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OM-182 702A June 1997 Eff. w/Serial Number KH387456 Miller Processes Cutting Gouging Air Plasma The Power fBlue. and Description Air Plasma Cutter FILE COPY ~ETUR~3 TO ~ Spectrumfi 300 (50/60 Hz) j~ Visit our website. at www~MiIloiWCldS~com OWNERS MANUAL From Miller to You Thank you and you can get the have time to do it any other way. you dont Thats congratulations on choosing Miller. Now job done and get it done right. We know why when Niels Miller first started building arc products offered long-lasting value and superior quality. Like you, his customers couldnt afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. welders in 1929, he made sure his people that build and sell Miller products continue the Theyre just as committed to providing equipment and service meets the high standards of quality and value established in 1929. Today, the tradition. that This Owners Miller help Manual is products. designed to help you get the most out of your Please take time to read the yourself against potential you protect Safety precautions. They hazards made installation and on will the worksite. Weve and easy. of reliable years service with proper maintenance. And if for some reason the unit needs repair, theres a 4k1IiIIW With Miller you I REGISTERED SYSTEM _______________ can operation quick count on Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller Is tIe first welding equip menttunutacturorlntbeU.S.A.te Is registered to Ike ISO 9001 Quality System Standard. ~1~Th1~ 1~ftflfl~~ L~ Working as lard as yen I,. every .me Miller Electric manufactures of welders and welding For information products, on catalog ~ equipment. quality Miller ~ ~, local Miller distributor to receive the latest full line individual full line related other contact your a power source trim Miller is lacked ly the most lasslo-troe warranty I. the buslooss. catalog or sheets. To locate your nearest distributor call 1-800-4-A-Miller. f/IA Miller heThwer9fBhse~ Call 1 -800-4-A-MILLER for your local Miller dlslributor. TABLE OF CONTENTS SECTION 1 Service You always get the fast, reliable response you need. Most replacement parts can be in your answers SECTION 1 1-1. 1-2. 1-3. to the Contact your distributor. expertise of the distributor and Miller is there to help you, every step of the way. a more parts Technical provides detailed service and information for your SECURITE - normes 1-5. Information sur SECTION 2 2-1. 2-2. 2-3. 2-4. 2-7. - los 7 7 champs ØlectromagnØtiques INSTALLATION Selecting A Location Connecting Work Clamp Connecting Input Power 9 9 9 10 11 And Gas/Air Supply website at www.MIIIeiWeId&com 12 12 13 Controls 13 SECTION 6- PARTS LIST our 8 9 Specifications Symbols And Definitions Cutting Speed Duty Cycle And Overheating practical information on welding, process applica tions, and Miller products, For visit 5 le fonctionnement de sØcurit~ SECTION 4- MAINTENANCE & TROUBLESHOOTING a 5 5 SECTION 3-OPERATION 3-1. 2 3 LIRE AVANT UTILISATION Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. unit. To obtain And Maintenance Signification des symboles Dangers lies au coupage a Iarc au plasma Dangers supplØmentaires en relation avec Iinstallation, Principales 2-6. Manual which 1 4 CONSIGNES DE 1-4. 2-5. Miller offers - 1 1 et Ia maintenance tough welding questions? The READ BEFORE USING EMF Information hands in 24 hours. Support Need fast - 1-5. 1-3. gives you SAFETY PRECAUTIONS 1-4. 1-2. Your distributor - Symbol Usage Plasma Arc Cutting Hazards Additional Symbols For Installation, Operation, Principal Safety Standards 1-1. 14 4-1. Routine Maintenance 4-2. Overload Protection: Trouble 4-3. Torch And Work Cable Connections 16 4-4. Troubleshooting 17 14 Lights & Checking Shield Cup Shutdown System 15 SECTION 5- ELECTRICAL DIAGRAM WARRANTY .20 SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING - porn 1-1 Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are a A _nd_5/97 shown in the Marks special safety a ~ Means Note; 1-2 adjoining symbols. not 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. safety related. Cutting Plasma Arc Hazards ~ A The symbols are used throughout this manual identify possible hazards. When you shown below to call attention to and the symbol, watch out, and follow the related instructions to avoid the hazard. The safety Information given below is only a summary of the more complete safety information ~ Do not touch live electrical parts. dry, hole-free insulating gloves Wear and body protection. see found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards. A Only qualified persons should install, operate, maintain, and repair this unit. A During operation, keep everybody, especially children, away. i w iriG can cause fire or explosion flying sparks possible, tightly Be alert that sparks Watch br fire, and Be aware cause that fire strike flammable material. keep cutting a on a openings on closed containers such prevent cutting to unknown to If cutting can easily go adjacent areas. fire extinguisher nearby. ceiling, floor, bulkhead, or partition Connect work cable to the work practical (10.7 m) of the cutting arc. them with approved covers. can the hidden side. on Do not cut paths and as as current from causing tanks parts at once. a safety Keep all electric shock and fire hazards. atmospheres containing explosive pressurized cylinders, pipes, or or vapors. vessels. Do not cut containers that have held combustibles. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Do not locate unit on or over ~ki~, con Do not Use harness if panels bypass and or try working above floor level. covers securely in place. safety interlock systems. to defeat the only torch(es) specified in Owners Manual. Keep away from torch tip and pilot arc when trigger is pressed. Clamp work cable with good metal-to-metal contact to workpiece (not piece that will fall away) or worktable as near the cut as practical. Insulate work clamp when not connected to contact with any metal workpiece to prevent object. combustible surfaces. Remove any combustibles, such as a butane from your person before doing any cutting. 