Miller | MD370543P | Owner Manual | Miller SPECTRUM 875 AND XT60 TORCH User manual

Miller SPECTRUM 875 AND XT60 TORCH User manual
OM-264 259B
2013−10
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum 875
R
And XT60 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 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
4
4
4
5
5
5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
9
9
9
10
10
10
11
11
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Torch Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Power Source Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
12
13
13
14
14
15
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
Connecting And Disconnecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting And Disconnecting Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Plasma Cutter To Miller Or Hobart Generator Equipped With A
Full KVA Receptacle (NEMA 14-50R) Using Adapter Cord (Part No. 300 158) . . . . . . . . . . . . . . . . . .
5-9. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat, Trailblazer
Or Hobart Champion 10,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Generator Settings For Plasma Cutter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Installing Alternative Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
17
17
18
20
21
22
22
23
23
24
24
25
6-5.
6-6.
Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
6-7.
6-8.
Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Consumables Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
29
TABLE OF CONTENTS
SECTION 7 − MECHANIZED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. XT60M Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Remote Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Remote Control Cable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Remote Voltage Sense Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Shield Sense Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Cut Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Wrapper Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Checking Or Replacing Filter Element (Part No. 227 877) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Status/Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
29
29
30
30
31
31
32
34
34
34
35
36
37
38
39
40
42
46
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
pom_2011-10
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Plasma Arc Cutting Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
CUTTING can cause fire or explosion.
Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and burns. Check
and be sure the area is safe before doing any cutting.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this
is not possible, tightly cover them with approved covers.
Do not cut where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not cut on containers that have held combustibles, or on closed
containers such as tanks, drums, or pipes unless they are properly
prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
Connect work cable to the work as close to the cutting area as practical to prevent cutting current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
Do not use plasma cutter to thaw frozen pipes.
Never cut containers with potentially flammable materials inside −
they must be emptied and properly cleaned first.
Do not cut where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Do not cut pressurized cylinders, pipes, or vessels.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Do not locate unit on or over combustible surfaces.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any cutting.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but may also use torches designed with safety
interlock systems which turn off the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. Incorrectly
installed or improperly grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
D Do not touch torch parts if in contact with the work or ground.
D Turn off power before checking, cleaning, or changing torch parts.
D Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA CFR
1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to its
Owner’s Manual and national, state, and local codes.
D Check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet − always verify
the supply ground.
D When making input connections, attach proper grounding conductor first.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Inspect and replace any worn or damaged torch cable leads.
D Do not wrap torch cable around your body.
D Ground the workpiece to a good electrical (earth) ground if required
by codes.
D Use only well-maintained equipment. Repair or replace damaged
parts at once.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Do not bypass or try to defeat the safety interlock systems.
D Use only torch(es) specified in Owner’s Manual.
D Keep away from torch tip and pilot arc when trigger is pressed.
D Clamp work cable with good metal-to-metal contact to workpiece
(not piece that will fall away) or worktable as near the cut as
practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D
D
D
OM-264 259 Page 1
ELECTRIC SHOCK can kill.
FUMES AND GASES can be hazardous.
SIGNIFICANT DC VOLTAGE exists in
inverter power sources AFTER the removal of input power.
Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Maintenance Section of Owner’s Manual or Technical Manual before
touching any parts.
EXPLODING PARTS can injure.
D On inverter power sources, failed parts can explode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.
D
D
D
D
D
D
D
FLYING SPARKS can injure.
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
D
D
D
D
Wear approved face shield or safety goggles with side shields.
Wear proper body protection to protect skin.
Wear flame-resistant ear plugs or ear muffs to prevent sparks from
entering ears.
PLASMA ARC can injure.
ARC RAYS can burn eyes and skin.
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
D
D
D
D
Wear face protection (helmet or shield) with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks when
cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a
No. 9 shade (with No. 8 as minimum) for all cutting currents less
than 300 amperes. Z49.1 adds that lighter filter shades may be used
when the arc is hidden by the workpiece. As this is normally the case
with low current cutting, the shades suggested in Table 1 are provided for the operator’s convenience.
Wear approved safety glasses with side shields under your helmet
or shield.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
Table 1. Eye Protection For Plasma Arc Cutting
Current Level In Amperes
Below 20
20 − 40
40 − 60
60 − 100
Minimum Shade Number
#4
#5
#6
#8
NOISE can damage hearing.
Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
D
D
Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.
OM-264 259 Page 2
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove cutting fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals to be cut, coatings,
and cleaners.
Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Fumes from cutting and oxygen depletion
can alter air quality causing injury or death. Be sure the breathing air
is safe.
Do not cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not cut on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the cutting area, the
area is well ventilated, and while wearing an air-supplied respirator.
The coatings and any metals containing these elements can give off
toxic fumes when cut.
Do not cut containers with toxic or reactive materials inside or
containers that have held toxic or reactive materials − they must be
emptied and properly cleaned first.
D
D
D
D
D
D
D
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.
Keep away from the torch tip.
Do not grip material near the cutting path.
The pilot arc can cause burns − keep away from torch tip when trigger is pressed.
Wear proper flame-retardant clothing covering all exposed body areas.
Point torch away from your body and toward work when pressing
the torch trigger − pilot arc comes on immediately.
Turn off power source and disconnect input power before disassembling torch or changing torch parts.
Use only torch(es) specified in the Owner’s Manual.
CYLINDERS can explode if damaged.
Compressed 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 compressed gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number
of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
D
1-3. Additional Symbols For Installation, Operation, And Maintenance
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
FLYING METAL or DIRT can injure eyes.
D Wear safety glasses with side shields or wear
face shield.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
EXPLODING HYDROGEN hazard.
D When cutting aluminum underwater or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the workpiece.
D See your cutting engineer and water table instructions for help.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift unit.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually
lifting heavy parts or equipment.
FIRE OR EXPLOSION hazard.
D Do not locate unit on, over, or near combustible
surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
D High frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment
at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC CUTTING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D To reduce possible interference, keep cables as short as possible,
close together, and down low, such as on the floor.
D Locate cutting operation 100 meters from any sensitive electronic
equipment.
D Be sure this cutting power source is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures such
as moving the machine, using shielded cables, using line filters, or
shielding the work area.
BATTERY EXPLOSION can injure.
D Do not use plasma cutter to charge batteries or
jump start vehicles unless it has a battery charging feature designed for this purpose.
OM-264 259 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Recommended Practices for Plasma Arc Cutting and Gouging, American Welding Society Standard AWS C5.2, from Global Engineering
Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field around
the welding circuit and welding equipment. EMF fields may interfere with
some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict
access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to minimize
exposure to EMF fields from the welding circuit:
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
1. Keep cables close together by twisting or taping them, or using a
cable cover.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-264 259 Page 4
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
pom_2011−10fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers liés au coupage à l’arc au plasma
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 1-5. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
LE COUPAGE présente un risque de
feu ou d’explosion.
Des particules de métal chaud et des étincelles
peuvent jaillir de la pièce au moment du coupage.
Les étincelles et le métal chaud, la pièce à couper
chauffée et l’équipement chaud peuvcnt causer un
feu ou des brûlures. Avant de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.
D Déplacez toute matière inflammable se trouvant à l’intérieur d’un
périmètre de 10,7 m (35 pi) de la pièce à couper. Si cela est impossible, vous devez les couvrir avec des housses approuvées et bien
ajustées.
