Miller Electric ICE-100TM, 1251, ICE-100T User Manual

OM-201 872D 2007−03
Processes

Air Plasma Cutting
and Gouging

Descriptio n

Air Plasma Cutter

R

Spectrum 1251 And

ICE-100T/TM 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 9001:2000 Quality
System Standard.

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

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog 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 4/05

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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Symbols And Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Duty Cycle and Overheating 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Cutting Speed 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Selecting a Location 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Connecting Work Clamp and Gas/Air Supply 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting And Disconnecting Torch 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Electrical Service Guide 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Extension Cord Data 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Connecting 3-Phase Input Power 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant 17 . . . . . . . . . . . . . . . . . . .

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

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

5-2. Setting Gas/Air Pressure 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 Gouging Operation 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Sequence Of Piercing Operation 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Consumables Storage Compartment 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MECHANIZED OPERATION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. ICE-100TM Mounting Position 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Remote Control Receptacle 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Remote Control Cable Functions 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. +24 Volts DC Hot Contacts For Relay Operation 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Dry Contacts Using An External Power Supply For Relay Operation 27 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation 28 . . . . . . . . . . . . .

6-8. Remote Voltage Sense Connection 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Shield Sense Tab 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Cut Charts 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 3 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Trouble Lights 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Checking Shield Cup Shutdown System 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Checking/Replacing Retaining Cup, Tip, And Electrode 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Checking Or Replacing Filter Element 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Troubleshooting Power Source 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Troubleshooting Torch 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAM 4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES
PARTS LIST − www.MillerWelds.com

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

Y Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

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

pom _4/05

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Plasma Arc Cutting Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only a
summary o f the more complete safety information found in the
Safety Standards listed in Section 1-5. Read and follow all Safe­ty Standards.

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

repair this unit.

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

CUTTING can cause fire or explosion.

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

D 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 closed containers such as tanks or drums.
D Connect work cable to the work as close to the cutting area as prac-

tical to prevent cutting current from traveling long, possibly unknown
paths and causing electric shock, 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 in atmospheres containing explosive dust or vapors.
D Do not cut pressurized cylinders, pipes, or vessels.
D Do not cut containers that have held combustibles.
D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Do not locate unit on or over combustible surfaces.
D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any cutting.

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

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

ELECTRIC SHOCK can kill.

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

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

live when power is on. Plasma arc cutting requires

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

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

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

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

ment. Lockout/tagout input power according to OSHA CFR

1910.147 (see Safety Standards).

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

Manual and national, state, and local codes.

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

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

D When making input connections, attach proper grounding conduc-

tor first.

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

place cord immediately if damaged − bare wiring can kill.

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

by codes.

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

parts at once.

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

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

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists in

inverter power sources AFTER the r e­moval of input power.

D Turn Of f unit, disconnect input power, check voltage on input ca-

pacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Mainte­nance Section of Owner’s Manual or Technical Manual before
touching any parts.

OM-201 872 Page 1

EXPLODING PARTS can injure.

.

D On inverter power sources, failed parts can ex-

plode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.

FLYING SPARKS can cause injury.

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

D Wear approved face shield or safety goggles with side shields.
D Wear proper body protection to protect skin.
D Wear flame-resistant ear plugs or ear muf fs to prevent sparks from

entering ears.

ARC RAYS can burn eyes and skin.

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.

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 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 − 80

#4
#5
#6
#8

NOISE can damage hearing.

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

D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.

FUMES AND GASES can be hazardous.

Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.

D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove cutting fumes and gases.

PLASMA ARC can cause injury.

The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.

D Keep away from the torch tip.
D Do not grip material near the cutting path.
D The pilot arc can cause burns − keep away from torch tip when trig-

ger is pressed.

D Wear proper flame-retardant clothing covering all exposed body ar-

eas.

D Point torch away from your body and toward work when pressing

the torch trigger − pilot arc comes on immediately.

D Turn off power source and disconnect input power before disas-

sembling torch or changing torch parts.

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

CYLINDERS can explode if damaged.

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

D Protect compressed gas cylinders from excessive heat, mechani-

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

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

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

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

cylinder.

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

signed for the specific application; maintain them and associated
parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient number

of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-201 872 Page 2

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

.

.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on torch.
D To handle hot parts, use proper tools and/or

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

MOVING PARTS can cause injury.

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

closed and securely in place.

D Have only qualified persons remove doors,

panels, covers, or guards for maintenance as
necessary.

D Reinstall doors, panels, covers, or guards

when maintenance is finished and before re­connecting input power.

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine Miller/Hobart replacement

parts.

FLYING METAL can injure eyes.

D Wear safety glasses with side shields or face

shield.

MAGNETIC FIELDS can affect pacemakers

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

ing near plasma arc cutting operations.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift unit.

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

tend beyond opposite side of unit.

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.

OVERUSE can cause OV E RHE ATING

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.

1-4. California Proposition 65 Warnings

Y W elding 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.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

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 t o this manual.

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

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

For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of

California t o cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

OM-201 872 Page 3

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

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

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

Welding Society Standard AWS F4.1, from Global Engineering Docu­ments (phone: [phone], website: www.global.ihs.com).

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.

1-6. EMF Information

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

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

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

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.

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

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000, 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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220, website: www.osha.gov).

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

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

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

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

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

About Pacemakers:

Pacemaker wearers consult your doctor before welding/cutting or going
near welding/cutting operations. If cleared by your doctor, then following
the above procedures is recommended.

OM-201 872 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Signification des symboles

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

Y Identifie un message de sécurité particulier.

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

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

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

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

présent manuel pour attirer votre attention et identifier les ris­ques de danger. Lorsque vous voyez un symbole, soyez
vigilant e t suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne font
que résumer l’information contenue dans les normes de sécu­rité énumérées à la section 2-4. Veuillez lire et respecter toutes
ces normes de sécurité.

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

vent être confiés qu’à des personnes qualifiées.

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

particulièrement les enfants.

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

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

feu ou des brûlures. Avant de commencer à travailler , assurez-vou
que l’endroit est sécuritaire.

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

périmètre d e 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 coupez pas sur un contenant fermé tel qu’un réservoir ou un b i-

don.

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

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

D Ne pas utiliser le coupeur plasma pour dégeler des conduites

gelées.

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

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

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

de la poussière ou des vapeurs explosives.

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

sés.

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

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

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

de celle−ci.

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

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

chauffée et l’équipement chaud peuvcnt causer u n

D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA

51B pour travaux de soudage et prévoir un détecteur d’incendie et
un extincteur à proximité.

UNE DÉCHARGE ÉLECTRIQUE peu
entraîner la mort.

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

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

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

sans trous.

D Isolez−vous d e l a 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.

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 Installez le poste correctement et mettez-le à la terre convenable-

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

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

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

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

le bon fil de terre.

D Vérifiez 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.

de masse sont automatiquement actifs lorsque le

OM-201 872 Page 5

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

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chette est enfoncée.

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

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

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

contact avec tout objet métallique.

LE BRUIT peut endommager l’ouïe.

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

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

sonore est élevé.

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

DÉCHARGES ÉLECTRIQUES poten­tiellement mortelles.