7 grounding Ground the workpiece to a good electrical (earth) ground if re quired by codes. Use only well-maintained equipment. Repair or replace damaged Wear dust attach proper Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. Turn off all equipment when not in use. Inspect and replace any worn or damaged torch cable leads. Do not wrap torch cable around your body. drums. Never cut containers with potentially flammable materials inside must be emptied and properly cleaned first. Do not cut making input connections, cutting area as traveling long, possibly or close to the they Do not cut in Manual and national, state, and local codes. sure that input power cord ground wire is properly ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet always verify the supply ground. and hot materials from small cracks and through cover ground. ductor first. Remove all flammables within 35 ft this is not or connected to flying sparks and hot metal. can parts if in contact with the work checking, cleaning, or changing torch parts. Disconnect input power before installing or servicing this equip ment. Lockout/tagout input power according to OSHA CFR 191 0.147 (see Safety Standards). Properly install and ground this equipment according to its Own When and others from Do not cut where Do not touch torch Turn off power before Check and be cutting. yourself yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. ers 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 bums. Check and be sure the area is safe before doing any Protect Insulate lighter or matches, SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Turn OFF ELECTRIC SHOCK can~ kill I Touching I shocks inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. live electrical parts can cause fatal burns. The torch and work circuit are electrically live whenever the output is on. The _J input power circuit and machine internal circuits are also live when power is on. Plasma arc cutting requires higher voltages than welding to start and maintain the arc (200 to 400 volts dc are common), but also uses torches designed with safety interlock systems which turn off the machine when the shield cup is loosened or if tip touches electrode inside the nozzle. Incorrectly installed or improperly grounded equipment is a hazard. or severe OM-1 82702 Page 1 ~.. . YING SPARKS can cause Sparks and hot metal blow out from the cutting Chipping and grinding cause flying metal. Wear approved face shield Wear proper body protection Wearflame-resistant entering or ear safety goggles with side to only if it is well ventilated, or while air-supplied respirator. Fumes from cutting and oxygen depletion can alter air quality causing injury or death. Be sure the breathing air is safe. Do not cut in locations near degreasing, cleaning, or spraying op injury arc. protect skin. an Do not cut bum eyes and skin coated metals, such as galvanized, lead, or unless the coating is removed from the on Do not cut containers with toxic protection (helmet or shield) emptied and with correct shade of filter properly reactive materials inside I or must be cleaned first. PLASMA ARC protect your face and eyes when cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a No. 9 shade (with No. 8 can cause injury ~ 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. 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 oper as S convenience. Wearapproved safety glasses with side shields under your helmet or or containers that have held toxic or reactive materials they to ators react with vapors to form cutting area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes when cut. Arc rays from the cutting process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Wear face arc can plated steel, cadmium ears. can a wearing erations. The heat and rays of the highly toxic and irritating gases. shields. plugs or ear muffs to prevent sparks from ARC RAYS confined space Work in Keep away from the torch tip. Do not grip material near the cutting path. The shield. keep away from torch tip when trig pilot arc can cause burns pressed. ger is Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection. Table 1. Eye Protection Current Level In 4060 80 exposed body all Point torch away from your body and toward work when pressing immediately. Turn off power source and disconnect input power before disas sembling torch or changing torch parts. Use only torch(es) specified in the Owners Manual. the torch Cutting trigger #4 TkH~ 2040 clothing covering areas. pilot arc comes on Minimum Shade Number Amperes Below 20 60 For Plasma Arc Wear proper flame-retardant ~UNDERS can explode if damaged #5 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. Gas #6 #8 _________ _________ compressed gas cylinders from excessive heat, mechani slag, open flame, sparks, and arcs. Install and secure cylinders in an upright position by chaining them to a stationary supportor equipmentcylinder rack to prevent falling or tipping. Protect ~7 I NOISE can damage hearing~ cal shocks, Prolonged noise from some cutting applications damage hearing if levels exceed limits speci fled by OSHA (see Safety Standards). can Keep cylinders away from any cutting _________ approved ear plugs or ear muffs if noise Warn others nearby about noise hazard. Use level is high. Never cut ha~a~dous~ arc torch and a on a pressurized cylinder explosion will result. parts in good condition. Turn face away from valve outlet when Keep protective cap use or in connected for opening cylinder valve. place over valve except when cylinder is in use. Read and follow instructions on compressed gas cylinders, asso ciated equipment, and CGA publication P-i listed in Safety fumes and gases. Standards. approved air-supplied respirator. Safety Data Sheets (MSDS5) and the manufac for metals to be cut, coatings, and cleaners. If ventilation is poor, instruction plasma only correct gas cylinders, regulators, hoses, and fittings de signed for the specific application; maintain them and associated Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove Read the Material other electrical circuits. Use Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. turers a cylinder. ~ cuthng or Never allow electrical contact between use an 4~dditIonaI.SymboIsFor I .... . .~ HOT PARTS can cause severe Do not touch hot Allow OM-182 7C12 Page 2 burns. parts bare handed. cooling period before working on torch. MO VING PARTS Keep Keep away from can cause moving parts injury such as all doors, panels, covers, and closed and securely in place. ~ fans. guards 7 FLYING METAL Wear can safety glasses STATIC(ESD)can damage PC Injure eyes with side shields or Put face shield. boards MAGNETIC FIELDS can affect strap BEFORE parts. or static-proof bags and or ship PC boards. Use proper store, move, 1 wrist grounded on handling board~] boxes to pacemakers H F RADIATION can cause Interference Pacemaker wearers keep away. Wearers should consult their doctor before go ing near plasma arc High frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. cutting operations. Have OVERUSE can cause tronic OVERHEATING The cooling period; follow rated duty cycle. Reduce amperage (thickness) or reduce duty cycle before starting to cut again. Allow user is responsible for having a qualified electrician promptly problem resulting from the installation. correct any interference If notified by the FCC about interference, ~.. minimize the When cutting aluminum underwaterorwith the watertouching the underside of the aluminum, free hydrogen gas may collect under the work- possibility AD! piece. cutting engineer and regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to of interference. CUTflNGanca~SØ;Intert~e. energy can interfere with electronic equipment such as Electromagnetic __________ See your stop using the equip ment at once. Have the installation EXPL~O DING HYDROGEN h~ard~:~: only qualified persons familiar with elec equipment perform this installation. water table instructions for help. sensitive computers and computer-driven equipment ~1 ~ FALLING UNIT can cause such Injury lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift Use . Locate cutting operation equipment. are long enough to robots. 