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Miller Electric 125C manual

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  • Page 1

    Spectrum 125C And ICE-12C T orch Processes Description R Air Plasma Cutting and Gouging Air Plasma Cutter OM-2248 213 990E 2007−02 File: Plasma Cutters V isit our website at www.MillerWelds.com[...]

  • Page 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[...]

  • 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-2248 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 messa[...]

  • Page 6

    OM-2248 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 injur[...]

  • Page 7

    OM-2248 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 inju[...]

  • Page 8

    OM-2248 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: 1-877-4[...]

  • Page 9

    OM-2248 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 5/04 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[...]

  • Page 10

    OM-2248 Page 6 D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Il y a DU COURANT CONTINU IMPORT ANT dans les convertisseurs après la suppression de l’ali- mentation électrique. D Arrêter les convertisseurs, débrancher le courant électrique, et dé- charger les condensateurs d’alime[...]

  • Page 11

    OM-2248 Page 7 Les bouteilles de gaz contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peu t exploser . Puisque les bouteilles de gaz font habituellemen t partie d’un processus de travail des métaux, assurez−vous de les manipuler correctement. LES BOUTEILLES peuvent explose r si elles sont endommagées. D Protégez[...]

  • Page 12

    OM-2248 Page 8 2-4. Principales normes de sécurité Safety in W elding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the Prep[...]

  • Page 13

    OM-2248 Page 9 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 Curren[...]

  • Page 14

    OM-2248 Page 10 SECTION 4 − INST ALLA TION 4-1. Specifications Primary V olts Primary Amperes Primary Service (Recommended) Secondary V olts (DC) Secondary Amperes KW KV A Rated Cutting Capacity Power Factor Max** OCV (DC) 120 20.32 (0.25*) 20A 11 0 12 2.01 2.44 0.25 in (6.4 mm) At 6 IPM (2.5 mm/s) 0.82 335 *While idling **10% High line condition[...]

  • Page 15

    OM-2248 Page 1 1 4-4. T orch Dimensions And Weight Ref. 801 397-A 3.0 lb (1.4 kg) 1 in (25 mm) 8-3/8 in (213 mm) 1-3/8 in (35 mm) 18 in (457 mm) 4-5. Selecting A Location loc_2 3/96 - Ref. 802 459-B / 802 676-A / 802 460-B 1 Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 120 V AC Receptacle (Non-CE Mo[...]

  • Page 16

    OM-2248 Page 12 4-6. Connecting Work 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 4-7. Connecting Input Power 802 460-B Check input voltage available at site. 1 Grounded 120 V A C Receptacle (Non-CE Models) A 120 volt, 20 ampere individual branch[...]

  • Page 17

    OM-2248 Page 13 SECTION 5 − OPERA TION 5-1. Controls 2 3 1 OFF ON POWER CUP TEMP INPUT VOL T AGE 1 Power Switch 2 Power Light Us e light to tell if unit is energized and ready to operate. Light goes of f if input power is not with specified range (see trouble light infor- mation). 3 Trouble Light T rouble light comes on for the following conditio[...]

  • Page 18

    OM-2248 Page 14 5-3. T rigger Safety Lock T rigger Locked T rigger Unlocked 1 T rigger 801 545-A 1[...]

  • Page 19

    OM-2248 Page 15 out bottom of cut. 801 400-A 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 for a[...]

  • Page 20

    OM-2248 Page 16 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. 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 Use n T orch Tip, Electrode, And Shield Cup Every W eek n Shield C[...]

  • Page 21

    OM-2248 Page 17 6-2. Overload Protection: T rouble Light And Checking Shield Cup Shutdown System If certain problems occur , the trouble light comes on, and output stops. 1 T rouble Light a Lights if shield cup is loose. Turn power Off, and check shield cup connection (see Item 2 below). Power must be reset whenever the cup shutdown is activated. C[...]

  • Page 22

    OM-2248 Page 18 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. S[...]

  • Page 23

    OM-2248 Page 19 6-4. Checking/Replacing Retaining Cup, Tip, And Electrode Overtightening will strip threads. Do not overtighten retaining cup during assembly . Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed ha[...]

  • Page 24

    OM-2248 Page 20 6-5. T roubleshooting Power Source Connect unit to proper input voltage. (see Section 4-7). Ye s No Is input power connected to correct line voltage? Is Power switch in the On position? Place Power switch in the On position. (see Section 5-1 ). No Ye s Is the cooling fan running? Check Power switch S1, relay CR2, and thermistor R1. [...]

  • Page 25

    OM-2248 Page 21 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 of f while cutting? Does arc go out while cutting? No Ye s Be sure work clamp is sec[...]

  • Page 26

    OM-2248 Page 22 SECTION 7 − ELECTRICAL DIAGRAM 230 564-A Figure 7-1. Circuit Diagram[...]

  • Page 27

    OM-2248 Page 23 Notes[...]

  • Page 28

    OM-2248 Page 24 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 803 554-E 3 2 1 4 5 6 8 9 7 10 11 12 13 14 15 16 17 18 19 20 21 23 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Figure 8-1. Main Assembly[...]

  • Page 29

    OM-2248 Page 25 Description Part No. Item No. Figure 8-1. Main Assembly Quanti ty Dia. Mkgs. 220 328 COVER ASSY (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 204 326 CONSUMABLE ST ORAGE BOX w/DOOR (including) 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 30

    OM-2248 Page 26 1 18 3 427 Handle Assy , left and right w/screws (1) 2 171 248 Pushbutton Switch (1) 3 196 931 Leads, 20ft (1) 4 196 930 Label, ICE-12C (1) 5 196 932 Main Body (1) 6 185 833 Switch A ssy w/Spring (1) 190 220 Spring, trigger assy (1) 169 231 Grease, silicone (1) 195 172 T orch, replacement (1) Part No. Item No. Description 1 2 3 1 5 [...]

  • Page 31

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006−01 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[...]

  • Page 32

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F A X : 9 20-735-4125 European He a dquart er[...]