Miller | LG020472P | Owner Manual | Miller SPECTRUM 625 AND ICE-40C TORCH User manual

Miller SPECTRUM 625 AND ICE-40C TORCH User manual
OM-2239
207 542K
2006−01
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum 625
R
And ICE-40C Torch
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 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers liés au coupage à l’arc au plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Specifications For Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Torch Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Unit Dimensions, Weight, And Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or Champion 10,000
4-11. Installing Alternative Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Setting Gas/Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Overload Protection: Status Lights & Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . .
6-3. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Torch And Work Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
pom _4/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Plasma Arc Cutting Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only a
summary of the more complete safety information found in the
Safety Standards listed in Section 1-5. Read and follow all Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
D
D
D
D
D
D
CUTTING can cause fire or explosion.
D
Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and burns. Check
and be sure the area is safe before doing any cutting.
D
Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this
is not possible, tightly cover them with approved covers.
D Do not cut where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not cut on closed containers such as tanks or drums.
D Connect work cable to the work as close to the cutting area as practical to prevent cutting current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
D Do not use plasma cutter to thaw frozen pipes.
D Never cut containers with potentially flammable materials inside −
they must be emptied and properly cleaned first.
D Do not cut in atmospheres containing explosive dust or vapors.
D Do not cut pressurized cylinders, pipes, or vessels.
D Do not cut containers that have held combustibles.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Do not locate unit on or over combustible surfaces.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any cutting.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but also uses torches designed with safety
interlock systems which turn off the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. Incorrectly
installed or improperly grounded equipment is a hazard.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
Do not touch torch parts if in contact with the work or ground.
Turn off power before checking, cleaning, or changing torch parts.
Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
Check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet − always verify
the supply ground.
When making input connections, attach proper grounding conductor first.
Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Inspect and replace any worn or damaged torch cable leads.
Do not wrap torch cable around your body.
Ground the workpiece to a good electrical (earth) ground if required
by codes.
Use only well-maintained equipment. Repair or replace damaged
parts at once.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Do not bypass or try to defeat the safety interlock systems.
Use only torch(es) specified in Owner’s Manual.
Keep away from torch tip and pilot arc when trigger is pressed.
Clamp work cable with good metal-to-metal contact to workpiece
(not piece that will fall away) or worktable as near the cut as
practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists in
inverter power sources AFTER the removal of input power.
D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Maintenance Section of Owner’s Manual or Technical Manual before
touching any parts.
OM-2239 Page 1
D
D
D
EXPLODING PARTS can injure.
D
D
D On inverter power sources, failed parts can explode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.
D
FLYING SPARKS can cause injury.
D
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
D
Wear approved face shield or safety goggles with side shields.
Wear proper body protection to protect skin.
Wear flame-resistant ear plugs or ear muffs to prevent sparks from
entering ears.
D
ARC RAYS can burn eyes and skin.
PLASMA ARC can cause injury.
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
D
D
D
D
Wear face protection (helmet or shield) with a proper shade of filter
lenses to protect your face and eyes when cutting or watching. ANSI
Z49.1 (see Safety Standards) suggests a No. 9 shade (with No. 8 as
minimum) for all cutting currents less than 300 amperes. Z49.1 adds
that lighter filter shades may be used when the arc is hidden by the
workpiece. As this is normally the case with low current cutting, the
shades suggested in Table 1 are provided for the operator’s convenience.
Wear approved safety glasses with side shields under your helmet
or shield.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
D
D
D
D
D
D
D
Minimum Shade Number
#4
#5
#6
#8
NOISE can damage hearing.
Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
D
D
Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.
FUMES AND GASES can be hazardous.
Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove cutting fumes and gases.
OM-2239 Page 2
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.
Keep away from the torch tip.
Do not grip material near the cutting path.
The pilot arc can cause burns − keep away from torch tip when trigger is pressed.
Wear proper flame-retardant clothing covering all exposed body areas.
Point torch away from your body and toward work when pressing
the torch trigger − pilot arc comes on immediately.
Turn off power source and disconnect input power before disassembling torch or changing torch parts.
Use only torch(es) specified in the Owner’s Manual.
CYLINDERS can explode if damaged.
Table 1. Eye Protection For Plasma Arc Cutting
Current Level In Amperes
Below 20
20 − 40
40 − 60
60 − 100
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals to be cut, coatings,
and cleaners.
Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Fumes from cutting and oxygen depletion
can alter air quality causing injury or death. Be sure the breathing air
is safe.
Do not cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not cut on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the cutting area, the
area is well ventilated, and while wearing an air-supplied respirator.
The coatings and any metals containing these elements can give off
toxic fumes when cut.
Do not cut containers with toxic or reactive materials inside or
containers that have held toxic or reactive materials − they must be
emptied and properly cleaned first.
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are normally part of metalworking processes,
be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flame, sparks, and arcs.
D Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
D Keep cylinders away from any cutting or other electrical circuits.
D Never allow electrical contact between a plasma arc torch and a
cylinder.
D Never cut on a pressurized cylinder − explosion will result.
D Use only correct gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated
parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number
of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
D
1-3. Additional Symbols For Installation, Operation, And Maintenance
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before going near plasma arc cutting operations.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
EXPLODING HYDROGEN hazard.
D When cutting aluminum underwater or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the workpiece.
D See your cutting engineer and water table instructions for help.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift unit.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
FIRE OR EXPLOSION hazard.
D Do not locate unit on, over, or near combustible
surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D High frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment
at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC CUTTING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D To reduce possible interference, keep cables as short as possible,
close together, and down low, such as on the floor.
D Locate cutting operation 100 meters from any sensitive electronic
equipment.
D Be sure this cutting power source is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures such
as moving the machine, using shielded cables, using line filters, or
shielding the work area.
1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-2239 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding Or Cutting And The Effects Of Low
Frequency Electric And Magnetic Fields
Welding or cutting current, as it flows through the welding or cutting
cables, will cause electromagnetic fields. There has been and still is
some concern about such fields. However, after examining more than
500 studies spanning 17 years of research, a special blue ribbon
committee of the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a humanhealth hazard.” However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
OM-2239 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep cutting power source and cables as far away from operator
as practical.
