OM-237 974C 2010−04 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter R Spectrum 625 X-TREME And ICE-40T Torch 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.
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 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 Vérifiez fréquemment le cordon d’alimentation afin de vous assurer qu’il n’est pas altéré ou à nu, remplacez−le immédiatement s’il l’est. Un fil à nu peut entraîner la mort. D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
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. Specifications Power Supply Input Rated AC phase (PH) and line frequency (Hz) Rated Input Voltage (U1) and rated Input Current (I1) and I1 eff at rated output. I1 eff used to determine power cord rating 1 PH 60 Hz —— Volts AC RMS − (U1) Amps RMS − (I1) I1 eff 208 1 PH 33 23.3 230 1 PH 30 21.2 Volts AC RMS − (U1) Power Factor KVA/KW 208 0.98 6.8/6.6 230 0.98 6.8/6.6 10.
. A complete Parts List is available at www.MillerWelds.com 4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. For Units Connected to a 208 Volt Circuit or a 230 Volt Circuit: 50% Duty Cycle At 40 amperes, 140 volts DC (typical cutting) 5 Minutes Cutting If unit 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.
. A complete Parts List is available at www.MillerWelds.com 4-5. Connecting Gas/Air Supply . Use only clean, dry air with 90 to 120 psi (621 to 827 kPa) pressure. 1 Gas/Air Inlet Opening 2 Hose 3 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. 1 2 3 From Gas/Air Supply Tools Needed: 9/16 in. 805 326-A 4-6.
. A complete Parts List is available at www.MillerWelds.com 4-7. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source. NOTICE − INCORRECT INPUT POWER can damage this welding power source.
. A complete Parts List is available at www.MillerWelds.com 4-9. 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. 4-10.
. A complete Parts List is available at www.MillerWelds.com 4-11. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or Champion 10,000 Tools Needed: 2 3 3 4 4 7 240V 3/16 in.
. A complete Parts List is available at www.MillerWelds.com 4-12. Installing Alternative Plug . This procedure is necessary if the unit is to be connected to a 208/230 VAC receptacle that requires a plug that is different from the supplied plug. 2 3 1 6 7 4 5 Tools Needed: 1 Supplied 230 VAC Plug Cut cord close to plug.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 2 1 V 30 POWER PRESSURE 3 35 25 CUP TEMP 20 A 40 237 552-A 1 Output Control Use control to set cutting output.
. A complete Parts List is available at www.MillerWelds.com 5-2. Mild Steel Recommended Cut Speed . Aluminum and stainless steel cut speeds at these thicknesses may be reduced as much as 30%. Thickness Approximate Travel Speed* Inches Millimeters IPM mm/min 1/8 3.2 149 3785 1/4 6.4 60 1524 3/8 9.5 34 864 1/2 12.7 21 533 5/8 15.9 12 305 *Travel speeds are approximately 80% if maximum. The best cut quality is achieved by cutting near the table value.
. A complete Parts List is available at www.MillerWelds.com 5-4. Plasma Cutting System Practices ! 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. DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle and electrode. 90° Maintain approximately a 90° angle to the workpiece surface for proper cutting results.
. A complete Parts List is available at www.MillerWelds.com 5-5. Sequence Of Cutting Operation 90° Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. ! For standard (shielded) cutting, place drag shield on edge of metal. For extended (non-shielded) cutting, use 1/8 in. (3.2 mm) standoff distance (dragging tip will reduce tip life). The pilot arc starts immediately when trigger is pressed. Raise trigger lock and press trigger. Pilot arc starts.
. A complete Parts List is available at www.MillerWelds.com 5-6. Sequence Of Gouging Operation Trigger pilot arc once before starting to gouge. 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. 455 Hold torch at approximately 45° angle to workpiece. Raise trigger lock and press trigger. Pilot arc starts. Move tip to within approximately 3/16 in. (4.8 mm).
. A complete Parts List is available at www.MillerWelds.com 5-7. Sequence Of Piercing Operation ! Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 90° Rotate torch to upright position approximately 90° to surface. When arc has pierced through workpiece, start cutting. The pilot arc starts immediately when trigger is pressed. Hold torch at an angle to the workpiece. Raise trigger lock and press trigger. Pilot arc starts.
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Each Use Every Week Every 3 Months n Gas/Air Pressure . Maintain more often during severe conditions.
. A complete Parts List is available at www.MillerWelds.com 6-2. Wrapper Removal 2 1 ! Turn off power, and disconnect input power plug from receptacle before working on unit. Check to see that all diagnostic LEDs have stopped flashing before removing wrapper from unit. 1 2 Wrapper Torx Screws (Fine Thread) Remove Torx screws and slide wrapper off. Tools Needed: Torx 25 Ref.
. A complete Parts List is available at www.MillerWelds.com 6-3. Checking Or Replacing Filter Element ! Turn power Off, and disconnect input power plug from receptacle. Check to see that all diagnostic LEDs have stopped flashing before removing wrapper from unit. Remove wrapper from unit (see Section 6-2). 1 Filter Base 2 Filter 3 Filter Cup Unscrew filter cup from base. Remove cup. Unscrew filter element from base. Check filter element for dirt and moisture, and replace if necessary.
. A complete Parts List is available at www.MillerWelds.com 6-4. Status/Trouble Lights . Diffculty establishing a pilot arc may indicate consumables need to be cleaned or replaced. 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.
. A complete Parts List is available at www.MillerWelds.com 6-6. 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.
. A complete Parts List is available at www.MillerWelds.com 6-7. Troubleshooting Power Source Trouble Remedy No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see torch Owner’s Manual). arc. Check for damaged torch or torch cable (see torch Owner’s Manual). No cutting output; Power light off; status Place Power switch in On position. lights off; fan motor FM does not run. Place line disconnect device in On position (see Section 4-10).
. A complete Parts List is available at www.MillerWelds.com 6-8. Troubleshooting Torch Trouble Remedy Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 5-5). Clean or replace torch consumables as necessary (see Section 6-6). Be sure work clamp is securely attached to workpiece. Arc goes out while cutting. Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in. (1.6 mm) to 1/8 in. (3.2 mm)] workpiece (see Section 5-4).
Notes OM-237 974 Page 31
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
235 080-A OM-237 974 Page 33
SECTION 8 − PARTS LIST 8-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts . . . . . . . . . . . . . . . . . 211120 . . LABEL, ICE 40T CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 238486 . . FILTER,AIR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . 213619 . .
! Turn power Off, and disconnect input power plug from receptacle. Check to see that all diagnostic LED’s have stopped flashing before replacing any torch parts. . The ICE-40T torch is specifically for use only with this plasma cutting unit. Item Part No. No.
Notes
Notes
Notes
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.
