Miller Electric SPECTRUM 875 AUTO-LINE AND ICE-60T/TM TORCH Owner`s manual
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OM-242 880B 2010−05 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter Spectrum 875 Auto-Line And ICE-60T/TM Torch R Visit our website at www.MillerWelds.com File: Plasma Cutters 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 Quality System Warranty and service information for your 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 2009−09 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. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Torch Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. System Dimensions, Weight, And Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Connecting And Disconnecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Connecting And Disconnecting Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Power Cable Management Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat, Trailblazer Or Hobart Champion 10,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant . . . . . . . . . . . . . . . . . . . 4-17. Generator Settings For Plasma Cutter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Consumables Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 3 4 4 4 5 5 5 7 9 9 9 10 10 11 11 11 12 13 13 14 15 15 16 16 17 18 19 20 21 22 23 24 24 25 25 26 27 28 29 29 TABLE OF CONTENTS SECTION 6 − MECHANIZED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. ICE-60TM 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. Shield Sense Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10. Cut Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Wrapper Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Checking Or Replacing Filter Element (Part No. 227 877) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Status/Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY 30 30 30 30 31 32 33 34 35 35 36 39 39 39 40 41 42 43 44 46 48 50 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom_2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. NOTICE − Indicates statements not related to personal injury. . Indicates special instructions. This group of symbols means Warning! Watch Out! 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 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. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. CUTTING can cause fire or explosion. Hot metal and sparks blow out from the cutting arc. The flying sparks and hot metal, hot workpiece, and hot equipment can cause fires and burns. Check and be sure the area is safe before doing any cutting. D D D D D D D D D D D D D D D D D D 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. Do not cut where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that cutting on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not cut on closed containers such as tanks or drums. 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. Do not use plasma cutter to thaw frozen pipes. Never cut containers with potentially flammable materials inside − they must be emptied and properly cleaned first. Do not cut where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Do not cut pressurized cylinders, pipes, or vessels. Do not cut containers that have held combustibles. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Do not locate unit on or over combustible surfaces. Remove any combustibles, such as a butane lighter or matches, from your person before doing any cutting. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Use only correct fuses or circuit breakers. Do not oversize or bypass them. Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. 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 may also use 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. 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. D Do not touch torch parts if in contact with the work or ground. D Turn off power before checking, cleaning, or changing torch parts. D Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. D 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. D When making input connections, attach proper grounding conductor first. D Keep cords dry, free of oil and grease, and protected from hot metal and sparks. D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. D Turn off all equipment when not in use. D Inspect and replace any worn or damaged torch cable leads. D Do not wrap torch cable around your body. D Ground the workpiece to a good electrical (earth) ground if required by codes. D Use only well-maintained equipment. Repair or replace damaged parts at once. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Do not bypass or try to defeat the safety interlock systems. D Use only torch(es) specified in Owner’s Manual. D Keep away from torch tip and pilot arc when trigger is pressed. D 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. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D D D OM-242 880 Page 1 ELECTRIC SHOCK can kill. FUMES AND GASES can be hazardous. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input power. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 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. EXPLODING PARTS can injure. 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 D D D D D D FLYING SPARKS can injure. Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. D D D 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. PLASMA ARC can injure. ARC RAYS can burn eyes and skin. 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 from arc rays and sparks 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. Table 1. Eye Protection For Plasma Arc Cutting Current Level In Amperes Below 20 20 − 40 40 − 60 60 − 100 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. OM-242 880 Page 2 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. 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. D D D D D D D 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. 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 burn. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MOVING PARTS can injure. 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 and troubleshooting as necessary. D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. READ INSTRUCTIONS. D Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. D Use only genuine replacement parts from the manufacturer. D Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. FLYING METAL or DIRT can injure eyes. D Wear safety glasses with side shields or wear face shield. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. D Wearers of Pacemakers and other Implanted Medical Devices should keep away. D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating 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. FALLING EQUIPMENT can injure. 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. D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment. 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. D See your cutting engineer and water table instructions for help. OM-242 880 Page 3 1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Practices for Plasma Arc Cutting and Gouging, American Welding Society Standard AWS C5.2, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, 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 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1-6. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 1. Keep cables close together by twisting or taping them, or using a cable cover. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. OM-242 880 Page 4 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_2010−03fre Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. NOTE − Indique des déclarations pas en relation avec des blessures personnelles. . Indique des instructions spécifiques. Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger. 2-2. Dangers liés au coupage à l’arc au plasma 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 1-5. Veuillez lire et respecter toutes ces normes de sécurité. L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées. 