Miller
February
1997
Form:
OM-182701
Effective With Serial No. KG235604
OWNERS
MANUAL
CE
Spectrum
For Plasma Arc
Amperes Input at
Output
Rated Load
Rated
Output
50A @ 100 Volts
DC, 60% Duty
Cycle
*while
50
701
Cutting (PAC)
Plasma
Hz, Three-Phase
Gas
400V
KVA
KW
10.6
7.2
6.6
(1.7*)
(0.5*)
(0.2*)
Plasma
Gas Flow!
Pressure
Max OCV
IP
Rating
7 CGM
AirOrNitrogeri
Only
(170
L/min)At70
PSI (482 kPa)
265VDC
23
idling
cover_om 4/95
ST-801 454-A
'
1997 MILLER Electric Ml g. Co.
PRINTED IN (iSA
Conformity For
European Community (CE) Products
Declaration of
Name:
Manufacturers
Address:
Declares that the
conforms to the
Mfg. Co.
Miller Electric
Manufacturers
Spencer Street
Appleton, WI 54914 USA
1635 W.
S pe Ct r u m fi 701
product:
following
Directives and Standards:
Directives
Low
Voltage
Directive: 73/23/EEC
Machineiy Directives: 89/392/EEC, 91/368/EEC,
Electromagnetic Compatibility
93/C 1 33/04, 93/68/EEC
Directives: 89/336/EEC, 92/31/EEC
Standards
Arc
Welding Equipment,
Safety Requirements
Arc
forArc
Welding Equipment
Welding Equipment part
Part 1:
(August
Degrees
of Protection
Cutting Systems: prEN
Plasma
Welding
1996
Draft
50192:1995
1: EN 60974-1: 1990
Power Sources: lEG 974-1
revision)
provided by Enclosures (IP code):
IEC 529:1989
Insulation coordination for
Part 1:
equipment within low-voltage systems:
Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC)
Product standard for
EN50199:
European Contact:
Mr.
Luigi Vacchini, Managing
MILLER Europe S.P.A.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
Telephone:
Fax:
dec_coni 10/95
August
39(02)98290-1
39(02)9828 1 -552
1995
Director
arc
welding equipment:
SECTION 1
OM-182 701
1-1.
SAFETY FOR PLASMA ARC CUTTING
-
2/97
sat ety...pom 1 4/95
Symbol Usage
4A
A
Means
Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
Marks
I
special safety message.
a
~ Means NOTE; not
safety
I
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
I
actions to avoid the hazards.
____________________________________
1-2.
Plasma Arc
Cutting
Hazards
WARNING
a
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
persons should
install, operate, maintain, and repair this unit.
away.
-
During operation, keep everybody, especially children
CUTTING
fire
explosion.
7.
Do not cut
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
8.
Connect work cable to the work
can cause
or
cutting.
1.
3.
4.
5.
6.
yourself and others from flying sparks and hot metal.
flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the cutting arc. If
this is not possible, tightly cover them with approved covers.
Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that cutting on a ceiling, floor, bulkhead, or partition
as
as
tanks
close to the
or
drums.
cutting
area as
9.
to
Nevercut containers with
must be
10. Do not cut in
emptied
potentially flammable materials inside
properly cleaned first.
and
atmospheres containing explosive
Do not cut where
fire
on
the hidden side.
ELECTRIC SHOCK can kill.
Touching live electrical parts can
11. Do not cut
14. Do not locate unit on or
cause
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
11. Turn off all
12.
Inspect
15. Use
4.
Do not touch torch parts if in contact with the work
16.
5.
Turn oft power before
checking, cleaning,
ground.
changing
torch
required by
Properly
Owners
17.
18.
installing or servicing this
equipment. Lockout/tagout input power according to OSHA
CFR 1910.147 (see Safety Standards).
power
install and
before
ground
this
equipment according
19.
20.
21.
to its
Manual and national, state, and local codes.
FLYING SPARKS AND HOT METAL
can cause
equipment when not in use.
replace any worn or damaged
and
14. Ground the
parts.
input
supply ground.
making input connections, attach proper grounding
When
yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
or
injury.
Sparks and hot metal blow out from the cutting
Chipping and grinding cause flying metal.
arc.
lighter or matches,
conductor first.
10.
Insulate
or
butane
cutting.
the
verity
9.
a
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
3.
body protection.
vapors.
Check and be
Wear
and
or
combustible surfaces.
15. Remove any combustibles, such as
from your person before doing any
2.
Disconnect
over
13. Do not wrap torch cable around your
insulating gloves
dust
vessels.
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Do not touch live electrical parts.
hole-free
or
13. Wear oil-free
1.
dry,
pressurized cylinders, pipes,
12. Do not cut containers that have held combustibles.
8.
fatal
shocks or severe burns. The torch and work circuit
is 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.
