Miller Electric 1251 Owner`s manual

OM-201 872A
2005−09
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
R
Spectrum 1251 And
ICE-100T/TM Torch
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
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
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
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
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 exact part you may need to fix the problem.
the U.S.A. to be registered to
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.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers liés au coupage à l’arc au plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting And Disconnecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Setting Gas/Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Consumables Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MECHANIZED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. ICE-100TM Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Remote Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Remote Control Cable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. +24 Volts DC Hot Contacts For Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Dry Contacts Using An External Power Supply For Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation . . . . . . . . . . . . .
6-8. Remote Voltage Sense Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Cut Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Checking Or Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
38
38
39
39
40
41
42
43
44
46
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
pom _4/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
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.
1-2. Plasma Arc Cutting Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only a
summary of the more complete safety information found in the
Safety Standards listed in Section 1-5. Read and follow all Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
D
D
D
D
D
D
CUTTING can cause fire or explosion.
D
Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and burns. Check
and be sure the area is safe before doing any cutting.
D
Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this
is not possible, tightly cover them with approved covers.
D Do not cut where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not cut on closed containers such as tanks or drums.
D Connect work cable to the work as close to the cutting area as practical to prevent cutting current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
D Do not use plasma cutter to thaw frozen pipes.
D Never cut containers with potentially flammable materials inside −
they must be emptied and properly cleaned first.
D Do not cut in atmospheres containing explosive dust or vapors.
D Do not cut pressurized cylinders, pipes, or vessels.
D Do not cut containers that have held combustibles.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Do not locate unit on or over combustible surfaces.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any cutting.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but also uses torches designed with safety
interlock systems which turn off the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. Incorrectly
installed or improperly grounded equipment is a hazard.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
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.
Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
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.
When making input connections, attach proper grounding conductor first.
Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Inspect and replace any worn or damaged torch cable leads.
Do not wrap torch cable around your body.
Ground the workpiece to a good electrical (earth) ground if required
by codes.
Use only well-maintained equipment. Repair or replace damaged
parts at once.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Do not bypass or try to defeat the safety interlock systems.
Use only torch(es) specified in Owner’s Manual.
Keep away from torch tip and pilot arc when trigger is pressed.
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.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists in
inverter power sources AFTER the removal of input power.
D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Maintenance Section of Owner’s Manual or Technical Manual before
touching any parts.
OM-201 872 Page 1
D
D
D
EXPLODING PARTS can injure.
D
D
D On inverter power sources, failed parts can explode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.
D
FLYING SPARKS can cause injury.
D
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
D
Wear approved face shield or safety goggles with side shields.
Wear proper body protection to protect skin.
Wear flame-resistant ear plugs or ear muffs to prevent sparks from
entering ears.
D
ARC RAYS can burn eyes and skin.
PLASMA ARC can cause injury.
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
D
D
D
D
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 convenience.
Wear approved safety glasses with side shields under your helmet
or shield.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
D
D
D
D
D
D
D
Minimum Shade Number
#4
#5
#6
#8
NOISE can damage hearing.
Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
D
D
Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.
FUMES AND GASES can be hazardous.
Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove cutting fumes and gases.
OM-201 872 Page 2
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.
The pilot arc can cause burns − keep away from torch tip when trigger is pressed.
Wear proper flame-retardant clothing covering all exposed body areas.
Point torch away from your body and toward work when pressing
the torch trigger − pilot arc comes on immediately.
Turn off power source and disconnect input power before disassembling torch or changing torch parts.
Use only torch(es) specified in the Owner’s Manual.
CYLINDERS can explode if damaged.
Table 1. Eye Protection For Plasma Arc Cutting
Current Level In Amperes
Below 20
20 − 40
40 − 60
60 − 100
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals to be cut, coatings,
and cleaners.
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.
Do not cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
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.
Do not cut containers with toxic or reactive materials inside or
containers that have held toxic or reactive materials − they must be
emptied and properly cleaned first.
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are normally part of metalworking processes,
be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flame, sparks, and arcs.
D Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
D Keep cylinders away from any cutting or other electrical circuits.
D Never allow electrical contact between a plasma arc torch and a
cylinder.
D Never cut on a pressurized cylinder − explosion will result.
D Use only correct gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated
parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number
of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
D
1-3. Additional Symbols For Installation, Operation, And Maintenance
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before going near plasma arc cutting operations.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
EXPLODING HYDROGEN hazard.
D When cutting aluminum underwater or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the workpiece.
D See your cutting engineer and water table instructions for help.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift unit.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
FIRE OR EXPLOSION hazard.
D Do not locate unit on, over, or near combustible
surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D High frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment
at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC CUTTING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D To reduce possible interference, keep cables as short as possible,
close together, and down low, such as on the floor.
D Locate cutting operation 100 meters from any sensitive electronic
equipment.
D Be sure this cutting power source is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures such
as moving the machine, using shielded cables, using line filters, or
shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y 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.
For Diesel Engines:
Y 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 Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
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).
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
National Electrical Code, NFPA Standard 70, from National Fire Protection 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.
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, Superintendent 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).
1-6. 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 humanhealth 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 procedures:
OM-201 872 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep cutting power source and cables as far away from operator
as practical.
5. Connect work clamp to workpiece as close to the cut as 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 SÉCURITÉ − LIRE AVANT UTILISATION
pom_fre 4/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers liés au coupage à l’arc au plasma
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-4. Veuillez lire et respecter toutes
ces normes de sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
LE COUPAGE présente un risque de
feu ou d’explosion.
Des particules de métal chaud et des étincelles
peuvent jaillir de la pièce au moment du coupage.
Les étincelles et le métal chaud, la pièce à couper
chauffée et l’équipement chaud peuvcnt causer un
feu ou des brûlures. Avant de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.
Déplacez toute matière inflammable se trouvant à l’intérieur d’un
périmètre de 10,7 m (35 pi) de la pièce à couper. Si cela est impossible, vous devez les couvrir avec des housses approuvées et bien
ajustées.
D Ne coupez pas dans un endroit où des étincelles pourraient atteindre des matières inflammables.
D Protégez−vous, ainsi que toute autre personne travaillant sur les
lieux, contre les étincelles et le métal chaud.
D Assurez−vous qu’aucune étincelle ni particule de métal ne peut se
glisser dans de petites fissures ou tomber dans d’autres pièces.
D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur à la portée de la main.
D Si vous coupez sur un plafond, un plancher ou une cloison, soyez
conscient que cela peut entraîner un feu de l’autre côté.
D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un bidon.
D Fixez le câble de masse sur la pièce à couper, le plus près possible
de la zone à couper afin de prévenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une décharge électrique, d’étincelles ou un feu.
D Ne pas utiliser le coupeur plasma pour dégeler des conduites
gelées.
D Ne coupez jamais des contenants qui peuvent contenir des matières inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.
D Ne coupez pas dans un endroit où l’atmosphère risque de contenir
de la poussière ou des vapeurs explosives.
D Ne coupez pas de bouteilles, de tuyaux ou de contenants pressurisés.
D Ne coupez pas de contenants qui ont déjà reçu des combustibles.
D Portez des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Ne placez pas le poste sur une surface combustible ou au−dessus
de celle−ci.
D Avant le coupage, retirez tout combustible de vos poches, par
exemple un briquet au butane ou des allumettes.
D
Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA
51B pour travaux de soudage et prévoir un détecteur d’incendie et
un extincteur à proximité.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le fait de toucher à une pièce électrique sous
tension peut donner une décharge fatale ou entraîner des brûlures graves. Le chalumeau et le circuit
de masse sont automatiquement actifs lorsque le
poste est sous tension. L’alimentation d’entrée et les circuits internes
de l’appareil le sont également. Le coupage au plasma d’arc exige des
tensions plus élevées que le soudage pour amorcer et maintenir l’arc
(souvent de 200 à 400 V CC), c’est pourquoi on fait appel à des
chalumeaux conçus avec un système de verrouillage sécuritaire qui
met l’appareil hors tension lorsque la capsule anti−feu est desserrée
ou si le tube touche l’électrode à l’intérieur de la buse. Un poste
incorrectement installé ou inadéquatement mis à la terre constitue un
danger.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Ne touchez pas aux pièces électriques sous tension.