5. Connect work clamp to workpiece as close to the cut as possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding/cutting or going
near welding/cutting operations. If cleared by your doctor, then following
the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
pom_fre 4/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers liés au coupage à l’arc au plasma
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécurité énumérées à la section 2-4. Veuillez lire et respecter toutes
ces normes de sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
LE COUPAGE présente un risque de
feu ou d’explosion.
Des particules de métal chaud et des étincelles
peuvent jaillir de la pièce au moment du coupage.
Les étincelles et le métal chaud, la pièce à couper
chauffée et l’équipement chaud peuvcnt causer un
feu ou des brûlures. Avant de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.
Déplacez toute matière inflammable se trouvant à l’intérieur d’un
périmètre de 10,7 m (35 pi) de la pièce à couper. Si cela est impossible, vous devez les couvrir avec des housses approuvées et bien
ajustées.
D Ne coupez pas dans un endroit où des étincelles pourraient atteindre des matières inflammables.
D Protégez−vous, ainsi que toute autre personne travaillant sur les
lieux, contre les étincelles et le métal chaud.
D Assurez−vous qu’aucune étincelle ni particule de métal ne peut se
glisser dans de petites fissures ou tomber dans d’autres pièces.
D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur à la portée de la main.
D Si vous coupez sur un plafond, un plancher ou une cloison, soyez
conscient que cela peut entraîner un feu de l’autre côté.
D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un bidon.
D Fixez le câble de masse sur la pièce à couper, le plus près possible
de la zone à couper afin de prévenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une décharge électrique, d’étincelles ou un feu.
D Ne pas utiliser le coupeur plasma pour dégeler des conduites
gelées.
D Ne coupez jamais des contenants qui peuvent contenir des matières inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.
D Ne coupez pas dans un endroit où l’atmosphère risque de contenir
de la poussière ou des vapeurs explosives.
D Ne coupez pas de bouteilles, de tuyaux ou de contenants pressurisés.
D Ne coupez pas de contenants qui ont déjà reçu des combustibles.
D Portez des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Ne placez pas le poste sur une surface combustible ou au−dessus
de celle−ci.
D Avant le coupage, retirez tout combustible de vos poches, par
exemple un briquet au butane ou des allumettes.
D
Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA
51B pour travaux de soudage et prévoir un détecteur d’incendie et
un extincteur à proximité.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le fait de toucher à une pièce électrique sous
tension peut donner une décharge fatale ou entraîner des brûlures graves. Le chalumeau et le circuit
de masse sont automatiquement actifs lorsque le
poste est sous tension. L’alimentation d’entrée et les circuits internes
de l’appareil le sont également. Le coupage au plasma d’arc exige des
tensions plus élevées que le soudage pour amorcer et maintenir l’arc
(souvent de 200 à 400 V CC), c’est pourquoi on fait appel à des
chalumeaux conçus avec un système de verrouillage sécuritaire qui
met l’appareil hors tension lorsque la capsule anti−feu est desserrée
ou si le tube touche l’électrode à l’intérieur de la buse. Un poste
incorrectement installé ou inadéquatement mis à la terre constitue un
danger.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Ne touchez pas aux pièces électriques sous tension.
Portez des gants isolants et des vêtements de protection secs et
sans trous.
Isolez−vous de la pièce à couper et du sol en utilisant des housses
ou des tapis assez grands afin d’éviter tout contact physique avec
la pièce à couper ou le sol.
Ne touchez pas aux pièces du chalumeau si vous êtes en contact
avec la pièce à couper ou le sol.
Mettez l’appareil hors tension avant d’effectuer la vérification, le
nettoyage ou le changement d’une pièce du chalumeau.
Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation
selon la norme OSHA 29 CFR 1910.147 (reportez−vous aux Principales normes de sécurité).
Installez le poste correctement et mettez-le à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Assurez−vous que le fil de terre du cordon d’alimentation est correctement relié à la borne de terre dans la boîte de coupure ou que
la fiche du cordon est branchée à une prise correctement mise à la
terre − vous devez toujours vérifier la mise à la terre.
Avant d’effectuer les connexions d’alimentation, vous devez relier
le bon fil de terre.
Vérifiez fréquemment le cordon d’alimentation afin de vous assurer
qu’il n’est pas altéré ou à nu, remplacez−le immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Vérifiez et remplacez les cosses du câble du chalumeau si elles
sont usées ou altérées.
Le câble du chalumeau ne doit pas s’enrouler autour de votre corps.
Si les normes le stipulent, la pièce à couper doit être mise à la terre.
Utilisez uniquement de l’équipement en bonne condition. Réparez
ou remplacez immédiatement toute pièce altérée.
Portez un harnais de sécurité si vous devez travailler au−dessus du
sol.
Assurez−vous que tous les panneaux et couvercles sont correctement en place.
N’essayez pas d’aller à l’encontre des systèmes de verrrouillage
de sécurité ou de les contourner.
Utilisez uniquement le ou les chalumeaux recommandés dans le
manuel de l’opérateur.
OM-2239 Page 5
D
D
D
N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée.
Le câble de masse doit être pincé correctement sur la pièce à couper, métal contre métal (et non de telle sorte qu’il puisse se
détacher), ou sur la table de travail le plus près possible de la ligne
de coupage.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Certaines applications de coupage produisent un bruit
constant, ce qui peut endommager l’ouïe si le niveau
sonore dépasse les limites permises par l’OSHA (reportez−vous aux Principales normes de sécurité).
D Utilisez des protège−tympans ou un serre−tête antibruit si le niveau
sonore est élevé.
D Prévenez toute personne sur les lieux du danger relié au bruit.
DÉCHARGES ÉLECTRIQUES potentiellement mortelles.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Il y a DES CHARGES DC SIGNIFICATIVES dans le poste de soudage inverseur même APRÈS coupure du courant d’alimentation.
Le coupage produit des vapeurs et des gaz. Respirer
ces vapeurs et ces gaz peut être dangereux pour la
santé.