100 meters from any sensitive electronic grounded If interference still occurs, the user must take extra as moving the machine, using shielded cables, measures sure this according cutting power source to this manual. such filters, FIRE OR EXPLOSION hazard Do not locate unit on, over, or near as is installed and Be using lift forks to move unit, be sure forks extend beyond opposite side of unit. If as To reduce possible interference, keep cables as short possible, close together, and down low, such as on the floor. or shielding the work using line area. combus tible surfaces. Do not install unit near flammables. building wiring be sure power supply system is rated, and protected to handle this unit. Do not overload properly sized, 1~ Piincipal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49. 1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safetyand Health Standards, OSHA 29 CFR 1910, from Superinten dent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Practices for Plasma Arc Cutting, American Welding from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 Society Standard AWS C5.2, Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i, from Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. Code forSafelyin Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Bou levard, Rexdale, Ontario, Canada M9W 1 R3. 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. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, Ameri can Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 Cutting And Welding Processes, NFPA Standard 51 B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. National Electrical Code, NFPA Standard 70, from National Fire Pro Batterymarch Park, Quincy, MA 02269. tection Association, OM-182 702 Page 3 Information .~: :~. Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current, as it flows through the welding or cutting cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon Considerations About 1. Keep cables close together by twisting 2. Arrange 3 Do not coil 4. committee of the National Research Council concluded that: The To reduce magnetic fields in the dures: OM-182 702 Page 4 workplace, use the following proce- 5. or Keep cutting ator of evidence, in the committees body 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. cables to as one or taping side and away from the them. operator. dra P e cables around Y our bod Y. power source and cables as far away from oper p ractical Connect work clamp to workpiece as close to the cut as possi ble About Pacemakers: Pacemaker wearers consult yourdoctorfirst. If cleared byyourdoctor, then following the above procedures is recommended. SECTION 1 CONSIGNES DE - SECU RITE - LIRE AVANT UTILISATION porn_nd_f re_5/97 Signification dessymboles 1~ Signifie Mise en garde! Soyez vigilant! Cette procedure prØsente des risques do danger! Ceux-ci sont identifies par des symboles adjacents aux directives. a A Identifie Signifie un message de sØcuritØ NOTA nestpas particulier. Ce groupe de symboles signifie Mis~ en garde! Soyez vlgila.nt lily a des ns ques de danger reijes aux CHOCS ELECTRIQUES, aux PIECES EN MOU VEMENT et aux PIECES CHAUDES. Reportez-vous aux symboles 01 aux di rectives ci-dessous at in de connaltre les mesures a prendre pour Øvlter tout relatif ala sOcuritØ. danger DaiigE~ lies: ic.c.Upage ~::1arc 1~. A au .pIa~ma Les symboles prØsentes cl-aprŁs sont utilisØs tout au long du present manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnØes afin dØviter tout danger,. Les consignes de sØcuritØ prØsentCes cl-aprŁs ne font que rØsumer llnformation contenue dans les normes de sØcuritØ ØnumØrØes a Ia section 1-5. Veulllez lire et respecter toutes ces normes de sØcuritØ. A Llnstallatlon, lutilisation, doivent Œtre confiØs A Au cours de qu lentretlen et les reparations des personnes qualifiees. ne lutilisatlon, tenirtoute personne a lØcartet plus particuliŁrement les enfants. LE.COUPAGE teu ou presante~uri.iiØque .de~ dtexptosion chaud et des Øtincelles au moment du coupage. Les Łtincelles et le metal chaud, Ia piŁce a couper chauffOo et lequipement chaud peuvcnt causer un feu ou des brCilures. Avant de commencer a travailler, assurezvous que lendroit est sØcuritaire. Des particules de metal peuvent jaillir de Ia piŁce ProtØgezvous, ainsi que toute autre personne travaillant lioux, contre les Øtincelles et le metal chaud. No coupez pas dans un endroil o dre des matiŁres inflammables. sur les des Øtincelles pourraient attoin Deplacez toute matiŁre inflammable se trouvant a lintŁrieur dun pOrimŁtre de 10,7 m (35 pi) de Ia piŁce a couper. Si cola est im possible, vous devez los couvrir avec des housses approuvees et bien ajustØes. Assurezvous quaucune Øtincelle ni particule do metal ne peut so glisser dans de petitos fissures ou tomber dans dautres piŁces. Afin dØliminer tout risque do fou, soyez vigilant et gardez toujours un extincteur a Ia portŁo do Ia main. Si vous coupez sur un plafond, un plancher ou une cloison, soyez conscient que cela pout ontraIner un feu de lautro ctO. No coupez pas sur un contonant fermØ tel quun rØsorvoir ou un bidon. Fixez le cable do masse sur Ia piŁce a coupor, le plus prŁs possible do Ia zone a couper atm do prØvenir quo le courant do coupage ne pronne uno trajectoiro inconnuo ou longuo et no causo ainsi uno dØchargo electrique ou un fou. Nocoupezjamaisdoscontonantsqui peuvontcontonirdosmatiŁ ros inflammablos. Vous dovoz on premier lieu los vidor et les nottoyer convonablement. No coupez pas dans un ondroit o latmosphŁre risque do contenir do Ia poussiŁre ou dos vapeurs explosives. No coupoz pas do boutoilles, do rises. tuyaux ou do contenants prossu poste sur uno surface combustible UNE DEcHARGE~ELEc TRIO UE pe Ut entraIriŁrlÆ mart. Lo fait do toucher a une piŁce Ølectrique sous tension pout donnor uno decharge fatale ou ontrainor dos brOlures graves. Lo chalumoau otlo circuit de masse sont automatiquomont actits le Iorsque poste est sous tension. Lalimentation dentrŁo et los circuits intornes do Iappareil Ia sont Łgalemont. Le coupage au plasma darc exige des tensions plus ØlevØos quo le soudage pour amorcer et maintonir Iarc (souvent do 200 a 400 V CC), cost pourquoi on fait appel a des chalumeaux concus avec un systŁme do vorrouillage securitairo qui met Iapparoil hors tension Iorsque Ia capsulo