Page 1
OM-1572A August 1993
Processes
Air Plasma Cutting
and Gouging
Description
Air-Cooled Plasma Arc Cutting (PAC)
Torch
APT-1000 Torch
Visit our website at
www.MillerWelds.com
Page 2
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
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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 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.
figure out what the problem is. The parts list
will then help you to decide which 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 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 .
Page 3
PLASMA ARC CUTTING SAFETY PRECAUTIONS
WARNING
PLASMA ARC CUTTING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In cutting, as in most jobs, exposure to certain hazards occurs. Cutting is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
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.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not cut where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the cutting arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
arc (200 to 400 volts dc are common), but also uses 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.
1. Do not touch live electrical parts.
2. Wear dry , hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
4. Do not touch torch parts if in contact with the work or ground.
5. Turn off power before checking, cleaning, or changing torch
parts.
6. Disconnect input power before installing or servicing this
equipment. Lockout/tagout input power according to OSHA CFR
1910.147 (see Safety Standards).
7. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
higher voltages than welding to start and maintain the
7. Do not cut on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the cutting area as
practical to prevent cutting current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Never cut containers with potentially flammable materials inside
– they must be emptied and properly cleaned first.
10. Do not cut in atmospheres containing explosive dust or vapors.
11. Do not cut pressurized cylinders, pipes, or vessels.
12. Do not cut containers that have held combustibles.
13. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
14. Do not locate unit on or over combustible surfaces.
15. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any cutting.
8. 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.
9. When making input connections, attach proper grounding
conductor first.
10. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
11. T urn off all equipment when not in use.
12. Inspect and replace any worn or damaged torch cable leads.
13. Do not wrap torch cable around your body.
14. Ground the workpiece to a good electrical (earth) ground if
required by codes.
15. Use only well-maintained equipment. Repair or replace
damaged parts at once.
16. Wear a safety harness if working above floor level.
17. Keep all panels and covers securely in place.
18. Do not bypass or try to defeat the safety interlock systems.
19. Use only torch(es) specified in Owner’s Manual.
20. Keep away from torch tip and pilot arc when trigger is pressed.
21. 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.
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.
1. 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.
2. Wear approved safety glasses with side shields.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
NOISE can damage hearing.
Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
1. Use approved ear plugs or ear muffs if noise level is high.
2. Warn others nearby about noise hazard.
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
sr2 11/92
Page 4
FUMES AND GASES can be hazardous
to your health.
Cutting produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove cutting fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals to be cut, coatings, and
cleaners.
5. 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.
6. Do not cut in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. 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 a n air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes when cut.
8. 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.
1. Keep away from the torch tip.
2. Do not grip material near the cutting path.
FL YING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
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.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flame, sparks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent fa l ling or tipping.
3. The pilot arc can cause burns – keep away from torch tip when
trigger is pressed.
4. Wear proper flame-retardant clothing covering all exposed body
areas.
5. Point torch away from your body and toward work when pressing
the torch trigger – pilot arc comes on immediately.
6. Turn off power source and disconnect input power before
disassembling torch or changing torch parts.
7. Use only torch(es) specified in the Owner’s Manual.
1. Wear approved face shield or safety goggles with side shields.
2. Wear proper body protection to protect skin.
3. Wear flame-resistant ear plugs or ear muffs to prevent sparks
from entering ears.
3. Keep cylinders away from any cutting or other electrical circuits.
4. Never allow electrical contact between a plasma arc torch and a
cylinder.
5. Never cut on a pressurized cylinder – explosion will result.
6. Use only correct gas cylinders, regulators, hoses, and fittings
designed for the specific application; maintain them and
associated parts in good condition.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
9. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
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
sr2 11/92
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
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.
Page 5
EMF INFORMATION
NOTE
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us t o draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
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 the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
TABLE OF CONTENTS
SECTION 1 – SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mod10.1 4/93
SECTION 2 – SPECIFICATIONS
2-1. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION
3-1. Consumables And Parts Supplied With Torch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Torch 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATING THE TORCH 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Checking Detector Pins And Checking/Replacing Shield Cup, Tip, And Electrode 7. . . . . . .
5-3. Troubleshooting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST
Figure 6-1. Torch, APT-1000 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1572A 8/93
Page 6
Page 7
SECTION 1 – SAFETY INFORMATION
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 2
5
6
7
2
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
NOTE
3
4
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
Turn Off switch when using high frequency.
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
mod1.1 2/93
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And Re-
sult
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best oper-
ation – not related to safety.
Figure 1-1. Safety Information
SECTION 2 – SPECIFICATIONS
Table 2-1. Cutting Torch
Specification Description
Model Description APT: Air Plasma Torch; 1000: 10 Ampere Rating
Ampere Rating 10 Amperes At 60% Duty Cycle (See Section 2-1)
Cable Length 15 ft (4.6 m)
Plasma Gas Air Or Nitrogen Only
Plasma Gas Flow/Pressure 0.6 CFM At 35 PSI (17 L/min At 242 kPa)
Cooling Method Air
Cutting Capacity Up To 5/32 in (4 mm) Mild Steel
Overall Dimensions See Figure 2-1
Weight Net: 3.5 lb (1.6 kg); Ship: 4.5 lb (2 kg)
80
B
C
Inches Millimeters
A
B
C
7/8
1-13/16
5-1/4
22
46
133
A
S-0228
Figure 2-1. Overall Dimensions
OM-1572 Page 1
Page 8
2-1. Duty Cycle
CAUTION
EXCEEDING DUTY CYCLE RATINGS will damage power source and torch.
