Miller ICE-40C Owner's Manual

OM-2239 207 542C

November 2002

Processes

Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter

R

Spectrum 625

And ICE-40C Torch

Visit our website at

www.MillerWelds.com

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.

Today, the people that build and sell Miller products continue 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 operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.

WARNING

This product, when used
for welding or cutting,
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.)

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Plasma Arc Cutting Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers liés au coupage à l’arc au plasma 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symbols And Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Specifications For Torch 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Torch Dimensions And Weight 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Unit Dimensions, Weight, And Movement 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connecting Work Clamp and Gas/Air Supply 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Electrical Service Guide 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Extension Cord Data 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Selecting A Location And Connecting Input Power 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or

Champion 10,000 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Installing Alternative Plug 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Setting Gas/Air Pressure 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Cutting Speed 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Trigger Safety Lock 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Plasma Cutting System Practices 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Sequence Of Cutting Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Sequence Of Gouging Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Sequence Of Piercing Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection: Status Lights & Checking Shield Cup Shutdown System 23. . . . . . . . . . .

5-3. Checking/Replacing Retaining Cup, Tip, And Electrode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Torch And Work Cable Replacement 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Troubleshooting Power Source 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Troubleshooting Torch 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAM 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PARTS LIST 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-2239

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

pom _nd_9/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Plasma Arc Cutting Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

CUTTING can cause fire or explosion.

Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and burns. Check
and be sure the area is safe before doing any cutting.

D Protect yourself and others from flying sparks and hot metal.
D Do not cut where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this

is not possible, tightly cover them with approved covers.

D Be alert that sparks and hot materials from cutting can easily go

through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that cutting on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not cut on closed containers such as tanks or drums.
D Connect work cable to the work as close to the cutting area as prac-

tical to prevent cutting current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.

D Never cut containers with potentially flammable materials inside –

they must be emptied and properly cleaned first.

D Do not cut in atmospheres containing explosive dust or vapors.
D Do not cut pressurized cylinders, pipes, or vessels.
D Do not cut containers that have held combustibles.
D Wear oil-free protective garments 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 combustibles, such as a butane lighter or matches,

from your person before doing any cutting.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

D Do not touch live electrical parts.
D Wear dry , hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats or

covers big enough to prevent any physical contact with the work or
ground.

D Do not touch torch parts if in contact with the work or ground.
D Turn off power before checking, cleaning, or changing torch parts.
D Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA CFR

1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its Owner’s

Manual and national, state, and local codes.

D Check and be sure that input power cord ground wire is properly

connected t o ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet – always verify
the supply ground.

D When making input connections, attach proper grounding conduc-

tor first.

D Frequently inspect input power cord for damage or bare wiring – re-

place cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.
D Inspect and replace any worn or damaged torch cable leads.
D Do not wrap torch cable around your body.
D Ground the workpiece to a good electrical (earth) ground if required

by codes.

D Use only well-maintained equipment. Repair or replace damaged

parts at once.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Do not bypass or try to defeat the safety interlock systems.
D Use only torch(es) specified in Owner’s Manual.
D Keep away from torch tip and pilot arc when trigger is pressed.
D Clamp work cable with good metal-to-metal contact to workpiece

(not piece that will fall away) or worktable as near the cut as
practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

ELECTRIC SHOCK can kill.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also

higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but also uses torches designed with safety
interlock systems which turn of f the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. Incorrectly
installed or improperly grounded equipment is a hazard.

live when power is on. Plasma arc cutting requires

SIGNIFICANT DC VOLTAGE exists on
internal parts of inverter power
sources AFTER the removal 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.

OM-2239 Page 1

EXPLODING PARTS can injure.

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.

FLYING SPARKS can cause injury.

Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.

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 can burn eyes and skin.

Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.

D Wear face protection (helmet or shield) with correct shade of filter to

protect your face and eyes 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 provided 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 and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather and 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 – 80

#4
#5
#6
#8

NOISE can damage hearing.

Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).

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 exhaust at the arc to remove

cutting fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the manufac-

turer’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 if necessary, while wearing an air­supplied 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 cause injury.

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.

CYLINDERS can explode if damaged.

Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylin­ders are normally part of metalworking processes,
be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, 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 Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and CGA publication P-1 listed in Safety
Standards.

OM-2239 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on torch.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

FLYING METAL can injure eyes.

D Wear safety glasses with side shields or face

shield.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before go-

ing near plasma arc cutting operations.

OVERUSE can cause OV E RHEATING.

D Allow cooling period; follow rated duty cycle.
D Reduce amperage (thickness) or reduce duty

cycle before starting to cut again.

FIRE OR EXPLOSION hazard.

D Do not locate unit on, over, or near combustible

surfaces.

D Do not install unit near flammables.

D Do not overload building wiring – be sure power supply system is

properly sized, rated, and protected to handle this unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

H.F. RADIATION can cause interference.

D High frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with elec-

tronic equipment perform this installation.

D The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the equipment

at once.

D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

EXPLODING HYDROGEN hazard.

D When cutting aluminum underwater or with the

water touching the underside of the aluminum,
free hydrogen gas may collect under the work­piece.

D See your cutting engineer and water table instructions for help.

FALLING UNIT can cause injury.

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 move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

ARC CUTTING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D T o reduce possible interference, keep cables as short as possible,

close together, and down low, such as on the floor.

D Locate cutting operation 100 meters from any sensitive electronic

equipment.

D Be sure this cutting power source is installed and grounded

according t o this manual.

D If interference still occurs, the user must take extra measures such

as moving the machine, using shielded cables, using line filters, or
shielding the work area.

OM-2239 Page 3

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W . LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten­dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.
Recommended Practices for Plasma Arc Cutting, American Welding

Society Standard A WS C5.2, from American W elding Society, 550 N.W.
LeJeune R d , M i a m i , F L 3 3 1 2 6

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Batterymarch Park, Quincy, MA 02269.

1-5. EMF Information

Considerations About Welding Or Cutting And The Effects Of Low
Frequency Electric And Magnetic Fields

Welding or cutting current, as it flows through the welding or cutting
cables, will cause electromagnetic fields. There has been and still is
some concern about such fields. However, after examining more than
500 studies spanning 17 years of research, a special blue ribbon
committee of the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a human­health hazard.” However, studies are still going forth and evidence
continues t o b e examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following proce­dures:

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou­levard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep cutting power source and cables as far away from operator
as practical.