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. D 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 quand l’atmosphère peut contenir des poussières, gaz ou vapeurs (comme l’essence) inflammables. 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 Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. D Utiliser exclusivement des fusibles ou coupe−circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. D Avant le coupage, retirez tout combustible de vos poches, par exemple un briquet au butane ou des allumettes. UN CHOC ÉLECTRIQUE peut tuer. 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. Le coupage plasma nécessite des tensions plus importantes que le soudage pour amorcer et maintenir l’arc (200 à 400VDC est typique), mais peut être utilisé avec des torches équipées de systèmes de verrouillage de sécurité qui arrêtent la machine en cas de buse desserrée ou si l’électrode touche la tuyère. Incorrectly installed or improperly grounded equipment is a hazard. D Ne touchez pas aux pièces électriques sous tension. D Portez des gants isolants et des vêtements de protection secs et sans trous. D 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. D Ne touchez pas aux pièces du chalumeau si vous êtes en contact avec la pièce à couper ou le sol. D Mettez l’appareil hors tension avant d’effectuer la vérification, le nettoyage ou le changement d’une pièce du chalumeau. D 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). D 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. OM-242 880 Page 5 D 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. D Avant d’effectuer les connexions d’alimentation, vous devez relier le bon fil de terre. D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes. D 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. D L’équipement doit être hors tension lorsqu’il n’est pas utilisé. D Vérifiez et remplacez les cosses du câble du chalumeau si elles sont usées ou altérées. D Le câble du chalumeau ne doit pas s’enrouler autour de votre corps. D Si les normes le stipulent, la pièce à couper doit être mise à la terre. D Utilisez uniquement de l’équipement en bonne condition. Réparez ou remplacez immédiatement toute pièce altérée. D Portez un harnais de sécurité si vous devez travailler au−dessus du sol. D Assurez−vous que tous les panneaux et couvercles sont correctement en place. D N’essayez pas d’aller à l’encontre des systèmes de verrrouillage de sécurité ou de les contourner. D Utilisez uniquement le ou les chalumeaux recommandés dans le manuel de l’opérateur. D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée. D 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. 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 Une protection faciale (casque ou masque) avec des lunettes filtrantes de teinte adéquate est indispensable pour protéger le visage et les yeux des rayonnements de l’arc et des étincelles pendant la découpe ou en regardant simplement 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 D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. DÉCHARGES ÉLECTRIQUES potentiellement mortelles. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. 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 PROJETÉES peuvent 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. OM-242 880 Page 6 LE BRUIT peut endommager l’ouïe. sécurité). 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 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. LES FUMÉES ET LES GAZ peuvent être dangereux. Le coupage produit des vapeurs et des gaz. Respirer ces vapeurs et ces gaz peut être dangereux pour la santé. 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. L’ARC PLASMA peut provoquer 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 LES PIÈCES CHAUDES provoquer des brûlures. peuvent D Ne pas toucher des parties chaudes à mains nues. D Prévoir une période de refroidissement avant d’utiliser l’équipement. 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. Les PIÈCES MOBILES provoquer des blessures. peuvent D S’abstenir de toucher des organes mobiles tels que des ventilateurs. D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié. D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique. LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. OM-242 880 Page 7 Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. D Prévoir une période de refroidissement; respecter le cycle opératoire nominal. D Réduire l’ampérage (épaisseur) avant de continuer à couper ou réduire le facteur de marche. Danger D’EXPLOSION D’HYDROGÈNE. D Lors du coupage d’aluminium partiellement ou totalement immergé dans l’eau, de l’hydrogène libre peut s’accumuler sous la pièce. D Consultez votre ingénieur de coupage et les instructions de la table de coupage. LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures. D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire. D 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. D Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur. D Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds. Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D 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. OM-242 880 Page 8 LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D 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. 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 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). 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. 2-4. Proposition californienne 65 Avertissements cancérogène ainsi que provoquant des malformations congénitales ou autres problèmes de procréation. Se laver les mains après toute manipulation. Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Pour les moteurs à essence : Ce produit contient des produits chimiques, compris du plomb, dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation. Pour les moteurs diesel : Ce produit contient des éléments chimiques, dont le plomb, reconnus par l’État de Californie pour leur caractère Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation. 2-5. 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). Recommended Practices for Plasma Arc Cutting and Gouging, American Welding Society Standard AWS C5.2, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, site Internet : www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 1-800-344-3555, site Internet : www.nfpa.org). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone: 1-877-413-5184, site internet : www.global.ihs.com). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 1-800-344-3555, site Internet : www.nfpa.org et www.sparky.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 15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux −le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet : www.cganet.com). Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (téléphone: 1-800-232-4636, site internet : www.cdc.gov/NIOSH). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone : 800-463-6727, site internet : www.csa-international.org). 2-6. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM provenant du circuit de soudage: 1. Rassembler les câbles en les torsadant ou en les attachant avec du ruban adhésif ou avec une housse. 2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur. 3. Ne pas courber et ne pas entourer les câbles autour de votre corps. 4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage. 5. Connecter la pince sur la pièce aussi près que possible de la soudure. 