antifeu est dessorrŁo ou silo tube toucho Ielectrode a lintŁrieurde Ia buso. Un posto incorrectement installØ ou inadØqua tomont mis a Ia terre constitue un danger. No touchoz pas aux piŁces loctriquos sous tension. Portoz des gants isolants ot des vØtomonts do protection sans trous. ou Avant le coupage, retirez tout combustible do vos exemplo un briquet au butane ou des allumettos. audessus lsolozvous de Ia piŁce a couper ot du solon utilisant des housses dos tapis assez grands afin dØvitor tout contact physique avoc Ia piŁce a couper ou 10 sol. Ne touchez pas aux piŁces du chalumoau si Ia piŁce a couper ou le sot. par vous Œtes en contact avec Mettoz lapparoil hors tension avant deffectuer Ia verification, nottoyage ou lo changoment dune piŁce du chalumeau. le Coupoz lalimentation dentrŁo avant dinstaller Iappareil ou dot foctuor Ientrotien. Vorrouillez ou etiquetez Ia sortie dalimontation solon Ia norme OSHA 29 CFR 1910.147 (reportozvous aux Prin cipalos normes do sØcuritØ). Installez Ia posto correctement et mettezle ala terre convenablo mont solon los consignes du manuel do loperateur et les normes nationales, provincialos et locales. Assurezvous quo lo fil do terre du cordon dalimontation est cor roctoment rouØ ala borne do terre dans Ia boito do coupure ou quo Ia fiche du cordon ost branchØo a une prise correctemont miso ala terre vous devez toujours verifier Ia miso a Ia terre. Avant doffectuor los connexions le bon fil de terre. dalimontatiori, vous dovez rolior VØrifiez rer frequomment le cordon dalimentation afin de vous assu nest pas altØrØ ou a nu, remplacozlo immØdiatomont sil Un fil a nu pout entralner Ia mort. quil Iost. LØquipement doit Øtre hors tension VØrifioz ot remplacez los sont usØos ou altereos. cosses Le cable du chalumoau ne Iorsquil nest pas utilisØ. du cable du chalumoau si olles doit pas senrouler autour do votre corps. Si los normes 10 stipulent, Ia piŁce a coupor doit Łtre miso ala terre. uniquementde lequipemont en bonno condition. RØparoz romplacez immØdiatement touto piŁce altØrØo. Utilisoz Portoz du sol. un harnais do sØcuritØ si Assurozvous mont place. Nessayez pas vous devez travailler audessus quo tousles panneaux 01 couvorcles sont corrode on de sØcuritØ pochos, secs et ou ou No coupez pas de contenants qui ont deja rou dos combustibles. Portoz des vŒtemonts do protection exempts dhuilo lois quo dos gants en cuir, uno vosto rØsistanto, dos pantalons sans rovors, des boltos ot un casquo. No placoz pas le de celleci. . ou dallor ~ lencontro do los contourner. (Jtilisez uniquement le manuel de lopOrateur. ou dos systŁmos do vorrrouillago los chalumeaux recommandØs dans le OM-182 702 Page 5 Napprochez pas le tube du chalumeau et arc photo lorsque Ia gchette est enfoncØo. Le cable do doit Œtre pince corroctement sur Ia piŁce a couper, mOtal (et non de telle sorte quiI puisso so detacher), ou sur Ia table plus pres possible de Ia ligne de coupago. Isoler Ia pince de masse quand pas mis a Ia piŁce pour Øviter le contact avec tout objet mØtallique. masse Contre metal de travail 10 II y a DU COURANT CONTINU IMPORTANT dans les convertisseurs aprŁs Ia suppression de Iali mentation No mettez pas votre tŒte audessus des vapours. No resplrez pas cos va pours. Si vous Œtos a IintØfleur au moment du coupago, vonliloz Ia piŁce ou ayez rocours a uno ventilation aspiranto lnstallØe prŁs do larc pour Øvacuor los vapeurs of los gaz. Si Ia rovoquer des blessures. Le coupage plasma produit des Øtincelles et projections de metal a trŁs haute temperature. Lorsque Ia piŁce ref roidit, du laitier pout se former. visiŁre ou des lunettes de sØcuritO avecdes Øcrans latØraux ap prouvees. Portez des vŒtements do protection adequats at in de proteger votro peau. Ayez recours a des protegetympans oti a tin serretŒte ignifuges atm dØviter quo les etincelles nentrent dans vos oreilles. I ~ RAYONS DARC peuvent en ier des bthlures aux yeux et a Ia Los rayons darc provenant du procØdØ do coupage produisent des rayons visiblos et invisibles intenses (ultraviolets et mnfrarouges) qui peuvent entrainordes brlures aux yeux eta Ia peau. Lorsque vous coupez ou regardez quelquun couper, portez un masque ou un Łcran facial avec le filtre appropriØ. La norme ANSI Z49.1 (reportez vous aux Pflncipales normes do sØcuntØ) suggŁro dutiliser un filtre do teinte no 9 (nO 8 Łtant le minimum) pour tout travail do coupago faisant ap pel a un courant de moms do 300 A. On mentionno egalomont dans Ia norme Z49.1 quun filtro plus faiblo pout Œtre utilisØ Iorsque arc est cache par Ia piŁce a couper. Commo cola est habituollement le cas pour los tra do coupage a faible courant, les teintes ØnumØrØes au tableau 1 sont fournies a titre dmnformation pour loperateur. Porter des lunettes do sØcuritØ a coques latØrales sous votre casque ou Ocran facial. vaux recours a des Øcrans protecteurs autres contre los sonne sur ou a des rideaux pour proteger los Øblouissemonts; prØvonez touto per pas regarder larc. rayonnements et los lieux do no es Portez dos vŒtements confectionnØs fugos (cuir of lame) et des bottes do avec des rnatiŁres rØslstantes ot igni protection. en TkH~ 2040 40 60 60 80 tJ Utilisoz des ost ØlevC. LE BRUIT pour Ia sante. No coupez pas dans un ondroit prŁs dopOrations de dØcapago, do not toyage ou do vaponsation. La chalour et los rayons darc peuvent rØagir avec los vapeurs of former des gaz hautement toxiques et ir,ilants. Ne coupez pas des mØtaux enrobØs tels quo des mØtaux galvanises, contenant du p10mb ou do lacier plaque au cadmium, a moms que lenro bage no soit tØ do Ia surface du metal a coupor, quo londroil o vous travaillez ne soit bien ventilØ, OU, Si nŁcessairo, quo vous no portiez tin res pirateurantivapeurs. Los enrobages ou tous mØtaux qul contlennent ces ØlØments peuvent crØer dos vapours toxiques sils sont coupes. Ne coupez pas do contonants qui renforment ou ont renfermØs dos matiŁ res toxiquos ou rØactives vous dovez en premier lieu los vider et les nettoyerconvenablement. c1~ LE PLASMA DARC blessures. _______________ I J ~ ~ Ss 4 no. 5 no. 6 no. 8 matiquoment. Mettoz lalimontation Utilisez uniquemont lo do IopØratour. ~ applications do coupage produisent un bruit Si le niveau ce qui pout ondommager louIe depasso los limites permises par lOSHA (ropor tezvous aux Principales normes do sØcuritØ). ~ stir ou un serretOte antibruit silo niveau los lioux du danger reliØ au sonore bruit. FUMEES ET LES GAZ peuvent dangereux. Le coupageproduit des vapeurs of des gaz. Respirer vapeurs et ces gaz peut Otre dangereux pour a sante. ces OM-182 702 Page 6 ou los chalumeaux recommandØs dans to manuel LES BOUTEILLES peuvent SI elles sont endommagØes. _____________ Protegez sonore hors tension ot dØbranchoz le cordon dalimontatlon ou do changer une piŁce du chalumoau. avant do dØmonter 10 chalumoau chocs peut endommager Itouie. La chaleur degageo par le plasma darc pout entrainor do sOrleusos