Il y a DES CHARGES DC SIGNIFICA TI­VES dans le poste de soudage inver­seur même APRÈS coupure du cou­rant d’alimentation.

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

d’entrée et s’assurer qu’elle est pratiquement nulle avant de tou­cher à l’une quelconque des pièces. Mesurer cette tension 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 VOLANTES ris
quent de provoquer des blessures.

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

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

raux approuvées.

D Portez des vêtements de protection adéquats afin de protéger votre

peau.

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

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

LES RAYONS D’ARC peuvent entra
ner des brûlures aux yeux et à la peau

Les rayons d’arc provenant du procédé de coupage

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

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

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

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

ou écran facial.

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

les autres contre les rayonnements, 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 résistantes

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)

OM-201 872 Page 6

produisent des rayons visibles et invisibles intenses

Moins de 20 no. 4

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

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

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

vapeurs.

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

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

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

approuvé.

D 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 causées par
le coupage et l’épuisement de l’oxygène peuvent altérer la qualité de
l’air et entraîner des blessures ou la mort. Assurez−vous que l’air am­biant est sain pour la santé.

D Ne coupez pas dans un endroit près d’opérations de décapage, de

nettoyage ou de vaporisation. La chaleur et les rayons d’arc peuvent
réagir avec les vapeurs et former des gaz hautement toxiques et irri­tants.

D Ne coupez pas des métaux enrobés tels que des métaux galvanisés,

contenant du plomb ou de l’acier plaqué au cadmium, à moins que
l’enrobage n e soit ôté de la surface du métal à couper, que l’endroit où
vous travaillez ne soit bien ventilé, ou que vous ne portiez un respira­teur anti−vapeurs. Les enrobages ou tous métaux qui contiennent ces
éléments peuvent créer des vapeurs toxiques s’ils sont coupés.

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

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

LE PLASMA D’ARC peut entraîner
des blessures.

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

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

lumeau lorsque vous avez appuyé sur le gâchette.

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

tre corps.

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

à couper lorsque vous appuyez sur la gâchette − l’arc pilote s’allume
automatiquement.

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

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

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

nuel de l’opérateur .

LES BOUTEILLES peuvent explose
si elles sont endommagées.

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

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

les chocs mécaniques, 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 chalumeau

de plasma d’arc et une bouteille.

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

résulterait.

D Utilisez uniquement des bouteilles de gaz, des détendeurs, des

boyaux et des raccords conçus pour l’application déterminée. Gar­dez−les, ainsi que toute autre pièce associée, en bonne condition.

D Détournez votre visage du détendeur−régulateur lorsque vous ouvrez

la soupape de la bouteille.

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

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

D Utiliser les équipements corrects, les bonnes procédures et suffisam-

ment 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.

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

et la maintenance

DES PIECES CHAUDES peuvent pro­voquer des brûlures graves.

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

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

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

DES ORGANES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels que

des ventilateurs.

D Maintenir fermés et verrouillés les portes, panneaux,

D Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour
l’entretien.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

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

recouvrements et dispositifs de protection.

DES PARTICULES VOLANTES
peuvent blesser les yeux.

D Porter des lunettes de sécurité avec protections laté-

rales ou frontales.

LES CHAMPS MAGNÉTIQUES peu­vent affecter les stimulateurs cardia­ques.

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

avant d’approcher les opérations de coupage
plasma.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement; respecter le

cycle opératoire nominal.

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

couper ou réduire le facteur de marche.

Danger D’EXPLOSION
D’HYDROGÈNE.

D Lors du coupage d’aluminium partiellement ou totale-

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

D Consultez votre ingénieur de coupage et les instruc-

tions de la table de coupage.

LA CHUTE DE L’APPAREIL peut
blesser.

D Utiliser l’anneau de levage uniquement pour soulever

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

D Utiliser un engin d’une capacité appropriée pour sou-

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

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

lever l’appareil.

Risque D’INCENDIE OU
D’EXPLOSION.

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

de surfaces infllammables.

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

flammables

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

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

LES CHARGES 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 provo-

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

ces de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindag e p ou r r éd ui re l es in te rf é­rences éventuelles.

OM-201 872 Page 7

LE COUPAGE Ã L’ARC peut causer
des interférence.

D L’énergie électromagnétique peut gêner le fonction-

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

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

courts que possible, les grouper, et les poser aussi bas que po s si bl e
(ex. par terre).

2-4. Principales normes de sécurité

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard A WS C5.2, de Global Engineering Documents (télé­phone : [phone], site Internet : www.global.ihs.com).

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

F4.1, de l’American Welding Society de Global Engineering Documents
(téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

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

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

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

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

électronique sensible.

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

mise à la terre.

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

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

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

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

Protection Association, Batterymarch Park, Quincy, MA 02269.

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

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101
(téléphone : 617-770-3000, site Internet : 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, de U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).

2-5. Information sur les champs électromagnétiques

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

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

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

1 Garder les câbles ensembles en les torsadant ou en les

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

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

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

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder/couper ou d’approcher des opérations de soudage/
couper. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-201 872 Page 8

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

U

U

X

I

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

A
V

I

1max

IP

1eff

Protective Earth

Rated No Load

Voltage (A verage)

0

Rated Maximum

Supply Current

Maximum Effective

Supply Current

Amperes

Volts Increase

(Ground)

On Off Percent Direct Current

I

Degree Of
Protection

pf

Plasma Arc Cutting

1

2

(PAC)

Single Phase Constant Current Voltage Input

Primary Voltage

Rated Welding

Current

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

1/3 f1

Hz

S

Low Air Pressure

Temperature

Line Connection

Single Phase Or

Three Phase Static

f2

1

Frequency
Converter-

Transformer-

Rectifier

Hertz

Power Rating,

Product Of Voltage

And Current (KVA)

Light

OM-201 872 Page 9

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

Rated

Maximum

Output

Output

Gas

Cutting

Circuit

Voltage DC

Voltage DC

SECTION 4 − INSTALLATION

4-1. Specifications

Amperes Input at Rated Load

Output 60 Hz, Three-Phase*

Duty Cycle

40% 50% 80% 80%

Rated

T ype of

Plasma

Cutting

Capacity

208 V 230 V 460 V 575 V KVA KW

9.2 CFM

100 A @

55 49 24 19 19.1 18.2

*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition.

160 Volts

DC

Direct

Current,

Straight
Polarity

(DCEN)

(261

L/min) At

75 PSI

(517 kPa)

Air Or

Nitrogen

Only

1.25 in

(32 mm)

At 12 IPM

(305 mm/min)

Amperes Input

at Rated Load
Output 50 Hz,

Three-Phase*

Rated

Output

T ype of

Output

Plasma

Gas

Rated Cutting

Capacity

400 V KVA KW

28 19.2 18.3

100 A @ 160

Volts DC, 80%

Duty Cycle

Direct Current,

Straight Polarity

(DCEN)

9.2 CFM

(261 L/min) At

75 PSI (517

kPa) Air Or

Nitrogen Only

1.25 in

(32 mm)

At 12 IPM

(305 mm/min)

Maximum

Open-

Voltage DC

265

Maximum

Open-Circuit

Voltage DC

265

*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition..