D Ne coupez pas dans un endroit où des étincelles pourraient atteindre des matières inflammables.
D Protégez−vous, ainsi que toute autre personne travaillant sur les
lieux, contre les étincelles et le métal chaud.
D Assurez−vous qu’aucune étincelle ni particule de métal ne peut se
glisser dans de petites fissures ou tomber dans d’autres pièces.
D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur à la portée de la main.
D Si vous coupez sur un plafond, un plancher ou une cloison, soyez
conscient que cela peut entraîner un feu de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un bidon.
D Fixez le câble de masse sur la pièce à couper, le plus près possible
de la zone à couper afin de prévenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une
décharge électrique, d’étincelles ou un feu.
D Ne pas utiliser le coupeur plasma pour dégeler des conduites gelées.
D Ne coupez jamais des contenants qui peuvent contenir des matières inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.
D Ne coupez pas quand l’atmosphère peut contenir des poussières,
gaz ou vapeurs (comme l’essence) inflammables.
D Ne coupez pas dans un endroit où l’atmosphère risque de contenir
de la poussière ou des vapeurs explosives.
D Ne coupez pas de bouteilles, de tuyaux ou de contenants pressurisés.
D Portez des vêtements de protection exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Ne placez pas le poste sur une surface combustible ou au−dessus
de celle−ci.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Avant le coupage, retirez tout combustible de vos poches, par
exemple un briquet au butane ou des allumettes.
UN CHOC ÉLECTRIQUE peut tuer.
Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Le coupage plasma nécessite
des tensions plus importantes que le soudage pour amorcer et
maintenir l’arc (200 à 400VDC est typique), mais peut être utilisé avec
des torches équipées de systèmes de verrouillage de sécurité qui
arrêtent la machine en cas de buse desserrée ou si l’électrode touche
la tuyère. Incorrectly installed or improperly grounded equipment is a
hazard.
D Ne touchez pas aux pièces électriques sous tension.
D Portez des gants isolants et des vêtements de protection secs et
sans trous.
D Isolez−vous de la pièce à couper et du sol en utilisant des housses
ou des tapis assez grands afin d’éviter tout contact physique avec
la pièce à couper ou le sol.
D Ne touchez pas aux pièces du chalumeau si vous êtes en contact
avec la pièce à couper ou le sol.
D Mettez l’appareil hors tension avant d’effectuer la vérification, le
nettoyage ou le changement d’une pièce du chalumeau.
OM-264 259 Page 5
D Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation
selon la norme OSHA 29 CFR 1910.147 (reportez−vous aux Principales normes de sécurité).
D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les
normes nationales, départementales et locales.
D Assurez−vous que le fil de terre du cordon d’alimentation est correctement relié à la borne de terre dans la boîte de coupure ou que
la fiche du cordon est branchée à une prise correctement mise à la
terre − vous devez toujours vérifier la mise à la terre.
D Avant d’effectuer les connexions d’alimentation, vous devez relier
le bon fil de terre.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
D Vérifiez fréquemment le cordon d’alimentation afin de vous assurer
qu’il n’est pas altéré ou à nu, remplacez−le immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Vérifiez et remplacez les cosses du câble du chalumeau si elles
sont usées ou altérées.
D Le câble du chalumeau ne doit pas s’enrouler autour de votre
corps.
D Si les normes le stipulent, la pièce à couper doit être mise à la terre.
D Utilisez uniquement de l’équipement en bonne condition. Réparez
ou remplacez immédiatement toute pièce altérée.
D Portez un harnais de sécurité si vous devez travailler au−dessus
du sol.
D Assurez−vous que tous les panneaux et couvercles sont correctement en place.
D N’essayez pas d’aller à l’encontre des systèmes de verrrouillage
de sécurité ou de les contourner.
D Utilisez uniquement le ou les chalumeaux recommandés dans le
manuel de l’opérateur.
D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée.
D Le câble de masse doit être pincé correctement sur la pièce à couper, métal contre métal (et non de telle sorte qu’il puisse se
détacher), ou sur la table de travail le plus près possible de la ligne
de coupage.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
LES
ÉTINCELLES
PROJETÉES
peuvent provoquer des blessures.
Le coupage plasma produit des étincelles et projections de métal à très haute température. Lorsque la
pièce refroidit, du laitier peut se former.
D Portez une visière ou des lunettes de sécurité avec des écrans latéraux approuvées.
D Portez des vêtements de protection adéquats afin de protéger votre peau.
D Ayez recours à des protège−tympans ou à un serre−tête ignifuges
afin d’éviter que les étincelles n’entrent dans vos oreilles.
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau.
Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner
des brûlures aux yeux et à la peau.
D Une protection faciale (casque ou masque) avec des lunettes filtrantes de teinte adéquate est indispensable pour protéger le
visage et les yeux des rayonnements de l’arc et des étincelles
pendant la découpe ou en regardant simplement ANSI Z49.1 (reportez−vous aux Principales normes de sécurité) suggère
d’utiliser un filtre de teinte nd 9 (nd 8 étant le minimum) pour tout
travail de coupage faisant appel à un courant de moins de 300 A.
On mentionne également dans la norme Z49.1 qu’un filtre plus faible peut être utilisé lorsque l’arc est caché par la pièce à couper.
Comme cela est habituellement le cas pour les travaux de coupage
à faible courant, les teintes énumérées au tableau 1 sont fournies à
titre d’information pour l’opérateur.
D Porter des lunettes de sécurité à coques latérales sous votre casque ou écran facial.
D Ayez recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements, les étincelles et les
éblouissements; prévenez toute personne sur les lieux de ne pas
regarder l’arc.
D Portez des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
Tableau 1. Protection des yeux pour le coupage au plasma d’arc
Intensité de courant en ampères
Filtre de teinte (minimum)
Moins de 20
20 − 40
40 − 60
60 − 100
no. 4
no. 5
no. 6
no. 8
DÉCHARGES ÉLECTRIQUES potentiellement mortelles.
Il reste une TENSION DC NON
NÉGLIGEABLE dans les sources de
soudage onduleur UNE FOIS
l’alimentation coupée.
D Mettre l’unité hors tension, mesurer la tension des condensateurs d’entrée et s’assurer qu’elle est pratiquement nulle avant
de toucher à l’une quelconque des pièces. Mesurer cette tension
conformément aux directives énoncées à la section Entretien du
manuel de l’utilisateur ou du manuel technique avant de toucher
à l’une quelconque des pièces.
Risque de blessure en cas
D’EXPLOSION DES PIÈCES.
D Mise sous tension, toute pièce défectueuse
des sources d’alimentation de l’inverseur peut
exploser ou faire exploser d’autres pièces.
Pour entretenir les inverseurs, toujours porter
un masque protecteur et un vêtement à manches longues.
OM-264 259 Page 6
LE BRUIT peut endommager l’ouïe.
sécurité).
Certaines applications de coupage produisent un
bruit constant, ce qui peut endommager l’ouïe si le
niveau sonore dépasse les limites permises par
l’OSHA (reportez−vous aux Principales normes de
D Utilisez des protège−tympans ou un serre−tête antibruit si le niveau sonore est élevé.
D Prévenez toute personne sur les lieux du danger relié au bruit.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le coupage produit des vapeurs et des gaz.