7.
closed containers such
Protect
can cause
6.
on
prevent cutting current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
practical
they
2.
~
Only qualified
workpiece
to
a
torch cable leads.
body.
good electrical (earth) ground
if
codes.
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 Owners 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.
approved face
1.
Wear
2.
Wear proper
3.
Wear flame-resistant
from
entering
shield
or
safety goggles
body protection
protect
ear plugs or ear muffs
to
with side shields.
skin.
to
prevent sparks
ears.
OM-182701
Page
1
ARC RAYS
burn eyes and skin.
can
NOISE
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
protection (helmet or shield) with correct shade of
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
can
damage hearing.
Prolonged noise from some cutting applications
damage hearing if levels exceed limits
specified by OSHA (see Safety Standards).
can
Wear face
1.
filter to
5.
Use
6.
Warn others
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
are
with low current
provided for
the
cutting, the
shades
suggested
Table 1.
4.
material
(wool
and
leather)
and foot
be
can
40
Read the
Cutting
#4
_________
________
#5
I
#6
I
#8
________
5.
only if it is well ventilated, or while
air-supplied respirator. Fumes from cutting and
oxygen depletion can alter airquality causing injury or death. Be
sure the breathing air is safe.
Work in
6.
confined space
a
an
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.
on coated metals, such as galvanized, lead, or
plated steel, unless the coating is removed from the
cutting area, the area is well ventilated, and if necessary, while
Do not cut
cadmium
If ventilation is poor,
4.
high.
Minimum Shade Number
L~H~
60
6080
use
exhaust at the
to
arc
remove
3.
Plasma Arc
I
2040
7.
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
cutting fumes and gases.
2.
muffs if noise level is
Amperes
Below 20
wearing
Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your
or ear
about noise hazard.
protection.
FUMES
AND
GASES
hazardous to your health.
1.
plugs
Eye Protection For
Current Level In
operators convenience.
Wear
3.
ear
nearby
in Table 1
approved safety glasses with side shields.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
2.
approved
Material
manufacturers
use an
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes when cut.
approved air-supplied respirator.
Safety
Data Sheets
(MSDSs) and the
coatings, and
8.
instruction for metals to be cut,
Do not cut containers with toxic
containers that have held toxic
be
cleaners.
PLASMA ARC
c~
can cause
3.
injury.
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.
~
or
reactive materials inside
reactive materials
or
they
or
must
emptied and properly cleaned first.
pilot arc can cause burns keep away from torch tip when
trigger is pressed.
Wearproperflame-retardantclothingcoveringallexposedbody
The
areas.
5.
Point torch away from your body and toward work when
torch trigger
pilot arc comes on immediately.
pressing the
1.
Keep away from
2.
Do not
grip
the torch
material
near
6.
Turn oft power source and disconnect input power before
disassembling torch or changing torch parts.
7.
Use
tip.
the
CYLINDERS
culling path.
can
explode
if
damaged.
4.
in the Owners
only torch(es) specified
Never allow electrical contact between
a
Manual.
plasma arc torch
and
a
cylinder.
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.
5.
Never cut
6.
Use
only
designed
compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flame, sparks, and arcs.
7.
Turn face away from valve outlet when
8.
Keep protective cap
on a
pressurized cylinder
associated parts in
1.
2.
Protect
cylinders in an upright position by chaining
stationary support or equipment cylinder rack tO
prevent falling or tipping.
Keep cylinders away from any cutting or other electrical circuits.
Install and
them to
3.
1-3.
Additional
can cause severe
burns.
Do not touch hot
1.
parts bare handed.
Allow cooling period before working on torch.
2.
FLYING PIECES OF METAL
or
DIRT
can
injure
eyes.
Wear safety glasses
1.
shield.
Page
2
9.
use or
will result.
good condition.
in
place
connected for
over
equipment,
opening cylinder
valve.
except when cylinder is
use.
Read and follow instructions
associated
valve
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
Installation, Operation, And Maintenance Hazards
HOT PARTS
OM-182 701
in
secure
a
explosion
correct gas cylinders, regulators, hoses, and fittings
for the specific application; maintain them and
with side shields
or
face
FALLING
EQUIPMENT
can
cause
serious personal injury and equipment
damage.
1.
Use lifting eye to lift unit only, NOT running gear,
gas cylinders, or any other accessories.
2.
Use
3.
If
equipment of adequate capacity
lift forks to
using
long enough
unit.
move
to extend
unit, be
to lift unit.
sure
forks
beyond opposite
are
side of
FIRE OR EXPLOSION
can
result from
unit
on,
over,
combustible surfaces.
placing
1.