OM-201 872 Page 10

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

4-2. Duty Cycle and Overheating

208 Volts AC Three-Phase Input Power:

40% Duty Cycle

4 Minutes Cutting 6 Minutes Resting

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

If unit overheats, output stops, and
cooling fan runs. Wait fifteen min­utes for unit to cool. Reduce amper­age or duty cycle before cutting.

Y Exceeding duty cycle can

damage unit and void war­ranty.

230 Volts AC Three-Phase Input Power:

50% Duty Cycle

5 Minutes Cutting 5 Minutes Resting 8 Minutes Cutting 2 Minutes Resting

Overheating

0

15

Minutes

380-575 Volts AC Three-Phase Input Power:

80% Duty Cycle

A

OR

Reduce Duty Cycle

4-3. Cutting Speed

Rated Cutting Speed vs Material Type & Thickness

170
160
150
140
130
120
110
100

90
80
70
60
50
40

Cutting Speed (Inches per Minute)

30
20
10

0

0.25” 0.375” 0.5” 0.625” 0.75” 1” 1.25”

Material Thickness (Inches)

The cutting speed curve shows the
rated cutting speed capabilities of
the power source and torch for mild
steel, stainless steel, and aluminum
of various thicknesses.

Y Exceeding recommended

cutting speeds will cause
rapid erosion of the tip and
electrode.

duty1 4/95

Aluminum Stainless Steel Mild Steel

OM-201 872 Page 11

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

4-4. Selecting a Location

Dimensions And Weight

95 lb (43 kg) w/Torch

24 in

(610 mm)

17 in

(432 mm)

12-1/2 in

(318 mm)

Movement

1

Location

1 Lifting Handles

1

Y Do not move or operate unit

where it could tip.

2

3

18 in

(460 mm)

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

unit.
3 Line Disconnect Device
Locate unit near correct input

power supply.

Y Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 2 0 .

18 in

(460 mm)

OM-201 872 Page 12

loc_2 3/96 - Ref. 151 556 / 802 183

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

4-5. Connecting Work Clamp and Gas/Air Supply

5

From

Gas/Air

Supply

1

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

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

. Use only clean, dry air with 90

2

AIR/N

2

90-120 psi

@ 9.2 CFM

3

(260 L/min)
minimum

4

Tools Needed:

to 120 psi (621 to 827 kPa)
pressure @ 9.2 CFM
(260L/min) minimum.

3 Gas/Air Filter Inlet Opening
4 Hose

. Hose must have a minimum

inside diameter of 3/8 in
(9.5 mm).

5 Teflon Tape
Obtain hose with 1/4 NPT right-

hand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.

Adjust gas/air pressure according
to Section 5-2.

Rear of Uni t

4-6. Connecting And Disconnecting Torch

1

5

2

3

4

9/16 in

Ref. 803 640-A / Ref. 192 441 / Ref. 804 026-A

Y Turn off power source and

disconnect input power.

1 Torch Connector
2 Quick Connect Collar
3 Nipple
4 Receptacle
5 Securing Pin
To connect torch:

Push torch connector onto
receptacle and quick connect until
collar secures nipple.

Rotate securing pin to lock
connector to unit.

To disconnect torch:
Rotate securing pin to unlock

connector from unit.
Push quick connect collar back

towards unit to release nipple, and
pull torch connector away from unit.

804 055-A

OM-201 872 Page 13

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

4-7. Electrical Service Guide

Y CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding power

source requires a CONTINUOUS supply of 50 or 60 Hz (+10%) power at +10% of 575V or −10% of 208V
input voltage. Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a gener­ator with automatic idle device (that idles engine when no load is sensed) to supply input power to this
plasma power source.

60 Hz Three Phase

Input Voltage 208 230 460 575
Input Amperes At Rated Output 55 49 24 19
Max Recommended Standard Fuse Rating In Amperes

Time-Delay

Normal Operating

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .

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

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

310.16. 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.

Input Voltage 400
Input Amperes At Rated Output 28
Max Recommended Standard Fuse Rating In Amperes

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

4

4

Time-Delay

Normal Operating

4

4

1
2
3

1
2
3

60 60 30 20
80 70 35 30

8 8 10 12

89

(27)

8 8 10 12

108
(33)

50 Hz Three Phase

284
(87)

25
35
12

155

(47)

12

268
(82)

Reference: 2005 National Electrical Code (NEC) (including article 630)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .

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

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

310.16. 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.

OM-201 872 Page 14

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

4-8. Extension Cord Data

NOTE

Input Power

Input Voltage

208 V 3 60

230 V 3 60

460 V 3 60

575 V 3 60

400 V 3 50

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

above).

Phase

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

Fuse Size Or

Hertz

Circuit Breaker Rating

Time-Delay
Normal Operating 380 A

Time-Delay
Normal Operating 370 A

Time-Delay
Normal Operating 335 A

Time-Delay
Normal Operating 330 A

Time-Delay
Normal Operating 335 A

2

2

2

2

2

60 A

60 A

30 A

20 A

25 A

Conductor Size Max. Cord Length

8 AWG 89 ft (27 m)

8 AWG 108 ft (33 m)

10 AWG 284 ft (87 m)

12 AWG 268 ft (82 m)

12 AWG 155 ft (47 m)

OM-201 872 Page 15

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

4-9. Connecting 3-Phase Input Power

3

4

3

6

1

= GND/PE Earth Ground

7

2

L1

5

L2
L3

Y Installation must meet all National

and Local Codes − have only
qualified persons make this
installation.

Y Disconnect and lockout/tagout

input power before connecting
input conductors from unit.

Y Always connect green or green/

yellow conductor to supply
grounding t e r m i n a l f i r s t , a n d never
to a line terminal.

. The Auto-Line circuitry in this unit

automatically adapts the power
source to the primary voltage being
applied. Check input voltage available
at site. This unit can be connected to
any input power between 208 and 57 5
VAC without removing cover to relink
the power source.

1 Input Power Cord.
2 Disconnect Device (switch shown in

the OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding

Terminal
5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor t o disconnect device grounding
terminal first.

Connect input conductors L1, L2, and L3
to disconnect device line terminals.

7 Over-Current Protection
Select type and size of over-current

protection using Section 4-7 (fused dis­connect switch shown).

Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

OM-201 872 Page 16

3/8 in

3/8 in

803 766-A / 802 183

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

4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant

Three-Phase Generator Power

Y Stop engine.
Y Power and weld outputs are

live at the same time. Discon-

Three-Phase Power Connection

nect or insulate unused
cables.

. Have qualified person install ac-

cording to circuit diagram and
Generator Power Guidelines
(see generator Owner’s Manual).

Remove generator power panel
mounting screws. Tilt panel forward.

1 Circuit Breaker CB7
2 Lead 93
3 Lead 92
4 Lead 91
5 Lead 42 (Circuit Grounding

Lead)
6 Lead 90 (Neutral)
7 Isolated Neutral Terminal
8 Jumper Lead 42
9 Grounding Terminal
Jumper 42 i s connected to lead 90 a t

factory. Jumper 42 may be discon­nected from neutral to meet applica­ble electrical codes.

Lead 42 connects to front panel
Ground stud.