Respirer ces vapeurs et ces gaz peut être
dangereux pour la santé.
D Ne mettez pas votre tête au−dessus des vapeurs. Ne respirez pas
ces vapeurs.
D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce
ou ayez recours à une ventilation aspirante installée près de l’arc
pour évacuer les vapeurs et les gaz.
D Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travaillez dans un espace restreint uniquement s’il est bien ventilé
ou si vous portez un respirateur anti−vapeurs. Les vapeurs causées par le coupage et l’épuisement de l’oxygène peuvent altérer la
qualité de l’air et entraîner des blessures ou la mort. Assurez−vous
que l’air ambiant est sain pour la santé.
D Ne coupez pas dans un endroit près d’opérations de décapage, de
nettoyage ou de vaporisation. La chaleur et les rayons d’arc peuvent réagir avec les vapeurs et former des gaz hautement toxiques
et irritants.
D Ne coupez pas des métaux enrobés tels que des métaux galvanisés, contenant du plomb ou de l’acier plaqué au cadmium, à moins
que l’enrobage ne soit ôté de la surface du métal à couper, que l’endroit où vous travaillez ne soit bien ventilé, ou que vous ne portiez
un respirateur anti−vapeurs. Les enrobages ou tous métaux qui
contiennent ces éléments peuvent créer des vapeurs toxiques s’ils
sont coupés.
D Ne coupez pas de contenants qui renferment ou ont renfermés des
matières toxiques ou réactives − vous devez en premier lieu les vider et les nettoyer convenablement.
L’ARC PLASMA peut provoquer des
blessures.
La chaleur dégagée par le plasma d’arc peut
entraîner de sérieuses brûlures. La force de l’arc est
un facteur qui s’ajoute au danger de brûlures. La
chaleur intense et la puissance de l’arc peuvent
rapidement passer au travers de gants et de tissus.
D N’approchez pas le tube du chalumeau.
D Ne saisissez pas la pièce à couper près de la ligne de coupage.
D L’arc pilote peut causer des brûlures − n’approchez pas le tube du
chalumeau lorsque vous avez appuyé sur le gâchette.
D Portez des vêtements de protection adéquats qui recouvrent tout
votre corps.
D Ne pointez pas le chalumeau en direction de votre corps ni de la
pièce à couper lorsque vous appuyez sur la gâchette − l’arc pilote
s’allume automatiquement.
D Mettez l’alimentation hors tension et débranchez le cordon d’alimentation avant de démonter le chalumeau ou de changer une
pièce du chalumeau.
D Utilisez uniquement le ou les chalumeaux recommandés dans le
manuel de l’opérateur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé 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 comprimé , des détendeurs, des boyaux et des raccords conçus pour l’application
déterminée. Gardez−les, ainsi que toute autre pièce associée, en
bonne condition.
D Détournez votre visage du détendeur−régulateur lorsque vous ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
vous utilisez la bouteille ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
LES PIÈCES CHAUDES
provoquer des brûlures.
peuvent
D Ne pas toucher des parties chaudes à mains
nues.
D Prévoir une période de refroidissement avant
d’utiliser l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.
Les PIÈCES MOBILES
provoquer des blessures.
peuvent
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-264 259 Page 7
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement; respecter le cycle opératoire nominal.
D Réduire l’ampérage (épaisseur) avant de continuer à couper ou réduire le facteur de marche.
Danger D’EXPLOSION
D’HYDROGÈNE.
D Lors du coupage d’aluminium partiellement ou
totalement immergé dans l’eau, de l’hydrogène
libre peut s’accumuler sous la pièce.
D Consultez votre ingénieur de coupage et les instructions de la
table de coupage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser le découpeur plasma pour charger
des batteries ou faire démarrer des véhicules à
l’aide de câbles de démarrage, sauf si l’appareil
dispose d’une fonctionnalité de charge de
batterie destinée à cet usage.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariot, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacité appropriée
pour soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
OM-264 259 Page 8
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces infllammables.
D Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Etablir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes PC.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
D Le Rayonnement haute frequence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les
interférences éventuelles.
LE COUPAGE Ã L’ARC peut causer
des interférence.
D L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
D Pour réduire la possibilité d’interférence, maintenir les câbles aussi
courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
D Veiller à couper à une distance de 100 mètres de tout équipement
électronique sensible.
D S’assurer que la source de coupage est correctement branchée et
mise à la terre.
D Si l’interférence persiste, l’utilisateur doit prendre des mesures
supplémentaires comme écarter la machine, utiliser des câbles
blindés de des filtres, ou boucler la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver les
mains après toute manipulation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Recommended Practices for Plasma Arc Cutting and Gouging, American Welding Society Standard AWS C5.2, from Global Engineering
Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-264 259 Page 9
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
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)
U1
Primary Voltage
Rated Maximum
Supply Current
I2
Rated Welding
Current
Degree Of
Protection
Maximum Effective
Supply Current
OM-264 259 Page 10
pf
U2
X
Loose Shield Cup
Input
Hz
Hertz
power factor
Suitable for Some
Hazardous
Locations
S1
Power Rating,
Product Of Voltage
And Current (KVA)
S
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications
Power Supply
Input
Rated AC phase (PH) and line frequency (Hz)
Rated Input Voltage (U1) and rated Input
Current (I1) and I1 eff at rated output. I1 eff used
to determine power cord rating
Power Factor/KVA/KW at Rated Output
1 PH
50-60 Hz
——
Volts AC RMS − (U1)
Amps RMS − (I1)
I1 eff
208 1 PH
46.9
29.7
230 1 PH
41.6
29.4
Volts AC RMS − (U1)
Power Factor
KVA/KW
208
0.99
9.92/9.85
230
0.99
9.71/9.66
15.5 KW
——
——
400 Volts DC/Electrode Negative
——
——
Constant Current
——
——
Output Current Rating (I2)
60 A
——
——
Output Voltage Rating (U2)
140 Volts DC
——
——
20-60 A
——
——
Volts AC RMS − (U1)
Duty Cycle %
——
208 Volts AC 1 PH
40
——
230 Volts AC 1 PH
50
——
Up to 15 incline
——
——
Air or Nitrogen
——
——
Clean, moisture-free, oil-free
——
——
90 to 120 PSI at 6.5 SCFM
——
——
Particulates to 5 microns
——
——
——
——
——
Peak KW at Arc Stretch
Output
Rated Open Circuit Voltage (U0) Type
Output Characteristic
Output Current Range
Duty Cycle at 1045 F (405 C) at rated conditions
(U1, I1, U2, I2) based on a 10 minute period
General
Toppling or tilting
Gas Type
Gas Quality
Gas Inlet Pressure and Flow
Gas Filtering
Torch
Mild Steel capacities (see Section 6-7 for
cutting speeds vs material type and thickness)
Rated Capacity (edge start)
7/8 in.
——
——
1-1/4 in.
——
——
Pierce Capacity
7/16 in.
——
——
Gouge Capacity
10.0 lbs (4.5 kg) per hour
——
——
Sever Cut Capacity (edge start)
OM-264 259 Page 11
. A complete Parts List is available at www.MillerWelds.com
4-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating. Duty
cycle is based on an ambient temperature of 104 F (40 C).
40% Duty Cycle
4 Minutes Cutting
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.
