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Miller Electric UPC 838 manual

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Table of contents for the manual

  • Page 1

    Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM-202 515C 2005 − 12 UPC 838[...]

  • 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

    dec_con1_1 1/02 Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: UPC 838 conforms to the fol[...]

  • Page 5

    OM-202 515 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_8/03 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 message. . Means “Note”; not safety related. This group of symbols means W arning! Wat[...]

  • Page 6

    OM-202 515 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 inj[...]

  • Page 7

    OM-202 515 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. MOVING P ARTS can cause injury . D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely [...]

  • Page 8

    OM-202 515 Page 4 1-5. Principal Safety Standards Safety in W elding and Cutting , ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 Safety and Health Standards , OSHA 29 CFR 1910, from Superinten- dent of Documents, U.S. Government Printing Of fice, W ashington, D.C. 20402. Recommended Practices for Plasma [...]

  • Page 9

    OM-202 515 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 8/03 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 . . Signi[...]

  • Page 10

    OM-202 515 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’al[...]

  • Page 11

    OM-202 515 Page 7 Les bouteilles de gaz contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser . Puisque les bouteilles de gaz font habituellement partie d’un processus de travail des métaux, assurez − vous de les manipuler correctement. LES BOUTEILLES peuvent exploser si elles sont endommagées. D Protég[...]

  • Page 12

    OM-202 515 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 P[...]

  • Page 13

    OM-202 515 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Cutting sparks can cause explosion or fire. 1.1 Keep flammables away from cutting. Do not cut near flammables. 1.2 Cutting sparks can cause fires. Have a fire extinguisher nearby , and have a watchpe[...]

  • Page 14

    OM-202515 Page 10 S-185 836 > 60 s V V V 1 W arning! Watch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 5 Always wait 60 s[...]

  • Page 15

    OM-202 515 Page 1 1 3-3. Manufacturer ’ s Rating Label For CE Products U 2 1 12V I 2 80A X 60% 30A/92V 80A/1 12V I 1max = 21.6A U 1 = 380V I 1max = 19.3A U 1 = 440V I 1eff = 16.7A I 1eff = 14.9A 3-4. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Plasma Arc Cutting (P AC) Adjust Air/Gas Pressure Air Pressure V [...]

  • Page 16

    OM-202 515 Page 12 SECTION 4 − INST ALLA TION 4-1. Specifications Input Model/Rated Output V olts @ 50/60 Hz, 3 Phase Amperes @ Rated Cutting Capacity KV A KW Rated Cutting Capacity T ype of Output Plasma Gas Maximum Open-Circuit V oltage DC UPC 838 80 A @ 1 12 380 21.6 14.21 13.50 7/8 in (22 mm) At 10 IPM Direct Current, Straight Air Or Nitrogen[...]

  • Page 17

    OM-202 515 Page 13 4-3. Cutting Speed The cutting speed curve shows the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness. Y Exceeding recommended cutting speeds will cause rapid erosion of the tip and electrode. UPC 838 191 831 Cutting speed is approximately 10 inches per minute at 0.8[...]

  • Page 18

    OM-202 515 Page 14 4-4. Selecting a Location loc_2 3/96 - 802 140 / Ref. 151 556 1 Lifting Handles Use handles to lift unit. 2 Hand Cart Use cart or similar device to move unit. 3 Rating Label Use rating label to determine input power needs. 4 Line Disconnect Device Locate unit near correct input power supply . Y Special installation may be require[...]

  • Page 19

    OM-202 515 Page 15 4-5. Connecting Work Clamp And Gas/Air Supply Ref. 803 640-A / 802 803-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. . Use only clean, dry air with 90 to 150 psi pressure. 3 Gas/Air Inlet Opening 4 Hose 5 T eflon T ap e Obtain hose with 3/8 in (9[...]

  • Page 20

    OM-202 515 Page 16 4-7. Connecting Input Power L1 input_2 3/96 - Ref. 144 221 / Ref. 070 399-C / 802 140 Check input voltage available at site. 1 Input And Grounding Conductors 2 Line Disconnect Device See Section 4-6. Y Always connect green wire to supply grounding termi- nal, never to a line terminal. Connect black, brown, and blue wires (L1, L2,[...]

