Miller Electric 125C Welder User Manual
Contents
1. 44444 etn eee eee 1 ae dads Marne eda esce mta 197 251 FIBTER Compressor s zero nei dala wane peo netur RET ERS 602 205 WASHER tooth 195 ID 381 x 025T stl pld 4 M2 esie eee Ales 197 255 RUBBER MOUNT 4422 4 216 277 FTG brs elbow qdisc 1 8 NPT X 250 TBG 1 SPB ZO ULL ste Di 216 276 TUBING copper coil heat exchanger 1 ix AO iraniens 216 296 CLAMP cable 1 4 ID stl galv 1 ce UB et hs 216 280 FTG brs straight qdisc 1 4 OD X 1 4 OD tubing 1 28 PCT 214585 CIRCUIT CARD ASSY control 1 Lama usc Pr 197 892 2 THERMOSTAT area te ae eat Ep Rs Er 1 Tg sheds See EEE 138 044 BUSHING strain relief 1 OC PERS eius 121276 STRAIN RELIEF 2 fonte hires ye Re nn ea 1 sias spi 1951025 TORGEIGE 12G da ns fu Mme tiens 1 Rees SKER 199 022 CABLE work 15ft 12ga w clamp amp term 1 pibe es 203 988 CLAMP work 150 1 ne Has PALAIS 199 995 CONTACT TIP work clamp 150A 2 51 111 997 SWITCH rocker SPST 10 250VAC2. 1 EOD ess T1 194 475 TRANSFORMER toroid main 1 oP BO sos teases ak 213 604 LABEL CAUTION DO NOT ADJUST 1 ie TR 2 14 007 3 BAFFLE centers eurent IER RQ nn EXE alee 1 DELE NT A FRELSE NAMEPLATE order by model and serial no 1 When ordering a component originally displaying a precautionary label the label should also be ordered Optional To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2248 Page 25 Part ge No No Description 183427 Handle Assy left and right w screws 1 171248 Pushbutton Switch 1 196 931 Leads 20ft 1 196 930 Label ICE 12C 1 196 932 Main Body 1 185833 Switch Assy w Spring 1 190220 Spring trigger assy 1 169231 Grease silicone 1 195172 Torch replacement 1 Figure 8 2 Torch ICE 12C a S and CE markings only apply when the torch is used with shielded parts retaining cup 197 567 and drag shield 196 929 Drag Retaining Swirl Shield up Tip Electrode Ring O Ring 196929 197567 196926 196925 196927 196935 Apply siicone V y grease 169 231 before installing Retaining up 196928 1 8 8mm Eu FAILURETO PLACEWORNTIP
3. Exceeding duty cycle can damage unit and void warranty 23 duty1 4 95 802 459 B Overheating 15 A Minutes OM 2248 Page 10 4 4 Torch Dimensions And Weight 3 0 Ib 1 4 kg 35 mm Ref 801 397 A 4 5 Selecting A Location e Dimensions Weight 44 Ib 20 kg Non CE Models 52 Ib 24 kg CE Models Movement 1 Lifting Handle Use handle to lift unit 2 Hand Cart Use cart or similar device to move unit 3 120 VAC Receptacle Non CE Models 4 230 VAC Receptacle Location And Airflow CE Models Locate unit near correct input power supply Serial Number Rating Label located on rear panel of plasma cutter use label to 3 determine input power for unit ay Al n P rd 2 Special installation be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 4 loc 2 3 96 Ref 802 459 B 802 676 A 802 460 B OM 2248 Page 11 4 6 Connecting Work Clamp 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible 802 463 A Check input voltage available at site 1 Grounded 120 VAC Receptacle Non CE Models A 120 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is require
4. sp om 2 5 55 SED ms I P MC us Oy Ca mL Fr al cre 8 uam UE atze _ 2 aO tHe RIT us T 4 EOE ER as LT H a Or Oo j 5 M mus ay s 214585 mci Jb B eem i em FS oat SS B ge mu RESO pe F L B8 J Tel 4 E thee oem z Maa O 108 Bq Pon Le m7 7 0 Tools Needed 6 5 8 in If torch or work cable needs to be removed or replaced proceed as follows Turn power Off and disconnect input power plug from receptacle Remove wrapper from unit Torch Connections Remove existing torch cable from unit 1 Strain Relief 2 Torch Cable Insert cable through strain relief Slide strain relief nut onto torch cable but do not tighten 3 Air Line Connector Install air line connector into compressor fitting 4 Plug PLG4 Receptacle RC4 Connect PLG4 to receptacle RC4 on circuit board PC1 5 Female And Male Friction Terminal RC11 ELECT WHITE Connect female friction terminal on end of white leads to RC11 ELECT WHITE 6 Female And Male Friction Terminal RC7 PILOT RED Connect female friction terminal on end red leads to RC7 PILOT RED Tighten strain relief nut Tighten strain relief around cable Work Cable Connections Remove existing work cable from unit 7 Strain R
5. OM 2248 213 990E 2007 02 L Miller n Air Plasma Cutting and Gouging Description Air Plasma Cutter Spectrum 125C And ICE 12C Torch OWNER S MANUAL Visit our website at File Plasma Cutters gt www MillerWelds com From Miller to You Thank you and congratulations on choosing Miller Now you can get the job done and get it done right We know you don t have time to do it any other way That s why when Niels Miller first started building arc welders in 1929 he made sure his products offered long lasting value and superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 n U 3 BI E E a This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They Working as hard as you do f every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most hassle free warranty in the We ve made installation and operation quick business and easy With Miller you can count on years 90 00012000 of reliable service with proper
6. e Travaillez dans un espace restreint uniquement s il est bien ventil ou Si vous portez un respirateur anti vapeurs Les vapeurs caus es par le coupage et l puisement de l oxyg ne peuvent alt rer la qualit de l air et entrainer des blessures ou la mort Assurez vous que l air am biant est sain pour la sant e Ne coupez pas dans un endroit pr s d op rations de d capage de nettoyage ou de vaporisation La chaleur et les rayons d arc peuvent r agir avec les vapeurs et former des gaz hautement toxiques et irri tants e Ne coupez pas des m taux enrob s tels que des m taux galvanis s contenant du plomb ou de l acier plaqu au cadmium moins que l enrobage ne soit t de la surface du m tal couper que l endroit o vous travaillez ne soit bien ventil ou si n cessaire que vous ne por tiez un respirateur anti vapeurs Les enrobages ou tous m taux qui contiennent ces l ments peuvent cr er des vapeurs toxiques s ils sont coup s e Ne coupez pas de contenants qui renferment ou ont renferm s des mati res toxiques ou r actives vous devez en premier lieu les vider et les nettoyer convenablement LE PLASMA D ARC peut entra ner des blessures La chaleur d gag e par le plasma d arc peut entrainer de s rieuses br lures La force de l arc est un facteur qui s ajoute au danger de br lures La chaleur intense et la puissance de l arc peuvent rapidement passer au travers de gants et de tissus e
