OM-201 872D
Processes
2007−03
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
R
Spectrum 1251 And
ICE-100T/TM Torch
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File: Plasma Cutters
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers liés au coupage à l’arc au plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Duty Cycle and Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-3. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Connecting And Disconnecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-8. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-9. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant . . . . . . . . . . . . . . . . . . . 17
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-2. Setting Gas/Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-3. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-4. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-5. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-6. Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-7. Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-8. Consumables Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 − MECHANIZED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. ICE-100TM Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Remote Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-3. Remote Control Cable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-4. +24 Volts DC Hot Contacts For Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-6. Dry Contacts Using An External Power Supply For Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation . . . . . . . . . . . . . 28
6-8. Remote Voltage Sense Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-9. Shield Sense Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-10. Cut Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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TABLE OF CONTENTS
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-2. Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-3. Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-4. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-5. Checking Or Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-6. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7-7. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
pom _4/05
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y
Marks a special safety message.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
. Means “Note”; not safety related.
1-2. Plasma Arc Cutting Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only a
summaryof the more complete safety information found in the
ty Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
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Do not touch live electrical parts.
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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.
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Do not touch torch parts if in contact with the work or ground.
Turn off power before checking, cleaning, or changing torch parts.
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Disconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA CFR
1910.147(see Safety Standards).
D
D
Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
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.
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.
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Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this
is not possible, tightly cover them with approved covers.
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When making input connections, attach proper grounding conduc-
tor first.
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Do not cut where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Frequentlyinspect input power cord for damage or bare wiring − re-
place cord immediately if damaged − bare wiring can kill.
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Turn off all equipment when not in use.
Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
Inspect and replace any worn or damaged torch cable leads.
Do not wrap torch cable around your body.
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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.
Ground the workpiece to a good electrical (earth) ground if required
by codes.
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Do not cut on closed containers such as tanks or drums.
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Use only well-maintained equipment. Repair or replace damaged
parts at once.
Connect work cable to the work as close to the cutting area as prac-
tical to prevent cutting current from traveling long, possibly unknown
paths and causing electric shock, sparks, and fire hazards.
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
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Do not use plasma cutter to thaw frozen pipes.
Do not bypass or try to defeat the safety interlock systems.
Use only torch(es) specified in Owner’s Manual.
Never cut containers with potentially flammable materials inside −
they must be emptied and properly cleaned first.
Keep away from torch tip and pilot arc when trigger is pressed.
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Do not cut in atmospheres containing explosive dust or vapors.
Do not cut pressurized cylinders, pipes, or vessels.
Do not cut containers that have held combustibles.
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.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D
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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.
ELECTRIC SHOCK can kill.
D
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
SIGNIFICANT DC VOLTAGE exists in
inverter power sources AFTER the re-
moval of input power.
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
D
Turn Off unit, disconnect input power, check voltage on input ca-
pacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Mainte-
nance Section of Owner’s Manual or Technical Manual before
touching any parts.
higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but also uses torches designed with safety
interlock systems which turn off the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. Incorrectly
installed or improperly grounded equipment is a hazard.
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D
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If ventilation is poor, wear an approved air-supplied respirator.
EXPLODING PARTS can injure.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals to be cut, coatings,
and cleaners.
D
On inverter power sources, failed parts can ex-
plode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.
D
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.
D
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Do not cut in locations near degreasing, cleaning, or spraying oper-
ations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
FLYING SPARKS can cause injury.
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
Do not cut on coated metals, such as galvanized, lead, or cadmium
platedsteel, 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.
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Wear approved face shield or safety goggles with side shields.
Wear proper body protection to protect skin.
Wear flame-resistant ear plugs or ear muffs to prevent sparks from
entering ears.
D
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.
ARC RAYS can burn eyes and skin.
PLASMA ARC can cause injury.
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
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.
D
Wear face protection (helmet or shield) with a proper shade of filter
lenses to protect your face and eyes when cutting or watching. ANSI
Z49.1 (see Safety Standards) suggests a No. 9 shade (with No. 8 as
minimum) for all cutting currents less than 300 amperes. Z49.1 adds
that lighter filter shades may be used when the arc is hidden by the
workpiece. As this is normally the case with low current cutting, the
shades suggested in Table 1 are provided for the operator’s conve-
nience.
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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 trig-
ger is pressed.
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Wear proper flame-retardant clothing covering all exposed body ar-
eas.
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Wear approved safety glasses with side shields under your helmet
or shield.
Point torch away from your body and toward work when pressing
the torch trigger − pilot arc comes on immediately.
Use protective screens or barriers to protect others from flash, glare
and sparks; warn others not to watch the arc.
Turn off power source and disconnect input power before disas-
sembling torch or changing torch parts.
Wear protective clothing made from durable, flame-resistant
material(leather, heavy cotton, or wool) and foot protection.
Use only torch(es) specified in the Owner’s Manual.
CYLINDERS can explode if damaged.
Table 1. Eye Protection For Plasma Arc Cutting
Gas cylinders contain gas under high pressure. If
damaged,a cylinder can explode. Since gas cylin-
ders are normally part of metalworking processes,
be sure to treat them carefully.
Current Level In Amperes
Below 20
Minimum Shade Number
#4
#5
#6
#8
20 − 40
40 − 60
60 − 80
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flame, sparks, and arcs.
Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
NOISE can damage hearing.
D
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Keep cylinders away from any cutting or other electrical circuits.
Prolongednoise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
Never allow electrical contact between a plasma arc torch and a
cylinder.
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Never cut on a pressurized cylinder − explosion will result.
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Use approved ear plugs or ear muffs if noise level is high.
Warn others nearby about noise hazard.
Use only correct gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated
parts in good condition.
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Turn face away from valve outlet when opening cylinder valve.
FUMES AND GASES can be hazardous.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
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, asso-
ciated equipment, and Compressed Gas Association (CGA)
publicationP-1 listed in Safety Standards.
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove cutting fumes and gases.
OM-201 872 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
HOT PARTS can cause severe burns.
FALLING UNIT can cause injury.
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Do not touch hot parts bare handed.
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Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Allow cooling period before working on torch.
Use equipment of adequate capacity to lift unit.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
D
If using lift forks to move unit, be sure forks are long enough to ex-
tend beyond opposite side of unit.
MOVING PARTS can cause injury.
FIRE OR EXPLOSION hazard.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Do not locate unit on, over, or near combustible
surfaces.
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Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
Do not install unit near flammables.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
STATIC (ESD) can damage PC boards.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
READ INSTRUCTIONS.
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Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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Read Owner’s Manual before using or servic-
ing unit.
Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
D
High frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
FLYING METAL can injure eyes.
D
Wear safety glasses with side shields or face
shield.
D
Have only qualified persons familiar with elec-
tronic equipment perform this installation.
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The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
MAGNETIC FIELDS can affect pacemakers.
If notified by the FCC about interference, stop using the equipment
at once.
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Pacemaker wearers keep away.
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Have the installation regularly checked and maintained.
Wearers should consult their doctor before go-
ing near plasma arc cutting operations.
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.
OVERUSE can cause OVERHEATING.
ARC CUTTING can cause interference.
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Allow cooling period; follow rated duty cycle.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
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To reduce possible interference, keep cables as short as possible,
close together, and down low, such as on the floor.
EXPLODING HYDROGEN hazard.
Locate cutting operation 100 meters from any sensitive electronic
equipment.
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When cutting aluminum underwater or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the work-
piece.
Be sure this cutting power source is installed and grounded
according to this manual.
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.
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See your cutting engineer and water table instructions for help.
1-4. California Proposition 65 Warnings
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Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
For Diesel Engines:
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-201 872 Page 3
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1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from Global Engineering Docu-
ments (phone: 1-877-413-5184, website: www.global.ihs.com).
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
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, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
1-6. EMF Information
Considerations About Welding Or Cutting And The Effects Of Low
Frequency Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding or cutting current, as it flows through the welding or cutting
cables, will cause electromagnetic fields. There has been and still is
some concern about such fields. However, after examining more than
500 studies spanning 17 years of research, a special blue ribbon
committeeof the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human-
health hazard.” However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when welding or cutting.
4. Keep cutting power source and cables as far away from operator
as practical.
5. Connect work clamp to workpiece as close to the cut as possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding/cutting or going
near welding/cutting operations. If cleared by your doctor, then following
the above procedures is recommended.