Do not locate unit on, over,
surfaces.
2.
Do not install unit
near
services,
or near
can cause
Have
electronic
injury.
Keep away from moving parts
2.
all doors, panels, covers, and
and securely in place.
such
Keep
and
equipment.
only qualified persons familiar with
equipment perform this installation.
The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
If notified by the FCC about interference, stop
using the equipment at once.
Have the installation regularly checked and
1.
flammables.
1.
can
navigation, safety
computers,
communications
combustible
2.
MOVING PARTS
RADIATION
HIGH-FREQUENCY
interfere with radio
near
or
as
fans.
3.
guards closed
4.
maintained.
STATIC ELECTRICITY
on circuit boards.
1.
Put
on
boards
2.
grounded
or
can
wrist strap BEFORE
static-proof bags
ship PC boards.
OVERUSE
2.
Allow
can
cause
and boxes to store,
OVERHEATED
4
MAGNETIC
FIELDS
CURRENTS
can
1.
cooling period.
Follow rated
HIGH
pacemaker
Pacemaker wearers keep away.
Wearers should consult their doctor before
2.
near
Reduce amperage (thickness) or reduce
before starting to cut again.
FROM
affect
operation.
duty -c
plasma
going
cutting operations.
arc
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
cycle
3.
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.
handling
EQUIPMENT.
1.
5.
parts.
Use proper
move, or
damage parts
duty cycle.
Turn Off inverter, disconnect
1.
input
discharge
in
instructions
capacitors
input power,
according
Maintenance
Section
arid
to
before
touching any parts.
1-4.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from Ameri
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
can
Safely and
Health Standards, OSHA 29 CFR 1910, from
tendent of Documents, U.S. Government
Safe
Handling
of
Compressed Gases
in
CGA
Cylinders,
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Superin
Printing Office, Washing
Code for
ton, D.C. 20402.
Recommended Practices for Plasma Arc Cutting, American Weld
AWS C5.2, from American Welding Society,
Safety
in
Welding
and
Cutting,
CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
ing Society Standard
550 N.W. LeJeune
Ad, Miami, FL
33126
Safe Practices For Occupation And Educational
Recommended Safe Practices for the
Cutting
Preparation for Welding and
of Containers That Have Held Hazardous
Substances,
Eye And Face Pro
tection, ANSI Standard Z87. 1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Ad, Miami, FL 33126
American
Cutting And Welding Processes,
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5.
al Fire Protection Association,
02269.
NFPA Standard SiB, from Nation
Batterymarch Park, Quincy, MA
EMF Information
Considerations About
To reduce
Electric And
Welding And The Effects Of Low Frequency
Magnetic Fields
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989): .
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
procedures:
.
.
magnetic fields
in the
1.
Keep
2.
Arrange cables
3.
Do not coil
4.
Keep welding power
practical.
source
5.
Connect work
to
cables close
or
to
workplace,
together by twisting
one
clamp
as
following
operator.
body.
and cables
workpiece
the
taping them.
side and away from the
cables around the
drape
or
use
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above
wearers.
procedures are also recommended for pacemaker
Consult your doctor for complete information.
OM-182 701
Page
3
SECTION 2- DEFINITIONS
2-1.
Warning
Label Definitions
Warning! Watch
possible hazards
symbols.
1
Cutting sparks
explosion
1.1
Out! There are
shown by the
as
or
can cause
fire.
Keep flammables away
cutting. Do not cut near
from
flammables.
1.2
Cutting sparks
can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
1.3 Do not cut on drums
closed containers.
2
The
plasma arc can
injury and burns.
or
any
cause
2.1 Turn off power before
disassembling torch.
2.2 Do not
grip material
cutting path.
near
2.3 Wear
complete body
protection.
3
Electric shock from torch
can kill.
or
wiring
3.1 Wear
dry insulating gloves.
wear wet or damaged
gloves.
Do not
3.2 Protect
yourself
from electric
shock
by insulating yourself
from work and ground.
3.3 Disconnect input plug
power before working
machine.
or
on
4
Breathing cutting
4.1
Keep your head out of the
fumes.
fumes can
be hazardous to your health.
4.2 Use forced ventilation
exhaust to
4.3 Use
remove
ventilating fan
or
local
the fumes.
to remove
fumes.
5
Arc rays can burn eyes and
injure skin.
5.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
6
Become trained and read the
instructions before working
on the machine or cutting.
7
Do not
remove or
(cover)
the label.
paint
over
1/96
OM-182 701
Page
4
Warning! Watch
possible hazards
symbols.
Out! There
are
shown
by
the
can
kill.
as
Electric shock from
wiring
Disconnect input plug or power
before working on machine.