7. crans lat raux approuv es Portez des v tements de protection ad quats afin de prot ger votre peau e Ayez recours des prot ge tympans ou un serre t te ignifuges afin d viter que les tincelles n entrent dans vos oreilles LES RAYONS D ARC peuvent entrai 28 ner des br lures aux yeux et la peau 2 42 Les rayons d arc provenant du proc d de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entrainer des br lures aux yeux et la peau Lorsque vous coupez ou regardez quelqu un couper portez un mas que ou un cran facial avec le filtre appropri La norme ANSI Z49 1 reportez vous aux Principales normes de s curit sugg re d utiliser un filtre de teinte no 9 no 8 tant le minimum pour tout travail de cou page faisant appel un courant de moins de 300 A On mentionne galement dans la norme Z49 1 qu un filtre plus faible peut tre utilis lorsque l arc est cach par la pi ce couper Comme cela est habi tuellement le cas pour les travaux de coupage faible courant les teintes num r es au tableau 1 sont fournies titre d information pour l op rateur e Porter des lunettes de s curit coques lat rales sous votre casque ou cran facial e Ayez recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements et les blouissements pr venez toute personne sur les lie
8. SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 2 1 4 Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Identifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit APA pom fre 5 04 Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des ris ques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVE MENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directi ves ci dessous afin de connaitre les mesures prendre pour viter tout dan ger 2 2 Dangers li s au coupage l arc au plasma Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s cu rit num r es la section 2 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus
9. Clean or replace r torch consumables as necessary see Section 6 4 Torch travel speed too fast reduce travel speed see Section 5 2 Clean or replace torch consumables as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 1 Check torch shield cup see Section 6 2 reset unit Power switch Check torch j and connections inside unit Go to Section 6 5 Go to Section 6 5 Go to Section 6 5 Servicing procedure to be performed only by authorized Service Station OM 2248 Page 21 engine before servicing e Do not operate with covers removed Do not touch live electrical parts Disconnect input power or stop Have only qualified persons install use or service this unit D ELECTRIC SHOCK HAZARD 4 WARNING zr z t6 lt b Ea oe 694 Jet gt gt acy gt gt 01 124 9 2M 4 08 L 69 LE SH 12d 6 PINZA AIT OVAOZ OVAOZ a zu lt lt 99 Z 019M LLOId L LOU 01914 0194 zu ITS 6919 60 1531 hrs L 0132 1914 L94 E MOSS3HdWOO 9919 9938 Sm VON Es G91d GS93
10. Current Duty Cycle QD MEE Transformer Rectifier Converter Degree Of H P Protection Lee Loose Shield Cup Input Z Hertz Suitable for Some Power Rating pf power factor iS Hazardous S Product Of Voltage leff pply Locations 1 And Current KVA OM 2248 Page 9 SECTION 4 INSTALLATION 4 1 Specifications Rated Max Primary Primary Primary Service Secondary Secondary Cutting Power OCV Volts Amperes Recommended Volts DC Amperes KW KVA Factor DC 0 25 in 4 120 s 20A 110 12 2 01 244 84 ogo 335 0 25 At 6 IPM 2 5 mm s While idling 10 High line condition 4 2 Specifications For Torch Air cooled torch for plasma arc cutting PAC 35 duty cycle Compressor output 1 2 scfm 28 3 L min at 50 PSI 345 kPa at 700 ft 213 m Safety interlock devices shut down power source Safety trigger guard Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can cut at rated load without overheating If unit overheats thermostat s opens output stops Temperature 2 trouble light goes cooling fan runs Wait fifteen minutes for unit to cool or temperature light to 3 go off Reduce amperage or duty 3 1 2 Minutes Cutting 6 1 2 Minutes Resting cycle before cutting or gouging
11. N approchez pas le tube du chalumeau e Ne saisissez pas la pi ce couper pr s de la ligne de coupage e Larc pilote peut causer des br lures n approchez pas le tube du cha lumeau lorsque vous avez appuy sur le gachette e Portez des v tements de protection ad quats qui recouvrent tout vo tre corps e Ne pointez pas le chalumeau en direction de votre corps ni de la pi ce couper lorsque vous appuyez sur la g chette l arc pilote s allume automatiquement e Mettez l alimentation hors tension et d branchez le cordon d alimen tation avant de d monter le chalumeau ou de changer une pi ce du chalumeau e Utilisez uniquement le ou les chalumeaux recommand s dans le ma nuel de l op rateur LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles de gaz contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Puisque les bouteilles de gaz font habituellement partie d un processus de travail des m taux assurez vous de les manipuler correctement Prot gez les bouteilles de gaz comprim contre la chaleur excessive les chocs m caniques le laitier la flamme les tincelles et l arc Installez et attachez les bouteilles dans la position verticale l aide d une cha ne sur un support stationnaire ou un ch ssis porte bouteil le afin de pr venir qu elles ne tombent ou ne basculent Les bouteilles ne doivent pas tre pr s de la zone de cou
12. Off power source when changing or Turn Power On and loosen shield checking consumables cup If shutdown system works properly trouble light comes on If not turn power Off and check for loose shield cup Check consumables see Sections 6 4 and Parts List If system works properly retighten cup and reset power Ref 192 492 Ref 801 300 A OM 2248 Page 17 6 3 Torch And Work Cable Connections OL SOL MO CS te I 0 Osa O LE Pan AF TT FOT rt le 1 HR 9 E OOF vx Ec RC Ca nn c s 8 RS 4 01 nay ER um S M mi El T is rE bes at ET er CY Y OES e LE mms 2 cat a EJ os _ HO lt WE COE CR Las mos 7 R44 a 7 mz 1 ce2 dL dl mx ar C E C ma me LS L5