10 Power Cord
11 Circuit Breaker CB7 User

Terminals

Remove plug
before inserting
leads. Reinstall
bushing.

4

5

6

Y Close panel opening

if no connections are
made to generator.

Rear Of Panel

91 92 93

42

90

3

2

1
11

9

. Circuit breaker CB7 protects

10

Y Close panel

opening if no

8

connections
are made to
generator.

7

240V

240V

3-Phase

240V

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all three-phase

generator output stops and the

receptacle does not work.

Connect user-supplied ring lug to
green (ground) lead. Connect ring
lug on end of green (ground) lead
to grounding terminal (9).

Connect black, white, and red
leads to circuit breaker CB7 user
terminals (11).

Reinstall power panel.

. Engine control must be set to

Run NOT Run/Idle to adequately

power the plasma cutter.

Three

Phase

3

240

48
20

60 HzFrequency

93

91

90

92

Tools Needed:

AC

Output

Volts

Amps

KVA/KW

Engine Speed 1850 RPM

Lead 42 connects to GROUND stud on
front of unit.

Jumper 42 i s connected to 90 at factory.

Ref. 197 399 / 802 332-B

OM-201 872 Page 17

5-1. Controls

7

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

SECTION 5 − OPERATION

1

3

5

4

6

1 Gas/Air Pressure Gauge
2 Gas/Air Pressure Control
3 Output Control

Use control to select cutting output in am­peres. Gas/air automatically flows at the set
pressure.

2

Use Gas/Air Set area of control range for set­ting gas/air pressure (see Section 5-2 ).

4 Trouble Lights (see Section 7-2)
5 Power Light
6 Cut/Gouge Switch
Set pressure as indicated on nameplate for

appropriate switch position.

201 853-A

After the cutting arc goes out, the torch
will automatically re-ignite the pilot arc if
the trigger is held down.

7 Power Switch

OM-201 872 Page 18

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

5-2. Setting Gas/Air Pressure

1

3

Setting Gas/Air Pressure

Unit Requires 90-120 PSI

(621-827 kPa) Supply At

9.2 CFM (260 L/min)
Minimum Flow Rate

Turn On Gas/Air Supply.

2

1 Power Switch

Power Switch On.

AIR/N

2

90-120 psi

Rear of Unit

Ref. 804 025-A / Ref. 804 026-A

2 Output Control 3 Gas/Air Pressure

Place Output Control in
Gas/Air Set Position.

Adjustment Knob

Pull knob and turn, set
pressure to 75 PSI
(517 kPa). Push knob in
to lock setting.

Select desired cutting
output with Output
Control.

5-3. Trigger Safety Lock

1 Trigger

1

Trigger Locked Trigger Unlocked

801 397-A

OM-201 872 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 metal workpiece, as

close to cutting area as possible.

90°

Maintain approximately a 90° angle to the

workpiece surface for proper cutting results.

1/8 in

(3.2 mm)

. Set correct air pressure for process:

75 PSI (517 kPa) for cutting,
60 PSI (414 kPa) for gouging.

Sparks should pass through the workpiece

and out the bottom when cutting.

Wt

DO NOT start pilot arc without cutting or

gouging as this shortens the service life

of the nozzle and electrode.

If sparks flare back from surface, this

usually is an indication that either travel

speed is too fast, amperage is set too low,

or consumables are worn.

When doing non-shielded cutting, maintain

approximately 1/8 in standoff between

electrode and surface.

OM-201 872 Page 20

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. 803 640-A / 801 400-B / Ref. 802 878

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

5-5. Sequence Of Cutting Operation

Connect work clamp to a clean, paint-free

location on metal workpiece, as close to

cutting area as possible.

90°

For standard (shielded) cutting, place drag

shield on edge of metal. For non-shielded

cutting, use 1/8 in (3.2 mm) standoff distance

(dragging tip will reduce tip life).

. Set air pressure to 75 PSI

(517 kPa) for cutting.

The pilot arc starts immediately
when trigger is pressed.

Raise trigger lock and press

trigger. Pilot arc starts.

Set Mode switch to CUT.

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. 803 640-A / 801 400-B

OM-201 872 Page 21

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

5-6. Sequence Of Gouging Operation

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

area as possible.

455

Hold torch at approximately

45° angle to workpiece.

. Set air pressure to 60 PSI

(414 kPa) for gouging.

The pilot arc starts immediately
when trigger is pressed.

Raise trigger lock and press trigger. Pilot

arc starts. Move tip to within approxi-

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

across workpiece surface. Maintain

approximately a 45° angle to surface.

Set Mode switch to GOUGE.

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.

Ref. 803 640-A / 801 400-B

OM-201 872 Page 22

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

5-7. Sequence Of Piercing Operation

The pilot arc starts immediately
when trigger is pressed.

Connect work clamp to a

clean, paint-free location

on workpiece, as close to

cutting area as possible.

90°

Rotate torch to upright position

approximately 90° to surface.

When arc has pierced through

workpiece, start cutting.

. Set air pressure to 75 PSI

(517 kPa) for cutting.

Maintain approximately 90° torch

position to surface, and continue

Set Mode switch to CUT.

90°

cutting.

Hold torch at an angle to t h e

workpiece. Raise trigger lock and

press trigger. Pilot arc starts.

Release trigger. Postflow continues for

approx. 20 seconds after releasing trigger;

arc can be instantly restarted during postflow

by raising trigger lock and pressing trigger.

Ref. 803 640-A / 801 400-B

5-8. Consumables Storage Compartment

Rear of Uni t

1 Consumables Storage

Compartment

This compartment provides
convenient access to consumables

1

and parts.

804 026-A

OM-201 872 Page 23

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

Remote Start

provide a remote trigger input signal to RC61 sockets 1 and 5 for the remote

Okay To Move

RMT2 receptacle on Control board PC1.

SECTION 6 − MECHANIZED OPERATION

6-1. ICE-100TM Mounting Position

1 ICE-100TM Machine Torch
2 Square
Use a square to align torch perpen-

dicular to the work surface.

1

90°

6-2. Remote Control Receptacle

1

21

53476

9811 10

1214 13

2

1 Remote Control Receptacle

RC61

RC61 provides a remote arc start
input when using the ICE-100TM
machine torch. Connect supplied
remote control cable or remote
pendant control to receptacle on
rear panel. See Section 6-3 for
remote control cable input and
output functions.

6-3. Remote Control Cable Functions

Function Lead Socket Lead Information

White 1 White and red leads connect to a set of customer-supplied remote contacts to

Red 5

Black 2 Black and green leads connect to a customer-supplied machine torch drive

Green 4

Noise Suppression Shielding 3 Chassis ground.

OM-201 872 Page 24

804 026-A

start function.

device. Normally open contacts close after arc start to provide an output
signal to begin machine torch movement. These contacts can be either dry
(RMT1) or hot [RMT2 (+24 volts dc)] depending on plug position at RMT1 or

NOTE: The Spectrum 1251 is shipped from the factory with the plug
connected to RMT1 (dry contacts). To power a relay or isolated input module
with +24 volts dc on black lead (socket 2) and circuit common on green lead
(socket 4), see Section 6-4 or 6-5.

