Miller Spectrum 375, XT30C Owner's Manual

OM-255 590A 2011−12

Processes

Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter

R

Spectrum 375

And XT30C Torch

Visit our website at

www.MillerWelds.com

File: Plasma Cutters

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 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 or individual specification 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.

Mil_Thank 2009−09

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. California Proposition 65 Warnings 4.......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4......................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Signification des symboles 5.............................................................

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

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7......

2-4. Proposition californienne 65 Avertissements 9...............................................

2-5. Principales normes de sécurité 9..........................................................

2-6. Informations relatives aux CEM 9.........................................................

SECTION 3 − DEFINITIONS 10...................................................................

3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label 10......................

SECTION 4 − INSTALLATION 11..................................................................

4-1. Unit Specifications 11....................................................................

4-2. Duty Cycle And Overheating 13............................................................

4-3. Torch Dimensions And Weight 13..........................................................

4-4. Serial Number And Rating Label Location 14.................................................

4-5. Selecting A Location 14...................................................................

4-6. Connecting Gas/Air Supply 15.............................................................

4-7. Connecting Work Clamp 15...............................................................

4-8. Electrical Service Guide 16................................................................

4-9. Extension Cord Data 16..................................................................

4-10. Primary Changeover Switch 16............................................................

4-11. Installing Alternative Plug 17...............................................................

SECTION 5 − OPERATION 18....................................................................

5-1. Controls 18.............................................................................

5-2. Cutting Speed 19........................................................................

5-3. Trigger Safety Lock 19...................................................................

5-4. Plasma Cutting System Practices 20........................................................

5-5. Sequence Of Cutting Operation 21.........................................................

5-6. Sequence Of Piercing Operation 22........................................................

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 23...........................................

6-1. Routine Maintenance 23..................................................................

6-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System 24..................

6-3. Torch And Work Cable Connections 25......................................................

6-4. Checking/Replacing Retaining Cup, Tip, And Electrode 26......................................

6-5. Troubleshooting Power Source 27..........................................................

6-6. Troubleshooting Torch 28.................................................................

SECTION 7 − ELECTRICAL DIAGRAM 29..........................................................

SECTION 8 − PARTS LIST 30.....................................................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

pom_2011-10

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Plasma Arc Cutting Hazards

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 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

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 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 Do not cut where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
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 containers that have held combustibles, or on closed

containers such as tanks, drums, or pipes unless they are properly
prepared according to AWS F4.1 and AWS A6.0 (see Safety Stan­dards).

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, sparks, and fire hazards.

D Do not use plasma cutter to thaw frozen pipes.
D Never cut containers with potentially flammable materials inside −

they must be emptied and properly cleaned first.

D Do not cut where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Do not cut pressurized cylinders, pipes, or vessels.
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.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

. Indicates special instructions.

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

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 may also use torches designed with safety
interlock systems which turn off 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.

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, ground, and operate 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 to 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 Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

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.

live when power is on. Plasma arc cutting requires

OM-255 590 Page 1

ELECTRIC SHOCK can kill.

FUMES AND GASES can be hazardous.

SIGNIFICANT DC VOLTAGE exists in
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.

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 injure.

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 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 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, 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

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.

OM-255 590 Page 2

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.

CYLINDERS can explode if damaged.

Compressed 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, physical damage, slag, open flame, sparks, and arcs.

D Install and secure cylinders in an upright position by chaining them

to a stationary support or equipment cylinder rack to prevent falling
or tipping.

D Keep cylinders away from any cutting or other electrical circuits.
D Never allow electrical contact between a plasma arc torch and a

cylinder.

D Never cut on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and 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.

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

HOT PARTS can burn.

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

equipment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

MOVING PARTS can injure.

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

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or wear

face shield.

ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

OVERUSE can cause OVERHEATING.

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

cycle before starting to cut again.

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 EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift unit.

D If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manually
lifting heavy parts or equipment.

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.

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 To 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 to 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.

BATTERY EXPLOSION can injure.

D Do not use plasma cutter to charge batteries or

jump start vehicles unless it has a battery char­ging feature designed for this purpose.