D Mettre l’unité hors tension, mesurer la tension des condensateurs
d’entrée et s’assurer qu’elle est pratiquement nulle avant de toucher à l’une quelconque des pièces. Mesurer cette tension conformément aux directives énoncées à la section Entretien du manuel
de l’utilisateur ou du manuel technique avant de toucher à l’une
quelconque des pièces.
Risque de blessure en cas
D’EXPLOSION DES PIÈCES.
D Mise sous tension, toute pièce défectueuse des
sources d’alimentation de l’inverseur peut exploser ou faire exploser d’autres pièces. Pour entretenir les inverseurs, toujours porter un masque
protecteur et un vêtement à manches longues.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
Le coupage plasma produit des étincelles et projections de
métal à très haute température. Lorsque la pièce refroidit,
du laitier peut se former.
D Portez une visière ou des lunettes de sécurité avec des écrans latéraux approuvées.
D Portez des vêtements de protection adéquats afin de protéger votre
peau.
D Ayez recours à des protège−tympans ou à un serre−tête ignifuges afin
d’éviter que les étincelles n’entrent dans vos oreilles.
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau.
Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner des brûlures aux yeux et à la
peau.
D Lorsque vous coupez ou regardez quelqu’un couper, portez un casque de soudage approuvé muni de verres filtrants approprié. La
norme ANSI Z49.1 (reportez−vous aux Principales normes de sécurité) suggère d’utiliser un filtre de teinte nd 9 (nd 8 étant le minimum)
pour tout travail de coupage faisant appel à un courant de moins de
300 A. On mentionne également dans la norme Z49.1 qu’un filtre plus
faible peut être utilisé lorsque l’arc est caché par la pièce à couper.
Comme cela est habituellement le cas pour les travaux de coupage à
faible courant, les teintes énumérées au tableau 1 sont fournies à titre
d’information pour l’opérateur.
D Porter des lunettes de sécurité à coques latérales sous votre casque
ou écran facial.
D Ayez recours à des écrans protecteurs ou à des rideaux pour protéger
les autres contre les rayonnements, les étincelles et les éblouissements; prévenez toute personne sur les lieux de ne pas regarder l’arc.
D Portez des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
Tableau 1. Protection des yeux pour le coupage au plasma d’arc
Intensité de courant en ampères
Filtre de teinte (minimum)
Moins de 20
20 − 40
40 − 60
60 − 100
no. 4
no. 5
no. 6
no. 8
OM-2239 Page 6
LE BRUIT peut endommager l’ouïe.
D Ne mettez pas votre tête au−dessus des vapeurs. Ne respirez pas ces
vapeurs.
D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce ou
ayez recours à une ventilation aspirante installée près de l’arc pour
évacuer les vapeurs et les gaz.
D Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travaillez dans un espace restreint uniquement s’il est bien ventilé ou
si vous portez un respirateur anti−vapeurs. Les vapeurs causées par
le coupage et l’épuisement de l’oxygène peuvent altérer la qualité de
l’air et entraîner des blessures ou la mort. Assurez−vous que l’air ambiant est sain pour la santé.
D Ne coupez pas dans un endroit près d’opérations de décapage, de
nettoyage ou de vaporisation. La chaleur et les rayons d’arc peuvent
réagir avec les vapeurs et former des gaz hautement toxiques et irritants.
D Ne coupez pas des métaux enrobés tels que des métaux galvanisés,
contenant du plomb ou de l’acier plaqué au cadmium, à moins que
l’enrobage ne soit ôté de la surface du métal à couper, que l’endroit où
vous travaillez ne soit bien ventilé, ou que vous ne portiez un respirateur anti−vapeurs. Les enrobages ou tous métaux qui contiennent ces
éléments peuvent créer des vapeurs toxiques s’ils sont coupés.
D Ne coupez pas de contenants qui renferment ou ont renfermés des
matières toxiques ou réactives − vous devez en premier lieu les vider
et les nettoyer convenablement.
LE PLASMA D’ARC peut entraîner
des blessures.
La chaleur dégagée par le plasma d’arc peut entraîner de
sérieuses brûlures. La force de l’arc est un facteur qui
s’ajoute au danger de brûlures. La chaleur intense et la
puissance de l’arc peuvent rapidement passer au travers
de gants et de tissus.
D N’approchez pas le tube du chalumeau.
D Ne saisissez pas la pièce à couper près de la ligne de coupage.
D L’arc pilote peut causer des brûlures − n’approchez pas le tube du chalumeau lorsque vous avez appuyé sur le gâchette.
D Portez des vêtements de protection adéquats qui recouvrent tout votre corps.
D Ne pointez pas le chalumeau en direction de votre corps ni de la pièce
à couper lorsque vous appuyez sur la gâchette − l’arc pilote s’allume
automatiquement.
D Mettez l’alimentation hors tension et débranchez le cordon d’alimentation avant de démonter le chalumeau ou de changer une pièce du
chalumeau.
D Utilisez uniquement le ou les chalumeaux recommandés dans le manuel de l’opérateur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz contiennent du gaz sous haute
pression. Si une bouteille est endommagée, elle peut
exploser. Puisque les bouteilles de gaz font habituellement
partie d’un processus de travail des métaux, assurez−vous
de les manipuler correctement.
D Protégez les bouteilles de gaz comprimé contre la chaleur excessive,
les chocs mécaniques, des dommages physiques, le laitier, la flamme, les étincelles et l’arc.
D Installez et attachez les bouteilles dans la position verticale à l’aide
d’une chaîne, sur un support stationnaire ou un châssis porte−bouteille afin de prévenir qu’elles ne tombent ou ne basculent.
D Les bouteilles ne doivent pas être près de la zone de coupage ni de
tout autre circuit électrique.
D Un contact électrique ne doit jamais se produire entre un chalumeau
de plasma d’arc et une bouteille.
D Ne coupez jamais sur une bouteille pressurisée − une explosion en
résulterait.
D Utilisez uniquement des bouteilles de gaz, des détendeurs, des
boyaux et des raccords conçus pour l’application déterminée. Gardez−les, ainsi que toute autre pièce associée, en bonne condition.
D Détournez votre visage du détendeur−régulateur lorsque vous ouvrez
la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
vous utilisez la bouteille ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
DES PIECES CHAUDES peuvent provoquer des brûlures graves.