13. air supplied respirator The coatings and any metals containing these elements can give off toxic fumes when cut e 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 Keep away from the torch tip Do not grip material near the cutting path e The pilot arc can cause burns keep away from torch tip when trig ger is pressed e Wear proper flame retardant clothing covering all exposed body ar eas Point torch away from your body and toward work when pressing the torch trigger pilot arc comes on immediately e Turn off power source and disconnect input power before disas sembling torch or changing torch parts e 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 Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flame sparks and arcs e Install and secure cylinders in an upright position by chaining them to a sta
14. bon fil de terre e V rifiez fr quemment le cordon d alimentation afin de vous assurer qu il n est pas alt r ou nu remplacez le imm diatement s il l est Un fil nu peut entrainer la mort e L quipement doit tre hors tension lorsqu il n est pas utilis e V rifiez et remplacez les cosses du c ble du chalumeau si elles sont us es ou alt r es e Le c ble du chalumeau ne doit pas s enrouler autour de votre corps e Siles normes le stipulent la pi ce couper doit tre mise la terre e Utilisez uniquement de l quipement en bonne condition R parez ou remplacez imm diatement toute pi ce alt r e e Portez un harnais de s curit si vous devez travailler au dessus du Sol e Assurez vous que tous les panneaux et couvercles sont correcte ment en place e Nressayez pas d aller l encontre des syst mes de verrrouillage de s curit ou de les contourner e Utilisez uniquement le ou les chalumeaux recommand s dans le manuel de l op rateur e N approchez pas le tube du chalumeau et l arc pilote lorsque la g chette est enfonc e Le c ble de masse doit tre pinc correctement sur la pi ce cou per m tal contre m tal et non de telle sorte qu il puisse se d tacher ou sur la table de travail le plus pr s possible de la ligne de coupage OM 2248 Page 5 e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il ya DU COURANT CONT
15. is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts FLYING METAL can injure eyes e Wear safety glasses with side shields or face shield MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before go ing near plasma arc cutting operations OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce amperage thickness or reduce duty cycle before starting to cut again EXPLODING HYDROGEN hazard e When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the work piece e See your cutting engineer and water table instructions for help 1 4 California Proposition 65 Warnings A 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 amp Safety Code Section 25249 5 et seq A 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 Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit only NO
16. particuli rement les enfants LE LE COUPAGE pr sente un risque de feu ou d explosion Des particules de m tal chaud et des tincelles peuvent jaillir de la piece au moment du coupage Les tincelles et le m tal chaud la pi ce a couper chauff e et l quipement chaud peuvent causer un feu ou des br lures Avant de commencer travailler assurez vous que l endroit est s curitaire Prot gez vous ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Ne coupez pas dans un endroit ou des tincelles pourraient attein dre des mati res inflammables D placez toute mati re inflammable se trouvant l int rieur d un p rim tre de 10 7 m 35 pi de la pi ce couper Si cela est impos Sible vous devez les couvrir avec des housses approuv es et bien ajust es Assurez vous qu aucune tincelle ni particule de m tal ne peut se glisser dans de petites fissures ou tomber dans d autres pi ces Afin d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main Si vous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entrainer un feu de l autre c t Ne coupez pas sur un contenant ferm tel qu un r servoir ou un bi don Fixez le c ble de masse sur la pi ce couper le plus pr s possible de la zone couper afin de pr venir que le courant de coupage ne prenne une trajectoire inconnue ou lon
17. tiques pendant le soudage ou le coupage Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes OM 2248 Page 8 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de VOUS 4 Garder le poste de soudage et les c bles le plus loin possible de VOUS 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les consignes mentionn es pr c demment font partie de celles desti n es aux personnes ayant recours un stimulateur cardiaque Veuillez consulter votre m decin pour obtenir plus de d tails SECTION 3 DEFINITIONS 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label A Be Plasma Arc Cutting w Adjust Air Gas Low Air Pressure Inperes _ _ Pressure Light V Volts Increase SO No mut Do E Temperature Protective Earth D Ground 1 Single Phase BNI Constant Current lt Voltage Input On O Off Percent Direct Current Rated No Load U Conventional Load U 0 Voltage Average 1 Primary Voltage U 2 Voltage LE Line Connection Single Phase Rated Maximum Rated Welding X m a Static Frequency 1 Supply Current L
18. torch consumables Reset Power switch S1 If unit is overheated wait while fan cools down unit temperature Press torch trigger and listen for compressor operation Check for Postflow air at torch Check Control board PC1 compressor filter and compressor connections to PC1 and torch Press torch trigger and check if pilot arc ignites Check torch consumables Check torch connections relay CR1 compressor and torch Place torch near workpiece and check if pilot arc jumps or transfers to workpiece Check work clamp connec tion Check Control board PC1 and connections and torch and its connections Servicing procedure to be performed only by authorized Service Station OM 2248 Page 20 6 6 Troubleshooting Torch EU T M 7 SD Does arc go on and off while cutting Does arc go out while cutting Do sparks come out of top of cut or cut is not clean Yes Is Trouble light On unit has no cutting output No Go to Section 6 5 Torch travel speed too slow increase travel speed see Section 5 2 Clean or replace torch consumables ____ as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece Be sure work clamp is securely attached to work piece Make sure drag shield contacts metal while cutting