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

6-4. +24 Volts DC Hot Contacts For Relay Operation

2

3

1

4

Y Turn off and disconnect

input power.

Control board PC1 can supply +24
volts dc from receptacle RMT2 to
operate a customer-supplied relay
for the Okay To Move signal.

1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RMT2
4 Receptacle RC61

Move plug from RMT1 into
receptacle RMT2 on PC1. Be
sure remote control cable plug is
connected to RC61 on rear of
unit.

If voltage sensing is required, see
Section 6-8.

Install wrapper on unit.
Required Items:
Customer-supplied 24 volts dc

relay coil with resistance greater
than 240 ohms.

Suppression diode (1A, 100V) such
as type IN4002 through IN4004
across relay coil.

. Plasma cutter is shipped from

the factory with plug connected
to receptacle RMT1 (dry
contacts).

Remote Control Cable

Tools Needed:

White

Red

Black

+24 VDC

Green

. +24 volts dc will activate relay coil after unit is triggered and

the cutting arc is initiated.

5/16 in

+

Relay

−

Remote

Start

Relay

Contacts

Okay To

Move

804 041-A

OM-201 872 Page 25

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

6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation

Y Turn off and disconnect

input power.

Control board PC1 can supply +24
volts dc from receptacle RMT2 to
operate a customer-supplied
isolated input module for the Okay
To Move signal.

1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RMT2
4 Receptacle RC61

Move plug from RMT1 into
receptacle RMT2 on PC1. Be
sure remote control cable plug is

2

3

1

4

connected to RC61 on rear of
unit.

If voltage sensing is required, see
Section 6-8.

Install wrapper on unit.
Required Items:
Customer-supplied isolated input

module.

. Plasma cutter is shipped from

the factory with plug connected
to receptacle RMT1 (dry
contacts).

Remote Control Cable

Tools Needed:

OM-201 872 Page 26

5/16 in

White

Red

Black

Green

+24 VDC

Remote

Start

+

Output

−

. +24 volts dc will activate relay coil after unit is triggered and

the cutting arc is initiated.

Okay To

Move

804 041-A

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

6-6. Dry Contacts Using An External Power Supply For Relay Operation

Y Turn off and disconnect

input power.

Control board PC1 can provide dry
contacts from receptacle RMT1 to
operate a customer-supplied relay
using an external power supply for
the Okay To Move signal.

1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RC61
Unit is shipped from factory with

plug connected to receptacle
RMT1.

Be sure that remote control cable

2

1

3

plug is connected to RC61 on rear
of unit.

If voltage sensing is required, see
Section 6-8.

Install wrapper on unit.
Required Items:
Customer-supplied +24 volts dc

power supply.
24 volts dc relay coil with resistance

greater than 240 ohms.
Suppression diode (1A, 100V) such

as type IN4002 through IN4004
across relay coil.

White

Red

Green

Black

Remote Control Cable

. +24 volts dc will activate relay coil after unit is triggered and

the cutting arc is initiated.

Tools Needed:

5/16 in

Relay

Remote

Start

+

+24 VDC

−

Power

Supply

Relay

Contacts

Okay To

Move

804 041-A

OM-201 872 Page 27

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

6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation

Y Turn off and disconnect

input power.

Control board PC1 can provide dry
contacts from receptacle RMT1 to
operate a customer-supplied
isolated input module using an
external power supply for the Okay
To Move signal.

1 Control Board PC1
2 Receptacle RMT2
3 Receptacle RC61
Unit is shipped from factory with

plug connected to receptacle
RMT1.

2

1

3

Be sure that remote control cable
plug is connected to RC61 on rear
of unit.

If voltage sensing is required, see
Section 6-8.

Install wrapper on unit.
Required Items:
Customer-supplied +24 volts dc

power supply.
Isolated input module.

Remote Control Cable

. +24 volts dc will activate relay coil after unit is triggered and

the cutting arc is initiated.

Tools Needed:

5/16 in

OM-201 872 Page 28

White

Red

Green

Black

Remote

Start

+

+24 VDC

Power

Supply

−

Output

Okay To

Move

804 041-A

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

6-8. Remote Voltage Sense Connection

2

1

Y Turn off and disconnect

input power.

Remote voltage sense is an arc
voltage output signal for automatic
torch height adjustment.

1 Snap-in Blank
2 Nylon Bushing
3 Secondary Interconnect

Board PC4
4 Receptacle RC48
Remove snap-in blank from rear

panel.
Remove nut from strain relief, and

route plug end of cable through
opening in rear panel.

Slide nut over cable, and secure
strain relief to rear panel.

Route plug end of cable through
nylon bushing and over to PC4.

Connect plug to RC48 on PC4.
Install wrapper on unit.
Cut off crimped terminals on lead

ends, and connect white lead to

4

+volts dc and black lead to −volts dc
on customer-supplied voltage
sense device.

Tools Needed:

15/16 in

5/16 in

6-9. Shield Sense Tab

3

804 041-A

. Shield sense tab is located in

the consumable storage box

on left side of unit wrapper.

OM-201 872 Page 29

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

Arc Current

Arc Voltage

Pierce

100

Arc Current

Arc Voltage

Pierce

100

Arc Current

Arc Voltage

Pierce

100

6-10. Cut Charts

100 Amp Machine Torch Shielded Consumables

The following cut charts are based on a distance of 1/8 in (3.2 mm) between torch and workpiece for all cuts.

Sense Tab*

219 684219 687 219 677219 678219 679

226 763

*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.

Swirl RingElectrodeTipRetaining CapShield

ICE-100TM Torch

. Shield sense tab is located in the consumable storage box on left side of unit wrapper.

Mild Steel

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

100

Pierce

Delay

152 0.5 1/4 6.4 208 5,283 135 3,429
154 0.5 3/8 9.5 119 3,022 77 1,955
157 1.0 1/2 12.7 88 2,235 57 1,447
159 1.0 5/8 15.9 61 1,549 40 1,016
162 1.5 3/4 19.0 47 1,193 26 660
164 2.0 1 25.4 28 711 18 457
166 2.5 1-1/4 31.8 19 482 12 305

Stainless

100

Aluminum

Pierce

Delay

153 0.5 1/4 6.4 231 5,867 150 3,810
157 0.5 3/8 9.5 122 3,099 79 2,006
161 1.0 1/2 12.7 79 2,006 52 1,320
162 1.0 5/8 15.9 52 1,320 34 863
165 1.5 3/4 19.0 39 990 25 635
166 2.0 1 25.4 23 584 15 381
170 2.5 1-1/4 31.8 14 355 9 228

Pierce

Delay

155 0.5 1/4 6.4 253 6,426 164 4,165
157 0.5 3/8 9.5 142 3,606 92 2,336
161 1.0 1/2 12.7 108 2,743 70 1,778
162 1.0 5/8 15.9 77 1,955 50 1,270
163 1.5 3/4 19.0 57 1,447 33 838
165 2.0 1 25.4 33 838 21 533

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

OM-201 872 Page 30

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

Arc Current

Arc Voltage

Pierce

80

Arc Current

Arc Voltage

Pierce

80

Arc Current

Arc Voltage

Pierce

80

80 Amp Machine Torch Shielded Consumables

The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts.