Portez des gants isolants et des vêtements de protection secs et
sans trous.
Isolez−vous de la pièce à couper et du sol en utilisant des housses
ou des tapis assez grands afin d’éviter tout contact physique avec
la pièce à couper ou le sol.
Ne touchez pas aux pièces du chalumeau si vous êtes en contact
avec la pièce à couper ou le sol.
Mettez l’appareil hors tension avant d’effectuer la vérification, le
nettoyage ou le changement d’une pièce du chalumeau.
Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation
selon la norme OSHA 29 CFR 1910.147 (reportez−vous aux Principales normes de sécurité).
Installez le poste correctement et mettez-le à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Assurez−vous que le fil de terre du cordon d’alimentation est correctement relié à la borne de terre dans la boîte de coupure ou que
la fiche du cordon est branchée à une prise correctement mise à la
terre − vous devez toujours vérifier la mise à la terre.
Avant d’effectuer les connexions d’alimentation, vous devez relier
le bon fil de terre.
Vérifiez fréquemment le cordon d’alimentation afin de vous assurer
qu’il n’est pas altéré ou à nu, remplacez−le immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Vérifiez et remplacez les cosses du câble du chalumeau si elles
sont usées ou altérées.
Le câble du chalumeau ne doit pas s’enrouler autour de votre corps.
Si les normes le stipulent, la pièce à couper doit être mise à la terre.
Utilisez uniquement de l’équipement en bonne condition. Réparez
ou remplacez immédiatement toute pièce altérée.
Portez un harnais de sécurité si vous devez travailler au−dessus du
sol.
Assurez−vous que tous les panneaux et couvercles sont correctement en place.
N’essayez pas d’aller à l’encontre des systèmes de verrrouillage
de sécurité ou de les contourner.
Utilisez uniquement le ou les chalumeaux recommandés dans le
manuel de l’opérateur.
OM-201 872 Page 5
D
D
D
N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée.
Le câble de masse doit être pincé correctement sur la pièce à couper, métal contre métal (et non de telle sorte qu’il puisse se
détacher), ou sur la table de travail le plus près possible de la ligne
de coupage.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
LE BRUIT peut endommager l’ouïe.
Certaines applications de coupage produisent un bruit
constant, ce qui peut endommager l’ouïe si le niveau
sonore dépasse les limites permises par l’OSHA (reportez−vous aux Principales normes de sécurité).
D Utilisez des protège−tympans ou un serre−tête antibruit si le niveau
sonore est élevé.
D Prévenez toute personne sur les lieux du danger relié au bruit.
DÉCHARGES ÉLECTRIQUES potentiellement mortelles.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Il y a DES CHARGES DC SIGNIFICATIVES dans le poste de soudage inverseur même APRÈS coupure du courant d’alimentation.
Le coupage produit des vapeurs et des gaz. Respirer
ces vapeurs et ces gaz peut être dangereux pour la
santé.
D Mettre l’unité hors tension, mesurer la tension des condensateurs
d’entrée et s’assurer qu’elle est pratiquement nulle avant de toucher à l’une quelconque des pièces. Mesurer cette tension conformément aux directives énoncées à la section Entretien du manuel
de l’utilisateur ou du manuel technique avant de toucher à l’une
quelconque des pièces.
Risque de blessure en cas
D’EXPLOSION DES PIÈCES.
D Mise sous tension, toute pièce défectueuse des
sources d’alimentation de l’inverseur peut exploser ou faire exploser d’autres pièces. Pour entretenir les inverseurs, toujours porter un masque
protecteur et un vêtement à manches longues.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Le coupage plasma produit des étincelles et projections de
métal à très haute température. Lorsque la pièce refroidit,
du laitier peut se former.
D Portez une visière ou des lunettes de sécurité avec des écrans latéraux approuvées.
D Portez des vêtements de protection adéquats afin de protéger votre
peau.
D Ayez recours à des protège−tympans ou à un serre−tête ignifuges afin
d’éviter que les étincelles n’entrent dans vos oreilles.
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau.
Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner des brûlures aux yeux et à la
peau.
D Lorsque vous coupez ou regardez quelqu’un couper, portez un casque de soudage approuvé muni de verres filtrants approprié. La
norme ANSI Z49.1 (reportez−vous aux Principales normes de sécurité) suggère d’utiliser un filtre de teinte nd 9 (nd 8 étant le minimum)
pour tout travail de coupage faisant appel à un courant de moins de
300 A. On mentionne également dans la norme Z49.1 qu’un filtre plus
faible peut être utilisé lorsque l’arc est caché par la pièce à couper.
Comme cela est habituellement le cas pour les travaux de coupage à
faible courant, les teintes énumérées au tableau 1 sont fournies à titre
d’information pour l’opérateur.
D Porter des lunettes de sécurité à coques latérales sous votre casque
ou écran facial.
D Ayez recours à des écrans protecteurs ou à des rideaux pour protéger
les autres contre les rayonnements, les étincelles et les éblouissements; prévenez toute personne sur les lieux de ne pas regarder l’arc.
D Portez des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
Tableau 1. Protection des yeux pour le coupage au plasma d’arc
Intensité de courant en ampères
Filtre de teinte (minimum)
Moins de 20
20 − 40
40 − 60
60 − 100
no. 4
no. 5
no. 6
no. 8
OM-201 872 Page 6
D Ne mettez pas votre tête au−dessus des vapeurs. Ne respirez pas ces
vapeurs.
D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce ou
ayez recours à une ventilation aspirante installée près de l’arc pour
évacuer les vapeurs et les gaz.
D Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travaillez dans un espace restreint uniquement s’il est bien ventilé ou
si vous portez un respirateur anti−vapeurs. Les vapeurs causées par
le coupage et l’épuisement de l’oxygène peuvent altérer la qualité de
l’air et entraîner des blessures ou la mort. Assurez−vous que l’air ambiant est sain pour la santé.
D Ne coupez pas dans un endroit près d’opérations de décapage, de
nettoyage ou de vaporisation. La chaleur et les rayons d’arc peuvent
réagir avec les vapeurs et former des gaz hautement toxiques et irritants.
D Ne coupez pas des métaux enrobés tels que des métaux galvanisés,
contenant du plomb ou de l’acier plaqué au cadmium, à moins que
l’enrobage ne soit ôté de la surface du métal à couper, que l’endroit où
vous travaillez ne soit bien ventilé, ou que vous ne portiez un respirateur anti−vapeurs. Les enrobages ou tous métaux qui contiennent ces
éléments peuvent créer des vapeurs toxiques s’ils sont coupés.
D Ne coupez pas de contenants qui renferment ou ont renfermés des
matières toxiques ou réactives − vous devez en premier lieu les vider
et les nettoyer convenablement.
LE PLASMA D’ARC peut entraîner
des blessures.
La chaleur dégagée par le plasma d’arc peut entraîner de
sérieuses brûlures. La force de l’arc est un facteur qui
s’ajoute au danger de brûlures. La chaleur intense et la
puissance de l’arc peuvent rapidement passer au travers
de gants et de tissus.
D N’approchez pas le tube du chalumeau.
D Ne saisissez pas la pièce à couper près de la ligne de coupage.
D L’arc pilote peut causer des brûlures − n’approchez pas le tube du chalumeau lorsque vous avez appuyé sur le gâchette.
D Portez des vêtements de protection adéquats qui recouvrent tout votre corps.
D Ne pointez pas le chalumeau en direction de votre corps ni de la pièce
à couper lorsque vous appuyez sur la gâchette − l’arc pilote s’allume
automatiquement.
D Mettez l’alimentation hors tension et débranchez le cordon d’alimentation avant de démonter le chalumeau ou de changer une pièce du
chalumeau.
D Utilisez uniquement le ou les chalumeaux recommandés dans le manuel de l’opérateur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz contiennent du gaz sous haute
pression. Si une bouteille est endommagée, elle peut
exploser. Puisque les bouteilles de gaz font habituellement
partie d’un processus de travail des métaux, assurez−vous
de les manipuler correctement.
D Protégez les bouteilles de gaz comprimé contre la chaleur excessive,
les chocs mécaniques, des dommages physiques, le laitier, la flamme, les étincelles et l’arc.