brUluros. La force do arc ost un facteur qui sajoute au danger do brUlures. La chalour intense et Ia puissance do larc pouvont rapidoment passer au travors do gants of do (issus. corps. No pointoz pas le chalumeau on dIrection de votre corps nI de Ia piŁce a larc pilote satlumo aufo coupor Iorsque vous appuyoz sur la gachette ~ (minimum> no. peut entraIner des Napprochez pas le tube du chalumeau. No salsissez pas Ia pIŁce a couper prØs do a ligne do coupage. Larc pilote pout causor dos brOlures napprochoz pas le tube du chalu meau lorsque vous avoz appuye sur to gachette. Portez des vOtemonts do protection adequats qul recouvront tout votre darc constant, PrØvonez touto personno - plasma Certaines protŁgetympans I au Filtro do teinte amperes Moms do 20 rospiratour antivapours un ~ Tableau 1. Protection des yeux pour Ia coupage lntensitEi do courant tin tin ospace restreint uniquoment sil ost blen vontilØ OU SI rosplrateur antivapours. Los vapours causØes perle cou page of lepuisement do ioxygene pouvent altØror a qualitØ do laIr of entrainerdes blossurosou Ia mort. Assurezvousque lairamblanl esl sam portez au. Ayoz mediocre, utllisez Veuillez lire 10 Material Safety Data Sheets (MSDS) et los instructions du tabricant pour obtenirplus do renseignoments sur los mØtaux a couper, los enrobages et los nettoyants. vous une ost Travaillez dans electrique. ArrOter los convertisseurs, dØbranchor 10 courant electflque, et decharger es condensateurs dalimentation selon los instructions indiquees dans Ia partie entretien avant de toucher es piŁces. Portez ventilation approuvŁ. expIoser~ Los bouteillos do gaz contiennent du gaz sous haute prossion. Si uno boutoillo ost endommagee, elle pout oxploser. Puisquolosbouteillesdegazfonthabituollomont partio dun procossus do travail des mOtaux, assurezvous do los manipulor corroctement. los bouteilles do gaz comprime contre Ia chalour excessive, los Ia flamme, los Øtmncollos ot arc. mecaniques, ie laitior, lnstalloz et attachez los bouteilles dans Ia position vorticalo a Ialdo dune chaino, sur un support stationnaire ou un chassis portobouteiile afin do prevenirquollos no tombont ou no basculent. Los boutoillos no doivent pas Otre prOs do Ia zone do coupago nI do tout autre circuit Øloctriquo. Un contact eloctrique no doit jamals so produire ontre un chalumeau do plasma darc ot uno boutoille. Ne coupez jamais stir uno bouteille pressurisee uno explosIon on rØsulterait. Utillsez uniquement dos boutoillos do gaz, des dØtendours, dos boyaux 01 des raccords concus pour lappllcation dØterrnlnØo. Gardozles, alnsl quo touto autre piŁce associØo, DØtoumoz votro visage du soupapo do Ia bouteille. en bonno condition. detondourregulateur Iorsque vous ouvrez Lo couvercle du dØtendour doit toujours Œtro on place, saul lorsque utilisoz Ia bouteille ou quolle ost reliØe pour usage ultØrieur. Ia vous Lisoz et suivoz los instructions stir los bouteilles de gaz comprlmO, lequl do Ia CGA mentionnØ dans los connexe et 10 dØpllant Pi Prmncipales normos do sØcuritØ. pement ti ~ :~Yp~ngerjtjppiomentajres:jnrejatjon:.avec. IinStaiiatiOn,.! \et Ja~mauntenance S PIECES CHAUDES peuvent pro brOlures graves Ne pas toucher des parties chaudes a mains Laisser retroidir avant dintervenir sur Ne pas placer lappareil sur, au-dessus ou a te de surfaces Infliammables. nues. Ia torche. Ne pas Installer flammables MOBILES :pi~ent;~ ~DES~9RGANES Ne prvoqter:.desblessure proximi lapparell a proximite de produits In passurchargerlinstallation electriquesassurerque lalimentatlon est et protØgØ avant de mettre lappareil en correctement dimensionnO service. Sabstenirde ~C toucher des organes mobiles tels que ELECTROSTAflQUES des ventilateurs. LES CHARGES Maintenirfermes et verrouillOs les portes, panneaux, recouvrements et dispositits de protection. peuvent endommager les circuits im primes DES PARTICULES VOL.ANTES biesser les yeux Etablirla S ZN peuvent connexion avec manipulerdes Ia barrette de terre avant de piŁces pochettes et des boites antistatiques pourstocker, dOpiacerou expedlerdescartes PC. ___________ cartes ou des Utiliser des PorterdesiunettesdesecuriteavecprotectionslatO____________J rales ou frontaies ~ ______________ . ..~AUt:~ .. a~ I ~., ~. LES CHAMPS .~.. . MAGNETIQUES peuv- - Th7j les stimutateurs cardia- a fl ~ LE:: ...:AAtoNNEM QUENCE (H F) risque desinterfØrences~~ Le Rayonnement haute trequence (HF.) peut provo quer des interferences avec les Oqulpements de ra dionavigation et de communication, les services de securitO et ies ordunateurs. S Porteursde stimuiateurcardiaque, restez a distance. pries de consulter ieur medecin dapprocher ies operations de coupage plasma. FRE-i de provoquer Les porteurs sont avant Demander seulement a des personnes qualifiOes tamiiiarisees avec des de faire fonctionner iinstaliation. Øquipements Olectroniques LEMPLOI EXCESSIF peut . SURCHAUFFER LEQUIPSENt:.T~ Lutiiisateur est tenu de faire corriger rapidement par les interferences resultant de linstaliation. Si ie FCC signaie un Olectricien des interferences, arrOter immOdiatement quaiifiO iappareil. reguiiŁrement le contrOie et ientretien de iinstaiiation. Maintenlrsoigneusement fermOs ies portes et ies panneaux des Effectuer PrOvoirune periode de ref roidissement; respecter cycle opOratoire nominal. ROduire le de haute Iamperage (Łpaisseur) avant de continuer a frOquence, sources maintenir les Oclateurs a une distance correcte et utiii biindage pour reduire les interferences Oventueiles. ser une terre et et un couper ou reduire le facteur de marche. LE COUPAGE A LARC peut causer Danger D~EXPLOSION D~HVDROGEN~ LorsducoupagedaluminiumpartieIlementou tofale ment immergO dans Ieau, de IhydrogOne libre peut saccumuier sous Ia piŁce. Consultez votre ingenieurde coupage et les instruc S nateurs et des robots. Pour reduire Ia possibilitO dlnterference, maintenir les cObles aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veillera couper a une distance de 100 metres de tout Oquipement Olectro nique sensible. tions de Ia table de coupage. ft ~ I I LA CHUTE DE LAPPAREIL peut biesser. ~: Sassurer que Ia Ia terre. Utiliser lanneau de levage uniquement pour soule lappareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire. source de coupage est correctement branchOe et mise a Si IinterfOrence persiste, lutilisateur doit prendre des mesures supple mentaires comme Ocarter Ia machine, utiiiser des cAbles blindOs de des filtres, ou boucier Ia zone de travail. ver Utiliserun engin dune lever lappareil. LØnergie Olectromagnetlque peut gOner le fonclion nement dappareiis Olectroniques comme des ordi capacitO appropriee poursou En utilisant des fourches de levage pour deplacer lunitO, sassurer que Ies fourches sont suffisamment longues pour dŁpasser du cAtØ oppose de lappareil. 