TM-926A 2007−05

Eff w/Serial Number LC309838 And

Following
Processes
Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter

AirForce 625
And ICE-40C Torch

File: Plasma Cutters

 TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-2. Specifications For Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-4. Torch Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3-5. Unit Dimensions, Weight, And Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-6. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-8. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-9. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-10. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or Champion 10,000 9
3-11. Installing Alternative Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-12. Setting Gas/Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-2. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-3. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-7. Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 5 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 6 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-1. Power Source Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-2. Torch Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-3. Pilot IGBT, Input Rectifier SR1, And Output Rectifier SR2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 20
6-4. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-5. Replacement Procedure For Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-6. Overload Protection: Status Lights & Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . 26
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7-2. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-3. Torch And Work Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

OM-926L - 2007−04, safety_ptm 2007−04

DANGER! − Indicates a hazardous situation which, if  Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions  Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
 Use proper static-proof bags to store, move, or
ship PC boards.
Only qualified persons should service, test, maintain, and
repair this unit.
FIRE OR EXPLOSION hazard.
During servicing, keep everybody, especially children, away.
 Do not place unit on, over, or near combustible
surfaces.
ELECTRIC SHOCK can kill.  Do not service unit near flammables.

 Do not touch live electrical parts. FLYING METAL or DIRT can injure eyes.
 Turn OFF power source, and disconnect and
lockout input power using line disconnect  Wear safety glasses with side shields or face
switch, circuit breakers, or by removing plug shield during servicing.
from receptacle before servicing unless the  Be careful not to short metal tools, parts, or
procedure specifically requires an energized wires together during testing and servicing.
unit.
 Insulate yourself from ground by standing or working on dry insu-
lating mats big enough to prevent contact with the ground. HOT PARTS can cause severe burns.
 Do not leave live unit unattended.
 Do not touch hot parts bare handed.
 If this procedure requires an energized unit, have only personnel
 Allow cooling period before working on equip-
familiar with and following standard safety practices do the job.
ment.
 When testing a live unit, use the one-hand method. Do not put
 To handle hot parts, use proper tools and/or
both hands inside unit. Keep one hand free.
wear heavy, insulated welding gloves and
 Do not touch torch parts if in contact with the work or ground. clothing to prevent burns.
 Turn off power before checking, cleaning, or changing torch
parts.
EXPLODING PARTS can cause injury.
 Do not bypass or try to defeat the safety interlock systems.
 Use only torch(es) specified in Owner’s Manual.  Failed parts can explode or cause other parts to
 Point torch away from your body and toward workpiece when explode when power is applied to inverters.
pressing the torch trigger − pilot arc comes on immediately.  Always wear a face shield and long sleeves
 The pilot arc can cause burns − keep away from torch tip when when servicing inverters.
trigger is pressed.
 Disconnect input power conductors from deenergized supply line SHOCK HAZARD from testing.
BEFORE moving power source.
 Turn Off power source before making or chang-
SIGNIFICANT DC VOLTAGE exists after removal of ing meter lead connections.
input power on inverters.  Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
 Turn Off inverter, disconnect input power, and discharge input ca-
 Read instructions for test equipment.
pacitors according to instructions in Troubleshooting Section
before touching any parts.

AirForce 625 TM-926 Page 1

 H.F. RADIATION can cause interference.
 High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
 Have only qualified persons familiar with electronic equipment
install, test, and service H.F. producing units.
 The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
 If notified by the FCC about interference, stop using the equip-
ment at once.
 Have the installation regularly checked and maintained.
 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.
FALLING UNIT can cause injury.
 Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
 Use equipment of adequate capacity to lift and
support unit.
 If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
 Wearers of Pacemakers and other Implanted
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the
device manufacturer.
MOVING PARTS can cause injury.
 Keep away from moving parts such as fans.
 Have only qualified people remove doors, pan-
els, covers, or guards for maintenance and
troubleshooting as necessary.
 Keep hands, hair, loose clothing, and tools away from moving
parts.
 Reinstall doors, panels, covers, or guards when servicing is
finished.
1-3. 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
1-4. EMF Information
Considerations About Welding Or Cutting And The Effects Of Low
Frequency Electric And Magnetic Fields
Welding or cutting current, as it flows through the welding or cutting
cables, will cause electromagnetic fields. There has been and still is
some concern about such fields. However, after examining more than
500 studies spanning 17 years of research, a special blue ribbon
committee of the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human-
health hazard.” However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following proce-
dures:
TM-926 Page 2
CUTTING can cause fire or explosion.
 Protect yourself and others from flying sparks
and hot metal.
 Do not cut where flying sparks can strike flam-
mable material.
 If test cuts are required, follow Safety Precautions in Owner’s
Manual and on safety label(s).
NOISE can damage hearing.
Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
 Use approved ear plugs or ear muffs if noise level is high.
 Warn others nearby about noise hazard.
OVERUSE can cause OVERHEATING.
 Allow cooling period; follow rated duty cycle.
 Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
 Do not block or filter airflow to unit.
READ INSTRUCTIONS.
 Use Testing Booklet (Part No. 150 853) when
servicing this unit.
 Consult the Owner’s Manual for cutting safety
precautions.
 Use only genuine replacement parts from the
manufacturer.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep cutting power source and cables as far away from operator
as practical.
5. Connect work clamp to workpiece as close to the cut as possi-
ble.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
AirForce 625
 SECTION 2 − DEFINITIONS
2-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label

A Amperes
Plasma Arc Cutting
(PAC)
Adjust Air/Gas
Pressure
Low Air Pressure
Light

V Volts Increase
No − Do Not Do
This
Temperature

Protective Earth
Single Phase Constant Current Voltage Input
(Ground)

On Off Percent Direct Current

U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional Load
Voltage
Line Connection

Single Phase
Static Frequency
I1max Rated Maximum
Supply Current I2 Rated Welding
Current X Duty Cycle Converter-
Transformer-
Rectifier