5. Connect work clamp to workpiece as close to the cut as possi­ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

OM-2239 Page 4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION

pom_nd_fre_9/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.

Y Identifie un message de sécurité particulier.

. Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers liés au coupage à l’arc au plasma

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des ris­ques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVE-
MENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directi­ves ci-dessous afin de connaître les mesures à prendre pour éviter tout dan­ger.

Y Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant e t suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu­rité énumérées à la section 1-5. V euillez lire et respecter toutes
ces normes de sécurité.

Y L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

Y Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrement les enfants.

LE COUPAGE présente un risque de
feu ou d’explosion.

Des particules de métal chaud et des étincelles
peuvent jaillir de la pièce au moment du coupage.
Les étincelles et le métal chaud, la pièce à couper

feu ou des brûlures. Avant d e commencer à travailler, assurez–vous
que l’endroit est sécuritaire.

D Protégez–vous, ainsi que toute autre personne travaillant sur les

lieux, contre les étincelles et le métal chaud.

D Ne coupez pas dans un endroit où des étincelles pourraient attein-

dre des matières inflammables.

D Déplacez toute matière inflammable se trouvant à l’intérieur d’un

périmètre de 10,7 m (35 pi) de la pièce à couper. Si cela est impos­sible, vous devez les couvrir avec des housses approuvées et bien
ajustées.

D Assurez–vous qu’aucune étincelle ni particule de métal ne peut se

glisser dans de petites fissures ou tomber dans d’autres pièces.

D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours

un extincteur à la portée de la main.

D Si vous coupez sur un plafond, un plancher ou une cloison, soyez

conscient que cela peut entraîner un feu de l’autre côté.

D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou u n b i-

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 dé-
charge électrique ou un feu.

D Ne coupez jamais des contenants qui peuvent contenir des matiè-

res inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.

D Ne coupez pas dans un endroit où l’atmosphère risque de contenir

de la poussière ou des vapeurs explosives.

D Ne coupez pas de bouteilles, de tuyaux ou de contenants pressuri-

sés.

D Ne coupez pas de contenants qui ont déjà reçu des combustibles.
D Portez des vêtements de protection exempts d’huile tels que des

gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.

D Ne placez pas le poste sur une surface combustible ou au–dessus

de celle–ci.

D Avant le coupage, retirez tout combustible de vos poches, par

exemple u n b r i q u e t a u butane ou des allumettes.

chauffée et l’équipement chaud peuvcnt causer un

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le fait de toucher à une pièce électrique sous
tension peut donner une décharge fatale ou entraî-
ner des brûlures graves. Le chalumeau et le circuit

poste est sous tension. L’alimentation d’entrée et les circuits internes
de l’appareil le sont également. Le coupage au plasma d’arc exige des
tensions plus élevées que le soudage pour amorcer et maintenir l’arc
(souvent de 200 à 400 V CC), c’est pourquoi on fait appel à des
chalumeaux conçus avec un système de verrouillage sécuritaire qui
met l’appareil hors tension lorsque la capsule anti–feu est desserrée
ou si le tube touche l’électrode à l’intérieur de la buse. Un poste
incorrectement installé ou inadéquatement mis à la terre constitue un
danger.

D Ne touchez pas aux pièces électriques sous tension.
D Portez des gants isolants et des vêtements de protection secs et

sans trous.

D Isolez–vous d e l a p i èce à couper et du sol en utilisant des housses

ou des tapis assez grands afin d’éviter tout contact physique avec
la pièce à couper ou le sol.

D Ne touchez pas aux pièces du chalumeau si vous êtes en contact

avec la pièce à couper ou le sol.

D Mettez l’appareil hors tension avant d’effectuer la vérification, le

nettoyage ou le changement d’une pièce du chalumeau.

D Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’ef-

fectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation
selon la norme OSHA 29 CFR 1910.147 (reportez–vous aux Princi-
pales normes de sécurité).

D Installez l e poste correctement et mettez–le à la terre convenable-

ment selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.

D Assurez–vous que le fil de terre du cordon d’alimentation est cor-

rectement relié à la borne de terre dans la boîte de coupure ou que
la fiche du cordon est branchée à une prise correctement mise à la
terre – vous devez toujours vérifier la mise à la terre.

D Avant d’effectuer les connexions d’alimentation, vous devez relier

le bon fil de terre.

D Vérifiez f r équemment 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 Vérifiez et remplacez les cosses du câble du chalumeau si elles

sont usées ou altérées.

D Le câble du chalumeau ne doit pas s’enrouler autour de votre corps.
D Si les normes le stipulent, la pièce à couper doit être mise à la terre.
D Utilisez uniquement de l’équipement en bonne condition. Réparez

ou remplacez immédiatement toute pièce altérée.

D Portez un harnais de sécurité si vous devez travailler au–dessus du

sol.

D Assurez–vous que tous les panneaux et couvercles sont correcte-

ment en place.

D N’essayez pas d’aller à l’encontre des systèmes de verrrouillage

de sécurité ou de les contourner.

D Utilisez uniquement le ou les chalumeaux recommandés dans le

manuel de l’opérateur.

D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ-

chette est enfoncée.

D Le câble de masse doit être pincé correctement sur la pièce à cou-

per, métal contre métal (et non de telle sorte qu’il puisse se
détacher), o u sur la table de travail le plus près possible de la ligne
de coupage.

de masse sont automatiquement actifs lorsque le

OM-2239 Page 5

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

Il y a DU COURANT CONTINU IMPORTANT dans
les convertisseurs après la suppression de l’ali-
mentation électrique.

D Arrêter les convertisseurs, débrancher le courant électrique, et dé-

charger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.

DÉCHARGES ÉLECTRIQUES poten­tiellement mortelles.

Les pièces internes des sources d’ali-
mentation de l’inverseur ont DES
CHARGES C.C. SIGNIFICATIVES
même APRÈS coupure du courant
d’alimentation.

D Mettre l’unité hors tension, mesurer la tension des condensateurs

d’entrée et s’assurer qu’elle est pratiquement nulle avant de touch­er à l’une quelconque des pièces. Mesurer cette tension conformé-
ment aux directives énoncées à la section Entretien du manuel de
l’utilisateur ou du manuel technique avant de toucher à l’une quel­conque des pièces.

Risque de blessure en cas
D’EXPLOSION DES PIÈCES.