OM-255 590 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting and Gouging, Ameri­can Welding Society Standard AWS C5.2, from Global Engineering
Documents (phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).

This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—phone
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field around
the welding circuit and welding equipment. EMF fields may interfere with
some medical implants, e.g. pacemakers. Protective measures for per­sons wearing medical implants have to be taken. For example, restrict
access for passers−by or conduct individual risk assessment for weld­ers. All welders should use the following procedures in order to minimize
exposure to EMF fields from the welding circuit:

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

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in the weld­ing circuit as possible.

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

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

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

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-255 590 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

pom_2011−10fre

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

. Indique des instructions spécifiques.

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

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 et 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. Veuillez lire et respecter
toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne doi­vent être confiés qu’à des personnes qualifiées.

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 de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.

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

dre des matières inflammables.

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

lieux, contre les étincelles et le métal chaud.

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 pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un bi-

don.

D Fixez le câble de masse sur la pièce à couper, le plus près possible

de la zone à couper afin de prévenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une
décharge électrique, d’étincelles ou un feu.

chauffée et l’équipement chaud peuvcnt causer un

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

D Ne pas utiliser le coupeur plasma pour dégeler des conduites ge-

lées.

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 quand l’atmosphère peut contenir des poussières,

gaz ou vapeurs (comme l’essence) inflammables.

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 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 Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

exemple un briquet au butane ou des allumettes.

UN CHOC ÉLECTRIQUE peut tuer.

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

des tensions plus importantes que le soudage pour amorcer et
maintenir l’arc (200 à 400VDC est typique), mais peut être utilisé avec
des torches équipées de systèmes de verrouillage de sécurité qui
arrêtent la machine en cas de buse desserrée ou si l’électrode touche
la tuyère. Incorrectly installed or improperly grounded equipment is a
hazard.

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 de la pièce 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.

live when power is on. Le coupage plasma nécessite

OM-255 590 Page 5

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 Prin­cipales normes de sécurité).

D Installer le poste correctement et le mettre à la terre convena-

blement selon les consignes du manuel de l’opérateur et les
normes nationales, départementales 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 Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau­des.

D Vérifiez fréquemment 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), ou sur la table de travail le plus près possible de la ligne
de coupage.

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

contact avec tout objet métallique.

DÉCHARGES ÉLECTRIQUES poten­tiellement mortelles.

Il reste une TENSION DC NON
NÉGLIGEABLE dans les sources de
soudage onduleur UNE FOIS
l’alimentation coupée.

D Mettre l’unité hors tension, mesurer la tension des condensa-

teurs d’entrée et s’assurer qu’elle est pratiquement nulle avant
de toucher à l’une quelconque des pièces. Mesurer cette tension
conformément 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
exploser ou faire exploser d’autres pièces.
Pour entretenir les inverseurs, toujours porter
un masque protecteur et un vêtement à man­ches longues.

LES ÉTINCELLES PROJETÉES
peuvent 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 la-

téraux approuvées.

D Portez des vêtements de protection adéquats afin de protéger vo-

tre peau.

D Ayez recours à des protège−tympans ou à un serre−tête ignifuges

afin d’éviter que les étincelles n’entrent dans vos oreilles.

LES RAYONS D’ARC peuvent entraî­ner des brûlures aux yeux et à la peau.

Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner
des brûlures aux yeux et à la peau.

D Une protection faciale (casque ou masque) avec des lunettes filt-

rantes de teinte adéquate est indispensable pour protéger le
visage et les yeux des rayonnements de l’arc et des étincelles
pendant la découpe ou en regardant simplement 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 cas-

que ou écran facial.

D Ayez recours à des écrans protecteurs ou à des rideaux pour pro-

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

D Portez des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

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 − 100 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

sécurité).
D Utilisez des protège−tympans ou un serre−tête antibruit si le ni-

veau sonore est élevé.

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

l’OSHA (reportez−vous aux Principales normes de

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.

OM-255 590 Page 6

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 Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais­seurs.

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

ou si vous portez un respirateur anti−vapeurs. Les vapeurs cau-
sées 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 galvani-

sés, contenant du plomb ou de l’acier plaqué au cadmium, à moins
que l’enrobage ne soit ôté de la surface du métal à couper, que l’en­droit où vous travaillez ne soit bien ventilé, ou 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 vi-
der et les nettoyer convenablement.

