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Miller Electric 1251 Welder User Manual

1. Tools Needed E J 3 8 in CIF 38 in A Installation must meet all National and Local Codes have only qualified persons make this installation A Disconnect and lockout tagout input power before connecting input conductors from unit A Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal The Auto Line circuitry in this unit automatically adapts the power source to the primary voltage being applied Check input voltage available at site This unit can be connected to any input power between 208 and 575 VAC without removing cover to relink the power source 1 Input Power Cord 2 Disconnect Device switch shown in the OFF position 3 Green Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Over Current Protection Select type and size of over current protection using Section 4 7 fused dis connect switch shown Close and secure door on disconnect device Remove lockout tagout device and pl
2. Means Note not safety related 1 2 Plasma Arc Cutting Hazards A 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 e 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 bulkhead or partition can cause fire on the hidden side Do not cut on closed containers such as tanks or drums e Conn
3. OM 201 872D 2007 03 Mill Processes Air Plasma Cutting I er and Gouging Description El Air Plasma Cutter Spectrum 1251 And ICE 100T TM Torch Ey WW SS j OWNER S MANUAL File Plasma Cutters Visit our website at 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 1t 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 Bl 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 NII 00012000 of reliable service with prop
4. Item Dia Part No Mkgs No Description Quantity Recommended Spare Parts os 224749 COVER ASSY including d PM en 223835 LABEL ICE 100T CONSUMABLES 1 o DEL oe 215089 FILTER AIR ELEMENT 5 MICRON d MEE CMT NEUE 223834 CABLE WORK 25 FT 4 GA W CLAMP STRAIN RLF amp TERM including 1 201846 CABLE WORK 50 FT NO 4 W CLAMP STRAIN RLF amp TERM including 1 iud pfe rice 213619 CLAMP WORK 300 AMP STL CHROME PLD W COP CONTACTS 1 TS 134900 STRAIN RELIEF CABLE FLEXIBLE 270 480 CABLE d T 225702 ICE 100T 25 FT HAND HELD REPLACEMENT TORCH 1 A E 225704 ICE 100T 50 FT HAND HELD REPLACEMENT TORCH 1 vadat Es 225706 ICE 100TM 25 FT MACHINE REPLACEMENT TORCH 1 cls ael e ala 225708 ICE 100TM 50 FT MACHINE REPLACEMENT TORCH 1 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 Item Part Item Part No No No No Description Description 215594 Handle w Screws 1 215606 Clip retaining 1 215478 Switch cup sensor 1 212735 O Ring main body 1 223775 Torch Head Repair Kit 1 169231 Grease silicon 185833 Swi
5. LE COUPAGE pr sente un risque de feu ou d explosion Des particules de m tal chaud et des tincelles peuvent jaillir de la pi ce au moment du coupage Les tincelles et le m tal chaud la pi ce couper chauff e et l quipement chaud peuvcnt causer un feu ou des br lures Avant de commencer travailler assurez vous que l endroit est s curitaire e 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 e Ne coupez pas dans un endroit o des tincelles pourraient attein dre des mati res inflammables e Prot gez vous ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud 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 e Afin d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main e Si vous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entra ner un feu de l autre c t e Ne coupez pas sur un contenant ferm tel qu un r servoir ou un bi don e Fixezle 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 longue et ne ca
6. X Damaged Or Unreadable gt Cracked Parts Q Air Filter Regulator 1 Gas Air Hose 3 Labels Assembly Filter Months Every 6 Months Q Inside Unit OM 201 872 Page 38 FF A complete Parts List is available at www MillerWelds com 7 2 Trouble Lights 1 Pressure Light Lights if gas air pressure at torch is Difficulty establishing pilot arc may indicate below 50 PSI 344 kPa or above 90 consumables need to be cleaned or replaced PSI 620 kPa Turn power Off and check for prop er gas air pressure see Section 5 2 2 Cup Light 1 Lights if shield cup is loose Turn power Off and check shield PRESSURE lt 3 OT 2 cup connection see torch Owner s Manual Power must be reset CUP o OT whenever the cup shutdown is 3 activated Check shield cup shutdown system TEMP E Or once a week see Section 7 3 3 Temperature Light Lights if power source overheats see Section 4 2 7 3 Checking Shield Cup Shutdown System X l 1 Torch Shield Cu gt Le Power must be reset whenever the cup shutdown P system is activated Always turn Off power when Turn Power On and loosen shield changing or checking consumables Do NOT cup If shutdown system works overtighten torch shield cup Gently finger tight properly Ready light goes off and en cup onto torch Cup light comes on If not immedi ately turn Off power and have Fac tory Authorized Service Agent check safety control boa
7. 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 g chette 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 e Prot gez les bouteilles de gaz comprim contre la chaleur excessive les chocs m caniques des dommages physiques le laitier la flam me les tincelles et l arc e 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 coupage ni de tout aut
8. Ex INPUT POWER AEL AE PESA DC MM E MAT ol I 2 mr 1 3 lt 1e re Ex s hee BI cac ee Lor wer d al ss a Es Y l re L INPUT RECTIFIER k u z em TR mS 2 I m N NE j ges y AA B PoZ AA PRIMARY El 2 INTERCONNECT CATE LEMI N RC20 PLG20 DRIVE I Re Riel EXT RC22 PLG22 ROT SZ n cou m al r g 2 E g 4 E ZE be g y 3 Y Y Y Y Y YU Y YY Y Y mer N N N rhe N dad a y dd y BED STRAP in Pay IIIF pisas Jees IRE Ed amp LEE SR i S 4 Gl S AA AA AA AARAAR RR RRR RR RRR RK TA TA ne SNS eo ARTO Oe NI T 112 di didi dade dd liii ij Be RE ge EEEX ES EEEE DD EEEE geo L Rc10 1 QYZ Zhen CHASSIS END CENTER SOLDER PAD 2 E RCE 1 CUT GOUGE SWITCH Kncs 2 Sonne Re1 PLG1 PC3 LED POT RC2 PLG2 RC30 1 gt rca pare Ro RC30 2 gt nei ROS PLCE POWER RC30 3 2 ne 1 3 RoB PLGs XX PRESSURE RC30 4 2 E RCM 4 ao a RC30 5 gt RCI 1 5 RC13 PLO13 O cue RC30 6 gt RCI 6 ROMPE Y mr RC30 7 S RI 1 7 RCTE PLGIB N RC30 8 amp D KRC F RMT1 PLG RMT1 RMT2 RCS0 PLG30 RCI1 ye 1 OM 201 872 Page 44 Figure 8 1 Circuit Diagram For Power Source va OUTPUT INDUCTOR Yel E m m Us 1272 TORCH WORK RC49 1 9 ELECTI mm RC
9. Okay To Move RMT2 receptacle on Control board PC1 Green 4 NOTE The Spectrum 1251 is shipped from the factory with the plug connected to RMT1 dry contacts To power a relay or isolated input module with 24 volts dc on black lead socket 2 and circuit common on green lead socket 4 see Section 6 4 or 6 5 Noise Suppression Shielding 3 Chassis ground OM 201 872 Page 24 A complete Parts List is available at www MillerWelds com 6 4 24 Volts DC Hot Contacts For Relay Operation A Turn off and disconnect EP input power Control board PC1 can supply 24 volts dc from receptacle RMT2 to operate a customer supplied relay for the Okay To Move signal f 1 Control Board PC1 2 Receptacle RMT1 Nj 3 Receptacle RMT2 LA gt 4 Receptacle RC61 Move plug from RMT1 into receptacle RMT2 on PC1 Be sure remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied 24 volts dc relay coil with resistance greater than 240 ohms Suppression diode 1A 100V such as type IN4002 through IN4004 across relay coil Plasma cutter is shipped from the factory with plug connected to receptacle RMT1 dry contacts White z Remote Red Start Black 24 VDC EN P Green e S 4 7 Relay aes Okay To d A f
