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Miller Electric ICE-100TM manual

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Buen manual de instrucciones

Las leyes obligan al vendedor a entregarle al comprador, junto con el producto, el manual de instrucciones Miller Electric ICE-100TM. La falta del manual o facilitar información incorrecta al consumidor constituyen una base de reclamación por no estar de acuerdo el producto con el contrato. Según la ley, está permitido adjuntar un manual de otra forma que no sea en papel, lo cual últimamente es bastante común y los fabricantes nos facilitan un manual gráfico, su versión electrónica Miller Electric ICE-100TM o vídeos de instrucciones para usuarios. La condición es que tenga una forma legible y entendible.

¿Qué es un manual de instrucciones?

El nombre proviene de la palabra latina “instructio”, es decir, ordenar. Por lo tanto, en un manual Miller Electric ICE-100TM se puede encontrar la descripción de las etapas de actuación. El propósito de un manual es enseñar, facilitar el encendido o el uso de un dispositivo o la realización de acciones concretas. Un manual de instrucciones también es una fuente de información acerca de un objeto o un servicio, es una pista.

Desafortunadamente pocos usuarios destinan su tiempo a leer manuales Miller Electric ICE-100TM, sin embargo, un buen manual nos permite, no solo conocer una cantidad de funcionalidades adicionales del dispositivo comprado, sino también evitar la mayoría de fallos.

Entonces, ¿qué debe contener el manual de instrucciones perfecto?

Sobre todo, un manual de instrucciones Miller Electric ICE-100TM debe contener:
- información acerca de las especificaciones técnicas del dispositivo Miller Electric ICE-100TM
- nombre de fabricante y año de fabricación del dispositivo Miller Electric ICE-100TM
- condiciones de uso, configuración y mantenimiento del dispositivo Miller Electric ICE-100TM
- marcas de seguridad y certificados que confirmen su concordancia con determinadas normativas

¿Por qué no leemos los manuales de instrucciones?

Normalmente es por la falta de tiempo y seguridad acerca de las funcionalidades determinadas de los dispositivos comprados. Desafortunadamente la conexión y el encendido de Miller Electric ICE-100TM no es suficiente. El manual de instrucciones siempre contiene una serie de indicaciones acerca de determinadas funcionalidades, normas de seguridad, consejos de mantenimiento (incluso qué productos usar), fallos eventuales de Miller Electric ICE-100TM y maneras de solucionar los problemas que puedan ocurrir durante su uso. Al final, en un manual se pueden encontrar los detalles de servicio técnico Miller Electric en caso de que las soluciones propuestas no hayan funcionado. Actualmente gozan de éxito manuales de instrucciones en forma de animaciones interesantes o vídeo manuales que llegan al usuario mucho mejor que en forma de un folleto. Este tipo de manual ayuda a que el usuario vea el vídeo entero sin saltarse las especificaciones y las descripciones técnicas complicadas de Miller Electric ICE-100TM, como se suele hacer teniendo una versión en papel.

¿Por qué vale la pena leer los manuales de instrucciones?

Sobre todo es en ellos donde encontraremos las respuestas acerca de la construcción, las posibilidades del dispositivo Miller Electric ICE-100TM, el uso de determinados accesorios y una serie de informaciones que permiten aprovechar completamente sus funciones y comodidades.

Tras una compra exitosa de un equipo o un dispositivo, vale la pena dedicar un momento para familiarizarse con cada parte del manual Miller Electric ICE-100TM. Actualmente se preparan y traducen con dedicación, para que no solo sean comprensibles para los usuarios, sino que también cumplan su función básica de información y ayuda.

Índice de manuales de instrucciones

  • Página 1

    Spectrum 1251 And ICE-100T/TM T orch Processes Descrip tio n Air Plasma Cutting and Gouging Air Plasma Cutter OM - 201 872D 2007−03 R File: Plasma Cutters V isit our website at www.MillerWelds.com[...]

  • Página 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Página 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards 1 . . . . . [...]

