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AUTO ARC pmn manual

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Table of contents for the manual

  • Page 1

    OM-228 305D 2007−06 Auto Arc Quick Cut 4500 And Ice-27C T orch R ® For W arranty Claims And T echnical Support, Contact: Milweld Inc., National Distributor P .O. Box 338, Hortonville, WI 54944-0338 T el 920-779-0916 Fax 920-779-0924 Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter File: Plasma Cutters[...]

  • Page 2

    [...]

  • Page 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 . . . . . [...]

  • Page 4

    [...]

  • Page 5

    OM-228 305 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-228 305 Page 2 SIGNIFICANT DC VOL T AGE exists in inverter power sources AFTER the re - moval 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 Mainte- nance Section of Owner ’s Ma nual o[...]

  • Page 7

    OM-228 305 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[...]

  • Page 8

    OM-228 305 Page 4 1-4. California Proposition 65 W arnings 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.) Battery posts, terminals and related accessories contain lead and [...]

  • Page 9

    OM-228 305 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom2007−04fre Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves[...]

  • Page 10

    OM-228 305 Page 6 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 A vant d’ef fectuer les connexions d’alimentation, [...]

  • Page 11

    OM-228 305 Page 7 D Ne coupez pas dans un endroit près d’opérations de décapage, de nettoyage ou d e vaporisation. La chaleur et les rayons d’arc peu- vent réagir avec les vapeurs et former des gaz hautement toxiques et irritants. D Ne coupez pas des métaux enrobés tels que des métaux galvani- sés, contenant du plomb ou de l’acier pla[...]

  • Page 12

    OM-228 305 Page 8 Danger D’EXPLOSION D’HYDROGÈNE. D Lors d u coupage d’aluminium partiellement ou totalement immergé dans l’eau, de l’hydrogène libre peut s’accumuler sous la pièce. D Consultez votre ingénieur de coupage et les instructions de la table de coupage. LA CHUTE DE L ’APP AREIL peut blesser . D Utiliser l’anneau de l[...]

  • Page 13

    OM-228 305 Page 9 2-5. P r inc ip al es n or m es d e sé cur it é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, de Global Engine[...]

  • Page 14

    OM-228 305 Page 10 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label 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 Percent Direct Cu[...]

  • Page 15

    OM-228 305 Page 1 1 SECTION 4 − INST ALLA TION 4-1. Specifications . If the unit is operated from a 30* ampere, 1 15 volt circuit or a 15** ampere, 230 volt circuit, a different input power plug must be installed on the power cord. See Section 4-9 for instructions. *A 30 ampere branch circuit is recommended for maximum performance. Performance on[...]

  • Page 16

    OM-228 305 Page 12 4-4. T orch Dimensions And Weight Ref. 802 877 3.0 lb (1.4 kg) 1 in (25 mm) 8-3/8 in (213 mm) 1-3/8 in (35 mm) 4-5. Selecting A Location loc_2 3/96 - Ref. 804 486-A / 804 487-A / 804 488-A 1 Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 120 V AC Receptacle T o connect unit to 230 V[...]

  • Page 17

    OM-228 305 Page 13 4-6. Connecting Gas/Air Supply 802 787-A / Ref. 801 319-C / Ref. 804 486-A . Use only clean, dry air with 90 to 120 psi (621 to 827 kPa) pressure. 1 Gas/Air Inlet Opening 2 Hose 3 T eflon T ap e Obtain hose with 1/4 NPT right- hand thread fitting. Wrap threads with teflon tape (optional) or apply pipe sealant, and install fitting[...]

  • Page 18

    OM-228 305 Page 14 4-7. Connecting W ork Clamp 802 463-A 1 Work Clamp 2 W orkpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 1 2 4-8. Connecting Input Power Ref. 802 787-A / 804 488-A Check input voltage available at site. 1 Changeover Switch Switch is accessible through slot in rear pane[...]

  • Page 19

    OM-228 305 Page 15 4-9. Installing Alternative Plug 1 Supplied 1 1 5 V AC Plug Cut cord close to plug. 2 Alternative PLug (230 V AC Plug Shown) 3 Load 1 (Brass) T erminal 4 Load 2 (Brass) T erminal 5 Ground (Green) T erminal 6 Outer Shell 7 Cord Grip Strip cord jacket back enough to separate conductors. Strip conduc- tors enough to make good contac[...]