10. 5 8 Consumables Storage Compartment 1 Consumables Storage Compartment This compartment provides convenient access to consumables and parts 804 026 A OM 201 872 Page 23 A complete Parts List is available at www MillerWelds com SECTION 6 MECHANIZED OPERATION 6 1 ICE 100TM Mounting Position Her 1 ICE 100TM Machine Torch 2 Square Use a square to align torch perpen dicular to the work surface 6 2 Remote Control Receptacle 70 060504 10 0100908 1 Remote Control Receptacle RC61 RC61 provides a remote arc start input when using the ICE 100TM machine torch Connect supplied remote control cable or remote pendant control to receptacle on rear panel See Section 6 3 for remote control cable input and output functions 804 026 A 6 3 Remote Control Cable Functions Function Lead Socket Lead Information White 1 White and red leads connect to a set of customer supplied remote contacts to Remote Start provide a remote trigger input signal to RC61 sockets 1 and 5 for the remote Red 5 start function Black 2 Black and green leads connect to a customer supplied machine torch drive device Normally open contacts close after arc start to provide an output signal to begin machine torch movement These contacts can be either dry RMT1 or hot RMT2 24 volts dc depending on plug position at RMT1 or
11. Electrical Code NEC including article 630 1 Consult factory for circuit breaker applications 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 OM 201 872 Page 14 A complete Parts List is available at www MillerWelds com 4 8 Extension Cord Data NOTE Et 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 Circuit Breaker Rating Conductor Size Max Cord Length Time Delay 60A Time Delay 60A Time Delay 30A Time Delay 20A Time Delay 25A 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 OM 201 872 Page 15 A complete Parts List is available at www MillerWelds com 4 9 Connecting 3 Phase Input Power GND PE Earth Ground
12. 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 Devices 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 Millers 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
13. dad M 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 ves bes EET AG UU Eri ade eU E CM UE Ce eic BIA CA S l 2 4 Principales normes de s curit 8 2 5 Information sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS nca uer ele me bns ce aee neue e E RN E EDEN EE 9 31 Symbols And Definitions ze ek Ru ER RE E IUE GR CRUCE RELY NER 9 SECTION 4A INSTALLATION cech A eb I ED RE ED REIR 10 4 1 Specifications sies A HUE DNUS Ads 10 4 lt 2 Duty Gycle and Overhealirig 2x5 Re A A NEN ia DE 11 4 3 Gutting Speed sz 2o A a na Abd RERUM NDERIT REDIT ee 11 4 4 Selecting Location ss 204 00 ne Ius A A eus EP RE ed 12 4 5 Connecting Work Clamp and Gas Air Supply 13 4 6 Connecting And Disconnecting Torch 13 4 7 Electrical Servico Guide rroi o p A A A as 14 4 8 Extension Cord Data 22st casu etanan atia AR e A 15 4 9 Connecting 3 Phase Input Power ooccccccocccccccnc eI nn 16 4
14. 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 entra ner 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 que vous ne portiez un respira teur 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 entra ner 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 N approchez pas le tube du chalumeau
15. 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 entra An ner des br lures aux yeux et la peau 7 ne Les rayons d arc provenant du proc d de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entra ner des br lures aux yeux et la peau e Lorsque vous coupez ou regardez quelqu un couper portez un cas que de soudage approuv muni de verres filtrants appropri La norme ANSI Z49 1 reportez vous aux Principales normes de s curi t sugg re d utiliser un filtre de teinte no 9 no 8 tant le minimum pour tout travail de coupage 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 habituellement 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 les tincelles et les blouisse ments pr venez toute personne sur les lieux de ne pas regarder l arc Portez des v tements confectionn s ave
16. distributor OM 201 872 Page 47 Shield Sense Tab Retaining Cap Tip Electrode Swirl Ring FAILURE TO RE PLACE WORN TIP 40A 0 01 OR ELECTRODE WILL RUIN TORCH 212 732 212 733 212 725 AND VOID WARRANTY Turn off power before checking torch parts S Check before each 60A 4 T 93 A use and hourly during operation 212 732 212 733 219 676 212 724 212 734 226 763 226 763 P E O Ring a Q 0 9 0 at 212 732 212 733 212 726 226 763 1004 4 Q r 219 687 219 684 219 679 219 678 219 677 226 763 Machine Cutting Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process Deflector Retaining Cap Tip Electrode Swirl Ring O Ring 212 724 212 734 212 735 D 219 684 219 683 219 678 219 677 D are D N a o Extended Cutting Ref 213 031 B Ref 804 056 A Figure 9 3 Consumable Parts For ICE 100TM 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 201 872 Page 48 Item Part See Figure 9 3 for No No Description additional consumable parts 215607 Sleeve torch position 1 223614 Torch Lead 25ft 1 223615 Torch Lead 50ft 1 215599 Torch Sleeve 1 223773 Main Body w Switch 1 195513 Remot
17. shield cup see Section 7 3 Reset power switch Have Factory Authorized Service Agent check for proper torch connections Temperature Trouble light On Unit overheating Allow fan to run the Trouble light goes out when the unit has cooled Have Factory Authorized Service Agent check control board Trouble lights not working Have Factory Authorized Service Agent check unit Power light flashing Trouble lights off Reset power switch Have qualified technician check input line power Make sure line power is three phase Single phase power will cause an incorrect power condition Pressure trouble light flashes Unit lost pressure momentarily while cutting Check air line for leaks Short tip life Check and clean drag shield of any slag particles and debris Check position of cut gouge switch Place switch in correct position to match the process Check for correct gas air pressure adjustment see Section 5 2 OM 201 872 Page 42 FF A complete Parts List is available at www MillerWelds com 7 7 Troubleshooting Torch PER Trouble Remedy Arc goes on and off while cutting Torch travel speed too slow increase travel speed see Section 5 5 Clean or replace torch consumables as necessary see Section 7 4 Be sure work clamp is securely attached to workpiece Arc goes out while cutting Be sure work clamp is securely attached