19. ERATION 444444esc eee sh es hne 13 5 1 Controls shoot RIRs bese REA thea eee EAE ALL D Eade EPA RD ete IA TAE 13 5 2 Gutting Speed vine coii e b i AG 13 5 3 Trigger Safety Lock corso eR sus enhe er ARE E AA RE SEES 14 5 4 Sequence Of Operation 15 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 16 6 1 Routine Maintenance scende LEE p ERE ER RS EE e 16 6 2 Overload Protection Trouble Light And Checking Shield Cup Shutdown System 17 6 3 Torch And Work Cable Connections 18 6 4 Checking Replacing Retaining Cup Tip And Electrode 19 6 5 Troubleshooting Power Source 422 2 20 6 6 Troubleshooting Torch eere RR xn em che mer kr a e kane e EY Ken 21 SECTION 7 ELECTRICAL DIAGRAM 0 2 0c e cece eee enhn nne 22 SECTIONS PARTS LIST 2 2 2 iL kg lxxx PRX PREX messes ide EXE EE RESINA 24 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING pom 4 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage 4 Marks special safety message Means War
20. INU IMPORTANT dans les convertisseurs apr s la suppression de l ali mentation lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces e D CHARGES LECTRIQUES poten tiellement mortelles Les pieces internes des sources d ali mentation de l inverseur ont DES CHARGES C C SIGNIFICATIVES m me APRES coupure du courant d alimentation e Mettre l unit hors tension mesurer la tension des condensateurs d entr e et s assurer qu elle est pratiquement nulle avant de tou cher l une quelconque des pi ces Mesurer cette tension confor m ment aux directives nonc es la section Entretien du manuel de l utilisateur ou du manuel technique avant de toucher l une quelconque des pi ces Risque de blessure en cas D EXPLOSION DES PIECES e Mise sous tension toute pi ce d fectueuse des Sources d alimentation de l inverseur peut explo ser ou faire exploser d autres pi ces Pour entre tenir les inverseurs toujours porter un masque protecteur et un v tement manches longues DN LES TINCELLES VOLANTES ris quent de provoquer des blessures Le coupage plasma produit des tincelles et projections de m tal tr s haute temp rature Lorsque la pi ce refroidit du laitier peut se former N e Portez une visi re ou des lunettes de s curit avec des
21. L cOM M lt a c91d 94 isd v s os zo1d Z0M Y 128 zz SETE 1914 1934 9 19 HOLIMS SOS dno DET Z vOM d 19M 01 17 DA oe 2 104 5 lt lt 2 s L 198 e voM OM 2 9 yz ou ff zy LOU 19H L 29 HOHOL SECTION 7 ELECTRICAL DIAGRAM Te OVALZZ L lt 174 TON m 230 564 A ZU LMM YTF Olt 5 fi WAP 3 ly VOZ OVAGZ I al 724 07277 gt OVA0ZL 2 H3MOd a INdNI T oq Per gt i n m ircuit Diagram Figure 7 1 C OM 2248 Page 22 Notes OM 2248 Page 23 SECTION 8 PARTS LIST Hardware is common and not available unless listed 803 554 E Figure 8 1 Main Assembly OM 2248 Page 24 Item Dia Part No Mkgs No Description Quantity Figure 8 1 Main Assembly unmute urs 220 328 COVER ASSY including 1 sex Jelly nter retient 204 326 CONSUMABLE STORAGE BOX w DOOR including 1 TERES 089 899 LATCH slide Luo rete enr ese Br DEED P AER EI 1 Se dirait 206 304 LABEL consumables ICE 12C 1 A NT TEE 119 503 LABEL MILLER eure RR dae ee ERG EUN Ee RE E ERE RS et aeter sete 196 851 LABEL war
22. LUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province miller warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original cus
23. ORELECTRODE WILL RUIN TORCH AND VOID WARRANTY e Turn off power before checking torch parts ICE 12C e Check before each use and hourly CONSUMABLES during operation Figure 8 3 Consumable Parts For ICE 12C 206 304 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 2248 Page 26 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You always get the fast reliable response you need Most replacement parts can be in your hands in 24 hours Support Need fast answers to the tough welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way C Miller Effective January 1 2006 Equipment with a serial number preface of LG or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS
24. T running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift unit e f using lift forks to move unit be sure forks are long enough to ex tend beyond opposite side of unit FIRE OR EXPLOSION hazard e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables e 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 e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 79 5S K on H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with elec tronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If notified by the FCC about interference stop using the equipment 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 ARC CUTTING can cause interference e Electromagnetic energy can interf
25. WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devic
26. c d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 2 5 Information sur les champs lectromagn tiques Donn es sur le soudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage ou de coupage passant dans les c bles de puis sance cr e des causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du Natio nal Research Council a conclu L accumulation de preuves suivant le jugementdu comit n a pas d montr que l exposition aux champs ma gn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait sou haitable de r duire votre exposition aux champs lectromagn