D Installez et attachez les bouteilles dans la position verticale à l’aide
d’une chaîne, sur un support stationnaire ou un châssis porte−bouteille afin de prévenir qu’elles ne tombent ou ne basculent.
D Les bouteilles ne doivent pas être près de la zone de coupage ni de
tout autre circuit électrique.
D Un contact électrique ne doit jamais se produire entre un chalumeau
de plasma d’arc et une bouteille.
D Ne coupez jamais sur une bouteille pressurisée − une explosion en
résulterait.
D Utilisez uniquement des bouteilles de gaz, des détendeurs, des
boyaux et des raccords conçus pour l’application déterminée. Gardez−les, ainsi que toute autre pièce associée, en bonne condition.
D Détournez votre visage du détendeur−régulateur lorsque vous ouvrez
la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
vous utilisez la bouteille ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
DES PIECES CHAUDES peuvent provoquer des brûlures graves.
D
D
Ne pas toucher des parties chaudes à mains nues.
Laisser refroidir avant d’intervenir sur la torche.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
S’abstenir de toucher des organes mobiles tels que
des ventilateurs.
Maintenir fermés et verrouillés les portes, panneaux,
recouvrements et dispositifs de protection.
D Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour
l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
Porter des lunettes de sécurité avec protections latérales ou frontales.
LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs sont priés de consulter leur médecin
avant d’approcher les opérations de coupage
plasma.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
Prévoir une période de refroidissement; respecter le
cycle opératoire nominal.
Réduire l’ampérage (épaisseur) avant de continuer à
couper ou réduire le facteur de marche.
Danger D’EXPLOSION
D’HYDROGÈNE.
D
D
LA CHUTE DE L’APPAREIL peut
blesser.
D
D
Utiliser l’anneau de levage uniquement pour soulever
l’appareil, NON PAS les chariot, les bouteilles de gaz
ou tout autre accessoire.
Utiliser un engin d’une capacité appropriée pour soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
Risque D’INCENDIE OU
D’EXPLOSION.
D
D
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces infllammables.
Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionné et protégé avant de
mettre l’appareil en service.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D
D
Etablir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes PC.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
D
Le Rayonnement haute frequence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de
sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
Lors du coupage d’aluminium partiellement ou totalement immergé dans l’eau, de l’hydrogène libre peut
s’accumuler sous la pièce.
Consultez votre ingénieur de coupage et les instructions de la table de coupage.
OM-201 872 Page 7
LE COUPAGE Ã L’ARC peut causer
des interférence.
D
L’énergie électromagnétique peut gêner le fonctionnement d’appareils électroniques comme des ordinateurs et des robots.
D Veiller à couper à une distance de 100 mètres de tout équipement
électronique sensible.
D S’assurer que la source de coupage est correctement branchée et
mise à la terre.
D Si l’interférence persiste, l’utilisateur doit prendre des mesures supplémentaires comme écarter la machine, utiliser des câbles blindés
de des filtres, ou boucler la zone de travail.
D Pour réduire la possibilité d’interférence, maintenir les câbles aussi
courts que possible, les grouper, et les poser aussi bas que possible
(ex. par terre).
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society de Global Engineering Documents
(téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de la National Fire Protection 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.
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
(téléphone : 617-770-3000, site Internet : 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, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
1
Le courant de soudage ou de coupage passant dans les câbles de puissance crée des causera des champs électromagnétiques. Il y a eu et
il y a encore un certain souci à propos de tels champs. Cependant,
après avoir examiné plus de 500 études qui ont été faites pendant une
période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques
pendant le soudage ou le coupage.
2
3
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
OM-201 872 Page 8
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
vous.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder/couper ou d’approcher des opérations de soudage/
couper. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
A
V
U0
I1max
IP
I1eff
Amperes
Plasma Arc Cutting
(PAC)
Adjust Air/Gas
Pressure
Low Air Pressure
Light
Volts
Increase
No − Do Not Do
This
Temperature
Protective Earth
(Ground)
Single Phase
Constant Current
Voltage Input
On
Off
Percent
Direct Current
Conventional Load
Voltage
Line Connection
Duty Cycle
Single Phase Or
Three Phase Static
Frequency
ConverterTransformerRectifier
Rated No Load
Voltage (Average)
Rated Maximum
Supply Current
U1
I2
Degree Of
Protection
Maximum Effective
Supply Current
pf
Primary Voltage
Rated Welding
Current
U2
X
1/3
f1
f2
Loose Shield Cup
Input
Hz
Hertz
power factor
Suitable for Some
Hazardous
Locations
S1
Power Rating,
Product Of Voltage
And Current (KVA)
S
OM-201 872 Page 9
SECTION 4 − INSTALLATION
4-1. Specifications
Amperes Input at Rated Load
Output 60 Hz, Three-Phase*
Duty Cycle
40%
50%
80%
80%
208 V
230 V
460 V
575 V
55
49
24
19
KVA
19.1
Rated
Output
Type of
Output
Plasma
Gas
Rated
Cutting
Capacity
Maximum
O
OpenCircuit
Voltage
g DC
100 A @
160 Volts
DC
Direct
Current,
Straight
Polarity
(DCEN)
9.2 CFM
(261
L/min) At
75 PSI
(517 kPa)
Air Or
Nitrogen
Only
1.25 in
(32 mm)
At 12 IPM
(305 mm/min)
265
KW
18.2
*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
Output 50 Hz,
Three-Phase*
400 V
28
KVA
19.2
Rated
Output
Type of
Output
Plasma
Gas
Rated Cutting
Capacity
Maximum
Open-Circuit
Voltage DC
100 A @ 160
Volts DC, 80%
Duty Cycle
Direct Current,
Straight Polarity
(DCEN)
9.2 CFM
(261 L/min) At
75 PSI (517
kPa) Air Or
Nitrogen Only
1.25 in
(32 mm)
At 12 IPM
(305 mm/min)
265
KW
18.3
*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition..
OM-201 872 Page 10
4-2. Duty Cycle and Overheating
Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.
208 Volts AC Three-Phase Input Power:
40% Duty Cycle
4 Minutes Cutting
Y Exceeding duty cycle can
damage unit and void warranty.
6 Minutes Resting
230 Volts AC Three-Phase Input Power:
50% Duty Cycle
5 Minutes Cutting
If unit overheats, output stops, and
cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before cutting.
380-575 Volts AC Three-Phase Input Power:
80% Duty Cycle
5 Minutes Resting
8 Minutes Cutting
2 Minutes Resting
Overheating
A
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95
4-3. Cutting Speed
Rated Cutting Speed vs Material Type & Thickness
The cutting speed curve shows the
rated cutting speed capabilities of
the power source and torch for mild
steel, stainless steel, and aluminum
of various thicknesses.
170
160
Cutting Speed (Inches per Minute)
150
Y Exceeding recommended
cutting speeds will cause
rapid erosion of the tip and
electrode.
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0.25”
0.375”
0.5”
0.625”
0.75”
1”
1.25”
Material Thickness (Inches)
Aluminum
Stainless Steel
Mild Steel
OM-201 872 Page 11
4-4. Selecting a Location
24 in
(610 mm)
Dimensions And Weight
95 lb (43 kg) w/Torch
17 in
(432 mm)
12-1/2 in
(318 mm)
1
Movement
1
Y Do not move or operate unit
where it could tip.
1
2
Hand Cart
Use cart or similar device to move
unit.
3
Line Disconnect Device
Locate unit near correct input
power supply.
2
Location
Lifting Handles
Use handles to lift unit.
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
3
18 in
(460 mm)
18 in
(460 mm)
OM-201 872 Page 12
loc_2 3/96 - Ref. 151 556 / 802 183
4-5. Connecting Work Clamp and Gas/Air Supply
1
2
1
Work Clamp
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 150 psi (620 to 1035 kPa)
pressure
@
9.2
CFM
(260L/min) minimum.
2
AIR/N2
90-150 psi
5
@ 9.2 CFM
(260 L/min)
minimum
3
3
Gas/Air Filter Inlet Opening
4
Hose
. Hose
must have a minimum
inside diameter of 3/8 in
(9.5 mm).
5
Teflon Tape
Obtain hose with 1/4 NPT righthand 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.