IP Degree Of
Protection
Loose Shield Cup Input Hz Hertz

Suitable for Some Power Rating,

I1eff Maximum Effective
Supply Current pf power factor
S Hazardous
Locations
S1 Product Of Voltage
And Current (KVA)

AirForce 625 TM-926 Page 3

 SECTION 3 − INSTALLATION
3-1. Specifications
Amperes Input at
Rated Load Rated Maximum
Rated Type of Plasma
50/60 Hz Output 50/60 Hz Cutting Open-Circuit
Output Output Gas
Capacity Voltage DC
208 V 230 V KVA KW
Direct
40 A @ 140
Current, Air Or 0.5 in
Single- Volts DC,
33 30 6.8 6.7 Straight Nitrogen (12.7 mm) 260
Phase 50% Duty
Polarity Only At 16 IPM
Cycle
(DCEN)

3-2. Specifications For Torch

Air-cooled torch for plasma arc cutting (PAC)

50% duty cycle

Safety interlock devices disable power source

Safety trigger guard

Cutting capacity: see Section 3-1

3-3. Duty Cycle And Overheating

For Units Connected to a 208 Volt Circuit or a 230 Volt Circuit: Duty Cycle is percentage of 10
50% Duty Cycle At 40 amperes, 140 volts dc (typical cutting) minutes that unit can cut at rated
load without overheating.
If unit overheats, output stops,
temperature status light
illuminates, 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.
5 Minutes Cutting 5 Minutes Resting
! Exceeding duty cycle can
damage unit and void
warranty.
Overheating
A

15
OR
Minutes Reduce Duty Cycle sduty1 5/95 / Ref. 803 219

3-4. Torch Dimensions And Weight

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

3.5 lb (1.6 kg) With 25 ft (7.6 m) Cable

1-3/8 in (35 mm)
Ref. 801 397-A

TM-926 Page 4 AirForce 625

3-5. Unit Dimensions, Weight, And Movement

17-1/4 in
Dimensions And Weight (438 mm)

57 lb (25.9 kg)

15-1/4 in
(387 mm)

10-1/4 in
(260 mm)

Movement 1 Lifting Handles

Use handles to lift unit.
! Do not move or operate unit where 2 Hand Cart
it could tip. Use cart or similar device to move
unit.

loc_2 3/96 - Ref. 803 219 / 803 220

AirForce 625 TM-926 Page 5

3-6. Connecting Work Clamp and Gas/Air Supply
1 1 Work Clamp
2 Workpiece
Connect work clamp to a clean,
paint-free location on workpiece, as
close to cutting area as possible.

 Use only clean, dry air with 90

2 to 120 psi (621 to 827 kPa)
pressure. Prevent moisture
from entering air supply at
extreme cold temperatures.
3 Gas/Air Inlet Opening
4 Hose

 Hose must have a minimum

5 inside diameter of 3/8 in
3 (9.5 mm).
5 Teflon Tape
Obtain hose with 1/4 NPT right-
hand thread fitting. Wrap threads
with teflon tape (optional) or apply
4 pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
Or
From Gas/Air Supply
Install supplied quick connect male
1/4 in NPT pipe fitting.
Connect female quick connect
AIR/N2 fitting to pipe fitting.
Tools Needed:
90-120 psi Rear of Unit Route hose to gas/air supply.
5/8, 1-1/8 in ! Incorrect plasma gas can
cause torch and power
source damage. Use only air
or nitrogen for the plasma
gas.

Ref. 801 319-C / Ref. 803 221

TM-926 Page 6 AirForce 625

3-7. Electrical Service Guide
50/60 Hz Single Phase
Input Voltage 208 230
Input Amperes At Rated Output 33 30
Max Recommended Standard Fuse Rating In Amperes
Cricuit Breaker 1, Time-Delay 2 40 35
Normal Operating 3 50 45
Min Input Conductor Size In AWG 4 10 10
80 98
Max Recommended Input Conductor Length In Feet (Meters)
(24) (30)
Min Grounding Conductor Size In AWG 4 10 10

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp 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
310.16. 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.

Warning: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

3-8. Extension Cord Data

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

Input Power Fuse Size Or

Input Voltage Phase Hertz Circuit Breaker Rating Conductor Size Max. Cord Length

Time-Delay 2 40 A
208 V 1 50/60 10 AWG 80 ft (24 m)
Normal Operating 3 50 A

Time-Delay 2 35 A
230 V 1 50/60 10 AWG 98 ft (30 m)
Normal Operating 3 45 A

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

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

AirForce 625 TM-926 Page 7

3-9. Selecting A Location And Connecting Input Power

1 Plug (NEMA Type 6-50P)

2 Receptacle
(NEMA Type 6-50R)
Connect plug to receptacle.
3 Input And Grounding
Conductors
For single-phase operation:
18 in (457 mm) of
space for airflow ! Do not move or operate unit ! Make input power
where it could tip. connections to the machine
before making connections
into a deenergized line
disconnect device. In the line
disconnect device, always
connect green or
green/yellow grounding
= GND/PE conductor to supply
grounding terminal first,
! Always connect never to a line terminal.
grounding conductor first. Connect directly to line disconnect
device if hard wiring is required.
4 Line Disconnect Device
Green Or See Section 3-7.
Green/Yellow
! Special installation may be
required where gasoline or
volatile liquids are present −
4 see NEC Article 511 or CEC
Section 20.
L1 (Black)
L2 (White)

Install conductors into

a deenergized line
disconnect device.

L2 L1
 Serial Number/Rating Label located on
rear panel of plasma cutter; use label to
determine input power for unit.
230 VAC, 1

208 959 / 803 222

TM-926 Page 8 AirForce 625

3-10. 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: 2 3 3 Neutral (Brass) Terminal And
3 Prong (Not Used)
4 4
7 4 Load 1 (Brass)Terminal And
Prong
5 Load 2 (Brass) Terminal And
240V Prong
3/16 in 5 6 Ground (Brass) Terminal And
6 Prong
6 5
8 Plug Front 7 Black And White Input
View 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 Green Or
Green/Yellow

! Engine Control Switch must be set at ! Set generator Fine Adjustment Control to 10
“RUN” position − not “RUN/IDLE”. for maximum auxiliary power, if applicable.

