Miller QUICK CUT 3800 Owner's Manual

May
Form:
1997
OM-181 460B
Effective With Serial No. KH387456
OWNERS
MANUAL
Auto Arcfi Quick Cut 3800
Air Plasma
Cutting System
For Plasma Arc
Cutting
Amperes Input at
Rated Output,
60
Rated
Hz,
Plasma
Single-Phase
Rated
Output
115 VAC
115 V
230 V
KVA
KW
115 VAC
115 VAC
26
17
Input: 3.1
(0.05*)
Input: 2.4
(O.04~)
(0.4*)
(0.2*)
230 VAC
230 VAC
Input. 4.0
(0.05*)
Input: 3.1
(0.04*)
Cutting
Plasma
Gas Flow/
Gas
Pressure
10 1PM
4.5 CFM
(129 Umin)
Input: 1/4 in
(6 mm)
At 60 PSI
230 VAC
(414 kPa)
Input: 5/16
(8 mm)
Capacity
At
Max
OCV
Input:
20 A ' 89 Volts DC
(20
A
Input Circuit);
25 A ' 89 Volts DC
A
Input Circuit);
Input:
25 A ' 89 Volts DC;
(30
230 VAC
35%
Duty Cycle
In All
115 VAC
Air Or
Nitrogen
Only
265 Volts DC
in
Cases
While
idling
auto_arc 6/95
ST-801 302-B
PRINTED IN USA
If
J
ax
L
N~t
LIMITED WARRANTY
(Equipment
This limited werrenty supersedes all
with
Effective January 1, 1997
serial number preface of KU
a
previous msnufscturers wsrrenties snd is exclusive with
LIMITED WARRANTY
Subject to the terms snd conditions below, wsrrsnts to its
originsl retell purcheserthet new equipment sold efter the effective dste of this lim
ited werrerrty is free of defects in msterlsl end worirmenship et the time it is shipped
from fectory. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OThER WAR
no
newer)
or
other
gusrentses
or
wsrrsnties
expressed
or
implied.
MIG Guns/hG Torches
*
APT, ZIPCUT & PLAZCUT Model Plesme Cutting Torches
Remote Controls
*
lOts
Accessory
RANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTiES OF MER
CHANTABILITY AND FITNESS.
Replacement Pens (No lebor)
*
Spoolmete
185
Within the
warrentyperiods listed below, manufecturerwilt repeiror replece snywer
or components that fell due to such defects in meterial orworkmanehip.
Menufecturer must be notified in writing within thirty (30) days of such defect or fell
rented pelts
Limited
ure, et which time menufecturer will provide instructions
cedures to be followed.
1.
on
the werrenty cleim pro
Werrenty ehsll
Items fumished
not
epply
to:
bymenufecturer, but msnufsctured by others, such es engines
ere covered bythe menufecturerewerrenty,
ortrsde accessonee. These items
if any.
Menufecturer shell honor warrenfy claims. on werrented equipment listed below in
the event of such
2.
feilure within the warrenty time periods. All werrenty time periods
equipment wex delivered to the originel rebel purcheser, or
one yeer eher the equipment is sent to e North Americen distributor or eighteen
months efter the equipment is sent to en Intemetionel distributor.
e
1.
Originel
2.
3.
5YeamPerts3YeersLebor
*
Invertem
msin power rectifiers
(input
end
Pleems Arc
Cutting
Power Sources
Supplies
Inteltitig
Robots
Engine Driven Welding Generetom
(NOTE: Engines ere werrented eeperetely by
3.
1 Yeer
upon ectuel
retum of the
chese
price (less reesoneble deprecietion bxsed
goods
et customers risk end expense. Mxnufecturere option of repeir or replece
FOB., Fectory at Appleton, Wisconsin, or FOB. et en euthorized ser
use) upon
ment wilt be
the
engine menufecturer.)
facility as determined by menufecturer. Therefore no compensation
bursement for trensportation costs of eny kind will be allowed,
vice
Pens end Lsbor
Motor Driven Gune
Equipment thet hes been modified by eny party other then menufecturer, or
equipment thet hex been improperiy inetelled, improperfy opersted or misused
bsssd upon industry atenderds, or equipment which has not hed reexoneble
end necexeery meintenence, or equipment which hex been used for operstion
outside of the specificetions for the equipment.
In the event of 5 werrenty claim covered by this werrenry, the exclusive remedies
shell be, xl menufecturers option: (1) repeir or(2( replacement; or, where authorized
in writing by manufacturer in eppropriete cexex, (3) the reeeoneble cost of repeir or
reptecement et en euthorized service ststion; or (4) payment of orcredit for the pur
Semi-Automatic end Autometrc Wire Feeders
Inverter Power
as contect tips, cutting nozzles, contectors,
pens thet fell due to normel weer.
