-thread parts causing stripping. Use care during torch
assembly and parts replacement.

Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly
reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.

A good practice is to replace both the tip and electrode at the same time.

Turn Off power source before checking torch parts.

Make sure this area is clean of

any debris.

6
Make sure swirl ring is clean of any
5
debris and no holes are obstructed.

4
3
New
1/16 in
(2 mm)
1 Pit

2
New

Worn

Worn
802 465-A

Turn Off power source. 4 Opening 6 Swirl Ring

1 Shield Cup
2 O-Ring
Remove shield cup. Check cup for cracks,
and replace if necessary.
Check O-ring for cracks or worn spots,
replace shield cup if necessary.
3 Tip
Remove tip. Check tip, and replace if
opening 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.
5 Electrode
Check electrode. If center has a pit more
than a 1/16 in (2 mm) deep, remove and
replace electrode.
Remove swirl ring. Check ring, and replace
if side holes are plugged.
7 O-Ring
Check O-ring for cracks or worn spots, and
replace if necessary.
Carefully reassemble parts in reverse order.

TM-203 653 Page 28 AirForce 400

Notes

AirForce 400 TM-203 653 Page 29

 SECTION 7 − ELECTRICAL DIAGRAMS

. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact distributor for further information.

Model Serial Or Style Number Circuit Diagram Wiring Diagram

AirForce 400 LB101130 and following 200 809-D ♦♦

Circuit Board PC1 LB101130 thru LB225380 200 174-C ♦♦

LB225381 thru LC487300 207 844 ♦♦

LC487301 and following 210 802-A ♦♦

Changeover Board PC2 LB101130 and following 200 671-A ♦♦

♦♦ Not included in this manual

TM-203 653 Page 30 AirForce 400

 200 809-D

Figure 7-1. Circuit Diagram For Power Source Effective With Serial No. LB101130 And Following

AirForce 400 TM-203 653 Page 31

 Figure 7-2. Circuit Diagram For Control Board PC1 Effective With
Serial No. LB101130 Thru LB225380 (Part 1 Of 2)
TM-203 653 Page 32 AirForce 400
 200 174-C (Part 1 Of 2)

AirForce 400 TM-203 653 Page 33

 Figure 7-3. Circuit Diagram For Control Board PC1 Effective With
Serial No. LB101130 Thru LB225380 (Part 2 Of 2)
TM-203 653 Page 34 AirForce 400
 200 174-C (Part 2 Of 2)

AirForce 400 TM-203 653 Page 35

 Figure 7-4. Circuit Diagram For Control Board PC1 Effective With
Serial No. LB225381 Thru LC487300 (Part 1 Of 2)
TM-203 653 Page 36 AirForce 400
 207 844 (Part 1 Of 2)

AirForce 400 TM-203 653 Page 37

 Figure 7-5. Circuit Diagram For Control Board PC1 Effective With
Serial No. LB225381 Thru LC487300 (Part 2 Of 2)
TM-203 653 Page 38 AirForce 400
 207 844 (Part 2 Of 2)

AirForce 400 TM-203 653 Page 39

 Figure 7-6. Circuit Diagram For Control Board PC1 Effective With
Serial No. LC487301 And Following (Part 1 Of 2)
TM-203 653 Page 40 AirForce 400
 210 802-A (Part 1 Of 2)

AirForce 400 TM-203 653 Page 41

 Figure 7-7. Circuit Diagram For Control Board PC1 Effective With
Serial No. LC487301 And Following (Part 2 Of 2)
TM-203 653 Page 42 AirForce 400
 210 802-A (Part 2 Of 2)

AirForce 400 TM-203 653 Page 43

 200 671-A

Figure 7-8. Circuit Diagram For Changeover Board PC2 Effective With
Serial No. LB101130 And Following