L’ARC PLASMA peut provoquer 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

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

chalumeau lorsque vous avez appuyé sur le gâchette.

D Portez des vêtements de protection adéquats qui recouvrent tout

votre corps.

chaleur intense et la puissance de l’arc peuvent

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’ali-

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

D Utilisez uniquement le ou les chalumeaux recommandés dans le

manuel de l’opérateur.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est endomma­gée, elle peut exploser. Puisque les bouteilles de

travail des métaux, assurez−vous de les manipuler correctement.
D Protégez les bouteilles de gaz comprimé contre la chaleur excessi-

ve, les chocs mécaniques, des dommages physiques, le laitier, la
flamme, les étincelles et l’arc.

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

d’une chaîne, sur un support stationnaire ou un châssis porte−bou­teille 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 chalu-

meau de plasma d’arc et une bouteille.

D Ne coupez jamais sur une bouteille pressurisée − une explosion en

résulterait.

D Utilisez uniquement des bouteilles de gaz comprimé , des déten-

deurs, 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 ou-

vrez 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 Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécu­rité.

gaz font habituellement partie d’un processus de

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la

maintenance

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher des parties chaudes à mains

nues.

D Prévoir une période de refroidissement avant

d’utiliser l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recom-

mandés et porter des gants de soudage et des vêtements épais
pour éviter les brûlures.

D Lorsque cela est nécessaire pour des travaux d’entretien et de

dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qua­lifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

Les PIÈCES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protec­tion.

OM-255 590 Page 7

LIRE LES INSTRUCTIONS.

E

D Lire et appliquer les instructions sur les

étiquettes et le Mode d’emploi avant l’instal­lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’entretien en respectant les manuels d’utilisation, les

normes industrielles et les codes nationaux, d’état et locaux.

DES PIECES DE METAL ou DES SA­LETES peuvent provoquer des bles­sures dans les yeux.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur

médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement; re-

specter le cycle opératoire nominal.

D Réduire l’ampérage (épaisseur) avant de con-

tinuer à couper ou réduire le facteur de marche.

Danger D’EXPLOSION
D’HYDROGÈNE.

D Lors du coupage d’aluminium partiellement ou

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

D Consultez votre ingénieur de coupage et les instructions de la

table de coupage.

L’EXPLOSION DE LA BATTERI
peut provoquer des blessures.

D Ne pas utiliser le découpeur plasma pour charger

des batteries ou faire démarrer des véhicules à
l’aide de câbles de démarrage, sauf si l’appareil
dispose d’une fonctionnalité de charge de
batterie destinée à cet usage.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

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 un engin d’une capacité appropriée

pour soulever l’appareil.

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

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

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

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 pro-

duits inflammables

D Ne pas surcharger l’installation électrique − s’assurer que l’alimen-

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

LES CHARGES ÉLECTROSTATI­QUES 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 FRÉ­QUENCE (H.F.) risque de provoquer
des interférences.

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

provoquer des interférences avec les équipe­ments de radio−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’appa-

reil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et et un blindage pour réduire les
interférences éventuelles.

LE COUPAGE Ã L’ARC peut causer
des interférence.

D L’énergie électromagnétique peut gêner le

fonctionnement 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 que possi­ble (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

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

OM-255 590 Page 8

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting and Gouging, Ameri­can Welding Society Standard AWS C5.2, from Global Engineering
Documents (phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).

Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver les

mains après toute manipulation.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry,

Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—phone
for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précé­dentes.