MANUFACTURERS PRODUCTS ARE INTENDED FOR PURCHASE AND USE
BY COMMERCIALI1NDUSTRIAL USERS AND PERSONS TRAINED AND EXPE
RIENCED IN ThE USE AND MAINTENANCE OF WELDING EOUIPMENT
Trensformer/Rectifier Power Sources
*
or
output rectifiers onily)
Pens and Lsbor
3 Yeera
Consumeble components; such
reteye, brushes, slip rings,
etsi on the dete thst the
(w/exception of Spoolmete 185)
or
reim
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENTSHALL MANUFAC
Process Controllers
*
Poeitioners end Controllers
*
Autometic Motion Devices
TURER BE UABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CON
SEQUENT1AL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED
ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
Orbitsl Weld Heede
IHPS Power Sources
*
Weter Coolent
*
HFUnits
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTA11ON ASTO PERFORMANCE, AND ANY
Systems
REMEDY
Grids
*
FOR
BREACH
OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHTARISE BY IMPLICATiON,
Loed Benks
OPERA11ON OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WiTH RESPECT TO ANY AND ALL EOUIPMENT
SoXTrensformere
FURNISHED BY MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MAN
Spot
Welders
UFACTURER.
Running Geer/Treilers
Pleeme Cuthng Torches (except APT, ZIPCUT & PLAZCUT Models)
Deutz Engines (outside North Americe)
Field Options
(NOTE: Field options ere covered under the limited werrenty for the re
meining werrenty period of the product they ere inetelled in, or fore mini
whichever is greeter.)
mum of one yeer
4.
6 Months
5.
gO
Deye
Some etetes in the U.S.A. do not ellow limitations of how long en implied werrerrty
lasts, or the exclusion of incidental, indirect, special or consequentiel dameges, so
the above limitetlon or exclusion mey not epply to you. This warrenty provides spe
cific legal rights, end other rights may be eveileble, but mey vary from state to stete.
In Ceneda, legislation in some provinces provides for certein additionel warranties
or remedies other then as stated herein, end to the exrent that they mey not be
weived, the limitations end exclusions set out above mey not epply. This Limited
Werranty provides specific legsl rights, end other rights mey be evaileble, but mey
very from province to province.
Bettenee
Pens end Labor
__~1
:i~U
I
RECEIVING-HANDLING
Before
Unpacking eqUjpment,
with the
delivering
check carton for any
carrier. AssiStance for
filing
damage that may have occurred during shipment, File any claims for (oss or damaga
sett(ing claims may be obtained from distributor and/or eqUjpment manufacturers
or
Transportation Department.
When
requesting information about
following spaces to
nameplate.
Use the
or
thjs
record Model
equipment, always provide
Designation and
Serial
or
Model
Style
Designation
and Serial
or
Style
Number,
Number of your unit. The information is loca(ed
on
the
rating label
Model
_________
Serial
or
Style No.
Date of Purchase
brand_wer ~
SECTION 1
OM-181 460B
1-1.
SAFETY FOR PLASMA ARC CUTTING
-
8afety._poml
5/9~
4195
Symbol Usage
4A
A Marks
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
a
special safety message.
I
~ Means NOTE; not safety related.
This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards. Consult symbols and re!ated instructions be!ow for necessary
~
actions to avoid the hazards.
________________________________
1-2.
Plasma Arc
Hazards
Cutting
WARNING
a
The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The
safety information given below is only a summary of the more complete safety information found in the
Safety Standards listed in Section 1-4. Read and follow all Safety Standards.
Only qualified
persons should install, operate,
maintain, and repair this unit.
During operation, keep everybody, especially children,
away.
7.
Do not cut
Hot metal and sparks blow out from the cuthng arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and bums. Check
and be sure the area is safe before doing any
8.
Connect work cable to the work
can cause
fire
or
cutting.
and others from
1.
Protect
2.
Do not cut where
yourself
Be alert that
6.
sparks
cover
9.
fire
on
(10.7 m) of the cutting arc.
approved covers.
must be
If
them with
and hot materials from
can
the hidden side.
ELECTRIC SHOCK can kill.
Touching live electrical parts can
Do not touch live electrical parts.
2.
Wear
3.
Insulate
4.
5.
6.
7.
and
15. Remove any combustibles, such as
from your person before doing any
checking, cleaning,
or
or
ground.
changing torch
9.
10.
11. Turn offal!
12.
Inspect
equipment
and
14. Ground the
required by
when not in
replace any
worn or
use.
damaged
17.
to a
good
(earth) ground
electrical
if
codes.
Repair
or
replace
a safety harness if working above floor level.
Keep all panels and covers securely in place.
bypass or try to defeat the safety interlock systems.
only torch(es) specified in Owners Manual.
and
when
20.
Keep away from
21.
good metal-to-metal contact to
workpiece (not piece that will fall away) or worktable as near the
cut as practical.
1.
Wear
2.
Wear proper
to its
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
workpiece
torch cable leads.
body.
only well-maintained equipment.
damaged parts at once.
Owners Manual and national, state, and local codes.
injury.
lighteror matches,
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
19. Use
FLYING SPARKS AND HOT METAL
butane
cutting.
conductor first.
18. Do not
can cause
a
making input connections, attach proper grounding
When
Disconnect
equipment according
cap.
sure that input power cord ground wire is properly
ground terminal in disconnect box orthat cord plug
is connected to a properly grounded receptacle outlet
always
verify the supply ground.
parts.
input power before installing or servicing this
equipment. Lockout/tagout input power according to OSHA
CFR 191 0.147 (see Safety Standards).
a
connected to
16. Wear
this
vapors.
Check and be
Do not touch torch parts if in contact with the work
ground
or
vessels.