18. to workpiece Make sure tip is on or near 1 16 in 1 6 mm to 1 8 in 3 2 mm workpiece see Section 5 5 Clean or replace torch consumables as necessary see Section 7 4 Sparks come out top of cut or cut is not clean Torch travel speed too fast reduce travel speed see Section 5 5 Clean or replace torch consumables as necessary see Section 7 4 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 3 Trouble lights are on unit has no cutting output Check torch consumables Check for gas air flow at torch Check air supply connection and pressure to unit and torch Reset unit Power switch Have Factory Authorized Service Agent check torch and connections inside unit OM 201 872 Page 43 SECTION 8 ELECTRICAL DIAGRAM amp WARNING Do not touch live electrical parts S e Disconnect input power or stop 3 engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or service this unit u BOOST INDUCTOR CLEAR CLAR E
19. when no load is sensed to supply input power to this plasma power source 60 Hz Three Phase Input Voltage 208 230 460 575 Input Amperes At Rated Output 55 49 24 19 Max Recommended Standard Fuse Rating In Amperes Time Delay 60 60 30 20 Normal Operating 80 70 35 30 Min Input Conductor Size In AWG 4 8 8 10 12 Max Recommended Input Conductor Length In Feet Meters en des us 2 Min Grounding Conductor Size In AWG 4 8 8 10 12 Reference 2005 National Electrical Code NEC including article 630 1 Consult factory for circuit breaker applications 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 50 Hz Three Phase Input Voltage 400 Input Amperes At Rated Output 28 Max Recommended Standard Fuse Rating In Amperes Time Delay 25 Normal Operating 35 Min Input Conductor Size In AWG 4 12 Max Recommended Input Conductor Length In Feet Meters d Min Grounding Conductor Size In AWG 4 12 Reference 2005 National
20. 10 Connecting To Miller Welder Generator With A Three Phase AC Power Plant 17 SECTIONS OPERATION a EO 18 Bliecos rr AAA AAA AAA a VA ESI T E 18 5 2 Setting Gas Air Pressure 19 5 3 Trigger Safety LOCK unes soria A El HAE Rs 19 5 4 Plasma Cutting System Practices 442 2 20 5 5 Sequence Of Cutting Operation 21 5 6 Sequence Of Gouging Operation 22 557 Sequence Of Piercing Operation se xx A X E EXE E aus 23 5 8 Consumables Storage Compartment 23 SECTION 6 MECHANIZED OPERATION 000 e cece eee e nnns nnne 24 6 1 IGE 100 TM Mounting POSION izes zr re tai ER Hb RE ede Reg RES 24 6 2 Remote Control Receptacle 24 6 3 Remote Control Cable Functions 24 6 4 24 Volts DC Hot Contacts For Relay Operation 25 6 5 24 Volts DC Hot Contacts For Isolated Input Module Operation 26 6 6 Dry Contacts Using An External Power Supply For Relay Operation 27 6 7 Dry Contacts Using An External Power Supply For Isolated Input Module Op
21. 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux r gionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 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 tiques pendant le sou
22. 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 0 90 D 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 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION pom fre 4 05 A Avertissement se prot ger et prot ger le
23. BO LEM2 PM S ax ar ELECI 11 2 1 1 e 7 3 lt AK ar lt et ELECTS 4 CeRCAS 5 dA 5 lt ELECTRODE y 11 1 5 lt 11 10 1 1 EK PILOT 11 ue AUOT AY tlt 3 1775 N L y PILOT A Li 1 P 12 UD eue ivi eb LO WORK m i UN n IV P lt gt itt rt 13 A WORK ag Au loa i 49 en HA O19 oh seconoary LA xd gu Vos INTERCONNECT 2 iv mo TRIGGER pp a RC40 PLG40 ly m 23 18 CAPACITOR RCA1 PLG41 tit HS RC47 NO CONN 1 le RC48 PLG4B ra RC49 PLG49 de TEM3 175 26 Nm 13 lt iilii ii wem TORCH E E E 93 g LY Y Y Y Y Y Y y l WIRE PRESENT SENSE FOR MACHINE TORCH ONLY REMOTE ELECTRODE SENSE y y 3 3 a REMOTE WORK SENSE AR RARRAR AARNA ux 1 1 g 2 i i i i I M i i i RuTI 1 gt gt 4_ lt 5 RENTE 5 EERE ER EEE TRIGGER E RuT1 2 gt gt 22 1 o ur En RMTI 3Y 27 2 lt S m N Q DRY RMT1 4 gt gt 4 lt CONTACTS RENOTE CONTROL RUT2 13 gt lt 5 RENDTE TRIGGER RMT2 2 gt gt lt 1 G RWI2 cei 28V RMT2 3 gt gt XZX w o nar RMTZ 4 gt 4 lt CONTACTS Vono_za vo 3 3 RC2 2 AED GND 4 AS1 Rez SOLENOID VALVE PRESSURE r a TRANSDUCER p rs fi FAN 9 RC1 2 gt gt A OR Bik J gt TO TORCH INPUT AR lt gt d IT JINI gt Ro AR FILTER LJ REGULATOR SONON Asi PNEUMATIC CIRCUIT 201 858 A OM 201 872 Page 45 SECTION 9 PARTS LIST 9 1 Recommended Spare Parts
24. Supply Current L Current Duty Cycle ACD Converter Transformer Rectifier Degree Of H P Protection a Loose Shield Cup Input Z Hertz Maximum Effective 1eff Supply Current power factor S Suitable for Some Hazardous Locations Power Rating Product Of Voltage And Current KVA S OM 201 872 Page 9 FF A complete Parts List is available at www MillerWelds com SECTION 4 INSTALLATION 4 1 Specifications Amperes Input at Rated Load Output 60 Hz Three Phase faui Maximum Duty Cycle Rated Type of Plasma Open Re Output Output Gas enung Circuit 40 50 80 80 ap y Voltage DC 208 V 230V 460V 575V KVA KW 9 2 CFM 1 261 one urea L min At 1 25 in 55 49 24 19 19 1 18 2 160 Volts Straight SSI 32 mm 265 DC Polarit 517 kPa At 12 IPM DEN AirOr 305 mm min Nitrogen Only Power light will flash if torch trigger is pressed when unit is connected to single phase input power indicating an incorrect power condition Amperes Input at Rated Load A Output 50 Hz Rated Type of Plasma Rated Cutting co Three Phase Output Output Gas Capacity Voltage DC 400 V KVA KW 9 2 CFM 1 25 in 100 160 Direct Current 261 L min At 32 mm 28 19 2 18 3 Volts DC 80 Straight Polarity 75 PSI 517 At 12 IPM 265 Duty Cycle DCEN kPa Air Or 305 mm min Nitrogen Only Power light will fl
25. ace switch in the On position 803 766 A 802 183 OM 201 872 Page 16 FF A complete Parts List is available at www MillerWelds com 4 10 Connecting To Miller Welder Generator With A Three Phase AC Power Plant Ay NAW Three Phase Power Connection A Close panel opening if no connections are made to generator wt AD AS b 6 ve plug before inserting leads Reinstall bushing Rear Of Panel 92 93 A Close panel E opening if no connections are made to generator 3 Phase AC Three Output AES Volts 240 Amps 48 KVA KW 20 Tools Needed Frequency 60 Hz Engine Speed 1850 RPM Lead 42 connects to GROUND stud on front of unit Jumper 42 is connected to 90 at factory 93 91 90 92 Three Phase Generator Power A Stop engine A Power and weld outputs are live at the same time Discon nect or insulate unused cables gt Have qualified person install ac cording to circuit diagram and Generator Power Guidelines see generator Owner s Manual Remove generator power panel mounting screws Tilt panel forward 1 Circuit Breaker CB7 Lead 93 Lead 92 Lead 91 Lead 42 Circuit Grounding Lead Lead 90 Neutral Isolated Neutral Terminal a Oo n
26. al 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 is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing u
