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OM-234 163 Page 2

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 Mainte-

nance Section of Owner’s Manual or Technical Manual before

touching any parts.

ELECTRIC SHOCK can kill.

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 protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

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.

D

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

D

Read and understand the Material Safety Data Sheets (MSDSs)

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 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 proper flame-retardant clothing covering all exposed body ar-

eas.

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.

Gas cylinders contain gas under high pressure. If

damaged, a cylinder can explode. Since gas cylin-

ders are normally part of metalworking processes,

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 gas cylinders, regulators, hoses, and fittings de-

signed for the specific application; maintain them and associated

parts in good condition.

D

Turn face away from valve outlet when opening cylinder 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.

Содержание ICE-60T Torch

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 42: ...Notes...

Страница 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...

Страница 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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