6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus. 7. Ne pas souder tout en portant la source de soudage ou le dévidoir. En ce qui concerne les implants médicaux : Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. OM-242 880 Page 9 . A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label 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 Static Frequency ConverterTransformerRectifier Rated No Load Voltage (Average) Rated Maximum Supply Current U1 I2 Degree Of Protection Maximum Effective Supply Current OM-242 880 Page 10 pf Primary Voltage Rated Welding Or Cutting Current U2 X Loose Shield Cup Input Hz Hertz power factor Suitable for Some Hazardous Locations S1 Power Rating, Product Of Voltage And Current (kVA) S . A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2. Specifications Power Supply Input Rated AC Phase and line frequency (Hz) Rated Input Voltage (U1) and rated Input Current (I1) and I1 eff at rated output. I1 eff used to determine power cord rating 1 − 3−Phase 50 / 60 Hz −− Volts AC RMS − (U1) Amps RMS − (I1) I1 eff 208 VAC 1−Phase 47.4 30 230 VAC 1−Phase 42.2 26.7 208 VAC 3−Phase 27.5 19.4 230 VAC 3−Phase 25 17.7 380 VAC 3−Phase 15 11.6 460 VAC 3−Phase 12.4 9.6 575 VAC 3−Phase 9.8 7.6 Volts AC RMS − (U1) Power Factor kVA/kW 208 VAC 1−Phase 0.98 9.9 / 9.7 230 VAC 1−Phase 0.98 9.7 / 9.6 208 VAC 3−Phase 0.95 9.9 / 9.5 230 VAC 3−Phase 0.95 9.9 / 9.5 380 VAC 3−Phase 0.95 9.9 / 9.4 460 VAC 3−Phase 0.95 9.9 / 9.4 575 VAC 3−Phase 0.95 9.8 / 9.3 15.5 kW −− −− 400 Volts DC/Electrode Negative −− −− Constant Current −− −− Rated Output Current (I2) 60 A −− −− Rated Output Voltage (U2) 140 Volts DC −− −− 20 − 60 A −− −− Duty Cycle % Amps DC − (I2) Volts AC RMS − (U1) 40 60 A 208−230 VAC 1−Phase 50 60 A 208−230 VAC 3−Phase 60 60 A 380−575 VAC 3−Phase 100 50 A 208−230 VAC 1−Phase 100 50 A 208−575 VAC 3−Phase Power Factor/kVA/kW at Rated Output Peak kW at Arc Stretch Output Rated Open Circuit Voltage (U0) Type Output Characteristic Output Current Range Duty Cycle at 104°F (405C) and Rated Conditions (U1, I1, U2, I2) based on a 10 minute period OM-242 880 Page 11 . A complete Parts List is available at www.MillerWelds.com General Operating Temperature 5° to 104° F (−15° to 40° C) −− −− IP23CS −− −− IP − International Protection −− −− 2 − No ingress of foreign objects ≥12.5 mm (0.5 in.) −− −− 3 − No harmful ingress spraying water −− −− C − AC line circuits protected against ingress of tool . 2.5 mm dia x 100 mm long (0.1 in. x 4 in.) −− −− S − Fan stationary during water test −− −− Up to 15° incline −− −− IP Code − Degree of protection provided by enclosure Toppling or tilting Air or Nitrogen −− −− Clean, moisture−free, oil−free −− −− 6.75 SCFM (191 L/min) 90 PSI (621 kPa) Min 120 PSI (827 kPa) Max Particulates to 5 microns −− −− Gas Type Gas Quality Gas Inlet Flow and Pressure Gas Filtering Torch Mild Steel capacities (see Section for cutting speeds vs material type and thickness) 7/8 in. at 10 ipm (254 mm/min)* −− −− Sever Cut Capacity (edge start) 1−1/4 in. −− −− Pierce Capacity 7/16 in. −− −− Rated Capacity (edge start) *Travel speeds are approximately 80% of maximum. 4-3. Duty Cycle And Overheating 40% Duty Cycle 4 Minutes Cutting Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. Duty cycle is based on an ambient temperature of 104° F (40° C). 6 Minutes Resting 50% Duty Cycle 5 Minutes Cutting 5 Minutes Resting If unit overheats, output stops, temperature status light illuminates, and cooling fan runs. Wait fifteen minutes for unit to cool or temperature light to go off. Reduce amperage or duty cycle before cutting or gouging. NOTICE − Exceeding duty cycle can damage unit and void warranty. 60% Duty Cycle 6 Minutes Welding 4 Minutes Resting Overheating A 0 15 Minutes OR Reduce Duty Cycle Duty1 4/95 − Ref. 805 159-A OM-242 880 Page 12 . A complete Parts List is available at www.MillerWelds.com 4-4. Torch Dimensions 8-27/32 in. (225 mm) Hand-Held Torch 1-1/2 in (38 mm) 4 in. (100 mm) 2-5/16 in. (58 mm) 1-1/16 in. (27 mm) Machine Torch 15-9/32 in. (388 mm) 2-9/64 in. (54 mm) 1-1/16 in. (27 mm) Gear rack 32 pitch 1/8 in. (3.2 mm) width 1/8 in. (3.2 mm) height 1-3/8 in. (35 mm) 8 in. (202 mm) 4-5. System Dimensions, Weight, And Movement ! Do not move or operate unit where it could tip. 18-1/2 in. (470 mm) 13-1/2 in. (343 mm) Unit Dimensions And Weight 47 lb (21.3 kg) Torch Weight Hand-Held: 20 ft (6.1 m) 6 lb (2.7 kg) Hand-Held: 50 ft (15.2 m) 12-3/4 lb (5.8 kg) Machine: 25 ft (7.6 m) 8 lb (3.6 kg) Machine: 50 ft (15.2 m) 13-1/2 lb (6.1 kg) 8-3/4 in. (222 mm) Work Cable Weight 20 ft (6.1 m) 3-1/2 lb (1.6 kg) 50 ft (15.2 m) 7-1/2 lb (3.4 kg) loc_2 3/96 - Ref. 805 159-A OM-242 880 Page 13 . A complete Parts List is available at www.MillerWelds.com 4-6. Connecting Work Clamp and Gas/Air Supply 1 2 1 Work Clamp Workpiece . Connect work clamp to portion of workpiece that does not fall away after being cut. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 . Use only clean, dry air with 90 AIR/N2 90-120 psi 5 @ 6.75 CFM (191 L/min) minimum 3 to 120 psi (621 to 827 kPa) pressure @ 6.75 CFM (191L/min) minimum. . Use filter kit 300 491 or 228 926 where conditions at the worksite allow moisture, oil or other particulates into the air line. 3 Gas/Air Filter Inlet Opening 4 Hose . Hose must have a minimum inside diameter of 3/8 in (9.5 mm). 5 4 From Gas/Air Supply Tools Needed: 9/16 in. OM-242 880 Page 14 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. Rear of Unit NOTICE − Exceeding input pressure rating of 120 PSI (827 kPa) can damage unit. Ref. 803 640-A / Ref. 192 441 / Ref. 805 160-A . A complete Parts List is available at www.MillerWelds.com 4-7. Connecting And Disconnecting Torch 2 1 3 ! Turn off power source and disconnect input power. 1 2 3 4 5 Torch Connector Quick Connect Collar Nipple Receptacle Securing Pin To connect torch: Push torch connector onto receptacle and quick connect until collar secures nipple. Rotate securing pin clockwise to lock connector to unit. 4 5 To disconnect torch: Rotate securing pin counterclockwise to unlock connector from unit. Push quick connect collar back towards unit to release nipple, and pull torch connector away from unit. . Use supplied hook and loop strap to manage torch and work cables. 805 161-A 4-8. Connecting And Disconnecting Work Cable 1 2 Work Cable Receptacle Work Cable Plug To connect plug, align key with receptacle keyway and insert into receptacle. Rotate plug clockwise (hand tight only) to secure in receptacle. To disconnect plug, rotate counterclockwise until key aligns with keyway and pull plug from receptacle. . Use supplied hook and loop strap to manage torch and work cables. 2 1 Ref. 805 161-A / Ref. 803 475-G OM-242 880 Page 15 . A complete Parts List is available at www.MillerWelds.com 4-9. Power Cable Management Strap 1 Power Cable Management Strap Coil power cable and secure to unit using the power cable management strap. 1 Ref. 805 275-A 4-10. Selecting a Location 1 1 ! Lifting Handle Use handle to lift unit. 2 Do not move or operate unit where it could tip. Line Disconnect Device Locate unit near correct input power supply. Locate unit at least 18 in. (460 mm) away from a wall or other obstuction to allow adequate clearance for cooling air flow. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Location 2 18 in. (460 mm) 18 in. (460 mm) loc_2 3/96 - Ref. ST-151 556 / Ref. 805 159 OM-242 880 Page 16 . A complete Parts List is available at www.MillerWelds.com 4-11. Electrical Service Guide NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. . Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available. Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. Single-Phase Input Voltage (V) 208 230 Input Amperes (A) At Rated Output 48 42 Time-Delay Fuses 2 50 50 Normal Operating Fuses 3 70 60 Min Input Conductor Size In AWG/Kcmil 4 10 10 55 (17) 68 (21) 10 10 Max Recommended Standard Fuse Rating In Amperes 1 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil 4 Three-Phase Input Voltage (V) 208 230 380 460 575 Input Amperes (A) At Rated Output 27 25 15 12 10 Time-Delay Fuses 2 30 30 15 15 10 Normal Operating Fuses 3 40 35 20 20 15 Min Input Conductor Size In AWG/Kcmil 4 12 12 14 14 14 68 (21) 83 (25) 148 (45) 216 (66) 341 (104) 12 12 14 14 14 Max Recommended Standard Fuse Rating In Amperes 1 Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil 4 Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps 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-242 880 Page 17 . A complete Parts List is available at www.MillerWelds.com 4-12. Extension Cord Data . 