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OM-234 163 Page 4

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.

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other

reproductive harm. 

Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,

 ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting and Gouging

, Ameri-

can Welding Society Standard AWS C5.2, from Global Engineering

Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting,

 American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

National Electrical Code,

 NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders,

 CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes,

 CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational 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 Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and

Part 1926, Subpart J, from U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone

for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation

, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF field around

the welding circuit and welding equipment. EMF fields may interfere with

some medical implants, e.g. pacemakers. Protective measures for per-

sons wearing medical implants have to be taken. For example, access

restrictions for passers

by or individual risk assessment for welders. All

welders should use the following procedures in order to minimize expos-

ure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the weld-

ing circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding,  spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

Summary of Contents for ICE-60T Torch

Page 1: ...Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM 234 163B 2010 04 Spectrum 875 And ICE 60T Torch R File Plasma Cutters Visit our website at www MillerWelds com...

Page 2: ...ntinue 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...

Page 3: ...orch Dimensions 12 4 4 Power Source Dimensions And Weight 13 4 5 Connecting Work Clamp and Gas Air Supply 13 4 6 Connecting And Disconnecting Torch 14 4 7 Connecting And Disconnecting Work Cable 14 4...

Page 4: ...stem 27 6 3 Checking Replacing Retaining Cup Tip And Electrode 28 6 4 Wrapper Removal Installation 29 6 5 Checking Or Replacing Filter Element Part No 227 877 30 6 6 Status Trouble Lights 31 6 7 Troub...

Page 5: ...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...

Page 6: ...s 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...

Page 7: ...ar 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 K...

Page 8: ...ational 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 Prevent...

Page 9: ...upez pas sur un contenant ferm tel qu un r servoir ou un bi don D Fixez le c ble de masse sur la pi ce couper le plus pr s possible de la zone couper afin de pr venir que le courant de coupage ne pren...

Page 10: ...ad quats afin de prot ger vo tre peau D Ayez recours des prot ge tympans ou un serre t te ignifuges afin d viter que les tincelles n entrent dans vos oreilles Les rayons d arc provenant du proc d de...

Page 11: ...ne basculent D Les bouteilles ne doivent pas tre pr s de la zone de coupage ni de tout autre circuit lectrique D Un contact lectrique ne doit jamais se produire entre un chalu meau de plasma d arc et...

Page 12: ...ables D Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareilen service LES CHARGES LECTROSTATI QUES peuvent endomma...

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...

Page 14: ...nd 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...

Page 15: ...A Duty Cycle at 1045 F 405 C at rated conditions U1 I1 U2 I2 based on a 10 minute period Volts AC RMS U1 Duty Cycle 208 Volts AC 1 PH 40 230 Volts AC 1 PH 50 General Operating Temperature 5 to 104 F...

Page 16: ...mperature status light illuminates and cooling fan runs Wait fifteen minutes for unit to cool or temperature light to go off Reduce amperage or duty cycle before cutting or gouging NOTICE Exceeding du...

Page 17: ...ean paint freelocation on workpiece as close to cutting area as possible Use only clean dry air with 90 to 120 psi 621 to 827 kPa pressure 6 75 CFM 191L min minimum Use filter kit 300 491 or 228 926 w...

Page 18: ...ck 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 ca...

Page 19: ...rts List is available at www MillerWelds com OM 234 163 Page 15 4 8 Power Cable Management Strap 805 275 A 1 Power Cable Management Strap Coil power cable and secure to unit using the power cable mana...

Page 20: ...e recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class H 65 amps and a...

Page 21: ...NEMA Type 6 50P 2 Receptacle NEMA Type 6 50R Connect plug to receptacle 3 Black And White Input Conductor L1 And L2 4 Green Or Green Yellow Grounding Conductor 5 Input Power Cord 6 Disconnect Device s...

Page 22: ...nerator Equipped With A Full KVA Receptacle NEMA 14 50R Using Adapter Cord Part No 300 158 805 304 A 1 Adapter Cord 2 Plasma Cutter Plug 3 Generator Receptacle Use adapter cord to connect plasma cutte...

Page 23: ...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 Conductors 8 Green...

Page 24: ...ling Alternative Plug 1 Supplied 230 VAC Plug Cut cord close to plug 2 Alternative Plug 230 VAC Plug Shown 3 Input Black Lead Brass Terminal 4 Input White Lead Brass Terminal 5 Ground Green Terminal 6...

Page 25: ...rocess 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...

Page 26: ...workpiece as close to 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 t...

Page 27: ...ed Postflow continues 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 press...

Page 28: ...Move tip to within approximately 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...

Page 29: ...is pressed Hold torch 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...

Page 30: ...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 m...

Page 31: ...Unreadable Labels l Cracked Parts Air Filter Regulator Assembly Filter n Gas Air Hose n l Torch Body Cable Every 6 Months OR Inside Unit 6 2 Checking Shield Cup Shutdown System Ref 801 300 A 1 Torch...

Page 32: ...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 st...

Page 33: ...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 a...

Page 34: ...r from unit see Section 6 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...

Page 35: ...ted 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...

Page 36: ...ersists have Factory Authorized Service Agent check torch and unit Temperature status light On Unit overheating see Section 4 2 Allow fan to run the Trouble light goes out when the unit has cooled If...

Page 37: ...n drag shield of any slag particles and debris Check position of cut gouge switch Place switch in correct position to match the process Check input air pressure Check that compressed air is clean dry...

Page 38: ...OM 234 163 Page 34 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Circuit Diagram...

Page 39: ...OM 234 163 Page 35 234 157 B...

Page 40: ...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...

Page 41: ...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 25ft 1 234 134 Torch replacement...

Page 42: ...Notes...

Page 43: ...bles 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 Cont...

Page 44: ...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 Equip...

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