4
From
Gas/Air
Supply
Tools Needed:
Rear of Unit
9/16 in
Ref. 803 640-A / Ref. 192 441 / Ref. 804 026-A
4-6. Connecting And Disconnecting Torch
Y Turn off power source and
disconnect input power.
2
1
1
2
3
4
5
3
Torch Connector
Quick Connect Collar
Nipple
Receptacle
Securing Pin
To connect torch:
4
5
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
4-7. Electrical Service Guide
Y
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 generator with automatic idle device (that idles engine 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
Time-Delay 2
60
60
30
20
3
80
70
35
30
Max Recommended Standard Fuse Rating In Amperes 1
Normal Operating
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
8
8
10
12
89
(27)
108
(33)
284
(87)
268
(82)
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
400
Input Voltage
28
Input Amperes At Rated Output
Max Recommended Standard Fuse Rating In Amperes
Min Input Conductor Size In AWG
1
Time-Delay 2
25
Normal Operating 3
35
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
12
155
(47)
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.
OM-201 872 Page 14
4-8. Extension Cord Data
NOTE
When calculating max. cord length, remember to include conductor length from
line disconnect device to input power receptacle.
Input Voltage
Input Power
Phase
Hertz
Fuse Size Or
Circuit Breaker Rating
208 V
3
60
Time-Delay 2
Normal Operating 3
230 V
3
60
460 V
3
575 V
400 V
Conductor Size
Max. Cord Length
60 A
80 A
8 AWG
89 ft (27 m)
Time-Delay 2
Normal Operating 3
60 A
70 A
8 AWG
108 ft (33 m)
60
Time-Delay 2
Normal Operating 3
30 A
35 A
10 AWG
284 ft (87 m)
3
60
Time-Delay 2
Normal Operating 3
20 A
30 A
12 AWG
268 ft (82 m)
3
50
Time-Delay 2
Normal Operating 3
25 A
35 A
12 AWG
155 ft (47 m)
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
4-9. Connecting 3-Phase Input Power
Y Installation must meet all National
and Local Codes − have only
qualified persons make this
installation.
3
= GND/PE Earth Ground
Y Disconnect and lockout/tagout
input power before connecting
input conductors from unit.
Y Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4
. 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.
7
2
1
2
3
4
L1
3
L2
L3
6
5
5
6
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
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 disconnect switch shown).
1
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
3/8 in
3/8 in
803 766-A / 802 183
OM-201 872 Page 16
4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant
Three-Phase Generator Power
Y Stop engine.
Y Power and weld outputs are
live at the same time. Disconnect or insulate unused
cables.
Three-Phase Power Connection
. Have qualified person install ac-
cording to circuit diagram and
Generator Power Guidelines
(see generator Owner’s Manual).
Y Close panel opening
if no connections are
made to generator.
Remove generator power panel
mounting screws. Tilt panel forward.
Remove plug
before inserting
leads. Reinstall
bushing.
3
Rear Of Panel
4
91
92
93
1
90
Lead 93
3
Lead 92
4
Lead 91
5
Lead 42 (Circuit Grounding
Lead)
6
Lead 90 (Neutral)
7
Isolated Neutral Terminal
8
Jumper Lead 42
9
Grounding Terminal
Lead 42 connects to front panel
Ground stud.
11
6
Circuit Breaker CB7
2
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes.
2
42
5
1
10 Power Cord
11 Circuit Breaker CB7 User
Terminals
9
. 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.
10
Y Close
panel
opening if no
connections
are made to
generator.
8
Connect user-supplied ring lug to
green (ground) lead. Connect ring
lug on end of green (ground) lead
to grounding terminal (9).
240V
7
3-Phase
240V
240V
Connect black, white, and red
leads to circuit breaker CB7 user
terminals (11).
Reinstall power panel.
. Engine control
must be set to
Run NOT Run/Idle to adequately
power the plasma cutter.
Volts
Three
Phase
3
240
Amps
48
KVA/KW
20
AC
Output
Tools Needed:
Frequency
Engine Speed
60 Hz
1850 RPM
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
93
91
90
92
Ref. 197 399 / 802 332-B
OM-201 872 Page 17
SECTION 5 − OPERATION
5-1. Controls
1
3
7
5
4
6
2
1
Gas/Air Pressure Gauge
2
Gas/Air Pressure Control
3
Output Control
Use control to select cutting output in amperes. Gas/air automatically flows at the set
pressure.
OM-201 872 Page 18
Use Gas/Air Set area of control range for setting gas/air pressure (see Section 5-2).
4 Trouble Lights (see Section 7-2)
5 Power Light
6 Cut/Gouge Switch
Set pressure as indicated on nameplate for
appropriate switch position.
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
5-2. Setting Gas/Air Pressure
2
1
3
Rear of Unit
Ref. 804 025-A / Ref. 804 026-A
Setting Gas/Air Pressure
Unit Requires 90-150 PSI
(620-1035 kPa) Supply At
9.2 CFM (260 L/min)
Minimum Flow Rate
1
Power Switch
Turn On Gas/Air Supply.
Power Switch On.
2
Output Control
3
Gas/Air Pressure
Adjustment Knob
Pull knob and turn, set
pressure to 75 PSI
(517 kPa). Push knob in
to lock setting.
Place Output Control in
Gas/Air Set Position.
Select desired cutting
output with Output
Control.
5-3. Trigger Safety Lock
1
Trigger
1
Trigger Locked
Trigger Unlocked
801 397-A
OM-201 872 Page 19
5-4. Plasma Cutting System Practices
The pilot arc starts immediately
when trigger is pressed.
Always connect work clamp to a clean,
paint-free location on metal workpiece, as
close to cutting area as possible.
. Set correct air pressure for process:
75 PSI (517 kPa) for cutting,
60 PSI (414 kPa) for gouging.
DO NOT start pilot arc without cutting or
gouging as this shortens the service life
of the nozzle and electrode.
90°
Maintain approximately a 90° angle to the
workpiece surface for proper cutting results.
Sparks should pass through the workpiece
and out the bottom when cutting.
If sparks flare back from surface, this
usually is an indication that either travel
speed is too fast, amperage is set too low,
or consumables are worn.
Wt
1/8 in
(3.2 mm)
When doing non-shielded cutting, maintain
approximately 1/8 in standoff between
electrode and surface.
DO NOT put pressure on shield when
drag cutting; instead, slide shield along
the surface for proper cutting results.
Pulling rather than pushing the torch
makes cutting easier. Use a proper guide
or template for accurate cutting operations.
Ref. 803 640-A / 801 400-B / Ref. 802 878
OM-201 872 Page 20
5-5. Sequence Of Cutting Operation
Connect work clamp to a clean, paint-free
location on metal workpiece, as close to
cutting area as possible.
. Set air pressure to 75 PSI
Set Mode switch to CUT.
(517 kPa) for cutting.
The pilot arc starts immediately
when trigger is pressed.
90°
For standard (shielded) cutting, place drag
shield on edge of metal. For non-shielded
cutting, use 1/8 in (3.2 mm) standoff distance
(dragging tip will reduce tip life).
Adjust torch speed so
sparks go thru metal and
out bottom of cut.
Raise trigger lock and press
trigger. Pilot arc starts.
Pause briefly at end of
cut before releasing trigger.
After cutting arc starts, slowly
start moving torch across metal.
Postflow continues for approx. 20 seconds
after releasing trigger; cutting arc can be
instantly restarted during postflow by raising
trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
OM-201 872 Page 21
5-6. Sequence Of Gouging Operation
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
. Set air pressure to 60 PSI
Set Mode switch to GOUGE.
(414 kPa) for gouging.
The pilot arc starts immediately
when trigger is pressed.
455
Hold torch at approximately
45° angle to workpiece.
Raise trigger lock and press trigger. Pilot
arc starts. Move tip to within approximately 3/16 in (4.8 mm). Start gouging
across workpiece surface. Maintain
approximately a 45° angle to surface.
Release trigger. Postflow continues for
approx. 20 seconds after releasing trigger;
arc can be instantly restarted during postflow
by raising trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
OM-201 872 Page 22
5-7. Sequence Of Piercing Operation
The pilot arc starts immediately
when trigger is pressed.