Read the Owners Manual before
on this machine.
working
1
Consult
rating
label for
input
power requirements, and
check power available at the
job site they must match.
2
Read Owners
Manual and
inside labels for connection
and
points
3
Move
on
4
procedures.
jumper
links
as
shown
inside label to match
voltage
at
Having
a
connect
job site.
loop of extra length,
grounding conductor
first.
5
Connect line
as
shown
on
input
conductors
inside label
double-check all
connections,
jumper link positions, and
input voltage before applying
power.
1/96
2-2.
Manufacturers
Rating
Label For CE Products
-
~-~D-1I~
EN 60974-1
prEN
50A/100V
32N93V
Li
£=
U0
Ii ~D=
3--
,,
=
50192
x
100%
60%
12
35A
50A
U2
94V
1 OOV
Iimax=lO.6A
Iien=8.3A
265V
50Hz
U1=400V
IP 23
S-183 506
OM-182 701
Page
5
2-3.
Symbols
And Definitions
A
Amperes
\f
Volts
Protective Earth
(Ground)
j~.
Plasma Arc
()
Increase
3~\,
Three Phase
fr
Rated No Load
Metal
IP
Degree Of
I 1 eff
Maximum Effective
OM-182 701
Protection
Supply Current
Page
6
Ui
Primary Voltage
U2
12
Rated Welding
Current
X
O–
Loose Shield
~
E1?iJ
Pilot Arc
Air Pressure
Pressure
Do Not Do
Temperature
This
O,/~
Voltage (Average)
Expanded
Adjust Air/Gas
+
No
On
Uo
~~\
Cutting (PAC)
Cup
Z
Constant Current
Voltage Input
Percent
Direct Current
Conventional Load
EL~
Voltage
Duty Cycle
Hertz
3~I~J-~
Ii
max
Line Connection
Three Phase
Transformer
Rectifier
Rated Maximum
Supply Current
SECTION 3-INSTALLATION
3-1.
Selecting
A Location
21 in
(533
Dimensions And
168 lb
(76 kg)
mmj,~
Weight
Without Torch
36-3/4 in
(934 mm)
24-1/2 in
(622 mm)
Handle
1
Movement
Use handle
distances.
2
Lifting Eye
3
Lifting
Use
unit
eye
or
lifting
forks to
unit.
If using lifting forks, extend
beyond opposite side of unit.
Rating
Door)
4
A
Do not move or operate unit
where it could tip.
Use
short
Forks
lifting
move
roll
to
Label
rating label
forks
(Under Access
to determine
input
power needs.
5
Line Disconnect Device
Locate unit
er
near
correct
input pow
supply.
A Special installation may be
required where gasoline or
volatile liquids are present
see
NEC ArtIcle 511
or
CEC
Section 20.
Location And Airflow
8 in
(460 mm)
8
(203 mm)
Do not block airflow
around base of unit.
Ref. ST-801 454-A / 5T-800 402 / Ref. ST-801 454-A
OM-182 701 Page 7
Connecting Gas/Air Supply
3-2.
Use
only clean
(483
to 1034
1
and
kPa)
dry gas/air with
70 to 150
psi
Unit Gas
Fitting (Female
pressure.
2
Quick Connect Gas Fitting
3
Standard Gas
Fitting
Obtain and install desired
4
fitting.
Hose
Obtain suitable hose
installed fitting, and
Route
fitting.
supply.
hose
according
to
connect
to
gas/air
to
Adjust gas/air pressure according
3/~
/
1/4
NPT)
to Section 4-2.
A
From Gas/Air
Supply
Incorrect
cause
plasma gas
torch
can
and
source
power
Use only air
or
the
damage.
nitrogen for
plasma
gas.
Rel. ST-aOl 455
Installing
3-3.
And
Connecting
Work
Clamp
1
Work Cable From Unit
2
Ring
3
Screw
Terminal
4
Work
Clamp Handle
Connect ring terminal end of cable
to handle using screw.
Connect work clamp to a clean,
paint-free location on workpiece,
close to cutting
as
area
as
possible.
Tools Needed:
==~
ST-BOO 958
Electrical Service Guide
3-4.
Input Voltage
Input Amperes
400
At Rated
Output
10.6
Max Recommended Standard Fuse Or Circuit Breaker
Mm
Input
Conductor Size In AWG/Kcmil
Max Recommended
In Feet
Mm
Input
Conductor
Length
(Meters)
Grounding
Conductor Size In AWGIKcmiI
Reference: 1993 National Electrical Code
OM-182 701
Page
8
(NEC)
Rating
In
Amperes
15
14
201
(61)
14
S-0o92.i
3-5.
