OM-242 880B 2010−05 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter Spectrum 875 Auto-Line And ICE-60T/TM Torch R 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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
TABLE OF CONTENTS SECTION 6 − MECHANIZED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. ICE-60TM Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Remote Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Remote Control Cable Functions . . . . .
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom_2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
ELECTRIC SHOCK can kill. FUMES AND GASES can be hazardous. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input power. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any parts.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can burn. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MOVING PARTS can injure. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_2010−03fre Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
D Assurez−vous que le fil de terre du cordon d’alimentation est correctement relié à la borne de terre dans la boîte de coupure ou que la fiche du cordon est branchée à une prise correctement mise à la terre − vous devez toujours vérifier la mise à la terre. D Avant d’effectuer les connexions d’alimentation, vous devez relier le bon fil de terre. D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.
D Ne coupez pas dans un endroit près d’opérations de décapage, de nettoyage ou de vaporisation. La chaleur et les rayons d’arc peuvent réagir avec les vapeurs et former des gaz hautement toxiques et irritants. D Ne coupez pas des métaux enrobés tels que des métaux galvanisés, contenant du plomb ou de l’acier plaqué au cadmium, à moins que l’enrobage ne soit ôté de la surface du métal à couper, que l’endroit où vous travaillez ne soit bien ventilé, ou que vous ne portiez un respirateur anti−vapeurs.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.
2-4. Proposition californienne 65 Avertissements cancérogène ainsi que provoquant des malformations congénitales ou autres problèmes de procréation. Se laver les mains après toute manipulation. Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.
. A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1.
. A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.
. A complete Parts List is available at www.MillerWelds.com General Operating Temperature 5° to 104° F (−15° to 40° C) −− −− IP23CS −− −− IP − International Protection −− −− 2 − No ingress of foreign objects ≥12.5 mm (0.5 in.) −− −− 3 − No harmful ingress spraying water −− −− C − AC line circuits protected against ingress of tool . 2.5 mm dia x 100 mm long (0.1 in. x 4 in.
. A complete Parts List is available at www.MillerWelds.com 4-4. Torch Dimensions 8-27/32 in. (225 mm) Hand-Held Torch 1-1/2 in (38 mm) 4 in. (100 mm) 2-5/16 in. (58 mm) 1-1/16 in. (27 mm) Machine Torch 15-9/32 in. (388 mm) 2-9/64 in. (54 mm) 1-1/16 in. (27 mm) Gear rack 32 pitch 1/8 in. (3.2 mm) width 1/8 in. (3.2 mm) height 1-3/8 in. (35 mm) 8 in. (202 mm) 4-5. System Dimensions, Weight, And Movement ! Do not move or operate unit where it could tip. 18-1/2 in. (470 mm) 13-1/2 in.
. A complete Parts List is available at www.MillerWelds.com 4-6. Connecting Work Clamp and Gas/Air Supply 1 2 1 Work Clamp Workpiece . Connect work clamp to portion of workpiece that does not fall away after being cut. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 . Use only clean, dry air with 90 AIR/N2 90-120 psi 5 @ 6.75 CFM (191 L/min) minimum 3 to 120 psi (621 to 827 kPa) pressure @ 6.75 CFM (191L/min) minimum. .
. A complete Parts List is available at www.MillerWelds.com 4-7. Connecting And Disconnecting Torch 2 1 3 ! Turn off power source and disconnect input power. 1 2 3 4 5 Torch Connector Quick Connect Collar Nipple Receptacle Securing Pin To connect torch: Push torch connector onto receptacle and quick connect until collar secures nipple. Rotate securing pin clockwise to lock connector to unit. 4 5 To disconnect torch: Rotate securing pin counterclockwise to unlock connector from unit.
. A complete Parts List is available at www.MillerWelds.com 4-9. Power Cable Management Strap 1 Power Cable Management Strap Coil power cable and secure to unit using the power cable management strap. 1 Ref. 805 275-A 4-10. Selecting a Location 1 1 ! Lifting Handle Use handle to lift unit. 2 Do not move or operate unit where it could tip. Line Disconnect Device Locate unit near correct input power supply. Locate unit at least 18 in.
. A complete Parts List is available at www.MillerWelds.com 4-11. Electrical Service Guide NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input voltage. . Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be be available.
. A complete Parts List is available at www.MillerWelds.com 4-12. Extension Cord Data . When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle. Input Voltage Input Power Phase Hertz Fuse Size Or Circuit Breaker Rating 208 V 1 50/60 Time-Delay 2 Normal Operating 3 50 A 230 V 1 50/60 Time-Delay 2 Normal Operating 3 50 A 60 A 208 V 3 50/60 Time-Delay 2 Normal Operating 3 230 V 3 50/60 Conductor Size Max.
. A complete Parts List is available at www.MillerWelds.com 4-13. Connecting 1-Phase Input Power Installation must meet all National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. 1 Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.
. A complete Parts List is available at www.MillerWelds.com 4-14. Connecting 3-Phase Input Power Installation must meet all National and Local Codes − have only qualified persons make this installation. Disconnect and lockout/tagout input power before connecting input conductors from unit. 3 = GND/PE Earth Ground 4 7 Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.