6 Minutes Resting
50% Duty Cycle
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
5 Minutes Cutting
5 Minutes Resting
Overheating
A
0
15
OR
Reduce Duty Cycle
Minutes
Duty1 4/95 − Ref. 805 159-A
4-4. Torch Dimensions
Hand-Held Torch
8-3/4 in.
(222 mm)
1-1/2 in.
(38 mm)
1-3/16 in.
(30 mm)
Machine Torch
Ref. 253 554-A
15-19/32 in. (396 mm) long body
6-19/32 in. (168 mm) short body
2-9/64 in. (54 mm)
1-1/16 in. (27 mm)
Gear rack 32 pitch
1/8 in. (3.2 mm) width
1/8 in. (3.2 mm) height
1-3/8 in. (35 mm)
8 in. (202 mm)
. Gear rack not included with short
OM-264 259 Page 12
body torch.
. A complete Parts List is available at www.MillerWelds.com
4-5. Power Source Dimensions And Weight
Unit Dimensions And Weight
18-1/2 in.
(470 mm)
42 lb (19.1 kg)
Torch Weight
13-1/2 in.
(343 mm)
Handheld 20 ft (6.1 m) 3.8 lb (1.7 kg)
Handheld 50 ft (15.2 m) 8.0 lb (3.6 kg)
Short body machine 25 ft (7.6 m) 4.8 lb (2.2 kg)
Long body machine 25 ft (7.6 m) 5.2 lb (2.4 kg)
Work Cable Weight
20 ft (6.1 m) 3-1/2 lb (1.6 kg)
50 ft (15.2 m) 7 lb (3.2 kg)
8-3/4 in. (222 mm)
loc_2 3/96 - Ref. 805 159-A
4-6. Environmental Specifications
A. IP Rating
IP Rating
Operating Temperature Range
IP23CS
This equipment is designed for outdoor use. It may be stored, but is
not intended to be used outside during precipitation unless sheltered.
5 to 104 F (−15 to 40 C)
OM-264 259 Page 13
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting a Location
1
1
!
Lifting Handle
Use handle to lift unit.
2
Do not move or operate
unit where it could tip.
Line Disconnect Device
Locate unit near correct input
power supply.
Locate unit at least 18 in. (460 mm)
away from a wall or other obstruction to allow adequate clearance for
cooling air flow.
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Location
2
18 in.
(460 mm)
18 in.
(460 mm)
loc_2 3/96 - Ref. ST-151 556 / Ref. 805 159
OM-264 259 Page 14
. A complete Parts List is available at www.MillerWelds.com
5-2. Connecting Work Clamp and Gas/Air Supply
1
2
1
Work Clamp
Workpiece
. Connect work clamp to portion
of workpiece that does not fall
away after being cut.
Connect work clamp to a clean,
paint-free location on workpiece, as
close to cutting area as possible.
2
. Use only clean, dry air with 90
AIR/N2
90-120 psi
5
@ 6.75 CFM
(191 L/min)
minimum
3
to 120 psi (621 to 827 kPa)
pressure @ 6.75 CFM
(191L/min) minimum.
. Use filter kit 300 491 or 228 926
where conditions at the worksite allow moisture, oil or other
particulates into the air line.
3
Gas/Air Filter Inlet Opening
4
Hose
. Hose
must have a minimum
inside diameter of 3/8 in.
(9.5 mm).
5
4
From
Gas/Air
Supply
Tools Needed:
9/16 in.
Teflon Tape
Obtain hose with 1/4 NPT righthand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
Rear of Unit
NOTICE − Exceeding input
pressure rating of 120 PSI (827
kPa) can damage unit.
Ref. 803 640-A / Ref. 192 441 / Ref. 805 160-A
OM-264 259 Page 15
. A complete Parts List is available at www.MillerWelds.com
5-3. Connecting And Disconnecting Torch
2
1
3
!
Turn off power source and
disconnect input power.
1
2
3
4
5
Torch Connector
Quick Connect Collar
Nipple
Receptacle
Securing Pin
To connect torch:
Push torch connector onto
receptacle and quick connect until
collar secures nipple.
Rotate securing pin clockwise to
lock connector to unit.
4
To disconnect torch:
5
Rotate securing pin counterclockwise to unlock connector from unit.
Push quick connect collar back
towards unit to release nipple, and
pull torch connector away from unit.
. Use
supplied hook and loop
strap to manage torch and
work cables.
805 161-A
5-4. Connecting And Disconnecting Work Cable
1
2
Work Cable Receptacle
Work Cable Plug
To connect plug, align key with
receptacle keyway and insert into
receptacle. Rotate plug clockwise
(hand tight only) to secure in
receptacle.
To disconnect plug, rotate counterclockwise until key aligns with keyway and pull plug from receptacle.
. Use
supplied hook and loop
strap to manage torch and
work cables.
2
1
Ref. 805 161-A / Ref. 803 475-G
OM-264 259 Page 16
. A complete Parts List is available at www.MillerWelds.com
5-5. Electrical Service Guide
Elec Serv 2011−08
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Single-Phase
Input Voltage (V)
208
230
Input Amperes (A) At Rated Output
47
42
Time-Delay Fuses 2
50
50
3
70
60
10
10
55
(17)
67
(21)
10
10
Max Recommended Standard Fuse Rating In Amperes 1
Normal Operating Fuses
Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(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.
5-6. Extension Cord Data
. When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.
Input Voltage
Input Power
Phase
Hertz
Fuse Size Or
Circuit Breaker Rating
208 V
1
50/60
Time-Delay 2
Normal Operating 3
50 A
230 V
1
50/60
Time-Delay 2
Normal Operating 3
50 A
60 A
70 A
Conductor Size
Max. Cord Length
10 AWG
55 ft (17 m)
10 AWG
67 ft (21 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-264 259 Page 17
. A complete Parts List is available at www.MillerWelds.com
5-7. Selecting A Location And Connecting Input Power
1
5
=GND/PE Earth Ground
9
4
6
8
L1
L2
7
Install conductors into
a deenergized line
disconnect device.
1
3
2
L2
L1
230 VAC, 1
Ref. 805 159-A / 805 162-A
OM-264 259 Page 18
. A complete Parts List is available at www.MillerWelds.com
5-7. Connecting 1-Phase Input Power (Continued)
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
1
Plug (NEMA Type 6-50P)
2
Receptacle
(NEMA Type 6-50R)
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
Connect plug to receptacle.
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
6
7
Disconnect Device Line Terminals
Black And White Input Conductor (L1
And L2)
See rating label on unit and check input voltage available at site.
8
Green Or Green/Yellow Grounding
Conductor
!
!
3
Input Power Cord
4
Disconnect Device (switch shown in the
OFF position)
Disconnect Device Grounding Terminal
5
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to disconnect device line terminals.
9
Over-Current Protection
Select type and size of over-current protection using Section 5-5 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
input4 2012−05
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-264 259 Page 19
. A complete Parts List is available at www.MillerWelds.com
5-8. Connecting Plasma Cutter To Miller Or Hobart Generator Equipped With A
Full KVA Receptacle (NEMA 14-50R) Using Adapter Cord (Part No. 300 158)
3
1
2
3
Adapter Cord
Plasma Cutter Plug
Generator Receptacle
Use adapter cord to connect
plasma cutter to Miller Bobcat,
Trailblazer, or Hobart Champ
10,000 and any other generator
equipped with a full kVA receptacle
(NEMA 14-50R).