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 1 50/60 Time-Delay 2 Normal Operating 3 50 A 230 V 1 50/60 Time-Delay 2 Normal Operating 3 50 A 60 A 208 V 3 50/60 Time-Delay 2 Normal Operating 3 230 V 3 50/60 Conductor Size Max. Cord Length 10 AWG 55 ft (17 m) 10 AWG 67 ft (21 m) 30 A 40 A 12 AWG 68 ft (21 m) Time-Delay 2 Normal Operating 3 30 A 12 AWG 83 ft (25 m) 70 A 35 A 380 V 3 50/60 Time-Delay 2 Normal Operating 3 15 A 20 A 14 AWG 148 ft (45 m) 460 V 3 50/60 Time-Delay 2 Normal Operating 3 15 A 20 A 14 AWG 216 ft (66 m) 575 V 3 50/60 Time-Delay 2 Normal Operating 3 10 A 15 A 14 AWG 341 ft (104 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). Notes OM-242 880 Page 18 . A complete Parts List is available at www.MillerWelds.com 4-13. Connecting 1-Phase Input Power Installation must meet all National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. 1 Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. 8 NOTICE − 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 230 VAC without removing cover to relink the power source. =GND/PE Earth Ground 10 7 1 9 L1 L2 2 3 1 4 5 3 Black And White Input Conductor (L1 And L2) Red Input Conductor Green Or Green/Yellow Grounding Conductor Insulation Sleeving Electrical Tape Insulate and isolate red conductor as shown. 6 Input Power Cord. 7 Disconnect Device (switch shown in the OFF position) 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals 6 Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. Connect input conductors L1 and L2 to disconnect device line terminals. 10 Over-Current Protection Select type and size of over-current protection using Section 4-11 (fused disconnect switch shown). Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position. 1 2 3 6 5 4 Tools Needed: input1 20008−01 − 803 766-C / 805 159 OM-242 880 Page 19 . A complete Parts List is available at www.MillerWelds.com 4-14. Connecting 3-Phase Input Power Installation must meet all National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. 3 = GND/PE Earth Ground 4 7 Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. NOTICE − 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. For Three-Phase Operation 1 2 2 3 4 5 6 L1 3 L2 L3 6 5 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 4-11 (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: input2 2008−01 − 803 766-C / 805 159 OM-242 880 Page 20 . A complete Parts List is available at www.MillerWelds.com 4-15. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat, Trailblazer Or Hobart Champion 10,000 Check input voltage available at the power supply. . The Auto-LineE circuitry in this 2 3 7 3 4 4 240V 5 11 unit automatically adapts the power source to the 240 volts, single-phase, 50 or 60 Hz primary voltage from the power supply. 6 6 5 Plug Front View 7 1 Input And Grounding Conductors 2 Plug Wired for 240 V, 2-Wire Load 3 Neutral (Brass) Terminal And Prong (Not Used) 4 Load 1 (Brass)Terminal And Prong 5 Load 2 (Brass) Terminal And Prong 6 Ground (Brass) Terminal And Prong 7 Black And White Input Conductors 8 Red Input Conductor 9 Insulation Sleeving 10 Electrical Tape 11 1 11 Green Or Green/Yellow Ground Conductor 8 Insulate and isolate red conductor as shown. Green Or Green/Yellow 1 10 ! 9 Always connect green or green/yellow wire to ground terminal, never to a load terminal. Connect black (L1) and white (L2) wires to load terminals. Tools Needed: 3/16 in. Ref. 120 813-D / Ref. 805 161-A OM-242 880 Page 21 . A complete Parts List is available at www.MillerWelds.com 4-16. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant Three-Phase Generator Power ! Stop engine. ! Power and weld outputs are live at the same time. Disconnect or insulate unused cables. Three-Phase Power Connection ! . Have qualified person install ac- Close panel opening if no connections are made to generator. cording to circuit diagram and Generator Power Guidelines (see generator Owner’s Manual). Remove generator power panel mounting screws. Tilt panel forward. Remove plug before inserting leads. Reinstall bushing. 3 Rear Of Panel 4 91 92 93 2 Circuit Breaker CB7 2 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 Jumper 42 is connected to lead 90 at factory. Jumper 42 may be disconnected from neutral to meet applicable electrical codes. 5 1 11 6 1 Lead 42 connects to front panel Ground stud. 10 Power Cord 9 11 Circuit Breaker CB7 User Terminals . 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 ! 8 7 Close panel opening if no connections are made to generator. 1-Phase Connect user-supplied ring lug to green (ground) lead. Connect ring lug on end of green (ground) lead to grounding terminal (9). 3-Phase Connect black, white, and red leads to circuit breaker CB7 user terminals (11). 240V 120V 120V 240V 240V 240V Reinstall power panel. Volts Single Phase 1 120/240 Three Phase 3 240 Amps 50 48 KVA/KW 12 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-242 880 Page 22 . A complete Parts List is available at www.MillerWelds.com 4-17. Generator Settings For Plasma Cutter Operation ! Engine Control Switch must be set at “RUN” position − not “RUN/IDLE”. ! Set generator Fine Adjustment Control to 10 for maximum auxiliary power, if applicable. . The peak kW at arc stretch of this plasma power source is 15.5 kW. Reducing output to 45 amps may be necessary to operate the unit using a 10 kW generator. Ref. 803 222 Notes OM-242 880 Page 23 . A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 1 40 V 50 30 ON POWER P R E S S UR E C UP 3 V 20 A TE M P 60 OFF C UT GOUGE 2 4 1 Output Control Use control to set cutting output. 2 Status Lights (See Section 7-6) 3 Power Switch . The fan will operate for approximately 10 seconds after power switch is placed in the Off position to reduce DC bus voltage. OM-242 880 Page 24 4 Cut/Gouge Switch Place switch in appropriate position for desired process. Unit will automatically regulate pressure to 70 psi (483 kPa) for cutting and 60 psi (413 kPa) for gouging. Pilot current is automatically increased in gouge mode to provide better gouging starts. Ref. 234 155-A . Use only clean, dry air with 90 to 120 psi (621 to 827 kPa) pressure. Prevent moisture from entering air supply at extreme cold temperatures. . Use filter kit 300 491 or 228 926 where conditions at the worksite allow moisture, oil or other particulates into the air line. . A complete Parts List is available at www.MillerWelds.com 5-2. Trigger Safety Lock 1 Trigger 1 Trigger Locked Trigger Unlocked 801 397-A 5-3. Plasma Cutting System Practices ! CUT GOUGE . Set Always connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. The pilot arc starts immediately when trigger is pressed. switch to either cut or gouge depending on desired process. DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle and electrode. . Connect work clamp to portion of workpiece that does not fall away after being cut. 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 or amperage is set too low. Wt 1/8 in (3.2 mm) When doing extended (non-shielded) cutting, maintain approximately 1/8 in standoff between tip 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. . For more information, go to MillerWelds.com. Ref. 803 640-A / 801 400-B / Ref. 802 878 OM-242 880 Page 25 . A complete Parts List is available at www.MillerWelds.com 5-4. Sequence Of Cutting Operation CUT GOUGE . Unit automatically regulates pressure to 70 psi Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. (483 kPa) for cutting. . Connect work clamp to portion of workpiece that does not fall away after being cut. ! The pilot arc starts immediately when trigger is pressed. 