Ref. 120 813-D / Ref. 803 222

AirForce 625 TM-926 Page 9

3-11. Installing Alternative Plug
 This procedure is necessary if the unit is to be connected to a 208/230 VAC
receptacle that requires a plug that is different from the supplied plug.
Tools Needed:
3-12. Setting Gas/Air Pressure
2
3
4 AIR/N2
Setting Gas/Air Pressure
Place Output Control in
Gas/Air Set Position
Power Switch On
Set Controls
1 Power Switch
Place power switch in On position
TM-926 Page 10
1 Supplied 230 VAC Plug
Cut cord close to plug.
2 Alternative Plug (230 VAC
Plug Shown)
2
3 Input (Black Lead)
(Brass) Terminal
4 Neutral (White Lead)
3 (Brass) Terminal
6 5 Ground (Green) Terminal
1 6 Outer Shell
7
7 Cord Grip
4
Strip cord jacket back enough to
5 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.
Ref. 801 305-A / 801 611
90-120 psi
Rear of Unit
Ref. 803 219 / Ref. 803 221
Requires
90−120 PSI Supply Set To 75 PSI (517 kPa) For Cutting
(621−827 kPa) Or 55 PSI (379 kPa) For Gouging
Select Desired
Turn On Gas/Air Supply Adjust Pressure Amperage To
On Unit Begin Cutting
2 Output Control 4 Gas/Air Pressure Adjustment Knob
Place output control in Gas/Air position. Adjust pressure to 75 psi (517 kPa) on
3 Pressure Gauge pressure gauge by pulling and turning knob.
Push knob in to lock setting.
Select desired cutting output with Output
Control.
AirForce 625
 SECTION 4 − OPERATION
4-1. Controls

5 6
Ref. 211 048

1 Output Control 4 Power Switch  At ambient temperatures below −55 C

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.
2 Status Lights (See Section 6-6)
3 Power Light
 The fan will normally run for
approximately 5 seconds after power
switch is placed in the Off position.
5 Pressure Gauge
6 Pressure Adjustment Knob
(235 F), readjustment of gas/air
pressure regulator may be necessary
(see Section 3-12).
Use only clean, dry air with 90 to 120 psi
(621 to 827 kPa) pressure. Prevent
moisture from entering air supply at
extreme cold temperatures.

4-2. Cutting Speed

400 The cutting speed curve shows the
recommended maximum cutting
350 speed capabilities of the power
source and torch for mild steel of
Cut Speed(in./min.)

various thickness.
300
The best cut quality is achieved by
250 cutting near the chart line. Cutting
below the line (too slow) will result
in excess dross. Cutting above the
200 line (too fast) will cause blowback
and lack of penetration.
150
100
50
0
16GA 1/8th 1/4th 3/8th 5/8th
(0.060)
Mild Steel Thickness(inches)

AirForce 625 TM-926 Page 11

4-3. Trigger Safety Lock
1 Trigger

Trigger Locked Trigger Unlocked

801 397-A

4-4. Plasma Cutting System Practices

! The pilot arc starts immediately when
trigger is pressed.

Always connect work clamp to a clean,  Set correct air pressure for process: DO NOT start pilot arc without cutting or
paint-free location on workpiece, as close to 75 PSI (517 kPa) for cutting, gouging as this shortens the service life
cutting area as possible. 55 PSI (379 kPa) for gouging. of the nozzle and electrode.

90°

Maintain approximately a 90° angle to the Sparks should pass through the workpiece If sparks flare back from surface, this
workpiece surface for proper cutting results. and out the bottom when cutting. usually is an indication that either travel
speed is too fast or amperage is set too low.

Wt

1/8 in
(3.2 mm)

When doing extended (non-shielded) DO NOT put pressure on shield when Pulling rather than pushing the torch
cutting, maintain approximately 1/8 in drag cutting; instead, slide shield along makes cutting easier. Use a proper guide
standoff between electrode and surface. the surface for proper cutting results. or template for accurate cutting operations.

801 400-B / Ref. 802 878

TM-926 Page 12 AirForce 625

4-5. Sequence Of Cutting Operation

Connect work clamp to a clean, paint-free  Set air pressure to 75 PSI (517 kPa) for cutting.
location on workpiece, as close to cutting
area as possible.

! The pilot arc starts immediately when

trigger is pressed.

90°

For standard (shielded) cutting, place drag Raise trigger lock and press After cutting arc starts, slowly
shield on edge of metal. For extended trigger. Pilot arc starts. start moving torch across metal.
(non-shielded) cutting, use 1/8 in (3.2 mm)
standoff distance (dragging tip will reduce tip
life).

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

801 400-B

AirForce 625 TM-926 Page 13

4-6. Sequence Of Gouging Operation

Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
 Set air pressure to 55 PSI (379 kPa) for gouging.
! The pilot arc starts immediately when
trigger is pressed.

455

Hold torch at approximately
45° angle to workpiece.
Raise trigger lock and press trigger. Pilot
arc starts. Move tip to within approxi-
mately 3/16 in (4.8 mm). Start gouging
across workpiece surface. Maintain
approximately a 45° angle to surface.
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.

801 400-B

TM-926 Page 14 AirForce 625

4-7. Sequence Of Piercing Operation

! The pilot arc starts immediately when

trigger is pressed.

Connect work clamp to a clean, paint-free  Set air pressure to 75 PSI Hold torch at an angle to the
location on workpiece, as close to cutting (517 kPa) for cutting. workpiece. Raise trigger lock and
area as possible. press trigger. Pilot arc starts.