1~4 Pnncipales normes de sØcuntØ SafetyinweldingandCutting,norrne ANSI Z49.i,de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CAR 1910, du Superfntendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances, norme AWS F4.1 de IAmeri can Welding Society, 550 N.W. Lejeune Rd, Mia mi FL 33126 , Code, NFPA Standard 70, de Ia National Fire Pro tection Association, Batterymarch Park, Quincy, MA 02269. National Electrical J Handling of Compressed Gases in Gylmnders,CGA Pamphlet P-I, de Ia Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. Safe Rbgles de sdcurite en soudage, coupage etprocØdes connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente de normes, 178 lRexdale Boulevard, Rexdale (Ontario) Canada M9W 1 R3. me Safe Practices ForOccupation And Educational Eye And Face Protec tion, norme ANSI Z87.1, de IAmerican National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA SiB, de Ia National Association, Batterymarch Park, Quincy, MA 02269. Fire Protection OM-182 702 Page 7 1-5 Information sur les champs ØlectromagnØtiques DonnØes des sur le soudage electrique et sur les effets, pour lorganisme, champs magnØtiques basse frØquence passant dans les cables de electromagnetiques. Ily a eu et ii y a encore un certain souci a propos de tels champs. Cependant, aprØs avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pØriode de recherche de 17 ans, un comitØ special ruban bleu du Na Le courant de soudage puissance ciØe des Cu causera de coupage des champs tional Research Council a conclu: Laccumulation de preuves, suivant le jugement du comitØ, na pas dØmontrØ que lexposition aux champs magnetiques et champs electriques a haute frequence reprØsente un risque a Ia santO humaine. Toutefois, des Otudes sont toujours en cours et les preuves continuent a Œtre examinOes. En attendant que les conclusions finales de Ia recherche soient Otablies, 1 vous serait souhaitable de rOduiro votre exposition aux champs OlectromagnOti ques pendant 10 soudage ou le coupage. Afin de rOduire los de travail, champs electromagnetiques dans lenvironnement respecter les consignes suivantes OM-182 702 Page 8 1 Garder les cables ensembles en les torsadant attachant avec du ruban adhØsif. 2 Mettre tous les cables du ctO 3 Ne pas courber pas et ne oppose de ou en los lopOrateur. pas entourer pas les cables autour de vous. 4 5 Garder le de vous. Relier Ia poste do pince de soudage masse le et les cables le plus loin possible plus prOs possible do Ia zone de soudure. Consignes relatives aux stimulateurs cardlaques Los consignes mentionnOes prOcOdemmentfontpartie de cellos desti nOes aux personnes ayant recours a un stimulateur cardiaque. Veuillez consulter votre mOdecin pour obtenir plus do details. SECTION 2- INSTALLATION Specifications 2-1. Amperes Input at Rated Output, 50 Hz, Single-Phase Plasma Gas Flow! Rated Cutting Output 25 A *While KVA 17 (0.2*) Duty Cycle 4.0 (0.05*) Air Or Nitrogen Only (0.04*) 3.1 (129 1./mm) At 60 PSI (414 kPa) 265 Volts DC idling And Definitions Symbols ,P~\ Plasma Arc Amperes (~) Adjust Air/Gas + Cutting (PAC) Volts Air Pressure Pressure No Increase Do Not Do Temperature This Protective Earth Loose Shield (Ground) On 2-3. Max OCV Pressure Plasma Gas KW 4.5 CFM @ 89 Volts DC At 35% 2-2. 230 V Cup i_i~~~ Input Off Loose Shield Voltage Input Cup Cutting Speed The Recommended approximately production cutting speed 10 imp at vs. material thickness is 5/16 in mild steel thickness at max setting. cutting speed recommended curves show the maximum cutting speed capabilities of the power and torch for mild steel of various thickness. source 70 Cut at speeds below the lines shown to avoid poor cuts and torch - wear. \ o ~MAX0UTPtITSFTThG ~ 40 U ~30 U) I 20 - ~ - U 20 A~vF0UTPIJT SETTNG ~ .. o 0.05 0.1 0.15 0.2 0.25 MATERIAL THICKNESS 0.3 IN. 0.35 0.4 ST-179 507 OM-182 702 Page 9 2-4. Duty Cycle And Overheating Duty Cycle is percentage of minutes that unit load without If 35% Duty Cycle At 25 Amperes unit can 10 cut at rated overheating. overheats, thermostat(s) opens, output stops, Temperature trouble light goes On, and cooling fan runs. Wait fifteen minutes for unit to cool or Temperature light to go Off. Reduce amperage or duty cycle before cutting or gouging. A Exceeding duty cycle can damage unit and void warranty. 3-1/2 Minutes Cutting 6-1/2 Minutes Resting Overheating AorV sdutyl OM-182 702 Page 10 5/95 Selecting 2-5. Dimensions And 42 lb A Location Weight (19.1 kg) 17 in (432 mm) 18 in (457 mm) Movement 1 A 1 Do not move or operate unit where it couid tip. Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart unit. 3 or Rating similar device to Label (On Lower move Right Rear Of Unit) Use label to determine input power needs. 4 230 VAC Locate unit power supply. Receptacle near correct input A Special Instailation may be required where gasoiine or voiatiie liquids are present Location And Airfiow see NEC Articie 511 Section 20. or CEC 4 lOin (254 mm) 3 Ioc_2 3/98- ST-8O1 648/ ST-801 847 OM-182 702 Page 11 2-6. Connecting Work Clamp And Gas/Air Supply 1 Work 2 Workpiece Clamp Connect work clamp to a clean, paint-free location on workpiece, close to cutting area as as possible. ~T Use only clean, thy air with 70 psi (483 to 1034 kPa) to 150 2 pressure. 3 Air 4 Gas/Air Inlet Opening Filter/Regulator 5 Hose 6 Teflon Tape Obtain hose with 1/4 NPT righthand thread fitting. Wrap threads with teflon tape (optional) or apply pipe sealant, and install fitting in opening. Route hose to gas/air supply. Adjust gas/air pressure according to Section 3-1. From Gas/Air Supply Tools Needed: ~ 2-7. 5/8,1-1/8in Connecting Input Ref. ST-091 547-C I Ref. ST-801 648 Power 1 User-Installed 230 VAC Install proper Plug input power plug. Be A sure Input power con nection meets all applicable national, regional, and local electrical codes. 2 230 VAC To use Receptacle maximum output, an indi vidual branch circuit capable of carrying 17 amperes, 230 VAC at 35% duty cycle, and protected fuses or circuit breakers is by re quired. Connect Be sure load. plug to proper receptacle receptacle. can handle Tools Needed: ST-801 646 OM-182 702 Page 12 SECTION 3- OPERATION 3-1. Controls Setting Gas/Air Pressure 7 Requires -* -~ 70-150 PSI (483-1034 kPa) Supply A 1 Power Switch 2 Power 3 Output Control Light Use control to set cutting output. The yellow zone is for use on 20 A or greater primary circuits. 4 Ready Light Use light to tell if unit is Setting Gas/Air ready for operation. Ready light comes on when Power switch is placed in On position, indicating that all safety shutdown systems are okay. If Ready light Place control in Gas/Air Set position to safe ly adjust gas/air pressure. Only gas/air cir Trouble cuit is activated. 