27. ash if torch trigger is pressed when unit is connected to single phase input power indicating an incorrect power condition OM 201 872 Page 10 A complete Parts List is available at www MillerWelds com 4 2 Duty Cycle and Overheating 208 Volts AC Three Phase In 40 Duty Cycle DI gt 4 Minutes Cutting 230 Volts AC Three Phase Input Power 50 Duty Cycle 3 9 OB 5 Minutes Cutting 5 Minutes Resting put Power NS 6 Minutes Resting Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating If unit overheats output stops and cooling fan runs Wait fifteen min utes for unit to cool Reduce amper age or duty cycle before cutting A Exceeding duty cycle can damage unit and void war ranty 380 575 Volts AC Three Phase Input Power 80 Duty Cycle de 8 Minutes Cutting 2 Minutes Resting Overheating Minutes PS A TE Reduce Duty Cycle duty1 4 95 4 3 Cutting Speed Cutting Speed Inches per Minute A om 8388388833835 oo Rated Cutting Speed vs Material Type amp Thickness 0 25 1 25 0 375 0 5 0 625 0 75 1 Material Thickness Inches Aluminum Stainless Steel Mild Steel The cutting speed curve shows the rated cutting speed capabiliti
28. c des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection Tableau 1 Protection des yeux pour le coupage au plasma d arc Intensit de courant en amp res Filtre de teinte minimum Moins de 20 no 4 20 40 no 5 40 60 no 6 60 80 no 8 OM 201 872 Page 6 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 Ne mettez pas votre t te au dessus des vapeurs Ne respirez pas ces vapeurs e 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 Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travaillez
29. cern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 35 FF A complete Parts List is available at www MillerWelds com 60 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3 16 in 4 8 mm between torch tip and workpiece for all cuts Deflector Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch Q a e 212 736 212 733 219 682 212 724 212734 Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds a RS COR me ESS nes meme 25s JR E Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Without concern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 36 FF A complete Parts List is available at www MillerWelds com 40 Amp Machine Torch Extended Consumables The following c
30. 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 e 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 e 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 stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any cutting or other electric
31. dage ou le coupage Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes OM 201 872 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 porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder couper ou d approcher des op rations de soudage couper Si le m decin approuve il est recommand de suivre les proc dures pr c dentes gt A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbols And Definitions Plasma Arc Cutting YN Adjust Air Gas Low Air Pressure A Amperes P 5 PAC Pressure Light V Volts Increase SO No mut Do E Temperature Protective Earth D Ground 1 ENG Single Phase K Constant Current Voltage Input On O Off Percent Direct Current Rated No Load U Primary Voltage U Conventional Load J DE Line Connection Voltage Average Voltage Single Phase Or Three Phase Static Rated Maximum Rated Welding X T Z Frequency li max
32. de inside the nozzle Incorrectly installed or improperly grounded equipment is a hazard a ALS 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 immediately if damaged bare wiring can kill e Turn off all equipment when not in use e Inspect and replace any worn o
33. e but may vary from province to province miller warr 2007 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 customer 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 O 2007 Miller Electric Mfg Co 2007 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 8 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
34. e Pendant Control 1 215478 Switch cup sensor 1 225706 Torch replacement 25ft 1 225708 Torch replacement 50ft 1 220240 Cable remote control trigger 25ft 1 220241 Cable remote voltage sense 26 5ft 1 804 036 A Figure 9 4 Torch ICE 100TM NOTE gt A complete Parts List is available on liine at www MillerWelds com To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 201 872 Page 49 Notes 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 2007 Equipment with a serial number preface of LH 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 Ap
35. ect 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 designed with safety interlock systems which turn off the machine when the shield cup is loosened or if tip touches electro
36. er 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 gt He US Aaea 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 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 TES Symbol US GOR ai tn a Ys e e dina dao en dates de 1 1 2 Plasma Arc Cutting Hazards ist rice ER xe be xot rx vi text pr ee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 0 4 1 6 EME InformaltiOr de iie d aida eet ere rad La ss Bel s e dM os dU s es
37. era T Contacts Move Remote Control Cable E TH EF 24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated Tools Needed CFO 5 16 in 804 041 A OM 201 872 Page 25 6 5 FF A complete Parts List is available at www MillerWelds com 24 Volts DC Hot Contacts For Isolated Input Module Operation Her White Red Black 24 VDC Green Tools Needed CFO 5 16 in Remote Control Cable Remote Start Output EF 24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated A Turn off and disconnect input power Control board PC1 can supply 24 volts dc from receptacle RMT2 to operate a customer supplied isolated input module for the Okay To Move signal 1 Control Board PC1 2 Receptacle RMT1 3 Receptacle RMT2 4 Receptacle RC61 Move plug from RMT1 into receptacle RMT2 on PC1 Be sure remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied isolated input module Plasma cutter is shipped from the factory with plug connected to receptacle RMT1 dry contacts Okay To Move 804 041 A OM 201 872 Page 26 FF A complete Parts List is availab
38. eration 28 6 8 Remote Voltage Sense Connection 29 6 9 Shield Sense Tab ciclo ciue RR RA A REAPER ERA web ey Gata 29 6 10 Cut Chats oto mese pL e pino AA e A E ee nbn ES 30 TABLE OF CONTENTS SECTION 7 MAINTENANCE amp TROUBLESHOOTING 38 731 JRoutine Maintenance on ero va xe cxt rH ee ux C ex Rte Xia ade ke ane ts 38 7 2 Trouble Lights odere IET xb a a xxx tex dete xi a ades 39 7 3 Checking Shield Cup Shutdown System 39 7 4 Checking Replacing Retaining Cup Tip And Electrode 40 7 5 Checking Or Replacing Filter Element 2 41 7 6 Troubleshooting Power Source 0 m 42 7 7 Troubleshooting Torch ssssssssssesseese III 43 SECTION G ELECTRICAL DIAGRAM 2 3 we a 44 SECTION 9 PARIS LIST oui E RII X a a x REIR ees See ee oe seriei we iX 46 OPTIONS AND ACCESSORIES PARTS LIST www MillerWelds com 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 A Marks a special safety message Means Warning Watch Out There are possible hazards With this procedure The possible hazards are shown in the adjoining symbols