90° 90°

Rotate torch to upright position Maintain approximately 90° torch Release trigger. Postflow continues for
approximately 90° to surface. position to surface, and continue approx. 20 seconds after releasing trigger;
When arc has pierced through cutting. arc can be instantly restarted during postflow
workpiece, start cutting. by raising trigger lock and pressing trigger.

801 400-B

AirForce 625 TM-926 Page 15

 SECTION 5 − THEORY OF OPERATION
1 Power Cord
Provides input power to the
machine and defines the chassis
potential.
2 Line Filter Board PC3
Provides filtering to protect other
equipment connected to the same
branch circuit from noise generated
by unit.
3 Power Switch S1
Provides on/off control of power to 5 6
Power Control board PC1.
4 Power Control Board PC1
Boost Buss Capacitor
Delivers 40 amperes of controlled Inductor
C85
output current through L2 to the L1
torch (approximately 12 amperes
for pilot arc).
Delivers a regulated 28 Vdc to the
air solenoid AS1 and fan whenever 4
the torch trigger contacts close.
2 3
Controls voltage across buss
capacitor C85 to ensure good 1 Power Cord
cutting performance at low line Power
voltages. Line Filter
Switch
208 or 230 Board PC3
Actively power factor corrects line S1
draw to improve line current draw VAC Single
and total harmonic distortion. Phase Line
Input Power
Controls all logic and timing 16
functions as follows: Power Control Board
Pot Command
 20 seconds of postflow through PC1
LED/POT
air solenoid valve AS1
Board
 3.5 seconds for pilot arc timeout PC2 LED Status
 Instantaneous detection of arc
outage at end of cut to maintain
a pilot arc
 Active line voltage monitoring to
protect unit from over or under
voltage extremes.
Receives inputs as follows:
 Safety protection for torch cup to 28Vdc Closed upon increasing
ensure consumables are pressure
40 psi setpoint
correctly installed
15
 Temperature feedback from 14
thermistors RT1 (T1) and
R1 (Boost IGBT) Air Solenoid Pressure
Valve Switch
 Torch trigger signal allows AS1 S2
operator to begin and end the
cutting process
 Pressure switch S2 provides
feedback of the regulated gas/
air pressure that supplies the
torch
 Shuts down inverter if Current
transformer CT1 signal is too
high.
5 Boost Inductor L1
Stores energy in order to control
boost voltage across C85 and
power factor correct line draw.
6 Buss Capacitor C85
Stores voltage (approximately
390V) for use in controlling output.

TM-926 Page 16 AirForce 625

 7 Current Transformer CT1
AC Or DC Control Circuits Provides instantaneous feedback
of main transformer current in case
of surges.
1φ Power
8 Main Transformer T1
Supplies power for cutting circuit
Cutting And Pilot Current Circuits and isolates output from line power.
Gas/Air 9 Thermistor RT1
Provides feedback to power control
board PC1 to protect transformer
7 8 10 from overheating. Power control
board also uses RT1 to detect cold
Main Transformer extremes and open conditions.
T1 Output
Current 10 Output Inductor L2
Transformer Inductor
9 Thermistor L2 Directly connected to torch
CT1
RT1 electrode. L2 sustains/smooths
output amperage.
Primary 10K ohms
Current 11 Torch
at 25° C
Feedback Receives inputs from:
 PC1 − supplies 12 A for pilot arc
and 15-40 A for cutting
 Solenoid AS1 − supplies air for
cutting and cooling.
Provides outputs to PC1:
 Torch cup − safety protection
to ensure consumables are
correctly installed
 Torch trigger signal allows
operator to begin and end
Power Control Board the cutting process.
PC1
12 Work Clamp/Workpiece

Electrode Connecting clamp to workpiece

Leads (−) provides closure of cutting circuit
(clamp must be connected to
workpiece for unit to operate
Pilot Leads (+) properly).
13 Fan FM1
Provides cooling of internal
components as needed. Fan turns
28Vdc on when trigger is pressed or as
Trigger 11 needed to cool overheated
13 components.
Cup 14 Pressure Switch S2
Fan
FM1 Provides air pressure feedback to
Electrode (−) PC1. Switch closes at regulator
12 pressures above 40 psi; otherwise,
switch is open.
Work Clamp Workpiece (+) 15 Air Solenoid Valve AS1
& Cable (+)
Controls air used for cutting and
cooling the torch.
16 LED/Pot Board PC2
Provides interface to operator.
LED’s indicate unit status.
Potentiometer provides amperage
control of output current supplied to
torch (see Section 6-6).

AirForce 625 TM-926 Page 17

 SECTION 6 − TROUBLESHOOTING
6-1. Power Source Troubleshooting Table
 The pilot IGBT, input rectifier SR1, and output rectifier SR2 troubleshooting should be followed if any of the following conditions exist
(see Section 6-3):
S the symptoms are unknown;
S visual damage is found on the input rectifier SR1 or output rectifier SR2;
S there is no output or limited output.
S the unit is completely inoperative;

 See Section 6-4 for test points and values and

Parts List for parts location.

! Check voltage on capacitor C85 according to Section 6-5 and be sure voltage is near zero (0) before touching any parts.

Trouble
No cutting output; Power light off; Status
lights off; fan motor does not run.
No cutting output; Cup Status light on or
flashing.
Remedy
Check input power supply (see Section 6-4).
Check resistance at Power switch S1 and replace if necessary (see Section 6-4).
Check Control board PC1 and connections, and replace if necessary (see Sections 6-3 and 6-4).
Turn Power switch S1 off and back on again (see Section 6-6).

Check torch consumables/cup (see Sections 7-2 and 6-6).

