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Miller Electric CE-60T, Owner'S Manual

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Miller Electric CE-60T Owner'S Manual Download Page 27

.

A complete Parts List is available at www.MillerWelds.com

OM-242 880 Page 23

4-17. Generator Settings For Plasma Cutter Operation

Ref. 803 222

!

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.

Notes

Summary of Contents for CE-60T

Page 1: ...Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM 242 880B 2010 05 Spectrum 875 Auto Line And ICE 60T TM Torch R File Plasma Cutters Visit our website at www MillerWelds com ...

Page 2: ...ontinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operati...

Page 3: ... Location 11 4 2 Specifications 11 4 3 Duty Cycle And Overheating 12 4 4 Torch Dimensions 13 4 5 System Dimensions Weight And Movement 13 4 6 Connecting Work Clamp and Gas Air Supply 14 4 7 Connecting And Disconnecting Torch 15 4 8 Connecting And Disconnecting Work Cable 15 4 9 Power Cable Management Strap 16 4 10 Selecting a Location 16 4 11 Electrical Service Guide 17 4 12 Extension Cord Data 18...

Page 4: ...g An External Power Supply For Isolated Input Module Operation 34 6 8 Remote Voltage Sense Connection 35 6 9 Shield Sense Tab 35 6 10 Cut Charts 36 SECTION 7 MAINTENANCE TROUBLESHOOTING 39 7 1 Routine Maintenance 39 7 2 Checking Shield Cup Shutdown System 39 7 3 Checking Replacing Retaining Cup Tip And Electrode 40 7 4 Wrapper Removal Installation 41 7 5 Checking Or Replacing Filter Element Part N...

Page 5: ...s high shoes and a cap D Do not locate unit on or over combustible surfaces D Remove any combustibles such as a butane lighter or matches from your person before doing any cutting D After completion of work inspect area to ensure it is free of sparks glowing embers and flames D Use only correct fuses or circuit breakers Do not oversize or by pass them D Follow requirements in OSHA 1910 252 a 2 iv ...

Page 6: ...Ss and the manufacturer s instruction for metals to be cut coatings and cleaners D Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Fumes from cutting and oxygen depletion can alter air quality causing injury or death Be sure the breathing air is safe D Do not cut in locations near degreasing cleaning or spraying oper ations The heat and rays of th...

Page 7: ...ear gas cylinders or any other accessories D Use equipment of adequate capacity to lift unit D If using lift forks to move unit be sure forks are long enough to ex tend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No ...

Page 8: ...cational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health...

Page 9: ...e coupez pas sur un contenant fermé tel qu un réservoir ou un bi don D Fixez le câble de masse sur la pièce à couper le plus près possible de la zone à couper afin de prévenir que le courant de coupage ne prenne une trajectoire inconnue ou longue et ne cause ainsi une décharge électrique d étincelles ou un feu D Ne pas utiliser le coupeur plasma pour dégeler des conduites ge lées D Ne coupez jamai...

Page 10: ...adéquats afin de protéger vo tre peau D Ayez recours à des protège tympans ou à un serre tête ignifuges afin d éviter que les étincelles n entrent dans vos oreilles Les rayons d arc provenant du procédé de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entraîner des brûlures aux yeux et à la peau LES RAYONS D ARC peuvent entraî ner des brûlure...

Page 11: ...ne basculent D Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique D Un contact électrique ne doit jamais se produire entre un chalu meau de plasma d arc et une bouteille D Ne coupez jamais sur une bouteille pressurisée une explosion en résulterait D Utilisez uniquement des bouteilles de gaz des détendeurs des boyaux et des raccords conçus pour l appli...

Page 12: ...les D Ne pas surcharger l installation électrique s assurer que l alimen tation est correctement dimensionné et protégé avant de mettre l appareilen service LES CHARGES ÉLECTROSTATI QUES peuvent endommager les cir cuits imprimés D Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces D Utiliser des pochettes et des boîtes antistatiques pour stocker déplacer ou ...

Page 13: ...phone 800 463 6727 site internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 25 West 43rd Street New York NY 10036 téléphone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Ass...

