Owner`s manual

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OWNER’S MANUAL

OM-1593 176 877T

Use above FORM number when ordering extra manuals.

2007−08

ICE-12C, ICE-25C, ICE-25CX, ICE-27C, ICE-27T

ICE-40C, ICE-50C, ICE-50CM, ICE-55C, ICE-55CM, ICE-80C, ICE-80CM,

ICE-80CX, ICE-80CXM, ICE-80T, ICE-80TM, ICE-100T, And ICE-100TM Torches

1. Specifications

Air-cooled torches for plasma arc cutting (PAC)

12 A model: 12 A at 35% duty cycle;

25 A model: 25 A at 35% duty cycle;

27 A model: 27 A at 35% duty cycle;

40 A model: 40 A at 50% duty cycle;

50 A models: 50 A at 60% duty cycle;

55 A model: 55 A at 60% duty cycle;

80 A model: 80 A at 50% duty cycle

100 A model: 100 A at 80% duty cycle

12 A model equipped with 20 ft (6.1 m) cable

25 A model equipped with 15 ft (4.6 m) cable; available with optional 25 ft (7.6 m) cable

27 A model equipped with 20 ft (6.1 m) cable;

40 A model equipped with 25 ft (7.6m) cable; available with optional 50 ft (15.2 m) cable

50 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable

55 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable

80 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable

100 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable

Use air or nitrogen plasma gas:

12 A model: 1 CFM (28.3 L/min) at 40 PSI (276 kPa);

25 A model: 4.5 CFM (129 L/min) at 60 PSI (414 kPa);

27 A model : 4.5 CFM (129 L/min) at 60 PSI (414 kPa);

40 A model: 6 CFM (170 L/min) at 75 PSI (517 kPa);

50 A model: 5.3 CFM (152 L/min) at 70 PSI (482 kPa);

55 A model: 6 CFM (172 L/min) at 70 PSI (482 kPa);

80 A (C, CM, CX, and CXM) model: 7.2 CFM (207 L/min) at 80 PSI (551 kPa)

80 A (T and TM) model: 7.8 CFM (221 L/min) at 70 PSI (482 kPa)

100 A model: 9.2 CFM (260 L/min) at 75 PSI (517 kPa)

Safety interlock devices shut down power source

12 A, 27 A, 40 A, 50 A, 55 A, 80 A and 100 A models have safety trigger guard

Gear rack pitch for 50 A, 55 A, 80 A and 100A machine-held models: 32

Cutting capacity for mild steel:

12 A model − up to 3/16 in (5 mm) at 12 A;

25 A model − up to 3/8 in (10 mm) at 25 A;

27 A model − up to 3/8 in (10 mm) at 27 A;

40 A model − up to 1/2 in (12.7 mm) at 40 A;

50 A model − up to 7/8 in (22 mm) at 50 A;

55 A model - up to 1 in (25.4 mm) at 55 A;

80 A model − up to 1-1/4 in (32 mm) at 80 A

100 A model − up to 1-1/2 in (38 mm) at 100 A

Summary of content (38 pages)