Connecting Input
Power
1
Strain Relief
Clamp
Route
input and grounding con
ductors through clamp to terminal
board.
2
Input
And
Grounding
Conductors
3
Line Disconnect Device
Select
type and size of overcurrent
protection using Section 3-4.
A
Always connect
grounding conductor
=
first.
GND/PE
Tools Needed:
7/16 in
1/2 in
Ref. ST-AOl 455 / Ret. ST-144 221 / Ret. ST-070 399-C / Ref. ST-AOl 454-A
OM-182 701
Page
9
SECTION 4- OPERATION
4-1.
Front Panel Controls
3
4
5
7
-e
-e
1
Ret. ST-183 505
1
Pilot Arc Switch
Use switch to control
Saver
pilot
arc.
Place switch in Expanded Metal
continuous pilot arc. Use while
panded metals only.
position for
cutting ex
~ The Expanded Metal position keeps the
pilot arc in the circuit at all times. Life of
consumables will be significantly re
duced while in Expanded Metal mode.
Place switch in
Tip
Saver
pilot
for
arc
arc
output
OM-182 701
Page
10
position to provide
starting only. Use Tip
position in most applications to
lengthen the life of the torch and its consum
ables, and to obtain maximum cutting
performance.
Torch trigger must be reset after every
cut while in Tip Saver mode.
2
Gas/Air Pressure
3
Output
Gauge
Control
Use control to select
Use Gas/Air Set
setting gas/air
area
pressure
4
Trouble
5
Ready Light
Lights (see
of control range for
(see Section 4-2).
Section
5-3)
Ready light comes On when unit is On to in
dicate that all safety shutdown systems are
okay. If Ready light does not come On,
check trouble
lights.
cutting output in am
peres. Gas/air automatically flows at the set
6
Power
pressure.
7
Power Switch
Light
4-2.
Setting
Gas/Air Pressure
I~H
Place controls in
to
positions shown
adjust air pressure. Only gas/air
circuit is activated when the Power
switch is turned On with
Control in Gas/Air Set
Output
position.
1
Pressure
Gauge
2
Pressure
Adjustment
Knob
Lift knob and turn to adjust pres
sure. Push knob down to lock in
setting. Place output control in de
sired cutting output.
.45
Set pressure to 70 PSI
2
(483 kPa).
Requires 701 50 PSI
(4831034 kPa) Supply
)
Set Controls
Turn On Gas/Air
Supply
)
Adjust
Select Desired
Amperage To
Pressure
Begin Cutting
Rel. ST-aol 454-A
4-3.
Duty Cycle
And
Overheating
Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.
60%
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before cutting.
Duty Cycle
A
Exceeding duty cycle
damage unit and void
can
war
ranty.
6 Minutes
Cutting
4 Minutes
Resting
Overheating
Minutes
Reduce
Duty Cycle
dutyl 4/95
OM-182701
Page
11
4-4.
Cutting Speed
The cutting speed curve shows the
recommended maximum cutting
RECOMMENDED PRODUCTION CUTTING
SPEED
z
vs.
MATERIAL THICKNESS
speed capabilities of
the power
and torch for mild steel of
180
(4.5)
160
(4.0)
various thickness.
140
(3.5)
A
120
(3.0)
100
(2.5)
80
(2.0)
60
(1.5)
40
(1.0)
source
MATERIAL MILD STEEL
recommended
Exceeding
cutting speeds will cause
rapid erosion of the tip and
electrode.
z
0
LU
uJ
0,
0
~
0
I
I
I
I
I
1/8
1/4
3/8
1/2
5/8
3/4
7/8
(3.2)
(6.4)
(9.5)
(12.7)
(15.9)
(19.1)
(22.3
0
MATERIAL THICKNESS
Sequence
Of
IN.(MM)
ST-180 909
Do not clean torch by hitting it against a
hard surface. Hitting hard surfaces can
damage
torch
a
cup, tip, and electrode for
cutting or whenever cutting
speed has been significantly reduced (see
torch Owners
Manual). Do not operate
torch without a tip or electrode in place.
Inspect shield
wear
parts and stop proper op
eration.
))
Install &
Connect
J
Equipment
approximately
Operation
a
\
is
10 inches per minute at 0.7 in
mild steel thickness at max
setting in tip saver mode.
(.5)
20
4-5.
Cutting speed
Put On
Personai\~\
Safety
Equipment
I
))
Tip~\\
Check Torch
Electrode, And
Retaining
1
Gas/Air))
Check
Pressure
Cup)
before
))I~s!~rcD.~
Set
Controls
_________________
)
EXAMPLE Of
)
Begin
Cutting
pilot arc starts immediately
trigger is pressed.