D
D
Ne pas toucher des parties chaudes à mains nues.
Laisser refroidir avant d’intervenir sur la torche.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
S’abstenir de toucher des organes mobiles tels que
des ventilateurs.
Maintenir fermés et verrouillés les portes, panneaux,
recouvrements et dispositifs de protection.
D Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour
l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
Porter des lunettes de sécurité avec protections latérales ou frontales.
LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs sont priés de consulter leur médecin
avant d’approcher les opérations de coupage
plasma.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
Prévoir une période de refroidissement; respecter le
cycle opératoire nominal.
Réduire l’ampérage (épaisseur) avant de continuer à
couper ou réduire le facteur de marche.
Danger D’EXPLOSION
D’HYDROGÈNE.
D
D
LA CHUTE DE L’APPAREIL peut
blesser.
D
D
Utiliser l’anneau de levage uniquement pour soulever
l’appareil, NON PAS les chariot, les bouteilles de gaz
ou tout autre accessoire.
Utiliser un engin d’une capacité appropriée pour soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
Risque D’INCENDIE OU
D’EXPLOSION.
D
D
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces infllammables.
Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionné et protégé avant de
mettre l’appareil en service.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D
D
Etablir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes PC.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
D
Le Rayonnement haute frequence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de
sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
Lors du coupage d’aluminium partiellement ou totalement immergé dans l’eau, de l’hydrogène libre peut
s’accumuler sous la pièce.
Consultez votre ingénieur de coupage et les instructions de la table de coupage.
OM-2239 Page 7
LE COUPAGE Ã L’ARC peut causer
des interférence.
D
L’énergie électromagnétique peut gêner le fonctionnement d’appareils électroniques comme des ordinateurs et des robots.
D Veiller à couper à une distance de 100 mètres de tout équipement
électronique sensible.
D S’assurer que la source de coupage est correctement branchée et
mise à la terre.
D Si l’interférence persiste, l’utilisateur doit prendre des mesures supplémentaires comme écarter la machine, utiliser des câbles blindés
de des filtres, ou boucler la zone de travail.
D Pour réduire la possibilité d’interférence, maintenir les câbles aussi
courts que possible, les grouper, et les poser aussi bas que possible
(ex. par terre).
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society de Global Engineering Documents
(téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101
(téléphone : 617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
1
Le courant de soudage ou de coupage passant dans les câbles de puissance crée des causera des champs électromagnétiques. Il y a eu et
il y a encore un certain souci à propos de tels champs. Cependant,
après avoir examiné plus de 500 études qui ont été faites pendant une
période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques
pendant le soudage ou le coupage.
2
3
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
OM-2239 Page 8
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
vous.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder/couper ou d’approcher des opérations de soudage/
couper. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions 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
pf
Primary Voltage
Rated Welding
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
OM-2239 Page 9
SECTION 4 − INSTALLATION
4-1. Specifications
50/60 Hz
Amperes Input
at Rated Load
Output 50/60
Hz
208 V
SinglePhase
33
230 V
30
KVA
6.8
Rated
Output
Type of
Output
Plasma
Gas
Flow/
Pressure
Rated
Cutting
Capacity
Maximum
OpenCircuit
Voltage DC
40 A @
140 Volts
DC, 50%
Duty Cycle
Direct
Current,
Straight
Polarity
(DCEN)
Air Or
Nitrogen
Only
6 CFM
(170 L/min)
at 75 PSI
(517 kPa)
0.5 in
(12.7 mm)
At 16 IPM
260
KW
6.7
4-2. Specifications For Torch
Air-cooled torch for plasma arc cutting (PAC)
50% duty cycle
Safety interlock devices disable power source
Safety trigger guard
Cutting capacity: see Section 4-1
4-3. Duty Cycle And Overheating
For Units Connected to a 208 Volt Circuit or a 230 Volt Circuit:
50% Duty Cycle At 40 amperes, 140 volts dc (typical cutting)
Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.
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.
5 Minutes Cutting
5 Minutes Resting
Y Exceeding duty cycle can
damage unit and void
warranty.
Overheating
A
0
15
Minutes
OM-2239 Page 10
OR
Reduce Duty Cycle
Ref. 803 219
4-4. Torch Dimensions And Weight
8-3/8 in
(213 mm)
1 in (25 mm)
3.5 lb (1.6 kg) With 25 ft (7.6 m) Cable
1-3/8 in (35 mm)
Ref. 801 397-A
4-5. Unit Dimensions, Weight, And Movement
17-1/4 in
(438 mm)
Dimensions And Weight
57 lb (25.9 kg)
15-1/4 in
(387 mm)
10-1/4 in
(260 mm)
1
Movement
Lifting Handles
Use handles to lift unit.
Y Do not move or operate unit
where it could tip.
2
Hand Cart
Use cart or similar device to move
unit.
loc_2 3/96 - Ref. 803 219 / 803 220
OM-2239 Page 11
4-6. Connecting Work Clamp and Gas/Air Supply
1
2
1
Work Clamp
Workpiece
Connect work clamp to a clean,
paint-free location on workpiece, as
close to cutting area as possible.
. Use only clean, dry air with 90
to 150 psi (620 to 1035 kPa)
pressure. Prevent moisture
from entering air supply at
extreme cold temperatures.
2
3
Gas/Air Inlet Opening
4
Hose
. Hose
must have a minimum
inside diameter of 3/8 in
(9.5 mm).
5
3
5
Teflon Tape
Obtain hose with 1/4 NPT righthand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
4
Or
From Gas/Air Supply
Install supplied quick connect male
1/4 in NPT pipe fitting.
Tools Needed:
Rear of Unit
5/8, 1-1/8 in
Connect female quick connect
fitting to pipe fitting.
Route hose to gas/air supply.
Y Incorrect plasma gas can
cause torch and power
source damage. Use only air
or nitrogen for the plasma
gas.