PAGE 1
OWNER’S MANUAL OM-1593 176 877T Use above FORM number when ordering extra manuals. 2007−08 ICE-12C, ICE-25C, ICE-25CX, ICE-27C, ICE-27T ICE-40C, ICE-50C, ICE-50CM, ICE-55C, ICE-55CM, ICE-80C, ICE-80CM, ICE-80CX, ICE-80CXM, ICE-80T, ICE-80TM, ICE-100T, And ICE-100TM Torches 1.
PAGE 2
. Safety Symbol Definitions NOTICE DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Wear safety glasses with side shields. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Cutting processes cause flying pieces of metal and sparks.
PAGE 3
4. Installing 12 Ampere Torch And Work Cable, And Using Trigger Safety Lock If torch or work cable needs to be removed or replaced, proceed as follows: ! Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. Torch Connections 5 4 7 8 6 1 Strain Relief 2 Torch Cable Insert cable through strain relief. Slide strain relief nut onto torch cable, but do not tighten. 1 5 Remove existing torch cable from unit.
PAGE 4
5. Installing 25 Ampere Torch And Work Cable ! Turn Off power source, and disconnect input power plug from receptacle before installing torch and work cable. Remove top and screws holding front panel in place. Without disconnecting any plugs, move front panel to allow access. 8 Torch Connections 8 9 1 Strain Relief Clamp 2 Torch Cable Insert cable through strain relief clamp. 2 5 3 13 10 7 Gas Connector 4 Gas Valve Install gas connector onto gas valve.
PAGE 5
6. Installing 27 Ampere (ICE-27C) Torch And Work Cable, And Using Trigger Safety Lock If torch or work cable needs to be removed or replaced, proceed as follows: 5 4 8 ! 6 7 Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. Torch Connections Remove existing torch cable from unit. 1 5 Strain Relief 2 Torch Cable Insert cable through strain relief. Slide strain relief nut onto torch cable, but do not tighten.
PAGE 6
7. Installing 27 Ampere (ICE-27T) Torch And Work Cable, And Using Trigger Safety Lock ! 6 4 8 Check DC bus voltage according to Owner’s Manual, and be sure voltage is near zero before touching any parts. If torch or work cable needs to be removed or replaced, proceed as follows: 5 7 Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit (see Owner’s Manual). 2 Torch Connections Remove existing torch cable from unit. 1 Strain Relief Loosen strain relief screw.
PAGE 7
8. Installing 40 Ampere Torch And Work Cable 1 3 4 7 6 2 5 8 2 3 5 4 If torch or work cable needs to be removed or replaced, proceed as follows: ! Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. Torch Replacement 1 Strain Relief 2 Torch Cable Loosen outer strain relief pigtail so that torch cable can slide freely. 3 Plug PLG1/Receptacle RC1 Disconnect PLG1 from receptacle RC1 on Control board PC1.
PAGE 8
9. Installing 50 Ampere, 55 Ampere or 80 Ampere Torch And Using Trigger Safety Lock . The 50 ampere torch is shown in the illustrations below. ! Turn Off power source, and disconnect input power plug from receptacle before installing torch. 1 Power Source 2 Torch Connection Receptacle 3 Plug 4 Threaded Collar 5 Keyway The procedure for the 55 ampere and 80 ampere torches is identical. . The 55 ampere torch can be used on a 50 ampere model power source.
PAGE 9
10. Installing Either 80 Ampere Or 100 Ampere T/TM Torch 2 1 3 ! Turn off power source and disconnect input power. 1 2 3 4 5 Torch Connector Quick Connect Collar Nipple Receptacle Securing Pin To connect torch: Push torch connector onto receptacle and quick connect until collar secures nipple. Rotate securing pin to lock connector to unit. 4 5 To disconnect torch: Rotate securing pin to unlock connector from unit.
PAGE 10
11. Sequence Of Operation For 12 Ampere Torch . 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).
PAGE 11
12. Sequence Of Operation For 27 Ampere Torch EXAMPLE Of Cutting Operation ! The pilot arc starts immediately when trigger is pressed. Place tip on work for drag cutting. . For maximum cutting speed and tip life, Raise trigger lock and press trigger. Pilot arc starts. After cutting arc starts, slowly start moving torch across metal. use a standoff distance of 1/16 in (1.6 mm) to 1/8 in (3.2 mm). Dragging tip will reduce tip life. Adjust torch speed so sparks go thru metal and out bottom of cut.
PAGE 12
13. Sequence Of Operation For 25, 40, 50, 55, 80, And 100 Ampere Torches ! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced (see Section 17). Do not operate torch without a tip or electrode in place. NOTICE − Do not clean torch by hitting it against a hard surface. Hitting hard surfaces can damage torch parts and stop proper operation.