To reduce magnetic fields in the workplace, use the following proce-
dures:
OM-201 872 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
pom_fre 4/05
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Avertissement: se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Signification des symboles
SignifieMise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y
Identifie un message de sécurité particulier.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des ris-
ques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVE-
MENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directi-
ves ci-dessous afin de connaître les mesures à prendre pour éviter tout dan-
ger.
. Signifie NOTA ; n’est pas relatif à la sécurité.
2-2. Dangers liés au coupage à l’arc au plasma
Y
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques 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 sécu-
ces normes de sécurité.
D
Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA
51B pour travaux de soudage et prévoir un détecteur d’incendie et
un extincteur à proximité.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le fait de toucher à une pièce électrique sous
tension peut donner une décharge fatale ou entraî-
ner des brûlures graves. Le chalumeau et le circuit
de masse sont automatiquement actifs lorsque le
Y
Y
L’installation,l’utilisation, l’entretien et les réparations ne doi-
vent être confiés qu’à des personnes qualifiées.
poste est sous tension. L’alimentation d’entrée et les circuits internes
de l’appareil le sont également. Le coupage au plasma d’arc exige des
tensions plus élevées que le soudage pour amorcer et maintenir l’arc
(souvent de 200 à 400 V CC), c’est pourquoi on fait appel à des
chalumeauxconçus avec un système de verrouillage sécuritaire qui
met l’appareil hors tension lorsque la capsule anti−feu est desserrée
ou si le tube touche l’électrode à l’intérieur de la buse. Un poste
incorrectementinstallé ou inadéquatement mis à la terre constitue un
danger.
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
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Ne touchez pas aux pièces électriques sous tension.
Portez des gants isolants et des vêtements de protection secs et
sans trous.
Isolez−vousde la pièce à couper et du sol en utilisant des housses
ou des tapis assez grands afin d’éviter tout contact physique avec
la pièce à couper ou le sol.
Ne touchez pas aux pièces du chalumeau si vous êtes en contact
avec la pièce à couper ou le sol.
Mettez l’appareil hors tension avant d’effectuer la vérification, le
nettoyageou le changement d’une pièce du chalumeau.
Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’ef-
fectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation
selon la norme OSHA 29 CFR 1910.147 (reportez−vous aux Princi-
pales normes de sécurité).
Installez le poste correctement et mettez-le à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
Assurez−vous que le fil de terre du cordon d’alimentation est cor-
rectementrelié 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.
feu ou des brûlures. Avant de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.
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Déplacez toute matière inflammable se trouvant à l’intérieur d’un
périmètrede 10,7 m (35 pi) de la pièce à couper. Si cela est impos-
sible, vous devez les couvrir avec des housses approuvées et bien
ajustées.
Ne coupez pas dans un endroit où des étincelles pourraient attein-
dre des matières inflammables.
Protégez−vous, ainsi que toute autre personne travaillant sur les
lieux, contre les étincelles et le métal chaud.
Assurez−vous qu’aucune étincelle ni particule de métal ne peut se
glisser dans de petites fissures ou tomber dans d’autres pièces.
Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur à la portée de la main.
Si vous coupez sur un plafond, un plancher ou une cloison, soyez
conscient que cela peut entraîner un feu de l’autre côté.
Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un bi-
don.
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
prenneune trajectoire inconnue ou longue et ne cause ainsi une dé-
charge électrique, d’étincelles ou un feu.
Ne pas utiliser le coupeur plasma pour dégeler des conduites
gelées.
Ne coupez jamais des contenants qui peuvent contenir des matiè-
res inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.
Ne coupez pas dans un endroit où l’atmosphère risque de contenir
de la poussière ou des vapeurs explosives.
Ne coupez pas de bouteilles, de tuyaux ou de contenants pressuri-
sés.
Ne coupez pas de contenants qui ont déjà reçu des combustibles.
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.
Ne placez pas le poste sur une surface combustible ou au−dessus
de celle−ci.
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Avant d’effectuer les connexions d’alimentation, vous devez relier
le bon fil de terre.
Vérifiez fréquemment le cordon d’alimentation afin de vous assurer
qu’il n’est pas altéré ou à nu, remplacez−le immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Vérifiez et remplacez les cosses du câble du chalumeau si elles
sont usées ou altérées.
Le câble du chalumeau ne doit pas s’enrouler autour de votre corps.
Si les normes le stipulent, la pièce à couper doit être mise à la terre.
Utilisez uniquement de l’équipement en bonne condition. Réparez
ou remplacez immédiatement toute pièce altérée.
Portez un harnais de sécurité si vous devez travailler au−dessus du
sol.
Assurez−vous que tous les panneaux et couvercles sont correcte-
ment en place.
N’essayez pas d’aller à l’encontre des systèmes de verrrouillage
de sécurité ou de les contourner.
Utilisez uniquement le ou les chalumeaux recommandés dans le
manuel de l’opérateur.
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Avant le coupage, retirez tout combustible de vos poches, par
exemple un briquet au butane ou des allumettes.
OM-201 872 Page 5
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N’approchezpas le tube du chalumeau et l’arc pilote lorsque la gâ-
chette est enfoncée.
Le câble de masse doit être pincé correctement sur la pièce à cou-
per, 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.
LE BRUIT peut endommager l’ouïe.
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 (repor-
tez−vous aux Principales normes de sécurité).
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Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
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Utilisez des protège−tympans ou un serre−tête antibruit si le niveau
sonore est élevé.
Prévenez toute personne sur les lieux du danger relié au bruit.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
DÉCHARGES ÉLECTRIQUES poten-
tiellement mortelles.
Le coupage produit des vapeurs et des gaz. Respirer
ces vapeurs et ces gaz peut être dangereux pour la
santé.
Il y a DES CHARGES DC SIGNIFICATI-
VES dans le poste de soudage inver-
seur même APRÈS coupure du cou-
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Ne mettez pas votre tête au−dessus des vapeurs. Ne respirez pas ces
vapeurs.
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.
Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs
approuvé.
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.
rant d’alimentation.
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Mettre l’unité hors tension, mesurer la tension des condensateurs
d’entrée et s’assurer qu’elle est pratiquement nulle avant de tou-
cher à l’une quelconque des pièces. Mesurer cette tension confor-
mément 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.
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Risque de blessure en cas
D’EXPLOSION DES PIÈCES.
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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 am-
biant est sain pour la santé.
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 irri-
tants.
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’enrobagene 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 respira-
teur anti−vapeurs. Les enrobages ou tous métaux qui contiennent ces
éléments peuvent créer des vapeurs toxiques s’ils sont coupés.
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.
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Mise sous tension, toute pièce défectueuse des
sources d’alimentation de l’inverseur peut explo-
ser ou faire exploser d’autres pièces. Pour entre-
tenir les inverseurs, toujours porter un masque
protecteur et un vêtement à manches longues.
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LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
Le coupage plasma produit des étincelles et projections de
métal à très haute température. Lorsque la pièce refroidit,
du laitier peut se former.
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Portez une visière ou des lunettes de sécurité avec des écrans laté-
raux approuvées.
Portez des vêtements de protection adéquats afin de protéger votre
peau.
Ayez recours à des protège−tympans ou à un serre−tête ignifuges afin
d’éviter que les étincelles n’entrent dans vos oreilles.
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LE PLASMA D’ARC peut entraîner
des blessures.
La chaleur dégagée par le plasma d’arc peut entraîner de
sérieuses brûlures. La force de l’arc est un facteur qui
s’ajoute au danger de brûlures. La chaleur intense et la
puissance de l’arc peuvent rapidement passer au travers
de gants et de tissus.
LES RAYONS D’ARC peuvent entraî-
ner des brûlures aux yeux et à la peau.
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N’approchez pas le tube du chalumeau.
Ne saisissez pas la pièce à couper près de la ligne de coupage.
L’arc pilote peut causer des brûlures − n’approchez pas le tube du cha-
lumeau lorsque vous avez appuyé sur le gâchette.
Portez des vêtements de protection adéquats qui recouvrent tout vo-
tre corps.
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.
Mettez l’alimentation hors tension et débranchez le cordon d’alimen-
tation avant de démonter le chalumeau ou de changer une pièce du
chalumeau.
Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner des brûlures aux yeux et à la
peau.
D
Lorsque vous coupez ou regardez quelqu’un couper, portez un cas-
que de soudage approuvé muni de verres filtrants approprié. La
norme ANSI Z49.1 (reportez−vous aux Principales normes de sécuri-
té) 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.
Porter des lunettes de sécurité à coques latérales sous votre casque
ou écran facial.