27. d see Section 4 1 2 Plug From Unit Select extension cord of 12 AWG for up to 53 ft 16 m 3 Grounded 230 VAC Receptacle CE Models A 230 volt 10 ampere individual branch circuit protected by time delay fuses or circuit breaker is required see Section 4 1 4 Plug From Unit Customer Supplied Select extension cord of 14 AWG for up to 133 ft 41 m A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 802 460 B OM 2248 Page 12 SECTION 5 OPERATION 5 1 Controls 3 1 Power Switch 3 Trouble Light b If unit overheats c f input power is not within 2 Power Light Trouble light comes on for the following specification 93 to 137 vac non conditions CE models 186 to 274 vac CE Due models If input power is outside of Use light to tell if unit is energized and ready specified range cycle power by to operate Light goes off if input power is not a If cup is removed from torch unit placing the power switch in the off with specified range see trouble light infor power must be turned off and back position and back on again Check mation on again input power if problem continues 5 2 Cutting Speed The cutting speed curve shows the recommended maximum cutting n Recommended production cutting speed vs material thickness is approxi speed capabilit
28. diately if damaged bare wiring can kill e Turn off all equipment when not in use e Inspect and replace any worn or damaged torch cable leads e Do not wrap torch cable around your body e Ground the workpiece to a good electrical earth ground if required by codes e Use only well maintained equipment Repair or replace damaged parts at once e Wear a safety harness if working above floor level Keep all panels and covers securely place e Do not bypass or try to defeat the safety interlock systems e Use only torch es specified in Owner s Manual Keep away from torch tip and pilot arc when trigger is pressed e 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 e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the re moval of input power e 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 OM 2248 Page 1 EXPLODING PARTS can injure e On inverter power sources failed parts can ex plode or cause other parts to explode when power is applied Always wear a face
29. ek AA s e dM Ss dU s 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles 5 2 2 Dangers li s au coupage l arc au plasma 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement eta malntenarnce ss bere Rae AG UU E radere eU E GM AUD Ce eA DICA CA S l 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 22 teri NIU RN DANN EE 9 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 9 SECTION 4 INSTALLATION pem ee ec eee RR ED REIR 10 Specifications ic rra IL EI eae VASO E Van Mees eae Bae ey men ea 10 4 2 Specifications FOr TOrchi us iex uin Ae vane de ve en oe aa eee ee fe eae A RER Dee 10 4 3 Duty Cycle And Overheating ER eee re 10 4 4 Torch Dimensions And Weight 060 0 cece eet teen m rn 11 4 5 Selecting A Location Rede oa Red Boe eae AREA RO RE 11 4 6 Connecting Work Clamp zone cece HII n n nnn 12 47 gt Connecting Input POWEF lt vans adder ean soa EAM E S ns ee dha RR eee 12 SECTION 5 OP
30. elief Be sure to allow some work cable slack inside the unit Insert work clamp lead through strain relief and install strain relief into front panel 8 Work Lead Male Friction Terminal Connect work clamp lead to male friction terminal labeled WORK LEAD on circuit board PC1 Route lead along torch lead bundle Ref 803 639 B Ref 801 300 B 204 308 A OM 2248 Page 18 6 4 Checking Replacing Retaining Cup Tip And Electrode x F Overtightening will strip threads Do not overtighten retaining cup during c 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 s A good practice is to replace both the tip and electrode at the same time a Turn Off power source before checking torch parts Make sure this area is clean of any debris ege 6 Make sure swirl ring is clean of any debris and no holes are obstructed 7 Worn 802 465 Turn Off power source Remove tip Check tip and replace if open 7 O Ring 1 Shield Cup ing is deformed or 50 oversize If inside of Remove swirl ring Check ring and replace 2 ORi tip is not clean and bright clean with steel ide hol d Ring side holes are plugged
31. ere with sensitive electronic equipment such as computers and computer driven equipment such as robots e To reduce possible interference keep cables as short as possible close together and down low such as on the floor e Locate cutting operation 100 meters from any sensitive electronic equipment e Be sure this cutting power source is installed and grounded according to this manual e f 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 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 2248 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com RecommendedSafe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from Globa
32. es RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 6 Months Batteries 90 Days Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Bobcat Trailblazer and Legend models 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the man
33. esigned 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 OPA 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 e Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not touch torch parts if in contact with the work or ground Turn off power before checking cleaning or changing torch parts e Disconnect input power before installing or servicing this equip ment Lockout tagout input power according to OSHA CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e 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 e When making input connections attach proper grounding conduc tor first e Frequently inspect input power cord for damage or bare wiring re place cord imme
34. eu est desserr e ou si le tube touche l lectrode l int rieur de la buse Un poste incorrectement install ou inad quatement mis la terre constitue un danger Ne touchez pas aux pi ces lectriques sous tension Portez des gants isolants et des v tements de protection secs et sans trous solez vous de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne touchez pas aux pi ces du chalumeau si vous tes en contact avec la pi ce couper ou le sol e Mettez l appareil hors tension avant d effectuer la v rification le nettoyage ou le changement d une pi ce du chalumeau e Coupez l alimentation d entr e avant d installer l appareil ou d ef fectuer l entretien Verrouillez ou tiquetez la sortie d alimentation selon la norme OSHA 29 CFR 1910 147 reportez vous aux Princi pales normes de s curit e Installez le poste correctement et mettez le la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Assurez vous que le fil de terre du cordon d alimentation est cor rectement reli la borne de terre dans la boite de coupure ou que la fiche du cordon est branch e une prise correctement mise la terre vous devez toujours v rifier la mise la terre e Avant d effectuer les connexions d alimentation vous devez relier le