PAGE 13
14. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Turn Off power source and disconnect input power plug before maintaining. . 25 ampere torch is shown. Maintenance schedule for 50 and 80 ampere torches is the same.
PAGE 14
16. Checking/Replacing Retaining Cup, Tip, And Electrode For 12 And 27 Ampere Torch ! 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. NOTICE − 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. .
PAGE 15
17. Checking/Replacing Retaining Cup, Tip, And Electrode For 25, 40, 50, And 55 Ampere Torches ! 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. NOTICE − Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping.
PAGE 16
18. Checking/Replacing Retaining Cup, Tip, And Electrode For 80 Ampere (C/CM) Torch ! 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. NOTICE − Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping.
PAGE 17
19. Checking/Replacing Retaining Cup, Tip, And Electrode For 80 Ampere (CX/CXM/ T/TM, And 100 T/TM) Torch ! 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. NOTICE − Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping.
PAGE 18
20. Troubleshooting For 12 Ampere Torch Does arc go on and off while cutting? Yes Torch travel speed too slow; increase travel speed (see Power Source Owner’s Manual). Clean or replace torch consumables as necessary (see Section 16). Be sure work clamp is securely attached to workpiece. See Power Source Owner’s Manual. No Does arc go out while cutting? Yes Be sure work clamp is securely attached to workpiece. Make sure drag shield contacts metal while cutting.
PAGE 19
21. Troubleshooting For 25, 27, 40, 50, 55, 80, And 100 Ampere Torches Trouble Remedy Power source Cup trouble light On; no Tighten cup onto torch and reset Power (see Section 15). cutting output. Check torch connections on power source. See power source Owner’s Manual. Sparks come out top of cut, or cut is not Torch travel speed too fast; reduce travel speed (see Section 13). clean. Clean or replace worn consumables as necessary (see Section 17).
PAGE 20
22. Parts Lists Item Part No. No. 1 2 1 183 427 2 3 4 5 6 171 248 196 931 196 930 196 932 185 833 190 220 169 231 196 923 3 6 5 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 20ft (1) 1 4 See Figure 22-2 for additional consumable parts. Figure 22-1.
PAGE 21
1 Item Part No. No. 1 2 2 3 4 2 183 428 177 893 177 894 178 550 171 248 169 231 195 007 Description Handle Assy, complete (1) Leads, 15ft (1) Leads, 25ft (1) Main Body (1) Push Button Switch (1) Grease, silicone (1) Torch, replacement 20ft (1) 4 3 1 See Figure 22-4 for additional consumable parts. 2 Ref. 801 300-B Figure 22-3. Torch, ICE-25C O-ring 169232 Electrode 176655 Retaining Cup 202808 Swirl Ring 202809 Tip 176656 Ref. 178 744 Figure 22-4.
PAGE 22
1 Item Part No. No. 2 3 1 2 3 4 5 183 427 171 248 205 881 203 119 185 833 190 220 169 231 195 007 5 Description Handle Assy, complete (1) Push Button Switch (1) Leads, 20ft (1) Main Body (1) Switch Assembly w/spring (1) Spring, trigger assembly Grease, silicone (1) Torch, replacement 20ft (1) 1 4 See Figure 22-6 for additional consumable parts. 3 Ref. 801 300-B Figure 22-5. Torch, ICE-25CX ICE-25CX Consumables Ref. 202 108-A Figure 22-6.
PAGE 23
Item Part No. No. 1 2 1 2 3 4 5 3 183 427 171 248 203 120 203 119 185 833 190 220 169 231 195 014 5 Description Handle Assy, complete (1) Push Button Switch (1) Leads, 20ft (1) Main Body (1) Switch Assembly w/spring (1) Spring, trigger assembly Grease, silicone (1) Torch, replacement 20ft (1) 1 4 See Figure 22-8 for additional consumable parts. Figure 22-7. Torch, ICE-27C 202 108-A Figure 22-8.
PAGE 24
1 2 3 Item No. Part No. 1 2 3 4 5 183 427 171 248 228 405 203 119 185 833 190 220 169 231 225 615 5 Description Handle Assy, complete (1) Push Button Switch (1) Leads, 12 ft (1) Main Body (1) Switch Assembly w/spring (1) Spring, trigger assembly Grease, silicone (1) Torch, replacement 12 ft (1) 1 4 See 22-10 for additional consumable parts. Figure 22-9.
PAGE 25
Item Part No. No. 1 Description 6 1 2 3 3 4 5 4 195 110 195 111 183 427 192 059 209 298 209 299 185 833 5 6 2 ICE-40C 25ft Torch ICE-40C 50ft Torch Handle Assy, complete (1) Main Body (1) Leads, 25ft (1) Leads, 50ft (1) Switch Assembly w/spring (1) Spring, trigger assembly Push Button Switch (1) Grease, silicone (1) 190 220 171 248 169 231 1 See Figure 22-12 for additional consumable parts. 3 Ref. 803 386 Figure 22-11. Torch, ICE-40C For extended tip use, set Amperage control to 35.
PAGE 26