90° For standard (shielded) cutting, place drag shield on edge of metal. For extended (non-shielded) cutting, use 1/8 in (3.2 mm) standoff distance (dragging tip will reduce tip life). Raise trigger lock and press trigger. Pilot arc starts and will go out after 3 seconds if cutting arc is not established. Adjust torch speed so sparks go thru metal and out bottom of cut. Pause briefly at end of cut before releasing trigger. After cutting arc starts, slowly start moving torch across metal. Postflow continues after releasing trigger; cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger. . For more information, go to MillerWelds.com. Ref. 803 640-A / 801 400-B OM-242 880 Page 26 . A complete Parts List is available at www.MillerWelds.com 5-5. Sequence Of Gouging Operation CUT GOUGE . Unit automatically regulates pressure to 60 psi (413 kPa) for gouging. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. . Connect work clamp to portion of workpiece that does not fall away after being cut. ! 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 and will go out after 3 seconds if gouging arc is not established. 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 after releasing trigger; arc can be instantly restarted during postflow by raising trigger lock and pressing trigger. . For more information, go to MillerWelds.com. Ref. 803 640-A / 801 400-B OM-242 880 Page 27 . A complete Parts List is available at www.MillerWelds.com 5-6. Sequence Of Piercing Operation ! The pilot arc starts immediately when trigger is pressed. . Recommended maximum piercing capacity is 7/16 in (11 mm). CUT GOUGE . Unit automatically regulates pressure to 70 psi (483 kPa) for cutting. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. Hold torch at an angle to the workpiece. Raise trigger lock and press trigger. Pilot arc starts and will go out after 3 seconds if cutting arc is not established. . Connect work clamp to portion of workpiece that does not fall away after being cut. 90° Rotate torch to upright position approximately 90° to surface. When arc has pierced through workpiece, start cutting. 90° Maintain approximately 90° torch position to surface, and continue cutting. Release trigger. Postflow continues after releasing trigger; arc can be instantly restarted during postflow by raising trigger lock and pressing trigger. . For more information, go to MillerWelds.com. Ref. 803 640-A / 801 400-B OM-242 880 Page 28 . A complete Parts List is available at www.MillerWelds.com 5-7. Cutting Speed Mild Steel Arc Current 60 Material Thickness Recommended Cut Speeds Inches mm IPM mm/min 1/4 6.4 86 2184 3/8 9.5 41 1041 1/2 12.7 27 686 5/8 15.9 20 512 3/4 19.1 14 363 7/8 22.2 10 254 Stainless Arc Current 60 Material Thickness Recommended Cut Speeds Inches mm IPM mm/min 1/4 6.4 72 1829 3/8 9.5 34 864 1/2 12.7 23 584 5/8 15.9 17 429 3/4 19.0 12 297 7/8 22.2 9 222 Aluminum Arc Current 60 Material Thickness Recommended Cut Speeds Inches mm IPM mm/min 1/4 6.4 94 2388 3/8 9.5 48 1219 1/2 12.7 30 762 5/8 15.9 21 545 . Recommended cut speed is approximately 80% of maximum. . Recommended maximum piercing capacity is 7/16 in (11 mm). 5-8. Consumables Storage Compartment 1 Consumables Storage Compartment This compartment provides convenient access to consumables and parts. 1 Rear of Unit Ref. 805 160-A OM-242 880 Page 29 . A complete Parts List is available at www.MillerWelds.com SECTION 6 − MECHANIZED OPERATION 6-1. ICE-60TM Mounting Position 1 2 ICE-60TM Machine Torch Square Use a square to align torch perpendicular to the work surface. 1 2 90° 6-2. Remote Control Receptacle . Remote trigger will only oper- ate with a machine torch installed. Remote trigger is disabled when a handheld torch is installed. 1 3 2 6 5 4 11 10 9 8 13 Remote Control Receptacle RC61 RC61 provides remote arc start inputs when using the ICE-60TM 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 7 14 1 12 243 336-A 6-3. Remote Control Cable Functions Function Remote Start Okay To Move Noise Suppression OM-242 880 Page 30 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. NOTE: The Spectrum 875 Auto-Line with factory-installed machine torch 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. . A complete Parts List is available at www.MillerWelds.com 6-4. +24 Volts DC Hot Contacts For Relay Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). 2 Control board PC1 can supply +24 volts DC from receptacle RMT2 to operate a customer-supplied relay for the Okay To Move signal. 3 1 2 3 4 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. 1 If voltage sensing is required, see Section 6-8. Install wrapper on unit. Required Items: Customer-supplied 24 volts DC relay coil with resistance greater than 240 ohms. Suppression diode (1A, 100V) such as type IN4002 through IN4004 across relay coil. . Machine torch equipped plasma cutter is shipped from the factory with plug connected to receptacle RMT1 (dry contacts). 4 White Remote Start Red Black +24 VDC Green + Relay Relay Contacts Okay To Move Remote Control Cable − Tools Needed: Torx 25 . +24 volts DC will activate relay coil after unit is triggered and the cutting arc is initiated. 243 336-A / 804 041-A OM-242 880 Page 31 . A complete Parts List is available at www.MillerWelds.com 6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). 2 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. 3 1 2 3 4 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. 1 If voltage sensing is required, see Section 6-8. Install wrapper on unit. Required Items: Customer-supplied isolated input module. . Machine torch equipped plasma cutter is shipped from the factory with plug connected to receptacle RMT1 (dry contacts). 4 White Remote Start Red Black +24 VDC Green + Output Remote Control Cable Okay To Move − Tools Needed: Torx 25 . +24 volts DC will activate relay coil after unit is triggered and the cutting arc is initiated. OM-242 880 Page 32 243 336-A / 804 041-A . A complete Parts List is available at www.MillerWelds.com 6-6. Dry Contacts Using An External Power Supply For Relay Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). 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. 2 1 2 3 Control Board PC1 Receptacle RMT1 Receptacle RC61 Machine torch equipped units are shipped from factory with plug connected to receptacle RMT1. 1 Be sure that remote control cable plug is connected to RC61 on rear of unit. If voltage sensing is required, see Section 6-8. Install wrapper on unit. Required Items: Customer-supplied +24 volts DC power supply. 24 volts DC relay coil with resistance greater than 240 ohms. Suppression diode (1A, 100V) such as type IN4002 through IN4004 across relay coil. 3 White Remote Start Red Green Black + +24 VDC Power Supply − Remote Control Cable Relay Tools Needed: Relay Contacts Okay To Move Torx 25 . +24 volts DC will activate relay coil after unit is triggered and the cutting arc is initiated. 243 336-A / 804 041-A OM-242 880 Page 33 . A complete Parts List is available at www.MillerWelds.com 6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). 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. 2 1 2 3 Control Board PC1 Receptacle RMT1 Receptacle RC61 Unit is shipped from factory with plug connected to receptacle RMT1. 1 Be sure that remote control cable plug is connected to RC61 on rear of unit. If voltage sensing is required, see Section 6-8. Install wrapper on unit. Required Items: Customer-supplied +24 volts DC power supply. Isolated input module. 3 White Red Green Black Remote Start + +24 VDC Power Supply − Remote Control Cable Tools Needed: Output Torx 25 Okay To Move . +24 volts DC will activate relay coil after unit is triggered and the cutting arc is initiated. 804 041-A OM-242 880 Page 34 . A complete Parts List is available at www.MillerWelds.com 6-8. Remote Voltage Sense Connection ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). Remote voltage sense is an arc voltage output signal for automatic torch height adjustment. 