Page 14: ...und Single Phase Constant Current Voltage Input On Off Percent Direct Current U0 Rated No Load Voltage Average U1 Primary Voltage U2 Conventional Load Voltage Line Connection I1max Rated Maximum Supply Current I2 Rated Welding Or Cutting Current X Duty Cycle Single Phase Static Frequency Converter Transformer Rectifier IP Degree Of Protection Loose Shield Cup Input Hz Hertz I1eff Maximum Effective...

Page 15: ...AC 3 Phase 27 5 19 4 230 VAC 3 Phase 25 17 7 380 VAC 3 Phase 15 11 6 460 VAC 3 Phase 12 4 9 6 575 VAC 3 Phase 9 8 7 6 Power Factor kVA kW at Rated Output Volts AC RMS U1 Power Factor kVA kW 208 VAC 1 Phase 0 98 9 9 9 7 230 VAC 1 Phase 0 98 9 7 9 6 208 VAC 3 Phase 0 95 9 9 9 5 230 VAC 3 Phase 0 95 9 9 9 5 380 VAC 3 Phase 0 95 9 9 9 4 460 VAC 3 Phase 0 95 9 9 9 4 575 VAC 3 Phase 0 95 9 8 9 3 Peak kW...

Page 16: ...n for cutting speeds vs material type and thickness Rated Capacity edge start 7 8 in at 10 ipm 254 mm min Sever Cut Capacity edge start 1 1 4 in Pierce Capacity 7 16 in Travel speeds are approximately 80 of maximum 4 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating Duty cycle is based on an ambient tem perature of 104 F 40 C If...

Page 17: ...ack 32 pitch 1 8 in 3 2 mm width 1 8 in 3 2 mm height 4 5 System Dimensions Weight And Movement loc_2 3 96 Ref 805 159 A Unit Dimensions And Weight 47 lb 21 3 kg Torch Weight Hand Held 20 ft 6 1 m 6 lb 2 7 kg Hand Held 50 ft 15 2 m 12 3 4 lb 5 8 kg Machine 25 ft 7 6 m 8 lb 3 6 kg Machine 50 ft 15 2 m 13 1 2 lb 6 1 kg Work Cable Weight 20 ft 6 1 m 3 1 2 lb 1 6 kg 50 ft 15 2 m 7 1 2 lb 3 4 kg 18 1 2...

Page 18: ...filter kit 300 491 or 228 926 where conditions at the work site allow moisture oil or other particulates into the air line 3 Gas Air Filter Inlet Opening 4 Hose Hose must have a minimum inside diameter of 3 8 in 9 5 mm 5 Teflon Tape Obtain hose with 1 4 NPT right hand thread fitting Wrap threads with teflon tape optional or apply pipe sealant and install fitting in opening Route hose to gas air su...

Page 19: ...ock wise to unlock connector from unit Push quick connect collar back towards unit to release nipple and pull torch connector away from unit Use supplied hook and loop strap to manage torch and work cables 805 161 A 2 1 3 4 5 4 8 Connecting And Disconnecting Work Cable Ref 805 161 A Ref 803 475 G 1 Work Cable Receptacle 2 Work Cable Plug To connect plug align key with receptacle keyway and insert ...

Page 20: ... 96 Ref ST 151 556 Ref 805 159 1 Lifting Handle Use handle to lift unit 2 Line Disconnect Device Locate unit near correct input power supply Locate unit at least 18 in 460 mm away from a wall or other obstuction to allow adequate clearance for cooling air flow Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Do not move or op...

Page 21: ...5 17 68 21 Min Grounding Conductor Size In AWG Kcmil 4 10 10 Three Phase Input Voltage V 208 230 380 460 575 Input Amperes A At Rated Output 27 25 15 12 10 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 30 30 15 15 10 Normal Operating Fuses 3 40 35 20 20 15 Min Input Conductor Size In AWG Kcmil 4 12 12 14 14 14 Max Recommended Input Conductor Length In Feet Meters 68 21 83 25...