1
2
ÌÌÌÌÌ
ÌÌÌÌÌ
ÌÌÌÌÌ
ÌÌÌÌÌ
ÌÌÌÌÌ
805 304-A
OM-264 259 Page 20
. A complete Parts List is available at www.MillerWelds.com
5-9. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat, Trailblazer
Or Hobart Champion 10,000
3
7
Tools Needed:
3 (Not Used)
2
4
4
240V
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
!
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.
5
8
3/16 in.
1
6
5
6
Plug Front
View
7
8
1
Green Or
Green/Yellow
Ref. 120 813-D / Ref. 805 161-A
OM-264 259 Page 21
. A complete Parts List is available at www.MillerWelds.com
5-10. Generator Settings For Plasma Cutter Operation
!
Engine Control Switch must be set at
“RUN” position − not “RUN/IDLE”.
!
Set generator Fine Adjustment Control to 10
for maximum auxiliary power, if applicable.
. The peak KW at arc stretch of this plasma power source
is 15.5 KW. Reducing output to 45 amps may be necessary
to operate the unit using a 10 KW generator.
Ref. 803 222
5-11. 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.
2
3
1
6
7
4
5
1
Supplied 230 VAC Plug
Cut cord close to plug.
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.
Tools Needed:
Ref. 801 305-A / 801 611
OM-264 259 Page 22
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATION
6-1. Controls
1
40
ON
V
50
30
POWER
P R E S S UR E
C UP
3
V
20
TE M P
60
A
OFF
C UT
GOUGE
2
4
1 Output Control
Use control to set cutting output.
2 Status Lights (See Section 8-6)
3 Power Switch
. The fan will operate for approximately 10
seconds after power switch is placed in
the Off position to reduce DC bus
voltage.
4
Cut/Gouge Switch
Place switch in appropriate position for desired process. Unit will automatically regulate pressure to 75 psi (517 kPa) for cutting
and 60 psi (413 kPa) for gouging. Pilot current is automatically increased in gouge
mode to provide better gouging starts.
Ref. 234 155-A
. Use only clean, dry air with 90 to 120 psi
(621 to 827 kPa) pressure. Prevent
moisture from entering air supply at
extreme cold temperatures.
. Use filter kit 300 491 or 228 926 where
conditions at the worksite allow moisture, oil or other particulates into the air
line.
OM-264 259 Page 23
. A complete Parts List is available at www.MillerWelds.com
6-2. Trigger Safety Lock
1
Trigger
1
Trigger Unlocked
Trigger Locked
Ref. 253 554-A
6-3. Plasma Cutting System Practices
!
CUT
GOUGE
. Set
Always connect work clamp to a clean,
paint-free location on workpiece, as close to
cutting area as possible.
The pilot arc starts immediately
when trigger is pressed.
switch to either cut or gouge
depending on desired process.
DO NOT start pilot arc without cutting or
gouging as this shortens the service life
of the nozzle and electrode.
. Connect work clamp to portion of workpiece
that does not fall away after being cut.
90
Maintain approximately a 90 angle to the
workpiece surface for proper cutting results.
Sparks should pass through the workpiece
and out the bottom when cutting.
If sparks flare back from surface, this
usually is an indication that either travel
speed is too fast or amperage is set too low.
Wt
1/16 in.
(1.6 mm)
When doing extended (non-shielded)
cutting, maintain approximately 1/16 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.
. For more information, go to MillerWelds.com.
Ref. 803 640-A / 801 400-B / Ref. 254 087-A
OM-264 259 Page 24
. A complete Parts List is available at www.MillerWelds.com
6-4. Sequence Of Cutting Operation
CUT
GOUGE
. Unit automatically regulates pressure to 75 psi
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
(517 kPa) for cutting.
. Connect work clamp to portion of workpiece
that does not fall away after being cut.
!
The pilot arc starts immediately
when trigger is pressed.
90
For standard (shielded) cutting, place drag shield
on edge of metal. For extended (non-shielded)
cutting, use 1/8 in. (3.2 mm) standoff distance
(dragging tip will reduce tip life).
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.
. For more information, go to MillerWelds.com.
Ref. 803 640-A / 801 400-B / Ref. 254 087-A
OM-264 259 Page 25
. A complete Parts List is available at www.MillerWelds.com
6-5. Sequence Of Gouging Operation
CUT
GOUGE
. Unit automatically regulates pressure
to 60 psi (413 kPa) for gouging.
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
Trigger pilot arc once
before starting to gouge.
. Connect work clamp to portion of workpiece
that does not fall away after being cut.
!
The pilot arc starts immediately
when trigger is pressed.
45
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.
. For more information, go to MillerWelds.com.
Ref. 803 640-A / 801 400-B / Ref. 254 087-A
OM-264 259 Page 26
. A complete Parts List is available at www.MillerWelds.com
6-6. Sequence Of Piercing Operation
!
The pilot arc starts immediately
when trigger is pressed.
. Recommended
maximum piercing
capacity is 7/16 in (11 mm).
CUT
GOUGE
45
. Unit automatically regulates pressure
to 75 psi (517 kPa) for cutting.
Connect work clamp to a clean,
paint-free location on workpiece, as
close to cutting area as possible.
Hold torch at approximately 45
to the workpiece. Raise trigger
lock and press trigger. Pilot arc
starts.
. Connect
work clamp to portion of
workpiece that does not fall away after
being cut.
90
Rotate torch to upright position
approximately 90 to surface.
When arc has pierced through
workpiece, start cutting.
90
Maintain approximately 90 torch
position to surface, and continue
cutting.
Release trigger. Postflow continues for
approx. 20 seconds after releasing trigger;
arc can be instantly restarted during postflow
by raising trigger lock and pressing trigger.
. For more information, go to MillerWelds.com.
Ref. 803 640-A / 801 400-B / Ref. 254 087-A
OM-264 259 Page 27
. A complete Parts List is available at www.MillerWelds.com
6-7. Cutting Speed
Mild Steel
Arc Current
40
60
Material Thickness
Recommended Cut Speeds
Inches
mm
IPM
mm/min
18ga (0.05)
1.2
455
11,557
16ga (0.06)
1.5
438
11,125
14ga (0.08)
1.9
275
6,985
1/8 (0.13)
3.2
195
2,311
3/16 (0.19)
4.8
91
1,549
1/4 (0.25)
6.4
61
254
1/4 (0.25)
6.4
105
2.667
3/8 (0.38)
9.5
54
1,372
1/2 (0.50)
12.7
34
684
5/8 (0.63)
15.9
27
686
3/4 (0.75)
19.1
18
457
7/8 (0.88)
22.2
10
254
Stainless
Arc Current
40
60
Material Thickness
Recommended Cut Speeds
Inches
mm
IPM
mm/min
14ga (0.08)
2.0
221
5,613
12ga (0.11)
2.7
189
4,800
1/8 (0.13)
3.2
111
2,819
3/16 (0.19)
4.8
81
2,057
1/4 (0.25)
6.4
52
1,321
1/4 (0.25)
6.4
119
3,023
3/8 (0.38)
9.5
61
1,549
1/2 (0.50)
12.7
42
1,067
5/8 ((0.63)
15.9
28
711
Aluminum
Arc Current
40
60
Material Thickness
Inches
mm
IPM
mm/min
16ga (0.06)
1.6
327
8,305
3/32 (0.09)
2.3
237
6,020
1/8 (0.13)
3.2
177
4,496
3/16 (0.19)
4.8
81
2,057
1/4 (0.25)
6.4
52
1,321
1/4 (0.25)
6.4
119
3,023
3/8 (0.38)
9.5
61
1,549
1/2 (0.50)
12.7
42
1,067
5/8 (0.63)
15.9
28
711
. Recommended cut speed is approximately 80% of maximum.