Sense Tab*

212 733212 732 212 734212 724212 726

226 763

*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.

Swirl RingElectrodeTipRetaining CapShield

ICE-100TM Torch

. Shield sense tab is located in the consumable storage box on left side of unit wrapper.

Mild Steel

Pierce

Delay

133 0.25 3/16 4.8 216 5,486 140 3,556
134 0.5 1/4 6.4 161 4,089 105 2,667
137 0.5 3/8 9.5 94 2,388 61 1,549
141 0.5 1/2 12.7 60 1,524 39 991
145 1.0 5/8 15.9 40 1,016 26 660
148 N/A 3/4 19.0 31 787 20 508
150 N/A 7/8 22.2 23 584 15 381
156 N/A 1 25.4 16 406 10 254

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Stainless

80

Aluminum

80

Pierce

Delay

134 0.25 3/16 4.8 216 5,486 140 3,556
136 0.5 1/4 6.4 158 4,013 103 2,616
140 0.75 3/8 9.5 83 2,108 54 1,372
142 0.75 1/2 12.7 50 1,270 33 838
145 N/A 5/8 15.9 34 864 22 559
150 N/A 3/4 19.0 24 610 16 406
153 N/A 1 25.4 14 356 9 229

Pierce

Delay

134 0.25 1/8 3.2 454 11,532 295 7,493
139 0.25 1/4 6.4 176 4,470 114 2,896
144 0.75 3/8 9.5 121 3,073 60 1,524
146 0.75 1/2 12.7 75 1,905 37 940
154 N/A 3/4 19.0 37 940 19 483

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

OM-201 872 Page 31

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

Arc Current

Arc Voltage

Pierce

60

Arc Current

Arc Voltage

Pierce

60

Arc Current

Arc Voltage

Pierce

60

60 Amp Machine Torch Shielded Consumables

The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts.

Sense Tab*

212 733212 732 212 734212 724219 676

226 763

*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.

Swirl RingElectrodeTipRetaining CapShield

ICE-100TM Torch

. Shield sense tab is located in the consumable storage box on left side of unit wrapper.

Mild Steel

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

60

Pierce

Delay

134 0 16 ga 1.5 627 15,926 502 12,751
134 0 10 ga 3.4 264 6,706 211 5,359
138 0.25 1/4 6.4 132 3,353 86 2,184
141 0.75 3/8 9.5 63 1,600 41 1,041
142 1.5 1/2 12.7 42 1,067 27 686
147 1.5 5/8 15.9 31 787 20 512
153 1.5 3/4 19.0 22 559 14 363

Stainless

60

Aluminum

Pierce

Delay

134 0 16 ga 1.5 625 15,875 406 10,312
136 0.25 10 ga 3.4 244 6,198 159 4,039
140 0.5 1/4 6.4 110 2,794 72 1,829
145 0.75 3/8 9.5 53 1,346 34 864
146 2 1/2 12.7 35 889 23 584
149 2 5/8 15.9 26 660 17 429
154 2 3/4 19.0 18 457 12 297

Pierce

Delay

135 0 1/16 1.6 666 16,916 433 10,995
138 0.25 1/8 3.2 400 10,160 260 6,604
141 0.75 1/4 6.4 145 3,683 94 2,388
146 1.5 3/8 9.5 74 1,880 48 1,219
150 1.5 1/2 12.7 51 1,295 30 762
153 1.5 5/8 15.9 33 838 21 545

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

OM-201 872 Page 32

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

Arc Current

Arc Voltage

Pierce

40

Arc Current

Arc Voltage

Pierce

40

Arc Current

Arc Voltage

Pierce

40

40 Amp Machine Torch Shielded Consumables

The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts.

Sense Tab*

212 733212 732 212 734212 724212 725

226 763

*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.

Swirl RingElectrodeTipRetaining CapShield

ICE-100TM Torch

. Shield sense tab is located in the consumable storage box on left side of unit wrapper.

Mild Steel

Pierce

Delay

142 0.25 14 ga 1.9 640 16,256 221 5,613
146 0.5 10 ga 3.4 151 3,835 98 2,489
147 0.75 3/16 4.7 97 2,464 63 1,600
149 1 1/4 6.4 74 1,880 48 1,219

Stainless

Pierce

Delay

141 0.25 18 ga 1.3 592 15,037 335 8,509
144 0.25 16 ga 1.5 374 9,500 243 6,172
144 0.25 14 ga 1.9 221 5,613 144 3,658
147 0.5 10 ga 3.4 107 2,718 70 1,778
149 0.75 3/16 4.7 67 1,702 44 1,118
149 1 1/4 6.4 47 1,194 31 787

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Aluminum

Pierce

Delay

145 0.25 3/32 2.4 293 7,442 190 4,826

40

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

149 0.5 1/8 3.2 204 5,182 133 3,378
151 1 1/4 6.4 76 1,930 49 1,245

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

OM-201 872 Page 33

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

Arc Current

Arc Voltage

Pierce

100

Arc Current

Arc Voltage

Pierce

100

Arc Current

Arc Voltage

Pierce

100

100 Amp Machine Torch Extended Consumables

The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.

Mild Steel

100

Stainless

100

Swirl RingElectrodeTipRetaining CapDeflector

219 677219 678219 683219 684212 736

Pierce

Delay

136 0.5 1/4 6.4 210 5,334 138 3,505
139 0.5 3/8 9.5 122 3,098 80 2,032
142 1.0 1/2 12.7 91 2,311 60 1,524
146 1.0 5/8 15.9 57 1,447 37 939
151 1.5 3/4 19.0 43 1,092 28 711
155 2.0 1 25.4 26 660 17 431
160 2.0 1-1/4 31.8 16 406 10 254

Pierce

Delay

142 0.5 1/4 6.4 240 6,121 153 3,886
145 0.5 3/8 9.5 131 3,327 85 2,159
148 1.0 1/2 12.7 80 2,032 53 1,346
151 1.0 5/8 15.9 51 1,295 33 838
156 1.5 3/4 19.0 33 838 22 558
161 2.0 1 25.4 22 558 14 355
173 2.0 1-1/4 31.8 11 279 7 177

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

ICE-100TM Torch

Aluminum

Pierce

Delay

144 0.5 1/4 6.4 260 6,604 167 4,242
146 0.5 3/8 9.5 153 3,886 99 2,514
148 1.0 1/2 12.7 107 2,717 72 1,828
153 1.0 5/8 15.9 77 1,955 50 1,270
157 1.5 3/4 19.0 51 1,295 33 838
160 2.0 1 25.4 31 787 20 508

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

OM-201 872 Page 34

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

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

Arc Current

Arc Voltage

Pierce

Arc Current

Arc Voltage

Pierce

80

Arc Current

Arc Voltage

Pierce

80 Amp Machine Torch Extended Consumables

The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.

