Miller XT30C Manual Download Page 6

OM-254 449 Page 2

ELECTRIC SHOCK can kill.

SIGNIFICANT DC VOLTAGE exists in

inverter power sources AFTER the re-

moval of input power.

D

Turn Off unit, disconnect input power, check voltage on input ca-

pacitors, and be sure it is near zero (0) volts before touching any

parts. Check capacitors according to instructions in Maintenance

Section of Owner’s Manual or Technical Manual before touching

any parts.

D

On inverter power sources, failed parts can ex-

plode or cause other parts to explode when

power is applied. Always wear a face shield

and long sleeves when servicing inverters.

EXPLODING PARTS can injure.

Sparks and hot metal blow out from the cutting arc.

Chipping and grinding cause flying metal.

FLYING SPARKS can injure.

D

Wear approved face shield or safety goggles with side shields.

D

Wear proper body protection to protect skin.

D

Wear flame-resistant ear plugs or ear muffs to prevent sparks from

entering ears.

Arc rays from the cutting process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin.

ARC RAYS can burn eyes and skin.

D

Wear face protection (helmet or shield) with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks when

cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a

No. 9 shade (with No. 8 as minimum) for all cutting currents less

than 300 amperes. Z49.1 adds that lighter filter shades may be used

when the arc is hidden by the workpiece. As this is normally the case

with low current cutting, the shades suggested in Table 1 are pro-

vided for the operator’s convenience.

D

Wear approved safety glasses with side shields under your helmet

or shield.

D

Use protective screens or barriers to protect others from flash, glare

and sparks; warn others not to watch the arc.

D

Wear body protection made from durable, flame

resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes

Minimum Shade Number

Below 20

20 

 40

40 

 60

60 

 100

#4
#5
#6
#8

Prolonged noise from some cutting applications can

damage hearing if levels exceed limits specified by

OSHA (see Safety Standards).

NOISE can damage hearing.

D

Use approved ear plugs or ear muffs if noise level is high.

D

Warn others nearby about noise hazard.

FUMES AND GASES can be hazardous

.

Cutting produces fumes and gases. Breathing

these fumes and gases can be hazardous to

your health.

D

Keep your head out of the fumes. Do not breathe the fumes.

D

If inside, ventilate the area and/or use local forced ventilation at the

arc to remove cutting fumes and gases. The recommended way to

determine adequate ventilation is to sample for the composition and

quantity of fumes and gases to which personnel are exposed.

D

If ventilation is poor, wear an approved air-supplied respirator.

D

Read and understand the Safety Data Sheets (SDSs) and the man-

ufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

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 the arc can react with vapors to form

highly toxic and irritating gases.

D

Do not cut on coated metals, such as galvanized, lead, or cadmium

plated steel, unless the coating is removed from the cutting area, the

area is well ventilated, and while wearing an air-supplied respirator.

The coatings and any metals containing these elements can give off

toxic fumes when cut.

D

Do not cut containers with toxic or reactive materials inside or

containers that have held toxic or reactive materials 

 they must be

emptied and properly cleaned first.

PLASMA ARC can injure.

The heat from the plasma arc can cause serious

burns. The force of the arc adds greatly to the burn

hazard. The intensely hot and powerful arc can

quickly cut through gloves and tissue.

D

Keep away from the torch tip.

D

Do not grip material near the cutting path.

D

The pilot arc can cause burns 

 keep away from torch tip when trig-

ger is pressed.

D

Wear body protection made from durable, flame

resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

D

Point torch away from your body and toward work when pressing

the torch trigger 

 pilot arc comes on immediately.

D

Turn off power source and disconnect input power before disas-

sembling torch or changing torch parts.

D

Use only torch(es) specified in the Owner’s Manual.

Compressed gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of metalworking pro-

cesses, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D

Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flame, sparks, and arcs.

D

Install and secure cylinders in an upright position by chaining them

to a stationary support or equipment cylinder rack to prevent falling

or tipping.