  • Página 4

    T ABLE OF CONTENTS SECTION 7 − MAINTENANCE & TROUBLESHOOTING 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. T rouble Lights 39 . . . . . [...]

  • Página 5

    OM-201 872 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _4/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me[...]

  • Página 6

    OM-201 872 Page 2 D On inverter power sources, failed parts can ex- plode or cause other parts to explode when power is applied. Always wear a face shield and long sleeves when servicing inverters. EXPLODING P ARTS can injure. Sparks and hot metal blow out from the cutting arc . Chipping and grinding cause flying metal. FL YING SP ARKS can cause in[...]

  • Página 7

    OM-201 872 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance HOT P ARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. D T o handle hot parts, use proper tools and/or wear heavy , insulated welding gloves and clothing to prevent burns. MOVING P ARTS can cause i[...]

  • Página 8

    OM-201 872 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Practices for Plasma Arc Cutting , American Welding Society Standard A WS C5.2, from Global Engineering Documents (phone: 1-87[...]

  • Página 9

    OM-201 872 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 4/05 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[...]

  • Página 10

    OM-201 872 Page 6 D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée. D Le câble de masse doit être pincé correctement sur la pièce à cou- per , métal contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table de travail le plus près possible de la ligne de coupage. D Isole[...]

  • Página 11

    OM-201 872 Page 7 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[...]

  • Página 12

    OM-201 872 Page 8 LE COUP AGE Ã L ’ARC peut causer des interférence. D L ’énergie électromagnétique peut gêner le fonction- nement d’appareils électroniques comme des ordi- nateurs 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 [...]

  • Página 13

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Plasma Arc Cutting (P AC) Adjust Air/Gas Pressure Low Air Pressure Light V V olts Increase No − Do Not Do This T emperature Protective Earth (Ground) Single Phase Constant Current Voltage Input On Of f P[...]

  • Página 14

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications Amperes Input at Rated Load Output 60 Hz, Three-Phase* Rated T ype of Plasma Rated Maximum Open- Duty Cycle Rated Output T ype of Output Plasma Gas Rated Cutting Capacity Maximum Open- Circuit 40% 50% 80% 80% Output Outp[...]

  • Página 15

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 1 1 4-2. Duty Cycle and Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. If unit overheats, output stops, an d cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or duty cycle before cutting.[...]

  • Página 16

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 12 4-4. Selecting a Location loc_2 3/96 - Ref. 151 556 / 802 183 1 Lifting Handles 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 [...]

  • Página 17

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 13 4-5. Connecting W ork Clamp and Gas/Air Supply 1 Work Clamp 2 W orkpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. . Use only clean, dry air with 90 to 120 psi (621 to 827 kPa) pressure @ 9.2 CFM (260L/min) m[...]

  • Página 18

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 14 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 [...]

  • Página 19

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 15 4-8. Extension Cord Data When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle. NOTE Input V oltage Input Power Phase Hertz Fuse Size Or Circuit Breaker Rating Conductor Size Max. Cord Length 208 V[...]

  • Página 20

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 16 4-9. Connecting 3-Phase Input Power 803 766-A / 802 183 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 conn[...]

  • Página 21

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 17 4-10. Connecting T o Miller Welder/Generator With A Three-Phase AC Power Plant Ref. 197 399 / 802 332-B Three-Phase Ge n e r a t o r P o w e r Y Stop engine. Y Power and weld outputs are live at the same time. Discon- nect or insulate unused cables. . Have qualified pe[...]

  • Página 22

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 18 SECTION 5 − OPERA TION 5-1. Controls 1 Gas/Air Pressure Gauge 2 Gas/Air Pressure Control 3 Output Control Use control to select cutting output in am- peres. Gas/air automatically flows at the set pressure. Us e Gas/Air Set area of control range for set- ting gas/air [...]

