OM-194 473J April 2003 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter R Spectrum Thunder And Ice-12C Torch And Non-CE Models Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, 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.) OM-194 473 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_9/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
EXPLODING PARTS can injure. D On inverter power sources, failed parts can explode or cause other parts to explode when power is applied. Always wear a face shield and long sleeves when servicing inverters. D D D D FLYING SPARKS can cause injury. D Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. D D D Wear approved face shield or safety goggles with side shields. Wear proper body protection to protect skin.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. FLYING METAL can injure eyes. D Wear safety glasses with side shields or face shield. MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away.
1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, from American Welding Society, 550 N.W.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION pom_nd_fre_5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
D D D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée. Le câble de masse doit être pincé correctement sur la pièce à couper, métal contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table de travail le plus près possible de la ligne de coupage. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance DES PIECES CHAUDES peuvent provoquer des brûlures graves. D D D D Ne pas toucher des parties chaudes à mains nues. Laisser refroidir avant d’intervenir sur la torche. DES ORGANES MOBILES peuvent provoquer des blessures. D Risque D’INCENDIE OU D’EXPLOSION. D D D D Porter des lunettes de sécurité avec protections latérales ou frontales. Porteurs de stimulateur cardiaque, restez à distance.
1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence 1 Le courant de soudage ou de coupage passant dans les câbles de puissance crée des causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs.
SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 1.2 1 1.1 1.2 1.3 1.3 2 2.1 2 2.1 2.2 2.3 2.2 2.3 3 3 3.1 3.2 3.1 3.3 3.2 3.3 4 4.2 4.1 4.3 4 4.1 4.2 5 4.3 5.1 + 6 + 5 + 5.1 7 + 6 7 S-179 219 Cutting sparks can cause explosion or fire. Keep flammables away from cutting. Do not cut near flammables. Cutting sparks can cause fires.
2-2. Manufacturer’s Rating Label For CE Products S and CE markings only apply when the torch is used with shielded parts: retaining cup (197 567) and drag shield (196 929). 2-3.
SECTION 3 – INSTALLATION 3-1. Specifications For Non-CE Power Sources Primary Volts Primary Amperes Primary Service (Recommended) Secondary Volts (DC) Secondary Amperes KW 120 20.32 (0.25*) 20A 110 12 2.01 KVA Power Factor Max** OCV (DC) 2.44 0.82 353 *While idling **10% High line condition 3-2. Specifications For CE Power Sources Primary Primary Volts Amperes 230 Primary Service (Recommended) Secondary Volts (DC) Secondary Amperes KW 10A 110 12 1.89 10 (0.
3-5. Torch Dimensions And Weight 8-3/8 in (213 mm) 1 in (25 mm) 1-3/8 in (35 mm) 3.0 lb (1.4 kg) Ref. 801 397-A 3-6. Selecting A Location 6-3/4 in (171 mm) Dimensions And Weight 17 in (432 mm) 42 lb (19.1 kg) – Non-CE Models 52.3 lb (23.7 kg) – CE Models 18 in (457 mm) 1 1 Movement Lifting Handle Use handle to lift unit. 2 2 Hand Cart Use cart or similar device to move unit. 3 Non-CE Or CE Plate Label Use label to determine input power needs.
3-7. Connecting Work Clamp 1 2 1 Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 802 463-A 3-8. Connecting Input Power Check input voltage available at site. 1 1 2 3 4 Grounded 120 VAC Receptacle (Non-CE Models) A 120 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required (see Section 3-1). 2 Plug From Unit Select extension cord of 12 AWG for up to 53 ft (16 m).
SECTION 4 – OPERATION 4-1. Controls 1 2 OFF POWER CUP ON TEMP INPUT VOLTAGE 3 1 2 Power Switch Power Light 3 Trouble Light Trouble light comes on for the following conditions: Use light to tell if unit is energized and ready to operate. Light goes off if input power is not with specified range (see trouble light information).
4-3.