• Do not exceed indicated duty cycles.
warn7.1* 2/92
Duty cycle is how long the torch and power source can operate within a ten minute period without causing overheating
or damage. This torch is rated at 60% duty cycle when operated at 10 amperes, allowing cutting 6 minutes out of 10. If
the cutting amperes decrease, the duty cycle increases.
SECTION 3 – INSTALLATION
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off power source, and disconnect input power before installing torch.
swarn3.1* 2/93
3-1. Consumables And Parts Supplied With Torch
T orch is shipped fully assembled and
ready to install onto power source.
1
3
2
4
The following consumables are
supplied with torch:
1 Shield Cup
2 Electrode
3Tip
4 Wrench
Use supplied wrench to change tips
and electrodes (see Section 5-2).
OM-1572 Page 2
ST-800 225
Figure 3-1. Consumables And Parts Supplied With Torch
Page 9
3-2. Installing Torch
WARNING
A. Installing Torch In Standard Power Source
1 234
S-137 691
6
7
3
4
5
READ SAFETY BLOCK at start of
Section 3 before proceeding.
Turn Off power source, and
disconnect input power plug. Remove wrapper.
1 Torch Cable
2 Front Panel Opening
3 Pilot Arc/Shield Cup Detector
Lead 1
4 Shield Cup Detector Lead 2
5 Torch Switch Leads 3 and 4
Route cable and leads through front
panel opening.
6 Terminal Strip 1T
7 Connection Label
Connect cable to air/torch (–) out-
put connector which is not visible in
Figure 3-2, but is located behind
terminal strip 1T.
Refer to label and connect leads a s
shown.
Install wrapper.
8 Work Cable (Supplied With
Power Source)
8
2
1
3
Tools Needed:
5
4
5/8 in
1/4 in
ST-128 701-C
Figure 3-2. Installing Torch In Standard Power Source
OM-1572 Page 3
Page 10
B. Installing Torch In Inverter Power Source
Label is located under
terminal strip.
6
5
1234
S-137 691
7
8
9
Turn Off power source, and
disconnect input power plug. Open
lower front access door.
1 Access Door
2 Strain Relief Clamp
3 Torch Cable
4 Torch (–) And Air/Gas Output
Connector
Connect torch cable as shown.
5 Terminal Strip1T
1
2
4
6 Connection Label
7 Pilot Arc/Shield Cup Detector
Lead 1
8 Shield Cup Detector Lead 2
9 Torch Switch Leads 3 And 4
Refer to label and connect leads as
shown.
Install strain relief clamp, and close
access door.
3
10 Work Cable (Supplied With
Power Source)
Tools Needed:
OM-1572 Page 4
10
5/8 in
Figure 3-3. Installing Torch In Inverter Power Source
SECTION 4 – OPERATING THE TORCH
WARNING
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Do not touch live electrical parts.
• Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material cut.
CUTTING can cause fire or explosion.
• Do not cut near flammable material.
• Provide protection from flying sparks.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not cut on closed containers.
• Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear face protection with correct shade of filter.
• Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
• Keep away from moving parts.
• Keep all doors, panels, covers, and guards closed
and securely in place.
See Safety Precautions at beginning of manual for basic cutting safety information.
ST-128 701-C
swarn6.1* 10/91
Page 11
1234 5
Figure 4-1. Safety Equipment
CAUTION
1 Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
4 Face Shield
Wear dry insulating gloves, safety
glasses with side shields, and a
welding helmet or face shield with a
correct shade of filter (see ANSI
Z49.1).
5 Ear Muffs
Wear approved ear muffs or ear
plugs if noise exposure exceeds
OSHA limits.
sb3.1 10/91
HITTING TORCH ON A HARD SURFACE to
remove spatter can damage torch.
• Do not clean torch by hitting it against a hard surface.
• Hitting hard surfaces can damage torch parts and stop proper
operation.
TIP AND ELECTRODE WEAR BEYOND
RECOMMENDED VALUES or OPERATION
WITHOUT TIP OR ELECTRODE can damage
torch.
• Inspect shield cup, tip, and electrode before cutting or whenever
• Do not operate torch without a tip or electrode in place.
Install &
Connect
Equipment
Begin
Cutting
Put On Personal
Safety
Equipment
EXAMPLE Of Cutting Operation
Place torch tip on edge Press trigger. After 2 seconds of preflow,
of metal.
Check Torch
Tip, Electrode,
And Shield Cup
pilot arc starts. Pilot arc stops after 2
seconds if cutting arc does not start.
cutting speed has been significantly reduced (see Section 5-2).