Connect work clamp to a
clean, paint-free location
on workpiece, as close to
cutting area as possible.
. Set air pressure to 75 PSI
Set Mode switch to CUT.
(517 kPa) for cutting.
90°
Hold torch at an angle to the
workpiece. Raise trigger lock and
press trigger. Pilot arc starts.
90°
Rotate torch to upright position
approximately 90° to surface.
When arc has pierced through
workpiece, start cutting.
Maintain approximately 90° torch
position to surface, and continue
cutting.
Release trigger. Postflow continues for
approx. 20 seconds after releasing trigger;
arc can be instantly restarted during postflow
by raising trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
5-8. Consumables Storage Compartment
1
1
Consumables Storage
Compartment
This compartment provides
convenient access to consumables
and parts.
Rear of Unit
804 026-A
OM-201 872 Page 23
SECTION 6 − MECHANIZED OPERATION
6-1. ICE-100TM Mounting Position
1
2
ICE-100TM Machine Torch
Square
Use a square to align torch perpendicular to the work surface.
1
2
90°
6-2. Remote Control Receptacle
1
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.
1
3
2
1
7
6
5
4
11
10
9
8
14
13
Remote Control Receptacle
RC61
12
804 026-A
6-3. Remote Control Cable Functions
Function
Remote Start
Okay To Move
Noise Suppression
OM-201 872 Page 24
Lead
Socket
Lead Information
White
1
Red
5
White and red leads connect to a set of customer-supplied remote contacts to
provide a remote trigger input signal to RC61 sockets 1 and 5 for the remote
start function.
Black
2
Green
4
Shielding
3
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
RMT2 receptacle on Control board PC1.
PC1
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.
Chassis ground.
6-4. +24 Volts DC Hot Contacts For Relay Operation
Y Turn off and
input power.
disconnect
Control board PC1 can supply +24
volts dc from receptacle RMT2 to
operate a customer-supplied relay
for the Okay To Move signal.
1
2
3
4
2
Control Board PC1
Receptacle RMT1
Receptacle RMT2
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.
3
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.
1
Suppression diode (1A, 100V) such
as type IN4002 through IN4004
across relay coil.
4
. Plasma cutter is shipped from
the factory with plug connected
to receptacle RMT1 (dry
contacts).
White
Remote
Start
Red
Black +24 VDC
Green
+
Relay
Relay
Contacts
Okay To
Move
Remote Control Cable
−
. +24 volts dc will activate relay coil after unit is triggered and
the cutting arc is initiated.
Tools Needed:
5/16 in
804 041-A
OM-201 872 Page 25
6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation
Y Turn off and
input power.
disconnect
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
2
3
4
2
Control Board PC1
Receptacle RMT1
Receptacle RMT2
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.
3
If voltage sensing is required, see
Section 6-8.
Install wrapper on unit.
1
Required Items:
Customer-supplied isolated input
module.
. Plasma cutter is shipped from
4
the factory with plug connected
to receptacle RMT1 (dry
contacts).
White
Remote
Start
Red
Black +24 VDC
Green
+
Output
Remote Control Cable
Okay To
Move
−
. +24 volts dc will activate relay coil after unit is triggered and
Tools Needed:
the cutting arc is initiated.
5/16 in
804 041-A
OM-201 872 Page 26
6-6. Dry Contacts Using An External Power Supply For Relay Operation
Y Turn off and
input power.
disconnect
Control board PC1 can provide dry
contacts from receptacle RMT1 to
operate a customer-supplied relay
using an external power supply for
the Okay To Move signal.
1
2
3
Control Board PC1
Receptacle RMT1
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.
2
If voltage sensing is required, see
Section 6-8.
Install wrapper on unit.
Required Items:
1
Customer-supplied +24 volts dc
power supply.
24 volts dc relay coil with resistance
greater than 240 ohms.
3
Suppression diode (1A, 100V) such
as type IN4002 through IN4004
across relay coil.
White
Remote
Start
Red
Green
Black
+
+24 VDC
Power
Supply
−
Remote Control Cable
Relay
Relay
Contacts
Okay To
Move
. +24 volts dc will activate relay coil after unit is triggered and
the cutting arc is initiated.
Tools Needed:
5/16 in
804 041-A
OM-201 872 Page 27
6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation
Y Turn off and
input power.
disconnect
Control board PC1 can provide dry
contacts from receptacle RMT1 to
operate a customer-supplied
isolated input module using an
external power supply for the Okay
To Move signal.
1
2
3
Control Board PC1
Receptacle RMT2
Receptacle RC61
Unit is shipped from factory with
plug connected to receptacle
RMT1.
2
Be sure that remote control cable
plug is connected to RC61 on rear
of unit.
If voltage sensing is required, see
Section 6-8.
1
Install wrapper on unit.
Required Items:
Customer-supplied +24 volts dc
power supply.
3
Isolated input module.
White
Red
Green
Black
Remote
Start
+
+24 VDC
Power
Supply
−
Remote Control Cable
Output
. +24 volts dc will activate relay coil after unit is triggered and
Okay To
Move
the cutting arc is initiated.
Tools Needed:
5/16 in
804 041-A
OM-201 872 Page 28
6-8. Remote Voltage Sense Connection
Y Turn off and
input power.
disconnect
Remote voltage sense is an arc
voltage output signal for automatic
torch height adjustment.
1
2
3
2
1
4
Snap-in Blank
Nylon Bushing
Secondary Interconnect
Board PC4
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
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.
4
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.
3
Tools Needed:
15/16 in
5/16 in
804 041-A
OM-201 872 Page 29
6-9. 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
219 687
Retaining Cap
Tip
219 684
Electrode
Swirl Ring
219 678
219 677
219 679
ICE-100TM Torch
Mild Steel
100
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
152
0.5
1/4
6.4
208
5,283
135
3,429
154
0.5
3/8
9.5
119
3,022
77
1,955
157
1.0
1/2
12.7
88
2,235
57
1,447
159
1.0
5/8
15.9
61
1,549
40
1,016
162
1.5
3/4
19.0
47
1,193
26
660
164
2.0
1
25.4
28
711
18
457
166
2.5
1-1/4
31.8
19
482
12
305
Arc Current Arc Voltage
Stainless
100
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
153
0.5
1/4
6.4
231
5,867
150
3,810
157
0.5
3/8
9.5
122
3,099
79
2,006
161
1.0
1/2
12.7
79
2,006
52
1,320
162
1.0
5/8
15.9
52
1,320
34
863
165
1.5
3/4
19.0
39
990
25
635
166
2.0
1
25.4
23
584
15
381
170
2.5
1-1/4
31.8
14
355
9
228
Arc Current Arc Voltage
Aluminum
100
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
155
0.5
1/4
6.4
253
6,426
164
4,165
157
0.5
3/8
9.5
142
3,606
92
2,336
161
1.0
1/2
12.7
108
2,743
70
1,778
162
1.0
5/8
15.9
77
1,955
50
1,270
163
1.5
3/4
19.0
57
1,447
33
838
165
2.0
1
25.4
33
838
21
533
Arc Current Arc Voltage
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
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.
Drag Shield
212 732
Retaining Cap
Tip
212 733
Electrode
Swirl Ring
212 724
212 734
212 726
ICE-100TM Torch
Mild Steel
80
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
133
0.25
3/16
4.8
216
5,486
140
3,556
134
0.5
1/4
6.4
161
4,089
105
2,667
137
0.5
3/8
9.5
94
2,388
61
1,549
141
0.5
1/2
12.7
60
1,524
39
991
145
1.0
5/8
15.9
40
1,016
26
660
148
N/A
3/4
19.0
31
787
20
508
150
N/A
7/8
22.2
23
584
15
381
156
N/A
1
25.4
16
406
10
254
Arc Current Arc Voltage
Stainless
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
0.25
3/16
4.8
216
5,486
140
3,556
136
0.5
1/4
6.4
158
4,013
103
2,616
140
0.75
3/8
9.5
83
2,108
54
1,372
142
0.75
1/2
12.7
50
1,270
33
838
145
N/A
5/8
15.9
34
864
22
559
150
N/A
3/4
19.0
24
610
16
406
153
N/A
1
25.4
14
356
9
229
134
80
Material Thickness
Pierce
Delay
Arc Current Arc Voltage
Aluminum
80
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
134
0.25
1/8
3.2
454
11,532
295
7,493
139
0.25
1/4
6.4
176
4,470
114
2,896
144
0.75
3/8
9.5
121
3,073
60
1,524
146
0.75
1/2
12.7
75
1,905
37
940
154
N/A
3/4
19.0
37
940
19
483
Arc Current Arc Voltage
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 31
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.