4-4. Sequence Of Operation . Moisture from the compressor will form in the air line and at EXAMPLE Of Cutting Operation the torch. It will be normal to sometimes see moisture come out the end of the torch. The pilot arc starts immediately when trigger is pressed. For shielded cutting, place drag shield on edge of metal. For non-shielded cutting (non-CE only), use 1/8 in (3.2 mm) standoff distance (dragging tip will reduce tip life). Adjust torch speed so sparks go thru metal and out bottom of cut.
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
5-2. Overload Protection: Trouble Light And Checking Shield Cup Shutdown System If certain problems occur, the trouble light comes on, and output stops. 1 Trouble Light a CUP 1 TEMP INPUT VOLTAGE Turn power Off, and check shield cup connection (see Item 2 below). Power must be reset whenever the cup shutdown is activated. Check shield cup shutdown system once a week. Checking Torch Shield Cup Shutdown System Power source Power switch must be reset whenever cup shutdown system is activated.
5-3. Torch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: 5 4 7 8 6 Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. Torch Connections Remove existing torch cable from unit. 1 5 1 Strain Relief 2 Torch Cable Insert cable through strain relief. Slide strain relief nut onto torch cable, but do not tighten. 6 3 Air Line Connector Install air line connector onto compressor fitting.
5-4. Checking/Replacing Retaining Cup, Tip, And Electrode Overtightening will strip threads. Do not overtighten retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.
5-5. Troubleshooting Power Source Is input power connected to correct line voltage? No Connect unit to proper input voltage. (see Section 3-8). Yes Is Power switch in the On position? No Place Power switch in the On position. (see Section 4-1). Does pilot arc ignite? No Press torch trigger and check if pilot arc ignites. Check torch consumables. *Check torch connections, relay CR1, compressor, and torch. Yes No * Check Power switch S1, relay CR2, and thermistor R1.
5-6. Troubleshooting Torch Does arc go on and off while cutting? Yes Torch travel speed too slow; increase travel speed (see Section 4-2). Clean or replace torch consumables as necessary (see Section 5-4). Be sure work clamp is securely attached to workpiece. Go to Section 5-5. Be sure work clamp is securely attached to workpiece. Make sure drag shield contacts metal while cutting. Clean or replace torch consumables as necessary (see Section 5-4). Go to Section 5-5.
SECTION 6 – ELECTRICAL DIAGRAM 202 707 Figure 5-1.
202 701 Figure 5-2.
Notes OM-194 473 Page 25
SECTION 7 – PARTS LIST . Hardware is common and not available unless listed. 2 1 31 30 29 28 3 4 5 32 4 27 33 5 6 26 7 34 25 8 23 22 9 24 10 21 11 12 20 13 18 14 16 15 17 19 Figure 6-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Main Assembly . . . 1 . . . . . . . . . . . . +206 302 . . . 2 . . . . . . . . . . . . . 208 015 . . . 3 . . . . . FM . . . . 195 610 . . . 3 . . . . . FM . . . . 197 016 . . . 4 . . . . CR2 . . . 149 823 . . . 4 . . . . CR2 . . . 199 999 . . . 5 . . . . . R1 . . . . 182 486 . . . 6 . . . . CR1 . . . 106 462 . . . 7 . . . . . 1T . . . . 202 056 . . . 7 . . . . . 2T . . . . 202 056 . . . 8 . . . C1,C2 . . 197 739 . . . 9 . . . . . . . . . . .
1 Item Part No. No. 1 183 427 2 3 4 5 6 171 248 196 931 196 930 196 932 185 833 190 220 169 231 196 923 2 3 6 Description Handle Assy, left and right w/screws (1) Pushbutton Switch (1) Leads, 20ft (1) Label, ICE-12C (1) Main Body (1) Switch Assy w/Spring (1) Spring, trigger assy (1) Grease, silicone (1) Torch, replacement (1) 5 1 4 Figure 6-2. Torch, ICE-12C S and CE markings only apply when the torch is used with shielded parts: retaining cup (197 567) and drag shield (196 929).
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Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