35. gue et ne cause ainsi une d charge lectrique ou un feu Ne coupez jamais des contenants qui peuvent contenir des mati res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement Ne coupez pas dans un endroit o l atmosph re risque de contenir de la poussi re ou des vapeurs explosives Ne coupez pas de bouteilles de tuyaux ou de contenants pressuri S s Ne coupez pas de contenants qui ont d j re u des combustibles Portez des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Ne placez pas le poste sur une surface combustible ou au dessus de celle ci Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes UNE DECHARGE ELECTRIQUE peut entrainer la mort Le fait de toucher a une pi ce lectrique sous tension peut donner une d charge fatale ou entrai ner des br lures graves Le chalumeau et le circuit de masse sont automatiquement actifs lorsque le poste est sous tension L alimentation d entr e et les circuits internes de l appareil le sont galement Le coupage au plasma d arc exige des tensions plus lev es que le soudage pour amorcer et maintenir l arc souvent de 200 400 V CC c est pourquoi on fait appel des chalumeaux con us avec un syst me de verrouillage s curitaire qui met l appareil hors tension lorsque la capsule anti f
36. ies of the power mately 10 ipm at 1 8 in 3 2 mm mild steel thickness at max setting source and torch for mild steel of various thickness 7 The best cut quality is achieved by Cutting Speed vs Material Thickness cutting near the chart line Cutting 2 5 below the line too slow will result in excess dross Cutting above the 00 line too fast will cause blowback and lack of penetration 80 2 0 g g E 70 2 eo e 2 60 1 5 5 c 50 o o 2 0 8 GR 40 10 amp gt 30 d oO 20 0 5 2 10 0 0 0 0 18 12ga 7 1 8 3 16 14 12 27 46 32 48 64 Mild Steel Thickness Inches mm OM 2248 Page 13 5 3 Trigger Safety Lock Trigger Locked Trigger Unlocked 1 Trigger 801 545 A OM 2248 Page 14 5 4 Sequence Of Operation E Moisture from the compressor will form in the air line and at the torch It will be normal to sometimes see moisture come out the end of the torch EXAMPLE Of Cutting Operation a The pilot arc starts immediately when trigger is pressed E gt For shielded cutting place drag shield on edge Raise trigger lock and press After cutting arc starts slowly of metal For non shielded cutting non CE trigger Pilot arc starts start moving torch across metal only use 1 8 in 3 2 mm standoff distance dragging tip will reduce tip life f dos cs m E A Adjust t
37. khead or partition can cause fire on the hidden side Do not cut on closed containers such as tanks or drums e Connect work cable to the work as close to the cutting area as prac tical to prevent cutting current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use plasma cutter to thaw frozen pipes Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Do not cut in atmospheres containing explosive dust or vapors Do not cut pressurized cylinders pipes or vessels Do not cut containers that have held combustibles Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Do not locate unit on or over combustible surfaces e Remove any combustibles such as a butane lighter or matches from your person before doing any cutting e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby V 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 d
38. l Engineering Docu ments phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 1 6 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 OM 2248 Page 4 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou levard Rexdale O
39. maintenance And for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in che US besos exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your System Standard particular model are also provided Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web Mill mer Mil_Thank 2005 04 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 TES Symbol d cet Gates cee etse Ys e e dina tir ee vin eub bae de 1 1 2 Plasma Arc Cutting Hazards ist zorro mer ER xe be xot rx vi text pr xr US 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards ns 4 1 06 EME Informationes ss ne eme le am ed rad La ra tr
40. more often during severe conditions Check Change Clean be done by Factory Authorized Service Agent Replace Reference Each Use d S Torch Tip Electrode And Shield Cup Every A Week SE S Shield Cup Shutdown System TT A WARNY T 2 a xA E lt ua Every m s FS Months 0 Unreadable Labels x Torch Body Cable 1 Tape Torn Outer X Cracked Parts Covering Every 6 Months X Compressor Filter Clean With A Damp Cloth Or Replace If Necessary Q Inside Unit OM 2248 Page 16 6 2 Overload Protection Trouble Light And Checking Shield Cup Shutdown System e F If certain problems occur the trouble light comes on and output 1 Trouble Light a Lights if shield cup is loose Turn power Off and check shield cup connection 1 CUP see Item 2 below Power must be reset whenever O E TEMP the cup shutdown is activated INPUT VOLTAGE Check shield cup shutdown system once a week b Lights if power source overheats see Sections 4 3 and 4 5 Lights if input power is not within specification 93 to 137 vac Power must be reset whenever the input Checking Torch Shield Cup Shutdown System voltage shutdown is activated Power source Power switch must be reset whenever cup shutdown 2 Torch Shield Cup system is activated Always turn