D Mise sous tension, toute pièce défectueuse des

sources d’alimentation de l’inverseur peut explo-
ser ou faire exploser d’autres pièces. Pour entre­tenir les inverseurs, toujours porter un masque
protecteur et un vêtement à manches longues.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

Le coupage plasma produit des étincelles et projections de
métal à très haute température. Lorsque la pièce refroidit,
du laitier peut se former.

D Portez une visière ou des lunettes de sécurité avec des écrans laté-

raux approuvées.

D Portez des vêtements de protection adéquats afin de protéger votre

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 peuvent en­traîner des brûlures aux yeux et à la
peau.

Les rayons d’arc provenant du procédé de coupage

(ultraviolets et infrarouges) qui peuvent entraîner des brûlures aux yeux et à la
peau.

D Lorsque vous coupez ou regardez quelqu’un couper, portez un mas-

que ou un écran facial avec le filtre approprié. La norme ANSI Z49.1
(reportez–vous aux Principales normes de sécurité) suggère d’utiliser
un filtre de teinte nd 9 (nd 8 étant le minimum) pour tout travail de cou­page faisant appel à un courant de moins de 300 A. On mentionne
également dans la norme Z49.1 qu’un filtre plus faible peut être utilisé
lorsque l’arc est caché par la pièce à couper. Comme cela est habi­tuellement le cas pour les travaux de coupage à faible courant, les
teintes énumérées au tableau 1 sont fournies à titre d’information pour
l’opérateur.

D Porter des lunettes de sécurité à coques latérales sous votre casque

ou écran facial.

D Ayez recours à des écrans protecteurs ou à des rideaux pour protéger

les autres contre les rayonnements et les éblouissements; prévenez
toute personne sur les lieux de ne pas regarder l’arc.

D Portez des vêtements confectionnés avec des matières résistantes

et ignifuges (cuir et laine) et des bottes de protection.

produisent des rayons visibles et invisibles intenses

Tableau 1. Protection des yeux pour le coupage au plasma d’arc

Intensité de courant en ampères Filtre de teinte (minimum)

Moins de 20 no. 4

20 – 40 no. 5
40 – 60 no. 6
60 – 80 no. 8

LE BRUIT peut endommager l’ouïe.

Certaines applications de coupage produisent un bruit
constant, ce qui peut endommager l’ouïe si le niveau
sonore dépasse les limites permises par l’OSHA (repor­tez–vous aux Principales normes de sécurité).

D Utilisez des protège–tympans ou un serre–tête antibruit si le niveau

sonore est élevé.

D Prévenez toute personne sur les lieux du danger relié au bruit.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le coupage produit des vapeurs et des gaz. Respirer
ces vapeurs et ces gaz peut être dangereux pour la
santé.

D Ne mettez pas votre tête au–dessus des vapeurs. Ne respirez pas ces

vapeurs.

D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce ou

ayez recours à une ventilation aspirante installée près de l’arc pour
évacuer les vapeurs et les gaz.

D Si la ventilation est médiocre, utilisez un respirateur anti–vapeurs

approuvé.

D Veuillez lire le Material Safety Data Sheets (MSDS) et les instructions

du fabricant pour obtenir plus de renseignements sur les métaux à
couper, les enrobages et les nettoyants.

D Travaillez dans un espace restreint uniquement s’il est bien ventilé ou

si vous portez un respirateur anti–vapeurs. Les vapeurs causées par
le coupage et l’épuisement de l’oxygène peuvent altérer la qualité de
l’air et entraîner des blessures ou la mort. Assurez–vous que l’air am­biant est sain pour la santé.

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 n e soit ôté de la surface du métal à couper, que l’endroit où
vous travaillez ne soit bien ventilé, ou, si nécessaire, que vous ne por­tiez un respirateur anti–vapeurs. Les enrobages ou tous métaux qui
contiennent ces éléments peuvent créer des vapeurs toxiques s’ils
sont coupés.

D Ne coupez pas de contenants qui renferment ou ont renfermés des

matières toxiques ou réactives – vous devez en premier lieu les vider
et les nettoyer convenablement.

LE PLASMA D’ARC peut entraîner
des blessures.

La chaleur dégagée par le plasma d’arc peut entraîner de
sérieuses brûlures. La force de l’arc est un facteur qui
s’ajoute au danger de brûlures. La chaleur intense et la
puissance de l’arc peuvent rapidement passer au travers
de gants et de tissus.

D N’approchez pas le tube du chalumeau.
D Ne saisissez pas la pièce à couper près de la ligne de coupage.
D L’arc pilote peut causer des brûlures – n’approchez pas le tube du cha-

lumeau lorsque vous avez appuyé sur le gâchette.

D Portez des vêtements de protection adéquats qui recouvrent tout vo-

tre corps.

D Ne pointez pas le chalumeau en direction de votre corps ni de la pièce

à couper lorsque vous appuyez sur la gâchette – l’arc pilote s’allume

automatiquement.

D Mettez l’alimentation hors tension et débranchez le cordon d’alimen-

tation avant de démonter le chalumeau ou de changer une pièce du
chalumeau.

OM-2239 Page 6

D Utilisez uniquement le ou les chalumeaux recommandés dans le ma-

nuel de l’opérateur.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz contiennent du gaz sous haute
pression. Si une bouteille est endommagée, elle peut
exploser. Puisque les bouteilles de gaz font habituellement
partie d’un processus de travail des métaux, assurez–vous
de les manipuler correctement.

D Protégez les bouteilles de gaz comprimé contre la chaleur excessive,

les chocs mécaniques, le laitier, la flamme, les étincelles et l’arc.

D Installez et attachez les bouteilles dans la position verticale à l’aide

d’une cha îne, sur un support stationnaire ou un châssis porte–bouteil-
le afin de prévenir qu’elles ne tombent ou 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 chalumeau

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’application déterminée. Gar­dez–les, ainsi que toute autre pièce associée, en bonne condition.

D Détournez votre visage du détendeur–régulateur lorsque vous ouvrez

la soupape de la bouteille.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

vous utilisez la bouteille ou qu’elle est reliée pour usage ultérieur.

D Lisez et suivez les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P–1 de la CGA mentionné dans
les Principales normes de sécurité.

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

DES PIECES CHAUDES peuvent pro­voquer des brûlures graves.

D Ne pas toucher des parties chaudes à mains nues.
D Laisser refroidir avant d’intervenir sur la torche.

DES ORGANES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels que

des ventilateurs.