39. erwards 5 Electrode Check electrode lf center has a pit more than a 1 32 in 1 mm deep remove and replace electrode 6 Swirl Ring Make sure this area is clean of any debris 804 056 A Remove swirl ring Check ring and replace if side holes are plugged 7 O Ring Check O rings on torch If needed coat with thin film of silicone lubricant part no 169 231 Replace if damaged 8 Plunger Area Check this area for any debris or foreign material Clean out if necessary Carefully reassemble parts in reverse order OM 201 872 Page 40 FF A complete Parts List is available at www MillerWelds com 7 5 Checking Or Replacing Filter Element um Latch Filter Cup Retaining Nut Filter Element aR OU N Defuser Ring 6 Filter Cap Slide latch down and rotate filter cup approximately 1 4 turn Remove cup Remove retaining nut filter element and defuser ring Check filter element for dirt and moisture and replace if necessary Be sure that all parts are clean and dry Reinstall all parts and secure filter cup 804 054 A OM 201 872 Page 41 FF A complete Parts List is available at www MillerWelds com 7 6 Troubleshooting Power Source per P J NN D Trouble Remedy No pilot arc difficulty in establishing an arc Clean or replace worn consumables as necessary see torch Owner s Ma
40. es 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 congus avec un syst me de verrouillage s curitaire qui met l appareil hors tension lorsque la capsule anti feu 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 e Ne touchez pas aux pi ces lectriques sous tension Portez des gants isolants et des v tements de protection secs et sans trous Isolez 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 e 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 rel
41. es of the power source and torch for mild steel stainless steel and aluminum of various thicknesses A Exceeding recommended cutting speeds will cause rapid erosion of the tip and electrode OM 201 872 Page 11 FF A complete Parts List is available at www MillerWelds com 4 4 Selecting a Location I gt i WA ul V4 MS Dimensions And Weight 95 Ib 43 kg w Torch 17 in 432 mm 12 1 2in 318 mm Movement 1 2 A Do not move or operate unit where it could tip 3 IN i Location 3 18 in 460 mm Lifting Handles Use handles to lift unit Hand Cart Use cart or similar device to move unit Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 loc_2 3 96 Ref 151 556 802 183 OM 201 872 Page 12 FF A complete Parts List is available at www MillerWelds com 4 5 Connecting Work Clamp and Gas Air Supply 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 to 120 psi 621 to 827 kPa pressure 92 CFM 260L min minimum 3 Gas Air Filter Inlet Opening 4 Hose F Hose must have a minimum inside diameter of 3 8 in 9 5 mm 5 Tefl
42. fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 31 FF A complete Parts List is available at www MillerWelds com 60 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1 16 in 1 6 mm between torch and workpiece for all cuts Shield Sense Tab Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch 40 9 212 732 212 733 219 676 212 724 212 734 226 763 Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process Shield sense tab is located in the consumable storage box on left side of unit wrapper Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds ww 2 s ws zs s v ws Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Without concern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adju
43. 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 201 872 Page 4 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou levard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion ANSI Standard Z87 1 from
44. gineering Documents t l phone 1 877 413 5184 site Internet www global ihs com 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 proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 e Veiller couper une distance de 100 m tres de tout quipement lectronique sensible e S assurer que la source de coupage est correctement branch e et mise la terre e Sil 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 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 Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone
45. he pilot arc starts immediately KT when trigger is pressed 3 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 metal workpiece as 75 PSI 517 kPa for cutting gouging as this shortens the service life close to cutting area as possible 60 PSI 414 kPa for gouging of the nozzle and electrode a EX NC gt A 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 amperage is set too low or consumables are worn ie gt vein AN M 3 2 mm INN INN When doing non shielded cutting maintain DO NOT put pressure on shield when Pulling rather than pushing the torch approximately 1 8 in standoff between drag cutting instead slide shield along makes cutting easier Use a proper guide electrode and surface the surface for proper cutting results or template for accurate cutting operations Ref 803 640 A 801 400 B Ref 802 878 OM 201 872 Page 20 FF A complete Parts List is available at www MillerWelds com 5 5 Sequence Of Cutting Operation cur amp an NE coucE SET TO 75 PSI SET TO 60 PSI gt O gt MODE Connect work clamp
46. hin approxi mately 3 16 in 4 8 mm Start gouging al across workpiece surface Maintain approximately a 45 angle to surface Q cur amp O E GOUGE SET TO 75 PSI SET TO 60 PSI MODE Set Mode switch to GOUGE Release trigger Postflow continues for approx 20 seconds after releasing trigger rc can be instantly restarted during postflow by raising trigger lock and pressing trigger Ref 803 640 A 801 400 B OM 201 872 Page 22 FF A complete Parts List is available at www MillerWelds com 5 7 Sequence Of Piercing Operation Ak cur amp an NA GOUGE SET TO 75 PSI SET TO 60 PSI gt O MODE a The pilot arc starts immediately when trigger is pressed ee Wor clamp i a Set air pressure to 75 PSI Set Mode switch to CUT Hold torch at an angle to the clean pon tree S de 517 kPa for cutting workpiece Raise trigger lock and on workplece as close to press trigger Pilot arc starts cutting area as possible 90 A ds EE gt y gt L 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 Ref 803 640 A 801 400 B
47. i 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 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 OM 201 872 Page 5 e N approchez pas le tube du chalumeau et l arc pilote lorsque la g chette est enfonc e e Le c ble de masse doit tre pinc correctement sur la pi ce cou per m tal contre m ta
48. ible 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 201 872 Page 3 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 749 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 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from Global Engineering Docu ments phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70
49. ing 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 201 872 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 Donotcutin 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 air supplied respirator The coatings and any metals containing these elements can give off toxic fumes when cut e Do not