Drag Shield
212 732
Retaining Cap
Tip
212 733
ICE-100TM Torch
Electrode
Swirl Ring
212 724
212 734
219 676
Mild Steel
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
0
16 ga
1.5
627
15,926
502
12,751
134
0
10 ga
3.4
264
6,706
211
5,359
138
0.25
1/4
6.4
132
3,353
86
2,184
141
0.75
3/8
9.5
63
1,600
41
1,041
142
1.5
1/2
12.7
42
1,067
27
686
147
1.5
5/8
15.9
31
787
20
512
153
1.5
3/4
19.0
22
559
14
363
134
60
Material Thickness
Pierce
Delay
Arc Current Arc Voltage
Stainless
60
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
134
0
16 ga
1.5
625
15,875
406
10,312
136
0.25
10 ga
3.4
244
6,198
159
4,039
140
0.5
1/4
6.4
110
2,794
72
1,829
145
0.75
3/8
9.5
53
1,346
34
864
146
2
1/2
12.7
35
889
23
584
149
2
5/8
15.9
26
660
17
429
154
2
3/4
19.0
18
457
12
297
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
135
0
1/16
1.6
666
16,916
433
10,995
138
0.25
1/8
3.2
400
10,160
260
6,604
141
0.75
1/4
6.4
145
3,683
94
2,388
146
1.5
3/8
9.5
74
1,880
48
1,219
150
1.5
1/2
12.7
51
1,295
30
762
153
1.5
5/8
15.9
33
838
21
545
Arc Current Arc Voltage
Aluminum
Arc Current Arc Voltage
60
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 32
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.
Drag Shield
Retaining Cap
212 732
212 733
Tip
212 725
Electrode
Swirl Ring
212 724
212 734
ICE-100TM Torch
Mild Steel
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
0.25
14 ga
1.9
640
16,256
221
5,613
146
0.5
10 ga
3.4
151
3,835
98
2,489
147
0.75
3/16
4.7
97
2,464
63
1,600
149
1
1/4
6.4
74
1,880
48
1,219
142
40
Material Thickness
Pierce
Delay
Arc Current Arc Voltage
Stainless
40
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
141
0.25
18 ga
1.3
592
15,037
335
8,509
144
0.25
16 ga
1.5
374
9,500
243
6,172
144
0.25
14 ga
1.9
221
5,613
144
3,658
147
0.5
10 ga
3.4
107
2,718
70
1,778
149
0.75
3/16
4.7
67
1,702
44
1,118
149
1
1/4
6.4
47
1,194
31
787
Arc Current Arc Voltage
Aluminum
40
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
145
0.25
3/32
2.4
293
7,442
190
4,826
149
0.5
1/8
3.2
204
5,182
133
3,378
151
1
1/4
6.4
76
1,930
49
1,245
Arc Current Arc Voltage
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
100 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.
Shield
Retaining Cap
212 736
219 684
Tip
219 683
Electrode
Swirl Ring
219 678
219 677
ICE-100TM Torch
Mild Steel
100
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
136
0.5
1/4
6.4
210
5,334
138
3,505
139
0.5
3/8
9.5
122
3,098
80
2,032
142
1.0
1/2
12.7
91
2,311
60
1,524
146
1.0
5/8
15.9
57
1,447
37
939
151
1.5
3/4
19.0
43
1,092
28
711
155
2.0
1
25.4
26
660
17
431
160
2.0
1-1/4
31.8
16
406
10
254
Arc Current Arc Voltage
Stainless
100
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
142
0.5
1/4
6.4
240
6,121
153
3,886
145
0.5
3/8
9.5
131
3,327
85
2,159
148
1.0
1/2
12.7
80
2,032
53
1,346
151
1.0
5/8
15.9
51
1,295
33
838
156
1.5
3/4
19.0
33
838
22
558
161
2.0
1
25.4
22
558
14
355
173
2.0
1-1/4
31.8
11
279
7
177
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
144
0.5
1/4
6.4
260
6,604
167
4,242
146
0.5
3/8
9.5
153
3,886
99
2,514
148
1.0
1/2
12.7
107
2,717
72
1,828
153
1.0
5/8
15.9
77
1,955
50
1,270
157
1.5
3/4
19.0
51
1,295
33
838
160
2.0
1
25.4
31
787
20
508
Arc Current Arc Voltage
Aluminum
Arc Current Arc Voltage
100
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 34
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.
Shield
Retaining Cap
212 736
212 733
Tip
212 728
Electrode
Swirl Ring
212 724
212 734
ICE-100TM Torch
Mild Steel
Arc Current Arc Voltage
Pierce
Delay
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
80
138
0.25
3/16
4.7
221
5,613
142
3,607
80
140
0.5
1/4
6.4
170
4,318
110
2,794
80
143
0.5
3/8
9.5
98
2,489
63
1,600
80
146
0.5
1/2
12.7
62
1,574
42
1,067
80
149
1
5/8
15.8
42
1,066
28
711
Stainless
80
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
138
0.5
1/4
6.4
160
4,064
106
2,692
143
1
1/2
12.7
55
1,397
34
863
Arc Current Arc Voltage
Aluminum
Arc Current Arc Voltage
Material Thickness
Pierce
Delay
Inches
Maximum Cut Speeds
Optimum Cut Speeds
mm
IPM
mm/min
IPM
mm/min
80
140
0.25
1/4
6.4
140
3,556
120
3,048
80
147
1
1/2
12.7
80
2,032
42
1,067
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 35
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.
Shield
Retaining Cap
212 736
212 733
Tip
219 682
Electrode
Swirl Ring
212 724
212 734
ICE-100TM Torch
Mild Steel
Arc Current Arc Voltage
Pierce
Delay
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
60
136
0.25
3/16
4.5
185
4,699
105
2,667
60
139
0.25
1/4
6.4
131
3,327
87
2,210
60
141
0.75
3/8
9.5
70
1,778
44
1,118
Stainless
60
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
134
0
14 ga
2.2
610
15,494
385
9,779
138
0.5
1/4
6.4
114
2,896
74
1,879
Arc Current Arc Voltage
Aluminum
Arc Current Arc Voltage
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
60
138
0
1/16
1.6
669
16,992
436
11,074
60
142
0.25
1/4
6.4
153
3,886
97
2,463
60
147
1.25
1/2
12.7
56
1,422
33
838
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
40 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.
Shield
Retaining Cap
212 736
212 733
Tip
212 729
Electrode
Swirl Ring
212 724
212 734
ICE-100TM Torch
Mild Steel
40
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
126
0
14 ga
1.9
320
8,128
214
5,435
134
0.75
3/16
4.8
95
2,413
63
1,600
138
1
1/4
6.4
73
1,854
49
1,245
Arc Current Arc Voltage
Stainless
40
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
123
0
18 ga
1.3
515
13,081
328
8,331
130
0.25
14 ga
1.9
222
5,638
145
3,683
138
1
1/4
6.4
50
1,270
35
889
Arc Current Arc Voltage
Aluminum
40
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Inches
mm
IPM
mm/min
IPM
mm/min
148
0.5
1/8
3.2
214
5,435
135
3,429
150
1
1/4
6.4
81
2,057
52
1,320
Arc Current Arc Voltage
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
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
Each Use
Check Torch
Tip, Electrode,
And Shield Cup
Check Gas/Air
Pressure
Every Week
Check Shield
Cup Shutdown
System
3 Months
Service Air Filter
(see Section 7-5)
Replace
Unreadable
Labels
Replace
Cracked
Parts
Tape Torn Outer
Covering Or
Replace Cable
Check
Gas/Air Hose
Check Torch
Body
6 Months
OR
OM-201 872 Page 38
Blow Out Or
Vacuum Inside
7-2. Trouble Lights
1
Difficulty establishing pilot arc may indicate
consumables need to be cleaned or replaced.