Ayez recours à des écrans protecteurs ou à des rideaux pour protéger
les autres contre les rayonnements, les étincelles et les éblouisse-
ments; prévenez toute personne sur les lieux de ne pas regarder l’arc.
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Utilisez uniquement le ou les chalumeaux recommandés dans le ma-
nuel de l’opérateur.
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LES BOUTEILLES peuvent exploser
si elles sont endommagées.
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Portez des vêtements confectionnés avec des matières résistantes
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
Les bouteilles de gaz contiennent du gaz sous haute
pression. Si une bouteille est endommagée, elle peut
exploser. Puisque les bouteilles de gaz font habituellement
partie d’un processus de travail des métaux, assurez−vous
de les manipuler correctement.
Tableau 1. Protection des yeux pour le coupage au plasma d’arc
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Protégez les bouteilles de gaz comprimé contre la chaleur excessive,
les chocs mécaniques, des dommages physiques, le laitier, la flam-
me, les étincelles et l’arc.
Installez et attachez les bouteilles dans la position verticale à l’aide
d’une chaîne, sur un support stationnaire ou un châssis porte−bouteil-
le afin de prévenir qu’elles ne tombent ou ne basculent.
Intensité de courant en ampères
Filtre de teinte (minimum)
Moins de 20
20 − 40
40 − 60
no. 4
no. 5
no. 6
no. 8
60 − 80
OM-201 872 Page 6
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Les bouteilles ne doivent pas être près de la zone de coupage ni de
tout autre circuit électrique.
Un contact électrique ne doit jamais se produire entre un chalumeau
de plasma d’arc et une bouteille.
Ne coupez jamais sur une bouteille pressurisée − une explosion en
résulterait.
Utilisez uniquement des bouteilles de gaz, des détendeurs, des
boyaux et des raccords conçus pour l’application déterminée. Gar-
dez−les, ainsi que toute autre pièce associée, en bonne condition.
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Détournez votre visage du détendeur−régulateur lorsque vous ouvrez
la soupape de la bouteille.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
vous utilisez la bouteille ou qu’elle est reliée pour usage ultérieur.
Utiliser les équipements corrects, les bonnes procédures et suffisam-
ment de personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
DES PIECES CHAUDES peuvent pro-
voquer des brûlures graves.
LA CHUTE DE L’APPAREIL peut
blesser.
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Ne pas toucher des parties chaudes à mains nues.
Laisser refroidir avant d’intervenir sur la torche.
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Utiliser l’anneau de levage uniquement pour soulever
l’appareil, NON PAS les chariot, les bouteilles de gaz
ou tout autre accessoire.
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Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour évi-
ter les brûlures.
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Utiliser un engin d’une capacité appropriée pour sou-
lever l’appareil.
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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.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Risque D’INCENDIE OU
D’EXPLOSION.
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S’abstenir de toucher des organes mobiles tels que
des ventilateurs.
Maintenir fermés et verrouillés les portes, panneaux,
recouvrements et dispositifs de protection.
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Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces infllammables.
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Seules des personnes qualifiées sont autorisées à enlever les por-
tes, panneaux, recouvrements ou dispositifs de protection pour
l’entretien.
Ne pas installer l’appareil à proximité de produits in-
flammables
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Ne pas surcharger l’installation électrique
l’alimentation est correctement dimensionné et protégé avant de
mettre l’appareil en service.
−
s’assurer que
Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher l’ali-
mentation électrique.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir-
cuits imprimés.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
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Porter des lunettes de sécurité avec protections laté-
rales ou frontales.
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Etablir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes PC.
LES CHAMPS MAGNÉTIQUES peu-
vent affecter les stimulateurs cardia-
ques.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
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Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs sont priés de consulter leur médecin
avant d’approcher les opérations de coupage
plasma.
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Le Rayonnement haute frequence (H.F.) peut provo-
quer des interférences avec les équipements de ra-
dio−navigation et de communication, les services de
sécurité et les ordinateurs.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
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Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sour-
ces de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interfé-
rences éventuelles.
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Prévoir une période de refroidissement; respecter le
cycle opératoire nominal.
Réduire l’ampérage (épaisseur) avant de continuer à
couper ou réduire le facteur de marche.
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Danger D’EXPLOSION
D’HYDROGÈNE.
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Lors du coupage d’aluminium partiellement ou totale-
ment immergé dans l’eau, de l’hydrogène libre peut
s’accumuler sous la pièce.
D
Consultez votre ingénieur de coupage et les instruc-
tions de la table de coupage.
OM-201 872 Page 7
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D
D
D
Veiller à couper à une distance de 100 mètres de tout équipement
électronique sensible.
S’assurer que la source de coupage est correctement branchée et
mise à la terre.
Si l’interférence persiste, l’utilisateur doit prendre des mesures sup-
plémentaires comme écarter la machine, utiliser des câbles blindés
de des filtres, ou boucler la zone de travail.
LE COUPAGE Ã L’ARC peut causer
des interférence.
D
L’énergie électromagnétique peut gêner le fonction-
nement d’appareils électroniques comme des ordi-
nateurs 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).
2-4. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
RecommendedPractices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, de Global Engineering Documents (télé-
phone : 1-877-413-5184, site Internet : www.global.ihs.com).
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101
(téléphone: 617-770-3000, site Internet : www.nfpa.org).
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society de Global Engineering Documents
(téléphone: 1-877-413-5184, site Internet : www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220,site Internet : www.osha.gov).
NationalElectrical Code, NFPA Standard 70, de la National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
1
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2
3
Mettre tous les câbles du côté opposé de l’opérateur.
Le courant de soudage ou de coupage passant dans les câbles de puis-
sance crée des causera des champs électromagnétiques. Il y a eu et
il y a encore un certain souci à propos de tels champs. Cependant,
après avoir examiné plus de 500 études qui ont été faites pendant une
périodede recherche de 17 ans, un comité spécial ruban bleu du Natio-
nal Research Council a conclu: “L’accumulation de preuves, suivant le
jugementdu comité, n’a pas démontré que l’exposition aux champs ma-
gnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait sou-
haitablede réduire votre exposition aux champs électromagnétiques
pendantle soudage ou le coupage.
Ne pas courber pas et ne pas entourer pas les câbles autour de
vous.
4
5
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder/couper ou d’approcher des opérations de soudage/
couper. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
OM-201 872 Page 8
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SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
Plasma Arc Cutting
(PAC)
Adjust Air/Gas
Pressure
Low Air Pressure
Light
Amperes
A
V
No − Do Not Do
This
Volts
Increase
Single Phase
Off
Temperature
Voltage Input
Direct Current
Protective Earth
(Ground)
Constant Current
Percent
On
Rated No Load
Voltage (Average)
Conventional Load
Voltage
Primary Voltage
Line Connection
U0
U1
I2
U2
X
Single Phase Or
Three Phase Static
Frequency
Rated Maximum
Supply Current
Rated Welding
Current
1/3
f1
Duty Cycle
Input
f2
Converter-
Transformer-
Rectifier
I1max
Degree Of
Protection
Loose Shield Cup
power factor
Hertz
Hz
S1
IP
Suitable for Some
Hazardous
Power Rating,
Product Of Voltage
And Current (KVA)
Maximum Effective
Supply Current
pf
I1eff
S
Locations
OM-201 872 Page 9
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SECTION 4 − INSTALLATION
4-1. Specifications
Amperes Input at Rated Load
Output 60 Hz, Three-Phase*
Maximum
Open-
Circuit
Rated
Cutting
Capacity
Rated
Output
Type of
Output
Plasma
Gas
Duty Cycle
40%
50%
80%
80%
Voltage DC
208 V
230 V
460 V
575 V
KVA
KW
9.2 CFM
(261
L/min) At
75 PSI
(517 kPa)
Air Or
Direct
Current,
Straight
Polarity
(DCEN)
1.25 in
(32 mm)
At 12 IPM
(305 mm/min)
100 A @
160 Volts
DC
55
49
24
19
19.1
18.2
265
Nitrogen
Only
*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition.
Amperes Input
at Rated Load
Output 50 Hz,
Three-Phase*
Maximum
Open-Circuit
Voltage DC
Rated
Output
Type of
Output
Plasma
Gas
Rated Cutting
Capacity
400 V
KVA
KW
9.2 CFM
(261 L/min) At
75 PSI (517
kPa) Air Or
1.25 in
(32 mm)
At 12 IPM
(305 mm/min)
100 A @ 160
Volts DC, 80%
Duty Cycle
Direct Current,
Straight Polarity
(DCEN)
28
19.2
18.3
265
Nitrogen Only
*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition..