The
Cutting Operation
-*
-~
Place drag shield on edge of metal,
or allow correct standoff distance
approximately 1/8 in (3 mm).
when
Press
trigger.
Pilot
arc
starts.
After
start
cutting arc starts, slowly
moving torch across metal.
-,~
//~\\
Adjust torch speed
sparks go thru metal
out bottom of cut.
so
and
Pause briefly at end of
cut before releasing trigger.
Posthow continues for approx. 20
to 30 seconds after releasing
trigger: cutting arc can be instantly
during postflow by
pressing trigger.
restarted
ST-801 400-A
OM-182 701
Page
12
SECTION 5- MAiNTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
OM-182 701
Page
13
5-2.
Overload Protection: Fuses
A
Turn Off
nect
Remove
unit,
input
top
1
Fuse Fl
2
Fuse F2
and discon
power.
cover.
(See
Parts List)
(See Parts List)
Fl and F2 protect the secondary
winding of transformer Ti from
overload. If Fl or F2 opens, cutting
output stops and no pilot arc is
available. The trouble lights and
fan remain operational.
Replace
Fl and/or F2 if open.
Reinstall top
If
fuse
cover.
continues
Factoiy
Service Agent.
contact
to open,
Authorized
Tools Needed:
cIII~ZJ===u
3/8 in
Ref. ST-801 454-A
5-3.
Trouble
Lights
1
Pressure
Lights
gas/air pressure is below
(276 kPa).
40 PSI
Turn
power
proper
Section
Difficulty establishing pilot arc may indicate
consumables need to be cleaned or replaced.
2
Light
if
Off, and check for
gas/air
4-2).
pressure
(see
Cup Light
Lights
if shield cup is loose.
Turn power Off, and check shield
cup connection (see torch Owners
Manual). Power must be reset
whenever the
activated.
cup
shutdown
is
2
Check shield cup shutdown sys
(see Section 5-5).
tem once a week
3
Temperature Light
Lights if power source overheats
(see Section 4-3).
OM-182 701
Page
14
5-4.
Torch
Checking/Replacing
!1~~
Retaining Cup, Tip,
And Electrode
Overtightening will strip threads. Do not overtighten electrode, tip,
cup during assembly. Do not cross-thread parts causing stripping.
ing torch assembly and parts replacement.
and
Use
retaining
care
dur
lnspectshield cup, tip, and electrode forwear 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
a
both the
tip
and electrode at the
Turn Off power
source
before
same
checking
time.
torch parts.
Make sure this area is clean of
any debris.
The word fronton swirl ring must
face away from torch body.
Make
sure
any debris
obstructed.
swirl
and
ring
no
is clean of
holes
are
ST-801 139 / Ref. ST-8Q1 396-A / ST-801 405
Turn Off power
is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards,
tip
source.
Shield
1
Drag
2
Retaining Cup
retaining cup. Check retaining
for cracks, and replace if necessary.
Remove
5
cup
Electrode
Tip
place electrode.
4
Opening
6
Remove tip. Check tip, and replace if opening is deformed or 50% oversize. If inside of
Swirl
Ring
Remove swirl ring. Check
if side holes are plugged.
0-Ring
Check 0-rings on torch. If needed, coat with
thin film of supplied lubricant. Replace if
damaged.
Check electrode. If center has a pit more
than a 1/16 in (2mm) deep, remove and re
3
7
ring,
and
replace
8
Plunger
Area
Check this area for any debris
material. Clean out if necessary.
or
foreign
Carefully reassemble parts in reverse order.
Swirl ring must be installed with word fronr
facing away from torch body.
OM-182701
Page
15
5-5.
Checking Shield Cup
Shutdown
System
1
Power must be reset whenever the cup shutdown
system is activated. Always turn Off power when
changing
checking
or
Torch Shield
Cup
Turn Power On and loosen shield
cup. If shutdown system works
properly, Ready light goes oft and
Cup light comes on. It not, immedi
ately turn Oft power and have Fac
tory Authorized Service Agent
check safety control board PCi
consumables.
operation.
It
system works properly, retighten
cup and reset power.
Ret. ST-801 300-A
Troubleshooting
5-6.
r~iH*{
Trouble
No
pilot
arc;
difficulty
in
establishing
Remedy
an
Clean
or
replace
worn
consumables
as
necessary
(see
Section
5-4).
arc.
Check for
damaged
torch
or
torch cable
(see
torch Owners
Manual).
Service Agent check power switch Si, control relay CR1, CR5 and CR6, fuses
F2, rectifier SRi, safety control board PCi, power control boards PC2 and PC3, inductor Li,
resistor Ri, and check gas air system for leaks.