D

Keep cylinders away from any cutting or other electrical circuits.

D

Never allow electrical contact between a plasma arc torch and a

cylinder.

D

Never cut on a pressurized cylinder 

 explosion will result.

D

Use only correct compressed gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and as-

sociated parts in good condition.

D

Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D

Use the right equipment, correct procedures, and sufficient number

of persons to lift and move cylinders.

D

Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

Summary of Contents for XT30C

Page 1: ...XT Torches Processes Description OM 254 449B 2014 02 Plasma Cutting Torch Visit our website at www MillerWelds com Air Plasma Cutting and Gouging File Plasma Cutters...

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: ...y Lock 14 4 2 Installing 30 Ampere XT30 Torch And Work Cable On Spectrum 375 X TREME Stock No 907 303 And 907 339 Prior To Serial No MB290336P And Using Trigger Safety Lock 15 4 3 Installing 30 Ampere...

Page 4: ......

Page 5: ...vy cotton wool Body protection includes oil free clothing such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Do not locate unit on or over combustible surfaces D Remove any co...

Page 6: ...r s instructions for adhesives coatings cleaners consumables coolants degreasers fluxes and metals D Work in a confined space only if it is well ventilated or while wearing an air supplied respirator...

Page 7: ...pose FALLING EQUIPMENT can injure D Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories D Use equipment of adequate capacity to lift unit D If using lift forks to...

Page 8: ...b 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...

Page 9: ...udage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 et AWS A6 0 voir les Normes de S curit D Ne coupez pas...

Page 10: ...ise sous tension toute pi ce d fectueuse des sources d alimentation de l inverseur peut exploser ou faire exploser d autres pi ces Pour entretenir les inverseurs toujours porter un masque protecteur e...

Page 11: ...e vous appuyez sur la g chette l arc pilote s allume automatiquement D Mettez l alimentation hors tension et d branchez le cordon d ali mentation avant de d monter le chalumeau ou de changer une pi ce...

Page 12: ...l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur D Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 9...

Page 13: ...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 Occup...

Page 14: ...0 VDC at 1 Amp Approved Systems Spectrum 375 X TREME w XT30 torch Trigger Protection Safety trigger guard Safety Devices Safety interlock devices shut down power source Rated Capacity edge start 3 8 i...

Page 15: ...proved Systems Spectrum 375 X TREME w XT30 torch Trigger Protection Safety trigger guard Safety Devices Safety interlock devices shut down power source Rated Capacity edge start 3 8 in at 15 ipm 381 m...

Page 16: ...625 X TREME w XT40 torch Trigger Protection Safety trigger guard Safety Devices Safety interlock devices shut down power source Rated Capacity edge start 5 8 in at 13 ipm 330 mm min Sever Cut Capacit...

Page 17: ...Auto Line w XT60 torch Trigger Protection Safety trigger guard Safety Devices Safety interlock devices shut down power source Rated Capacity edge start 7 8 in at 13 ipm 22 2 mm at 330 mm min Sever Cut...

Page 18: ...ir line connector into solenoid fitting Pull slightly on torch to set fitting 4 Plug PLG1 Receptacle RC4 Connect PLG1 from torch to receptacle RC4 on end of wiring harness connected to circuit board P...

Page 19: ...do not tighten 4 Air Line Connector Insert air line connector into solenoid fitting Pull slightly on torch to set fitting 5 Plug PLG1 Receptacle RC1 Connect PLG1 from torch to receptacle RC1 on end o...

Page 20: ...end of wiring harness connected to circuit board PC1 5 Ring Terminal And Terminal PILOT Connect ring terminal on end of red leads to PILOT terminal 6 Ring Terminal And Terminal L2 RED Connect ring te...

Page 21: ...Connect PLG1 from torch to receptacle RC1 on end of wiring harness connected to circuit board PC1 6 Ring Terminal And Terminal PILOT Connect ring terminal on end of red leads to PILOT terminal 7 Ring...