Swirl RingElectrodeTipRetaining CapDeflector

212 734212 724212 728212 733212 736

ICE-100TM Torch

Mild Steel

Pierce

Delay

80 138 0.25 3/16 4.7 221 5,613 142 3,607
80 140 0.5 1/4 6.4 170 4,318 110 2,794
80 143 0.5 3/8 9.5 98 2,489 63 1,600
80 146 0.5 1/2 12.7 62 1,574 42 1,067
80 149 1 5/8 15.8 42 1,066 28 711

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Stainless

Pierce

Delay

138 0.5 1/4 6.4 160 4,064 106 2,692
143 1 1/2 12.7 55 1,397 34 863

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Aluminum

Pierce

Delay

80 140 0.25 1/4 6.4 140 3,556 120 3,048
80 147 1 1/2 12.7 80 2,032 42 1,067

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

OM-201 872 Page 35

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

Arc Current

Arc Voltage

Pierce

Arc Current

Arc Voltage

Pierce

60

Arc Current

Arc Voltage

Pierce

60 Amp Machine Torch Extended Consumables

The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.

Swirl RingElectrodeTipRetaining CapDeflector

212 734212 724219 682212 733212 736

ICE-100TM Torch

Mild Steel

Pierce

Delay

60 136 0.25 3/16 4.5 185 4,699 105 2,667
60 139 0.25 1/4 6.4 131 3,327 87 2,210
60 141 0.75 3/8 9.5 70 1,778 44 1,118

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Stainless

Pierce

Delay

134 0 14 ga 2.2 610 15,494 385 9,779
138 0.5 1/4 6.4 114 2,896 74 1,879

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Aluminum

Pierce

Delay

60 138 0 1/16 1.6 669 16,992 436 11,074
60 142 0.25 1/4 6.4 153 3,886 97 2,463
60 147 1.25 1/2 12.7 56 1,422 33 838

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

OM-201 872 Page 36

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

Arc Current

Arc Voltage

Pierce

40

Arc Current

Arc Voltage

Pierce

40

Arc Current

Arc Voltage

Pierce

40

40 Amp Machine Torch Extended Consumables

The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts.

Mild Steel

40

Stainless

40

Swirl RingElectrodeTipRetaining CapDeflector

212 734212 724212 729212 733212 736

Pierce

Delay

126 0 14 ga 1.9 320 8,128 214 5,435
134 0.75 3/16 4.8 95 2,413 63 1,600
138 1 1/4 6.4 73 1,854 49 1,245

Pierce

Delay

123 0 18 ga 1.3 515 13,081 328 8,331
130 0.25 14 ga 1.9 222 5,638 145 3,683
138 1 1/4 6.4 50 1,270 35 889

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

ICE-100TM Torch

Aluminum

Pierce

Delay

148 0.5 1/8 3.2 214 5,435 135 3,429
150 1 1/4 6.4 81 2,057 52 1,320

Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Inches mm IPM mm/min IPM mm/min

OM-201 872 Page 37

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

.

Week

Week

Months

Months

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

Each
Use

Every

Every
3

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

n Torch Tip, Electrode,
And Shield Cup

n Shield Cup Shutdown
System

l Damaged Or Unreadable
Labels

n Gas/Air Pressure

l Cracked Parts ~ Air Filter/Regulator

Assembly Filter

Y Disconnect power

before maintaining.

n Gas/Air Hose

. Maintain more often

during severe conditions

Reference

Every
6

n l Torch Body, Cable

OR

~ Inside Unit

OM-201 872 Page 38

7-2. Trouble Lights

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

Difficulty establishing pilot arc may indicate
consumables need to be cleaned or replaced.

1

2

3

1 Pressure Light
Lights if g as/air pressure at torch is

below 5 0 PSI (344 kPa) or above 90
PSI (620 kPa).

Turn power Off, and check for prop­er gas/air pressure (see Section
5-2).

2 Cup Light
Lights if shield cup is loose.
Turn power Off, and check shield

cup connection (see torch Owner’s
Manual). Power must be reset
whenever the cup shutdown is
activated.

Check shield cup shutdown system
once a week (see Section 7-3).

3 Temperature Light
Lights if power source overheats

(see Section 4-2).

7-3. Checking 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.

1

1 Torch Shield Cup
Turn Power On and loosen shield

cup. If shutdown system works
properly, Ready light goes off and
Cup light comes on. If not, immedi­ately turn Off power and have Fac­tory Authorized Service Agent
check safety control board PC1 op­eration.

If system works properly, retighten
cup and reset power.

Ref. 801 300-A

OM-201 872 Page 39

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

7-4. Checking/Replacing Retaining Cup, Tip, And Electrode

Overtightening will strip threads. Do not overtighten electrode, tip,
and retaining cup during assembly. Do not cross-thread parts causing
stripping. Use care during torch assembly and parts replacement.

Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly
reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.

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

Turn Off power source before checking torch parts.

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

3

New

4

Make sure this area i s
clean of any debris.

1

Worn

2

5

New

Worn

Make sure this area is
clean of any debris.

8

7

6

Turn Off power source.
1 Drag Shield
Check this area for any debris or foreign

material. Clean out if necessary.
2 Retaining Cup
Remove retaining cup. Check retaining cup

for cracks, and replace if necessary.
3Tip
4 Opening

OM-201 872 Page 40

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.

5 Electrode
Check electrode. If center has a pit more

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

6 Swirl Ring

804 056-A

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

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

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

8 Plunger Area
Check this area for any debris or foreign

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

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

7-5. Checking Or Replacing Filter Element

1 Latch
2 Filter Cup
3 Retaining Nut
4 Filter Element
5 Defuser Ring

6

5

4

3

6 Filter Cap
Slide latch down, and rotate filter

cup approximately 1/4 turn.
Remove cup.
Remove retaining nut, filter

element, and defuser ring.
Check filter element for dirt and

moisture, and replace if necessary.
Be sure that all parts are clean and

dry.
Reinstall all parts, and secure filter

cup.

1

2

804 054-A

OM-201 872 Page 41

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

arc.

7-6. Troubleshooting Power Source

Trouble Remedy

No pilot arc; difficulty in establishing an

No cutting output; Power light off;
Trouble lights off; Ready light off; fan
motor FM does not run.

Pilot arc working; no cutting output;
Power light on; Trouble lights off; fan
motor running.

No gas/air flow; Power light on; Trouble
lights off; fan motor running.

Pressure Trouble light On. Check for correct gas/air pressure adjustment (see Section 5-2).

Clean or replace worn consumables as necessary (see torch Owner’s Manual).
Check for damaged torch or torch cable (see torch Owner’s Manual).
Check position of cut/gouge switch. If using cutting consumables, be sure that switch is in the CUT

position. If using gouging consumables, be sure that switch is in the GOUGE position.

Place Power switch in On position.

Place line disconnect device in On position (see Section 4-7).
Check line fuse(s) and replace if needed or reset circuit breakers (see Section 4-9).
Be sure work clamp is connected.

Clean or replace worn consumables as necessary (see torch Owner’s Manual).
Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas

valve AS1, and check gas/air system for leaks. Check filter element (see Section 7-5).

Check for sufficient gas/air supply pressure (see Section 4-5).
Check for dirty air filter/regulator and replace, if necessary (see manufacturer’s instructions).
Check air lines for leaks.
Have Factory Authorized Service Agent check pressure switch and control board.

Cup Trouble light On. Check torch shield cup (see Section 7-3). Reset power switch.

Have Factory Authorized Service Agent check for proper torch connections.