14. Do not locate unit on or over combustible surfaces.
cause
body protection.
or
protective garments such as leather gloves, heavy
shirt, cuff less trousers, high shoes, and
15. Use
install and
atmospheres containing explosive dust
pressurized cylinders, pipes,
13. Wear oil-free
yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Properly
area as
and
emptied
13. Do not wrap torch cable around your
dry, hole-free insulating gloves
Turn off power before
cutting
12. Do not cut containers that have held combustibles.
8.
fatal
shocks or severe bums. The torch and work circuit
is electrically live whenever the output is on. The
input power circuit and machine internal circuits are
also live when power is on. Plasma arc cutting
requires higher voltages than welding to start and
maintain the arc (200 to 400 volts dc are common), but also uses
torches designed with safety interlock systems which turn off the
machine when the shield cup is loosened or if tip touches electrode
inside the nozzle. Incorrectly installed or improperly grounded
equipment is a hazard.
1.
drums.
potentially flammable materials inside
properly cleaned first.
Never cut containers with
10. Do not cut in
small cracks and
can cause
close to the
as
or
to
11. Do not cut
cutting
easily go
openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that cutting on a ceiling, floor, bulkhead, or partition
through
5.
possible, tightly
and hot metal.
tanks
as
strike flammable matenal.
can
Remove all flammables within 35 ft
this is not
4.
flying sparks
flying sparks
on
prevent cutting current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
practical
they
3.
closed containers such
explosion.
CUTTING
3.
Clamp
work
torch
cable
approved face shield
entering
pilot
arc
trigger
ear
safety goggles
or
body protection
Wear flame-resistant
from
tip
is
pressed.
with
to
plugs
with side shields.
protect skin.
or ear
muffs to prevent sparks
ears.
OM-181 460 Page 1
I
ARC RAYS
,~
-
1.
burn eyes and skin.
can
NOISE
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can bum eyes and skin.
Wear face protection (helmet or shield) with correct shade of
filter to protect your face and eyes when cutting or watching.
ANSI Z49.i (see Safety Standards) suggests a No. 9 shade
can
damage hearing.
Prolonged noise from some cutting applications
damage hearing if levels exceed limits
specified by OSHA (see Safety Standards).
can
5.
Use
6.
Wam others
ear plugs or ear muffs if noise
nearby about noise hazard.
approved
level is
high.
(with
No. 8 as minimum) for all cutting currents less than 300
amperes. Z49.i adds that lighter filter shades may be used
when the arc is hidden by the workpiece. As this is normally the
2.
3.
4.
FUMES
AND
GASES
hazardous to your health.
Cutting produces fumes
these fumes and gases
be
can
2.
3.
For Plasma Arc
Cutting
Keep your
6080
exhaust at the
5.
7.
arc to
If ventilation is poor,
approved air-supplied respirator.
Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals to be cut, coatings, and
use an
Read the Material
can cause
injury.
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the bum
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.
1.
Keep away from
Do not
grip
the torch
material
near
CYLINDERS
cutting path.
can
explode if damaged.
confined space
a
an
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.
3.
The
4
~
pilot arc can cause bums keep away from torch tip when
trigger is pressed.
Wear properflame-retardantclothing covering all exposed body
areas.
5.
Point torch away from your body and toward work when
the torch
pilot
trigger
immediately.
input power before
parts.
arc comes on
6.
Turn off power
7.
disassembling torch or changing torch
Use only torch(es) specified in the Owners
tip.
the
#8
only if it is well ventilated, or while
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 if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes when cut.
Work in
pressing
2.
#6
_________
8.
cleaners.
PLASMA ARC
#5
_______
_________
and gases. Breathing
be hazardous to your
use
I
I
I
4060
6.
If inside, ventilate the area and/or
cutting fumes and gases.
#4
I
2040
can
head out of the fumes. Do not breathe the fumes.
Minimum Shade Number
Amperes
Below 20
remove
4.
Eye Protection
Current Level In
wearing
health.
1.
Table 1.
with low current
cutting, the shades suggested in Table 1
are provided for the operators convenience.
Wear approved safety glasses with side shields.
Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
case
4.
and disconnect
source
Never allow electrical contact between
a
Manual.
plasma
arc
torch and
a
cylinder.
Gas
If
5.
Never cut
cylinder can explode. Since gas
cylinders are normally part of metalworking
processes, be sure to treat them carefully.
6.
Use
only
designed
7.
Turn face away from valve outlet when
8.
Keep protective cap
cylinders
damaged,
contain gas under
high pressure.
on a
Protect
compressed gas cylinders
slag, open flame, sparks,
from
mechanical shocks,
2.
3.
1-3.
Install and
cylinders in
them to a stationary support
prevent falling or tipping.
secure
excessive
heat,
and arcs.
an
upright position by chaining
or
equipment cylinder
rack to
Additional Installation,
HOT PARTS
Operation,
can cause severe
1.
Do not touch hot
2.
Allow
in
9.
use or
FLYING PIECES OF METAL
burns.
on
torch.
or
DIRT
can
injure
Page
eyes.
Wear safety glasses
2
in
condition.
place
connected for
over
opening cylinder valve.
valve except when
cylinder is
use.