1 2 1 3 Snap-in Blank Secondary Interconnect Board PC4 Receptacle RC48 Remove snap-in blank from rear panel. Route plug end of cable through opening in rear panel. Route plug end of cable over to PC4. Allowing adequate slack inside the machine, secure cable and strain relief by snapping strain relief into opening in rear panel. Connect plug to RC48 on PC4. Install wrapper on unit. Cut off crimped terminals on lead ends, and connect lead 1 to +volts DC (work) and lead 2 to −volts DC (electrode) on customer-supplied voltage sense device. 3 Tools Needed: Torx 25 2 Ref. 804 041-A / 243 336-A 6-9. Shield Sense Tab . Shield sense tab is located in the consumable storage box on left side of unit wrapper. Shield sense tab is included only with units originally sold with machine torches. Shield sense tab provides feedback to a compatible torch height controller before starting the cutting process. Place the shield sense tab between the cup and shield. OM-242 880 Page 35 . A complete Parts List is available at www.MillerWelds.com 6-10. Cut Charts 60 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 Tip 212 733 219 676 Electrode Swirl Ring 212 724 212 734 ICE-60TM Torch 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. . Shield sense tab is located in the consumable storage box on left side of unit wrapper. Mild Steel Arc Current Arc Voltage 134 136 60 Pierce Delay 0 Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 16 Ga 1.5 627 15926 502 12751 10 Ga 3.4 266 6756 213 5405 136 0.25 1/4 6.4 131 3327 85 2163 141 0.75 3/8 9.5 63 1600 41 1041 143 1.50 1/2 12.7 44 1118 29 726 147 5/8 15.9 31 787 20 508 153 3/4 19.0 22 559 14 356 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 15875 406 10312 136 0.25 10 Ga 3.4 244 6198 159 4039 139 0.50 1/4 6.4 112 2845 73 1849 145 0.75 3/8 9.5 53 1346 34 864 145 2.00 1/2 12.7 36 914 23 594 149 5/8 15.9 26 660 17 432 154 3/4 19.0 18 457 12 305 Arc Current Arc Voltage Aluminum Arc Current Arc Voltage 135 138 60 139 Material Thickness Maximum Cut Speeds Optimum Cut Speeds Pierce Delay Inches mm IPM mm/min IPM mm/min 0 1/16 1.6 666 16916 433 10998 1/8 3.2 400 10160 260 6604 0.25 1/4 6.4 147 3734 96 2427 146 0.75 3/8 9.5 74 1880 48 1219 147 1.50 1/2 12.7 51 1295 30 762 5/8 15.9 33 838 21 533 153 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-242 880 Page 36 . A complete Parts List is available at www.MillerWelds.com 40 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 Tip 212 733 212 725 Electrode Swirl Ring 212 724 212 734 ICE-60TM Torch 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. . Shield sense tab is located in the consumable storage box on left side of unit wrapper. Mild Steel Arc Current Arc Voltage 25 Pierce Delay Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 147 26 Ga 0.5 638 16205 415 10541 148 22 Ga 0.8 500 12700 325 8255 18 Ga 1.3 312 7925 203 5156 149 0 152 40 Material Thickness 16 Ga 1.5 176 4470 114 2896 144 0.25 14 Ga 1.9 640 16256 221 5613 146 0.50 10 Ga 3.4 152 3861 99 2510 147 0.75 3/16 4.7 97 2464 63 1600 149 1.00 1/4 6.4 73 1854 47 1205 Stainless Arc Current Arc Voltage 25 139 139 Pierce Delay 0 142 143 40 0.25 143 Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 26 Ga 0.5 631 16027 410 10414 22 Ga 0.8 496 12598 322 8179 18 Ga 1.3 592 15037 335 8509 16 Ga 1.5 374 9500 243 6172 14 Ga 1.9 224 5690 146 3698 147 0.50 10 Ga 3.4 107 2718 70 1778 149 0.75 3/16 4.7 67 1702 44 1118 149 1.00 1/4 6.4 48 1219 31 792 Aluminum Arc Current Arc Voltage 25 40 150 151 Pierce Delay 0 Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 1/32 0.8 610 15494 397 10084 1/16 1.5 188 4775 122 3104 146 0.25 3/32 2.4 293 7442 190 4826 149 0.50 1/8 3.2 276 7010 179 4557 150 1.00 1/4 6.4 78 1981 51 1288 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-242 880 Page 37 . A complete Parts List is available at www.MillerWelds.com 40 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch tip and workpiece for all cuts. Deflector Retaining Cap 212 736 212 733 Tip 212 729 Electrode Swirl Ring 212 724 212 734 ICE-60TM Torch Mild Steel Arc Current Arc Voltage Pierce Delay 125 25 128 128 0 130 40 129 0.25 Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 26 ga 0.5 550 13970 353 8966 22 ga 0.8 484 12294 315 8001 18 ga 1.3 232 5893 151 3830 16 Ga 1.5 167 4242 109 2757 14 Ga 1.9 336 8534 218 5547 Stainless Arc Current Arc Voltage 25 40 Pierce Delay Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 26 ga 0.5 561 14249 365 9271 22 ga 0.8 453 11506 295 7493 123 18 Ga 1.3 500 12700 325 8255 127 16 GA 1.5 365 9271 237 6026 14 GA 1.9 220 5588 143 3632 127 127 0 0.25 128 Aluminum Arc Current Arc Voltage 25 40 125 127 127 Pierce Delay 0 0.25 Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm/min IPM mm/min 1/32 0.8 564 14326 366 9296 1/16 1.5 236 5994 153 3886 3/32 2.4 268 6807 174 4425 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-242 880 Page 38 . A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. . Maintain more often during severe conditions. l = Replace Reference Each Use n Torch Tip, Electrode, And Shield Cup Every Week Every 3 Months n Gas/Air Pressure n Shield Cup Shutdown System l Damaged Or Unreadable Labels l Cracked Parts ~ Air Filter/Regulator Assembly Filter n Gas/Air Hose n l Torch Body, Cable Every 6 Months OR ~ Inside Unit 7-2. Checking Shield Cup Shutdown System . Power must be reset whenever the cup shutdown system is activated. Always turn Off power when changing or checking consumables. Do NOT overtighten torch shield cup. Gently finger tighten cup onto torch. 1 1 Torch Shield Cup Turn Power On and loosen shield cup. If shutdown system works properly, Cup light comes on. If not, immediately turn Off power and have Factory Authorized Service Agent check unit. If system works properly, retighten cup and reset power. . DO NOT overtighten torch shield cup. Ref. 801 300-A OM-242 880 Page 39 . A complete Parts List is available at www.MillerWelds.com 7-3. 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) to 1/16 in. (2 mm) maximum pit depth depending on acceptable cut quality 5 Worn New 3 Make sure this area is clean of any debris. 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 Tip 4 Opening OM-242 880 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. Performance may degrade 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. . A complete Parts List is available at www.MillerWelds.com 7-4. Wrapper Removal/Installation 4 ! Turn off power, and disconnect input power plug from receptacle or turn off and lockout/tagout line disconnect device before working on unit. ! Significant DC voltage can remain on capacitors after unit is Off. Check to see that front panel lights (LEDs) have stopped flashing and are off before removing wrapper. 1 Wrapper 2 Front Bezel 3 Rear Bezel 4 Torx Screw (Fine Thread) 1 3 2 Remove 13 screws from wrapper, and front and rear bezels as shown. Spread open tops of front and rear bezels. 5 1 3 2 Consumables Storage Compartment Opening Be sure that opening clears the storage compartment. Lift wrapper off unit. . When installing wrapper, front and rear wrapper flanges must be on outside of front and rear portion of metal chassis. 1 5 Tools Needed: Torx 25 805 209-A OM-242 880 Page 41 . A complete Parts List is available at www.MillerWelds.com 7-5. Checking Or Replacing Filter Element (Part No. 227 877) 1 ! Turn off power, and disconnect input power plug from receptacle or turn off and lockout/tagout line disconnect device before working on unit. ! Significant DC voltage can remain on capacitors after unit is Off. Check to see that front panel lights (LEDs) have stopped flashing and are off before removing wrapper. Remove wrapper from unit (see Section 7-4). 1 Rear Bezel Remove rear bezel from unit. 2 Filter Bracket Screws Remove filter bracket screws. Pull filter bracket toward front of unit until gas/air supply fitting is past rear panel, and swing filter assembly out to the side to allow filter cup removal. 