OM-201 872 Page 10
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4-2. Duty Cycle and Overheating
Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.
208 Volts AC Three-Phase Input Power:
40% Duty Cycle
If unit overheats, output stops, and
cooling fan runs. Wait fifteen min-
utes for unit to cool. Reduce amper-
age or duty cycle before cutting.
Y
Exceeding duty cycle can
damage unit and void war-
ranty.
4 Minutes Cutting
6 Minutes Resting
230 Volts AC Three-Phase Input Power:
50% Duty Cycle
380-575 Volts AC Three-Phase Input Power:
80% Duty Cycle
5 Minutes Cutting
5 Minutes Resting
8 Minutes Cutting
2 Minutes Resting
Overheating
0
A
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95
4-3. Cutting Speed
The cutting speed curve shows the
rated cutting speed capabilities of
the power source and torch for mild
steel, stainless steel, and aluminum
of various thicknesses.
Rated Cutting Speed vs Material Type & Thickness
170
160
150
140
130
120
110
100
90
Y
Exceeding recommended
cutting speeds will cause
rapid erosion of the tip and
electrode.
80
70
60
50
40
30
20
10
0
0.25”
0.375”
0.5”
0.625”
0.75”
1”
1.25”
Material Thickness (Inches)
Aluminum
Stainless Steel
Mild Steel
OM-201 872 Page 11
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4-4. Selecting a Location
24 in
(610 mm)
Dimensions And Weight
95 lb (43 kg) w/Torch
17 in
(432 mm)
12-1/2 in
(318 mm)
1
Lifting Handles
Movement
Use handles to lift unit.
Hand Cart
1
2
Y
Do not move or operate unit
where it could tip.
Use cart or similar device to move
unit.
1
3
Line Disconnect Device
Locate unit near correct input
power supply.
2
Y
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Location
3
18 in
(460 mm)
18 in
(460 mm)
loc_2 3/96 - Ref. 151 556 / 802 183
OM-201 872 Page 12
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4-5. Connecting Work Clamp and Gas/Air Supply
1
2
Work Clamp
Workpiece
1
Connect work clamp to a clean,
paint-freelocation on workpiece, as
close to cutting area as possible.
. Use only clean, dry air with 90
to 120 psi (621 to 827 kPa)
2
pressure
@
9.2
CFM
(260L/min)minimum.
3
4
Gas/Air Filter Inlet Opening
Hose
AIR/N2
90-120 psi
. Hose must have a minimum
inside diameter of 3/8 in
(9.5 mm).
@ 9.2 CFM
(260 L/min)
minimum
5
Teflon Tape
Obtain hose with 1/4 NPT right-
hand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
5
3
Adjust gas/air pressure according
4
From
Gas/Air
Supply
Tools Needed:
9/16 in
Rear of Unit
Ref. 803 640-A / Ref. 192 441 / Ref. 804 026-A
4-6. Connecting And Disconnecting Torch
Y
Turn off power source and
disconnectinput power.
2
1
2
3
4
5
Torch Connector
Quick Connect Collar
Nipple
1
3
Receptacle
Securing Pin
To connect torch:
Push torch connector onto
receptacle and quick connect until
collar secures nipple.
4
Rotate securing pin to lock
connector to unit.
5
To disconnect torch:
Rotate securing pin to unlock
connector from unit.
Push quick connect collar back
towards unit to release nipple, and
pull torch connector away from unit.
804 055-A
OM-201 872 Page 13
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4-7. Electrical Service Guide
Y CAUTION:INCORRECT INPUT POWER can damage this welding power source. This welding power
source requires a CONTINUOUS supply of 50 or 60 Hz (+10%) power at +10% of 575V or −10% of 208V
input voltage. Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a gener-
ator with automatic idle device (that idles engine when no load is sensed) to supply input power to this
plasma power source.
60 Hz Three Phase
Input Voltage
208
55
230
49
460
24
575
19
Input Amperes At Rated Output
Max Recommended Standard Fuse Rating In Amperes
Time-Delay
1
2
3
60
80
8
60
70
8
30
35
10
20
30
12
Normal Operating
4
Min Input Conductor Size In AWG
89
(27)
108
(33)
284
(87)
268
(82)
Max Recommended Input Conductor Length In Feet (Meters)
4
Min Grounding Conductor Size In AWG
8
8
10
12
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
50 Hz Three Phase
Input Voltage
400
28
Input Amperes At Rated Output
Max Recommended Standard Fuse Rating In Amperes
Time-Delay
1
2
3
25
35
12
Normal Operating
4
Min Input Conductor Size In AWG
155
(47)
Max Recommended Input Conductor Length In Feet (Meters)
4
Min Grounding Conductor Size In AWG
12
Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-201 872 Page 14
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4-8. Extension Cord Data
When calculating max. cord length, remember to include conductor length from
line disconnect device to input power receptacle.
NOTE
Input Power
Phase
Fuse Size Or
Circuit Breaker Rating
Input Voltage
Hertz
Conductor Size
Max. Cord Length
2
Time-Delay
60 A
80 A
208 V
3
3
3
3
3
60
8 AWG
89 ft (27 m)
3
3
3
3
3
Normal Operating
2
Time-Delay
60 A
70 A
230 V
460 V
575 V
400 V
60
60
60
50
8 AWG
10 AWG
12 AWG
12 AWG
108 ft (33 m)
284 ft (87 m)
268 ft (82 m)
155 ft (47 m)
Normal Operating
2
Time-Delay
30 A
35 A
Normal Operating
2
Time-Delay
20 A
30 A
Normal Operating
2
Time-Delay
25 A
35 A
Normal Operating
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-201 872 Page 15
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4-9. Connecting 3-Phase Input Power
Y
Installationmust meet all National
and Local Codes − have only
qualified persons make this
installation.
3
Y
Y
Disconnect and lockout/tagout
input power before connecting
input conductors from unit.
= GND/PE Earth Ground
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
4
. The Auto-Line circuitry in this unit
automatically adapts the power
source to the primary voltage being
applied.Check input voltage available
at site. This unit can be connected to
any input power between 208 and 575
VAC without removing cover to relink
the power source.
7
2
1
2
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
3
4
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
L1
3
5
6
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
5
L2
L3
6
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7
Over-Current Protection
Select type and size of over-current
connect switch shown).
1
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
3/8 in
3/8 in
803 766-A / 802 183
OM-201 872 Page 16
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4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant
Three-PhaseGenerator Power
Y
Y
Stop engine.
Power and weld outputs are
live at the same time. Discon-
nect or insulate unused
cables.
Three-Phase Power Connection
. Have qualified person install ac-
cording to circuit diagram and
Generator Power Guidelines
(see generator Owner’s Manual).
Y
Close panel opening
if no connections are
made to generator.
Remove generator power panel
mountingscrews. Tilt panel forward.
1
2
3
4
5
Circuit Breaker CB7
Lead 93
Lead 92
Lead 91
Lead 42 (Circuit Grounding
Lead)
Remove plug
before inserting
leads. Reinstall
bushing.
6
7
8
9
Lead 90 (Neutral)
Isolated Neutral Terminal
Jumper Lead 42
3
2
Rear Of Panel
Grounding Terminal
4
5
91
92
93
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be discon-
nected from neutral to meet applica-
ble electrical codes.
42
1
90
Lead 42 connects to front panel
Ground stud.
11
6
10 Power Cord
11 Circuit Breaker CB7 User
Terminals
9
. Circuit breaker CB7 protects
single-phase receptacle RC5
and the load wires from overload.
If CB7 opens, all three-phase
generator output stops and the
receptacle does not work.
10
Y
Close
panel
opening if no
connections
are made to
generator.
8
7
Connect user-supplied ring lug to
green (ground) lead. Connect ring
lug on end of green (ground) lead
to grounding terminal (9).
240V
3-Phase
240V
240V
Connect black, white, and red
leads to circuit breaker CB7 user
terminals (11).
Reinstall power panel.
. Engine control must be set to
Run NOT Run/Idle to adequately
power the plasma cutter.
Three
Phase
3
AC
Output
93
91
Volts
240
Amps
48
KVA/KW
Frequency
20
Tools Needed:
90
92
60 Hz
Engine Speed
1850 RPM
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
Ref. 197 399 / 802 332-B
OM-201 872 Page 17
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SECTION 5 − OPERATION
5-1. Controls
1
3
7
5
4
6
2
201 853-A
1
2
3
Gas/Air Pressure Gauge
Use Gas/Air Set area of control range for set- After the cutting arc goes out, the torch
will automatically re-ignite the pilot arc if
the trigger is held down.