OM-255 590 Page 9

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

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label

A
V

U

I

1max

IP

I

1eff

Amperes

Volts Increase

Protective Earth

(Ground)

On Off Percent Direct Current

Rated No Load

Voltage (Average) 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

1 f1

Hz

S

1

Low Air Pressure

Light

Temperature

Line Connection

Single Phase

Static Frequency

f2

Transformer-

Rectifier-Converter

Hertz

Power Rating,
Product Of Voltage
And Current (KVA)

OM-255 590 Page 10

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

SECTION 4 − INSTALLATION

4-1. Unit Specifications

Power Supply
Input

Rated AC Phase and line frequency (Hz) 1 − Phase 60 Hz
Rated Input Voltage (U1) and rated Input Current (I1)

eff at rated output. I1 eff used to determine power

and I

1

cord rating

Power Factor/kVA/kW at Rated Output Volts AC RMS − (U1) Power Factor kVA/kW

Peak kW at Arc Stretch kW 7.0

Volts AC RMS − (U1) Amps RMS − (I1) I1 eff

115 VAC, 1−Phase 28.0 16.6
230 VAC, 1−Phase 14.0 8.3

115 VAC, 1−Phase (20 A) 0.99 3.32 / 3.25

230 VAC, 1−Phase 0.99 3.25 / 3.19

Output

Rated Open Circuit Voltage (U0) Type 288 Volts DC/Electrode Negative
Output Characteristic Constant Current

Rated Output Current and Voltage (I2, U2) at rated Input
Voltage (U1)

Output Current Range 14 − 27 A
Duty Cycle at 104°F (405C) and Rated Conditions

(U1, I1, U2, I2) based on a 10 minute period

Volts AC RMS - (U1) Amps DC - (I2) Volts DC - (U2)

115 VAC, 1−Phase 27 A 92 V
230 VAC, 1−Phase 27 A 92 V

Volts AC RMS - (U1) Amps DC − (I2) Duty Cycle %

115 VAC, 1−Phase 27 A 35%
230 VAC, 1−Phase 27 A 35%

−− −−

−− −−

−− −−

−−

−−

OM-255 590 Page 11

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General

Operating Temperature 5° to 104° F (−15° to 40° C)
IP Code − Degree of protection provided by enclosure IP23CS

IP − International Protection

2 − No ingress of foreign objects

≥12.5 mm (0.5 in.)

3 − No harmful ingress spraying

water

C − AC line circuits protected

against ingress of tool . 2.5 mm

dia x 100 mm long (0.1 in. x 4 in.)

S − Fan stationary during water

test

Toppling or tilting Up to 15° incline

Torch − The XT30C torch is intended for handheld use only. The torch conforms to IEC 60974-7 when used with the Spectrum 375.

Do not use this torch in combination with any other machines.
Gas Type Air or Nitrogen

Gas Quality

Gas Inlet Flow and Pressure 5.0 SCFM (142 L/min)

Gas Filtering Particulates to 5 microns
Mild Steel capacities (see Section 5-2 for cutting speeds vs material type and thickness)

Cooling Method Air
Duty Cycle of Torch 100% at 30 Amps
Rating of Electrical Controls (Trigger) 30 VDC at .1 Amps − − − −

Rating of Electrical Controls (Cup) 30 VDC at 1 Amp − − − −
Approved Systems Spectrum 375 w/XT30C torch
Trigger Protection Safety trigger guard
Safety Devices Safety interlock devices shut

Rated Capacity (edge start) 3/8 in. at 15 ipm (457 mm/min)*
Sever Cut Capacity (edge start) 5/8 in.
Pierce Capacity 3/16 in.
*Travel speeds are approximately 80% of maximum.

Dimensions 13-1/8 in. (333 mm) L

Plasma Cutter Weight 55 lb (25 kg) including torch − − − −
Requirements for the torch connection

S Use only compressed air which is free from dirt, oil, and water.
S Ensure that the connections are properly assigned and tightened.
S For torch replacement, see Miller torch manual Part No. OM-1593
S Ensure correct air pressure (flow pressure) and airflow (volume) are set. Insufficient airflow can lead to the torch overheating.

Clean, moisture−free,

oil−free

down power source

5-1/2 in. (140 mm) W

9 in. (229 mm) H

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

90 PSI (621 kPa)

Min

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

− − − −

120 PSI (827 kPa)

Max

. If the unit is operated from a 30* ampere, 115 volt circuit or a 15** ampere, 230 volt circuit, a different input power plug must be installed on the

power cord. See Section 4-11 for instructions.

*A 30 ampere branch circuit is recommended for maximum performance. Performance on a 20 ampere branch service may be limited due to the circuit
breaker or line fuse. Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse.