41. ning 1 208 015 HANDLE carrying 1 206302 WRAPPER een Seks 1 EM 195010 cer Het diet eo aint ae 1 Dim OR2 5 199 999 RELAY terio e M tet mes oa tet Gen 1 Snr Bo venei R1 182 486 THERMISTOR igenre ndie n 1 E Qh arescit 200 000 DIOD ASS Yi Lek E Rte we ERR eds Ce RR HR XR eee 1 CRW 106 462 5 RELAY oce eee aa Bo RS A Ree Picea Pr get 1 Sees pas 17 0 2020507 STUD connection sie eee RAS ae eae ae adn RH ae 1 12 VR1 2 3 201 959 VARISTOR 4 444444 ete eens 3 13 C1 C2 197 739 CAPACITOR cer disc 2 PR EM 230 563 CASE SECTION base front rear 1 ERNE NEED 115 104 STRAIN RELIEF Re eee ees 1 has dO esas 194 480 CABLE power 10ft 16ga 115 volts ac plug 1 ox MPa ei SEER 019 663 FOOT rubber 4 osx Br sous L1 196 364 INDUCTOR output 1 19 TP1 020520 THERMOSTAT 2 1 separ oiu dei uds 156 734 NUT 010 32 31 hex 1 stl pld 8 21 AC1 207 999 COMPRESSOR
42. ning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols EF Means Note not safety related 1 2 Plasma Arc Cutting Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safe ty Standards A Only qualified persons should install operate maintain and repair this unit A 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 e Remove all flammables within 35 ft 10 7 m of the cutting arc If this is not possible tightly cover them with approved covers Do not cut where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that cutting on a ceiling floor bul
43. ntario 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 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Bu 0 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 possible About Pacemakers Pacemaker wearers consult your doctor before welding cutting or going near welding cutting operations If cleared by your doctor then following the above procedures is recommended
44. orch speed so Pause briefly at end of Postflow continues for approx 12 seconds sparks go thru metal and cut before releasing trigger after releasing trigger cutting arc can be in out bottom of cut stantly restarted during postflow by raising trigger lock and pressing trigger ecu A ne dan Maximum performance on thicker materials can be obtained by using or non shielded cutting The torch comes non shielded cutting with a 1 16 1 8 in 1 6 3 2 mm standoff standard with drag cutting Drag Cutting Non Shielded Cutting Q 196 926 Use retaining cup 197 567 and drag Use retaining cup 196 928 and hold a shield 196 929 to obtain a 1 16 in 1 16 1 8 in 1 6 3 2 mm standoff between 1 6 mm standoff automatically This C the workpiece and cutting tip combination is designed to allow EN Use non shielded when visually following dragging the torch directly on the a line workpiece 197 567 196 928 Use shields for ease of use when E This combination can be used for drag cutting with a template or when drag cutting but does not provide optimum cutting is preferred cutting performance on thicker material C 196 929 1 16 1 8 in 1 6 3 2 Z5 standoff workpiece 801 400 A OM 2248 Page 15 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 Routine Maintenance PASA ER esl Disconnect power before maintaining Maintain
45. page ni de tout autre circuit lectrique Un contact lectrique ne doit jamais se produire entre un chalumeau de plasma d arc et une bouteille Ne coupez jamais sur une bouteille pressuris e une explosion en r sulterait Utilisez uniquement des bouteilles de gaz des d tendeurs des boyaux et des raccords con us pour l application d termin e Gar dez les ainsi que toute autre pi ce associ e en bonne condition D tournez votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Le couvercle du d tendeur doit toujours tre en place sauf lorsque vous utilisez la bouteille ou qu elle est reli e pour usage ult rieur Lisez et suivez les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA mentionn dans les Principales normes de s curit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro voquer des br lures graves Ne pas toucher des parties chaudes mains nues e Laisser refroidir avant d intervenir sur la torche DES ORGANES MOBILES peuvent provoquer des blessures e S abstenir de toucher des organes mobiles tels que des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection DES PARTICULES VOLANTES peuvent blesser les yeux e Porter des lunettes de s curit a
46. shield and long sleeves when servicing inverters Ba FLYING SPARKS can cause injury Sparks and hot metal blow out from the cutting arc Chipping and grinding cause flying metal N Wear approved face shield or safety goggles with side shields Wear proper body protection to protect skin Wear flame resistant ear plugs or ear muffs to prevent sparks from entering ears ARC RAYS can burn eyes and skin 4 9 Arc rays from the cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin e Wear face protection helmet or shield with a proper shade of filter lenses 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 minimum for all cutting currents less than 300 amperes Z49 1 adds that lighter filter shades may be used when the arc is hidden by the workpiece As this is normally the case with low current cutting the shades suggested in Table 1 are provided for the operator s conve nience e Wear approved safety glasses with side shields under your helmet or shield e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection Table 1 Eye Protection For Plasma Arc Cutting Current Level In Amperes Minimum Shade N
47. t d appareils lectroniques comme des ordi nateurs et des robots Pour r duire la possibilit d interf rence maintenir les c bles aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller couper une distance de 100 m tres de tout quipement lectronique sensible S assurer que la source de coupage est correctement branch e et mise la terre Si l interf rence persiste l utilisateur doit prendre des mesures sup pl mentaires comme carter la machine utiliser des c bles blind s de des filtres ou boucler la zone de travail OM 2248 Page 7 2 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI Z49 1 de l American Wel ding Society 550 N W Lejeune Rd Miami FL 33126 Safety and Health Sandards OSHA 29 CFR 1910 du Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et pro