No cutting output; Temp Status on; fan
motor running.
No cutting output; Pilot arc does not
ignite.
Pilot arc ignites, but does not transfer to
work.
Check Control board PC1 and connections, and replace if necessary (see Sections 6-3 and 6-4).
If unit is overheated, wait while fan cools down unit temperature (see Section 6-6).
Check Control board PC1 and connections, and replace if necessary (see Sections 6-3 and 6-4).
Check torch consumables/cup, and replace if necessary (see Sections 7-2 and 6-6).
Check gas/air supply connection to unit and torch (see Section 3-6).
Check torch connections to Control board PC1 (see Section 6-4).
Check pressure switch S2, and replace if necessary (see Section 6-4).
Check gas/air valve AS1, and replace if necessary (see Section 6-4).
Check air filter, and replace if necessary.
Check Control board PC1 and connections, and replace if necessary (see Section 6-4).
Check work clamp and work cable connection, and replace if necessary (see Section 7-3). Be sure work
clamp is securely attached to a clean, dry surface on the workpiece (see Section 3-6).

Does unit make a quality cut?
Arc goes out while cutting. Power light
flashing; trouble lights off.
Place torch tip near workpiece and check if pilot arc “jumps” or transfers to workpiece.
Replace torch consumables (see Section 7-2).
Check Control board PC1 and connections, and replace if necessary (see Section 6-4). Check torch
and connections, and replace if necessary (see Section 7-3).
Replace torch consumables. Check torch and connections, and replace if necessary (see Section 7-3).
Check Control board PC1 and connections, and replace if necessary (see Sections 6-3 and 6-4).
Check input power supply (see Section 6-4). Input voltage must be within ±15% specified voltages
and connected using proper sized input conductors (see Sections 3-7 and 3-9).

Pressure Status light on.
Check gas/air supply connection to unit (see Section 3-6).
Turn Output control fully clockwise (see Section 4-1).
Check pressure switch S2, and replace if necessary (see Section 6-4).
Check gas/air valve AS1, and replace if necessary (see Section 6-4).
Check air filter, and replace if necessary.
Check Control board PC1 and connections, and replace if necessary (see Section 6-4).

TM-926 Page 18 AirForce 625

 Trouble Remedy
Pressure Status light flashing. Turn Power switch S1 off and back on again (see Section 6-6).
Check gas/air supply connection to unit (see Section 6-4).
Check air filter, and replace if necessary.
Check pressure switch S2, and replace if necessary (see Section 6-4).
Check gas hoses for leaks.
Check gas/air valve AS1, and replace if necessary (see Section 6-4).
Check Control board PC1 and connections, and replace if necessary (see Section 6-4).

6-2. Torch Troubleshooting Table

 See Parts List for parts location.

Trouble Remedy
Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 4-2). Clean or replace torch consumables
as necessary (see Section 7-2). Be sure work clamp is securely attached to workpiece.

Sparks come out of top of cut; or cut is Torch travel speed too fast; reduce travel speed (see Section 4-2). Clean or replace torch consumables
not clean. as necessary (see Section 7-2). Be sure work clamp is securely attached to workpiece. Unit not capable
of cutting metals thicker than rating (see Section 3-1).

Cup trouble light On; unit has no cutting Check torch shield cup (see Section 6-6); reset unit Power switch. Check torch and connections inside
output. unit.

AirForce 625 TM-926 Page 19

6-3. Pilot IGBT, Input Rectifier SR1, And Output Rectifier SR2 Troubleshooting
1 Capacitor C85
Test Equipment Needed:
2 Control Board PC1
3 Wind Tunnel
4 L2 (Red)
5 IGBT Work
6 L2 (Black)
7 SR2 T1-4
C85
− 8 SR2 T1-3
+
9 Plug PLG9
1 10 T1-1
11 T1-2
RC11 12 L1 (Red)
3 4 13 SR1 No. 3
2 5 14 L1 (Black)
2
65 1 6 15 SR1 No. 4
11
16 Capacitor Screws
17
1 17 Ground Strap (COM)
3 Follow these procedures to troubleshoot
4 unit:
10 ! Turn Off power source, disconnect
input power, and lockout/tagout the
7
supply circuit.
8
! Before touching any parts, check
16 DC voltage on capacitor C85 and be
sure it is near zero (0) .
a Put on grounded wrist strap
BEFORE handling boards or
9
parts.
b Check Pilot IGBT PM1 from work
15 to RC11-3, reading should be
12 greater than 10 k ohms.
13 c Check input rectifier SR1 accord-
14
ing to the checklist.
d Check output rectifier SR2 accord-
ing to the checklist.

 Input Rectifier SR1 Checklist

Set meter to diode range 
SR 1 No. 3 or AC1 (+) to L1-BLK (−) ≈ +0.481 volts dc 
SR1 No. 4 or AC2 (+) to L1-BLK (−) ≈ +0.638 volts dc♦ 
Negative side of C85 (+) to No. 4 or AC2 (−) ≈ +0.638 volts dc♦ 
Negative side of C85 (+) to No. 3 or AC1 (−) ≈ +0.481 volts dc 
♦ Higher reading due to resistor R115 in circuit. 

 Output Rectifier SR2 Checklist

Set meter to diode range 
SR2 T1-3 (+) to work (−) ≈ +0.363 volts dc 
SR2 T1-4 (+) to work (−) ≈ +0.363 volts dc 
L2-BLK (+) to T1-3 (−) ≈ +0.365 volts dc 
L2-BLK (+) to T1-4 (−) ≈ +0.365 volts dc 
Ref. 803 276

TM-926 Page 20 AirForce 625

 Receptacle Be sure plugs are secure before
RC11 testing. Use Section 6-4 for specific
Socket 3 values during testing.
Front View Of PC1
1 Control Board PC1
COM 2 Heatsink Location

3 4 8 7 5 6 13 14 1  Circuit board PC1 shown

without heat sink attached for
component reference only.
3 Receptacle RC1
4 Receptacle RC3
5 Receptacle RC4
6 Receptacle RC5
7 Receptacle RC7
10 8 Receptacle RC8