Page 22: ...0 60 Time Delay 2 50 A Normal Operating 3 60 A 10 AWG 67 ft 21 m 208 V 3 50 60 Time Delay 2 30 A Normal Operating 3 40 A 12 AWG 68 ft 21 m 230 V 3 50 60 Time Delay 2 30 A Normal Operating 3 35 A 12 AWG 83 ft 25 m 380 V 3 50 60 Time Delay 2 15 A Normal Operating 3 20 A 14 AWG 148 ft 45 m 460 V 3 50 60 Time Delay 2 15 A Normal Operating 3 20 A 14 AWG 216 ft 66 m 575 V 3 50 60 Time Delay 2 10 A Norma...

Page 23: ...hown in the OFF position 8 Disconnect Device Grounding Terminal 9 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 10 Over Current Protection Select type and size of over current protection using Section 4 11 fused dis connect switch shown Close and...

Page 24: ...ductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Over Current Protection Select type and size of over current protection using Section 4 11 fused dis connect switch shown Close and secure door on disconnect device Remove ...

Page 25: ...he power supply 1 Input And Grounding Conductors 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Brass Terminal And Prong Not Used 4 Load 1 Brass Terminal And Prong 5 Load 2 Brass Terminal And Prong 6 Ground Brass Terminal And Prong 7 Black And White Input Con ductors 8 Red Input Conductor 9 Insulation Sleeving 10 Electrical Tape 11 Green Or Green Yellow Ground Conductor Insulate and isolate red cond...

Page 26: ... to front panel Ground stud 10 Power Cord 11 Circuit Breaker CB7 User Terminals Circuit breaker CB7 protects single phase receptacle RC5 and the load wires from overload If CB7 opens all three phase generator output stops and the receptacle does not work Connect user supplied ring lug to green ground lead Connect ring lug on end of green ground lead to grounding terminal 9 Connect black white and ...

Page 27: ...ation Ref 803 222 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 Notes ...

Page 28: ...process Unit will automatically regu late pressure to 70 psi 483 kPa for cutting and 60 psi 413 kPa for gouging Pilot cur rent is automatically increased in gouge mode to provide better gouging starts Use only clean dry air with 90 to 120 psi 621 to 827 kPa pressure Prevent moisture from entering air supply at extreme cold temperatures Use filter kit 300 491 or 228 926 where conditions at the work...

Page 29: ...o cutting area as possible Set switch to either cut or gouge dependingon desired process 90 DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle and electrode Sparks should pass through the workpiece and out the bottom when cutting If sparks flare back from surface this usually is an indication that either travel speed is too fast or amperage is set too...

Page 30: ... after releasing trigger cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger The pilot arc starts immediately when trigger is pressed 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 Connect work clamp to a clean paint free location...

Page 31: ...pproximately 3 16 in 4 8 mm Start gouging across workpiece surface Maintain approximately a 45 angle to surface Release trigger Postflow continues after releasing trigger arc can be instantly restarted during postflow by raising trigger lock and pressing trigger The pilot arc starts immediately when trigger is pressed Hold torch at approximately 45 angle to workpiece 455 Unit automatically regulat...

Page 32: ... at an angle to the workpiece Raise trigger lock and press trigger Pilot arc starts and will go out after 3 seconds if cutting arc is not established Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible 90 90 Rotate torch to upright position approximately 90 to surface When arc has pierced through workpiece start cutting Unit automatically regulates p...

Page 33: ...s Inches mm IPM mm min 60 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 2 9 222 Aluminum Arc Current Material Thickness Recommended Cut Speeds Inches mm IPM mm min 60 1 4 6 4 94 2388 3 8 9 5 48 1219 1 2 12 7 30 762 5 8 15 9 21 545 Recommendedcut speed is approximately 80 of maximum Recommended maximum piercing capacity is 7 16 in 11 mm 5 8 Consumables Storag...

Page 34: ...l Cable Functions Function Lead Socket Lead Information Remote Start White 1 White and red leads connect to a set of customer supplied remote contacts to provide a remote trigger input signal to RC61 sockets 1 and 5 for the remote start function Red 5 Okay To Move Black 2 Black and green leads connect to a customer supplied machine torch drive device Normally open contacts close after arc start to...