Temperature Trouble light On. Unit overheating. Allow fan to run; the Trouble light goes out when the unit has cooled.

Have Factory Authorized Service Agent check control board.
Trouble lights not working. Have Factory Authorized Service Agent check unit.
Power light flashing, Trouble lights off. Reset power switch. Have qualified technician check input line power. Make sure line power is three

Pressure trouble light flashes. Unit lost pressure (momentarily) while cutting. Check air line for leaks.
Short tip life.

phase. Single phase power will cause an incorrect power condition.

Check and clean drag shield of any slag, particles, and debris.

Check position of cut/gouge switch. Place switch in correct position to match the process.

Check for correct gas/air pressure adjustment (see Section 5-2).

OM-201 872 Page 42

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

7-7. Troubleshooting Torch

Trouble Remedy

Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 5-5). Clean or replace torch consumables

Arc goes out while cutting. Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in (1.6 mm) to

Sparks come out top of cut or cut is not
clean.

Trouble lights are on; unit has no cutting
output.

as necessary (see Section 7-4). Be sure work clamp is securely attached to workpiece.

1/8 in (3.2 mm)] workpiece (see Section 5-5). Clean or replace torch consumables as necessary (see

Section 7-4).

Torch travel speed too fast; reduce travel speed (see Section 5-5). Clean or replace torch consumables

as necessary (see Section 7-4). Be sure work clamp is securely attached to workpiece. Unit not capable

of cutting metals thicker than rating (see Section 4-3).

Check torch consumables. Check for gas/air flow at torch. Check air supply connection and pressure to

unit and torch. Reset unit Power switch. Have Factory Authorized Service Agent check torch and

connections inside unit.

OM-201 872 Page 43

SECTION 8 − ELECTRICAL DIAGRAM

OM-201 872 Page 44

Figure 8-1. Circuit Diagram For Power Source

201 858-A

OM-201 872 Page 45

SECTION 9 − PARTS LIST

Part

Dia.

Item

ty

9-1. Recommended Spare Parts

No.

Mkgs.

No.

Description

Quanti

Recommended Spare Parts

224749 COVER ASSY (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223835 LABEL,ICE 100T CONSUMABLES 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215089 FILTER,AIR ELEMENT 5 MICRON 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223834 CABLE,WORK 25 FT 4 GA W/CLAMP STRAIN RLF & TERM (including) 1. . . . . . . . . . . . . . . . . . . .

201846 CABLE,WORK 50 FT NO 4 W/CLAMP STRAIN RLF & TERM (including) 1. . . . . . . . . . . . . . . . . . . .

213619 CLAMP,WORK 300 AMP STL CHROME PLD W/COP CONTACTS 1. . . . . . . . . . . . . . . . . . . . . . . . . .

134900 STRAIN RELIEF,CABLE FLEXIBLE .270−.480 CABLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225702 ICE−100T 25 FT HAND HELD REPLACEMENT TORCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225704 ICE−100T 50 FT HAND HELD REPLACEMENT TORCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225706 ICE−100TM 25 FT MACHINE REPLACEMENT TORCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225708 ICE−100TM 50 FT MACHINE REPLACEMENT TORCH 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.

Part

Item

No.

No. Description

1 215 59 4 Handle w/Screws (1)
2 215 478 Switch, cup sensor (1)
3 223 775 Torch Head Repair Kit (1)
4 185 833 Switch Assy w/Spring (1)
5 190 220 Trigger Spring (1)
6 215 592 Switch Trigger (1)
7 223 774 Main Body w/Switch (1)
8 223 612 Torch Lead, 25ft (1)
8 223 613 Torch Lead, 50ft (1)

Part

Item

No.

No. Description

9 215 606 Clip, retaining (1)

10 212 735 O-Ring, main body (1)

169 231 Grease, silicon
225 702 T orch, replacement 25ft (1)
225 704 T orch, replacement 50ft (1)

8

1

2

7

3

10

4

6

5

9

See Figure 9-2 for

additional consumable parts.

1

804 035-A

Figure 9-1. Torch, ICE-100T

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-201 872 Page 46

40A

60A

212 730

212 733

212 725

CAUTION

FAILURETORE−
PLACEWORNTIP

Swirl RingElectrodeTipRetaining CapDrag Shield

ORELECTRODE
WILLRUINTORCH
ANDVOID
WARRANTY.

Turnoffpowerbefore
checkingtorchparts.

Checkbeforeeach
useandhourly
duringoperation.

80A

100A

60A

80A

212 730

212 730

212 731

212 733

212 733

219 684219 685

212 733

219 676

212 726

Standard Cutting

219 680

212 724

219 678219 679

212 724

212 734

219 677

Swirl RingElectrodeTipRetaining CapShield

212 734

O-Ring

212 735

O-Ring

212 735

212 727

219 678219 681

219 677

100A

212 731

212 733

219 684212 731

Gouging

Ref. 213 031-B / Ref. 804 056-A

Figure 9-2. Consumable Parts For ICE-100T

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-201 872 Page 47

40A

60A

212 732

212 732

Sense Tab*

226 763

226 763

212 733

212 733

212 725

219 676

212 724

Swirl RingElectrodeTipRetaining CapShield

212 734

CAUTION

FAILURETORE−
PLACEWORNTIP
ORELECTRODE
WILLRUINTORCH
ANDVOID
WARRANTY.

Turnoffpowerbefore
checkingtorchparts.

Checkbeforeeach
useandhourly
duringoperation.

80A

100A

212 732

226 763

226 763

212 733

219 684219 687

212 726

219 678219 679

219 677

O-Ring

212 735

Machine Cutting

*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.

Swirl RingElectrodeTipRetaining CapDeflector

40A

212 729

219 682

212 734212 724

O-Ring

212 735

60A

212 736

212 736

212 733

212 733

80A

212 728

219 677219 678219 683219 684212 736

100A

212 736

212 733

Extended Cutting

Ref. 213 031-B / Ref. 804 056-A

Figure 9-3. Consumable Parts For ICE-100TM

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-201 872 Page 48

Part

Item

No.

No. Description

1 215 607 Sleeve, torch position (1)
2 223 614 Torch Lead, 25ft (1)
2 223 615 Torch Lead, 50ft (1)
3 215 599 Torch Sleeve (1)
4 223 773 Main Body w/Switch (1)
5 195 513 Remote Pendant Control (1)
6 215 478 Switch, cup sensor (1)

225 706 T orch, replacement 25ft (1)
225 708 T orch, replacement 50ft (1)
220 240 Cable, remote control trigger 25ft (1)
220 241 Cable, remote voltage sense 26.5ft (1)

6

See Figure 9-3 for

additional consumable parts.

1

2

4

3

5

804 036-A

Figure 9-4. Torch, ICE-100TM

NOTE

A complete Parts List is available on-liine 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-201 872 Page 49

Notes

Warranty Questions?

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

Y our distributor also gives
you ...

Service

Y ou always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2007

(Equipment with a serial number preface of “LH” 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 th e
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

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)

* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

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

1. Consumable components; such as contact tips,

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

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

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

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

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation 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 2007−01

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 Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 US A

International Headquarters− U SA

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

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

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.

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01