Read and follow instructions on compressed gas cylinders,
equipment, and CGA publication P-i listed in Safety
Standards.
FALLING
EQUIPMENT
can
cause
serious personal injury and equipment
damage.
gas
lifting eye tci lift unit only, NOT running gear,
cylinders, or any other accessories.
2.
Use
equipment of adequate capacity
3.
If
1.
OM-181 460
parts in good
And Maintenance Hazards
parts bare handed.
cooling period before working
shield.
will result.
associated
Keep cylinders away from any cutting or other electrical circuits.
1.
explosion
correct gas cylinders, regulators, hoses, and fittings
for the specific application; maintain them and
associated
1.
pressurized cylinder
a
with side shields
or
face
Use
lift forks to
using
long enough
unit.
move
to extend
unit, be
to lift unit.
sure
forks
beyond opposite
are
side of
HIGH-FREQUENCY
interfere with radio
FIRE OR EXPLOSION can result from
unit
or
near
over,
on,
combustible surfaces.
services,
1.
communications
placing
A
Do not locate unit on, over,
or near
combustible
surfaces.
2.
1.
Do not install unit
2.
MOVING PARTS
can cause
1.
Keep away from moving parts
2.
Keep all doors, panels,
and securely in place.
injury.
such
covers, and
can
and
computers,
equipment.
only qualified persons familiar with
equipment perform this installation.
The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
If notified by the FCC about interference, stop
using the equipment at once.
Have the installation regularly checked and
Have
electronic
flammables.
near
RADIATION
navigation, safety
as
fans.
3.
guards closed
4.
maintained.
STATIC ELECTRICITY can
on circuit boards.
1.
Put
on
boards
2.
grounded
or
strap BEFORE handling
wrist
static-proof bags
ship PC boards.
OVERUSE can
EQUIPMENT.
Allow
5.
parts.
Use proper
move, or
damage parts
cause
MAGNETIC
and boxes to store,
OVERHEATED
=4
can
operation.
1.
2.
Pacemaker wearers keep away.
Wearers should consult their doctor before
plasma
near
Reduce amperage (thickness) or reduce
before starting to cut again.
FIELDS
FROM
HIGH
affect
pacemaker
CURRENTS
cooling period.
duty
arc
going
cutting operations.
SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
cycle
Follow rated
Keep high.frequency source doors and panels
tighfly shut, keep spark gaps at correct setting,
and use grounding and shielding to minimize the
possibility of interference.
duty cycle.
1.
Turn Oft inverter, disconnect
input
discharge
in
instructions
capacitors
Maintenance
input power, and
to
according
Section
before
touching any parts.
1-4.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49. 1, from Ameri
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
can
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Suite 501,
Highway,
OSHA 29 CFR 1910, from Superin
tendent of Documents, U.S. Government Printing Office, Washing
ton, D.C. 20402.
Arlington,
VA 22202.
Safety and Health Standards,
Recommended Practices for Plasma Arc
ing Society Standard
Cutting, American Weld
Welding Society,
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2,
from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
AWS C5.2, from American
550 N.W. LeJeune Rd, Miami, FL 33126
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Safe Practices For Occupation And Educational Eye And Face Pro
tection, ANSI Standard Z87.i, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
NFPA Standard 51 B, from Nation
Association, Batterymarch Park, Quincy, MA
CuttingAnd Welding Processes,
National Electrical
Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5.
al Fire Protection
02269.
EMF Information
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989):
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is of
very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
The
To reduce
.
.
fields in the
cables close
1.
Keep
2.
Arrange
3.
Do not coil
of the U.S.
.
magnetic
workplace,
use
the
following
procedures:
cables to
or
together by twisting
one
drape
taping them.
side and away from the operator.
cables around the
4.
Keep welding power
practical.
source
5.
Connect work
to
clamp
or
body.
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above
wearers.
procedures
are
also recommended for pacemaker
complete information.
Consult your doctor for
OM-181 460
Page
3
SECTION 2- iNSTALLATION
2-1.
Selecting
Dimensions And
42 lb
A Location
Weight
(19.1 kg)
17 in
(432 mm)
18 in
(457 mm)
Movement
1
Lifting
Handle
Use handle to lift unit.
A
Do not move or operate unit
where it could tip.
2
Hand Cart
Use cart
unit.
or
3
Rating
Use
rating
similar device to
move
Label
label to determine
input
power needs.
4
Line Disconnect Device
Locate
unit
near
correct
input
power supply.
A Special installation may be
required where gasoline or
volatile liquids are present
see
NEC Article 511
or
CEC
Section 20.
Location
lOin
(254 mm)
ST-801 303-B / ST-801 319-B
OM-181 460
Page
4
2-2.
Connecting
Work
Clamp
And Gas/Air
Supply
1
Work
2
Workpieco
Clamp
Connect work clamp to
paint-free
location on
close
as
cutting
to
a
clean,
workpiece,
area
as
possible.
~ Use
only clean, diy gas/air
(483 to 1034
with 70 to 150 psi
kPa)
Use only clean and dry
to 150 psi (483 to 1034
gas/air
with 70
kPa) pressure.
pressure.
3
Air
4
Gas/Air Inlet
5
Hose
6
Teflon
Filter/Regulator
Opening
Tape
Obtain hose with 1/4 NPT righthand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
Adjust gas/air pressure according
to Section 3-1.