Pressure Light
Lights if gas/air pressure at torch is
below 50 PSI (344 kPa) or above 90
PSI (620 kPa).
Turn power Off, and check for proper gas/air pressure (see Section
5-2).
2
1
2
3
Cup Light
Lights if shield cup is loose.
Turn power Off, and check shield
cup connection (see torch Owner’s
Manual). Power must be reset
whenever the cup shutdown is
activated.
Check shield cup shutdown system
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
1
. Power must be reset whenever the cup shutdown
system is activated. Always turn Off power when
changing or checking consumables.
1
Torch Shield Cup
Turn Power On and loosen shield
cup. If shutdown system works
properly, Ready light goes off and
Cup light comes on. If not, immediately turn Off power and have Factory Authorized Service Agent
check safety control board PC1 operation.
If system works properly, retighten
cup and reset power.
Ref. 801 300-A
OM-201 872 Page 39
7-4. Checking/Replacing Retaining Cup, Tip, And Electrode
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.
Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly
reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.
A good practice is to replace both the tip and electrode at the same time.
Turn Off power source before checking torch parts.
1/32 in
(1 mm)
Pit
5
Worn
New
Make sure this area is
clean of any debris.
3
Worn
8
7
New
4
6
Make sure this area is
clean of any debris.
2
1
804 056-A
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
4
Tip
Opening
OM-201 872 Page 40
Remove tip. Check tip, and replace if opening is deformed or 50% oversize. If inside of
tip is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards.
5
Electrode
Check electrode. If center has a pit more
than a 1/32 in (1 mm) deep, remove and
replace electrode.
6
Swirl Ring
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.
7-5. Checking Or Replacing Filter Element
6
1
Latch
2
Filter Cup
3
Retaining Nut
4
Filter Element
5
Defuser Ring
6
Filter Cap
Slide latch down, and rotate filter
cup approximately 1/4 turn.
Remove cup.
5
Remove retaining nut,
element, and defuser ring.
filter
Check filter element for dirt and
moisture, and replace if necessary.
4
Be sure that all parts are clean and
dry.
Reinstall all parts, and secure filter
cup.
3
1
2
804 054-A
OM-201 872 Page 41
7-6. Troubleshooting Power Source
Trouble
Remedy
No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see torch Owner’s Manual).
arc
arc.
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; Place Power switch in On position.
Trouble lights off; Ready light off; fan
motor FM does not run.
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; Be sure work clamp is connected.
Power light on; Trouble lights off; fan
motor running.
Clean or replace worn consumables as necessary (see torch Owner’s Manual).
No gas/air flow; Power light on; Trouble Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas
lights off; fan motor running.
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 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
7-7. Troubleshooting Torch
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 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 Torch travel speed too fast; reduce travel speed (see Section 5-5). Clean or replace torch consumables
clean.
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 Check torch consumables. Check for gas/air flow at torch. Check air supply connection and pressure to
output.
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
Figure 8-1. Circuit Diagram For Power Source
OM-201 872 Page 44
201 858-A
OM-201 872 Page 45
SECTION 9 − PARTS LIST
. Hardware is common and
not available unless listed.
2
3
1
2
13
4
14
12
6 10
79
8
67
11
66
15
57
5
58
68
59
63
16
55
48
43
45
44
62
46
17
60
56
49
19
16
18
20
54
53
47
52
51
36
21
22
35
50
34
26
23
24
33
25
30
40
41
15
61
69
32
39
37
38
65
31
29
28
27
64
42
804 327-A
Figure 9-1. Main Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly
. . . . . . . . . . . . . . . . 224749
. . . 1 . . . . . . . . . +212017
. . . . . . . . . . . . . . . . 121389
. . . 2 . . . . . . . . . . 208015
. . . 3 . . . . . . . . . . 204326
. . . . . . . . . . . . . . . . 223835
. . . 4 . . . . . . . . . . 192460
. . . 5 . . . . . . . . . . 221913
. . . 6 . . . . . . . . . . 175256
. . . 7 . . . PC 1 . 223843
. . . 8 . . . . . . . . . . 219965
. . . 9 . . . . . . . . . . 217761
. . COVER ASSY (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WRAPPER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL,MILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONSUMABLE STORAGE BOX,W/DOOR & LATCH . . . . . . . . . . . . . . . . . .
. . . . LABEL,ICE 100T CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL,CAUTION/WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR,SIDE LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY,CNTRL SPECTRUM 1251 W/PGM NON−CE . . . . . .
. . FTG,BRS STRAIGHT QDISC 1/4 OD X 3/8 OD TUBING . . . . . . . . . . . . . . . .
. . FTG,AL COUPLING 1/4NPT X 1/4NPT PANEL MOUNT . . . . . . . . . . . . . . . . .
1
1
2
2
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-201 872 Page 46
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly (Continued)
. . . 10 . . . . . . . . . . 212000
. . . 11 . . . . . . . . . . 219970
. . . 12 . . . . . . . . . . 213280
. . . . . . . . . . . . . . . . 215089
. . . 13 . . . . . . . . . . 604102
. . . 14 . . . . . . . . . . 216489
. . . 15 . . . . . . . . . . 175138
. . . 16 . . . . . . . . . . 030170
. . . 17 . . . . . . . . . . 201875
. . . . . . . . . . . . . . . . 219489
. . . 18 . . . W1 . . 212217
. . . 19 . . . . L2 . . 201845
. . . 20 . . . . L1 . . 212015
. . . 21 . . . . . . . . . . 025248
. . . 22 . . . . C3 . . 186015
. . . 23 . . . . . . . . . . 179276
. . . 24 . . C5,C6 . 201857
. . . 25 . . . PC 2 . 223495
. . . 26 . . . CT1 . . 213892
. . . 27 . . . . . . . . . . 175140
. . . 28 . . . . . . . . . . . 181197
. . . 29 . . . . . . . . . . 175482
. . . 30 . . . . . . . . . . 221599
. . . 31 . . . . . . . . . . 109056
. . . 32 . . . . . . . . . . 201873
. . . 33 . . . . . . . . . . 212578
. . . 34 . . . . . . . . . . 224744
. . . 35 . . . . . . . . . . 224743
. . . 36 . . . . . . . . . . 224248
. . . 37 . . . . . . . . . . . 211999
. . . 38 . . . . . . . . . . 173693
. . . 39 . . . PC 3 . 212339
. . . 40 . . . FM1 . . 224694
. . . 41 . . . . . . . . . . . 211997
. . . 42 . . . . . . . . . . 223834
. . . 42 . . . . . . . . . . 201846
. . . . . . . . . . . . . . . . 213619
. . . . . . . . . . . . . . . . 134900
. . . 43 . . . . . . . . . . 213277
. . . 44 . . . . . . . . . . 212365
. . . 45 . . . . S2 . . 212358
. . . 46 . . . . . . . . . . 224821
. . . 47 . . . . . . . . . . 201853
. . . 48 . . . AS1 . . 212678
. . . 49 . . . . S1 . . 212437
. . . 50 . . . . . . . . . . 216650
. . . 51 . . . . . . . . . . 223959
. . . 52 . . . . . . . . . . 221794
. . . 53 . . . . . . . . . . 201866
. . . 54 . . . . . . . . . . 224748
. . . 55 . . . . . . . . . +201863
. . . 56 . . . PC 4 . 223499
. . PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING,NIPPLE 1/4 NPT W/SEALANT STL PLD . . . . . . . . . . . . . . . . . . . . . .
. . FILTER,AIR 1/4 NPT 150PSI 5 MICRON W/DRAIN . . . . . . . . . . . . . . . . . . . . .
. . FILTER,AIR ELEMENT 5 MICRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONN,CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE,POWER 12 FT 8GA 4C SPECTRUM 1000 . . . . . . . . . . . . . . . . . . . . . .
. . BOX,LOUVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING,SNAP−IN NYL .750 ID X 1.000 MTG HOLE . . . . . . . . . . . . . . . . . .
. . BRACKET,MTG CONTACTOR/PC BOARD CONTROL . . . . . . . . . . . . . . . . . .
. . CLIP,WIRE STDF .500 BUNDLE .250HOLE .031−.250 THK . . . . . . . . . . . . . .