  • Página 23

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 19 5-2. Setting Gas/Air Pressure Ref. 804 025-A / Ref. 804 026-A T urn On Gas/Air Supply . Power Switch On. Place Output Control in Gas/Air Set Position. Pull knob and turn, set pressure to 75 PSI (517 kPa). Push knob in to lock setting. 1 Power Switch Setting Gas/Air Pre[...]

  • Página 24

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 20 Ref. 803 640-A / 801 400-B / Ref. 802 878 5-4. Plasma Cutting System Practices Pulling rather than pushing the torch makes cutting easier . Use a proper guide or template for accurate cutting operations. The pilot arc starts immediately when trigger is pressed. Maintai[...]

  • Página 25

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 21 out bottom of cut. Ref. 803 640-A / 801 400-B 5-5. Sequence Of Cutting Operation After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and Pause briefly at end of cut before releasing trigger . Raise trigger lock a[...]

  • Página 26

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 22 Ref. 803 640-A / 801 400-B 5-6. Sequence Of Gouging Operation Raise trigger lock and press trigger . Pilot arc starts. Move tip to within approxi- mately 3/16 in (4.8 mm). Start gouging across workpiece surface. Maintain approximately a 45 ° angle to surface. Release [...]

  • Página 27

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 23 Ref. 803 640-A / 801 400-B 5-7. Sequence Of Piercing Operation Maintain approximately 90 ° torch position to surface, and continue cutting. Release trigger . Postflow continues for approx. 20 seconds after releasing trigger; arc can be instantly restarted during postf[...]

  • Página 28

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 24 SECTION 6 − MECHANIZED OPERA TION 6-1. ICE-100TM Mounting Position 1 ICE-100TM Machine T orch 2 Square Us e a square to align torch perpen- dicular to the work surface. 1 90 ° 2 6-2. Remote Control Receptacle 804 026-A 1 Remote Control Receptacle RC61 RC61 provides [...]

  • Página 29

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 25 6-4. +24 V olts DC Hot Contacts For Relay Operation 804 041-A Y T urn off and disconnect input power . Control board PC1 can supply +2 4 volts dc from receptacle RMT2 to operate a customer-supplied relay for the Okay T o Move signal. 1 Control Board PC1 2 Receptacle RM[...]

  • Página 30

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 26 6-5. +24 V olts DC Hot Contacts For Isolated Input Module Operation 804 041-A Y T urn off and disconnect input power . Control board PC1 can supply +2 4 volts dc from receptacle RMT2 to operate a customer-supplied isolated input module for the Okay T o Move signal. 1 C[...]

  • Página 31

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 27 6-6. Dry Contacts Using An External Power Supply For Relay Operation 804 041-A Y T urn 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 T o [...]

  • Página 32

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 28 6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation 804 041-A Y T urn 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 externa[...]

  • Página 33

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 29 6-8. Remote V oltage Sense Connection 804 041-A Y T urn 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 Rem[...]

  • Página 34

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 30 6-10. Cut Charts 100 Amp Machine T orch 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. 219 684 219 687 219 677 219 678 219 679 Swirl Ring Electrode Ti p Retaining Cap Shield ICE-100TM T[...]

  • Página 35

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 31 80 Amp Machine T orch 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. 212 733 212 732 212 734 212 724 212 726 Swirl Ring Electrode Ti p Retaining Cap Shield ICE-100TM T orch Sense T ab*[...]

  • Página 36

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 32 60 Amp Machine T orch 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. 212 733 212 732 212 734 212 724 219 676 Swirl Ring Electrode Ti p Retaining Cap Shield ICE-100TM T orch Sense T ab*[...]

  • Página 37

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 33 40 Amp Machine T orch 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. 212 733 212 732 212 734 212 724 212 725 Swirl Ring Electrode Ti p Retaining Cap Shield ICE-100TM T orch Sense T ab*[...]

  • Página 38

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 34 100 Amp Machine T orch 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. 219 677 219 678 219 683 219 684 212 736 Swirl Ring Electrode Ti p Retaining Cap Deflector ICE-100TM T orch Mil[...]