50. ion 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 INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY 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 availabl
51. isateur 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 OM 201 872 Page 7 LE COUPAGE L ARC peut causer des interf rence e L nergie lectromagn tique peut g ner le fonction nement d appareils lectroniques comme des ordi nateurs et des robots e 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 2 4 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com 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 de Global En
52. kness Maximum Cut Speeds Optimum Cut Speeds ws i sa wo s w 2 es Ep AAA eoe Jer sw lp l Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds 100 Without concern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 30 FF A complete Parts List is available at www MillerWelds com 80 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1 16 in 1 6 mm between torch and workpiece for all cuts Shield Sense Tab Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch 90 9 r 212 732 212 733 212 726 212 724 212 734 226 763 Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process Shield sense tab is located in the consumable storage box on left side of unit wrapper Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds sw wa 3 m s s ze Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Without concern for cut appearance the
53. l 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 e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique e D CHARGES LECTRIQUES poten tiellement mortelles Il y a DES CHARGES DC SIGNIFICATI VES dans le poste de soudage inver seur m me APRES coupure du cou rant 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 gt 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 e Portez une visi re ou des lunettes de s curit avec des crans lat raux approuv es Portez des v tements de protection ad quats afin
54. l Cable EF 24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated Tools Needed CFO 5 16 in Remote O A Turn off and disconnect input power Control board PC1 can provide dry contacts from receptacle RMT1 to customer supplied isolated input module using an external power supply for the Okay To Move signal operate 1 Control Board PC1 2 Receptacle RMT2 3 Receptacle RC61 Unit is shipped from factory with plug connected to RMT1 receptacle Be sure that remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied 24 volts dc power supply Isolated input module 24 VDC Power Supply Output Okay To Move 804 041 A OM 201 872 Page 28 FF A complete Parts List is available at www MillerWelds com 6 8 Remote Voltage Sense Connection EJ A Turn off and disconnect input power Remote voltage sense is an arc voltage output signal for automatic torch height adjustment 1 Snap in Blank 2 Nylon Bushing 3 Secondary Interconnect Board PC4 4 Receptacle RC48 Remove snap in blank from rear panel Remove nut from strain relief and route plug end of cable through opening in rear panel Slide nut over cable and secure
55. le at www MillerWelds com 6 6 Dry Contacts Using An External Power Supply For Relay Operation A Turn off and disconnect Eu input power Control board PC1 can provide dry contacts from receptacle RMT1 to operate a customer supplied relay using an external power supply for ex the Okay To Move signal 1 Control Board PC1 2 Receptacle RMT1 3 Receptacle RC61 Unit is shipped from factory with plug connected to receptacle RMT1 Be sure that remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied 24 volts dc power supply 24 volts dc relay coil with resistance greater than 240 ohms Suppression diode 1A 100V such as type IN4002 through IN4004 across relay coil Remote Start 24 VDC Power Supply Remote Control Cable Contacts cL Relay Okay To A fera Move EF 24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated o ES Tools Needed CFO 5 16 in 804 041 A OM 201 872 Page 27 FF A complete Parts List is available at www MillerWelds com 6 7 Dry Contacts Using An External Power Supply For Isolated Input Module Operation Her Remote Contro
56. nit 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 NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift unit e f using lif
57. nm o N o Jumper Lead 42 9 Grounding Terminal Jumper 42 is connected to lead 90 at factory Jumper 42 may be discon nected from neutral to meet applica ble electrical codes Lead 42 connects to front panel Ground stud 10 Power Cord 11 Circuit Breaker CB7 User Terminals x Circuit breaker CB7 protects single phase receptacle RC5 and the load wires from overload If CB7 opens all three phase generator output stops and the receptacle does not work Connect user supplied ring lug to green ground lead Connect ring lug on end of green ground lead to grounding terminal 9 Connect black white and red leads to circuit breaker CB7 user terminals 11 Reinstall power panel Lx Engine control must be set to Run NOT Run ldle to adequately power the plasma cutter Ref 197 399 802 332 B OM 201 872 Page 17 A complete Parts List is available at www MillerWelds com SECTION 5 OPERATION 5 1 Controls i Miller SUP 1251 MADE IN B R rn DC Plasma Cutting System with AUTO LINE Meg ne ee RERO 7 on 9 40 a Oorr 5 GAS AIR ST ZT A 100 4 POWER PRESSURE OUTPUT Z d A POWER O 7 PRESSURE lt 3 cup O TEMP cur amp DN a couce FO Ml SET TO 75 PSI SET TO 60 PSI O TO CONNECT TORCH TO DISCONNECT TORCH 1 ALIGN amp PUSH TO ENGAGE 1 UNLOCK KEY 2 TURN KEY TO LOCK 2 PUSH COLLAR TO RELEASE 1 Gas Air Press
58. 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 manufacturer 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 transportat
59. nual Check for damaged torch or torch cable see torch Owner s Manual Check position of cut gouge switch If using cutting consumables be sure that switch is in the CUT position If using gouging consumables be sure that switch is in the GOUGE position No cutting output Power light off Trouble lights off Ready light off fan motor FM does not run Place Power switch in On position Place line disconnect device in On position see Section 4 7 Check line fuse s and replace if needed or reset circuit breakers see Section 4 9 Pilot arc working no cutting output Power light on Trouble lights off fan motor running Be sure work clamp is connected Clean or replace worn consumables as necessary see torch Owner s Manual No gas air flow Power light on Trouble lights off fan motor running Have Factory Authorized Service Agent check for proper torch connections Check operation of gas valve AS1 and check gas air system for leaks Check filter element see Section 7 5 Pressure Trouble light On Check for correct gas air pressure adjustment see Section 5 2 Check for sufficient gas air supply pressure see Section 4 5 Check for dirty air filter regulator and replace if necessary see manufacturer s instructions Check air lines for leaks Have Factory Authorized Service Agent check pressure switch and control board Cup Trouble light On Check torch