A
Incorrect plasma gas can
and
torch
power
source damage. Use only air
or nitrogen for the plasma
cause
gas.
From Gas/Air
Supply
Tools Needed:
_ 5/8,1-1/8in
Ref. 51-091 547-C I Ref. ST-SQl 306-6
2-3.
Installing
Alternative
Plug
1
This procedure is necessary if the unit is to be connected to a 230
VAC receptacle, or to a 115 VAC receptacle that requires a plug
that is different from the supplied plug.
See Section 2-4 for instructions
switch for proper voltage.
on
setting input voltage
115 VAC
Supplied
Cut cord close to
selector
Plug
plug.
2
Alternative
3
Load 1
(Brass)
4
Load 2
(Brass) Terminal
Plug (230
Plug Shown)
5
Ground
6
Outer Shell
7
Cord
VAC
Terminal
(Green) Terminal
3
Strip
6
Gnp
cord
jacket
back
enough
separate conductors. Strip
7
ductors
4
5
enough to make good
tact with
plug
to
con
terminals. Make
con
plug
connections and reinstall outer
shell and cord grip. Tighten assem
bly screws
tighten.
onto shell. Do not over-
Tools Needed:
~ef. ST-801 305-A I ST-801 611
OM-181 460
Page
5
2-4.
Setting Input Voltage
Selector Switch And
Connecting Input
Power
Check
input voltage available
at
site.
Input Voltage Selector Switch
1
Switch is accessible
2
-
through
slot in
panel.
rear
Changeover Switch Label
Look at label to find correct switch
position.
Move
switch
to
match
input
voltage.
115V~.
A
Be sure input power con
nection meets all applicable
national, regional, and local
electrical codes.
3
Input Power Plug (115 VAC
Plug Shown)
See Section 2-3 to install 230 VAC
input power plug.
4
Input Power Receptacle (115
Receptacle Shown)
VAC
To
Rear Of Unit
rated output (see specifica
individual branch circuit
capable of carrying 26 amperes.
115 VAC at 35% duty cycle; or 17
amperes, 230 VAC at 35% duty
cycle, and protected by fuses or
circuit breakers is required.
use
tions),
an
Connect
Be
sure
plug
to proper
receptacle
receptacle.
can
handle
load.
Tools Needed:
51-801 304.B/S1-801 319-6
OM-181 460
Page
6
SECTION 3- OPERATION
3-1.
Controls
A
1
POWER
READY
~
~ro
-e
PRESSURE
CUP
82
LO
Ak~ BRANOI 0IRWTC~ 1I~ t*VT
OUTPUT
Setting
POWER
STATUS
Gas/Air Pressure
7
60
A
Requires
-4
70-1 50 PSI
(483-1034 kPa)
Supply
a
1
Power Switch
2
Power Light
3
Output Control
Use control to set
The yellow
primary
zone
protection on the input power circuit fre
quently opens, either reduce the cutting out
put and/or the cut time or find
quate power (see Section 2-4).
cutting output.
is for use
on
20 A
4
ade
Ready Light
orgreater
circuits.
more
Use
light
to tell if unit is
ready
for
operation.
cuit is activated.
Ready light comes on when Power switch is
in On position, indicating that all
safety shutdown systems are okay.
If 20-25 amperes of cutting output is used
with 115 VAC input power, and the overload
Trouble
Place control in Gas/Air Set
position to safe
ly adjust gas/air pressure. Only gas/air cir
placed
If
Ready light
Lights.
does not come on, check
5
Trouble
~
l~ara~
Lights (See Section 4-2)
Setting Gas/Air
6
Air
7
Pressure
Pressure
Filter/Regulator
Adjustment Knob
Place
Output control in Gas/Air position and
turn on gas/air supply. Lift knob and turn to
adjust pressure. Push knob down to lock in
setting.
Place
Output control
in
desired
cutting
output.
Ref. SC~1 81 337/Ref. ST-801 306-B
OM-181 460
Page
7
3-2.
Duty Cycle
And
Overheating
Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.
GUN
If
35%
Duty Cycle
At 25
unit
overheats,
thermostat(s)
opens, output stops, Temperature
trouble light goes On, and cooling
fan runs. Wait fifteen minutes for
unit to cool or temperature light to
Amperes
go off. Reduce amperage or duty
cycle before cutting or gouging.
A
3-1/2 Minutes
6-1/2 Minutes
Cutting
Resting
Exceeding duty cycle
damage unit and
can
void
warranty.
UNIT
115 VAC
Input
Power: 35%
115 VAC
Input
Power: 35%
230 VAC
At 20 Amperes, 20 Ampere Input Circuit
Duty Cycle At 25 Amperes, 30 Ampere Input Circuit
Duty Cycle
Input Power: 35% Duty Cycle
3-1/2 Minutes
At 25
Amperes
6-1/2 Minutes
Cutting
Resting
Overheating
A
sdutyl 5/95
3-3.
Cutting Speed
The
cutting speed
recommended
Recommended production cutting speed vs. material thickness is
approximately 10 ipm at 5/16 in mild steel thickness at max setting.
curves
show the
maximum
speed capabilities
cutting
of the
power
and torch for mild steel of
various thickness.
source
Cut at speeds below the lines
shown to avoid poor cuts and torch
70
wear.