**A 15 ampere branch circuit is recommended for maximum performance. Performance on a 10 ampere branch service may be limited due to the circuit
breaker or line fuse. Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse.

OM-255 590 Page 12

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4-2. Duty Cycle And Overheating

For Units Connected to a 115 Volt Circuit
or a 230 Volt Circuit:

35% Duty Cycle At 27 amperes, 92 volts DC

35% duty cycle

3-1/2 Minutes Cutting 6-1/2 Minutes Resting

Overheating

Minutes

4-3. Torch Dimensions And Weight

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

If unit overheats, thermostat(s)
opens, output stops, Temperature
trouble light goes On, 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 duty cycle
can damage unit and void warranty.

A

0

15

OR

Reduce Duty Cycle

sduty1 5/95 / 804 486-B

Notes

1-3/16 in.

(30 mm)

2.2 lb (1.0 kg)

8-3/4 in.

(222 mm)

1-1/2 in.
(38 mm)

Ref. 253 554-A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-255 590 Page 13

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

4-4. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-5. Selecting A Location

8-1/2 in.

(216 mm)

Dimensions And Weight

49 lb (22.2 kg)
not including torch

*Add 13/16 in. (21 mm) for handle.

Movement

2

12-5/16 in.*

(313 mm)

16 in.

(406 mm)

1 Lifting Handle
Use handle to lift unit.
2 Hand Cart

1

Use cart or similar device to move
unit.

3 120 VAC Receptacle
To connect unit to 230 VAC input

power, a customer supplied plug is
necessary (see Section 4-11).

Locate unit near correct input
power supply.

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

Location And Airflow

(254 mm)

3

10 in.

(254 mm)

10 in.

loc_2 3/96 - Ref. 804 486-B / 804 487-B / 804 488-B

OM-255 590 Page 14

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4-6. Connecting Gas/Air Supply

Tools Needed:

5/8, 1-1/8 in.

3

. Use only clean, dry air with 90

to 120 psi (621 to 827 kPa)
pressure.

1 Gas/Air Inlet Opening
2 Hose
3 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.

4 Air Filter/Regulator
Adjust gas/air pressure according

1

to Section 5-1.

From Gas/Air

Supply

4-7. Connecting Work Clamp

2

4

802 787-C / Ref. 801 319-C / Ref. 804 486-B

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

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

1

2

Ref. 803 640-A

OM-255 590 Page 15

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

4-8. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.

50/60 Hz Single Phase

Input Voltage (V) 115 230
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Elec Serv 2011−04

Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the 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

above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

4

4

1

2

3

A 15 or 20

ampere individual

branch circuit

protected by

time-delay fuses

or circuit breaker

is required.

See Section 4-1

14

15
25
14
96

(29)

14

4-9. Extension Cord Data

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

Conductor Size − AWG (mm2)*

Single Phase AC

Input Voltage

115 156 (48) 98 (30) 62 (19) 39 (12) 24 (7)

230 624 (190) 391 (119) 246 (75) 155 (47) 98 (30)

*Conductor size is based on maximum 3% voltage drop

6 (13.3) 8 (8.4) 10 (5.3) 12 (3.3) 14 (2.1)

Maximum Allowable Cord Length in ft (m)

4-10. Primary Changeover Switch

2

1

Check input voltage available at site.
1 Changeover Switch
Switch is accessible through slot in rear

panel.
2 Changeover Switch Label
Look at label to find correct switch position.

OM-255 590 Page 16

! Be sure input power connection

meets all applicable national,
regional, and local electrical codes.

3 Grounded 120 VAC

Receptacle

! To use rated output (see

specifications), connect the unit to

Ref. 802 787-C

an individual branch circuit capable
of carrying the effective (eff) current
for the output being used. The unit
must have a properly sized plug
installed and the circuit must be
protected by properly sized fuses
or circuit breakers.

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

4-11. Installing Alternative Plug

. This procedure is necessary if the unit is to be connected to a 230 VAC receptacle,

or to a 115 VAC receptacle that requires a plug that is different from the supplied plug.

. See Section 4-10 for instructions on setting changeover switch for proper voltage.