Ref. 803 640-A / 803 221
OM-2239 Page 12
4-7. Electrical Service Guide
50/60 Hz Single Phase
Input Voltage
208
230
Input Amperes At Rated Output
33
30
Cricuit Breaker 1, Time-Delay 2
40
35
3
50
45
10
10
80
(24)
98
(30)
10
10
Max Recommended Standard Fuse Rating In Amperes
Normal Operating
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
4-8. Extension Cord Data
NOTE
When calculating max. cord length, remember to include conductor length from
line disconnect device to input power receptacle.
Input Voltage
Input Power
Phase
Hertz
Fuse Size Or
Circuit Breaker Rating
208 V
1
50/60
Time-Delay 2
Normal Operating 3
230 V
1
50/60
Time-Delay 2
Normal Operating 3
Conductor Size
Max. Cord Length
40 A
50 A
10 AWG
80 ft (24 m)
35 A
45 A
10 AWG
98 ft (30 m)
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
OM-2239 Page 13
4-9. Selecting A Location And Connecting Input Power
1
2
Plug (NEMA Type 6-50P)
Receptacle
(NEMA Type 6-50R)
Connect plug to receptacle.
3
18 in (457 mm) of
space for airflow
Input And Grounding
Conductors
For single-phase operation:
Y Do not move or operate unit
where it could tip.
Y Make
input
power
connections to the machine
before making connections
into a deenergized line
disconnect device. In the line
disconnect device, always
connect
green
or
green/yellow
grounding
conductor
to
supply
grounding terminal
first,
never to a line terminal.
= GND/PE
Y Always connect
grounding conductor first.
Connect directly to line disconnect
device if hard wiring is required.
4
Line Disconnect Device
See Section 4-7.
Green Or
Green/Yellow
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
4
L1 (Black)
L2 (White)
Install conductors into
a deenergized line
disconnect device.
1
3
2
. Serial Number/Rating Label located on
L2
L1
rear panel of plasma cutter; use label to
determine input power for unit.
230 VAC, 1
208 959 / 803 222
OM-2239 Page 14
4-10. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or
Champion 10,000
Tools Needed:
2
3
7
3
4
4
240V
3/16 in
5
8
6
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
Green Or Green/Yellow
Ground Conductor
6
5
Plug Front
View
Y 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.
7
8
1
Y Engine Control Switch must be set at “RUN”
position − not “RUN/IDLE”.
Green Or
Green/Yellow
Y Set generator Fine Adjustment Control to 10
for maximum auxiliary power, if applicable.
Ref. 120 813-D / Ref. 803 222
OM-2239 Page 15
4-11. Installing Alternative Plug
This procedure is necessary if the unit is to be connected to a 208/230 VAC
receptacle that requires a plug that is different from the supplied plug.
1
2
3
1
Supplied 230 VAC Plug
Cut cord close to plug.
6
7
4
2
Alternative Plug (230 VAC
Plug Shown)
3
Input (Black Lead)
(Brass) Terminal
4
Input (White Lead)
(Brass) Terminal
5
Ground (Green) Terminal
6
Outer Shell
7
Cord Grip
Strip cord jacket back enough to
separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip. Tighten
assembly screws onto shell. Do not
overtighten.
5
Tools Needed:
Ref. 801 305-A / 801 611
4-12. Setting Gas/Air Pressure
2
3
1
4
Rear of Unit
Ref. 803 219 / 803 221
Setting Gas/Air Pressure
Place Output Control in
Gas/Air Set Position
Power Switch On
Set Controls
1
Power Switch
Place power switch in On position
OM-2239 Page 16
Requires
90−150 PSI Supply
(620−1035 kPa)
Turn On Gas/Air Supply
Set To 75 PSI (517 kPa) For Cutting
Or 55 PSI (379 kPa) For Gouging
Adjust Pressure
On Unit
2 Output Control
Place output control in Gas/Air position.
3 Pressure Gauge
Select Desired
Amperage To
Begin Cutting
4 Gas/Air Pressure Adjustment Knob
Adjust pressure to 75 psi (517 kPa) on
pressure gauge by pulling and turning knob.
Push knob in to lock setting.
Select desired cutting output with Output
Control.
SECTION 5 − OPERATION
5-1. Controls
1
4
3
2
5
1 Output Control
Use control to set cutting output.
Place control in Gas/Air Set position to safely
adjust gas/air pressure. Only gas/air circuit
is activated.
2
3
Status Lights (See Section 6-2)
Power Light
6
4
Power Switch
. The fan will normally run for
approximately 5 seconds after power
switch is placed in the Off position.
5
Pressure Gauge
6
Pressure Adjustment Knob
Ref. 207 299
. At ambient temperatures below −55 C
(235 F), readjustment of gas/air
pressure regulator may be necessary
(see Section 4-12).
Use only clean, dry air with 90 to 150 psi
(620 to 1035 kPa) pressure. Prevent
moisture from entering air supply at
extreme cold temperatures.
5-2. Cutting Speed
400
The cutting speed curve shows the
recommended maximum cutting
speed capabilities of the power
source and torch for mild steel of
various thickness.
Cut Speed(in./min.)
350
300
The best cut quality is achieved by
cutting near the chart line. Cutting
below the line (too slow) will result
in excess dross. Cutting above the
line (too fast) will cause blowback
and lack of penetration.
250
200
150
100
50
0
16GA
1/8th
1/4th
3/8th
5/8th
(0.060)
Mild Steel Thickness(inches)
OM-2239 Page 17
5-3. Trigger Safety Lock
1
Trigger
1
Trigger Locked
Trigger Unlocked
801 397-A
5-4. Plasma Cutting System Practices
The pilot arc starts immediately
when trigger is pressed.
Always connect work clamp to a clean,
paint-free location on workpiece, as close to
cutting area as possible.
. Set correct air pressure for process:
75 PSI (517 kPa) for cutting,
55 PSI (379 kPa) for gouging.
DO NOT start pilot arc without cutting or
gouging as this shortens the service life
of the nozzle and electrode.
90°
Maintain approximately a 90° angle to the
workpiece surface for proper cutting results.
Sparks should pass through the workpiece
and out the bottom when cutting.
If sparks flare back from surface, this
usually is an indication that either travel
speed is too fast 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 electrode and surface.
DO NOT put pressure on shield when
drag cutting; instead, slide shield along
the surface for proper cutting results.