~s
~s ~s
z
~
z
a
40
UJ
uJ
0~
LI)
30
I
20
MAX OUTPUT SETTN G
P~iI~I
U
20 AMP OUTPUT SETTING
10
~-..
~
0
005
0.1
0.15
02
T
~
~-.
0.25
MATERIAL THICKNESS
E
0.3
EE E
035
0.4
IN.
ST.179 507
OM-181 460
Page
8
SECTION 4- MAINTENANCE & TROUBLESHOOTING
4-1.
Routine Maintenance
OM-181 460
Page
10
3-4.
Sequence Of Operation
1d~
! 4~\
) )
Equipment
JJ
_______________
by hitting it against a
Hitting hard surfaces can
~
Inspect shield cup, tip, and electrode for
wear
damage torch parts and stop proper
operation.
~\ \ Put On
Install &
Connect
J
Do not clean torch
hard surface.
Per~~\\
Safety
Equipment
Check Torch
) )
)
(See Section 4-4)
~ ,
before
cutting
~\
Check Gas/Air
Pressure
J(See Section
I
Set
Controls
EXAMPLE Of
whenever
3-1)
)
cutting
Turn On
Power
So~~~)
_______________
_______________
Begin
Cutting
)
or
speed has been significantly reduced (see
Section 4.4). Do not operate torch without
a tip or electrode in place.
_______________
~\
)
Cutting Operation
~
The
pilot arc starts immediately
trigger is pressed.
when
I
Place torch tip
on
edge of
metal.
Press
trigger.
Pilot arc starts.
After
start
cutting arc starts, slowly
moving torch across metal.
~
/1
Adjust torch speed so
sparks go thru metal and
out bottom of cut.
/1
Pause
briefly at end of
releasing trigger,
cut before
Postf low continues for approx. 20
to 30 seconds after releasing
tngger; cutting arc can be instantly
restarted during postflow by
pressing trigger.
ST-161 698-B
OM-181 460
Page
9
4-2.
Overload Protection: Trouble
Lights
&
Checking
Shield
Cup Shutdown System
1
Pressure Light
if
Lights
40 PSI
gas/air pressure is
(276 kPa).
below
Turn
power Off, and check for
proper gas/air pressure (see Sec
tion 2-2).
2
PRESSURE
~
~T~O
Cup Light
Lights if
shield cup is loose.
CUP
Turn power Off, and check shield
cup connection (see torch Owners
Manual). Power must be reset
TEMR
whenever the cup
activated.
shutdown
is
Check shield cup shutdown sys
tem once a week.
3
Temperature Light
Lights
Checking
Torch Shield
Cup.Shutdown System
4
Power must be reset whenever the cup shutdown system is activated.
turn Off power when changing or checking consumables.
Always
if power
source
overheats
(see Section 3-2).
Torch Shield Cup
Turn Power On and loosen shield
cup. If shutdown system works
properly, Ready light goes oft and
Cup light comes on. If not, turn
power Off and check for proper
gas/airpressure (see Section 3-1),
blocked or leaking hose, or loose
shield cup (see torch Owners
Manual).
If
system
works
properly, retighten
cup and reset power.
4
Ref. ST-181 337/Ref. ST-801 300-A
OM-181 460
Page
11
4-3.
Torch And Work Cable Connections
If torch
or
removed
follows:
work cable needs to be
or
replaced, proceed
as
Off, and disconnect in
put power plug from receptacle.
Remove top and screws holding
front panel in place. Without dis
connecting any plugs, move front
panel to allow access.
Turn power
Torch Connections
1
Strain Relief
2
Torch Cable
Clamp
through strain relief
Insert cable
clamp.
3
Gas Connector
4
Gas Valve
Install
gas
connector
onto
gas
valve.
5
Plug PLG18
6
Safety Control
7
Receptacle RC1 8
Board PC2
Connect PLG18 to RC18. Route
leads along existing lead bundle.
8
Female Friction Terminals
9
Male Friction Terminal
10
Power Control Board PCi
11
Receptacle RC4
Connect female terminals to leads
23 and 24 from RC4 (connect to
lead). Connect male termi
nal to lead 25 from RC4. Route
leads as shown.
either
Work Cable Connections
12
Strain Relief
Clamp
Insert work clamp
strain relief clamp.
13
Receptacle
Connect work
20 from RC6
Route leads
lead
through
RC6
clamp lead to lead
(leads not shown).
along existing lead
bundle.
Tools Needed:
5/8in
ST-801 423 I Ref. ST-801 300-B
OM-181 460
Page
12
4-4.
Checking/Replacing Retaining Cup, Tip,
~
And Electrode
Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during as
sembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts
replacement.
Inspect shield cup, tip, and electrode for
been
use
A
wear
before cutting or whenever cutting speed has
without a tip or electrode In place. Be sure to
significantly reduced. Do not operate torch
genuine replacement parts.
good practice is
to
replace both the tip
and electrode at the same time.
Turn Off power
Turn Off power source, and remove input power
from receptacle before checking torch parts.
plug
1
source.
Retaining Cup
Remove
retaining cup. Check re
cup for cracks, and replace
taining
if necessary.