3

6

1

Tools Needed:

7

1 Supplied 115 VAC Plug
Cut cord close to plug.
2 Alternative Plug (230 VAC

Plug Shown)
3 Load 1 (Brass) Terminal
4 Load 2 (Brass) Terminal
5 Ground (Green) Terminal

2

4

5

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.

Notes

Ref. 801 305-A / 801 611

OM-255 590 Page 17

5-1. Controls

4

ON

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

SECTION 5 − OPERATION

3

2

5

OFF

Setting Gas/Air Pressure

1

20

16

24

1

Requires

90-120 PSI

(621-827 kPa)

Supply

16

20

5

27

PRESSURE

60 PSI

6

24

Set To

60 PSI (414 kPa)

20

6

16

24

27

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.

If 22-27 amperes of cutting output is used
with 115 VAC input power, and the overload
protection on the input power circuit fre­quently opens, either reduce the cutting out-

OM-255 590 Page 18

put and/or the cut time or find more adequate
power (see Section 4-1).

2 Trouble Lights (See Section 6-2)
3 Power Light
4 Power Switch

Setting Gas/Air Pressure

5 Air Filter/Regulator
6 Pressure Adjustment Knob

27

Place Output control in Gas/Air position and
turn on gas/air supply. Lift knob and turn to
adjust pressure. Push knob down to lock in
setting.

Place Output control in desired cutting
output.

. At ambient temperatures below −55 C

(235 F), readjustment of gas/air
pressure regulator may be necessary.

Ref. 227 835-A / Ref. 804 486-B

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

5-2. Cutting Speed

Recommended Cut Speeds At 27 Amperes Output

Thickness Recommended Cut Speeds*

Inches mm ipm mm/min

1/8 3.2 70 1,778

Mild Steel

*Recommended Cut Speed is approximately 80% of maximum.

3/16 4.8 47 1,194

1/4 6.4 25 635
3/8 9.5 15 381
1/2 12.7 6 152

. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

Recommended Cut Speeds At 20 Amperes Output

Thickness Recommended Cut Speeds*

Inches mm ipm mm/min

Mild Steel

16 ga 1.5 162 4,115

3/16 4.8 26 660

1/4 6.4 18 457
3/8 9.5 7 178

*Recommended Cut Speed is approximately 80% of maximum.

. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

5-3. Trigger Safety Lock

Trigger Locked

Trigger Unlocked

1

1 Trigger

Ref. 253554-A

OM-255 590 Page 19

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

5-4. Plasma Cutting System Practices

! The pilot arc starts immediately

when trigger is pressed.

Always connect work clamp to a clean,

paint-free location on workpiece, as close to

90°

Maintain approximately a 90° angle to the

workpiece surface for proper cutting results.

cutting area as possible.

DO NOT start pilot arc without cutting or

gouging as this shortens the service life

of the nozzle and electrode.

Sparks should pass through the workpiece

and out the bottom when cutting.

If sparks flare back from surface, this

usually is an indication that either travel

speed is too fast or amperage is set too low.

1/16 in.

(1.6 mm)

When doing extended (non-shielded)

cutting, maintain approximately 1/16 in.

standoff between electrode and surface.

OM-255 590 Page 20

Wt

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.

Ref. 254 087-A

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

5-5. Sequence Of Cutting Operation

90°

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

! The pilot arc starts immediately

Raise trigger lock and press

trigger. Pilot arc starts.

area as possible.

when trigger is pressed.

For standard (shielded) cutting, place drag shield on edge

of metal. For extended (non-shielded) cutting, use 1/8 in.

(3.2 mm) standoff distance (dragging tip will reduce tip life).

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.

Ref. 254 087-A

OM-255 590 Page 21

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

5-6. Sequence Of Piercing Operation

! The pilot arc starts immediately

when trigger is pressed.

45°

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

Rotate torch to upright position

approximately 90° to surface.

When arc has pierced through

workpiece, start cutting.

area as possible.

90°

Hold torch at approximately 45°

to the workpiece. Raise trigger

lock and press trigger. Pilot arc

90°

Maintain approximately 90° torch

position to surface, and continue

cutting.

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.