11 9 Receptacle RC9
10 Receptacle RC11
11 Work
12 Pilot IGBT PM1
16
13 Capacitor C85
2 14 Precharge Resistor R115
15 Rectifier SR1
16 Rectifier SR2

12 15
9

Ref. 803 315 / 206 168-A

AirForce 625 TM-926 Page 21

6-4. Troubleshooting Circuit Diagram

F1

V4
R1

LED1
V1 V2 V3

R3
R4
R2

+5 VDC
Power
Pressure
Cup
Temp
+5 VDC
Output Adj (0 to +5 VDC)
COM
COM

See Section 6-3

for PC1 data
Resistance Values
a) Tolerance − ±10% unless specified
b) Turn Off unit and disconnect input power before
checking resistance
c) See Section 6-3 for PC1 receptacle locations
R1, R2 Power switch S1; off = open, on = approximately zero (0)
ohms
R3 Less than 10 ohms
R4 10 k ohms at 25° C/77° F, PLG7 disconnected from PC1
(reconnect after checking)
Test Equipment Needed:
R5 No trigger, 113 k ohms; triggered, zero (0) ohms
R6 Cup in place, zero (0) ohms; cup off or loose, 113 k ohms
R7 25 ohms

Figure 6-1. Troubleshooting Circuit Diagram For Power Source

TM-926 Page 22 AirForce 625
 Voltage Readings
Tolerance − ±10% unless specified
V1 Primary voltage 208/230 volts ac
V2 Switched primary voltage 208/230 volts
ac with S1 in On position
V3 +393 volts dc ±2%
V5
V6 V4 LED1 on when buss voltage (C85) is
above +100 volts dc
V5 +155 volts dc while in pilot mode
R5 R6 V6 +130-180 volts dc while cutting
V7 +28 volts dc (see Section 6-6 for
fan-on-demand operation
V8 +28 volts dc when Output control is in
gas set position or while cutting
V9 0 volts dc when pressure is 40 psi or
more; otherwise, + 5 volts dc
V8

V9 Frequency Readings
F1 19.8 Khz while unit is triggered

V7

R7

212 926-A

AirForce 625 TM-926 Page 23

6-5. Replacement Procedure For Control Board PC1
1 Capacitor C85
2 Control Board PC1
3 Wind Tunnel
4 L2 (Red)
5 Work
6 L2 (Black)
7 T1-4
8 T1-3
9 Plug PLG9
C85 10 T1-1
− 11 T1-2
+
12 L1 (Red)
1
13 #3
14 L1 (Black)
18 15 #4
1 16 Capacitor Screws
3
17 Ground Strap (CDM)
18 Securing Hardware On Top Of
Windtunnel (3)
4 2 19 Control Board Securing
17 65 Hardware (6)

11 19

7
8
18
9
10
16

15 19
12
19 13
14

Tools Needed:

5/16 (M5), 3/8 in

803 276

TM-926 Page 24 AirForce 625

  Have only qualified persons familiar with and following standard safety practices perform troubleshooting procedures.
A. PC1 Removal Procedure
! Turn Off power source, disconnect input power, and lockout/tagout the supply circuit.
! Before touching any parts, check DC voltage on capacitor C85 and be sure it is near zero (0) .
1. Put on grounded wrist strap BEFORE handling boards or parts.
2. Mark and disconnect all plugs from control board PC1. Be sure to disconnect plug PLG9 from receptacle
RC9 located in lower right corner of PC1.
3. Mark and disconnect all leads from stand-off terminals (designators are located near terminals). Be sure
to slide rubber boot away from work lead terminal. Remove and retain all brass nuts (11 total) from termi-
nals.
4. Remove and retain phillips head screws (6 total) securing PC1 to side of wind tunnel.
5. Remove and retain screws (2 total) that connect capacitor C85 to PC1.
6. Remove and retain screws (3 total) securing PC1 to top of wind tunnel.
7. Remove and retain brass nut (1) securing ground strap to top of wind tunnel.
8. Remove PC1 from unit.
B. PC1 Replacement Procedure
! Turn Off power source, disconnect input power, and lockout/tagout the supply circuit.
! Before touching any parts, check DC voltage on capacitor C85 and be sure it is near zero (0) .
1. Put on grounded wrist strap BEFORE handling boards or parts.
Remove two 10−32 x 3/8in screws and support bracket (3/4 x 3/16in) from the replacement heat sink/cir-
cuit board assembly and discard these pieces (these items are used for shipping purposes only).
2. Install replacement circuit board PC1 onto wind tunnel.
3. Align PC1 mounting holes with standoffs on wind tunnel (holes must align to prevent stripping stand-off
threads). Install phillips head screws (6 total), and torque to 12 in-lbs.
4. Install screws (2 total) that connect capacitor C85 to PC1, and torque to 33 in-lbs.
5. Install screws (3 total) that secure PC1 to top of wind tunnel, and torque to 15 in-lbs.
6. Install brass nut (1) that secure ground strap to top of wind tunnel, and torque to 35 in-lbs.
7. Connect all marked leads to stand-off terminals with brass nuts (11 total) (designators are located near
terminals), and torque nuts to 35 in-lbs. Be sure to slide rubber boot over work lead terminal.
8. Connect all marked plugs to PC1. Be sure to connect plug PLG9 to receptacle RC9 located in lower right
corner of PC1.

AirForce 625 TM-926 Page 25

6-6. Overload Protection: Status Lights & Checking Shield Cup Shutdown System
If certain problems occur, a status
light comes on, and output stops.
1 Pressure Light
Lights if gas/air pressure is below
40 PSI (276 kPa).
Turn power Off, and check for
1 proper gas/air pressure (see
Section 3-12).
2 A flashing Pressure light indicates
that gas/air system may be set too
low, faulty, leaking or has a flow
restriction (see Section 6-1).