. A complete Parts List is available at www.MillerWelds.com 4-15. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat, Trailblazer Or Hobart Champion 10,000 Check input voltage available at the power supply. . The Auto-LineE circuitry in this 2 3 7 3 4 4 240V 5 11 unit automatically adapts the power source to the 240 volts, single-phase, 50 or 60 Hz primary voltage from the power supply.
. A complete Parts List is available at www.MillerWelds.com 4-16. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant Three-Phase Generator Power ! Stop engine. ! Power and weld outputs are live at the same time. Disconnect or insulate unused cables. Three-Phase Power Connection ! . Have qualified person install ac- Close panel opening if no connections are made to generator. cording to circuit diagram and Generator Power Guidelines (see generator Owner’s Manual).
. A complete Parts List is available at www.MillerWelds.com 4-17. Generator Settings For Plasma Cutter Operation ! Engine Control Switch must be set at “RUN” position − not “RUN/IDLE”. ! Set generator Fine Adjustment Control to 10 for maximum auxiliary power, if applicable. . The peak kW at arc stretch of this plasma power source is 15.5 kW. Reducing output to 45 amps may be necessary to operate the unit using a 10 kW generator. Ref.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 1 40 V 50 30 ON POWER P R E S S UR E C UP 3 V 20 A TE M P 60 OFF C UT GOUGE 2 4 1 Output Control Use control to set cutting output. 2 Status Lights (See Section 7-6) 3 Power Switch . The fan will operate for approximately 10 seconds after power switch is placed in the Off position to reduce DC bus voltage.
. A complete Parts List is available at www.MillerWelds.com 5-2. Trigger Safety Lock 1 Trigger 1 Trigger Locked Trigger Unlocked 801 397-A 5-3. Plasma Cutting System Practices ! CUT GOUGE . Set Always connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. The pilot arc starts immediately when trigger is pressed. switch to either cut or gouge depending on desired process.
. A complete Parts List is available at www.MillerWelds.com 5-4. Sequence Of Cutting Operation CUT GOUGE . Unit automatically regulates pressure to 70 psi Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. (483 kPa) for cutting. . Connect work clamp to portion of workpiece that does not fall away after being cut. ! The pilot arc starts immediately when trigger is pressed. 90° For standard (shielded) cutting, place drag shield on edge of metal.
. A complete Parts List is available at www.MillerWelds.com 5-5. Sequence Of Gouging Operation CUT GOUGE . Unit automatically regulates pressure to 60 psi (413 kPa) for gouging. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. . Connect work clamp to portion of workpiece that does not fall away after being cut. ! The pilot arc starts immediately when trigger is pressed. 455 Hold torch at approximately 45° angle to workpiece.
. A complete Parts List is available at www.MillerWelds.com 5-6. Sequence Of Piercing Operation ! The pilot arc starts immediately when trigger is pressed. . Recommended maximum piercing capacity is 7/16 in (11 mm). CUT GOUGE . Unit automatically regulates pressure to 70 psi (483 kPa) for cutting. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. Hold torch at an angle to the workpiece. Raise trigger lock and press trigger.
. A complete Parts List is available at www.MillerWelds.com 5-7. Cutting Speed Mild Steel Arc Current 60 Material Thickness Recommended Cut Speeds Inches mm IPM mm/min 1/4 6.4 86 2184 3/8 9.5 41 1041 1/2 12.7 27 686 5/8 15.9 20 512 3/4 19.1 14 363 7/8 22.2 10 254 Stainless Arc Current 60 Material Thickness Recommended Cut Speeds Inches mm IPM mm/min 1/4 6.4 72 1829 3/8 9.5 34 864 1/2 12.7 23 584 5/8 15.9 17 429 3/4 19.0 12 297 7/8 22.
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MECHANIZED OPERATION 6-1. ICE-60TM Mounting Position 1 2 ICE-60TM Machine Torch Square Use a square to align torch perpendicular to the work surface. 1 2 90° 6-2. Remote Control Receptacle . Remote trigger will only oper- ate with a machine torch installed. Remote trigger is disabled when a handheld torch is installed.
. A complete Parts List is available at www.MillerWelds.com 6-4. +24 Volts DC Hot Contacts For Relay Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). 2 Control board PC1 can supply +24 volts DC from receptacle RMT2 to operate a customer-supplied relay for the Okay To Move signal. 3 1 2 3 4 Control Board PC1 Receptacle RMT1 Receptacle RMT2 Receptacle RC61 Move plug from RMT1 into receptacle RMT2 on PC1.
. A complete Parts List is available at www.MillerWelds.com 6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). 2 Control board PC1 can supply +24 volts DC from receptacle RMT2 to operate a customer-supplied isolated input module for the Okay To Move signal. 3 1 2 3 4 Control Board PC1 Receptacle RMT1 Receptacle RMT2 Receptacle RC61 Move plug from RMT1 into receptacle RMT2 on PC1.