Page 35: ...e RMT2 on PC1 Be sure remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied24 volts DC re lay coil with resistance greater than 240 ohms Suppressiondiode 1A 100V such as type IN4002 through IN4004 across relay coil Machine torch equipped plasma cutter is shipped from the factory with pl...

Page 36: ...tacle RMT1 3 Receptacle RMT2 4 Receptacle RC61 Move plug from RMT1 into receptacle RMT2 on PC1 Be sure remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied isolated input module Machine torch equipped plasma cutter is shipped from the factory with plug connected to receptacle RMT1 dry ...

Page 37: ...hine torch equipped units are shipped from factory with plug con nected to receptacle RMT1 Be sure that remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied 24 volts DC power supply 24 volts DC relay coil with resist ance greater than 240 ohms Suppressiondiode 1A 100V such as type IN40...

Page 38: ...ly for the Okay To Move signal 1 Control Board PC1 2 Receptacle RMT1 3 Receptacle RC61 Unit is shipped from factory with plug connected to receptacle RMT1 Be sure that remote control cable plug is connected to RC61 on rear of unit If voltage sensing is required see Section 6 8 Install wrapper on unit Required Items Customer supplied 24 volts DC power supply Isolated input module Remote Control Cab...

Page 39: ...lowing adequate slack inside the machine secure cable and strain relief by snapping strain relief into opening in rear panel Connect plug to RC48 on PC4 Install wrapper on unit Cut off crimped terminals on lead ends and connect lead 1 to volts DC work and lead 2 to volts DC electrode on customer supplied voltage sense device 3 2 1 Tools Needed Torx 25 6 9 Shield Sense Tab Shield sense tab is locat...

Page 40: ... 147 5 8 15 9 31 787 20 508 153 3 4 19 0 22 559 14 356 Stainless Arc Current Arc Voltage Pierce Delay Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm min IPM mm min 60 134 0 16 Ga 1 5 625 15875 406 10312 136 0 25 10 Ga 3 4 244 6198 159 4039 139 0 50 1 4 6 4 112 2845 73 1849 145 0 75 3 8 9 5 53 1346 34 864 145 2 00 1 2 12 7 36 914 23 594 149 5 8 15 9 26 660 17 432 154 3 4 ...

Page 41: ... 3 16 4 7 97 2464 63 1600 149 1 00 1 4 6 4 73 1854 47 1205 Stainless Arc Current Arc Voltage Pierce Delay Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm min IPM mm min 25 139 0 26 Ga 0 5 631 16027 410 10414 139 22 Ga 0 8 496 12598 322 8179 40 142 0 25 18 Ga 1 3 592 15037 335 8509 143 16 Ga 1 5 374 9500 243 6172 143 14 Ga 1 9 224 5690 146 3698 147 0 50 10 Ga 3 4 107 2718 ...

Page 42: ...rrent Arc Voltage Pierce Delay Material Thickness Maximum Cut Speeds Optimum Cut Speeds Inches mm IPM mm min IPM mm min 25 127 0 26 ga 0 5 561 14249 365 9271 127 22 ga 0 8 453 11506 295 7493 40 123 0 25 18 Ga 1 3 500 12700 325 8255 127 16 GA 1 5 365 9271 237 6026 128 14 GA 1 9 220 5588 143 3632 Aluminum Arc Current Arc Voltage Pierce Delay Material Thickness Maximum Cut Speeds Optimum Cut Speeds I...

Page 43: ...s l Cracked Parts Air Filter Regulator Assembly Filter n Gas Air Hose n l Torch Body Cable Every 6 Months OR Inside Unit 7 2 Checking Shield Cup Shutdown System Ref 801 300 A 1 Torch Shield Cup Turn Power On and loosen shield cup If shutdown system works properly Cup light comes on If not immediately turn Off power and have Factory Authorized Service Agent check unit If system works properly retig...