2
Tip
3
Opening
Remove tip. Check tip, and replace
if opening is deformed or 50%
oversize. If inside of
and
Be
bright,
tip
is not clean
clean with steel wool.
to remove any
sure
pieces of
steel wool afterwards.
4
Make sure this area is
clean of any debris.
Check electrode. If center has a pit
than a 1/16 in (2 mm) deep,
more
remove and replace electrode
ing supplied wrench. Do
overtighten.
5
The
word
swirl
ring
~fivnr
on
must
face
away from torch body.
sure
swirl
Swirl
replace
ring is
us
not
Ring
Remove swirl
6
Make
Electrode
ring.
Check nng, and
if side holes
are
plugged.
0-Ring
clean of any debris
and no holes are ob
Check
structed.
cant.
0-rings
on
torch. If needed,
supplied lubri
coat with thin film of
7
Replace
if
damaged.
Plunger Area
Check this
foreign
area for any debris or
material. Clean out if nec
essary.
Carefully
reassemble parts in re
order. Swirl ring must be in
stalled with word front
facing
verse
away from torch body.
Tools Needed:
(Supplied)
ST-801 301 /ST~801 139
OM-181 460
Page
13
4-5.
Troubleshooting
Remedy
Trouble
No
pilot
difficulty
arc;
in
establishing
an
Clean
or
replace
consumables
worn
as
(see
necessary
Section
4-4).
arc.
Check for
torch
damaged
or
torch cable.
check control relay CR6, power control board PCi
rectifier SRi, and check gas/air system for leaks.
Factory Authorized Service Agent
Have
trol board PC2, gas valve GS1
No
cutting output; Power light off;
lights off; Ready light oft; fan
Place Power switch in On
,
safety con
position.
Trouble
motor FM does not run.
Place line disconnect device in On
Check line
Have
fuse(s)
Factory
and
cutting output; Power light on;
Ready light on; Trouble lights off; fan
motor FM running.
Be
sure
Clean
work
or
replace if needed
or
reset circuit breakers
(see Section 2-4).
Agent check power switch Si, input voltage selector switch S2, input
relay CR6, safety control board PC2, and transformer Ti.
Authorized Service
resistor R2, control
No
position (see Section 2-4).
clamp
replace
is connected.
consumables
worn
as
necessary (see Section 4-4).
Factory Authorized Service Agent check contactor CR7, control relay CR6, safety control board
PC2, input resistor R2, and power control board PCi. Check for proper torch lead connections. Check
Have
operation of gas
No
cutting output;
Power
light
on;
Ready light off; Trouble lights oft;
motor FM running.
and check
gas/air system
for leaks.
Reset Power switch.
fan
Have
No control of
GS1,
valve
Factory
Check
output.
Have
Authorized Service
position
of
input voltage
Agent
check
safety
selector switch S2
control board PC2.
(see
Section
Factory Authorized Service Agent check power control
2-4).
board PCi ,and
safety control
board PC2.
No gas/air flow; Power light on; Ready
light on; Trouble lights off; fan motor FM
running.
Have Factory Authorized Service Agent check for proper torch connections, and check power control
board PCi. Check operation of gas valve GS1, and check gas/air system for leaks.
Pressure Trouble
off.
Check for correct
light On; Ready light
gas/air pressure adjustment (see
Check for sufficient
Check for
Cup Trouble light On; Ready light
off.
dirty
air
gas/air supply pressure (see
filter/regulator
Check torch shield cup
Have
Section
Section
and clean, if needed
3-i).
3-i).
(see manufacturers instructions).
(see Section 4-2).
Factory Authorized Service Agent
check for proper torch connections, and check
safety
control
board PC2
Temperature
light off.
Trouble
light On; Ready
Fan motor FM does not run; Power
Ready light both On.
light
Thermostat TP1 open
(see Section 3-2).
(overheating).
Authorized Service
Allow fan to run; the thermostat closes when the unit has cooled
Have
Factory
Have
Factory Authorized Service Agent
Have
Factory
Agent
check
safety
control board PC2 and transformer Ti.
check fan motor connections.
and
Trouble
lights
OM-18i 460
not
Page
working.
14
Authorized Service
Agent
check
safety
control board PC2.
SECTION 6- PARTS LIST
Co
Co
cJ
0)
cJ
0
C,)
cJ
0
ST-aol 412-C
Figure
OM-181 460
Page
16
6-1. Main
Assembly
U
C/) w C.) p 0 z U)
C-)
-J w C) I
-J 6
POWER ~jr
~
3
-~ 3>~ PLG2O/16
-~<24~ R02/G3
~
POWER
c~u
F~/ft~IW~4/PG4r~2/nr~2Rci/r&Gl ~
(0
Pci
N
PF~S9J
In
ERFETY
PO12/F~G12Rci/PLG1IOJ/P(~G1O O~1
PC2
o CD
L1~ a)
0
IU
a
a) 1~
E
CJ CD
184
Item
No.
Dia.
Part
No.
Mkgs.
Figure
6-1. Main
FRONT PANEL,
40
C1,2..