Pulling rather than pushing the torch
makes cutting easier. Use a proper guide
or template for accurate cutting operations.
Ref. 803 640-A / 801 400-B / Ref. 802 878
OM-2239 Page 18
5-5. Sequence Of Cutting Operation
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
. Set air pressure to 75 PSI (517 kPa) for cutting.
The pilot arc starts immediately
when trigger is pressed.
90°
For standard (shielded) cutting, place drag
shield on edge of metal. For extended
(non-shielded) cutting, use 1/8 in (3.2 mm)
standoff distance (dragging tip will reduce tip
life).
Adjust torch speed so
sparks go thru metal and
out bottom of cut.
Raise trigger lock and press
trigger. Pilot arc starts.
Pause briefly at end of
cut before releasing trigger.
After cutting arc starts, slowly
start moving torch across metal.
Postflow continues for approx. 20 seconds
after releasing trigger; cutting arc can be
instantly restarted during postflow by raising
trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
OM-2239 Page 19
5-6. Sequence Of Gouging Operation
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
. Set air pressure to 55 PSI (379 kPa) for gouging.
The pilot arc starts immediately
when trigger is pressed.
455
Hold torch at approximately
45° angle to workpiece.
Raise trigger lock and press trigger. Pilot
arc starts. Move tip to within approximately 3/16 in (4.8 mm). Start gouging
across workpiece surface. Maintain
approximately a 45° angle to surface.
Release trigger. Postflow continues for
approx. 20 seconds after releasing trigger;
arc can be instantly restarted during postflow
by raising trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
OM-2239 Page 20
5-7. Sequence Of Piercing Operation
The pilot arc starts immediately
when trigger is pressed.
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
90°
Rotate torch to upright position
approximately 90° to surface.
When arc has pierced through
workpiece, start cutting.
. Set air pressure to 75 PSI
(517 kPa) for cutting.
Hold torch at an angle to the
workpiece. Raise trigger lock and
press trigger. Pilot arc starts.
90°
Maintain approximately 90° torch
position to surface, and continue
cutting.
Release trigger. Postflow continues for
approx. 20 seconds after releasing trigger;
arc can be instantly restarted during postflow
by raising trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
OM-2239 Page 21
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
Each Use
Check Torch
Tip, Electrode,
And Shield Cup
Check Gas/Air
Pressure
Every Week
Check Shield
Cup Shutdown
System
3 Months
Service Air
Filter/Regulator
Assembly Filter
Replace
Unreadable
Labels
Replace
Cracked
Parts
Tape Torn Outer
Covering Or
Replace Cable
Check
Gas/Air Hose
Check Torch
Body
6 Months
OR
OM-2239 Page 22
Blow Out Or
Vacuum Inside
6-2. Overload Protection: Status Lights & Checking Shield Cup Shutdown System
If certain problems occur, a status
light comes on, and output stops.
1
Pressure Light
Lights if gas/air pressure is below
40 PSI (276 kPa).
Turn power Off, and check for
proper gas/air pressure (see
Section 4-12).
1
2
A flashing Pressure light indicates
that gas/air system may be set too
low, faulty, leaking or has a flow
restriction (see Section 6-5).
3
2
Cup Light
Lights if shield cup is loose/off.
Turn Power On and loosen shield
cup. If shutdown system works
properly, Cup light comes on. If not,
turn power Off and have a factory
authorized service agent check
unit.
Checking Torch Shield Cup Shutdown System
Power must be reset whenever the cup shutdown system is activated.
Always turn Off power when changing or checking consumables.
If system works properly, retighten
cup and reset power.
Turn power Off, and check shield
cup connection (see torch Owner’s
Manual). Power must be reset
whenever the cup shutdown is
activated.
A flashing Cup light indicates that
the torch consumables are stuck or
worn and should be inspected and/
or replaced (see Section 6-3).
Check shield cup shutdown system
once a week.
Shield
Cup
3
Temperature Light
Lights if power source overheats or
when ambient temperature is below
−20° C (−4° F) (see Section 4-3).
Fan-On-Demand
Cooling fan will operate during the
following conditions:
a
Unit is in an OVERTEMP
condition. TEMP indicator
light will illuminate and fan
will run until unit cools
down.
b
Unit gets hot during idle,
either from a change in
ambient air temperature or
after long periods of
cutting.
c
Unit is in cutting or postflow
mode.
Ref. 200 808 / Ref. 801 300-A
OM-2239 Page 23
6-3. Checking/Replacing Retaining Cup, Tip, And Electrode
Overtightening will strip threads. Do not overtighten 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.
Make sure this area is clean of
any debris.
8
5
7
6
Make sure swirl ring is clean of any
debris and no holes are
obstructed.
New
1/32 in
(1 mm)
Pit
Worn
4
2
3
1
New
Worn
Ref. 803 224
Turn Off power source.
1
2
Drag Shield
Retaining Cup
Remove retaining cup. Check retaining cup
for cracks, and replace if necessary.
3
Tip
OM-2239 Page 24
4 Opening
Remove tip. Check tip, and replace if opening is deformed or 50% oversize. If inside of
tip is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards.
5 Electrode
Check electrode. If center has a pit more
than a 1/32 in (0.8 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.
6-4. Torch And Work Cable Replacement
1
3
4
7
6
2
5
8
2
3
5
4
If torch or work cable needs to be removed
or replaced, proceed as follows:
Turn power Off, and disconnect input
power plug from receptacle. Remove
wrapper from unit.
Torch Replacement
1
Strain Relief
2
Torch Cable
Loosen outer strain relief pigtail so that
torch cable can slide freely.
3
Plug PLG1/Receptacle RC1
Disconnect PLG1 from receptacle RC1 on
Control board PC1.
4 Plug PLG11/Receptacle RC11
Disconnect PLG11 from receptacle RC11
on Control board PC1.
5
Air Line Connector
Push orange fitting inward toward air
solenoid while pulling connector out of
fitting.
Remove nut, located inside of unit, from
back of strain relief.
Slide torch cable, connector, and plugs
through nut and out of unit. Retain nut for
use on replacement strain relief.