3 2 Cup Light
Lights if shield cup is loose/off.
Turn Power On and loosen shield
cup. If shutdown system works
properly, Cup light comes on. If not,
turn power Off and have a factory
authorized service agent check
unit.
Checking Torch Shield Cup Shutdown System If system works properly, retighten
cup and reset power.

 Power must be reset whenever the cup shutdown system is activated. Turn power Off, and check shield
cup connection (see torch Owner’s
Always turn Off power when changing or checking consumables. Manual). Power must be reset
whenever the cup shutdown is
activated.
A flashing Cup light indicates that
the torch consumables are stuck or
worn and should be inspected and/
or replaced (see Section 7-2).
Check shield cup shutdown system
once a week.
Shield 3 Temperature Light
Cup Lights if power source overheats or
when ambient temperature is below
−20° C (−4° F) (see Section 3-3).
Fan-On-Demand
Cooling fan will operate during the
following conditions:
e Unit is in an OVERTEMP
condition. TEMP indicator
light will illuminate and fan
will run until unit cools
down.
f Unit gets hot during idle,
either from a change in
ambient air temperature or
after long periods of
cutting.
g Unit is in cutting or postflow
mode.

Ref. 200 808 / Ref. 801 300-A

TM-926 Page 26 AirForce 625

 SECTION 7 − MAINTENANCE

7-1. Routine Maintenance

! Disconnect power  Maintain more often

before maintaining. during severe conditions.

 = Check  = Change  = Clean  = Replace Reference

* To be done by Factory Authorized Service Agent

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

Every
Week
 Shield Cup Shutdown
System

Every  Damaged Or Unreadable  Cracked Parts  Air Filter/Regulator  Gas/Air Hose

3 Labels Assembly Filter
Months

  Torch Body, Cable

Every OR
6
Months
 Inside Unit

AirForce 625 TM-926 Page 27

7-2. 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.
8
7

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

New
4 1/32 in (1 mm) to 1/16 in
(2 mm) maximum pit
3 depth depending on
acceptable cut quality

New 2

Worn
1

Worn

Ref. 803 224

Turn Off power source. 4 Opening Remove swirl ring. Check ring, and replace
Remove tip. Check tip, and replace if open- if side holes are plugged.
1 Drag Shield ing is deformed or 50% oversize. If inside of 7 O-Ring
tip is not clean and bright, clean with steel
Check O-rings on torch. If needed, coat with
wool. Be sure to remove any pieces of steel
2 Retaining Cup thin film of silicone lubricant (part no.
wool afterwards.
169 231). Replace if damaged.
5 Electrode
Remove retaining cup. Check retaining cup 8 Plunger Area
Check electrode. If center has a pit more
for cracks, and replace if necessary. than a 1/32 in (0.8 mm) deep, remove and Check this area for any debris or foreign
replace electrode. material. Clean out if necessary.
3 Tip 6 Swirl Ring Carefully reassemble parts in reverse order.

TM-926 Page 28 AirForce 625

7-3. Torch And Work Cable Replacement

2
4
5
8

3
6

9
3

! Turn Off power source, and discon-
nect input power.
If torch or work cable needs to be removed
or replaced, proceed as follows:
1 Power Source
Remove wrapper.
Torch Replacement
2 Strain Relief
3 Torch Cable
Loosen outer strain relief pigtail so that
torch cable can slide freely.
4 Plug PLG1/Receptacle RC1
Disconnect PLG1 from receptacle RC1 on
Control board PC1.
5 Plug PLG11/Receptacle RC11
Disconnect PLG11 from receptacle RC11
on Control board PC1.
6 Air Line Connector
Push orange fitting inward toward air
solenoid while pulling connector out of
fitting.
Remove nut, located inside of unit, from
back of strain relief.
Slide torch cable, connector, and plugs
through nut and out of unit. Retain nut for
use on replacement strain relief.
Insert replacement cable with strain relief
through opening where old cable and strain
relief were removed. Slide strain relief nut
over plugs, connector, and cable. Install nut
onto strain relief, but do not tighten.
Insert air line connector into solenoid fitting.
Connect PLG1 to RC1 on Control board
PC1.
Connect PLG11 to RC11 on Control board
PC1.
Tighten strain relief nut.
Tighten strain relief around cable.
Work Cable Replacement
7 Rubber Boot
8 Work Cable Ring Terminal
Slide rubber boot away from ring terminal
connection on Control board PC1. Remove
hardware securing ring terminal to PC1.
9 Strain Relief
Remove nut, located inside of unit, from
back of strain relief.
Slide work cable through nut and out of unit.
Retain nut for use on replacement strain
relief.
Slide rubber boot over ring terminal and off
of work cable. Retain rubber boot for use on
replacement work cable.
 Be sure to allow some work cable
slack inside the unit.
Insert replacement cable with strain relief
through opening where old cable and strain
relief were removed. Slide strain relief nut
over ring terminal and cable. Install nut onto
strain relief, but do not tighten.
Route cable along bottom of unit and up to
PC1.
Slide rubber boot over ring terminal and
onto work clamp lead. Connect work cable
ring terminal to terminal labeled WORK on
circuit board PC1. Torque to 35 in lb
(4 N⋅m). Slide boot over connection.
Tighten strain relief nut.
Tighten strain relief around cable.

Tools Needed:

5/16, 3/8 in
803 386 / 803 385-A

AirForce 625 TM-926 Page 29

 SECTION 8 − 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 625 LC309838 thru LC320649 205 723 ♦♦

LC320650 and following 212 926-A ♦♦

Circuit Board PC1 LC309838 thru LC320649 206 169-D ♦♦ ♦♦

LC320650 and following 212 807-A ♦♦ ♦♦

♦♦ Not included in this manual

TM-926 Page 30 AirForce 625

 205 723

Figure 8-1. Circuit Diagram For Power Source Effective With Serial No. LC309838 Thru LC320649
AirForce 625 TM-926 Page 31
 212 926-A

Figure 8-2. Circuit Diagram For Power Source Effective With Serial No. LC320650 And Following
TM-926 Page 32 AirForce 625
 TM-926A 2007−04

Processes
Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter

AirForce 625
And ICE-40C Torch

Eff w/LC309838 And Following

For OM-926 (211 123) Revision * Thru L

File: Plasma Cutters

 SECTION 9 − PARTS LIST

 Hardware is common and

not available unless listed.