Have
Factory Authorized
Fl and
No
cutting output; Power light off;
lights off; Ready light off; fan
Place Power switch in On
position.
Trouble
motor FM does not run.
Place line disconnect device in On
Check line
Have
cutting output; Power light on;
Ready light on; Trouble lights off; fan
motor FM running.
No
Be
Factory
sure
Clean
Have
fuse(s)
work
or
and
replace
if needed
Authorized Service
clamp
replace
position (see Section 3-5).
Agent
or
reset circuit breakers
check power switch
(see Sections 3-4 and 3-5).
Si, transformer Ti, and fan
motor.
is connected.
worn
consumables
Factory Authorized
Service
as
necessary
(see Section 5-4).
Agent check safety control
board PCi ,power control boards PC2 and
PC3, fuses Fl and F2, and rectifier SRi.
No
cutting output; Power light on;
Ready light on; Trouble lights off; fan
motor FM running slowly.
No control of
output.
Check
Have
input power,
and check for proper
Factory Authorized
Service
input
connections
Agent check safety control
(see Sections
3-4 and
3-5).
board PCi and power control boards PC2
and PC3.
No gas/air flow; Power light on; Ready
light on; Trouble lights off; fan motor FM
running.
OM-i82701
Page
16
Have Factory Authorized Service Agent check for proper torch connections, and check
board PCi. Check operation of gas valve GSi, and check gas/air system for leaks.
safety
control
Remedy
Trouble
Pressure Trouble
oft.
light On; Ready light
Check for correct
gas/air
Check for sufficient
Check for
dirty
air
pressure
adjustment (see Section 4-2).
gas/air supply pressure (see Section 3-2).
filter/regulator
and clean, if needed
(see manufacturers instructions).
Check air lines for leaks.
Have
Cup
Trouble
light On; Ready light
oft.
Factory
Authorized Service
Check torch shield cup
Have
Factory
(see
Agent
Section
Authorized Service
check pressure switch S3 and
5-5).
Agent
safety
control board PCi.
Reset power switch.
check for proper torch connections, and check
safety
control
board PCi.
Temperature
light oft.
Trouble
light On; Ready
Main transformer
or
main rectifier
overheating. Allow fan to
run; the Trouble
light goes
out when the unit
has cooled.
Fan motor FM does not run; Power
Ready light both On.
light
Have
Factory
Authorized Service
Agent
check
Have
Factory
Authorized Service
Agent
check fan motor connections.
safety
control board PCi.
and
Check
Trouble
lights
not
working.
Have
input power,
Factory
and check for proper
Authorized Service
Agent
input
check
connections
safety
(see
Sections 3-4 and
3-5).
control board PCi.
OM-182 701
Page
17
Cl) m C)
0 z 0)
m I m C) -I
I D
C)
C
9-
~NW
AU~( d3MDd)~
cIw~d/L3 i~ru/~ ~~
£L-~3
r
Cl) 9 0
-Il
0
F\)
0
CD CO CD
C -q CD
-I
C)
C, C
0)
-I 0) 3
~Ti 0 -I
0
e -I
U) 0
-I C, CD
F0 0
NOTES
OM-182 701
Page
19
SECTION 7- PARTS LIST
8
31
32
7
6.
5.
4.
3
38
39
40
49
5\~i~
~41
46
45
42
47
ST-801 650
Figure
OM-182 701 Page 20
7-1. Main
Assembly
Item
No.
Dia.
Part
No.
Mkgs.
Quantity
Description
Figure
7-1. Main
Assembly
178158... PANEL, side LH
STAND-OFF, insul
1
2
1
026947...
4....
RS1
178162... BAFFLE, center
....169620... SWITCH, reed
5....
CR5
....006393...
3
1
1
1
8
178147
9....SR1..
179 542
RELAY, end 24VAC DPDT 1OAI12OVAC
CONTACTOR, def prp 40A 3P 24VAC coil/cover
INDUCTOR, 50A 70 micro henry
HEAT SINK, rectifier
RECTIFIER, integ 30A 800V
6
...
7
CR1,6
180 270
Li
179543
1
2
1
1
1
10
VR1
178 393
VARISTOR
1
11
TP2
032 810
THERMOSTAT, NC open 165F close 135F
COVER, top
FUSE, mintr cer slo-blo 30A 125V
HOLDER, fuse mintr 20A 2 fuses
1
12
13
178157
F1,2
142 751
14
15
098 376
Ri...
181 843
183 820
16
178153
17
170 647
18....
FM1
148 808
150 783
179 999
TP1
...21....
TEl
.
...166 063
....181204
038618
...22
23...
178161
PC2,3....