Gas/Air Pressure Control
Output Control
4
5
6
Power Light
7
Power Switch
Cut/Gouge Switch
Use control to select cutting output in am-
peres. Gas/air automatically flows at the set Set pressure as indicated on nameplate for
pressure.
appropriateswitch position.
OM-201 872 Page 18
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5-2. Setting Gas/Air Pressure
2
AIR/N
2
1
90-120 psi
3
Rear of Unit
Ref. 804 025-A / Ref. 804 026-A
Setting Gas/Air Pressure
Unit Requires 90-120 PSI
(621-827 kPa) Supply At
9.2 CFM (260 L/min)
Minimum Flow Rate
1
Power Switch
2
Output Control
3
Gas/Air Pressure
Adjustment Knob
Pull knob and turn, set
pressure to 75 PSI
(517 kPa). Push knob in
to lock setting.
Place Output Control in
Gas/Air Set Position.
Turn On Gas/Air Supply.
Power Switch On.
Select desired cutting
output with Output
Control.
5-3. Trigger Safety Lock
1
Trigger
1
Trigger Locked
Trigger Unlocked
801 397-A
OM-201 872 Page 19
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5-4. Plasma Cutting System Practices
The pilot arc starts immediately
when trigger is pressed.
Always connect work clamp to a clean,
paint-free location on metal workpiece, as
close to cutting area as possible.
DO NOT start pilot arc without cutting or
gouging as this shortens the service life
of the nozzle and electrode.
. Set correct air pressure for process:
75 PSI (517 kPa) for cutting,
60 PSI (414 kPa) for gouging.
90°
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, amperage is set too low,
or consumables are worn.
Maintain approximately a 90° angle to the
workpiece surface for proper cutting results.
Wt
1/8 in
(3.2 mm)
Pulling rather than pushing the torch
makes cutting easier. Use a proper guide
or template for accurate cutting operations.
When doing non-shielded cutting, maintain
approximately 1/8 in standoff between
electrode and surface.
DO NOT put pressure on shield when
drag cutting; instead, slide shield along
the surface for proper cutting results.
Ref. 803 640-A / 801 400-B / Ref. 802 878
OM-201 872 Page 20
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5-5. Sequence Of Cutting Operation
Set Mode switch to CUT.
Connect work clamp to a clean, paint-free
location on metal workpiece, as close to
cutting area as possible.
. Set air pressure to 75 PSI
(517 kPa) for cutting.
The pilot arc starts immediately
when trigger is pressed.
90°
After cutting arc starts, slowly
start moving torch across metal.
For standard (shielded) cutting, place drag
shield on edge of metal. For non-shielded
cutting, use 1/8 in (3.2 mm) standoff distance
(dragging tip will reduce tip life).
Raise trigger lock and press
trigger. Pilot arc starts.
Adjust torch speed so
sparks go thru metal and
out bottom of cut.
Pause briefly at end of
cut before releasing trigger.
Postflow continues for approx. 20 seconds
after releasing trigger; cutting arc can be
instantly restarted during postflow by raising
trigger lock and pressing trigger.
Ref. 803 640-A / 801 400-B
OM-201 872 Page 21
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5-6. Sequence Of Gouging Operation
Connect work clamp to a clean, paint-free
location on workpiece, as close to cutting
area as possible.
Set Mode switch to GOUGE.
. Set air pressure to 60 PSI
(414 kPa) for gouging.
The pilot arc starts immediately
when trigger is pressed.
455
Hold torch at approximately
45° angle to workpiece.
Raise trigger lock and press trigger. Pilot
arc starts. Move tip to within approxi-
mately 3/16 in (4.8 mm). Start gouging
across workpiece surface. Maintain
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.
approximately a 45° angle to surface.
Ref. 803 640-A / 801 400-B
OM-201 872 Page 22
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5-7. Sequence Of Piercing Operation
The pilot arc starts immediately
when trigger is pressed.
Connect work clamp to a
clean, paint-free location
on workpiece, as close to
cutting area as possible.
Set Mode switch to CUT.
. Set air pressure to 75 PSI
Hold torch at an angle to the
workpiece. Raise trigger lock and
press trigger. Pilot arc starts.
(517 kPa) for cutting.
90°
90°
Rotate torch to upright position
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.
Maintainapproximately 90° torch
position to surface, and continue
cutting.
approximately 90° to surface.
When arc has pierced through
workpiece, start cutting.
Ref. 803 640-A / 801 400-B
5-8. Consumables Storage Compartment
1
Consumables Storage
Compartment
This compartment provides
convenientaccess to consumables
and parts.
1
Rear of Unit
804 026-A
OM-201 872 Page 23
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SECTION 6 − MECHANIZED OPERATION
6-1. ICE-100TM Mounting Position
1
2
ICE-100TMMachine Torch
Square
Use a square to align torch perpen-
dicular to the work surface.
2
1
90°
6-2. Remote Control Receptacle
1
Remote Control Receptacle
RC61
RC61 provides a remote arc start
input when using the ICE-100TM
machine torch. Connect supplied
remote control cable or remote
pendant control to receptacle on
remote control cable input and
output functions.
1
3
2
1
7
6
5
4
8
11
10
9
14
13
12
804 026-A
6-3. Remote Control Cable Functions
Function
Lead
White
Red
Socket
Lead Information
1
5
2
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.
Remote Start
Black
Black and green leads connect to a customer-supplied machine torch drive
device. Normally open contacts close after arc start to provide an output
signal to begin machine torch movement. These contacts can be either dry
(RMT1) or hot [RMT2 (+24 volts dc)] depending on plug position at RMT1 or
RMT2 receptacle on Control board PC1.
Okay To Move
NOTE: The Spectrum 1251 is shipped from the factory with the plug
connected to RMT1 (dry contacts). To power a relay or isolated input module
with +24 volts dc on black lead (socket 2) and circuit common on green lead
Green
4
3
Noise Suppression
Shielding
Chassis ground.
OM-201 872 Page 24
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6-4. +24 Volts DC Hot Contacts For Relay Operation
Y
Turn off and disconnect
input power.
Control board PC1 can supply +24
volts dc from receptacle RMT2 to
operate a customer-supplied relay
for the Okay To Move signal.
1
2
3
4
Control Board PC1
Receptacle RMT1
Receptacle RMT2
Receptacle RC61
Move plug from RMT1 into
receptacle RMT2 on PC1. Be
sure remote control cable plug is
connected to RC61 on rear of
unit.
2
3
If voltage sensing is required, see
Install wrapper on unit.
Required Items:
Customer-supplied 24 volts dc
relay coil with resistance greater
than 240 ohms.
1
Suppressiondiode (1A, 100V) such
as type IN4002 through IN4004
across relay coil.
4
. Plasma cutter is shipped from
the factory with plug connected
to receptacle RMT1 (dry
contacts).
White
Remote
Start
Red
Black +24 VDC
Green
+
Okay To
Move
Relay
Contacts
Relay
Remote Control Cable
−
. +24 volts dc will activate relay coil after unit is triggered and
the cutting arc is initiated.
Tools Needed:
5/16 in
804 041-A
OM-201 872 Page 25
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6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation
Y
Turn off and disconnect
input power.
Control board PC1 can supply +24
volts dc from receptacle RMT2 to
operate
a
customer-supplied
isolated input module for the Okay
To Move signal.
1
2
3
4
Control Board PC1
Receptacle RMT1
Receptacle RMT2
Receptacle RC61
Move plug from RMT1 into
receptacle RMT2 on PC1. Be
sure remote control cable plug is
connected to RC61 on rear of
unit.
2
3
If voltage sensing is required, see
Install wrapper on unit.
Required Items:
1
Customer-supplied isolated input
module.
4
. Plasma cutter is shipped from
the factory with plug connected
to receptacle RMT1 (dry
contacts).
White
Remote
Start
Red
Black +24 VDC
Green
+
Okay To
Move
Output
Remote Control Cable
−
. +24 volts dc will activate relay coil after unit is triggered and
Tools Needed:
the cutting arc is initiated.
5/16 in
804 041-A
OM-201 872 Page 26
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6-6. Dry Contacts Using An External Power Supply For Relay Operation
Y
Turn off and disconnect
input power.
Control board PC1 can provide dry
contacts from receptacle RMT1 to
operate a customer-supplied relay
using an external power supply for
the Okay To Move signal.