Item Part No. No. 1 2 3 3 4 5 1 2 3 183 427 171 248 179 829 179 830 188 794 185 833 190 220 169 231 176 824 176 826 Description Handle Assy, complete (1) Push Button Switch (1) Leads, 25ft (1) Leads, 50ft (1) Main Body (1) Switch Assembly w/spring (1) Spring, trigger assembly Grease, silicone (1) Torch, replacement 25ft (1) Torch, replacement 50ft (1) 5 1 4 See Figure 22-14 for additional consumable parts. Figure 22-13. Torch, ICE-50C Ref. S-180 338-C Figure 22-14.
PAGE 27
Item Part No. No. 1 2 3 4 5 6 7 8 192 050 169 232 180 343 180 610 180 342 180 605 180 611 192 058 169 231 176 828 Description Cup, shield (1) O-Ring, 55A (1) Main Body (1) Position Sleeve (1) Leads, 50ft (1) Remote Pendent Control (1) Torch Sleeve (1) Shield, machine (1) Grease, silicone (1) Torch, replacement 50ft (1) 5 4 3 2 1 7 6 See Figure 22-14 for additional consumable parts. 8 Figure 22-15.
PAGE 28
Item Part No. No. 1 2 3 1 2 3 3 4 183 427 171 248 192 062 192 063 192 059 202 932 5 185 833 190 220 169 231 193 347 193 348 5 Description Handle Assy, complete (1) Push Button Switch (1) Leads, 25ft (1) Leads, 50ft (1) Main Body (1) Plunger Kit (for out-of-warranty torches) Switch Assembly w/spring (1) Spring, trigger assembly Grease, silicone (1) Torch, replacement 25ft (1) Torch, replacement 50ft (1) 1 4 See Figure 22-17 for additional consumable parts. Figure 22-16. Torch, ICE-55C Ref.
PAGE 29
Item Part No. No. 1 2 3 4 5 6 7 8 9 1 Description 192 050 169 232 192 060 180 610 192 061 180 605 198 643 192 058 198 644 169 231 193 349 Cup, shield (1) O-Ring, 55A (1) Main Body (1) Position Sleeve (1) Leads, 50ft (1) Remote Pendent Control (1) Torch Sleeve (1) Shield, machine (1) Ring, retaining (1) Grease, silicone (1) Torch, replacement 50ft (1) 3 2 4 9 5 7 8 See Figure 22-17 for additional consumable parts. 6 Figure 22-18.
PAGE 30
Item Part No. No. 1 2 3 187 300 190 502 190 503 4 196 682 190 504 187 301 187 298 177 902 5 6 7 Item Part No. No. Description 8 8 9 Handle (1) Boot (1) #6 x 5/8 Philips Screw, pan head (5) Trigger and Switch Replacement Kit (1) spring (1) Switch, cup sensor (1) Main Body (1) O-Ring, silicon .864 x .
PAGE 31
Item Part No. No. 1 2 3 180 610 196 417 190 497 4 5 6 187 305 190 498 187 299 177 902 7 8 9 Sleeve, torch position (1) Torch Lead, 50ft (1) Plug Assy, quick disconnect (1) O-Ring, quick disconnect (1) Plug, 3-socket female (1) Main Body (1) O-Ring, silicon .864 x .070 (1) Contact, cap-on sensor (2) Tubing, 5/8 in ID (4in) (1) Heatshrink 1/2 in ID (2.5in) (1) Torch, replacement 50ft (1) 190 499 190 500 190 501 176 834 2 4 Description 3 See Figure 22-20 for additional consumable parts.
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Item Part No. No. 1 2 3 4 5 6 7 8 8 215 594 215 478 215 479 185 833 190 220 215 592 215 477 216 309 218 045 Item Part No. No.
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Item Part No. No. 1 2 3 4 5 6 7 Description 215 607 219 964 218 177 190 498 215 599 215 598 187 305 219 944 Sleeve, torch position (1) Torch Lead, 50ft (1) Plug Assy, quick disconnect (1) Plug, 3 socket female (1) Torch Sleeve (1) Main Body w/Switch (1) O-ring, quick disconnect (2) Torch, replacement 50ft (1) 1 4 7 2 3 6 5 See Figure 22-23 for additional consumable parts. Figure 22-24. Torch, ICE-80CXM Item Part No. No. 1 2 3 4 5 6 7 8 8 Item Part No. No.
PAGE 34
80A Standard Cutting Retaining Drag Shield Cup Tip 212 730 212 733 212 726 Shield 212 732 Electrode 212 724 Swirl Ring 212 734 Apply silicone grease (169 231) before installing.
PAGE 35
Item Part No. No. 1 2 3 4 5 6 7 8 8 Item Part No. No.
PAGE 36
CAUTION Drag Shield Retaining Cap Tip Electrode FAILURE TO RE− PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Swirl Ring Turn off power before checking torch parts. Check before each use and hourly during operation.
PAGE 37
Shield Sense Tab* Retaining Cap Tip Electrode CAUTION Swirl Ring FAILURE TO RE− PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. 40A 212 732 212 733 212 725 Turn off power before checking torch parts. Check before each use and hourly during operation.
PAGE 38
Item Part No. No. 1 2 2 3 4 5 6 7 215 607 223 614 223 615 215 599 223 773 195 513 215 478 225 706 225 708 220 240 220 241 227 546 . See 22-30 for additional consumable parts. Description Sleeve, torch position (1) Torch Lead, 25ft (1) Torch Lead, 50ft (1) Torch Sleeve (1) Main Body (1) Remote Pendant Control (1) Sup Sensor Switch Kit (1) Torch, replacement 25ft (1) Torch, replacement 50ft (1) Cable, remote control trigger 25ft (1) Cable, remote voltage sense 26.