12

11

13

18
17
14
16
36

23
10

19
9

15
8

5
5

5
7

20
6

24
21
26
5

25
22
4

27

28
3

29
2

35
1

33

32
34

30
31

Ref. 803 223-C

Figure 9-1. Main Assembly

TM-926 Page 34 AirForce 625
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-1. Main Assembly

. . . 1 . . . . . . . . . . +211118 .. WRAPPER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 208015 .. HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . 207653 .. LABEL,CAUTION/WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 208170 .. INSULATOR,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 179276 .. BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE CENT . . . . . . . . . . . 8
. . . 6 . . . . . . . . . . 204329 .. BRACKET,MTG CAPACITOR/VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 207134 .. VALVE,AIR SEALED W/PRESSURE SW/ FTGS/BRKT . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . AS1 . . 206000 .. VALVE,24VDC 3 WAY 1/8NPT 3/32 ORF 100PSI . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . S2 . . 174670 .. SWITCH,PRESSURE AIR 40PSI FIXED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . PC3 . . 208417 .. CIRCUIT CARD ASSY,PRIMARY CONNECT/FILTER . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 230324 .. FILTER,AIR W/FITTINGS & BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 227877 .. FILTER,AIR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 204581 .. PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 604102 .. CONN,CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . 188911 .. CABLE,POWER 12FT 8−10GA 3C 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 207997 .. GUARD,FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . FM . . 225166 .. FAN,MUFFIN 24VDC 4000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 185835 .. LABEL,WARNING ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 212925 .. WINDTUNNEL, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . C85 . . 192935 .. CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA W/NUT . . . . . . . . . . 1
. . . 18 . . . PC1 . . 209884 .. KIT,REPLACEMENT CONTROL BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . R1 . . 207995 .. RESISTOR,WW FXD 50 W 25 OHM NI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 208168 .. BAFFLE,AIR WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . L2 . . 207298 .. INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . L1 . . 207297 .. INDUCTOR,BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . T1 . . 207296 .. XFMR,MAIN SPECTRUM 625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 173693 .. FOOT,MTG UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . 601965 .. SCREW,375−16X1.00 HEX HD−PLN GR5 PLD . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . 010909 .. NUT,375−16 .56HEX .46H STL PLD ELASTIC STOP NUT . . . . . . . . . . . . . . . 4
. . . 25 . . . . . . . . . . 204324 .. BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . PC2 . . 192965 .. CIRCUIT CARD ASSY,LED/POT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 174991 .. KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 230322 .. PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 216447 .. CABLE,WORK 25 FT 6 GA W/CLAMP STRAIN RLF & TERM . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 217891 .. CABLE,WORK 50 FT 6 GA W/CLAMP STRAIN RLF & TERM . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 213619 .. CLAMP,WORK 300A STL CHROME PLD W/COPPER CONTACTS . . . . . . . 1
. . . . . . . . . . . . . . . . 213620 .. CONTACT TIP,WORK CLAMP 300AMP COPPER . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . 175138 .. BOX,LOUVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . 195110 .. ICE−40C 25FT HAND HELD REPLACEMENT TORCH OR
. . . . . . . . . . . . . . . . . 195111 .. ICE−40C 50FT HAND HELD REPLACEMENT TORCH . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 207136 .. GAUGE,PRESSURE AIR W/FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . 230321 .. NAMEPLATE,HOBART AIRFORCE 625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . S1 . . . 124511 .. SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 230325 .. REGULATOR,AIR W/FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . 225 474 .. SPACER,NYLON CAPACITOR 76MM DIAMETER . . . . . . . . . . . . . . . . . . . . . . 1
+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.

AirForce 625 TM-926 Page 35

  The ICE-40C torch is specifically for use only with this plasma cutting unit. Item Part
No. No. Description
195 110 ICE-40C 25ft Torch
195 111 ICE-40C 50ft Torch
1 183 427 Handle Assy, complete (1)
2 192 059 Main Body (1)
1 3 209 298 Leads, 25ft (1)
3 209 299 Leads, 50ft (1)
4 185 833 Switch Assembly
w/spring (1)
5 171 248 Push Button Switch (1)
2
6 190 220 Spring, trigger assembly
169 231 Grease, silicone (1)

See Figure 9-3 for additional

consumable parts.

5
4
6

Ref. 195 092 / Ref. 803 224

Figure 9-2. Torch, ICE-40C

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-926 Page 36 AirForce 625

  For extended tip use, set Amperage control to 40.

Drag Shield Retaining Cup Tip Electrode Swirl Ring O−Ring

204 323 192 050 204 325 192 047 192 049 169 232

Standard
Cutting Apply silicone
Deflector Retaining Cup 40A Tip Electrode grease (169 231)
177 888 192 050 192 052 192 048 before installing.
Extended
Cutting —1/8” (3 mm)
standd−off
Shield Retaining Cup Tip Electrode recommended
192 203 192 050 204 332 192 047
Gouging 211 120−B

NOTE:
CAUTION
Set air pressure to 75 PSI for cutting
or 55 PSI for gouging. FAILURE TO REPLACE WORN TIP OR
ELECTRODE WILL RUIN TORCH AND
VOID WARRANTY.
ICE−40C
 Turn off power before checking torch parts.
CONSUMABLES
 Check before each use and hourly during operation.

211 120-B

Figure 9-3. Consumable Parts For ICE-40C

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.

AirForce 625 TM-926 Page 37

 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 © 2007 Hobart Welding Products