OM-255 590 Page 22

Ref. 254 087-A

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

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

Each
Use

Every
Week

Every
3
Months

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

n Gas/Air Pressure n Torch Tip, Electrode,

n Shield Cup Shutdown

System

l Damaged Or Unreadable
Labels

And Shield Cup

~ Air Filter/Regulator l Cracked Parts n l Gas/Air Hose

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

Section 4-6,
6-4

Section 6-2

Section 8

Every
6
Months

n l Torch Body, Cable

OR

~ Inside Unit

OM-255 590 Page 23

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6-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System

1 Power Light
Light is steady if input power is

okay. Light flashes for the following
conditions:

1

2

3

4

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.
Do NOT overtighten torch shield cup. Gently finger tighten cup
onto torch.

Shield

Cup

a If input power is 115 volts

AC, but power supply is
less than 92 volts AC or
greater than 138 volts AC.

b If input power is 230 volts

AC, but power supply is
less than 194 volts AC or
greater than 276 volts AC.

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

2 Pressure Light
Lights if gas/air pressure is below

40 PSI (276 kPa).
Turn power Off, and check for

proper gas/air pressure (see
Section 5-1).

A flashing Pressure light indicates
that gas/air system may be set too
low, faulty, leaking or has a flow re­striction (see Section 6-5).

3 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 6-4).

Check shield cup shutdown system
once a week.

4 Temperature Light
Lights if power source overheats or

when ambient temperature is below

−35° C (−31° F) (see Section 4-2).

OM-255 590 Page 24

Ref. 200 808 / Ref. 253 554-A

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

6-3. Torch And Work Cable Connections

5

8

6

7

1

2

6

5

2

4

3

4

86 5

4

3

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 Connections

Remove existing torch cable from
unit.

1 Strain Relief
2 Torch Cable
Insert cable through strain relief.

Slide strain relief nut onto torch
cable, but do not tighten.

3 Air Line Connector
Insert air line connector into

solenoid fitting.
4 Plug PLG1/Receptacle RC1
Connect PLG1 from torch to

receptacle RC1 on end of wiring
harness connected to circuit board
PC1.

5 Ring Terminal And TORCH

RED Terminal

Connect ring terminal on end of red
leads to TORCH RED terminal.

6 Ring Terminal And TORCH

WHITE Terminal

Connect ring terminal on end of
white leads to TORCH WHITE
terminal.

Tighten strain relief nut.
Tighten strain relief around cable.

Work Cable Connections

Remove existing work cable from
unit.

7 Work Cable

. Be sure to allow some work

cable slack inside the unit.

Insert work cable with strain relief
into front panel.

Tighten strain relief nut. Tighten
strain relief around cable.

8 Work Cable Ring Terminal
Route cable under center baffle.

Connect ring terminal on end of
work cable to terminal labeled
WORK on circuit board PC1.

Tools Needed:

1/4 in.

804 489-C / Ref. 802 860 / 226 678-C

OM-255 590 Page 25

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

6-4. 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 signifi-

cantly 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.

6

4

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

3

2

New

Worn

Turn Off power source.

1 Shield Cup

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

2Tip

3 Opening

5

1

Remove tip. Check tip, and replace if open­ing 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.

4 Electrode
Check electrode. If center has a pit more

than a 1/16 in. (2 mm) deep, remove and re­place electrode.

New

1/32 in. (1 mm) to 1/16
in. (2 mm) maximum pit
depth depending on
acceptable cut quality

Worn

Ref. 253554-A

5 Swirl Ring

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

6 O-Ring
Check O-ring for cracks or worn spots, and

replace if necessary.

Carefully reassemble parts in reverse order.

OM-255 590 Page 26

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

6-5. Troubleshooting Power Source

Is input power
connected to
correct line
voltage?

Yes

Is Changeover
switch S2 in
the 115V or
230V position?

Yes

Does the breaker
trip when unit is set
on 115V?

No

Connect unit to proper input

No

voltage (see Section 4-10).

Place Changeover switch in

No

proper position for input
voltage (see Section 4-10).

Yes

Turn down output current.
(see Section 5-1).

Is Cup Status
light On or
flashing?

No

Is Temp Status
light On?

No

Is Pressure Status
light On or flashing?

