Miller Electric 1251 Owner's Manual

ICE-100T/TM Torch Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM-201 872D 2007−03 � File: Plasma Cutters Visit our website at www.MillerWelds.com ...

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. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and su ...

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . ...

SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 7-2. Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7-3. Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 7-4. Checking/Replacing Retaining Cup, ...

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _4/05 � Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. � Marks a special safety message. � Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Plasma Arc Cutting Hazards � The symbols shown belo ...

� 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 PARTS can injure. Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. FLYING SPARKS can cause injury. � Wear approved face shield or safety goggles with side shields. � Wear proper body protection to protect skin. � Wear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears. Arc rays from the cutting process produce intense visible and invisible (ultraviolet and infrared) rays ...

1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can cause severe burns. � Do not touch hot parts bare handed. � Allow cooling period before working on torch. � To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MOVING PARTS can cause injury. � Keep away from moving parts such as fans. � Keep all doors, panels, covers, and guards closed and securely in place. � Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary. � Reinstall doors, panels, covers, or guards when maintenance is finished ...

1-5. Principal Safety Standards Safety in Welding, 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 AWS C5.2, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from Global Engineering Docu- ments (phone: 1-877-413-5184, website: www.global.ihs.com). National Electr ...

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_fre 4/05 � Avertissement : 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-ci sont identifiés par des symboles adjacents aux directives. � Identifie un message de sécurité particulier. � Signifie NOTA ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des ris- ques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCE ...

� N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée. � 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. � Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. DÉCHARGES ÉLECTRIQUES poten- tiellement mortelles. Il y a DES CHARGES DC SIGNIFICATI- VES dans le poste de soudage inver- seur même APRÈS coupure du cou- rant d’alimentation. � Mettre l’unité ho ...

� Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique. � Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille. � Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait. � Utilisez uniquement des bouteilles de gaz, des détendeurs, des boyaux et des raccords conçus pour l’application déterminée. Gar- dez−les, ainsi que toute autre pièce associée, en bonne condition. � Détournez votre visage du détendeur−régulateur lorsque vous ouvrez la soupape de la bouteille. � Le couvercle du déten ...

LE COUPAGE Ã L’ARC peut causer des interférence. � L’énergie électromagnétique peut gêner le fonction- nement d’appareils électroniques comme des ordi- nateurs et des robots. � Pour réduire la possibilité d’interférence, maintenir les câbles aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). � Veiller à couper à une distance de 100 mètres de tout équipement électronique sensible. � S’assurer que la source de coupage est correctement branchée et mise à la terre. � Si l’interférence persiste, l’utilisateur doit prendre des mesures sup- plémentaires com ...

OM-201 872 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Plasma Arc Cutting (PAC) Adjust Air/Gas Pressure Low Air Pressure Light V Volts Increase No − Do Not Do This Temperature Protective Earth (Ground) Single Phase Constant Current Voltage Input On Off Percent Direct Current U0 Rated No Load Voltage (Average) U1 Primary Voltage U2 Conventional Load Voltage Line Connection I1max Rated Maximum Supply Current I2 Rated Welding Current X Duty Cycle 1/3 f1 f2 Single Phase Or Three Phase Static Frequency Converter- Transformer- Rectifier IP Degree Of Protection Loose S ...

OM-201 872 Page 10 SECTION 4 − INSTALLATION 4-1. Specifications Amperes Input at Rated Load Output 60 Hz, Three-Phase* Rated Type of Plasma Rated Maximum Open- Duty Cycle Rated Output Type of Output Plasma Gas Rated Cutting Capacity Maximum Open- Circuit 40% 50% 80% 80% Output Output Gas Cutting Capacity Circuit Voltage DC 208 V 230 V 460 V 575 V KVA KW Voltage DC 55 49 24 19 19.1 18.2 100 A @ 160 Volts DC Direct Current, Straight Polarity (DCEN) 9.2 CFM (261 L/min) At 75 PSI (517 kPa) Air Or Nitrogen Only 1.25 in (32 mm) At 12 IPM (305 mm/min) 265 *Power light will flash if torch trigger ...

OM-201 872 Page 11 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, and cooling fan runs. Wait fifteen min- utes for unit to cool. Reduce amper- age or duty cycle before cutting. � Exceeding duty cycle can damage unit and void war- ranty. Overheating 0 15 A OR Reduce Duty Cycle Minutes duty1 4/95 230 Volts AC Three-Phase Input Power: 50% Duty Cycle 208 Volts AC Three-Phase Input Power: 40% Duty Cycle 380-575 Volts AC Three-Phase Input Power: 80% Duty Cycle 5 Minutes Cutting 5 Minutes ...

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. � Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 24 in (610 mm) 17 in (432 mm) 12-1/2 in (318 mm) Movement 2 � Do not move or operate unit where it could tip. Location 3 Dimensions And Weight 18 in (460 mm) 18 in (460 mm) 95 lb (43 kg) w/Torch 1 1 ...

OM-201 872 Page 13 4-5. Connecting Work Clamp and Gas/Air Supply 1 Work Clamp 2 Workpiece 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) minimum. 3 Gas/Air Filter Inlet Opening 4 Hose � Hose must have a minimum inside diameter of 3/8 in (9.5 mm). 5 Teflon Tape Obtain hose with 1/4 NPT right- hand thread fitting. Wrap threads with teflon tape (optional) or apply pipe sealant, and install fitting in opening. Route hose to gas/air supply. Adjust ...

OM-201 872 Page 14 4-7. Electrical Service Guide � 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 exceed +10% of rated input voltage. Do not use a gener- ator with automatic idle device (that idles engine when no load is sensed) to supply input power to this plasma power source. 60 Hz Three Phase Input Voltage 208 230 460 575 Input Amperes At Rated Output 55 49 24 19 Max Recommended Standard Fuse Rating ...

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 Voltage Input Power Phase Hertz Fuse Size Or Circuit Breaker Rating Conductor Size Max. Cord Length 208 V 3 60 Time-Delay 2 60 A Normal Operating 3 80 A 8 AWG 89 ft (27 m) 230 V 3 60 Time-Delay 2 60 A Normal Operating 3 70 A 8 AWG 108 ft (33 m) 460 V 3 60 Time-Delay 2 30 A Normal Operating 3 35 A 10 AWG 284 ft (87 m) 575 V 3 60 Time-Delay 2 20 A Normal Operating 3 30 A 12 AWG 268 ft (82 m) 400 V 3 50 Tim ...

OM-201 872 Page 16 4-9. Connecting 3-Phase Input Power 803 766-A / 802 183 � Installation must meet all National and Local Codes − have only qualified persons make this installation. � Disconnect and lockout/tagout input power before connecting input conductors from unit. � Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal. � The Auto-Line circuitry in this unit automatically adapts the power source to the primary voltage being applied. Check input voltage available at site. This unit can be connected to any input po ...