1
2
3
Control Board PC1
Receptacle RMT1
Receptacle RC61
Unit is shipped from factory with
plug connected to receptacle
RMT1.
Be sure that remote control cable
plug is connected to RC61 on rear
of unit.
2
If voltage sensing is required, see
Install wrapper on unit.
Required Items:
1
Customer-supplied +24 volts dc
power supply.
24 volts dc relay coil with resistance
greater than 240 ohms.
3
Suppressiondiode (1A, 100V) such
as type IN4002 through IN4004
across relay coil.
White
Remote
Start
Red
Green
Black
+
+24 VDC
Power
Supply
−
Remote Control Cable
Okay To
Move
Relay
Contacts
Relay
. +24 volts dc will activate relay coil after unit is triggered and
the cutting arc is initiated.
Tools Needed:
5/16 in
804 041-A
OM-201 872 Page 27
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6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation
Y
Turn off and disconnect
input power.
Control board PC1 can provide dry
contacts from receptacle RMT1 to
operate
a
customer-supplied
isolated input module using an
external power supply for the Okay
To Move signal.
1
2
3
Control Board PC1
Receptacle RMT2
Receptacle RC61
Unit is shipped from factory with
plug connected to receptacle
RMT1.
2
Be sure that remote control cable
plug is connected to RC61 on rear
of unit.
If voltage sensing is required, see
1
Install wrapper on unit.
Required Items:
Customer-supplied +24 volts dc
power supply.
3
Isolated input module.
White
Remote
Start
Red
Green
Black
+
+24 VDC
Power
Supply
−
Remote Control Cable
Okay To
Move
Output
. +24 volts dc will activate relay coil after unit is triggered and
the cutting arc is initiated.
Tools Needed:
5/16 in
804 041-A
OM-201 872 Page 28
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6-8. Remote Voltage Sense Connection
Y
Turn off and disconnect
input power.
Remote voltage sense is an arc
voltage output signal for automatic
torch height adjustment.
1
2
3
Snap-in Blank
Nylon Bushing
2
1
Secondary Interconnect
Board PC4
4
Receptacle RC48
Remove snap-in blank from rear
panel.
Remove nut from strain relief, and
route plug end of cable through
openingin rear panel.
Slide nut over cable, and secure
strain relief to rear panel.
Route plug end of cable through
nylon bushing and over to PC4.
Connect plug to RC48 on PC4.
Install wrapper on unit.
Cut off crimped terminals on lead
ends, and connect white lead to
+volts dc and black lead to −volts dc
on customer-supplied voltage
sense device.
4
3
Tools Needed:
15/16 in
5/16 in
804 041-A
6-9. Shield Sense Tab
. Shield sense tab is located in
the consumable storage box
on left side of unit wrapper.
OM-201 872 Page 29
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6-10. Cut Charts
100 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/8 in (3.2 mm) between torch and workpiece for all cuts.
ICE-100TM Torch
Shield Sense Tab*
Retaining Cap
Tip
Electrode
Swirl Ring
219 687
226 763
219 684
219 679
219 678
219 677
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
208
119
88
mm/min
5,283
3,022
2,235
1,549
1,193
711
IPM
135
77
mm/min
3,429
1,955
1,447
1,016
660
152
154
157
0.5
0.5
1.0
1.0
1.5
2.0
2.5
3/8
9.5
1/2
12.7
15.9
19.0
25.4
31.8
57
159
162
164
166
5/8
61
40
100
3/4
47
26
1
28
18
457
1-1/4
19
482
12
305
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
231
122
79
mm/min
5,867
3,099
2,006
1,320
990
IPM
150
79
52
34
25
15
9
mm/min
3,810
2,006
1,320
863
153
157
161
0.5
0.5
1.0
1.0
1.5
2.0
2.5
3/8
9.5
1/2
12.7
15.9
19.0
25.4
31.8
162
165
166
170
5/8
52
100
3/4
39
635
1
23
584
381
1-1/4
14
355
228
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
253
142
108
77
mm/min
6,426
3,606
2,743
1,955
1,447
838
IPM
164
92
mm/min
4,165
2,336
1,778
1,270
838
155
157
0.5
0.5
1.0
1.0
1.5
2.0
3/8
9.5
161
1/2
12.7
15.9
19.0
25.4
70
100
162
5/8
50
163
165
3/4
57
33
1
33
21
533
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-201 872 Page 30
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80 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts.
ICE-100TM Torch
Shield Sense Tab*
Retaining Cap
Tip
Electrode
Swirl Ring
212 732
226 763
212 733
212 726
212 724
212 734
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
3/16
1/4
mm
4.8
IPM
216
161
94
mm/min
5,486
4,089
2,388
1,524
1,016
787
IPM
140
105
61
mm/min
3,556
2,667
1,549
991
133
134
137
0.25
0.5
6.4
0.5
3/8
9.5
141
0.5
1/2
12.7
15.9
19.0
22.2
25.4
60
39
80
145
1.0
5/8
40
26
660
148
150
156
N/A
N/A
N/A
3/4
31
20
508
7/8
23
584
15
381
1
16
406
10
254
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
3/16
1/4
mm
4.8
IPM
216
158
83
mm/min
5,486
4,013
2,108
1,270
864
IPM
140
103
54
mm/min
3,556
2,616
1,372
838
134
136
140
0.25
0.5
6.4
0.75
0.75
N/A
N/A
N/A
3/8
9.5
142
145
150
153
1/2
12.7
15.9
19.0
25.4
50
33
80
5/8
34
22
559
3/4
24
610
16
406
1
14
356
9
229
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/8
mm
3.2
IPM
454
176
121
75
mm/min
11,532
4,470
3,073
1,905
940
IPM
295
114
60
mm/min
7,493
2,896
1,524
940
134
139
0.25
0.25
0.75
0.75
N/A
1/4
6.4
144
146
154
3/8
9.5
80
1/2
12.7
19.0
37
3/4
37
19
483
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-201 872 Page 31
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60 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts.
ICE-100TM Torch
Shield
Sense Tab*
Retaining Cap
Tip
Electrode
Swirl Ring
212 732
212 733
219 676
212 724
212 734
226 763
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
16 ga
10 ga
1/4
mm
1.5
IPM
627
264
132
63
mm/min
15,926
6,706
3,353
1,600
1,067
787
IPM
502
211
86
mm/min
12,751
5,359
2,184
1,041
686
134
134
138
0
0
3.4
0.25
0.75
1.5
1.5
1.5
6.4
141
142
147
153
3/8
9.5
41
60
1/2
12.7
15.9
19.0
42
27
5/8
31
20
512
3/4
22
559
14
363
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
16 ga
10 ga
1/4
mm
1.5
IPM
625
244
110
53
mm/min
15,875
6,198
2,794
1,346
889
IPM
406
159
72
mm/min
10,312
4,039
1,829
864
134
136
140
0
0.25
0.5
0.75
2
3.4
6.4
145
146
149
154
3/8
9.5
34
60
1/2
12.7
15.9
19.0
35
23
584
2
5/8
26
660
17
429
2
3/4
18
457
12
297
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/16
1/8
mm
1.6
IPM
666
400
145
74
mm/min
16,916
10,160
3,683
IPM
433
260
94
mm/min
10,995
6,604
2,388
1,219
762
135
138
0
0.25
0.75
1.5
3.2
141
1/4
6.4
60
146
3/8
9.5
1,880
48
150
153
1.5
1/2
12.7
15.9
51
1,295
30
1.5
5/8
33
838
21
545
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-201 872 Page 32
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40 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts.
ICE-100TM Torch
Shield
Sense Tab*
Retaining Cap
Tip
Electrode
Swirl Ring
212 732
212 733
212 725
212 724
212 734
226 763
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
14 ga
10 ga
3/16
mm
1.9
3.4
4.7
6.4
IPM
640
151
97
mm/min
16,256
3,835
IPM
221
98
mm/min
5,613
142
0.25
0.5
0.75
1
146
2,489
40
147
2,464
63
1,600
149
1/4
74
1,880
48
1,219
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
18 ga
16 ga
14 ga
10 ga
3/16
mm
1.3
1.5
1.9
3.4
4.7
6.4
IPM
592
374
221
107
67
mm/min
15,037
9,500
IPM
335
243
144
70
mm/min
8,509
6,172
3,658
1,778
1,118
787
141
144
0.25
0.25
0.25
0.5
144
5,613
40
147
2,718
149
149
0.75
1
1,702
44
1/4
47
1,194
31
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
3/32
1/8
mm
2.4
IPM
293
204
76
mm/min
7,442
IPM
190
133
49
mm/min
4,826
145
0.25
0.5
1
149
151
3.2
5,182
3,378
40
1/4
6.4
1,930
1,245
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-201 872 Page 33
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100 Amp Machine Torch Extended Consumables
The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.