Page 44: ...p Check retaining cup for cracks and replace if necessary 3 Tip 4 Opening Remove tip Check tip and replace if open ing is deformed or 50 oversize If inside of tip is not clean and bright clean with steel wool Be sure to remove any pieces of steel wool afterwards 5 Electrode Check electrode Performance may degrade if center has a pit more than a 1 32 in 1 mm deep remove and replace electrode 6 Swir...

Page 45: ... is Off Check to see that front panel lights LEDs have stopped flashing and are off before removing wrapper 1 Wrapper 2 Front Bezel 3 Rear Bezel 4 Torx Screw Fine Thread Remove 13 screws from wrapper and front and rear bezels as shown Spread open tops of front and rear bezels 5 Consumables Storage Compartment Opening Be sure that opening clears the storage compartment Lift wrapper off unit When in...

Page 46: ...er from unit see Section 7 4 1 Rear Bezel Remove rear bezel from unit 2 Filter Bracket Screws Remove filter bracket screws Pull filter bracket toward front of unit until gas air supply fitting is past rear panel and swing filter assembly out to the side to allow filter cup removal 3 Filter Base 4 Filter Element Part No 227877 5 Filter Cup Unscrew filter cup from base Remove cup Unscrew filter elem...

Page 47: ...ated pressure in the unit is high Cup On Torch cup is loose or off Once cup is finger tightened unit power must be cycled off and back on again Cup Flashing rate is steady for 15 seconds or until torch trigger is pressed again whichever comes first No arc was established Plasma system failed to strike an arc Cup Repetitive flashing rate of two quick cycles then a one second pause for a 15 second p...

Page 48: ...ion 7 2 Reset power switch If trouble persists have Factory Authorized Service Agent check torch and unit Temperature status light On Unit overheating see Section 4 3 Allow fan to run the Trouble light goes out when the unit has cooled If trouble persists have Factory Authorized Service Agent check unit Temperature status light On indefinitely Power source temperature sensors may have failed or am...

Page 49: ...Agent check unit Cup status light flashes at a rate of two quick cycles and then a one second pause for 15 seconds or until torch trig ger is pressed whichever comes first No pilot arc established The power source failed to maintain a pilot arc Try a different set of torch con sumables tip and electrode Check for input pressure between 90 120 PSI Cup status light flashes at a rate of three quick c...

Page 50: ...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 Use filter kit 300491 or 228926 if necessary Check retaining cup DO NOT overtighen cup hand tighten only Clean or replace worn consumables as necessary see Section 7 3 Sparks come ...

Page 51: ...OM 242 880 Page 47 Notes ...

Page 52: ...OM 242 880 Page 48 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 53: ...OM 242 880 Page 49 243 018 C ...

Page 54: ... required when ordering parts from your local distributor 234 843 B 234 843 B O Ring 212 735 Machine Cutting Gouging Apply silicone grease 169 231 before installing Electrode 212 724 Tip 212 725 Retaining Cup 212 733 Shield 212 731 Shield 212 732 Swirl Ring 212 734 Deflector 212 736 Drag Shield 212 730 Drag Shield 212 730 Deflector 212 736 Tip 219 676 Tip 212 729 Tip 219 682 Tip 219 680 60A Retain...

Page 55: ...al consumable parts 4 5 3 2 1 7 9 215 606 Clip Retaining 1 10 212 735 O Ring Main Body 1 11 234 829 Kit Ice 60T TM Quick Connect W Wing Head Fastener 1 169 231 Grease Silicon 234 132 Torch Replacement 20 ft 1 234 134 Torch Replacement 50 ft 1 Part No Item No Description 1 10 804 035 A 11 Figure 8 2 Torch ICE 60T To maintain the factory original performance of your equipment use only Manufacturer s...

Page 56: ...oltage Sense 26 5 ft 1 6 234 829 Kit Ice 60t Tm QD W Wing Head Fastener 7 215 606 Clip Retaining Part No Item No Description 4 See Figure 8 1 for additional consumable parts 3 2 1 804 036 A 5 7 6 Figure 8 3 Torch ICE 60TM A complete Parts List is available on liine at www MillerWelds com To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Pa...

Page 57: ...Notes ...

Page 58: ...Notes ...

Page 59: ...ables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumabl...

Page 60: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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