. Recommended maximum piercing capacity is 7/16 in. (11 mm).
OM-264 259 Page 28
Recommended Cut Speeds
. A complete Parts List is available at www.MillerWelds.com
6-8. Consumables Storage Compartment
1
Consumables Storage
Compartment
This compartment provides
convenient access to consumables
and parts.
1
Rear of Unit
Ref. 805 160-A
SECTION 7 − MECHANIZED OPERATION
7-1. XT60M Mounting Position
1
2
XT60M Machine Torch
Square
Use a square to align torch perpendicular to the work surface.
1
2
90
OM-264 259 Page 29
. A complete Parts List is available at www.MillerWelds.com
7-2.
Remote Control Receptacle
. Remote trigger will only oper-
ate with a machine torch installed. Remote trigger is disabled when a handheld torch is
installed.
1
1
RC61 provides remote arc start
inputs when using the XT60M
machine torch. Connect supplied
remote control cable or remote
pendant control to receptacle on
rear panel.
2
3
2
6
5
4
11
10
9
8
14
13
Hand Torch Adapter Plug
The supplied hand torch adapter
plug can be used for switching back
to a hand-held torch for hand cutting
operations or for using the
hand-held torch instead of the machine torch.
1
7
Remote Control Receptacle
RC61
12
2
243 336-A / 256 574-A
7-3. Remote Control Cable Functions
Function
Remote Start
Noise Suppression
OM-264 259 Page 30
Lead
Socket
Lead Information
White
1
Red
5
White and red leads connect to a set of customer-supplied remote contacts to
provide a remote trigger input signal to RC61 sockets 1 and 5 for the remote
start function.
Shielding
3
Chassis ground.
. A complete Parts List is available at www.MillerWelds.com
7-4. Remote Voltage Sense Connection
!
Turn off power source and
disconnect input power.
Remove wrapper (see Section 8-4).
Remote voltage sense is an arc
voltage output signal for automatic
torch height adjustment.
1
2
1
3
Snap-in Blank
Secondary Interconnect
Board PC4
Receptacle RC48
Remove snap-in blank from rear
panel.
Route plug end of cable through
opening in rear panel.
Route plug end of cable over to
PC4.
Allowing adequate slack inside the
machine, secure cable and strain
relief by snapping strain relief into
opening in rear panel.
Connect plug to RC48 on PC4.
Install wrapper on unit.
Cut off crimped terminals on lead
ends, and connect lead 1 to +volts
DC (work) and lead 2 to −volts DC
(electrode) on customer-supplied
voltage sense device.
3
Tools Needed:
Torx 25
2
Ref. 804 041-A / 243 336-A
7-5. Shield Sense Tab
. Shield sense tab is located in
the consumable storage box
on left side of unit wrapper.
Shield sense tab is included
only with units originally sold
with machine torches.
Shield sense tab provides feedback to a
compatible torch height controller before
starting the cutting process. Place the shield
sense tab between the cup and shield.
Ref. 256 001-A
OM-264 259 Page 31
. A complete Parts List is available at www.MillerWelds.com
7-6. Cut Charts
60 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts.
Shield
Retaining Cap
Tip
Electrode
265 226
256 029
249 929
256 026
Swirl Ring O−Ring
256 028
XT60M Torch
263 834
262 643
263 310
Sense Tab
Ref. 265 001-A
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel
Arc Current Arc Voltage
Optimum Cut Speeds
IPM
mm/min
IPM
mm/min
147
26 Ga
0.5
638
16205
415
10541
148
22 Ga
0.8
500
12700
325
8255
18 Ga
1.3
312
7925
203
5156
0
152
16 Ga
1.5
176
4470
114
2896
144
0.25
14 Ga
1.9
640
16256
221
5613
146
0.50
10 Ga
3.4
152
3861
99
2510
147
0.75
3/16
4.7
97
2464
63
1600
149
1.00
1/4
6.4
73
1854
47
1205
16 Ga
1.5
627
15926
502
12751
10 Ga
3.4
266
6756
213
5405
136
OM-264 259 Page 32
Maximum Cut Speeds
mm
134
60
Material Thickness
Inches
149
40
Pierce
Delay
0
136
0.25
1/4
6.4
131
3327
85
2163
141
0.75
3/8
9.5
63
1600
41
1041
143
1.50
1/2
12.7
44
1118
29
726
147
5/8
15.9
31
787
20
508
153
3/4
19.0
22
559
14
356
. A complete Parts List is available at www.MillerWelds.com
Stainless
Arc Current Arc Voltage
139
139
Pierce
Delay
0
142
40
60
143
0.25
143
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
26 Ga
0.5
631
16027
410
10414
22 Ga
0.8
496
12598
322
8179
18 Ga
1.3
592
15037
335
8509
16 Ga
1.5
374
9500
243
6172
14 Ga
1.9
224
5690
146
3698
147
0.50
10 Ga
3.4
107
2718
70
1778
149
0.75
3/16
4.7
67
1702
44
1118
149
1.00
1/4
6.4
48
1219
31
792
134
0
16 Ga
1.5
625
15875
406
10312
136
0.25
10 Ga
3.4
244
6198
159
4039
139
0.50
1/4
6.4
112
2845
73
1849
145
0.75
3/8
9.5
53
1346
34
864
145
2.00
1/2
12.7
36
914
23
594
149
5/8
15.9
26
660
17
432
154
3/4
19.0
18
457
12
305
Aluminum
Arc Current Arc Voltage
150
151
40
0
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Inches
mm
IPM
mm/min
IPM
mm/min
1/32
0.8
610
15494
397
10084
1/16
1.5
188
4775
122
3104
146
0.25
3/32
2.4
293
7442
190
4826
149
0.50
1/8
3.2
276
7010
179
4557
150
1.00
1/4
6.4
78
1981
51
1288
135
0
1/16
1.6
666
16916
433
10998
1/8
3.2
400
10160
260
6604
1/4
6.4
147
3734
96
2427
138
60
Pierce
Delay
139
0.25
146
0.75
3/8
9.5
74
1880
48
1219
147
1.50
1/2
12.7
51
1295
30
762
5/8
15.9
33
838
21
533
153
Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.
OM-264 259 Page 33
. A complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
Reference
Each
Use
n Torch Tip, Electrode,
And Shield Cup
n Gas/Air Pressure
Every
Week
n Shield Cup Shutdown
System
Every
3
Months
l Damaged Or Unreadable
Labels
l Cracked Parts
~ Air Filter/Regulator
Assembly Filter
n Gas/Air Hose
n l Torch Body, Cable
Every
6
Months
OR
~ Inside Unit
8-2. Checking Shield Cup Shutdown System
. Power must be reset whenever the cup shutdown system
is activated. Always turn Off power when changing or
checking consumables. Do NOT overtighten torch
shield cup. Gently finger tighten cup onto torch.