TM-203 653 Page 44 AirForce 400

 TM-203 653 August 2003

Processes
Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter


AirForce 400
And Ice-27C Torch

Eff w/LB101130 And Following

For OM-203 653 Revision * Thru C

Visit our website at

www.HobartWelders.com
 SECTION 8 − PARTS LIST

. Hardware is common and

not available unless listed. 2
1 3

5
6
7
8

24

23
9

22

21

10
20

19

11

18
12

17

16 13

15

14

802 805
Figure 8-1. Main Assembly

TM-203 653 Page 46 AirForce 400

 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-1. Main Assembly

. . . . . . . . . . . . . . . . . . . 212 525 . . COVER ASSY (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . +195 621
. . . 2 . . . . . . . . . . . . . 196 851
. . . 3 . . . . . . . . . . . . . 208 015
. . . 4 . . . . . . . . . . . . . 202 108
. . . . . . . . . . . . . . . . . . . 184 791
. . . 5 . . . . . L2 . . . . 200 816
. . . 6 . . . . . L1 . . . . 200 815
. . . 7 . . . . PC2 . . . 200 666
. . . 8 . . . . . . . . . . . . . 200 726
. . . 9 . . . . . FM . . . . 195 610
. . . 10 . . . . . S1 . . . . . 124 511
. . . 11 . . . . . . . . . . . . . 200 724
. . . 12 . . . . . . . . . . . . . 202 674
. . . 13 . . . . . . . . . . . . +200 729
. . . . . . . . . . . . . . . . . . . 179 190
. . . 14 . . . . . . . . . . . . . 205 641
. . . . . . . . . . . . . . . . . . . 200 878
. . . . . . . . . . . . . . . . . . . 204 005
. . . . . . . . . . . . . . . . . . . 082 590
. . . 15 . . . . AS1 . . . 206 257
. . . . . . . . . . . . . . . . . . . 206 000
. . . . . . . . . . . . . . . . . . . 204 003
. . . . . . . . . . . . . . . . . . . 204 004
. . . 16 . . . . . . . . . . . . . 200 728
. . . 17 . . . . . . . . . . . . . 200 875
. . . . . . . . . . . . . . . . . . . 204 004
. . . . . . . . . . . . . . . . . . . 204 005
. . . 18 . . . . PC1 . . . *200 172
. . . 18 . . . . PC1 . . . *205 852
. . . 18 . . . . PC1 . . . 213 150
. . . 19 . . . . . . . . . . . . . 138 044
. . . 20 . . . . . . . . . . . . . 195 014
. . . . . . . . . . . . . . . . . . . 121 276
. . . 21 . . . . . . . . . . . . . 199 021
. . . . . . . . . . . . . . . . . . . 203 988
. . . . . . . . . . . . . . . . . . . 199 995
. . . 22 . . . . . . . . . . . . . 200 517
. . . 23 . . . . . S3 . . . . 200 876
. . . . . . . . . . . . . . . . . . . 204 012
. . . 24 . . . . . T1 . . . . 208 825
. . . . . . . . . . . . . . . . . . . 201 201
*Part numbers 200 172 and 205 852 both supercede to 213 150.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
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.
. . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LABEL, warning precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . HANDLE, carrying rubberized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LABEL, ICE-27C consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . LABEL, HOBART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . INDUCTOR, buck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . INDUCTOR, boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD ASSY, primary change-over . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FAN, muffin 115V 50/60HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, power 10ft 14ga 3c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . VALVE/AIR FILTER ASSY, w/ftgs brkt & sealed valve (including) . . . . . . . 1
. . . . FILTER, air 5 micron 1/4NPT ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, elbow quick disconnect 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, pipe adapter 1/4NPTM x 1/4NPTF . . . . . . . . . . . . . . . . . . . . . . 1
. . VALVE, air w/fittings (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . VALVE, 24VDC 3 way 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, straight quick disconnect 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, elbow quick disconnect 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BRACKET, mtg air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . REGULATOR, air w/fittings (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, elbow quick disconnect 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . FITTING, elbow quick disconnect 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . CIRCUIT CARD ASSY, control w/pgm (Prior to LB225381) . . . . . . . . . . . . 1
. . CIRCUIT CARD ASSY, control w/pgmEff w/ LB225381 thru LC487300) . 1
. . CIRCUIT CARD ASSY, control w/pgm (Eff w/ LC487301 and following) . 1
. . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . ICE-27C 20ft hand held (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, work 15ft 12ga w/clamp (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . CLAMP, work 150A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . TIP, contact work clamp copper 150A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . GAUGE, air w/pressure switch & fitting (consisting of) . . . . . . . . . . . . . . . . 1
. . . . FITTING, quick disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . TRANSFORMER, toroid main 60HZ 115/230V pri . . . . . . . . . . . . . . . . . . . . 1
. . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

AirForce 400 TM-203 653 Page 47

 Item Part
No. No. Description
1 183 427 Handle Assy, complete (1)
1 2 171 248 Push Button Switch (1)
3 203 120 Leads, 20ft (1)
4 203 119 Main Body (1)
2 3
5 185 833 Switch Assembly
w/spring (1)
190 220 Spring, trigger assembly
169 231 Grease, silicone (1)
195 014 Torch, replacement 20ft (1)

See Figure 8-3 for

additional consumable parts.

Figure 8-2. Torch, ICE-27C

202 108-A

Figure 8-3. Consumable Parts For ICE-27C

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.

TM-203 653 Page 48 AirForce 400

Notes
 Hobart Welding Products
An Illinois Tool Works Company
600 West Main Street
Troy, OH 45373 USA
For Technical Assistance:
Call1-800-332-3281
For Literature Or Nearest Dealer:
Call 1-877-Hobart1

PRINTED IN USA  2003 Hobart Welding Products