  • Page 20

    OM-228 305 Page 16 SECTION 5 − OPERA TION 5-1. Controls 1 42 3 ON OFF PRESSURE 60 PSI 5 6 24 27 20 16 24 27 20 16 1 24 27 20 16 Requires 90-120 PSI (621-827 kPa) Supply Setting Gas/Air Pressure 1 Output Control Use control to set cutting output. Place control in Gas/Air Set position to safely adjust gas/air pressure. Only gas/air circuit is activ[...]

  • Page 21

    OM-228 305 Page 17 5-2. Cutting Speed Recommended Cut Speeds At 27 Amperes Output Thickness Recommended Cut Speeds* Inches mm ipm mm/min Mild Steel 16 ga 1.5 188 4,775 Mild Steel 3/16 4.8 40 1,016 1/4 6.4 24 610 3/8 9.5 14 256 1/2 12.7 6 152 *Recommended Cut Speed is approximately 80% of maximum. . Aluminum and Stainless Steel cut speeds at these t[...]

  • Page 22

    OM-228 305 Page 18 out bottom of cut. Ref. 802 878 5-4. Sequence Of 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 . EXAMPLE Of Cutting Operation Raise trigger lock and press trigger . Pilot arc starts. Postflow continues[...]

  • Page 23

    OM-228 305 Page 19 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! 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 Use Section 4-6 , 6-4 Use n Gas/Air Pressure n T orch Tip, Ele[...]

  • Page 24

    OM-228 305 Page 20 6-2. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System If certain problems occur , the Ready light goes off, a trouble light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). T urn power Off, and check for proper gas/air pressure (see Section 5-1). A fl[...]

  • Page 25

    OM-228 305 Page 21 6-3. T orch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: T urn power Of f, and disconnect input power plug from receptacle. Remove wrapper from unit. T orch Connections Remove existing torch cable from unit. 1 Strain Relief 2 T orch Cable Insert cable through strain relief[...]

  • Page 26

    OM-228 305 Page 22 6-4. Checking/Replacing Retaining Cup, Tip, And Electrode ! Overtightening will strip threads. Do not overtighten retaining cup during assembly . Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. ! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting s[...]

  • Page 27

    OM-228 305 Page 23 6-5. T roubleshooting Power Source Connect unit to proper input voltage (see Section 4-8). Ye s No Is input power connected to correct line voltage? Is Changeover switch S2 in the 1 15V or 230V position? Place Changeover switch i n proper position for input voltage (see Section 4-8). No Ye s Is the cooling fan running? Check Powe[...]

  • Page 28

    OM-228 305 Page 24 6-6. T roubleshooting T orch T orch travel speed too slow; increase travel speed (see Section 5-2). Clean or replace torch consumables as necessary (see Section 6-4 ). Be sure work clamp is securely attached to workpiece. Ye s No Does arc go on and off while cutting? Does arc go out while cutting? No Ye s Be sure work clamp is se[...]

  • Page 29

    OM-228 305 Page 25 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram 227 893-A[...]

  • Page 30

    OM-228 305 Page 26 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 804 490-B 13 18 16 4 5 1 2 26 6 25 24 22 20 19 21 7 8 9 10 11 12 15 23 3 17 14 Figure 8-1. Main Assembly[...]

  • Page 31

    OM-228 305 Page 27 Figure 8-1. Main Assembly Diagram marking Item No. Part No. Description Quantit y 1 204 326 CONSUMABLE ST ORAGE BOX w/DOOR (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 089 899 LA TCH, slide 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    OM-228 305 Page 28 1 183 427 Handle Assy , complete (1) 2 171 248 Push Button Switch (1) 3 203 120 Leads, 20ft (1) 4 203 1 1 9 Main Body (1) 5 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 195 014 T orch, replacement 20ft (1) See Figure 8-3 for additional consumable parts. 1 1 2 3 4 5 Item No. Pa[...]

  • Page 33

    Notes[...]

  • Page 34

    Notes[...]

  • Page 35

    Effective January 1, 2007 (Equipment with a serial number preface of “LH” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties express ed or implied. LIMITED W ARRANTY − Subject to the terms and conditions below , warrants to its original retail purchaser that[...]

  • Page 36

    PRINTED IN USA 2007−01 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Acces[...]