...24
171 668
1
2
1
RESISTOR, WW fxd 675W 3 ohm
INSULATOR, end resistor
BRACKET, rectifier
BUSHING, snap-in nyl 1.312 ID x 1.SOOmtg hole
MOTOR, fan 230V 50/60Hz 1550rpm .3l2dia shaft
BLADE, fan 9.000 5wg 39deg .3l2dia bore
TRANSFORMER, pwr main 400 (consisting of)
THERMOSTAT, NC open 135C
TERMINAL ASSEMBLY, pri 3ph 1V
LINK, jumper
PANEL, rear
CIRCUIT CARD ASSEMBLY, power control
1
2
1
3
1
1
1
1
1
6
1
2
176123
FITTING, plstc Qdisc elbow 1/8NPT
175827
1
1
x
1/4 OD
tubing
2
34
015733
35
073655
VALVE, 24VAC 3 way 1/8NPT 5/32 ort lOOpsi
FITTING, pipe brs tee B 1/8NPT
SWITCH, pressure air 4opsi fixed
FITTING, hose brs barbed fern 3/l6tbg x 1/8NPT
REGULATOR/FILTER, 2sopsig in lOOpsig max out 1/4P
FITTING, pipe galv plug schhd 1/4NPT
GASKET, neoprene 1.500 OD x .688 thick
BRACKET, mtg regulator
FITTING, pipe brs coupling 1/4NPT
FITTING, pipe brs nipple L 1/4NPT x 2.00
FITTING, pipe brs nipple hex 1/8NPT
36
179863
LIFT EYE
178148
HANDLE
134201
081 960
STAND-OFF, support PC card .312/.375 w/post and lock
DOOR, access
CONNECTOR, clamp cable
PANEL, side RH
WHEEL, polyolefin 6 in dia x 1.375w .500 hub dia
AXLE, running gear .SOOdia x 24.5
RING, rtng ext .500 shaft x .O3Sthk C style
179862
BASE
1
PANEL, front (consisting of)
PANEL,front
NAMEPLATE, (order by model and serial number)
1
602946
27
174670
175999
29
174668
602938
181693
...32
178146
602963
38
39
179864
40
044426
178159
...42
095094
178163
44
+178 160
179942
CONSUMABLE STORAGE BOX
181 854
DOOR, consumable box (consisting of)
CATCH, door
CIRCUIT CARD ASSEMBLY, safety control
LENS, LED clear panel rntg
CLIP, retainer lens
STAND-OFF, support PC card
SWITCH, toggle SPST 20A 125VDC
181 855
PCi
.
...183 712
159036
159035
176478
S2
089085
1
1
1
1
1
1
1
1
1
1
1
16
1
1
1
2
1
2
1
1
1
.1
.1
.1
.5
.5
.4
1
OM-182 701
Page
21
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
i8i 708
091 141
CAPACITOR
128 756
Ci,2,3
...
Assembly (Continued)
KNOB, pointer
SWITCH, toggle SPST 40A 600VAC
GASKET, switch
174 991
Si
7-1. Main
Quantity
1
1
scr
1
3
171 001
FITTING, plstc Qdisc straight fern 1/8NPT
TUBING, pneumatic .250 OD x .170 ID x 10.00
TUBING, pneumatic .250 OD x .170 ID x 17.00
GAUGE, pressure air 0l6Opsi 1/8NPT
HOSE, SAE .187 ID x .410 OD x 28.00
HINGE, cont polyolefin 2.00 Lw/.125H
LABEL, general precautionary
CABLE, work 2Oft No. 6 w/strain relief and term
CLAMP~ work 100A
164 900
CONNECTOR & SOCKETS
3
PLG1O
164899... CONNECTOR & SOCKETS
PLG5....167640... CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
168 071
PLG24,34
1
2
PLG26,36
2
178 739
179 536
179 537
178 740
179 539
168 343
46
179 219
47.... Work
48.... Work
....
....
PLG22,27,37
169 687...
...
PLG21,31
PLG11
PLG2,8
PLG25
..
.
176 121
..153 501
..
158720...
...
169240...
...
170888...
...
131 056...
176824...
176826...
176828...
180605...
50
+When
178262...
ordering
a
CONNECTOR,
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
rect univ 084
Page 22
1
1
2
1
1
1
1
& SOCKETS
2
& SOCKETS
& SOCKETS
1
& SOCKETS
1
1
a
precautionary label,
1
1
1
use
w/ICE-5OCM)
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM.182 701
1
& SOCKETS
ICE-50C, (order separately)
ICE-50C, 25ft
ICE-50C, 5Oft
ICE-5OCM, SOft machine mounted
PENDANT CONTROL, (recommended for
DISCONNECT, quick ICE-50
component originally displaying
1
1
..
PLG12
1
1
1