1
181 708
GASKET switch
1
1
178 956
RELAY, end 12VDC SPST
THERMISTOR, PTC 8A 250V
MAGNET, adhesive mounted
178 981
CAPACITOR
1
136 156
LABEL, warning precautionary
LABEL, warning electric shock
1
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
1
182 486
126 026
PLG2O
167 640
PLG22
136 810
PC2.. 183 712
PLG11
CIRCUIT CARD ASSEMBLY,
CONNECTOR & SOCKETS
169240
ordering
Optional
a
1
1
1
1
1
safety
control
1
1
DOOR, consumable storage
181 716
+When
(consisting of) (Continued)
124 511
....
CR6.. 149 823
R2...
Assembly (Continued)
LINER, polycarbonate
SWITCH, toggle DPST 40A 600VAC
544
Si...
Quantity
Description
component originally displaying
a
precautionary label,
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Item
No.
5
3
6
7
8
Figure
OM-181 460
Page
18
6-2.
Torch, ICE 25C
Part
No.
Description
4
181 334
5
181 336
Cup, shield
Tip, 25A(Qty 5)
Electrode, 25A (Qty 5)
Swirl Ring, 25A
0-Ring, 55A (Qty 2)
1
181 335
2
181 333
3
181 332
6
171 248
Push Button Switch
7
178550
Main
8
177893
Leads,l5tt
8
177894
Leads,25ft
Body
178 549
Plunger (Not Shown)
169 231
Grease, silicone
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
..
CONNECTOR& SOCKETS
1
..
158720
PLG4.. 168071
CONNECTOR&SOCKETS
1
PLG6.. 176121
CONNECTOR,
plug
CONNECTOR, rect skt 20-i4ga
STAND-OFF SUPPORT, PC card
STAND-OFF, 6-32 x .437 Ig
MOTOR FAN, 115V 50/60 Hz 31 00RPM
CASE, base/back/sides
AIR VALVE ASSEMBLY, (consisting of)
TUBING, pneurnatic .250 OD x .170 ID x 13.500
FITTING, plstc Qdisc straight 1/8NPT x 1/4 OD
SWITCH, pressure air 4OPSI fixed
FITTING, pipe brs tee 1/8NPT
FITTING, pipe brs nipple hex 1/8NPT
VALVE, 24VAC 3 way 1/8NPT 5/32 ort 100PSI
BRACKET, valve
FITTING, pipe brs adaptor 1/8NPT/.375-24 LH
ICE-25C PLASMA ARC CUTTING TORCH, 15ft (Fig 6-2)
ICE-25C PLASMA ARC CUTTING TORCH, 25ft (Fig 6-2)
BUSHING, strain relief .455/.629 ID x 1.ll5mtg
CABLE, work 15ft (consisting of)
CLAMP, univ 50A
175145
3
175366
4
177347
5
175999
6
174668
7
176518
8
176517
9
602963
118134
10
174783
11
174562
12
176123
PCi
PLG1
114066
134201
070026
...14... FM... 088566
15
183162
16
175365
..17
177346
18
176122
19
174670
602965
073655
GSi
175827
..
23
157057
24
175998
25
176499
25
,176822
139041
26
176071
601 222
600 848
S2...
PLG21
34... Ri
...36
VR1
..37
SRi
.
...
..
..
..39.
PLG5O
.
1
1
1
1
1
1
row
1
3
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
l5ft
WIRE, strd i2ga600V(orderbyft)
1
175058
178393
VARISTOR
1
179682
RECTIFIER, integ 40A 800V
CONNECTOR, clamp cable
CABLE, poweriofti4ga3/C
FRONT PANEL, (consisting of)
PANEL, front
KNOB, pointer
NAMEPLATE, (order by model and serial number)
1
010916
38
1
RESISTOR, WW fxd 338W 1.5 ohm
BRACKET, resistor
175056
...33...
1
CONNECTOR& SOCKETS
176500
32
1
1
136810
175828
175144
.31... Ti
1
176505
019663
..
1
1
28
CR7
1
011611
020577
30
rect 1
1
TUBING, plstc PVC blk .250 ID x .375 OD x 9.000
BUSHING, strain relief .500 ID x .465mtg hole
MOUNT, nprn
CONTACTOR, def prp 25A 1 P 24VAC
BRACKET, transformer
TRANSFORMER, main power 115/230
BRACKET, switch
SWITCH, toggle DPDT 15A 125VAC
176089
27
29..
1
184973
183161
...22
Assembly
COVER, top
HANDLE, lifting
REGULATOR ASSEMBLY, (consisting of)
HOSE, SAE .187 ID x .410 OD x 6.500
FITTING, brs barbed fern 3/i6tbg x 1/8NPT
REGULATOR/FILTER, 250 PSIG in 100 PSIG rnax out
FITTING, pipe brs elbow st i/4NPT
FITTING, pipe brs nipple L 1/4NPT x 2.500
FITTING, pipe brs coupling 1/4NPT
FITTING, pipe brs plug shhd 1/4NPT
GAUGE, pressure air 0-160 PSI 1/8NPT
BRACKET, rntg air filter/regulator
FITTING, plstc Qdisc elbow 1/4NPT x 1/4 OD tubing
CIRCUIT CARD ASSEMBLY, power control
1
2
13..
6-1. Main
Quantity
181 269
.40
+181 717
174991
1
1
6
1
1
1
1
1
1
1
1
1
1
1
1
OM-181 460
Page
17