Miller Electric ICE-100TM manual

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[...]

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[...]

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

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

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

. 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[...]

. 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[...]

. 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.[...]

. 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 [...]

. 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[...]

. 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 [...]

. 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[...]

. 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[...]

. 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[...]

. 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 [...]

. 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[...]

. 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[...]

. 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[...]

. 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 [...]

. 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[...]

. 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 [...]

. 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[...]

. 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[...]

. 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 [...]

. 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[...]

. 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[...]

. 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[...]

. 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*[...]

. 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*[...]

. 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*[...]

. 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[...]

. 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[...]

. 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[...]

. 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[...]

. 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 [...]

. 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[...]

. 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[...]

. 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 [...]

. 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[...]

. 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[...]

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

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

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 . . . . .[...]

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 [...]

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 [...]

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[...]

Notes[...]

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[...]

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[...]