60. on Tape Obtain hose with 1 4 NPT right hand thread fitting Wrap threads with teflon tape optional or apply pipe sealant and install fitting in opening Route hose to gas air supply Adjust gas air pressure according to Section 5 2 90 120 psi 9 2 CFM 260 L min minimum From Gas Air Supply Tools Needed 3j ce ghein Ref 803 640 A Ref 192 441 Ref 804 026 A A Turn off power source and disconnect input power Torch Connector Quick Connect Collar Nipple Receptacle Securing Pin To connect torch c1 ND Push torch connector onto receptacle and quick connect until collar secures nipple Rotate securing pin to lock connector to unit To disconnect torch Rotate securing pin to unlock connector from unit Push quick connect collar back towards unit to release nipple and pull torch connector away from unit 804 055 A OM 201 872 Page 13 A complete Parts List is available at www MillerWelds com 4 7 Electrical Service Guide A CAUTION INCORRECT INPUT POWER can damage this welding power source This welding power source requires a CONTINUOUS supply of 50 or 60 Hz 10 power at 10 of 575V or 10 of 208V input voltage Phase to ground voltage shall not exceed 10 of rated input voltage Do not use a gener ator with automatic idle device that idles engine
61. pleton 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 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 delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped 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
62. r 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 e Keep all panels and covers securely in place e Do not bypass or try to defeat the safety interlock systems e Use only torch es specified in Owner s Manual e 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 201 872 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 shield and long sleeves when servicing inverters Ba FLYING SPARKS can cause injury Sparks and hot metal blow ou
63. rd PC1 op eration If system works properly retighten cup and reset power Ref 801 300 A OM 201 872 Page 39 FF A complete Parts List is available at www MillerWelds com 7 4 Checking Replacing Retaining Cup Tip And Electrode ay T 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 Overtightening will strip threads Do not overtighten electrode tip and retaining cup during assembly Do not cross thread parts causing stripping Use care during torch assembly and parts replacement V LE Me A good practice is to replace both the tip and electrode at the same time Turn Off power source before checking torch parts 1 32 in 1 mm to 1 16 in 2 mm maximum pit depth depending on acceptable cut quality Make sure this area is zt clean of any debris pd amp 2 4 Turn Off power source 1 Drag Shield Check this area for any debris or foreign material Clean out if necessary 2 Retaining Cup Remove retaining cup Check retaining cup for cracks and replace if necessary 3 Tip 4 Opening Remove tip Check tip and replace if open ing is deformed or 5096 oversize If inside of tip is not clean and bright clean with steel wool Be sure to remove any pieces of steel wool aft
64. re 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 Utiliser les quipements corrects les bonnes proc dures et suffisam ment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association 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 e Ne pas toucher des parties chaudes mains nues e Laisser refroidir avant d intervenir sur la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour vi ter les br lures x DES ORGANES MOBILES peuven
65. s autres contre le risque de blessure lire et respecter ces consignes 2 1 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 A EX 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 conna tre les mesures prendre pour viter tout dan ger 2 2 Dangers li s au coupage l arc au plasma A 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 ne doi vent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus particulierement les enfants
66. ser 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 e Ne pas placer l appareil sur au dessus ou proximit de surfaces infllammables e Ne pas installer l appareil proximit de produits in flammables Ne pas surcharger l installation lectrique s assurer que l alimentation est correctement dimensionn et prot g avant de mettre l appareil en service gt e LES CHARGES LECTROSTATI QUES peuvent endommager les cir o cuits imprim s SIS Le 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 util
67. stment to achieve the best cut characteristics OM 201 872 Page 32 FF A complete Parts List is available at www MillerWelds com 40 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1 16 in 1 6 mm between torch and workpiece for all cuts Shield Sense Tab Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch 90 9 2 212 732 212 733 212 725 212 724 212 734 226 763 Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process Shield sense tab is located in the consumable storage box on left side of unit wrapper Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds 40 tat Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds 40 Without concern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 33 FF A complete Parts List is available at www MillerWelds com 100 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3 16 in 4 8 mm between torch
68. strain relief to rear panel Route plug end of cable through nylon bushing and over to PC4 Connect plug to RC48 on PC4 Install wrapper on unit Cut off crimped terminals on lead ends and connect white lead to volts dc and black lead to volts dc on customer supplied voltage sense device Tools Needed IZ 15 16 in CO 5 16 in 804 041 A 6 9 Shield Sense Tab P Shield sense tab is located in the consumable storage box on left side of unit wrapper Shield sense tab provides feedback to a compatible torch height controller before starting the cutting process Place the shield sense tab between the cup and shield OM 201 872 Page 29 A complete Parts List is available at www MillerWelds com 6 10 Cut Charts 100 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1 8 in 3 2 mm between torch and workpiece for all cuts Shield Sense Tab Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch D G 0_ 0 m 219 687 219 684 219 679 219 678 219677 226 763 Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process Shield sense tab is located in the consumable storage box on left side of unit wrapper Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Stainless Pierce Material Thic
69. t 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 e Seules des personnes qualifi es sont autoris es enlever les por tes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l ali mentation lectrique DES PARTICULES VOLANTES peuvent blesser les yeux LA e Porter des lunettes de s curit avec 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 e Consultez votre ing nieur de coupage et les instruc tions de la table de coupage LA CHUTE DE L APPAREIL peut blesser e Utili