ICE-100TM Torch
Deflector
Retaining Cap
Tip
Electrode
Swirl Ring
212 736
219 684
219 683
219 678
219 677
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
210
122
91
mm/min
5,334
3,098
2,311
1,447
1,092
660
IPM
138
80
mm/min
3,505
2,032
1,524
939
136
139
142
0.5
0.5
1.0
1.0
1.5
2.0
2.0
3/8
9.5
1/2
12.7
15.9
19.0
25.4
31.8
60
146
151
155
160
5/8
57
37
100
3/4
43
28
711
1
26
17
431
1-1/4
16
406
10
254
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
240
131
80
mm/min
6,121
3,327
2,032
1,295
838
IPM
153
85
53
33
22
14
7
mm/min
3,886
2,159
1,346
838
142
145
148
0.5
0.5
1.0
1.0
1.5
2.0
2.0
3/8
9.5
1/2
12.7
15.9
19.0
25.4
31.8
151
156
161
173
5/8
51
100
3/4
33
558
1
22
558
355
1-1/4
11
279
177
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
260
153
107
77
mm/min
6,604
3,886
2,717
1,955
1,295
787
IPM
167
99
mm/min
4,242
2,514
1,828
1,270
838
144
146
0.5
0.5
1.0
1.0
1.5
2.0
3/8
9.5
148
1/2
12.7
15.9
19.0
25.4
72
100
153
5/8
50
157
160
3/4
51
33
1
31
20
508
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-201 872 Page 34
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80 Amp Machine Torch Extended Consumables
The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.
ICE-100TM Torch
Deflector
Retaining Cap
Tip
Electrode
Swirl Ring
212 736
212 733
212 728
212 724
212 734
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
3/16
1/4
mm
4.7
IPM
221
170
98
mm/min
5,613
IPM
142
110
63
mm/min
3,607
2,794
1,600
1,067
711
80
80
80
80
80
138
140
143
146
149
0.25
0.5
0.5
0.5
1
6.4
4,318
3/8
9.5
2,489
1/2
12.7
15.8
62
1,574
42
5/8
42
1,066
28
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
160
55
mm/min
4,064
IPM
106
34
mm/min
2,692
138
0.5
1
80
143
1/2
12.7
1,397
863
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/4
mm
6.4
IPM
140
80
mm/min
3,556
IPM
120
42
mm/min
3,048
80
80
140
147
0.25
1
1/2
12.7
2,032
1,067
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-201 872 Page 35
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60 Amp Machine Torch Extended Consumables
The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.
ICE-100TM Torch
Deflector
Retaining Cap
Tip
Electrode
Swirl Ring
212 736
212 733
219 682
212 724
212 734
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
3/16
1/4
mm
4.5
IPM
185
131
70
mm/min
4,699
IPM
105
87
mm/min
2,667
60
60
60
136
139
141
0.25
0.25
0.75
6.4
3,327
2,210
3/8
9.5
1,778
44
1,118
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
14 ga
1/4
mm
2.2
IPM
610
114
mm/min
15,494
2,896
IPM
385
74
mm/min
9,779
134
0
60
138
0.5
6.4
1,879
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/16
1/4
mm
1.6
IPM
669
153
56
mm/min
16,992
3,886
IPM
436
97
mm/min
11,074
2,463
60
60
60
138
142
147
0
0.25
1.25
6.4
1/2
12.7
1,422
33
838
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-201 872 Page 36
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40 Amp Machine Torch Extended Consumables
The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.
ICE-100TM Torch
Deflector
Retaining Cap
Tip
Electrode
Swirl Ring
212 736
212 733
212 729
212 724
212 734
Mild Steel
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
14 ga
3/16
mm
1.9
IPM
320
95
mm/min
8,128
IPM
214
63
mm/min
5,435
126
0
0.75
1
134
138
4.8
2,413
1,600
40
1/4
6.4
73
1,854
49
1,245
Stainless
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
18 ga
14 ga
1/4
mm
1.3
IPM
515
222
50
mm/min
13,081
5,638
IPM
328
145
35
mm/min
8,331
3,683
889
123
0
0.25
1
130
138
1.9
40
6.4
1,270
Aluminum
Material Thickness
Maximum Cut Speeds
Optimum Cut Speeds
Pierce
Delay
Arc Current Arc Voltage
Inches
1/8
mm
3.2
IPM
214
81
mm/min
5,435
IPM
135
52
mm/min
3,429
148
0.5
1
40
150
1/4
6.4
2,057
1,320
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-201 872 Page 37
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SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
. Maintain more often
Y
Disconnect power
before maintaining.
during severe conditions.
n = Check
Z = Change
~ = Clean
l = Replace
Reference
* To be done by Factory Authorized Service Agent
Each
Use
n Torch Tip, Electrode,
n Gas/Air Pressure
And Shield Cup
Every
Week
n Shield Cup Shutdown
System
Every
3
Months
l Damaged Or Unreadable l Cracked Parts
Labels
~ Air Filter/Regulator
Assembly Filter
n Gas/Air Hose
n l Torch Body, Cable
Every
6
OR
Months
~ Inside Unit
OM-201 872 Page 38
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7-2. Trouble Lights
1
Pressure Light
Lights if gas/air pressure at torch is
below 50 PSI (344 kPa) or above 90
PSI (620 kPa).
Difficulty establishing pilot arc may indicate
consumablesneed to be cleaned or replaced.
Turn power Off, and check for prop-
er gas/air pressure (see Section
5-2).
2
Cup Light
Lights if shield cup is loose.
1
Turn power Off, and check shield
cup connection (see torch Owner’s
Manual). Power must be reset
whenever the cup shutdown is
activated.
2
3
Check shield cup shutdown system
3
Temperature Light
Lights if power source overheats
7-3. Checking Shield Cup Shutdown System
1
Torch Shield Cup
. Power must be reset whenever the cup shutdown
Turn Power On and loosen shield
cup. If shutdown system works
properly, Ready light goes off and
Cup light comes on. If not, immedi-
ately turn Off power and have Fac-
tory Authorized Service Agent
check safety control board PC1 op-
eration.
system is activated. Always turn Off power when
changing or checking consumables. Do NOT
overtightentorch shield cup. Gently finger tight-
en cup onto torch.
1
If system works properly, retighten
cup and reset power.
Ref. 801 300-A
OM-201 872 Page 39
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7-4. Checking/Replacing Retaining Cup, Tip, And Electrode
Overtightening will strip threads. Do not overtighten electrode, tip,
and retaining cup during assembly. Do not cross-thread parts causing
stripping. Use care during torch assembly and parts replacement.
Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly
reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.
A good practice is to replace both the tip and electrode at the same time.
Turn Off power source before checking torch parts.
1/32 in (1 mm) to 1/16 in
(2 mm) maximum pit
depth depending on
acceptable cut quality
5
Worn
New
Make sure this area is
clean of any debris.
3
Worn
8
7
New
4
6
Make sure this area is
clean of any debris.
2
1
804 056-A
Turn Off power source.
Drag Shield
Remove tip. Check tip, and replace if open- Remove swirl ring. Check ring, and replace
ing is deformed or 50% oversize. If inside of if side holes are plugged.
1
tip is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards.
7
O-Ring
Check this area for any debris or foreign
material. Clean out if necessary.
Check O-rings on torch. If needed, coat with
thin film of silicone lubricant (part no.
169 231). Replace if damaged.
2
Retaining Cup
5
Electrode
Remove retaining cup. Check retaining cup
for cracks, and replace if necessary.
8
Plunger Area
Check electrode. If center has a pit more
than a 1/32 in (1 mm) deep, remove and
replace electrode.
Check this area for any debris or foreign
material. Clean out if necessary.
3
4
Tip
Opening
6
Swirl Ring
Carefully reassemble parts in reverse order.
OM-201 872 Page 40
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7-5. Checking Or Replacing Filter Element
1
2
3
4
5
6
Latch
Filter Cup
Retaining Nut
Filter Element
Defuser Ring
Filter Cap
6
Slide latch down, and rotate filter
cup approximately 1/4 turn.