  • Página 39

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 35 80 Amp Machine T orch 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. 212 734 212 724 212 728 212 733 212 736 Swirl Ring Electrode Ti p Retaining Cap Deflector ICE-100TM T orch Mild[...]

  • Página 40

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 36 60 Amp Machine T orch 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. 212 734 212 724 219 682 212 733 212 736 Swirl Ring Electrode Ti p Retaining Cap Deflector ICE-100TM T orch Mild[...]

  • Página 41

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 37 40 Amp Machine T orch 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. 212 734 212 724 212 729 212 733 212 736 Swirl Ring Electrode Ti p Retaining Cap Deflector ICE-100TM T orch Mild[...]

  • Página 42

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 38 SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions . n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Each [...]

  • Página 43

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 39 7-2. T rouble Lights 1 Pressure Light Lights if g as/air pressure at torch is below 5 0 PSI (344 kPa) or above 90 PSI (620 kPa). Tur n power Of f, and check for prop- er gas/air pressure (see Section 5-2 ). 2 Cup Light Lights if shield cup is loose. T urn power Of f, a[...]

  • Página 44

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 40 7-4. Checking/Replacing Retaining Cup, Tip, And Electrode Overtightening will strip threads. Do not overtighten electrode, tip, an d retaining cup during assembly . Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspe[...]

  • Página 45

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 41 7-5. Checking Or Replacing Filter Element 1 Latch 2 Filter Cup 3 Retaining Nut 4 Filter Element 5 Defuser Ring 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 [...]

  • Página 46

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 42 7-6. T roubleshooting Power Source T rouble Remedy No pilot arc; dif ficulty in establishing an arc. Clean or replace worn consumables as necessary (see torch Owner ’s Manual). arc. Check for damaged torch or torch cable (see torch Owner’s Manual). Check position o[...]

  • Página 47

    . A complete Parts List is available at www .MillerW elds.com OM-201 872 Page 43 7-7. T roubleshooting T orch T rouble Remedy Arc goes on and of f while cutting. T orch travel speed too slow; increase 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 workpi[...]

  • Página 48

    OM-201 872 Page 44 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Power Source[...]

  • Página 49

    OM-201 872 Page 45 201 858-A[...]

  • Página 50

    OM-201 872 Page 46 SECTION 9 − P ARTS LIST 9-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Item No. Recommended Spare Parts Quanti ty 224749 COVER ASSY (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223835 LABEL,ICE 100T CONSUMABLES 1 . . . . .[...]

  • Página 51

    OM-201 872 Page 47 Ref. 213 031-B / Ref. 804 056-A Turnoffpowerbefore checkingtorchparts. Checkbeforeeach useandhourly duringoperation. CAUTION FAILURETORE− PLACEWORNTIP ORELECTRODE WILLRUINTORCH ANDVOID WARRANTY. Standard Cutting O-Ring 212 735 Swirl Ring Electrode Ti [...]

  • Página 52

    OM-201 872 Page 48 Ref. 213 031-B / Ref. 804 056-A Turnoffpowerbefore checkingtorchparts. Checkbeforeeach useandhourly duringoperation. CAUTION FAILURETORE− PLACEWORNTIP ORELECTRODE WILLRUINTORCH ANDVOID WARRANTY. Machine Cutting O-Ring 212 735 Swirl Ring Electrode Tip [...]

  • Página 53

    OM-201 872 Page 49 1 215 60 7 Sleeve, torch position (1) 2 223 614 T orch Lead, 25ft (1) 2 223 615 T orch Lead, 50ft (1) 3 215 599 T orch 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 co[...]

  • Página 54

    Notes[...]

  • Página 55

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 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 expert[...]

  • Página 56

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West S pencer Street Applet on, WI 5 4914 US A International He adquarters− USA USA Phone: 920-735-4505 Auto-At t ended USA & Canada FAX: 920-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rt ers − Unit[...]