70. t 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 y 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 interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e To reduce poss
71. t 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 LB 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 Number Below 20 4 20 40 5 40 60 6 60 80 8 A NOISE can damage hearing Prolonged noise from some cutt
72. tch Assy w Spring 1 225 702 Torch replacement 25ft 1 190220 Trigger Spring 1 225 704 Torch replacement 50ft 1 215592 Switch Trigger 1 223774 Main Body w Switch 1 223612 Torch Lead 25ft 1 223613 Torch Lead 50ft 1 1 2 3 4 5 6 7 8 8 See Figure 9 2 for additional consumable parts Figure 9 1 Torch ICE 100T 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 201 872 Page 46 FAILURE TO RE PLACE WORN TIP E OR ELECTRODE Drag Shield Retaining Cap Electrode Swirl Ring WILL RUIN TORCH AND VOID WARRANTY Turn off power before checking torch parts Check before each 212 733 use and hourly during operation 2127 212 724 212 734 O Ring 33 212735 212 733 m e 219 685 219 684 219 678 219 677 Standard Cutting Shield Retaining Cap Tip Electrode Swirl Ring Q0 212 731 212 733 219 680 lt I O Ring 80A 3 J 212 724 212 734 212 735 212 731 212 733 212 727 Q a 212 731 219 684 219 681 219 678 219 677 Gouging Ref 213 031 B Ref 804 056 A Figure 9 2 Consumable Parts For ICE 100T 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
73. tip and workpiece for all cuts Deflector Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch 212736 219 684 219 683 219678 219677 Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds we 2 a s e wv e EL Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds E Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds 100 Without concern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 34 FF A complete Parts List is available at www MillerWelds com 80 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3 16 in 4 8 mm between torch tip and workpiece for all cuts Deflector Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch 212736 212733 212728 212724 212734 Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds e ws om se ar a sss we se Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds ENT uan mam umm m imr a 9 Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Without con
74. to a clean paint free Set air pressure to 75 PSI Set Mode switch to CUT location on metal workpiece as close to 517 kPa for cutting cutting area as possible 4 The pilot arc starts immediately when trigger is pressed em EX gt For standard shielded cutting place drag Raise trigger lock and press After cutting arc starts slowly shield on edge of metal For non shielded trigger Pilot arc starts start moving torch across metal cutting use 1 8 in 3 2 mm standoff distance dragging tip will reduce tip life E ee ee ET j IN O 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 Ref 803 640 A 801 400 B OM 201 872 Page 21 5 6 Sequence Of Gouging Operation gt A complete Parts List is available at www MillerWelds com E A Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Hold torch at approximately 45 angle to workpiece E Set air pressure to 60 PSI 414 kPa for gouging 4 The pilot arc starts immediately when trigger is pressed Raise trigger lock and press trigger Pilot arc starts Move tip to wit
75. ure Gauge 2 Gas Air Pressure Control 3 Output Control Use control to select cutting output in am peres Gas air automatically flows at the set pressure Use Gas Air Set area of control range for set ting gas air pressure see Section 5 2 4 Trouble Lights see Section 7 2 5 Power Light 6 Cut Gouge Switch 201 853 A After the cutting arc goes out the torch will automatically re ignite the pilot arc if the trigger is held down 7 Power Switch Set pressure as indicated on nameplate for appropriate switch position OM 201 872 Page 18 A complete Parts List is available at www MillerWelds com 5 2 Setting Gas Air Pressure lt 9 90 120 psi Rear of Unit Ref 804 025 A Ref 804 026 A Setting Gas Air Pressure Unit Requires 90 120 PSI 1 Power Switch 621 827 kPa Supply At 9 2 CFM 260 L min Minimum Flow Rate 2 Output Control Place Output Control in Turn On Gas Air Supply Power Switch On Gas Air Set Position pressure to 75 PSI 3 Gas Air Pressure Adjustment Knob Pull knob and turn set 517 kPa Push knob in to lock setting Select desired cutting output with Output Control 5 3 Trigger Safety Lock Trigger Locked Trigger Unlocked 1 Trigger 801 397 A OM 201 872 Page 19 FF A complete Parts List is available at www MillerWelds com 5 4 Plasma Cutting System Practices Y a T
76. use ainsi une d charge lectrique d tincelles ou un feu e Ne pas utiliser le coupeur plasma pour d geler des conduites gel es e Ne coupez jamais des contenants qui peuvent contenir des mati res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement e Ne coupez pas dans un endroit o l atmosph re risque de contenir de la poussi re ou des vapeurs explosives e Necoupez pas de bouteilles de tuyaux ou de contenants pressuri S s e Ne coupez pas de contenants qui ont d j re u des combustibles e 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 e Ne placez pas le poste sur une surface combustible ou au dessus de celle ci e Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes e Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un extincteur proximit i UNE D CHARGE LECTRIQUE peut entrainer la mort Le fait de toucher une pi ce lectrique sous tension peut donner une d charge fatale ou entra 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 d
77. ut charts are based on a distance of 3 16 in 4 8 mm between torch tip and workpiece for all cuts Deflector Retaining Cap Tip Electrode Swirl Ring ICE 100TM Torch 212736 212 733 212 729 212 724 Mild Steel Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Arc Current Arc Voltage m o9 we 3 ES su ETES Stainless Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Aluminum Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds Without concern for cut appearance the fastest speed for cutting material is the maximum cut speed For better cut angle less dross and cut surface appearance use the optimum cut speed The values in the cut charts are basic starting points and each application may require some adjustment to achieve the best cut characteristics OM 201 872 Page 37 A complete Parts List is available at www MillerWelds com SECTION 7 MAINTENANCE 8 TROUBLESHOOTING 7 1 Routine Maintenance PA pu Rr A Disconnect power EF Maintain more often T SES 7 sS before maintaining during severe conditions So eh 17 Check Change Q Clean Replace Reference To be done by Factory Authorized Service Agent Each Use Torch Tip Electrode Y Gas Air Pressure And Shield Cup Every Week Y Shield Cup Shutdown System A FN yes NZ Ki O LE AG oO Every

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