Remove cup.
Remove retaining nut, filter
element,and defuser ring.
5
4
Check filter element for dirt and
moisture, and replace if necessary.
Be sure that all parts are clean and
dry.
Reinstall all parts, and secure filter
cup.
3
1
2
804 054-A
OM-201 872 Page 41
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7-6. Troubleshooting Power Source
Trouble
Remedy
Clean or replace worn consumables as necessary (see torch Owner’s Manual).
Check for damaged torch or torch cable (see torch Owner’s Manual).
No pilot arc; difficulty in establishing an
arc.
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; Place Power switch in On position.
Trouble lights off; Ready light off; fan
motor FM does not run.
Pilot arc working; no cutting output; Be sure work clamp is connected.
Power light on; Trouble lights off; fan
motor running.
Clean or replace worn consumables as necessary (see torch Owner’s Manual).
No gas/air flow; Power light on; Trouble Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas
lights off; fan motor running.
Check for dirty air filter/regulator and replace, if necessary (see manufacturer’s instructions).
Check air lines for leaks.
Pressure Trouble light On.
Have Factory Authorized Service Agent check pressure switch and control board.
Check torch shield cup (see Section 7-3). Reset power switch.
Have Factory Authorized Service Agent check for proper torch connections.
Unit overheating. Allow fan to run; the Trouble light goes out when the unit has cooled.
Have Factory Authorized Service Agent check control board.
Cup Trouble light On.
Temperature Trouble light On.
Trouble lights not working.
Have Factory Authorized Service Agent check unit.
Power light flashing, Trouble lights off.
Reset power switch. Have qualified technician check input line power. Make sure line power is three
phase. Single phase power will cause an incorrect power condition.
Pressure trouble light flashes.
Short tip life.
Unit lost pressure (momentarily) while cutting. Check air line for leaks.
Check and clean drag shield of any slag, particles, and debris.
Check position of cut/gouge switch. Place switch in correct position to match the process.
OM-201 872 Page 42
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7-7. Troubleshooting Torch
Trouble
Remedy
Arc goes on and off while cutting.
Torch travel speed too slow; increase travel speed (see Section 5-5). Clean or replace torch consumables
Arc goes out while cutting.
Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in (1.6 mm) to
Sparks come out top of cut or cut is not Torch travel speed too fast; reduce travel speed (see Section 5-5). Clean or replace torch consumables
clean.
as necessary (see Section 7-4). Be sure work clamp is securely attached to workpiece. Unit not capable
Trouble lights are on; unit has no cutting Check torch consumables. Check for gas/air flow at torch. Check air supply connection and pressure to
output.
unit and torch. Reset unit Power switch. Have Factory Authorized Service Agent check torch and
connections inside unit.
OM-201 872 Page 43
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201 858-A
OM-201 872 Page 45
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SECTION 9 − PARTS LIST
9-1. Recommended Spare Parts
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Recommended Spare Parts
. . . . . . . . . . . . . . . . 224749 . . COVER ASSY (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 223835 . . . . LABEL,ICE 100T CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 215089 . . FILTER,AIR ELEMENT 5 MICRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 223834 . . CABLE,WORK 25 FT 4 GA W/CLAMP STRAIN RLF & TERM (including) . . 1
. . . . . . . . . . . . . . . . 201846 . . CABLE,WORK 50 FT NO 4 W/CLAMP STRAIN RLF & TERM (including) . . 1
. . . . . . . . . . . . . . . . 213619 . . . . CLAMP,WORK 300 AMP STL CHROME PLD W/COP CONTACTS . . . . . . 1
. . . . . . . . . . . . . . . . 134900 . . . . STRAIN RELIEF,CABLE FLEXIBLE .270−.480 CABLE . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 225702 . . ICE−100T 25 FT HAND HELD REPLACEMENT TORCH . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 225704 . . ICE−100T 50 FT HAND HELD REPLACEMENT TORCH . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 225706 . . ICE−100TM 25 FT MACHINE REPLACEMENT TORCH . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 225708 . . ICE−100TM 50 FT MACHINE REPLACEMENT TORCH . . . . . . . . . . . . . . . . . 1
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.
Item Part
No. No.
Item Part
No. No.
Description
Description
1
2
3
4
5
6
7
8
215 594 Handle w/Screws (1)
215 478 Switch, cup sensor (1)
223 775 Torch Head Repair Kit (1)
185 833 Switch Assy w/Spring (1)
190 220 Trigger Spring (1)
9
10
215 606 Clip, retaining (1)
212 735 O-Ring, main body (1)
169 231 Grease, silicon
225 702 Torch, replacement 25ft (1)
225 704 Torch, replacement 50ft (1)
215 592 Switch Trigger (1)
223 774 Main Body w/Switch (1)
223 612 Torch Lead, 25ft (1)
223 613 Torch Lead, 50ft (1)
8
9
1
additional consumable parts.
2
7
6
3
5
10
1
4
804 035-A
Figure 9-1. Torch, ICE-100T
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-201 872 Page 46
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CAUTION
FAILUREꢀꢁTOꢀꢁRE−
PLACEꢀꢁWORNꢀꢁTIP
ORꢀꢁELECTRODE
WILLꢀꢁRUINꢀꢁTORCH
ANDꢀꢁVOID
Drag Shield
Retaining Cap
Tip
Electrode
Swirl Ring
WARRANTY.
Turnꢀoffꢀpowerꢀbefore
checkingꢀtorchꢀparts.
40A
Checkꢀbeforeꢀeach
useꢀandꢀhourly
duringꢀoperation.
212 730
212 733
212 725
60A
80A
O-Ring
212 735
212 730
212 730
212 733
212 733
219 676
212 726
212 724
212 734
100A
219 685
219 684
219 679
219 678
219 677
Standard Cutting
Shield
Retaining Cap
Tip
Electrode
Swirl Ring
60A
80A
212 731
212 731
212 733
212 733
219 680
212 727
O-Ring
212 735
212 724
212 734
100A
212 731
219 684
219 681
219 678
219 677
Gouging
Ref. 213 031-B / Ref. 804 056-A
Figure 9-2. Consumable Parts For ICE-100T
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-201 872 Page 47
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Shield Sense Tab* Retaining Cap
Tip
Electrode
Swirl Ring
CAUTION
FAILUREꢀꢁTOꢀꢁRE−
PLACEꢀꢁWORNꢀꢁTIP
ORꢀꢁELECTRODE
WILLꢀꢁRUINꢀꢁTORCH
ANDꢀꢁVOID
WARRANTY.
Turnꢀoffꢀpowerꢀbefore
checkingꢀtorchꢀparts.
40A
60A
212 732
212 732
212 733
212 733
212 725
226 763
226 763
Checkꢀbeforeꢀeach
useꢀandꢀhourly
duringꢀoperation.
219 676
212 726
212 724
212 734
O-Ring
212 735
80A
212 732
212 733
226 763
226 763
100A
219 687
219 684
219 679
219 678
219 677
Machine Cutting
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
Deflector
Retaining Cap
Tip
Electrode
Swirl Ring
40A
212 736
212 733
212 729
60A
80A
O-Ring
212 735
212 736
212 736
212 733
212 733
219 682
212 728
212 724
212 734
100A
212 736
219 684
219 683
219 678
219 677
Extended Cutting
Ref. 213 031-B / Ref. 804 056-A
Figure 9-3. Consumable Parts For ICE-100TM
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-201 872 Page 48
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additional consumable parts.
Item Part
No. No.
Description
1
2
3
4
5
6
215 607 Sleeve, torch position (1)
223 614 Torch Lead, 25ft (1)
223 615 Torch Lead, 50ft (1)
215 599 Torch Sleeve (1)
223 773 Main Body w/Switch (1)
195 513 Remote Pendant Control (1)
215 478 Switch, cup sensor (1)
225 706 Torch, replacement 25ft (1)
225 708 Torch, replacement 50ft (1)
220 240 Cable, remote control trigger 25ft (1)
220 241 Cable, remote voltage sense 26.5ft (1)
1
2
6
5
4
3
804 036-A
Figure 9-4. Torch, ICE-100TM
NOTE
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-201 872 Page 49
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Notes
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
APT & SAF Model Plasma Cutting Torches
Remote Controls
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
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.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
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.
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
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.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
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,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
INCLUDING
ANY
IMPLIED
WARRANTY
OF
Running Gear/Trailers
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Plasma Cutting Torches (except APT & SAF
Models)
*
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
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.
*
*
*
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
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,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
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)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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