1
1
Torch Shield Cup
Turn Power On and loosen shield
cup. If shutdown system works
properly, Cup light comes on. If not,
immediately turn Off power and
have Factory Authorized Service
Agent check unit.
If system works properly, retighten
cup and reset power.
Ref. 253 554-A
OM-264 259 Page 34
. A complete Parts List is available at www.MillerWelds.com
8-3. 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.
4
6
Make sure swirl ring is clean of any
debris and no holes are obstructed.
5
3
New
2
1
New
1/32 in. (1 mm) to 1/16
in. (2 mm) maximum pit
depth depending on
acceptable cut quality
Worn
Worn
Ref. 253554-A
Turn Off power source.
1
Shield Cup
Remove shield cup. Check cup for cracks,
and replace if necessary.
2
Tip
3
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.
4
Electrode
Check electrode. If center has a pit more
than a 1/16 in. (2 mm) deep, remove and replace electrode.
5
Swirl Ring
Remove swirl ring. Check ring, and replace
if side holes are plugged.
6
O-Ring
Check O-ring for cracks or worn spots, and
replace if necessary.
Carefully reassemble parts in reverse order.
OM-264 259 Page 35
. A complete Parts List is available at www.MillerWelds.com
8-4. Wrapper Removal/Installation
4
!
Turn
off
power,
and
disconnect input power plug
from receptacle or turn off
and lockout/tagout line disconnect
device
before
working on unit.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Check to see that
front panel lights (LEDs) have
stopped flashing and are off
before removing wrapper.
1
Wrapper
2
Front Bezel
3
Rear Bezel
4
Torx Screw (Fine Thread)
1
3
2
Remove 13 screws from wrapper,
and front and rear bezels as shown.
Spread open tops of front and rear
bezels.
5
1
3
2
Consumables Storage
Compartment Opening
Be sure that opening clears the
storage compartment. Lift wrapper
off unit.
. When installing wrapper, front
and rear wrapper flanges must
be on outside of front and rear
portion of metal chassis.
1
5
Tools Needed:
Torx 25
805 209-A
OM-264 259 Page 36
. A complete Parts List is available at www.MillerWelds.com
8-5. Checking Or Replacing Filter Element (Part No. 227 877)
!
Turn
off
power,
and
disconnect input power plug
from receptacle or turn off
and lockout/tagout line disconnect
device
before
working on unit.
!
Significant DC voltage can
remain on capacitors after
unit is Off. Check to see that
front panel lights (LEDs)
have stopped flashing and
are off before removing
wrapper.
1
Remove wrapper from unit (see
Section 8-4).
1
Rear Bezel
Remove rear bezel from unit.
2
Filter Bracket Screws
Remove filter bracket screws. Pull
filter bracket toward front of unit
until gas/air supply fitting is past
rear panel, and swing filter
assembly out to the side to allow
filter cup removal.
2
3
Filter Base
4
Filter Element
(Part No. 227877)
5
Filter Cup
Unscrew filter cup from base.
Remove cup.
Unscrew filter element from base.
3
4
Check filter element for dirt and
moisture, and replace if necessary.
Be sure that all parts are clean and
dry.
Reinstall filter element, and secure
filter cup.
Secure filter bracket to rear panel.
5
Reinstall wrapper and rear bezel.
Tools Needed:
5/16 in.
rEF. 805 211-A
OM-264 259 Page 37
. A complete Parts List is available at www.MillerWelds.com
8-6. Status/Trouble Lights
V
POWER
PRESSURE
CUP
TEMP
Light
Power
Condition
Status/Possible Cause
On
Input power is okay.
Off
When Power light is on, system is normal if these lights
are off.
Power
Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.
Input power was above 300 volts AC or below 156 volts
AC, but has returned to normal.
Power
Repetitive flashing rate of two quick cycles, then a one
second pause.
Input power is above 300 volts AC or below 156 volts AC
or precharge PTCs have overheated.
Pressure
On
No or low [below 40 psi (276 kPa)] input pressure.
Pressure
Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.
Regulated pressure in the unit is low.
Pressure
Repetitive flashing rate of two quick cycles, then a one
second pause for a 15 second period.
Regulated pressure in the unit is high.
On
Torch cup is loose or off. Once cup is finger tightened, unit
power must be cycled off and back on again.
Cup
Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.
No arc was established. Plasma system failed to strike an
arc.
Cup
Repetitive flashing rate of two quick cycles, then a one
second pause for a 15 second period or until torch trigger
is pressed again, whichever comes first.
No pilot arc established possibly due to a loss of current.
Cup
Repetitive flashing rate of three quick cycles, then a one
second pause for a 15 second period or until torch trigger
is pressed again, whichever comes first.
Consumables in torch failed to separate during pilot arc
possibly due to being stuck.
On
Power source overheated.
On (indefinitely)
Power source temperature sensors may have failed or
ambient temperature is below -22 F (-30 C).
Flashing rate is steady (indefinitely).
Power source temperature sensor provided inaccurate
readings, but returned to normal. Unit power must be
cycled off and back on again.
Pressure/Cup/Temp
Cup
Temperature
Temperature
Temperature
For system troubleshooting see Section 8-7 and Section 8-8.
OM-264 259 Page 38
. A complete Parts List is available at www.MillerWelds.com
8-7. Troubleshooting Power Source
Trouble
Remedy
No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see Section 8-3).
arc.
Check for damaged torch or torch cable.
Check position of cut/gouge switch. If using cutting consumables, be sure that switch is in the CUT
position. If using gouging consumables, be sure that switch is in the GOUGE position.
No cutting output; Power light off; status Place Power switch in On position.
lights off; fan motor FM does not run.
Place line disconnect device in On position (see Section 5-7).
Check line fuse(s) and replace if needed or reset circuit breakers (see Section 5-7).
Pilot arc working; no cutting output; Be sure work clamp is connected to a clean, rust-free workpiece.
Power light on; status lights off; fan
motor running.
Clean or replace worn consumables as necessary (see Section 8-3).
No gas/air flow; Power light on; status Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas
lights off; fan motor running.
valve AS1, and check gas/air system for leaks. Check filter element (see Section 8-5).
Pressure status light On.
Check for sufficient gas/air supply pressure (see Section 5-2).
Check for dirty air filter and replace, if necessary (see Section 8-5).
Check air lines for leaks.
Have Factory Authorized Service Agent check pressure switch and control board.
Cup status light On.
Check torch shield cup (see Section 8-2). Reset power switch.
If trouble persists, have Factory Authorized Service Agent check torch and unit.
Temperature status light On.
Unit overheating (see Section 4-3). Allow fan to run; the Trouble light goes out when the unit has cooled.
If trouble persists, have Factory Authorized Service Agent check unit.
Temperature status light On indefinitely. Power source temperature sensors may have failed or ambient temperature is below −22 F (−30 C).
Operate unit in a warmer ambient temperature.
Temperature status light flashing rate Power source temperature sensor(s) provided inaccurate feedback, but have returned to normal. Unit
steady (indefinitely).
power must be cycled off and back on again.
Power light flashing steady for 15 sec- Input power was above 300 volts AC or below 156 volts AC, but has returned to normal. Have a qualified
onds or until torch trigger is pressed, technician check input line power at idle and while cutting.
whichever happens first.