. A complete Parts List is available at www.MillerWelds.com 6-6. Dry Contacts Using An External Power Supply For Relay Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). Control board PC1 can provide dry contacts from receptacle RMT1 to operate a customer-supplied relay using an external power supply for the Okay To Move signal.
. A complete Parts List is available at www.MillerWelds.com 6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). Control board PC1 can provide dry contacts from receptacle RMT1 to operate a customer-supplied isolated input module using an external power supply for the Okay To Move signal.
. A complete Parts List is available at www.MillerWelds.com 6-8. Remote Voltage Sense Connection ! Turn off power source and disconnect input power. Remove wrapper (see Section 7-4). Remote voltage sense is an arc voltage output signal for automatic torch height adjustment. 1 2 1 3 Snap-in Blank Secondary Interconnect Board PC4 Receptacle RC48 Remove snap-in blank from rear panel. Route plug end of cable through opening in rear panel. Route plug end of cable over to PC4.
. A complete Parts List is available at www.MillerWelds.com 6-10. Cut Charts 60 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 Tip 212 733 219 676 Electrode Swirl Ring 212 724 212 734 ICE-60TM Torch 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. .
. A complete Parts List is available at www.MillerWelds.com 40 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 Tip 212 733 212 725 Electrode Swirl Ring 212 724 212 734 ICE-60TM Torch 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. .
. A complete Parts List is available at www.MillerWelds.com 40 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch tip and workpiece for all cuts. Deflector Retaining Cap 212 736 212 733 Tip 212 729 Electrode Swirl Ring 212 724 212 734 ICE-60TM Torch Mild Steel Arc Current Arc Voltage Pierce Delay 125 25 128 128 0 130 40 129 0.
. A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. . Maintain more often during severe conditions.
. A complete Parts List is available at www.MillerWelds.com 7-3. Checking/Replacing Retaining Cup, Tip, And Electrode Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place.
. A complete Parts List is available at www.MillerWelds.com 7-4. Wrapper Removal/Installation 4 ! Turn off power, and disconnect input power plug from receptacle or turn off and lockout/tagout line disconnect device before working on unit. ! Significant DC voltage can remain on capacitors after unit is Off. Check to see that front panel lights (LEDs) have stopped flashing and are off before removing wrapper.
. A complete Parts List is available at www.MillerWelds.com 7-5. Checking Or Replacing Filter Element (Part No. 227 877) 1 ! Turn off power, and disconnect input power plug from receptacle or turn off and lockout/tagout line disconnect device before working on unit. ! Significant DC voltage can remain on capacitors after unit is Off. Check to see that front panel lights (LEDs) have stopped flashing and are off before removing wrapper. Remove wrapper from unit (see Section 7-4).
. A complete Parts List is available at www.MillerWelds.com 7-6. Status/Trouble Lights V POWER PRESSURE CUP TEMP Light Power Condition Status/Possible Cause On Input power is okay. Off When Power light is on, system is normal if these lights are off. Power Flashing rate is steady for 15 seconds or until torch trigger is pressed again, whichever comes first. Input power was above 300 volts AC or below 156 volts AC, but has returned to normal.
. A complete Parts List is available at www.MillerWelds.com 7-7. Troubleshooting Power Source Trouble Remedy No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see Section 7-3). arc. Check for damaged torch or torch cable. Check position of cut/gouge switch. If using cutting consumables, be sure that switch is in the CUT position. If using gouging consumables, be sure that switch is in the GOUGE position. Check retaining cup.
. A complete Parts List is available at www.MillerWelds.com Trouble Arc goes out while cutting. Remedy Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece. Make sure drag shield is on the workpiece or the extended tip is 1/16 in. (1.6 mm) to 1/8 in. (3.2 mm) from workpiece while cutting (see Section 5-4). On thin metal, check travel speed. Constant travel speed must be maintained when cutting thin material. Check that compressed air is clean, dry and oil-free.
. A complete Parts List is available at www.MillerWelds.com 7-8. Troubleshooting Torch Trouble Arc goes on and off while cutting. Remedy Torch travel speed too slow; increase travel speed (see Section 5-4). Clean or replace worn consumables as necessary (see Section 7-3). Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece. Arc goes out while cutting. Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece.
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SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1.
243 018-C OM-242 880 Page 49
SECTION 9 − PARTS LIST . A complete Parts List is available on-line at www.MillerWelds.com 9-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts . . . . . . . . . . . . . . . . 234843 . . Label, Ice 60t Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 227877 . . Filter, Air Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item Part No. No. Item Part No. No.
Item Part No. No. 1 2 2 3 4 5 6 7 See Figure 8-1 for additional consumable parts. Description 215 607 234 172 234 173 215 599 215 598 195 513 234 136 234 138 220 240 246 285 234 829 215 606 Sleeve, Torch Position (1) Torch Lead, Replacement W/QD 25 ft (1) Torch Lead, Replacement W/QD 50 ft (1) Torch Sleeve (1) Main Body W/Switch (1) Remote Pendant Control (1) Torch, Replacement 25 ft (1) Torch, Replacement 50 ft (1) Cable, Remote Control Trigger 25 ft (1) Cable, Remote Voltage Sense 26.
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Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