5 does not come on, check Pressure Filter/Regulator 6 Air 7 Pressure Adjustment Knob Output control in Gas/Air position and turn on gas/air supply. Lift knob and turn to adjust pressure. Push knob down to lock in setting. Place Lights. Place Trouble Lights (See Section 4-2) Output control in desired cutting output. Ref. ST-801 848 / Ref. 5T.181 786 OM-182 702 Page 13 SECTION 4- MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance OM-182 702 Page 14 4-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System If certain problems occur, the Ready light goes off, a trouble light comes on, Light gas/air pressure PSI (276 kPa). Turn ~eo output stops. if Lights 40 and Pressure 1 Off, power proper and is below check for gas/air pressure (see Sec tion 3-1). 2 Cup Light Lights if shield cup is loose. Turn power Off, and check shield cup connection (see torch Owners Manual). Power must be reset whenever the activated. cup shutdown is Check shield cup shutdown sys tem once a week. Checking Torch Shield Cup Shutdown System 3 Temperature Light Lights if power source (see Section 2-4). Power must be reset whenever the cup shutdown system is activated. turn Off power when changing or checking consumables. Always 4 Torch Shield overheats Cup Turn Power On and loosen shield cup. If shutdown system works properly, Ready light goes off Cup light comes on. If not, and turn power Off and check for proper gas/air pressure (see Section 3-1), blocked or leaking hose, or loose shield cup (see torch Owners Manual). If system works properly, cup and reset power. retighten Ref. ST-181 264-Al Ref. ST.801 300-A OM-182 702 Page 15 4-3. Torch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: Off, and disconnect in put power plug from receptacle. Remove top and screws holding front panel in place. Without dis Turn power connecting any plugs, panel to allow access. move front Torch Connections 1 Strain Relief Clamp 2 Torch Cable Insert cable strain relief through clamp. 3 Gas Connector 4 Gas Valve Install onto connector gas gas valve. 5 Plug PLG18 6 Safety 7 Receptacle 11 Control Board PC2 RC18 Connect PLG18 to RC1S. Route leads along existing lead bundle. 8 Female Friction Terminals 9 Male Friction Terminal 10 Power Control Board PCi 11 Receptacle RC4 Connect female terminals to leads 23 and 24 from RC4 either lead). Connect (connect to male termi nal to lead 25 from RC4. Route leads as shown. 1 Work Cable Connections 12 Strain Relief Clamp Insert work clamp strain relief clamp. 13 lead through Receptacle RC6 Connect work clamp lead to lead 20 from RC6 (leads not shown). Route leads bundle. along existing lead Tools Needed: ~r 5/8 in ST-801 649 / Ref. 5T-801 300-B OM-182 702 Page 16 Troubleshooting 4-4. Trouble No pilot arc; difficulty in Remedy establishing an Clean replace or worn consumables as necessary (see torch Owners Manual). arc. Check for Have damaged torch or torch cable (see torch Owners Manual). Factory Authorized Service Agent check control relay CR6, power control board PCi safety con PC2, gas valve GS1, rectifier SRi, and check gas/air system for leaks. trol board No cutting output; Power light off; light off; fan Place Power switch in On position. Trouble lights off; Ready motor FM does not run. Place line disconnect device in On Check line Have Factory safety cutting output; Power light Ready light on; Trouble lights off; motor FM running. No on; Be and fuse(s) replace position (see if needed or Section 2-7). reset circuit breakers Authorized Service Agent check power switch Si, PC2, and transformer Ti. (see Section 2-7). input resistor R2, control relay CR6, control board sure work is connected. clamp fan Clean Have or replace worn consumables as necessary (see torch Owners Factory Authorized Service Agent check contactor W, control Manual). relay CR3, and safety control board PC2. cutting output; Power light Ready light off; Trouble lights off; motor FM running. No on; Reset Power switch. fan Factory Authorized Service Agent check contactor CR7, control relay CR6, safety control board PC2, input resistor R2, power control board PCi. Check for proper torch lead connections. Check op eration of gas valve GS1, and check gas/air system for leaks. Have Have Factory Authorized Service Agent check power control No gas/air flow; Power light on; Ready light on; Trouble lights off; fan motor FM running. Have Factory Pressure Trouble Check for correct No control of output. light On; Ready light Authorized Service board PCi. Check operation gas/air Agent board PCi, and safety control board PC2. check for proper torch connections, and check power control GSi, and check gas/air system for leaks. of gas valve pressure adjustment (see Section 3-i). off. Check for sufficient Check for Cup Trouble light On; Ready light off. dirty air gas/air supply filter/regulator Check torch shield cup Have pressure and (see Section 2-6). clean, if needed (see manufacturers instructions). (see Section 4-2). Factory Authorized Service Agent check for proper torch connections, and check safety control board PC2. Temperature light off. Trouble light On; Ready lights (overheating). Allow fan to run; the thermostat closes when the unit has cooled (see Section 4-2). Fan motor FM does not run; Power and Ready light both On. Trouble Thermostat TP1 open not working, light Authorized Service Have Factory Have Factory Authorized Service Agent Have Factory Authorized Service Agent check safety control board PC2. Agent check safety control board PC2 and transformer Ti. check fan motor connections. OM-i82 702 Page 17 SECTION 5- ELECTRICAL DIAGRAM ~1p1~ ~123 RC12-4>) > .15V R~11-4 ~ ~ ~>~!? QJh.4AI~D i~cii-~ RC11-3 ~ I~L 6 ~ RC11-6 ) )~( ~cii <cZRC1-8 iJ~ F! 15V ST~R~ Rd-b> Rd-h> ~ ~-<<RC1-6 _________ Rc1115: Rd11-2 Rdll-1: RC11-16 ~Ii Rc~-4: RC1O-1~. SC-182 866 Figure OM-182 702 Page 18 5-1. Circuit Diagram For Power Source Notes _____ CM1827~P.gs19 SECTION 6- PARTS LIST Haniware is common and not available unless listed. (U (0 0, CJ 0) cJ 0 C., C.) 0, C., ST.8O~ 644-A c~) Figure OM-182 702 Page 20 6-1. Main Assembly Item No. Dia. Part No. Mkgs. Description Figure 183161 ... 6-1. Main Assembly COVER,top 1 175 145... HANDLE, lifting 175 366... REGULATOR ASSEMBLY, 175 999 174 668 176 518 176 517 602 963 118 134 . 174 562 11 176 123 181 693 1 1 1 1 1 1 1 1 PLG4... 168 071 PLG6... 176 121 1 ... 134 201 ... ... FM 088 566... 183 162... 16 175 365... 17 177 346 18 176122 S3 174 670 20 602 965 21 073 655 22.... 1 out 1 15 19 1 rnax PCi.... 184 973... PLG1... 158720... CONNECTOR&SOCKETS 070 026... 14 1 1 GAUGE, pressure air 0-160 PSI 1/8NPT BRACKET, mtg air filter/regulator FITTING, plstc Qdisc elbow 1/4NPT x 1/4 OD tubing GASKET, NPRN control knob cover CIRCUIT CARD ASSEMBLY, power control 174 783 . 1 (consisting of) HOSE, SAE .187 ID x .410 OD x 6.500 FITTING, brs barbed fern 3/l6tbg x 1/8NPT REGULATOR/FILTER, 250 PSIG in 100 PSIG FITTING, pipe brs elbow st 1/4NPT FiTTING, pipe brs nipple L 1/4NPTx 2.500 FITTING, pipe brs coupling 1/4NPT FITTING, pipe brs plug shhd 1/4NPT 177 347 Quantity GS1 .... 