No

Yes

Yes

Yes

Check torch consumables.
Reset Power switch S1.

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

*
Turn Output control

fully counterclockwise (see
Section 5-1). Check for
gas/air flow at torch. Check
Control board PC1,
pressure switch S3 (gauge),
air filter, valve AS1, and air
supply connection to unit
and torch.

Is Power switch
S1 in the On
position?

Yes

Is the cooling
fan running?

Yes

Is Power light
flashing?

No

No

No

Yes

Place Power switch in the
On position. (see Section
5-1).

*
Check Power switch S1 and

relay CR2 and thermistor R2
on PC2. Replace PC2 if R2
or CR2 are not functioning
correctly.

*

Reset Power switch S1
and verify line power
voltage (see Section 4-1).
Check relay CR2,
thermistor R2 on PC2,
and 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 buck inductor L2.
Return to 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.

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

OM-255 590 Page 27

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

6-6. 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 5-2). Clean or
replace torch consumables
as necessary (see Section
6-4). 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 5-4). Clean or
replace torch consumables
as necessary (see Section
6-4).

Go to Section 6-5.

Go to Section 6-5.

No

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

No

Is Trouble light
On; unit has no
cutting output?

No

Go to Section 6-5.

Yes

Yes

Torch travel speed too fast;
reduce travel speed (see
Section 4-1). Clean or
replace torch consumables
as necessary (see Section
6-4). Be sure work clamp is
securely attached to
workpiece. Unit not capable
of cutting metals thicker
than rating (see Section
4-1).

Check torch shield cup (see
Section 6-2); reset unit
Power switch. *Check torch
and connections inside unit.

Go to Section 6-5.

OM-255 590 Page 28

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

SECTION 7 − ELECTRICAL DIAGRAM

256 065-A

Figure 7-1. Circuit Diagram

OM-255 590 Page 29

SECTION 8 − PARTS LIST

8-1. Recommended Spare Parts

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Recommended Spare Parts

227877 Element, Filter Air 1................ .. ...................................................

255685 XT30C, 20 ft Hand Held (Replacement) 1................ .. ................................

227877 Cable, Work 20 ft 8 GA W/Clamp Strain RLF & TERM 1................ .. ...................

253524 LabeL, XT30C Consumables 1................ .. .........................................

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.

XT30C CONSUMABLES

FAILURE TO REPLACE WORN TIP OR
ELECTRODE WILL DAMAGE TORCH

CAUTION

Drag
Shield
249930

Retaining

AND VOID WARRANTY.

S

Turn off power before checking torch parts.

S

Check before each use and hourly during operation.

Cup

249932

Tip

249927

Swirl Ring

249931

Electrode

249926

O-Ring

249969

Extended Consumable

Shield Deflector

249933

Ref. 256 009-A

Figure 8-1. Consumable Parts For XT30C

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-255 590 Page 30

Item
No.

1

5

4

3

2

1

1 249 970 Torch Handle Kit (1)
2 249 971 Torch Trigger

3 255 686 Leads, 20 ft (1)
4 252 938 Torch Body Kit (1)
5 249 972 Torch Trigger Assembly

Part
No. Description

Microswitch (1)...............

w/Spring (1)
252 951 Grease, Silicone (1)
255 685 Torch, Replacement 20 ft (1)

See Figure 8-1 for

additional consumable parts.

Figure 8-2. Torch, XT30C

A complete Parts List is available on-line at www.MillerWelds.com

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-255 590 Page 31

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)

18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)

1/8 in. (.125 in.)

3/16 in. (.188 in.)

1/4 in. (.25 in.)

5/16 in. (.313 in.)

3/8 in. (.375 in.)

1/2 in. (.5 in.)

Notes

Warranty Questions?

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

Your distributor also gives
you ...

Service

You 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, 2011

(Equipment with a serial number preface of MB 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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to an
International distributor.

1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules

2. 3 Years — Parts and Labor
* Engine Driven Welding Generators

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

* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter

Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)

3. 2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and

Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)

guarantees or warranties expressed or implied.

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

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
based upon actual 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. IN NO 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 2011−01

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

Contact 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

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co. 2011−01

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.