Insert replacement cable with strain relief
through opening where old cable and strain
relief were removed. Slide strain relief nut
over plugs, connector, and cable. Install nut
onto strain relief, but do not tighten.
Insert air line connector into solenoid fitting.
Connect PLG1 to RC1 on Control board
PC1.
Connect PLG11 to RC11 on Control board
PC1.
Tighten strain relief nut.
Tighten strain relief around cable.
Work Cable Replacement
6 Rubber Boot
7 Work Cable Ring Terminal
Slide rubber boot away from ring terminal
connection on Control board PC1. Remove
hardware securing ring terminal to PC1.
8 Strain Relief
Remove nut, located inside of unit, from
back of strain relief.
Slide work cable through nut and out of unit.
Retain nut for use on replacement strain
relief.
Slide rubber boot over ring terminal and off
of work cable. Retain rubber boot for use on
replacement work cable.
. Be
sure to allow some work cable
slack inside the unit.
Insert replacement cable with strain relief
through opening where old cable and strain
relief were removed. Slide strain relief nut
over ring terminal and cable. Install nut onto
strain relief, but do not tighten.
Route cable along bottom of unit and up to
PC1.
Slide rubber boot over ring terminal and
onto work clamp lead. Connect work cable
ring terminal to terminal labeled WORK on
circuit board PC1. Torque to 35 in lb
(4 N⋅m). Slide boot over connection.
Tighten strain relief nut.
Tighten strain relief around cable.
Tools Needed:
5/16, 3/8 in
803 386 / 803 385-A
OM-2239 Page 25
6-5. Troubleshooting Power Source
Is Power switch
S1 in the On
position?
No
Place Power switch in the
On position. (see Section
5-1).
Does pilot arc
ignite?
No
Press torch trigger and
check if pilot arc ignites.
Check torch consumables.
*Check torch connections,
air filter, pressure switch S3,
valve AS1, air supply
connection to unit, torch,
and PC1.
Yes
Yes
Is Power light
flashing?
Yes
Reset Power switch S1.
Does pilot arc
transfer
to
workpiece?
No
Place torch near workpiece
and check if pilot arc “jumps”
or transfers to workpiece.
Check
work
clamp
connection. *Check Control
board PC1 and connections,
and torch and its connections.
Yes
No
Is Cup Status
light On or
flashing?
Yes
Check torch consumables/
cup. Reset Power switch
S1. *Check torch connections. *Check Control board
PC1.
NOTE: The fan will normally run for
approximately 5 seconds after power
switch is placed in the Off position (see
Section 5-1).
No
Is Temp Status
light On?
*
Check all connections,
Check main transformer T1,
Check boost inductor L1
and output inductor L2.
Return to beginning of chart.
Yes
If unit is overheated, wait
while fan cools down unit
temperature.
No
Is Pressure Status
light On or flashing?
Yes
Turn Output control
fully counterclockwise (see
Section 4-12). Check for
gas/air flow at torch. *Check
Control
board
PC1,
pressure switch, air filter,
valve AS1, and air supply
connection to unit and torch.
No
*Servicing procedure to be
performed only by authorized
Service Station.
OM-2239 Page 26
6-6. Troubleshooting Torch
Does arc go
on and off
while cutting?
Yes
Torch travel speed too slow;
increase travel speed (see
Section 5-5). Clean or
replace torch consumables
as necessary (see Section
6-3). Be sure work clamp is
securely
attached
to
workpiece.
Go to Section 6-5.
No
Does arc go out
while cutting?
Yes
Be sure work clamp is
securely attached to workpiece. Make sure tip is on or
near, 1/16 in (1.6 mm) to 1/8
in (3.2 mm) workpiece (see
Section 5-5). Clean or
replace torch consumables
as necessary (see Section
6-3).
Go to Section 6-5.
No
Do sparks come
out of top of cut;
or cut is not
clean?
Yes
No
Are
Trouble
lights On; unit
has no cutting
output?
Yes
Torch travel speed too fast;
reduce travel speed (see
Section 5-5). Clean or
replace torch consumables
as necessary (see Section
6-3). Be sure work clamp is
securely
attached
to
workpiece. Unit not capable
of cutting metals thicker
than rating (see Section
4-1).
Check torch consumables.
Check for gas/air flow at
torch. Check air supply connection and pressure to unit
and torch. Reset unit Power
switch. *Check torch and
connections inside unit.
Go to Section 6-5.
No
Go to Section 6-5.
*Servicing procedure to be performed
only by authorized Service Station.
OM-2239 Page 27
SECTION 7 − ELECTRICAL DIAGRAM
212 926-A
Figure 7-1. Circuit Diagram
OM-2239 Page 28
Notes
OM-2239 Page 29
SECTION 8 − PARTS LIST
. Hardware is common and
27
34
35
33
32
3
4
36
37
1
2
31
30
5
29
6
24
7
28
23
26
8
22
9
7
7
7
10
17
11
21
12
25
38
18
16
19
20
15
13
14
not available unless listed.