D Maintenir fermés et verrouillés les portes, panneaux,

recouvrements et dispositifs de protection.

DES PARTICULES VOLANTES
peuvent blesser les yeux.

D Porter des lunettes de sécurité avec protections laté-

rales ou frontales.

LES CHAMPS MAGNÉTIQUES peuv­ent affecter les stimulateurs cardia­ques.

D Porteurs d e stimulateur cardiaque, restez à distance.
D Les porteurs sont priés de consulter leur médecin

avant d’approcher les opérations de coupage
plasma.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement; respecter le

cycle opératoire nominal.

D Réduire l’ampérage (épaisseur) avant de continuer à

couper ou réduire le facteur de marche.

Danger D’EXPLOSION
D’HYDROGÈNE.

D Lors du coupage d’aluminium partiellement ou totale-

ment immergé dans l’eau, de l’hydrogène libre peut
s’accumuler sous la pièce.

D Consultez votre ingénieur de coupage et les instruc-

tions de la table de coupage.

LA CHUTE DE L’APPAREIL peut
blesser.

D Utiliser l’anneau de levage uniquement pour soulever

l’appareil, NON PAS les chariot, les bouteilles de gaz
ou tout autre accessoire.

D Utiliser u n engin d’une capacité appropriée pour sou-

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.

lever l’appareil.

Risque D’INCENDIE OU
D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou à proximité

de surfaces infllammables.

D Ne pas installer l’appareil à proximité de produits in-

flammables

D Ne pas surcharger l’installation électrique – s’assurer que

l’alimentation est correctement dimensionné et protégé avant de
mettre l’appareil en service.

LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir­cuits 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 expédier des cartes PC.

LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.

D Le Rayonnement haute frequence (H.F.) peut provo-

quer des interférences avec les équipements de ra-
dio–navigation et de communication, les services de
sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des sour-

ces de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blind a ge p o ur r éduire les interfé-
rences éventuelles.

LE COUPAGE Ã L’ARC peut causer
des interférence.

D L’énergie électromagnétique peut gêner le fonction-

nement d’appareils électroniques comme des ordi­nateurs et des robots.

D Pour réduire la possibilité d’interférence, maintenir les câbles aussi

courts que possible, les grouper, et les poser aussi bas qu e po ss i bl e
(ex. par terre).

D Veiller à couper à une distance de 100 mètres de tout équipement

électronique sensible.

D S’assurer que la source de coupage est correctement branchée et

mise à la terre.

D Si l’interférence persiste, l’utilisateur doit prendre des mesures sup-

plémentaires comme écarter la machine, utiliser des câbles blindés
de des filtres, ou boucler la zone de travail.

OM-2239 Page 7

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut­ting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l ’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec­tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protec­tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme,
des champs magnétiques basse fréquence

Le courant de soudage ou de coupage passant dans les câbles de puis-
sance crée des causera des champs électromagnétiques. Il y a eu et
il y a encore un certain souci à propos de tels champs. Cependant,
après avoir examiné plus de 500 études qui ont été faites pendant une
période d e recherche de 17 ans, un comité spécial ruban bleu du Natio-
nal Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs ma-
gnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait sou­haitable de réduire votre exposition aux champs électromagnétiques
pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.
3 Ne pas courber pas et ne pas entourer pas les câbles autour de

vous.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les consignes mentionnées précédemment font partie de celles desti­nées aux personnes ayant recours à un stimulateur cardiaque. Veuillez
consulter votre médecin pour obtenir plus de détails.

OM-2239 Page 8

SECTION 2 – DEFINITIONS

2-1. Symbols And Definitions

A
V

U

I

1max

IP

I

1eff

Amperes

Volts Increase

Protective Earth

(Ground)

On Off Percent Direct Current

Rated No Load

Voltage (A verage) U

0

Rated Maximum

Supply Current

Degree Of
Protection

Maximum Effective

Supply Current

I

2

pf

Plasma Arc Cutting

(PAC)

Single Phase Constant Current Voltage Input

1

Primary Voltage

Rated Welding

Current X

Loose Shield Cup Input

power factor

U

S

2

Adjust Air/Gas

Pressure

No – Do Not Do

This

Conventional Load

Voltage

Duty Cycle

Suitable for Some

Hazardous

Locations

Hz

S

1

Low Air Pressure

Light

Temperature

Line Connection

Single Phase

Static Frequency

Converter-

Transformer-

Rectifier

Hertz

KVA

OM-2239 Page 9

3-1. Specifications

SECTION 3 – INSTALLATION

Amperes Input at

Rated Load

50/60 Hz

Output 50/60 Hz

208 V 230 V KVA KW

Single-

Phase

33 30 6.8 6.7

3-2. Specifications For Torch

Air-cooled torch for plasma arc cutting (PAC)
50% duty cycle
Safety interlock devices disable power source
Safety trigger guard
Cutting capacity: see Section 3-1

3-3. Duty Cycle And 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 5 Minutes Resting

Overheating

Rated

Output

Output Output Gas

40 A @ 140

Volts DC,

50% Duty

Cycle

T ype of

Output

Direct

Current,

Straight
Polarity
(DCEN)

Plasma

Nitrogen

Rated

Gas

Air Or

Only

Cutting

Capacity Voltage DC

0.5 in

(12.7 mm)

At 16 IPM

Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.

If unit overheats, output stops,
temperature 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.

Y Exceeding duty cycle can

damage unit and void
warranty.

A

Maximum

Open-Circuit

260

3-4. Torch Dimensions And Weight

1 in (25 mm)

3.5 lb (1.6 kg) With 25 ft (7.6 m) Cable

OM-2239 Page 10

0

Minutes

15

1-3/8 in (35 mm)

8-3/8 in

(213 mm)

OR

Reduce Duty Cycle

sduty1 5/95 / Ref. 803 219

Ref. 801 397-A

3-5. Unit Dimensions, Weight, And Movement

17-1/4 in

Dimensions And Weight

57 lb (25.9 kg)

10-1/4 in

(260 mm)

(438 mm)

15-1/4 in

(387 mm)

Movement

Y Do not move or operate unit

where it could tip.

1 Lifting Handles
Use handles to lift unit.
2 Hand Cart
Use cart or similar device to move

unit.

loc_2 3/96 - Ref. 803 219 / 803 220

OM-2239 Page 11

3-6. Connecting Work Clamp and Gas/Air Supply

5

From Gas/Air Supply

1

2

1 Work Clamp
2 Workpiece
Connect work clamp to a clean,

paint-free location on workpiece, as
close to cutting area as possible.