2 3 Filter Base 4 Filter Element (Part No. 227877) 5 Filter Cup Unscrew filter cup from base. Remove cup. Unscrew filter element from base. 3 4 Check filter element for dirt and moisture, and replace if necessary. Be sure that all parts are clean and dry. Reinstall filter element, and secure filter cup. Secure filter bracket to rear panel. 5 Reinstall wrapper and rear bezel. Tools Needed: 5/16 in. rEF. 805 211-A OM-242 880 Page 42 . A complete Parts List is available at www.MillerWelds.com 7-6. Status/Trouble Lights V POWER PRESSURE CUP TEMP Light Power Condition Status/Possible Cause On Input power is okay. Off When Power light is on, system is normal if these lights are off. Power Flashing rate is steady for 15 seconds or until torch trigger is pressed again, whichever comes first. Input power was above 300 volts AC or below 156 volts AC, but has returned to normal. Power Repetitive flashing rate of two quick cycles, then a one second pause. Input power is above 300 volts AC or below 156 volts AC or precharge PTCs have overheated. Pressure On No or low [below 40 psi (276 kPa)] input pressure. Pressure Flashing rate is steady for 15 seconds or until torch trigger is pressed again, whichever comes first. Regulated pressure in the unit is low. Pressure Repetitive flashing rate of two quick cycles, then a one second pause for a 15 second period. Regulated pressure in the unit is high. On Torch cup is loose or off. Once cup is finger tightened, unit power must be cycled off and back on again. Cup Flashing rate is steady for 15 seconds or until torch trigger is pressed again, whichever comes first. No arc was established. Plasma system failed to strike an arc. Cup Repetitive flashing rate of two quick cycles, then a one second pause for a 15 second period or until torch trigger is pressed again, whichever comes first. No pilot arc established possibly due to a loss of current. Cup Repetitive flashing rate of three quick cycles, then a one second pause for a 15 second period or until torch trigger is pressed again, whichever comes first. Consumables in torch failed to separate during pilot arc possibly due to being stuck. On Power source overheated. On (indefinitely) Power source temperature sensors may have failed or ambient temperature is below -22° F (-30° C). Flashing rate is steady (indefinitely). Power source temperature sensor provided inaccurate readings, but returned to normal. Unit power must be cycled off and back on again. Pressure/Cup/Temp Cup Temperature Temperature Temperature For system troubleshooting see Section 7-7 and Section 7-8. OM-242 880 Page 43 . A complete Parts List is available at www.MillerWelds.com 7-7. Troubleshooting Power Source Trouble Remedy No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see Section 7-3). arc. Check for damaged torch or torch cable. 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. Check retaining cup. DO NOT overtighten cup, hand-tighten only. No cutting output; Power light off; status Place Power switch in On position. lights off; fan motor FM does not run. Place line disconnect device in On position (see Section 4-13 or 4-14). Check line fuse(s) and replace if needed or reset circuit breakers (see Section 4-13 or 4-14). Pilot arc working; no cutting output; Be sure work clamp is connected to a clean, rust-free workpiece. Power light on; status lights off; fan motor running. Clean or replace worn consumables as necessary (see Section 7-3). No gas/air flow; Power light on; status 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 status light On. Check for sufficient gas/air supply pressure (see Section 4-6). Check for dirty air filter and replace, if necessary (see Section 7-5). Check air lines for leaks. Have Factory Authorized Service Agent check pressure switch and control board. Cup status light On. Check torch shield cup (see Section 7-2). Reset power switch. If trouble persists, have Factory Authorized Service Agent check torch and unit. Temperature status light On. Unit overheating (see Section 4-3). Allow fan to run; the Trouble light goes out when the unit has cooled. If trouble persists, have Factory Authorized Service Agent check unit. Temperature status light On indefinitely. Power source temperature sensors may have failed or ambient temperature is below −22° F (−30° C). Operate unit in a warmer ambient temperature. Temperature status light flashing rate Power source temperature sensor(s) provided inaccurate feedback, but have returned to normal. Unit steady (indefinitely). power must be cycled off and back on again. Power light flashing steady for 15 sec- Input power was above 300 volts AC or below 156 volts AC, but has returned to normal. Have a qualified onds or until torch trigger is pressed, technician check input line power at idle and while cutting. whichever happens first. Power light is flashes at a rate of two Input power is above 300 volts AC or below 156 volts AC. Have a qualified technician check input power quick cycles and then a one second at idle and while cutting. pause. Pre-charge PTCs are overheated. Allow 15 minutes for unit to cool. Pressure status light flashes at a rate of Unit regulated pressure is too high. Check for input pressure between 90-120 PSI (see Section 4-6). If two quick flashes and then a one second trouble persists, have a Factory Authorized Service Agent check unit. Reset power switch. pause for a duration of 15 seconds. Pressure status light flashes steady for Regulated pressure is too low. Check torch for leaks. Check for input pressure between 90-120 PSI dur15 seconds or until torch trigger is ing cutting (see Section 4-6). pressed, whichever happens first. OM-242 880 Page 44 . A complete Parts List is available at www.MillerWelds.com Trouble Arc goes out while cutting. Remedy Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece. Make sure drag shield is on the workpiece or the extended tip is 1/16 in. (1.6 mm) to 1/8 in. (3.2 mm) from workpiece while cutting (see Section 5-4). On thin metal, check travel speed. Constant travel speed must be maintained when cutting thin material. Check that compressed air is clean, dry and oil-free. Use filter kit 300491 or 228926, if necessary. Check retaining cup. DO NOT overtighen cup, hand-tighten only. Clean or replace worn consumables as necessary (see Section 7-3). Cup status light flashes steady for 15 System failed to strike an arc. Power source failed to deliver current to the output. Check continuity of seconds or until torch trigger is pressed, torch connections (pilot lead and electrode lead). If torch connections are good, have a Factory Authowhichever happens first. rized Service Agent check unit. Cup status light flashes at a rate of two No pilot arc established. The power source failed to maintain a pilot arc. Try a different set of torch conquick cycles and then a one second sumables (tip and electrode). Check for input pressure between 90-120 PSI. pause for 15 seconds or until torch trigger is pressed, whichever comes first. Cup status light flashes at a rate of three Power source detected that tip and electrode failed to separate when gas valve turned on. Check that quick cycles and then a one second cup is not too tight (finger tight only). Check for correct torch consumables. Check for gas flow through pause for 15 seconds or until torch trig- the torch head. ger is pressed, whichever comes first. 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 input air pressure. Check that compressed air is clean, dry and oil-free. Use filter kit 300 491 or 228 926, if necessary. Maintain 1/8 in (3.2 mm) standoff for extended tip cutting over 40 amps. Do not drag tip on workpiece. If trouble persists, have system checked by a Factory Authorized Service Agent. OM-242 880 Page 45 . A complete Parts List is available at www.MillerWelds.com 7-8. Troubleshooting Torch Trouble Arc goes on and off while cutting. Remedy Torch travel speed too slow; increase travel speed (see Section 5-4). Clean or replace worn consumables as necessary (see Section 7-3). Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece. Arc goes out while cutting. Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece. Make sure drag shield is on the workpiece or the extended tip is 1/16 in. (1.6 mm) to 1/8 in. (3.2 mm) from workpiece while cutting (see Section 5-4). On thin metal, check travel speed. Constant travel speed must be maintained when cutting thin material. Check that compressed air is clean, dry and oil-free. Use filter kit 300491 or 228926, if necessary. Check retaining cup. DO NOT overtighen cup, hand-tighten only. Clean or replace worn consumables as necessary (see Section 7-3). Sparks come out top of cut or cut is not Torch travel speed too fast; reduce travel speed (see Section 5-4). clean. Clean or replace worn consumables as necessary (see Section 7-3). Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece. Unit not capable of cutting metals thicker than rating (see Section 4-2) or faster than shown in Section 5-7. OM-242 880 Page 46 Notes OM-242 880 Page 47 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-242 880 Page 48 243 018-C OM-242 880 Page 49 SECTION 9 − PARTS LIST . A complete Parts List is available on-line at www.MillerWelds.com 9-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts . . . . . . . . . . . . . . . . 234843 . . Label, Ice 60t Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 227877 . . Filter, Air Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 234838 . . Cable, Work 20 Ft 6 Ga W/Clamp And Male Dinse . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 234930 . . Cable, Work 50 Ft 6 Ga W/Clamp And Male Dinse . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 213619 . . Clamp, Work 300 A Stl Chrome Pld W/Copper Contacts . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 213620 . . Contact Tip, Work Clamp 300amp Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . 234132 . . ICE−60T 20 Ft Hand Held Replacement Torch Or . . . . . . . . . . . . . . . . 234134 . . ICE−60T 50 Ft Hand Held Replacement Torch . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 234136 . . ICE−60TM 25 Ft Machine Replacement Torch . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 234138 . . ICE−60TM 50 Ft Machine Replacement Torch . . . . . . . . . . . . . . . . . . . . . . . . . . 1 To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside bottom of plasma cutter base) is required when ordering parts from your local distributor. StandardCutting 60A Retaining DragShield Cup 212730 212733 Tip 219676 Shield 212732 (MachineCutting) 40A Retaining DragShield Cup Tip 212730 212733 212725 Electrode 212724 SwirlRing 212734 O-Ring 212735 Applysilicone grease(169231) beforeinstalling. ICE-60T CONSUMABLES ExtendedCutting 60A Deflector 212736 40A Deflector 212736 Retaining Cup 212733 Tip 219682 Retaining Cup 212733 Tip 212729 CAUTION FAILURETOREPLACE WORNTIPOR ELECTRODEMAY DAMAGETORCHAND VOIDWARRANTY. S Turnoffpowerbefore Gouging 60A Shield 212731 Retaining Cup 212733 Tip 219680 checkingtorchparts. S Checkbeforeeachuseand hourlyduringoperation. 234843-B CupInstallation:Donotovertighten—finger-tightonly. 234 843-B Figure 8-1. Consumable Parts For ICE-60T To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside bottom of plasma cutter base) is required when ordering parts from your local distributor. OM-242 880 Page 50 Item Part No. No. Item Part No. No. Description 1 2 3 4 5 6 7 8 215 594 215 478 215 479 185 833 190 220 215 592 215 477 234 170 8 234 171 Handle W/Screws (1) Kit, Cup Sensor (1) Torch Head Repair Kit (1) Switch Assy w/Spring (1) Trigger Spring (1) Switch Trigger (1) Main Body (1) Torch Lead, Replacement w/Quick Disconnect 20ft (1) Torch Lead, Replacement w/Quick Disconnect 50ft (1) 9 10 11 215 606 212 735 234 829 169 231 234 132 234 134 Description Clip, Retaining (1) O-Ring, Main Body (1) Kit, Ice 60T/TM Quick Connect W/Wing Head Fastener (1) Grease, Silicon Torch, Replacement 20 ft (1) Torch, Replacement 50 ft (1) 11 8 9 1 See Figure 8-1 for additional consumable parts. 2 7 6 3 5 10 1 4 804 035-A Figure 8-2. Torch, ICE-60T To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside bottom of plasma cutter base) is required when ordering parts from your local distributor. OM-242 880 Page 51 Item Part No. No. 1 2 2 3 4 5 6 7 See Figure 8-1 for additional consumable parts. Description 215 607 234 172 234 173 215 599 215 598 195 513 234 136 234 138 220 240 246 285 234 829 215 606 Sleeve, Torch Position (1) Torch Lead, Replacement W/QD 25 ft (1) Torch Lead, Replacement W/QD 50 ft (1) Torch Sleeve (1) Main Body W/Switch (1) Remote Pendant Control (1) Torch, Replacement 25 ft (1) Torch, Replacement 50 ft (1) Cable, Remote Control Trigger 25 ft (1) Cable, Remote Voltage Sense 26.5 ft (1) Kit, Ice-60t/Tm QD W/Wing Head Fastener Clip, Retaining 6 1 2 5 4 3 7 804 036-A Figure 8-3. Torch, ICE-60TM A complete Parts List is available on-liine at www.MillerWelds.com To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside bottom of plasma cutter base) is required when ordering parts from your local distributor. OM-242 880 Page 52 Notes Notes Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) 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. This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its * Accessory (Kits) original retail purchaser that new Miller equipment sold after the * Canvas Covers effective date of this limited warranty is free of defects in material * Induction Heating Coils and Blankets, Cables, and and workmanship at the time it is shipped by Miller. THIS Non-Electronic Controls WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * M-Guns WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * MIG Guns and Subarc (SAW) Guns WARRANTIES OF MERCHANTABILITY AND FITNESS. * Remote Controls and RFCS-RJ45 Within the warranty periods listed below, Miller will repair or replace * Replacement Parts (No labor) any warranted parts or components that fail due to such defects in * Roughneck Guns material or workmanship. Miller must be notified in writing within * Spoolmate Spoolguns thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor. 1. 2. 3. 4. 5. 5 Years Parts — 3 Years Labor * Original main power rectifiers only to include SCRs, diodes, and discrete rectifier modules 3 Years — Parts and Labor * Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) * Inverter Power Sources (Unless Otherwise Stated) * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Smith 30 Series Flowgauge and Flowmeter Regulators (No Labor) * Transformer/Rectifier Power Sources * Water Coolant Systems (Integrated) 2 Years — Parts * Auto-Darkening Helmet Lenses (No Labor) 1 Year — Parts and Labor Unless Specified * Automatic Motion Devices * CoolBelt and CoolBand Blower Unit (No Labor) * External Monitoring Equipment and Sensors * Field Options (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) * Flowgauge and Flowmeter Regulators (No Labor) * RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors * HF Units * ICE Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers, and Electronic Controls/Recorders * Load Banks * Motor Driven Guns (w/exception of Spoolmate Spoolguns) * PAPR Blower Unit (No Labor) * Positioners and Controllers * Racks * Running Gear/Trailers * Spot Welders * Subarc Wire Drive Assemblies * Water Coolant Systems (Non-Integrated) * Weldcraft-Branded TIG Torches (No Labor) * Work Stations/Weld Tables (No Labor) 6 Months — Parts * Batteries * Bernard Guns (No Labor) * Tregaskiss Guns (No Labor) Miller’s True Blue® Limited Warranty shall not apply to: 1. 2. 3. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.) 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. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (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 2010−01 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams For International Locations Visit www.MillerWelds.com Welding Process Handbooks To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 © 2010 Miller Electric Mfg. Co. 2010−01
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