  • Page 21

    OM-202 515 Page 17 SECTION 5 − OPERA TION 1 Gas/Air Pressure Gauge 2 Gas/Air Pressure Adjustment Knob 3 Output Control Use control to set cutting output. Gas/air automatically flows at the set pressure. Us e Gas/Air Set area of control range for set- ting gas/air pressure (see Section 5-2 ). 4 Trouble Lights (see Section 6-2 ) Power light comes O[...]

  • Page 22

    OM-202 515 Page 18 1 Output Control 2 Power Switch Place controls as indicated. Only gas/air circuit is activated when the Power switch is turned On with Output Control in Gas/Air Set position. 3 Gas/Air Pressure Adjustment Knob Pull knob and turn to adjust pressure. Push knob in to lock setting. Select desired cutting output with Output Control. 5[...]

  • Page 23

    OM-202 515 Page 19 5-3. Sequence Of Operation Put On Personal Safety Equipment 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 . Install & Connect Equipment EXAMPLE Of Cutting Operation Ref. 801 400-A Press tr[...]

  • Page 24

    OM-202 515 Page 20 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check T orch Tip, Electrode, And Shield Cup Check Gas/Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service Air Filter/Regulator Assembly Filt[...]

  • Page 25

    OM-202 515 Page 21 6-2. T rouble Lights 1 Pressure Light Lights if gas/air pressure is below 50 PSI (345 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, and check shield cup connection (see torch Owner ’s Manual). Power must be reset whenever the cup [...]

  • Page 26

    OM-202 515 Page 22 6-4. T roubleshooting T rouble Remedy No pilot arc; dif ficulty in establishing an arc. Clean or replace worn consumables as necessary (see torch Owner ’s Manual). Check for damaged torch or torch cable (see torch Owner’s Manual). No cutting output; Power light of f; T rouble lights of f; Ready light of f; fan mo- tor FM does[...]

  • Page 27

    OM-202 515 Page 23 Notes[...]

  • Page 28

    OM-202 515 Page 24 SECTION 7 − ELECTRICAL DIAGRAM Figure 6-1. Circuit Diagram For Power Source[...]

  • Page 29

    OM-202 515 Page 25 202 521[...]

  • Page 30

    OM-202 515 Page 26 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 802 804-B *Service Note: Item 29 is supplied as a two-circuit card assembly . Separate and discard breakaway portion of circuit card assembly located in lower right-hand corner , and replace with circuit card 670 349, Item 66. 1 2 3 5 12 11 13 10 9 8 [...]

  • Page 31

    OM-202 515 Page 27 Description Dia. Mkgs. Item No. Figure 7-1. Complete Assembly Quantity Unitor Part No. 1 671 222 WRAPPER, 206 278 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 671 073 HANDLE, molded, 126 416 2 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 32

    OM-202 515 Page 28 Description Dia. Mkgs. Item No. Figure 7-1. Complete Assembly (continued) Quantity Unitor Part No. 56 671 354 WORK CLAMP/CABLE ASSY , 6M No.8 . . . . . . . . . . . . . . . . . . . . . . . . . . w/clamp, strain relief & terminal, 216 447 1 . . . . . . . . . . . . . . . . . . . . . . 57 S2 SWITCH, rocker , 120 376 1 . . . . . .[...]

  • Page 33

    OM-202 515 Page 29 206 301 Standard Drag Shield 670 331 Deflector 670 364 Retaining Cup 670 323 Retaining Cup 670 323 Tip 670 356 Electrode 670 349 Retaining Cup 670 323 Tip 670 372 Tip 670 315 Electrode 670 307 Electrode 670 307 Electrode W rench 671 479 Swirl Ring 670 299 O − Ring 670 281 Cutting Gouging Extended Cutting 1/8” (3mm) stand − [...]

  • Page 34

    Notes[...]

  • Page 35

    Notes[...]

  • Page 36

    PRINTED IN USA 1/03 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 Accessorie[...]