. Use only clean, dry air with 90

to 150 psi (620 to 1035 kPa)
pressure. Prevent moisture
from entering air supply at
extreme cold temperatures.

3 Gas/Air Inlet Opening
4 Hose

. Hose must have a minimum

inside diameter of 3/8 in

3

4

Tools Needed:

Rear of Uni t

5/8, 1-1/8 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
supply.

Or
Install su p p l i e d q u i c k c o n n e c t male

1/4 in NPT pipe fitting.
Connect female quick connect

fitting t o pipe fitting.
Route hose to gas/air supply.

Y Incorrect plasma gas can

cause torch and power
source damage. Use only air
or nitrogen for the plasma
gas.

OM-2239 Page 12

Ref. 801 319-C / 803 221

3-7. Electrical Service Guide

50/60 Hz Models Single Phase

Input Voltage 208 230
Input Amperes At Rated Output 33 30
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Circuit Breaker 1, Time-Delay

Normal Operating

Min Input Conductor Size In AWG/Kcmil 10 10

Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil 10 10

Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.

2

3

40 35
50 45

80

(24)

98

(30)

3-8. Extension Cord Data

NOTE

Input Voltage

208 V 1 50/60

230 V 1 50/60

2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and

above).

Input Power

Phase

When calculating max. cord length, remember to include conductor length from
line disconnect device to input power receptacle.

Hertz

Time-Delay
Normal Operating 350 A

Time-Delay
Normal Operating 345 A

Fuse Size Or

Circuit Breaker Rating

2

2

40 A

35 A

Conductor Size Max. Cord Length

10 AWG 80 ft (24 m)

10 AWG 98 ft (30 m)

OM-2239 Page 13

3-9. Selecting A Location And Connecting Input Power

18 in (457 mm) of
space for airflow

X35

U0

S

260V
1

Hz

50/ 60
S1 U1=

U1=

6.8KVA

16.5A – 40A @ 140V

U2

208V
230V

I2

—

50%
40A

140V

pf =

.99

I1 max= I1 eff=

33A

I1 max= I1 eff=

30A

X@40

1

SERIALNO.STOCK NO.

—

—

—

—
—

—

LR5071

23A
21A

USC

Y Do not move or operate unit

where it could tip.

= GND/PE

Y Always connect

grounding conductor first.

Green Or

Green/Yellow

5

L1 (Black)

L2 (White)

1 Rating Label
Supply correct input power.
2 Plug (NEMA Type 6-50P)
3 Receptacle

(NEMA Type 6-50R)
Connect plug to receptacle.
4 Input And Grounding

Conductors

For single-phase operation:

Y Make input power

connections to the machine

before making connections

into a deenergized line

disconnect device. In the line

disconnect device, always

connect green or

green/yellow grounding

conductor to supply

grounding terminal first,

never to a line terminal.

Connect directly to line disconnect
device if hard wiring is required.

5 Line Disconnect Device
See Section 3-7.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 2 0 .

Install conductors into
a deenergized line
disconnect device.

4

2

3

L1L2

230 VAC, 1

208 959 / 803 222

OM-2239 Page 14

3-10. Wiring Optional 240 Volt Plug (119 172) For Connection To Bobcat, Trailblazer Or

Champion 10,000

1 Input And Grounding

Conductors

2 Plug Wired for 240 V, 2-Wire

Load

Tools Needed:

3/16 in

240V

2

3

4

7

5

5

6

8

6

7

3

Plug Front

View

3 Neutral (Brass) Terminal And

4

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 Or Green/Yellow

Ground Conductor

Y Always connect green or

green/yellow wire to ground
terminal, never to a load
terminal. Connect black (L1)
and white (L2) wires to load
terminals.

1

Y Engine Control Switch must be set at “RUN”

position – not “RUN/IDLE”.

8

Green Or

Green/Yellow

Y Set generator Fine Adjustment Control to 10

for maximum auxiliary power, if applicable.

Ref. 120 813-D / Ref. 803 222

OM-2239 Page 15

3-11. 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.

1

Tools Needed:

3-12. Setting Gas/Air Pressure

2

3

1 Supplied 230 VAC Plug
Cut cord close to plug.
2 Alternative Plug (230 VAC

2

3

6

7

4

5

Plug Shown)

3 Input (Black Lead)

(Brass) Terminal

4 Neutral (White Lead)

(Brass) Terminal

5 Ground (Green) Terminal
6 Outer Shell
7 Cord Grip
Strip cord jacket back enough to

separate conductors.
Strip conductors enough to make
good contact with plug terminals.
Make plug connections and reinstall
outer shell and cord grip. Tighten
assembly screws onto shell. Do not
overtighten.

Ref. 801 305-A / 801 611

1

4

Setting Gas/Air Pressure

Place Output Control in

Gas/Air Set Position

Power Switch On

Set Controls Turn On Gas/Air Supply Adjust Pressure

1 Power Switch
Place power switch in On position

Requires

90–150 PSI Supply

(620–1035 kPa)

2 Output Control
Place output control in Gas/Air position.
3 Pressure Gauge

Set To 75 PSI (517 kPa) For Cutting

Or 55 PSI (379 kPa) For Gouging

On Unit

Rear of Unit

Ref. 803 219 / 803 221

Select Desired

Amperage To
Begin Cutting

4 Gas/Air Pressure Adjustment Knob
Adjust pressure to 75 psi (517 kPa) on

pressure gauge by pulling and turning knob.
Push knob in to lock setting.

Select desired cutting output with Output
Control.

OM-2239 Page 16

4-1. Controls

4

SECTION 4 – OPERATION

1

3

2

5

1 Output Control
Use control to set cutting output.
Place control in Gas/Air Set position to safely

adjust gas/air pressure. Only gas/air circuit
is activated.

2 Status Lights (See Section 5-2)
3 Power Light

4-2. Cutting Speed

400
350
300
250
200
150
100

CutSpeed(in./min.)

50

6

4 Power Switch

. The fan will normally run for

approximately 5 seconds after power
switch is placed in the Off position.

5 Pressure Gauge
6 Pressure Adjustment Knob

Ref. 207 299

. At ambient temperatures below –55 C

(235 F), readjustment of gas/air
pressure regulator may be necessary
(see Section 3-12).
Use only clean, dry air with 90 to 15 0 ps i
(620 to 1035 kPa) pressure. Prevent
moisture from entering air supply at
extreme cold temperatures.