175 827 CONNECTOR, rect 1 row plug STAND-OFF SUPPORT, PC card STAND-OFF, 6-32 x .437 Ig MOTOR FAN, 115V 50/60 Hz 31 00RPM CASE, base/back/sides AIR VALVE ASSEMBLY, (consisting of) TUBING, pneumatic .250 OD x .170 ID x 13.500 FITTING, plstcQdiscstraight 1/8NPTx1/4OD SWITCH, pressure air 40P51 fixed FITTING, pipe brs tee 1/8NPT FITTING, pipe brs nipple hex 1/8NPT VALVE, 24VAC 3 way 1/8NPT 5/32 on 100PSI 1 3 4 1 1 1 1 1 1 1 1 1 BRACKET valve 157 057 23 1 CONNECTOR & SOCKETS 1 FITTING, pipe brs adaptor 1/8NPT/.375-24 LH 176499... ICE-25C PLASMA ARC CUTTING TORCH, 1 5ft (see OM-1 593) 25 .176 822... ICE-25C PLASMA ARC CUTTING TORCH, 25ft (see OM-1 593) 25 CABLE WORK l5ft, (consisting of) 26.... Work.... 176 071 24 175 998 ... CLAMP univ 50A 601 222 600 848 176 089 020 577... 27 019 663... ...29.,.. CR2.... 175828... 175 144... Ti 178 062... Ri 176 505... 059726... 175 058... 1 1 l5ft 1 1 6 1 1 1 1 2 1 VR1.... 178393... VARISTOR 38 1 1 WIRE, strd l2ga 600V (order by if) TUBING, plstc PVC blk .250 ID x .375 OD x 9.000 BUSHING, strain relief .120/.150 ID x .500mtg MOUNT~ nprn CONTACTOR, def prp 25A 1 P 24VAC BRACKE1~ transformer TRANSFORMER, main power 115/230 50/60Hz RESISTOR, WW fxd 338W 1.5 ohm INSULATOR, end BRACKET, resistor SRi.... 179 682... RECTIFIER, 141 690... GROMMET 1 1 integ 40A 800V 1 2 BUSHING, strain relief .455/.629 ID x 1.ll5mtg CABLE, power lOft l4ga 3/C FL1.... 181 262... FILTER, common mode 25A FRONT PANEL, (consisting of) 181 717 PANEL, front 174 991 KNOB, pointer NAMEPLATE, (order by model and serial number) 159 036 LENS, LED clear 159 035 CLlP~ lens retainer LED 124 511 Si SWITCH, toggle DPST 40A 600VAC 181 708 GASKET, switch 139 041 ... 2 182 521 ... 1 1 1 1 1 1 5 5 1 1 OM-182 702 Page 21 Item No. Dia. Part No. Mkgs. Description Figure 38 CR7 .... R2 149823 182 486 C1,2 .... 178 981 39 +When ordering Optional a To maintain the Replacement OM-182 702 Page ... FRONT PANEL, (consisting of) (Continued) RELAY, end 12VDCSPST THERMISTOR, PTC 8A 250V CAPACITOR 1 1 1 179 190 LABEL, warning shock 1 CONNECTOR & SOCKETS 1 CIRCUIT CARD ASSEMBLY, safety control 169 240 CONNECTOR & SOCKETS 181 716... DOOR, consumable storage box 1 1 186 475 component originally displaying a precautionary label, 1 1 the label should also be ordered. factory original performance of your equipment, use only Manufacturers Suggested required when ordering parts from your local distributor. Parts. Model and serial number 22 1 183 805 PLG2O,22.. 167 640 .... Assembly (Continued) MAGNET, adhesive mounted LABEL, warning precautionary 178 956 PC2 PLG11 6-1. Main Quantity Notes ___________ __ __ Notes __ ________ Notes ___ Notes ___ ____ __ Effective January 1, 1901 (Equipment with a serial number preface of 19 warranty supersedes all previous Miller warranties and is exclusive guarantees or warranties expressed or implied. This limited * 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 OF WARRANTIES INCLUDING THE IMPLIED, MERCHANTABILITY AND FITNESS. failure, at which time Miller will provide instructions on the Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the an International distributor. Original * Inverters * Remote Controls * Accessory * Replacement * Spoolmate Kits (No labor) Parts 185 True Bluefi Limited Warranty shall not apply to: 2. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 3. that has been modified by any party other 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 Equipment than is sent to specifications for the operation equipment. of the outside MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE main power rectifiers (input Cutting Model Plasma APT, ZIPCUT & PLAZCUT which has been used for and output rectifiers other Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. 3 Years Labor 5 Years Parts * equipment no 1. to be followed. warranty claim procedures with Torches Millers 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 Within the 1. newer) or only) AND MAINTENANCE OF WELDING EQUIPMENT. 2. 3. Parts and Labor 3 Years * Transformer/Rectifier Power Sources * Plasma Arc * Semi-Automatic and Automatic Wire Feeders * Inverter Power * Intellitig * Robots * Engine Driven Welding Generators (NOTE: Engines are warranted separately by engine manufacturer.) Supplies the Motor Driven Guns (w/exception of Spoolmate 185) Process Controllers * Positioners and Controllers * Automatic Motion Devices * Orbital Weld Heads * IHPS Power Sources * Water Coolant * HF Units * Grids * Spot * Load Banks * SDX Transformers * Miller * * ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS ARISE BY MIGHT IMPLICATION, PROVISION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Systems Welders Cutting Torches PLAZCUT Models) Plasma * Deutz * Field Engines (outside (except APT, ZIPCUT & installed in, North or for a greater.) Some states in the U.S.A. do not allow limitations of how long 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. an America) Options (NOTE: Field options are covered under True Bluefi forthe remaining warranty period of the product they whichever is TO THE EXTENT PERMlT~ED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. Cyclomatic Equipment Running Gearfrrailers are In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers 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 customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or FOB. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. Parts and Labor 1 Year * Cutting Power Sources minimum of one year In Canada, legislation in additional warranties 6 Months 5. 90 * Days Batteries Parts and Labor MIG Guns/TIG Torches for certain other than as stated may not be waived, the provinces provides remedies to the extent that they limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to herein, and 4. some or province. miller warr 5/97 Owners Record Please cornilete and retain witb your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment detivered to was original Customer.) Distributor Address City State Zip Resources Available Always provide Model Name and Seriallstyle Number. Contact your Distributor for: To locate distributor nearest you call 1-800-4-A-Miller. Weiding Suppiies Options and Consumabies and Accessories Personal Safety Equipment Service and Miiier Electric Repair Mfg. An Illinois Tool Works Replacement Parts 1635 West Appleton, Training (Schools, Videos, Books) Owners USA & Canada FAX: 414-735-4134 (Servicing Information International FAX: 414-735-4125 European Headquarters Kingdom (0) 1625-525556 Phone: 44 Diagrams FAX: 44 Welding Contact the Delivering Carrier for: Fiie a Headquarters-USA Phone: 414-734-9821 United Circuit Spencer Street WI 54914 USA International Manuals Technical Manuais and Parts) Co. Company (0)1625-537553 Process Handbooks claim for loss or damage during ship ment. For assistance in filing or settling claims, contact your disiributor and/or manufacturers equipment Transportation Department. , Miller PRINTED IN LISA ' TheThwerofBbi~ 1997 Miller Electric Mig. Co.
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