Miller Electric ICE-27C manual

Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM-2229 200 879N December 2004 Visit our website at www.MillerWelds.com Spectrum 375 And ICE-27C T orch R And Non-CE Models[...]

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

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

dec_plas_2/04 Declaration of Conformity for European Community (CE) Products This in for mat ion is p rov ided for uni ts w ith 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: SPECTRUM  375 conform[...]

OM-2229 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_5/04 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! Watch [...]

OM-2229 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 injury[...]

OM-2229 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 in [...]

OM-2229 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 o f Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Practices for Plasma Arc[...]

OM-2229 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[...]

OM-2229 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[...]

OM-2229 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 Protégez [...]

OM-2229 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[...]

OM-2229 Page 9 SECTION 3 − DEFINITIONS 3-1. W arning Label Definitions W arning! W atch 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 watchpers[...]

OM-2229 Page 10 3-2. 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 Current U 0 Rated No Load V olt[...]

OM-2229 Page 1 1 SECTION 4 − INST ALLA TION 4-1. Specifications If the unit is operated from a 30* ampere, 1 15 volt circu it 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. NOTE *A 30 ampere branch circuit is recommended for maximum performance. Performance o[...]

OM-2229 Page 12 4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can cut at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, T emperature trouble light goes On, and cooling fan runs. Wait fifteen minutes for unit to cool or temperature light to go off. Reduce amperage or duty cy[...]

OM-2229 Page 13 16 in (406 mm) 4-5. Selecting A Location loc_2 3/96 - Ref. 802 784-B / 802 785-A / 802 786-B / 209 098 / 203 892-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 AC input power , a customer supplied plug is necessary (see Section 4-9). Lo[...]

OM-2229 Page 14 4-6. Connecting Gas/Air Supply 802 787-B / Ref. 801 319-C / Ref. 802 784-B . Use only clean, dry air with 70 to 150 psi (483 to 1034 kPa) pressure. 1 Gas/Air Inlet Opening 2 Hose 3 T eflon T a pe Obtain hose with 1/4 NPT right- hand thread fitting. W rap threads with teflon tape (optional) or apply pipe sealant, and install fitting [...]

OM-2229 Page 15 4-7. 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 4-8. Connecting Input Power Ref. 802 787-B / 802 786-B Check input voltage available at site. 1 Changeover Switch Switch is accessible through slot in rear panel. 2[...]

OM-2229 Page 16 4-9. Installing Alternative Plug 1 Supplied 1 15 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 contact wi[...]

OM-2229 Page 17 SECTION 5 − OPERA TION 5-1. Controls 1 42 3 5 ON OFF PRESSURE 60 PSI 5 6 24 27 6 Set T o 60 PSI (414 kPa) 20 16 24 27 20 16 1 24 27 20 16 Requires 70-150 PSI (483-1034 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. On[...]

OM-2229 Page 18 5-2. Cutting Speed The cutting speed curves show the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness. Cut at speeds below the lines shown to avoid poor cuts and torch wear . wmdesign 5-3. T rigger Safety Lock T rigger Locked T rigger Unlocked 1 T rigger 802 877 1[...]

OM-2229 Page 19 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 fo[...]

OM-2229 Page 20 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check Gas/Air Pressure Check T orch Tip, Electrode, And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Unreadable Labels Service [...]

OM-2229 Page 21 6-2. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System 1 Power Light Light is steady if input power is okay . Light flashes for the following conditions: a If input power is 1 15 volts ac, but power supply is less than 92 volts ac or greater than 13 8 volts ac. b If input power is 230 volts ac, but power[...]

OM-2229 Page 22 6-3. T orch And W ork 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. [...]

OM-2229 Page 23 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[...]

OM-2229 Page 24 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 Power s[...]

OM-2229 Page 25 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 secu[...]

OM-2229 Page 26 SECTION 7 − ELECTRICAL DIAGRAM 200 809-D Figure 7-1. Circuit Diagram[...]

OM-2229 Page 27 Notes[...]

OM-2229 Page 28 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 802 805-C 26 2 1 25 24 23 22 21 20 19 18 17 16 14 13 12 11 10 9 8 7 6 5 4 3 15 27 Figure 8-1. Main Assembly[...]

OM-2229 Page 29 Figure 8-1. Main Assembly Diagram marking Item No. Part No. Description Quantity 212 476 COVER ASSY (non-CE) (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 477 COVER ASSY (CE) (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-2229 Page 30 1 183 42 7 Handle Assy , complete (1) 2 171 248 Push Button Switch (1) 3 203 120 Leads, 20ft (1) 4 203 1 19 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. Part [...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 6/04 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 expertise o[...]

PRINTED IN USA  2004 Miller Electric Mfg. Co. 10/04 Miller Elect ric M fg. Co. An Illinois T ool Wo rks Compan y 1635 W est Spencer Street Applet on, WI 5 4914 USA International He adquarters − USA USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F A X: 920-735-4134 Int ernational F AX : 920-735-4125 European Headqua rters − United K[...]