The cutting speed curve shows the
recommended maximum cutting
speed capabilities of the power
source and torch for mild steel of
various thickness.

The best cut quality is achieved by
cutting near the chart line. Cutting
below the line (too slow) will result
in excess dross. Cutting above the
line (too fast) will cause blowback
and lack of penetration.

0

16GA

1/8th 1/4th 3/8th 5/8th

(0.060)

MildSteelThickness(inches)

OM-2239 Page 17

4-3. Trigger Safety Lock

Trigger Locked Trigger Unlocked

4-4. Plasma Cutting System Practices

1 Trigger

1

801 397-A

The pilot arc starts immediately
when trigger is pressed.

Always connect work clamp to a clean,

paint-free location on workpiece, as close to

workpiece surface for proper cutting results.

(3.2 mm)

cutting area as possible.

90°

Maintain approximately a 90° angle to the

1/8 in

. Set correct air pressure for process:

75 PSI (517 kPa) for cutting,
55 PSI (379 kPa) for gouging.

Sparks should pass through the workpiece

and out the bottom when cutting.

Wt

DO NOT start pilot arc without cutting or

gouging as this shortens the service life

of the nozzle and electrode.

If sparks flare back from surface, this

usually is an indication that either travel

speed is too fast or amperage is set too low.

When doing extended (non-shielded)

cutting, maintain approximately 1/8 in

standof f between electrode and surface.

OM-2239 Page 18

DO NOT put pressure on shield when

drag cutting; instead, slide shield along

the surface for proper cutting results.

Pulling rather than pushing the torch

makes cutting easier. Use a proper guide

or template for accurate cutting operations.

801 400-B / Ref. 802 878

4-5. Sequence Of Cutting Operation

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

90°

For standard (shielded) cutting, place drag

shield on edge of metal. For extended

(non-shielded) cutting, use 1/8 in (3.2 mm)

standof f distance (dragging tip will reduce tip

area as possible.

life).

. Set air pressure to 75 PSI (517 kPa) for cutting.

The pilot arc starts immediately
when trigger is pressed.

Raise trigger lock and press

trigger. Pilot arc starts.

After cutting arc starts, slowly

start moving torch across metal.

Adjust torch speed so

sparks go thru metal and

out bottom of cut.

Pause briefly at end of

cut before releasing trigger.

Postflow continues for approx. 20 seconds

after releasing trigger; cutting arc can be

instantly restarted during postflow by raising

trigger lock and pressing trigger.

801 400-B

OM-2239 Page 19

4-6. Sequence Of Gouging Operation

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

area as possible.

455

Hold torch at approximately

45° angle to workpiece.

. Set air pressure to 55 PSI (379 kPa) for gouging.

The pilot arc starts immediately
when trigger is pressed.

Raise trigger lock and press trigger . Pilot

arc starts. Move tip to within approxi-

mately 3/16 in (4.8 mm). Start gouging

across workpiece surface. Maintain

approximately a 45° angle to surface.

Release trigger. Postflow continues for

approx. 20 seconds after releasing trigger;

arc can be instantly restarted during postflow

by raising trigger lock and pressing trigger.

801 400-B

OM-2239 Page 20

4-7. Sequence Of Piercing Operation

The pilot arc starts immediately
when trigger is pressed.

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

90°

Rotate torch to upright position

approximately 90° to surface.

When arc has pierced through

area as possible.

workpiece, start cutting.

. Set air pressure to 75 PSI

(517 kPa) for cutting.

90°

Maintain approximately 90° torch

position to surface, and continue

cutting.

Hold torch at an angle to t h e

workpiece. Raise trigger lock and

press trigger. Pilot arc starts.

Release trigger. Postflow continues for

approx. 20 seconds after releasing trigger;

arc can be instantly restarted during postflow

by raising trigger lock and pressing trigger.

801 400-B

OM-2239 Page 21

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

Check Torch

Tip, Electrode,

And Shield Cup

Replace

Unreadable

Labels

Replace

Cracked

Parts

Y Disconnect power

Each Use

Every Week

Check Shield

Cup Shutdown

System

3 Months

before maintaining.

. Maintain more often

during severe conditions.

Check Gas/Air

Pressure

Service Air
Filter/Regulator
Assembly Filter

Tape Torn Outer

Covering Or

Replace Cable

Check

Gas/Air Hose

OR

Check Torch

Body

6 Months

Blow Out Or

Vacuum Inside

OM-2239 Page 22

5-2. Overload Protection: Status Lights & Checking Shield Cup Shutdown System

If certain problems occur, a status
light comes on, and output stops.

1 Pressure Light
Lights if gas/air pressure is below

40 PSI (276 kPa).

1

2

3

Checking Torch Shield Cup Shutdown System

Power must be reset whenever the cup shutdown system is activated.

Always turn Off power when changing or checking consumables.

Shield

Cup

Turn power Off, and check for
proper gas/air pressure (see
Section 3-12).

A flashing Pressure light indicates
that gas/air system may be set too
low, faulty, leaking or has a flow
restriction (see Section 5-5).

2 Cup Light
Lights if shield cup is loose/off.
Turn Power On and loosen shield

cup. If shutdown system works
properly, Cup light comes on. If not,
turn power Off and have a factory
authorized service agent check
unit.

If system works properly, retighten
cup and reset power.

Turn power Off, and check shield
cup connection (see torch Owner’s
Manual). Power must be reset
whenever the cup shutdown is
activated.

A flashing Cup light indicates that
the torch consumables are stuck or
worn and should be inspected and/
or replaced (see Section 5-3).

Check shield cup shutdown system
once a week.

3 Temperature Light
Lights if power source overheats or

when ambient temperature is below
–20° C (–4° F) (see Section 3-3).

Fan-On-Demand
Cooling fan will operate during the

following conditions:

a Unit is in an OVERTEMP

condition. TEMP indicator
light will illuminate and fan
will run until unit cools
down.

b Unit gets hot during idle,

either from a change in
ambient air temperature or
after long periods of
cutting.

c Unit is i n cutting or postflow

mode.

Ref. 200 808 / Ref. 801 300-A

OM-2239 Page 23

5-3. 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. Be sure to use genuine replacement parts.

A good practice is to replace both the tip and electrode at the same time.