Ref. 803 223-C
Figure 8-1. Main Assembly
OM-2239 Page 30
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 8-1. Main Assembly
. . . . . . . . . . . . . . . . 213308
. . . 1 . . . . . . . . . +204582
. . . 2 . . . . . . . . . . 208015
. . . 3 . . . . . . . . . . 204326
. . . 4 . . . . . . . . . . 089 899
. . . 5 . . . . . . . . . . 207653
. . . 6 . . . . . . . . . . 208170
. . . . . . . . . . . . . . . . 207 686
. . . . . . . . . . . . . . . . 119 503
. . . 7 . . . . . . . . . . 179276
. . . 8 . . . . . . . . . . 204329
. . . 9 . . . . . . . . . . 207134
. . . . . . . . . AS1 . . 206000
. . . . . . . . . . S2 . . 174670
. . . 10 . . . PC3 . . 208417
. . . 11 . . . . . . . . . . 207137
. . . . . . . . . . . . . . . . 202687
. . . . . . . . . . . . . . . . 200878
. . . . . . . . . . . . . . . . 204330
. . . 12 . . . . . . . . . . 204581
. . . 13 . . . . . . . . . . 604 102
. . . 14 . . . . . . . . . . . 188911
. . . 15 . . . . . . . . . . 207997
. . . 16 . . . FM . . 225166
. . . 17 . . . . . . . . . . 185835
. . . 18 . . . . . . . . . . 212925
. . . 19 . . . C85 . . 192935
. . . 20 . . . PC1 . . 209884
. . . 21 . . . . R1 . . 207995
. . . 22 . . . . . . . . . . 208168
. . . 23 . . . . L2 . . 207298
. . . 24 . . . . L1 . . 207297
. . . 25 . . . . T1 . . 207296
. . . 26 . . . . . . . . . . 173693
. . . . . . . . . . . . . . . . 601965
. . . . . . . . . . . . . . . . 010909
. . . 27 . . . . . . . . . . 204324
. . . 28 . . . PC2 . . 192965
. . . 29 . . . . . . . . . . 174991
. . . 30 . . . . . . . . . . 204331
. . . 31 . . . . . . . . . . 216447
. . . 31 . . . . . . . . . . 217891
. . . . . . . . . . . . . . . . 213619
. . . . . . . . . . . . . . . . 213620
. . . 32 . . . . . . . . . . 175138
. . . 33 . . . . . . . . . . . 195110
. . . . . . . . . . . . . . . . . 195111
. . . 34 . . . . . . . . . . 207136
. . . 35 . . . . . . . . . . 207299
. . . 36 . . . . S1 . . . 124511
. . . 37 . . . . . . . . . . 207135
. . . 38 . . . . . . . . . . 225 474
. . COVER ASSY (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WRAPPER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HANDLE,RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONSUMABLE STORAGE BOX,W/DOOR & LATCH (INCLUDING) . . . . .
. . . . . . LATCH,SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL,CAUTION/WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . INSULATOR,SIDE RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, ICE 40C CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LABEL, MILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING,SNAP−IN NYL 1.000 ID X 1.375 MTG HOLE CENT . . . . . . . . . . .
. . BRACKET,MTG CAPACITOR/VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE,AIR SEALED W/PRESSURE SW/ FTGS/BRKT . . . . . . . . . . . . . . . . . .
. . VALVE,24VDC 3 WAY 1/8NPT 3/32 ORF 100PSI . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH,PRESSURE AIR 40PSI FIXED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY,PRIMARY CONNECT/FILTER . . . . . . . . . . . . . . . . . . .
. . FILTER,AIR W/FITTINGS & BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER,AIR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FILTER,AIR 5 MICRON 1/4NPT PORTS W/DRAIN . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET,MTG FILTER/PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL,REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONN,CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE,POWER 12FT 8−10GA 3C 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUARD,FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FAN,MUFFIN 24VDC 4000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL,WARNING ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WINDTUNNEL, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA W/NUT . . . . . . . . . .
. . KIT,REPLACEMENT CONTROL BD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RESISTOR,WW FXD 50 W 25 OHM NI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE,AIR WINDTUNNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INDUCTOR,OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INDUCTOR,BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . XFMR,MAIN SPECTRUM 625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FOOT,MTG UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW,375−16X1.00 HEX HD−PLN GR5 PLD . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT,375−16 .56HEX .46H STL PLD ELASTIC STOP NUT . . . . . . . . . . . . . . .
. . BASE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY,LED/POT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . . .
. . PANEL,FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE,WORK 25 FT 6 GA W/CLAMP STRAIN RLF & TERM . . . . . . . . . . . .
. . CABLE,WORK 50 FT 6 GA W/CLAMP STRAIN RLF & TERM . . . . . . . . . . . .
. . CLAMP,WORK 300A STL CHROME PLD W/COPPER CONTACTS . . . . . . .
. . CONTACT TIP,WORK CLAMP 300AMP COPPER . . . . . . . . . . . . . . . . . . . . . .
. . BOX,LOUVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ICE−40C 25FT HAND HELD REPLACEMENT TORCH OR
. . ICE−40C 50FT HAND HELD REPLACEMENT TORCH . . . . . . . . . . . . . . . . . .
. . GAUGE,PRESSURE AIR W/FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NAMEPLATE,MILLER SPECTRUM 625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REGULATOR,AIR W/FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER,NYLON CAPACITOR 76MM DIAMETER . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
2
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2239 Page 31
NOTE: The ICE-40C torch is specifically for use
only with this plasma cutting unit.
Item Part
No. No.
1
2
3
3
4
1
5
6
2
195 110
195 111
183 427
192 059
209 298
209 299
185 833
190 220
171 248
169 231
Description
ICE-40C 25ft Torch
ICE-40C 50ft Torch
Handle Assy, complete (1)
Main Body (1)
Leads, 25ft (1)
Leads, 50ft (1)
Switch Assembly
w/spring (1)
Spring, trigger assembly
Push Button Switch (1)
Grease, silicone (1)
See Figure 8-3 for additional
consumable parts.
6
5
4
3
Ref. 195 092 / Ref. 803 224
Figure 8-2. Torch, ICE-40C
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2239 Page 32
For extended tip use, set Amperage control to 35.
Drag Shield
204 323
Retaining Cup
192 050
Tip
204 325
Electrode
192 047
Swirl Ring
192 049
Standard
Cutting
Deflector
177 888
Retaining Cup
192 050
35A Tip
192 052
Electrode
Shield
192 203
Retaining Cup
192 050
Tip
204 332
Electrode
192 047
192 048
Extended
Cutting
O-Ring
169 232
Apply silicone grease
(169 231) before installing
1/8” (3 mm) stand-off
recommended
Gouging
CAUTION
NOTE:
Set air pressure to
75 PSI for cutting or
55 PSI for gouging.
FAILURE TO REPLACE WORN TIP OR
ELECTRODE WILL
RUIN TORCH AND
VOID WARRANTY.
S
ICE−40C
CONSUMABLES
S
Turn off power before
checking torch parts.
Check before each use
and hourly during operation.
207 686−A
207 686-A
Figure 8-3. Consumable Parts For ICE-40C
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2239 Page 33
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 1/05
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2006 Miller Electric Mfg. Co. 10/05
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
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