Check Air/Gas
Pressure
Set
Controls
After cutting arc starts, slowly
start moving torch across metal.
Turn On
Power Source
Adjust torch speed so
sparks go through metal and
out bottom of cut.
Pause briefly at end of
cut before releasing trigger.
Postflow continues for 20 seconds
after releasing trigger; cutting arc
can be instantly restarted during postflow.
Figure 4-2. Sequence Of Plasma Arc Cutting (PAC)
ST-161 698
OM-1572 Page 5
Page 12
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off power source, and disconnect input power
before inspecting, maintaining, or servicing.
5-1. Routine Maintenance
Turn Off all power before maintaining.
Each Use
Check
Torch Tip,
See
Section
5-2
Power
Source
Manual
Electrode,
And Shield
Cup
Check
Air/Gas
Pressure
Every Week
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or servicing.
Maintenance to be performed only by qualified persons.
swarn8.1* 2/93
3 Months
Tape
Torn
Outer
– –
3-2
Replace
Cracked
Parts
– –
Covering
Clean
And
Tighten
Torch
Connections
Torch Body
Check
Torch Tip
Power
Source
Manual ST-127 899-A
Shutdown
System
Figure 5-1. Maintenance Schedule
Air/Gas Hose
Torch Cable
OM-1572 Page 6
Page 13
5-2. Checking Detector Pins And Checking/Replacing Shield Cup, Tip, And Electrode
CAUTION
OVERTIGHTENING will strip threads.
• Do not overtighten electrode, tip, and shield cup during assembly.
• Do not cross-thread parts causing stripping.
• Use care during torch assembly and parts replacement.
5
3
New Worn
2
B3A
21
C
TIP AND ELECTRODE WEAR BEYOND
RECOMMENDED VALUES or OPERATION
WITHOUT TIP OR ELECTRODE can damage
torch.
• Inspect shield cup, tip, and electrode 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, and disconnect input power.
1 Shield Cup
2 Contact Surface
3 Detector Pins
4
Unscrew shield cup, and wipe contact surfaces with a soft cloth. Contact surfaces must be clean so
spring-loaded detector pins depress when shield cup is installed.
Check shield cup for cracks, and
replace if necessary.
Check detector pins to make sure
they move freely. If necessary, use
electrical contact cleaner to loosen
them.
4Tip
5 Opening
Remove tip using supplied wrench.
Check tip, and replace if opening is
deformed or 50% oversize.
6 Electrode
Check electrode. If more than 0.039
in (1 mm) of the end is eroded, remove electrode using supplied
wrench, and replace.
Carefully reassemble in reverse order.
Thread Sizes:
A M8 x .75
B M3 x .5
C M12 x 1
6
New
Worn
Ref. ST-800 225 / Ref. S-0093
OM-1572 Page 7
Page 14
Figure 5-2. Checking Detector Pins And Checking/Replacing Shield Cup, Tip, And Electrode
5-3. Troubleshooting
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or servicing.
• Turn Off power source, and disconnect input power
before inspecting, maintaining, or servicing.
Troubleshooting to be performed only by qualified
persons.
swarn8.1* 2/93
Table 5-1. Cutting Trouble
Trouble Remedy Section
Sparks come out top of cut, or cut is not
clean.
Arc goes out while cutting. Make sure torch tip is touching metal while cutting. Figure 4-2
Torch travel speed too fast; reduce travel speed. Figure 4-2
Check torch tip and electrode, and replace if necessary. 5-2
Metal being cut is too thick; increase power source Thickness
control setting.
Be sure work clamp is securely attached. *
*
Arc goes on and off while cutting. Torch travel speed is too slow; increase travel speed. Figure 4-2
Check torch tip and electrode, and replace if necessary. 5-2
*See power source Owner’s Manual.
OM-1572 Page 8
Page 15
13
SECTION 6 – PARTS LIST
5
4
1
15
14
3
2
6
12
78
11
9
10
ST-124 813-A
Figure 6-1. Torch, APT-1000
Item
No.
Part
No.
126 796
Description
Figure 6-1. Torch, Model APT-1000
Quantity
1 131 190 TORCH BODY KIT, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 131 184 DETECTIVE PIN 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 125 032 ELECTRODE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 125 031 TIP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 125 033 SHIELD CUP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 125 034 WRENCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 125 270 POWER CABLE ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 125 078 PILOT AND DETECTIVE LEAD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 125 079 TORCH SWITCH LEAD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 125 273 HOSE SHEATH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 125 269 HEAT SHRINKABLE TUBE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 125 268 SWITCH COVER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 125 074 TORCH SWITCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 125 266 TORCH HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 125 285 INSULATING TUBE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1572 Page 9
Page 16
Notes
Page 17
Notes
Page 18
Notes
Page 19
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, 2000
(Equipment with a serial number preface of “LA” 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
* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* 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 185 & Spoolmate 250
* 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.
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 7/00
Page 20
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: 920-735-4505 Auto-A t t ended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
File a claim for loss or damage during
shipment.
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