Turn Off power source before checking torch parts.

Make sure this area is clean of
any debris.

8

7

5

Make sure swirl ring is clean of any
debris and no holes are
obstructed.

Turn Off power source.

1 Drag Shield

2 Retaining Cup

Remove retaining cup. Check retaining cup
for cracks, and replace if necessary.

3Tip

6

New

Worn

2

1

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. If center has a pit more

than a 1/32 in (0.8 mm) deep, remove and
replace electrode.

6 Swirl Ring

4

3

New

Worn

1/32 in

(1 mm)

Pit

Remove swirl ring. Check ring, and replace
if side holes are plugged.

7 O-Ring
Check O-rings on torch. If needed, coat with

thin film of silicone lubricant (part no.
169 231). Replace if damaged.

8 Plunger Area
Check this area for any debris or foreign

material. Clean out if necessary.
Carefully reassemble parts in reverse order.

Ref. 803 224

OM-2239 Page 24

5-4. Torch And Work Cable Replacement

3

4

2

3

5

4

1

7

6

2

5

8

If torch or work cable needs to be removed
or replaced, proceed as follows:

Turn power Off, and disconnect input
power plug from receptacle. Remove
wrapper from unit.

Torch Replacement

1 Strain Relief
2 Torch Cable
Loosen outer strain relief pigtail so that

torch cable can slide freely .
3 Plug PLG1/Receptacle RC1
Disconnect PLG1 from receptacle RC1 o n

Control board PC1.
4 Plug PLG11/Receptacle RC11
Disconnect PLG11 from receptacle RC11

on Control board PC1.
5 Air Line Connector
Push orange fitting inward toward air

solenoid while pulling connector out of
fitting.

Remove nut, located inside of unit, from
back of strain relief.

Slide torch cable, connector, and plugs
through nut and out of unit. Retain nut for
use on replacement strain relief.

Insert replacement cable with strain relief
through opening where old cable and strain
relief were removed. Slide strain relief nut
over plugs, connector , and cable. Install nut
onto strain relief, but do not tighten.

Insert ai r line connector into solenoid fitting.
Connect PLG1 to RC1 on Control board

PC1.
Connect PLG11 to RC11 on Control board

PC1.
Tighten strain relief nut.
Tighten strain relief around cable.

Work Cable Replacement

6 Rubber Boot
7 Work Cable Ring Terminal
Slide rubber boot away from ring terminal

connection o n Control board PC1. Remove
hardware securing ring terminal to PC1.

8 Strain Relief
Remove nut, located inside of unit, from

back of strain relief.

Slide work cable through nut and out of unit.
Retain nut for use on replacement strain
relief.

Slide rubber boot over ring terminal and off
of work cable. Retain rubber boot for use on
replacement work cable.

. Be sure to allow some work cable

slack inside the unit.

Insert replacement cable with strain relief
through opening where old cable and strain
relief were removed. Slide strain relief nut
over ring terminal and cable. Install nut onto
strain relief, but do not tighten.

Route cable along bottom of unit and up to
PC1.

Slide rubber boot over ring terminal and
onto work clamp lead. Connect work cable
ring terminal to terminal labeled WORK on
circuit board PC1. Torque to 35 in lb
(4 N⋅m). Slide boot over connection.

Tighten strain relief nut.
Tighten strain relief around cable.

Tools Needed:

5/16, 3/8 in

803 386 / 803 385

OM-2239 Page 25

5-5. Troubleshooting Power Source

Is Power switch
S1 in the On
position?

Yes

Is Power light
flashing?

No

Is Cup Status
light On or
flashing?

No

Yes

Yes

Place Power switch in the
On position. (see Section
4-1).

Reset Power switch S1.

Check torch consumables/
cup. Reset Power switch
S1. *Check torch connec­tions. *Check Control board
PC1.

Does pilot arc
ignite?

Yes

Does pilot arc
transfer to
workpiece?

Yes

*
Check all connections,
Check main transformer T1,
Check boost inductor L1
and output inductor L2.
Return t o beginning of chart.

Press torch trigger and
check if pilot arc ignites.
Check torch consumables.

No

*Check torch connections,
air filter, pressure switch S3,
valve AS1, air supply
connection to unit, torch,
and PC1.

Place torch near workpiece
and check if pilot arc “jumps”
or transfers to workpiece.

No

Check work clamp
connection. *Check Control
board PC1 and connections,
and torch and its connections.

No

Is Temp Status
light On?

No

Is Pressure Status
light On or flashing?

No

Yes

Yes

NOTE: The fan will normally run for
approximately 5 seconds after power
switch is placed in the Off position (see
Section 4-1).

If unit is overheated, wait
while fan cools down unit
temperature.

Turn Output control
fully counterclockwise (see
Section 3-12). Check for
gas/air flow at torch. *Check
Control board PC1,
pressure switch, air filter,
valve AS1, and air supply
connection t o unit and torch.

OM-2239 Page 26

*Servicing procedure to be
performed only by authorized
Service Station.

5-6. Troubleshooting Torch

Does arc go
on and off
while cutting?

No

Does arc go out
while cutting?

Yes

Yes

Torch travel speed too slow;
increase travel speed (see
Section 4-5). Clean or
replace torch consumables
as necessary (see Section
5-3). Be sure work clamp is
securely attached to
workpiece.

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 4-5). Clean or
replace torch consumables
as necessary (see Section
5-3).

Go to Section 5-5.

Go to Section 5-5.

No

Do sparks come
out of top of cut;
or cut is not
clean?

No

Are Trouble
lights On; unit
has no cutting
output?

No

Go to Section 5-5.

Yes

Yes

Torch travel speed too fast;
reduce travel speed (see
Section 4-5). Clean or
replace torch consumables
as necessary (see Section
5-3). Be sure work clamp is
securely attached to
workpiece. Unit not capable
of cutting metals thicker
than rating (see Section
3-1).

Check torch consumables.
Check for gas/air flow at
torch. Check air supply con­nection and pressure to unit
and torch. Reset unit Power
switch. *Check torch and
connections inside unit.

Go to Section 5-5.

*Servicing procedure to be performed
only by authorized Service Station.

OM-2239 Page 27

SECTION 6 – ELECTRICAL DIAGRAM

OM-2229 Page 28

205 723

Figure 6-1. Circuit Diagram

SECTION 7 – PARTS LIST

19

28

32

33

22

4

18

3

9

26

10

35

13

29

38

23

23

not available unless listed.