48. tionary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any cutting or other electrical circuits Never allow electrical contact between a plasma arc torch and a cylinder Never cut on a pressurized cylinder explosion will result Use only correct gas cylinders regulators hoses and fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use e Use the right equipment correct procedures and sufficient number of persons to lift and move cylinders e Read and follow instructions on compressed gas cylinders asso ciated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on torch To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance
49. tomer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2006 Miller Electric Mfg Co 2006 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com C Miller
50. ue s assurer que l alimentation est correctement dimensionn et prot g avant de mettre l appareil en service LES CHARGES LECTROSTATI QUES peuvent endommager les cir re cuits imprim s SES D e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes PC LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le Rayonnement haute frequence H F peut provo quer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sour ces de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE COUPAGE L ARC peut causer des interf rence e L nergie lectromagn tique peut g ner le fonction nemen
51. ufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Miller authorized service facility as determined by Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INC
52. umber Below 20 4 20 40 5 40 60 6 60 80 8 n NOISE can damage hearing Prolonged noise from some cutting applications can damage hearing if levels exceed limits specified by OSHA see Safety Standards e Use approved ear plugs or ear muffs if noise level is high e 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 e Keep your head out of the fumes Do not breathe the fumes e f inside ventilate the area and or use local forced ventilation at the arc to remove cutting fumes and gases OM 2248 Page 2 If ventilation is poor wear an approved air supplied respirator e Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals to be cut coatings and cleaners e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Fumes from cutting and oxygen depletion can alter air quality causing injury or death Be sure the breathing air is safe e 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 e Do not cut on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the cutting area the area is well ventilated and while wearing an
53. ux de ne pas regarder l arc Portez des v tements confectionn s avec des mati res r sistantes et ignifuges cuir et laine et des bottes de protection OM 2248 Page 6 Tableau 1 Protection des yeux pour le coupage au plasma d arc Intensit de courant en amp res Moins de 20 20 40 40 60 60 80 Filtre de teinte minimum n LE BRUIT peut endommager l ouie Certaines applications de coupage produisent un bruit constant ce qui peut endommager l ouie si le niveau Sonore d passe les limites permises par l OSHA repor tez vous aux Principales normes de s curit e Utilisez des prot ge tympans ou un serre t te antibruit si le niveau sonore est lev e Pr venez toute personne sur les lieux du danger reli au bruit LES FUM ES ET LES GAZ peuvent tre dangereux Le coupage produit des vapeurs et des gaz Respirer ces vapeurs et ces gaz peut tre dangereux pour la sant e Nemettez pas votre t te au dessus des vapeurs Ne respirez pas ces vapeurs Si vous tes l int rieur au moment du coupage ventilez la pi ce ou ayez recours une ventilation aspirante install e pr s de l arc pour vacuer les vapeurs et les gaz e Sila ventilation est m diocre utilisez un respirateur anti vapeurs approuv e Veuillez lire le Material Safety Data Sheets MSDS et les instructions du fabricant pour obtenir plus de renseignements sur les m taux couper les enrobages et les nettoyants
54. vec protections lat rales ou frontales LES CHAMPS MAGN TIQUES peu vent affecter les stimulateurs cardia ques Porteurs de stimulateur cardiaque restez distance Les porteurs sont pri s de consulter leur m decin avant d approcher les op rations de coupage plasma L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire l amp rage paisseur avant de continuer couper ou r duire le facteur de marche Danger D EXPLOSION D HYDROGENE Lors du coupage d aluminium partiellement ou totale ment immerg dans l eau de l hydrog ne libre peut s accumuler sous la pi ce Consultez votre ing nieur de coupage et les instruc tions de la table de coupage LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour sou lever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil Risque D INCENDIE OU D EXPLOSION Ne pas placer l appareil sur au dessus ou proximit de surfaces infllammables Ne pas installer l appareil proximit de produits in flammables Ne pas surcharger l installation lectriq
55. wool Be sure to remove any pieces of steel Remove shield cup Check cup for cracks wool afterwards Check O ring for cracks or worn spots and replace if necessary 5 Electrode replace swirl ring if necessary Check O ring for cracks or worn spots re Check electrode If center has a pit more O Ring place shield cup if necessary than a 1 16 in 2 mm deep remove and re Check O ring for cracks or worn spots and 3 Tip place electrode replace if necessary 4 Opening 6 Swirl Ring Carefully reassemble parts in reverse order OM 2248 Page 19 Troubleshooting Power Source NU 3 Ut Is input power connected to correct line voltage Connect unit to proper input voltage see Section 4 7 Is Power switch in the On position Place Power switch in the On position see Section 5 1 Is the cooling fan running Check Power switch S1 relay CR2 and thermistor R1 Is compressor operating Does pilot arc ignite Does pilot arc transfer to workpiece Is Power light On Reset Power switch S1 and verify line power voltage Check relay CR2 thermistor R1 and Control board PC1 Check all connections Check main transformer T1 Check inductor L1 Return to beginning of chart Is Trouble light On Check
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