Power light is flashes at a rate of two Input power is above 300 volts AC or below 156 volts AC. Have a qualified technician check input power
quick cycles and then a one second at idle and while cutting.
pause.
Pre-charge PTCs are overheated. Allow 15 minutes for unit to cool.
Pressure status light flashes at a rate of Unit regulated pressure is too high. Check for input pressure between 90-120 PSI (see Section 5-2). If
two quick flashes and then a one second trouble persists, have a Factory Authorized Service Agent check unit. Reset power switch.
pause for a duration of 15 seconds.
Pressure status light flashes steady for Regulated pressure is too low. Check torch for leaks. Check for input pressure between 90-120 PSI dur15 seconds or until torch trigger is ing cutting (see Section 5-2).
pressed, whichever happens first.
OM-264 259 Page 39
. A complete Parts List is available at www.MillerWelds.com
Trouble
Remedy
Cup status light flashes steady for 15 System failed to strike an arc. Power source failed to deliver current to the output. Check continuity of
seconds or until torch trigger is pressed, torch connections (pilot lead and electrode lead). If torch connections are good, have a Factory Authowhichever happens first.
rized Service Agent check unit.
Cup status light flashes at a rate of two No pilot arc established. The power source failed to maintain a pilot arc. Try a different set of torch conquick cycles and then a one second sumables (tip and electrode). Check for input pressure between 90-120 PSI.
pause for 15 seconds or until torch trigger is pressed, whichever comes first.
Cup status light flashes at a rate of three Power source detected that tip and electrode failed to separate when gas valve turned on. Check that
quick cycles and then a one second cup is not too tight (finger tight only). Check for correct torch consumables. Check for gas flow through
pause for 15 seconds or until torch trig- the torch head.
ger is pressed, whichever comes first.
Check and clean drag shield of any slag, particles, and debris.
Short tip life.
Check position of cut/gouge switch. Place switch in correct position to match the process.
Check input air pressure.
Check that compressed air is clean, dry and oil-free. Use filter kit 300 491 or 228 926, if necessary.
Maintain 1/8 in. (3.2 mm) standoff for extended tip cutting over 40 amps. Do not drag tip on workpiece.
If trouble persists, have system checked by a Factory Authorized Service Agent.
8-8. Troubleshooting Torch
Trouble
Remedy
Arc goes on and off while cutting.
Torch travel speed too slow; increase travel speed (see Section 6-7). Clean or replace torch consumables
as necessary (see Section 8-2). Be sure work clamp is securely attached to clean, rust-free workpiece.
Arc goes out while cutting.
Be sure work clamp is securely attached to a clean, rust-free workpiece. Make sure drag shield is on the
workpiece or the extended tip is 1/16 in. (1.6 mm) to 1/8 in. (3.2 mm) from workpiece while cutting (see
Section 6-3). Clean or replace torch consumables as necessary (see Section 8-2).
Sparks come out top of cut or cut is not Torch travel speed too fast; reduce travel speed (see Section 6-3). Clean or replace torch consumables
clean.
as necessary (see Section 8-2). Be sure work clamp is securely attached to a clean, rust-free workpiece.
Unit not capable of cutting metals thicker than rating (see Section 4-2) or faster than shown in Section
6-7.
OM-264 259 Page 40
Notes
OM-264 259 Page 41
SECTION 9 − ELECTRICAL DIAGRAM
Figure 9-1. Circuit Diagram For Hand-Held Torch Applications
OM-264 259 Page 42
234 157-B
OM-264 259 Page 43
Figure 9-2. Circuit Diagram For Machine Torch Applications
OM-264 259 Page 44
265 998-A
OM-264 259 Page 45
SECTION 10 − PARTS LIST
10-1. Recommended Spare Parts
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
. . . . . . . . . . . . . . . . 265172 . . Label, XT60 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 227877 . . Filter, Air Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 234838 . . Cable, Work 20 ft 6 ga w/Clamp And Male Dinse . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 234930 . . Cable, Work 50 ft 6 ga w/Clamp And Male Dinse . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 213619 . . Clamp, Work 300A Stl Chrome Pld w/Copper Contacts . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 213620 . . Contact Tip, Work Clamp 300 Amp Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 249953 . . XT60 20 ft Handheld Replacement Torch Or
. . . . . . . . . . . . . . . . 249954 . . XT60 50 ft Handheld Replacement Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 249995 . . XT60M, 25 ft Long Body Machine Torch (Replacement) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 249956 . . XT60M, 50 ft Long Body Machine Torch (Replacement) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 257464 . . XT60M, 25 ft Short Body Machine Torch (Replacement) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 263952 . . XT60M, 50 ft Short Body Machine Torch (Replacement) . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside
bottom of plasma cutter base) is required when ordering parts from your local distributor.
265 172-A
Figure 9-1. Consumable Parts For XT60
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside
bottom of plasma cutter base) is required when ordering parts from your local distributor.
OM-264 259 Page 46
Item
No.
1
Part
No.
Description
1
263 950 Torch Handle Kit (1)
2
249 971 Torch Trigger
. . . . . . . . . . . . . . . Microswitch (1)
3
249 961 Leads, 20 ft (1)
3
249 962 Leads, 50 ft (1)
4
256 039 Torch Body Kit (1)
5
249 972 Torch Trigger Assembly
w/Spring (1)
252 951 Grease, Silicone (1)
249 953 Torch, Replacement 20 ft (1)
249 954 Torch, Replacement 50 ft (1)
2
5
4
1
3
See Figure 9-1 for
additional consumable parts.
Ref. 265 001-A
Figure 10-2. Torch, XT60
. A complete Parts List is available on-line at www.MillerWelds.com
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-264 259 Page 47
Item Part
No. No.
1
2
3
3
4
5
6
7
See Figure 9-1 for
additional consumable parts.
Description
259 357
263 389
249 963
249 962
259 361
256 040
259 334
243 754
249 955
249 956
257 464
263 952
Long Body Positioning Sleeve (1)
Short Body Positioning Sleeve (1)
Torch Lead, Replacement W/QD 25 ft (1)
Torch Lead, Replacement W/QD 50 ft (1)
Torch Sleeve (1)
Main Body W/Switch (1)
Cup Detect Switch
Kit, XT60M QD w/Wing Head Fastener
Torch, Machine Long Body Replacement 25 ft (1)
Torch, Machine Long Body Replacement 50 ft (1)
Torch, Machine Short Body Replacement 25 ft (1)
Torch, Machine Short Body Replacement 50 ft (1)
7
1
3
2
6
5
4
804 036-A / Ref. 265 001-A
Figure 9-2. Torch, XT60M
. A complete Parts List is available on-line at www. MilerWelds.com
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside
bottom of plasma cutter base) is required when ordering parts from your local distributor.
OM-264 259 Page 48
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)
18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)
1/8 in. (.125 in.)
3/16 in. (.188 in.)
1/4 in. (.25 in.)
5/16 in. (.313 in.)
3/8 in. (.375 in.)
1/2 in. (.5 in.)
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Guns
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed.
* Replacement Parts (No labor)
* Roughneck Guns
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed one year after
the equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welding Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Filtair 400 and Industrial Collector
Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* Load Banks
* Motor Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2013-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
 2013 Miller Electric Mfg. Co.
2013−01
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