6

. Hardware is common and

37

17

16

15

30

8

34

7

25

11

36

1

2

20

27

21

23

31

14

18

5

12

24

803 223

Figure 6-1. Main Assembly

OM-2239 Page 29

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 6-1. Main Assembly

1 204324 BASE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 204331 PANEL,FRONT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 204581 PANEL,REAR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 204583 WINDTUNNEL, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 204582 WRAPPER, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 T1 207296 XFMR,MAIN SPECTRUM 625 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 L1 207297 INDUCTOR,BOOST 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 L2 207298 INDUCTOR,OUTPUT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CT1 207300 XFMR,CURRENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 207137 FILTER,AIR W/FITTINGS & BRACKET 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202687 FILTER,AIR ELEMENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200878 FILTER,AIR 5 MICRON 1/4NPT PORTS W/DRAIN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204330 BRACKET,MTG FILTER/PC BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 207136 GAUGE,PRESSURE AIR W/FITTING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 207135 REGULATOR,AIR W/FITTINGS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 207134 VALVE,AIR SEALED W/PRESSURE SW/ FTGS/BRKT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AS1 206000 VALVE,24VDC 3 WAY 1/8NPT 3/32 ORF 100PSI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S2 174670 SWITCH,PRESSURE AIR 40PSI FIXED 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 207299 NAMEPLATE,MILLER SPECTRUM 625 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 204329 BRACKET,MTG CAPACITOR/VALVE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 208015 HANDLE,RUBBERIZED CARRYING 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 204326 CONSUMABLE STORAGE BOX,W/DOOR & LATCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 C85 192935 CAPACITOR,ELCTLT 2700 UF 450 VDC CAN 2.52 DIA W/NUT 1. . . . . . . . . . . . . . . . . . . .

19 188911 CABLE,POWER 12FT 8–10GA 3C 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 199020 CABLE,WORK 20FT NO8 W/CLAMP, STRAIN RELIEF & TERM 1. . . . . . . . . . . . . . . . . . . . . . . .

203988 CLAMP,WORK 150A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199995 CONTACT TIP,WORK CLAMP 150A 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 S1 124511 SWITCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 FM 208240 FAN,MUFFIN 24VDC 3000 RPM W/19.250 IN LEADS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 179276 BUSHING,SNAP–IN NYL 1.000 ID X 1.375 MTG HOLE CENT 7. . . . . . . . . . . . . . . . . . . . . . . . . .

24 173693 FOOT,MTG UNIT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601965 SCREW,375–16X1.00 HEX HD–PLN GR5 PLD 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010909 NUT,375–16 .56HEX .46H STL PLD ELASTIC STOP NUT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 174991 KNOB,POINTER 1.250 DIA X .250 ID W/SPRING CLIP–.21 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 177547 BUSHING,SNAP–IN NYL CT–MOUNT 1.125 MTG HOLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 175138 BOX,LOUVER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 186441 BUSHING,STRAIN RELIEF .710/ .980 ID X1.375 MTG HOL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 R1 207995 RESISTOR,WW FXD 50 W 25 OHM NI 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 208168 BAFFLE,AIR WINDTUNNEL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 208170 INSULATOR,SIDE RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 207997 GUARD,FAN 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 PC1 209884 KIT,REPLACEMENT CONTROL BD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 PC2 192965 CIRCUIT CARD ASSY,LED/POT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 PC3 208417 CIRCUIT CARD ASSY,PRIMARY CONNECT/FILTER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 195110 ICE–40C 25FT HAND HELD REPLACEMENT TORCH OR. . . . . . . . . . . . . . . .

195111 ICE–40C 50FT HAND HELD REPLACEMENT TORCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 207653 LABEL,CAUTION/WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 185835 LABEL,WARNING ELECTRIC SHOCK 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2239 Page 30

NOTE: The ICE-40C torch is specifically for use
only with this plasma cutting unit.

1

2

See Figure 6-3 for additional

consumable parts.

Part

Item

No.

No. Description

195 110 ICE-40C 25ft Torch
195 111 ICE-40C 50ft Torch

1 183 427 Handle Assy, complete (1)
2 192 059 Main Body (1)
3 209 298 Leads, 25ft (1)
3 209 299 Leads, 50ft (1)
4 185 833 Switch Assembly

5 171 248 Push Button Switch (1)
6 190 220 Spring, trigger assembly

169 231 Grease, silicone (1)

w/spring (1)

5

6

3

4

Ref. 195 092 / Ref. 803 224

Figure 6-2. Torch, ICE-40C

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2239 Page 31

For extended tip use, set Amperage control to 35.

Drag Shield

204 323

Deflector

177 888

Shield

192 203

Retaining Cup

Retaining Cup

Retaining Cup

NOTE:

Set air pressure to
75 PSI for cutting or
55 PSI for gouging.

ICE–40C

CONSUMABLES

192 050

192 050

192 050

Tip

204 325

35A Tip
192 052

Tip

204 332

Electrode

192 047

Electrode

192 048

Electrode

192 047

Swirl Ring

192 049

Standard

Cutting

Extended

Cutting 1/8” (3mm)

Gouging

O–Ring

169 232

Apply silicone
grease (169 231)
before installing.

stand–off

recommended

CAUTION

FAIL URE TO RE–
PLACE WORN TIP
OR ELECTRODE
WILL RUIN TORCH
AND VOID
WARRANTY .

Turn off power before

•

checking torch parts.
Check before each

•

use and hourly
during operation.

Figure 6-3. Consumable Parts For ICE-40C

207 686–A

207 686-A

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-2239 Page 32

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Notes

Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.

Y our distributor also gives
you ...

Service

Y ou 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.

Effective January 1, 2002

(Equipment with a serial number preface of “LC” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers
* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by
the engine manufacturer .)

3. 1 Year — Parts and Labor Unless Specified

* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Maxstar 85, 140
* Spot Welders
* Load Banks
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

Miller’s True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on B o b cat, Trailblazer, and Legend models.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation bas e d u p o n a c tual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. I N N O EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.

miller_warr 6/02

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

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

Miller Electric Mfg. Co.

An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: [phone] Auto-At t ended
USA & Canada FAX: [phone]
International FAX: [phone]

European Headquarters –
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

PRINTED IN USA  2002 Miller Electric Mfg. Co. 8/02

File a claim for loss or damage during
shipment.

For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.