. . CONTACTOR,DEF PRP 60A 3P 24VAC COIL W/STAND−OFFS . . . . . . . . . .
. . INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INDUCTOR,BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND−OFF,INSUL .250−20 X 1.250 LG X .437 THD . . . . . . . . . . . . . . . . . . .
. . CAPACITOR,POLYP FILM .33 UF 1000 VAC +8% −0% . . . . . . . . . . . . . . . . . .
. . BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE CENT . . . . . . . . . . .
. . CAPACITOR,ELCTLT 3300UF 500VDC 3.00DIA W/MT STUD . . . . . . . . . . .
. . CIRCUIT CARD ASSY,INTERCONNECTING PRIMARY 100 AMP . . . . . . . .
. . XFMR,CURRENT SENSING 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET,DI−DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GASKET,DI−DT RUBBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COIL,DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COIL,DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORE,FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . . . . .
. . WINDTUNNEL,RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT,TRANSISTOR IGBT POWER BOOST MODULE . . . . . . . . . . . . . . . . . . . .
. . KIT,DIODE POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT,TRANSISTOR IGBT INVERTER MODULE . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK,POWER MODULE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FOOT,MTG UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY,LED/POT 80 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FAN,MUFFIN 24VDC 4000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE,WORK 25 FT 4 GA W/CLAMP STRAIN RLF & TERM (including) . .
. . CABLE,WORK 50 FT NO 4 W/CLAMP STRAIN RLF & TERM (including) . .
. . . . CLAMP,WORK 300 AMP STL CHROME PLD W/COP CONTACTS . . . . . .
. . . . STRAIN RELIEF,CABLE FLEXIBLE .270−.480 CABLE . . . . . . . . . . . . . . . . .
. . GAUGE,PRESSURE AIR W/FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FTG,AIR QUICK DISCONNECT FEMALE METRIC . . . . . . . . . . . . . . . . . . . . .
. . SWITCH,PILOT CONTROL W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECEPTACLE,W/LEADS (TORCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE,MILLER SPECTRUM 1251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE,SOLENOID 24VDC W/FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH,POWER ON−OFF W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REGULATOR,AIR W/FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAT SINK,RECTIFIER LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR ASSY,W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MODULE,IGBT/DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KIT,DIODE ULTRA−FAST RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WINDTUNNEL,LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY,INTERCONNECTING SECONDARY . . . . . . . . . . . . .
1
1
1
1
1
1
2
5
1
8
1
1
1
2
1
2
2
1
1
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-201 872 Page 47
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly (Continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
57
58
59
60
61
62
63
64
65
66
67
68
69
. . . . . . . . . . 179276
. . . . . . . . . . 223723
. RT2,RT3 220584
. . . . . . . . . . 224554
. . . . . . . . . . 200517
. . . . . . . . . . 215472
. . . . . . . . . . 213417
PC 5,PC6 226011
. . . . . . . . . . 226185
. . . . . . . . . . 024103
. . . . . . . . . . 185836
. . . . . . . . . . 224042
. . . . . . . . . . 225 474
..
..
..
..
..
..
..
..
..
..
..
..
..
BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE CENT . . . . . . . . . . .
XFMR,HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMISTOR ASSY,NTC 30K OHM@25DEG C 21&26IN LEADS . . . . . . . .
CAPACITOR ASSY, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . . .
RECEPTACLE,FASTENER QUARTER TURN STUD . . . . . . . . . . . . . . . . . . . .
RECEPTACLE,W/LEADS & PLUG (REMOTE) . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT CARD ASSY,SNUBBER SPECTRUM 1251 . . . . . . . . . . . . . . . . . . . .
CAPACITOR,POLYP MET FILM 1.0 UF 1200 VDC W/TERM . . . . . . . . . . . . .
BLANK,SNAP−IN NYL .750 MTG HOLE BLACK . . . . . . . . . . . . . . . . . . . . . . .
LABEL,WARNING ELECTRIC SHOCK/EXPLODING PARTS−WDLES . . . . .
CONN,CIRC CPC PROTECTIVE CAP SIZE 17 PLASTIC . . . . . . . . . . . . . . . .
SPACER,NYLON CAPACITOR 76MM DIAMETER . . . . . . . . . . . . . . . . . . . . . .
3
1
1
2
1
1
1
2
1
1
2
1
2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Item Part
No. No.
1
2
3
4
5
6
7
8
8
Item Part
No. No.
Description
215 594
215 478
223 775
185 833
190 220
215 592
223 774
223 612
223 613
Handle w/Screws (1)
Switch, cup sensor (1)
Torch Head Repair Kit (1)
Switch Assy w/Spring (1)
Trigger Spring (1)
Switch Trigger (1)
Main Body w/Switch (1)
Torch Lead, 25ft (1)
Torch Lead, 50ft (1)
9
10
215 606
212 735
169 231
225 702
225 704
Description
Clip, retaining (1)
O-Ring, main body (1)
Grease, silicon
Torch, replacement 25ft (1)
Torch, replacement 50ft (1)
8
9
1
See Figure 9-3 for
additional consumable parts.
2
7
6
3
5
10
4
1
804 035-A
Figure 9-2. Torch, ICE-100T
OM-201 872 Page 48
CAUTION
Drag Shield
Retaining Cap
Tip
Electrode
FAILURETORE−
PLACEWORNTIP
ORELECTRODE
WILLRUINTORCH
ANDVOID
WARRANTY.
Swirl Ring
Turnoffpowerbefore
checkingtorchparts.
Checkbeforeeach
useandhourly
duringoperation.
40A
212 730
212 733
212 725
212 730
212 733
219 676
212 730
212 733
212 726
219 685
219 684
219 679
60A
212 724
212 734
O-Ring
212 735
80A
100A
219 678
219 677
Electrode
Swirl Ring
212 724
212 734
Standard Cutting
Shield
Retaining Cap
Tip
60A
212 731
212 733
219 680
80A
212 731
212 733
212 727
212 731
219 684
219 681
O-Ring
212 735
100A
219 678
219 677
Gouging
Ref. 213 031-B / Ref. 804 056-A
Figure 9-3. Consumable Parts For ICE-100T
OM-201 872 Page 49
CAUTION
Shield
Retaining Cap
Tip
Electrode
FAILURETORE−
PLACEWORNTIP
ORELECTRODE
WILLRUINTORCH
ANDVOID
WARRANTY.
Swirl Ring
Turnoffpowerbefore
checkingtorchparts.
Checkbeforeeach
useandhourly
duringoperation.
40A
212 732
212 733
212 725
212 732
212 733
219 676
212 732
212 733
212 726
219 687
219 684
219 679
60A
212 724
212 734
O-Ring
212 735
80A
100A
219 678
219 677
Electrode
Swirl Ring
212 724
212 734
219 678
219 677
Machine Cutting
Deflector
Retaining Cap
Tip
40A
212 736
212 733
212 729
212 736
212 733
219 682
212 736
212 733
212 728
212 736
219 684
219 683
60A
O-Ring
212 735
80A
100A
Extended Cutting
Ref. 213 031-B / Ref. 804 056-A
Figure 9-4. Consumable Parts For ICE-100TM
OM-201 872 Page 50
Item Part
No. No.
1
2
2
3
4
5
6
215 607
223 614
223 615
215 599
223 773
195 513
215 478
225 706
225 708
220 240
220 241
See Figure 9-4 for
additional consumable parts.
Description
Sleeve, torch position (1)
Torch Lead, 25ft (1)
Torch Lead, 50ft (1)
Torch Sleeve (1)
Main Body w/Switch (1)
Remote Pendant Control (1)
Switch, cup sensor (1)
Torch, replacement 25ft (1)
Torch, replacement 50ft (1)
Cable, remote control trigger 25ft (1)
Cable, remote voltage sense 26.5ft (1)
1
2
6
4
5
3
804 036-A
Figure 9-5. Torch, ICE-100TM
OM-201 872 Page 51
Notes
Notes
Notes
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
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’s True Blue® Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the 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.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & 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.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (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
available, but may vary from province to province.
miller_warr 1/05
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
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
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:
www.MillerWelds.com
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
© 2005 Miller Electric Mfg. Co.
1/05