Page 22: ...olenoid fitting Pull slightly on torch to set fitting 4 Plug PLG1 Receptacle RC4 Connect PLG1 from torch to receptacle RC4 on end of wiring harness connected to circuit board PC1 5 Ring Terminal And T...

Page 23: ...e collar to release torch connector from receptacle and pull torch connector away from unit 4 Trigger Ref 253554 A Ref 264 954 B 2 1 3 Trigger Locked Trigger Unlocked 4 4 7 Connecting And Disconnectin...

Page 24: ...ct torch Push torch connector onto receptacle and quick connect until collar secures nipple Rotate securing pin clockwise to lock connector to unit To disconnect torch Rotate securing pin counterclock...

Page 25: ...on workpiece as close to cutting area as possible 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 wor...

Page 26: ...arts Postflow continues for approx 20 seconds after releasing trigger cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger The pilot arc starts immediate...

Page 27: ...rted during postflow by raising trigger lock and pressing trigger The pilot arc starts immediately when trigger is pressed Hold torch at approximately 45 to the workpiece Raise trigger lock and press...

Page 28: ...Or Unreadable Labels Air Filter Regulator l Cracked Parts n l Gas Air Hose n l Torch Body Cable Every 6 Months OR Inside Unit 6 2 Shield Cup Shutdown System Ref 253 554 A 1 Torch Shield Cup Turn Power...

Page 29: ...or cracks and replace if necessary 2 Tip 3 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 rem...

Page 30: ...1 Clean or replace torch consumables as necessary see Section 6 3 Sparks come out top of cut or cut is not clean Torch travel speed too fast reduce travel speed see Section 5 1 Clean or replace torch...

Page 31: ...H THE BRANCH CIRCUITS SHOWN 15A MVP 120V 219 261 20A MVP 120V 219 259 50A MVP 240V 219 258 FAILURE TO REPLACE WORN TIP OR ELECTRODE WILL DAMAGE TORCH AND VOID WARRANTY S S Turn off power before checki...

Page 32: ...N 15A MVP 120V 219 261 20A MVP 120V 219 259 50A MVP 240V 219 258 FAILURE TO REPLACE WORN TIP OR ELECTRODE WILL DAMAGE TORCH AND VOID WARRANTY S S Turn off power before checking torch parts Check befor...

Page 33: ...er Microswitch 1 3 260 637 Leads XT40 12ft Hand Held Torch w Disconnect 1 3 260 638 Leads XT40 20ft Hand Held Torch w Disconnect 1 4 252 938 Torch Body Kit 1 5 249 972 Torch Trigger Assembly w Spring...

Page 34: ...se set Amperage control to 40 Figure 7 7 Consumable Parts For XT40 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model is required...

Page 35: ...dy 1 6 259 359 Strain Relief 1 7 259 330 Torch Replacement Leads 25 ft 1 Part No Item No Description 4 See 7 7 for additional consumable parts 3 2 1 Ref 264 954 A 5 7 6 Figure 7 8 Torch XT40M To maint...

Page 36: ...ip 1 7 249 931 30 40 Amp Swirl Ring 1 8 249 926 30 40 Amp Electrode 1 9 249 969 O Ring 1 Part No Item No Description See 7 7 for additional consumable parts Ref 264 954 A 1 2 3 4 5 6 7 8 9 Figure 7 9...

Page 37: ...cement 20 ft 1 249 954 Torch Replacement 50 ft 1 See Figure 7 11 for additional consumable parts 1 1 2 3 4 5 Item No Part No Description Ref 256 001 A Figure 7 10 Torch XT60 265 172 A For extended tip...

Page 38: ...249 956 Torch Machine Long Body Replacement 50 ft 1 257 464 Torch Machine Short Body Replacement 25 ft 1 263 952 Torch Machine Short Body Replacement 50 ft 1 Part No Item No Description 5 See 7 11 for...

Page 39: ...Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Ex...

Page 40: ...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...

Reviews: