section 1 - Pdfstream.manualsonline.com
Contents
1. 1 M A 206 442 2 WRAPPER autsta de 1 ee eee 196 851 LABEL warning precautionary 1 n p 208 015 HANDLE rubberized carrying 1 dl eue 227 776 SWITCH ASSY power voltage change over including 1 Ori E 101 200 42 GASKET SWileh i si thiet eu oot X Me a 1 A Sl uses 124 511 SWITCH tgl dpst 40 A 600 VAC 1 SEE MIN VPN MS 202 056 BLOCK term 60 amp 3 pole c ce ee a 2 OF ME O2 vds 011 611 SWITCH tgl dpdt 15 A 125 VAC 1 ERI 227 110 22 0 BRACKET SWICh sem ata tatiana 1 zu WN RA L1 x 200815 2x INDUCTOR POOSI 2 ia bdo 1 ee y isst L2 1225 200 816e INDUCTOR DUCK uses ee rc 1 EN c 202 674 CABLE power 10ft 14ga 3c 1 vlde acu du 227 870 CASE SECTION base front rear 1 eee ee A E TZ9 190 s LABEL Wali radio ii dc Y NN cH FM 195610 FAN muffin 115V 50 60HZ 1 16 AS1 227834 VALVE AIR FILTER ASSY air w ftgs brkt including 1 A A 206 000 VALVE 24VDC 3 way 1 8NPT 1 dd dada des si 227 840 FILTER air w drain amp ftgs 1 le tie 2er BIT zn FILTER all elemen cune etuer edo a Seeded 1 E 200 729 32 BRAGKET mig aliler but2. Tighten strain relief nut Tighten strain relief around cable Pies PO El ge Work Cable Connections 8 HE Remove existing work cable from unit 7 Work Cable Be sure to allow some work cable slack inside the unit Insert work cable with strain relief into front panel Tighten strain relief nut Tighten O strain relief around cable 8 Work Cable Ring Terminal 5 Route cable under center baffle Connect ring terminal on end of work cable to terminal labeled WORK on circuit board PC1 Les L 4 p N TORCH WHITE Tools Needed CF 1 4 in 804 489 B Ref 802 860 226 678 C OM 228 305 Page 21 6 4 Checking Replacing Retaining Cup Tip And Electrode X UF Overtightening will strip threads Do not overtighten retaining cup during assembly Do not cross thread parts causing stripping Use care during torch Ic assembly and parts replacement A Inspect shield cup tip and electrode for wear before cutting or whenever cutting speed has been significantly reduced Do not operate torch without a tip or electrode in place Be sure to use genuine replacement parts C7 A good practice is to replace both the tip and electrode at the same time A Turn Off power source before checking torch parts FEN GS ZJ a Make sure this area is clean of any debris Make sure swirl ring is clean of any debris and no holes are obstructed 1 32 in 1 mm to 1 16 in
3. lt RC4 1 MIT 11 TP oz 15 WT ROA 8 4L MSY A 0000040 AN E RC4 6 d i 8 PINK RC4 7 1 lt RC4 10 e O O Q VOLTAGE CHANGE OVER SWITCH use or service this unit engine before servicing e Do not operate with covers removed e Do not touch live electrical parts e Disconnect input power or stop e Have only qualified persons install ELECTRIC SHOCK HAZARD z z lt 3 L2 BLK Si GAN 16 E Jj ss PO RCS 1 A E 170VAC POWER SWITCH a AL RCS 2 ATIC o D gt gt m x Q x CO L2 REDO WAT ELECTRODE PILOTO RED PILOT WORK BLK WORK Res RC1 4 gt no l RC1 1 LT BLU POWER CONTROL RC1 PLG1 u 19 P Rc2 PLG2 Poe 12 RC3 PLG3 RC4 PLB4 RC6B 2 gt gt lt 2 RC6 PLG6 RC7 PLG7 7 5 TP1 TEST RC8 1 gt TP3 PROGRAM RCB PLGB pong sy 78 PC1 H55 Re2 1 gt 57 R2 mr E RC2 2 gt L1 BLK zen BOOST CHASSIS GND THROUGH ALUMINUM PCB STANDOFF 227 893 A ircuit Diagram Figure 7 1 C OM 228 305 Page 25 SECTION 8 PARTS LIST 3 Hardware is common and not available unless listed 804 490 B Figure 8 1 Main Assembly OM 228 305 Page 26 Item Diagram Part NO marking NO Description Quantity Figure 8 1 Main Assembly pc mig cae agent 204 326 CONSUMABLE STORAGE BOX w DOOR including 1 ae eue v eibar 089 899 LATOR SOS ta oo cd ae 1 ad DAR 203 492 LABEL ICE 27C consumables
4. Ground the workpiece to a good electrical earth ground if required by codes Use only well maintained equipment Repair or replace damaged parts at once Wear a safety harness if working above floor level Keep all panels and covers securely in place Do not bypass or try to defeat the safety interlock systems Use only torch es specified in Owner s Manual Keep away from torch tip and pilot arc when trigger is pressed Clamp work cable with good metal to metal contact to workpiece not piece that will fall away or worktable as near the cut as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object OM 228 305 Page 1 9 ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the re moval of input power e Turn Off unit disconnect input power check voltage on input ca pacitors and be sure it is near zero 0 volts before touching any parts Check capacitors according to instructions in Mainte nance Section of Owner s Manual or Technical Manual before touching any parts EXPLODING PARTS can injure e 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 D FLYING SPARKS can cause injury Aa Sparks and hot metal blow out from the cutting arc a Chipping and grinding cause flying metal Wear approved fa
5. 2 mm maximum pit depth depending on acceptable cut quality Worn 802 465 Turn Off power source Remove tip Check tip and replace ifopen 7 O Ring 1 Shield Cup ing is deformed or 50 oversize If inside of Remove swirl ring Check ring and replace tip is not clean and bright clean with steel side hol d nnd wool Be sure to remove any pi f A aes MN y pieces of steel Remove shield cup Check cup for cracks wool afterwards Check O ring for cracks or worn spots and replace if necessary 5 Electrode replace swirl ring if necessary Check O ring for cracks or worn spots re Check electrode If center has a pit more 9 O Ring place shield cup if necessary than a 1 16 in 2 mm deep remove and re Check O ring for cracks or worn spots and 3 Tip place electrode replace if necessary 4 Opening 6 Swirl Ring Carefully reassemble parts in reverse order OM 228 305 Page 22 6 5 Troubleshooting Power Source NAW of B Is input power connected to correct line voltage Connect unit to proper input voltage see Section 4 8 Is Changeover switch S2 in the 115V or 230V position Place Changeover switch in proper position for input voltage see Section 4 8 Does the breaker trip when unit is set on 115V Turn down output current see Section 5 1 ne Is Power switch Place Power switch in the o1 in the On ll position P see Section Yes Is the cooling fa
6. Checking Shield Cup Shutdown SysteM 20 6 3 Torch And Work Cable Connections acidosis ee Woke Sas oie ass 21 6 4 Checking Replacing Retaining Cup Tip And Electrode 22 6 5 Troubleshooting Power SOUICE s a3 x START Soak IRAE GEARS as 23 6 6 Troubleshooting Torch antaras ds dc be Rs End se 24 SECTION 7 ELECTRICAL DIA GRAM xeu eng 25 SECTIONS PAHTS LIST en 2 a E ed a eed equ tes A beeline been sue 26 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING pom _ 2007 04 Protect yourself and others from injury read and follow these precautions 1 1 NOTICE Indicates statements not related to personal injury 1 2 Plasma Arc Cutting Hazards Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text EF Indicates special instructions de Pd This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards The symbols shown below are used throughout this manual to call atte
7. shielding the work area OM 228 305 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 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 Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Wa
8. t oppos de l appareil Risque D INCENDIE OU D EXPLOSION e Ne pas placer l appareil sur au dessus ou proximit de surfaces infllammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l ali mentation est correctement dimensionn et prot g avant de mettre l appareil en service LES CHARGES ELECTROSTATI QUES peuvent endommager les cir cuits imprim s SS e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes PC LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Le Rayonnement haute frequence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement lappa reil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux
9. tre dangereux Le coupage produit des vapeurs et des gaz Respirer ces vapeurs et ces gaz peut tre dangereux pour la sant e Ne mettez pas votre t te au dessus des vapeurs Ne respirez pas ces vapeurs e Si vous tes l int rieur au moment du coupage ventilez la pi ce ou ayez recours une ventilation aspirante install e pr s de l arc pour vacuer les vapeurs et les gaz e Sila ventilation est m diocre utilisez un respirateur anti vapeurs approuv e lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais Seurs e Travaillez dans un espace restreint uniquement s il est bien ventil OU Si vous portez un respirateur anti vapeurs Les vapeurs cau sees par le coupage et l puisement de l oxyg ne peuvent alt rer la qualit de l air et entrainer des blessures ou la mort Assurez vous que l air ambiant est sain pour la sant e Ne coupez pas dans un endroit pr s d op rations de d capage de nettoyage ou de vaporisation La chaleur et les rayons d arc peu vent r agir avec les vapeurs et former des gaz hautement toxiques et irritants e Ne coupez pas des m taux enrob s tels que des m taux galvani s s contenant du plomb ou de l acier plaqu au cadmium moins que l enrobage ne soit t de la surface du m tal couper que len droit ou vous travaillez ne soi
10. without overheating If unit overheats thermostat s opens output stops Temperature 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 cycle before cutting or gouging A Exceeding duty cycle can damage unit and void 6 1 2 Minutes Resting warranty Overheating OR Minutes Reduce Duty Cycle sduty1 5 95 804 486 A OM 228 305 Page 11 4 4 Torch Dimensions And Weight 8 3 8 in 213 mm Dimensions And Weight 12 5 16 in 49 Ib 22 2 kg 313 mm not including torch Add 13 16 in 21 mm for handle P d p Pd Movement Location And Airflow E Serial Number Rating Label located on rear panel of plasma cutter use label to determine input power for unit eg 3 E 10 in 254 mm OM 228 305 Page 12 Ref 802 877 1 Lifting Handle Use handle to lift unit 2 Hand Cart Use cart or similar device to move unit 3 120 VAC Receptacle To connect unit to 230 VAC input power a customer supplied plug is necessary see Section 4 9 Locate unit near correct input power supply A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 loc 2 3 96 Ref 804 486 A 804 487 A 804 488 A 4 6 Connecting Gas Air Supply Tools Needed 3 C 5 8 1 1 8 in From Gas Air Supply Use only clean dry air with 90 to 120 ps
11. 3 2 er nee I Un RER 227 869 2 BAFFLE center ants serien th ane de eos daim selon eu 1 18 PC1 234 264 CIRCUIT CARD ASSY control w pgm 1 No CEPR 227 832 REGULATOR air w fittings amp switch 1 s m pd iden S3 221 843 xv SOVWIETGHSIDIGSSUFG ma RI m qul tal Ane 225425 REGULATOR li ia ko dul Sato sexs bade bok cad Dus unitis to 195014 ICE 27C 20ft hand held including 1 RE D ee 121276 BUSHING Strain relief ci ERR wet esce d luce sink thee ire 200 517 a KNOB DOIDIGI aan aeg daret ed N mitate ev piae va orate 1 OC wh dale diss 227 036 CABLE work 20ft 12ga w clamp including 1 NUN 213 619 CLAMP work 300A Los e as I jose a doas tem 213 620 TIP contact work clamp copper 300A 2 jugo en in NAMEPLATE order by model and serial number 1 TEL doh darted aa Bab din 227 833 GAUGE air w fitting sais bien ee nie 1 MEC AAA 227 831 NUT nylon strain relief 1 Decet T1 228354 TRANSFORMER toroid main 60HZ 115 230V 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number req
12. A 30 ampere branch circuit is recommended for maximum performance Performance on a 20 ampere branch service may be limited due to the circuit breaker or line fuse Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse A 15 ampere branch circuit is recommended for maximum performance Performance on a 10 ampere branch service may be limited due to the circuit breaker or line fuse Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse Amperes Input at Rated Output Rated 60 Hz Single Phase Plasma Cutting 115 V 230 V 115 V 230 V Plasma Gas Flow Capacity Max Rated Output 1596 1596 KVA KW KVA KW Gas Pressure at 10 IPM OCV Air Or 4 5 CFM 27 A at 92 Volts DC At 28 max 14 max 3 32 KVA 3 25 KVA Nironen 129 L min 3 8 in 288 Volts 35 Duty Cycle 0 30 0 13 3 25 KW 3 19 KW S At 60 PSI 10 mm DC y 414 kPa While idling 4 2 Specifications For Torch Air cooled torch for plasma arc cutting PAC 35 duty cycle Safety interlock devices shut down power source Safety trigger guard Cutting capacity see Section 4 1 4 3 Duty Cycle And Overheating For Units Connected to a 115 Volt Circuit or a 230 Volt Circuit 35 Duty Cycle At 27 amperes 92 volts dc 35 duty cycle 3 1 2 Minutes Cutting Duty Cycle is percentage of 10 min utes that unit can cut at rated load
13. GAS AIR supply SET Al A 27 OUTPUT 1 Output Control Use control to set cutting output Place control in Gas Air Set position to safely adjust gas air pressure Only gas air circuit is activated If 22 27 amperes of cutting output is used with 115 VAC input power and the overload protection on the input power circuit fre quently opens either reduce the cutting out OM 228 305 Page 16 16 GAS AIR 7 SET K POWER O 3 PRESSURE STATUS 24 dis 27 OUTPUT Set Ti 60 PSI 414 kPa put and or the cut time or find more adequate power see Section 4 1 2 Trouble Lights See Section 6 2 3 Power Light 4 Power Switch Setting Gas Air Pressure 5 Air Filter Regulator 6 Pressure Adjustment Knob 3 PRESSURE 60 PSI O Place Output control in Gas Air position and turn on gas air supply Lift knob and turn to adjust pressure Push knob down to lock in setting Place Output control in desired cutting output E At ambient temperatures below 5 C 23 F readjustment of gas air pressure regulator may be necessary Ref 227 835 A Ref 804 486 A 5 2 Cutting Speed Recommended Cut Speeds At 27 Amperes Output mes Jm in Recommended Cut Speed is approximately 80 of maximum 7 Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20 Recommended Cut Speeds At 20 Amperes Output Thickness Recommended Cut Speeds ro
14. S Section 6 2 1 Shield Cup Shutdown System KZ NY Xx Every Damaged Or Unreadable Air Filter Regulator Cracked Parts x Gas Air Hose 3 Labels Section 8 Months Every 6 Months Inside Unit OM 228 305 Page 19 6 2 Overload Protection Trouble Lights amp Checking Shield Cup Shutdown System NF e x NS C 43 PRESSURE O cur O E Temp STATUS Checking Torch Shield Cup Shutdown System 7 Power must be reset whenever the cup shutdown system is activated Always turn Off power when changing or checking consumables Do NOT overtighten torch shield cup Gently finger tighten cup onto torch OM 228 305 Page 20 If certain problems occur the Ready light goes off a trouble light comes on and output stops 1 Pressure Light Lights if gas air pressure is below 40 PSI 276 kPa Turn power Off and check for proper gas air pressure see Section 5 1 A flashing Pressure light indicates that gas air system may be set too low faulty leaking or has a flow re striction see Section 6 5 2 Cup Light Lights if shield cup is loose Turn power Off and check shield cup connection see torch Owner s Manual Power must be reset whenever the cup shutdown is activated A flashing Cup light indicates that the torch consumables are stuck or worn and should be inspected and or replaced see Section 6 4 Check shield cup shutdown system once a week 3 Temperature Ligh
15. a pressurized cylinder explosion will result e Use only correct gas cylinders regulators hoses and fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use e Use the right equipment correct procedures and sufficient number of persons to lift and move cylinders e Read and follow instructions on compressed gas cylinders asso ciated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation HOT PARTS can cause severe burns Do not touch hot parts bare handed e 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 e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer FLYING METAL or DIRT ca
16. any 3 Equipment that has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MANUFACTURER S PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at manufacturer s option 1 repair or 2 replacement or where authorized in writing by manufacturer in appropriate cases 3 the reasonable cost of repair or replacement at an authorized service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Manufacturer s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at an authorized service facility as determined by manufacturer Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL D
17. de gaz contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Puisque les bouteilles de gaz font habituellementpartie d un processus de travail des m taux assurez vous de les manipuler correctement e Prot gez les bouteilles de gaz comprim contre la chaleur excessi ve les chocs m caniques des dommages physiques le laitier la flamme les tincelles et l arc e Installez et attachez les bouteilles dans la position verticale l aide d une chaine sur un support stationnaire ou un chassis porte bou teille afin de pr venir qu elles ne tombent ou ne basculent e les bouteilles ne doivent pas tre pr s de la zone de coupage ni de tout autre circuit lectrique e Un contact lectrique ne doit jamais se produire entre un chalu meau de plasma d arc et une bouteille e Necoupez jamais sur une bouteille pressuris e une explosion en r sulterait e Utilisez uniquement des bouteilles de gaz des d tendeurs des boyaux et des raccords concus pour l application d termin e Gar dez les ainsi que toute autre pi ce associ e en bonne condition e D tournez votre visage du d tendeur r gulateur lorsque vous ou vrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque vous utilisez la bouteille ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes p
18. directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 5 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particulierementles enfants LE COUPAGE pr sente un risque de feu ou d explosion Des particules de m tal chaud et des tincelles peuvent jaillir de la pi ce au moment du coupage Les tincelles et le m tal chaud la pi ce couper chauff e et l quipement chaud peuvent causer un feu ou des br lures Avant de commencer travailler assurez vous que l endroit est s curitaire e D placez toute mati re inflammable se trouvant l int rieur d un p rim tre de 10 7 m 35 pi de la piece couper Si cela est impos sible vous devez les couvrir avec des housses approuv es et bien ajust es e Ne coupez pas dans un endroit o des tincelles pourraient attein dre des mati res inflammables e Prot gez vous ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud e Assurez vous qu aucune tincelle ni particule de m tal ne peut se glisser dans de petites fissures ou tomber dans d autres pi ces e Af
19. for up to 53 ft 16 m To connect unit to 230 VAC input power a customer supplied plug is necessary see Section 4 9 A 230 volt 15 ampere minimum individual branch circuit protected by time delay fuses or circuit breaker is required see Section 4 1 If an extension cord is necessary select a cord of 14 AWG for up to 133 ft 41 m A Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Ref 802 787 A 804 488 A OM 228 305 Page 14 4 9 Installing Alternative Plug This procedure is necessary if the unit is to be connected to a 230 VAC receptacle 1 Supplied 115 VAC Plug or toa 115 VAC receptacle that requires a plug that is different from the supplied plug Cut cord close to plug G See Section 4 8 for instructions on setting changeover switch for proper voltage 2 Alternative PLug 230 VAC Plug Shown Load 1 Brass Terminal Load 2 Brass Terminal Ground Green Terminal Outer Shell Cord Grip Strip cord jacket back enough to separate conductors Strip conduc tors enough to make good contact with plug terminals Make plug con nections and reinstall outer shell and cord grip Tighten assembly screws Tools Needed onto shell Do not overtighten Ref 801 305 A 801 611 OM 228 305 Page 15 SECTION 5 OPERATION 5 1 Controls POWER Setting Gas Air Pressure 20 Requires 16 24 00 120PSI 621 827 kPa
20. ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes UN CHOC LECTRIQUE peut tuer Touching live electrical parts can cause fatal shocks or severe burns The torch and work circuit are electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on Le coupage plasma n cessite des tensions plus importantes que le soudage pour amorcer et maintenir l arc 200 400VDC est typique mais peut tre utilis avec des torches quip es de syst mes de verrouillage de s curit qui arr tent la machine en cas de buse desserr e ou si l lectrode touche la tuy re Incorrectly installed or improperly grounded equipment is a hazard e Ne touchez pas aux pi ces lectriques sous tension e Portez des gants isolants et des v tements de protection secs et sans trous e Isolez vous de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne touchez pas aux pi ces du chalumeau si vous tes en contact avec la pi ce couper ou le sol e Mettez l appareil hors tension avant d effectuer la v rification le nettoyag
21. that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below manufacturer will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Manufacturer must be notified in writing within thirty 30 days of such defect or failure at which time manufacturer will provide instructions on the warranty claim procedures to be followed Manufacturer shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to the distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor Unless Specifi
22. 4W 5NS telephone 800 463 6727 ou a Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard 287 1 de American National Standards Institute 11 West 48rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 telephone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et a distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants d
23. AMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MANUFACTURER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province brand warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delive
24. OM 228 305D 2007 06 Tra ee AUTO ARC Air Plasma Cutting and Gouging Description Air Plasma Cutter Auto Arc Quick Cut 4500 And Ice 27C Torch For Warranty Claims And Technical Support Contact Milweld Inc National Distributor P O Box 338 Hortonville WI 54944 0338 Tel 920 779 0916 Fax 920 779 0924 OWNER S MANUAL File Plasma Cutters gt TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Tl SOVIMDOWOSAGE cardio ake Rate eee ee eae 1 1 2 Plasma Arc Coin Hazards aae anh SARI ae Aliens 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 Galeria Proposition 65 Warnings sser wea xs erg xx n Ee E ERROR E A Ae 4 155 Prinicipaksately Standards ie den Sache Dele arado aaa 4 126 EMPINO Mato 4 2 ire tete drole sedes valete moet eden docte tour ou nd at M aa hone ncaa du 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Signification des symboles En an db ir OR e see aora 5 2 2 Dangers li s au coupage a l arc au plasma nen e aa 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement eha Maintenance caia eer ae owe A MR ar od Oper i b put idit ord cdd 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit ios duree nr kode eed o
25. TAL ou DES SA c uu LETES peuvent provoquer des bles sures dans les yeux e Porter des lunettes de s curit avec crans lat raux ou un cran facial LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou dage par points de gougeage du coupage plasma ou de chauf fage par induction L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT gt e Prevoir une periode de refroidissement re 6 specter le cycle op ratoire nominal 9 TE is e R duire l amp rage paisseur avant de con tinuer couper ou r duire le facteur de marche OM 228 305 Page 7 Danger D EXPLOSION D HYDROGENE e Lors du coupage d aluminium partiellement ou totalementimmerg dans l eau de l hydrog ne libre peut s accumuler sous la piece e Consultez votre ing nieur de coupage et les instructions de la table de coupage NEZ LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariot les bouteilles de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c
26. ce 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 can burn eyes and skin Arc rays from the cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin e Wear face protection helmet or shield with a proper shade of filter lenses to protect your face and eyes when cutting or watching ANSI Z49 1 see Safety Standards suggests a No 9 shade with No 8 as minimum for all cutting currents less than 300 amperes 749 1 adds that lighter filter shades may be used when the arc is hidden by the workpiece As this is normally the case with low current cutting the shades suggested in Table 1 are provided for the operator s conve nience e Wear approved safety glasses with side shields under your helmet or shield e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection Table 1 Eye Protection For Plasma Arc Cutting Current Level In Amperes Minimum Shade Number Below 20 20 40 40 60 60 80 n NOISE can damage hearing Prolonged noise from some cutting applications can damage hearing if levels exceed limits specified by OSHA see Safety Standards
27. des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE COUPAGE A L ARC peut causer des interf rence e l nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Pour r duire la possibilit d interf rence maintenir les c bles aussi courts que possible les grouper et les poser aussi bas que possi ble ex par terre e Veiller couper une distance de 100 m tres de tout quipement lectronique sensible e S assurer que la source de coupage est correctement branch e et mise la terre e Si l interf rence persiste l utilisateur doit prendre des mesures suppl mentaires comme carter la machine utiliser des c bles blind s de des filtres ou boucler la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs essence Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations con
28. ds e Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with elec tronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC CUTTING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e To reduce possible interference keep cables as short as possible close together and down low such as on the floor e Locate cutting operation 100 meters from any sensitive electronic equipment e Be sure this cutting power source is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the machine using shielded cables using line filters or
29. e Use approved ear plugs or ear muffs if noise level is high e Warn others nearby about noise hazard OM 228 305 Page 2 FUMES AND GASES can be hazardous Cutting produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove cutting fumes and gases e If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals to be cut coatings and cleaners e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Fumes from cutting and oxygen depletion can alter air quality causing injury or death Be sure the breathing air is safe e Do not cut in locations near degreasing cleaning or spraying oper ations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases e Do not cut on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the cutting area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes when cut e Do not cut containers with toxic or reactive materials inside or containers that have held toxic or react
30. e ou le changement d une pi ce du chalumeau e Coupez l alimentation d entr e avant d installer l appareil ou d ef fectuer l entretien Verrouillez ou tiquetez la sortie d alimentation selon la norme OSHA 29 CFR 1910 147 reportez vous aux Prin cipales normes de s curit e Installez le poste correctement et mettez le la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales OM 228 305 Page 5 e Assurez vous que le fil de terre du cordon d alimentation est cor rectement reli la borne de terre dans la boite de coupure ou que la fiche du cordon est branch e une prise correctement mise la terre vous devez toujours v rifier la mise la terre e Avant d effectuer les connexions d alimentation vous devez relier le bon fil de terre e les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifiez fr quemment le cordon d alimentation afin de vous assurer qu il n est pas alt r ou nu remplacez le imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis V rifiez et remplacez les cosses du c ble du chalumeau si elles sont us es ou alt r es e Le c ble du chalumeau ne doit pas s enrouler autour de votre corps Si les normes le stipulent la piece a couper doit t
31. ed Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF models Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard Branded Mig Guns No Labor Welacraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Days Parts and Labor MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No Labor Spoolmate Spoolguns Canvas Covers Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 2 Items furnished by manufacturer but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if
32. es Risque de blessure en cas D EXPLOSION DES PIECES e Mise sous tension toute pi ce d fectueuse des sources d alimentation de l inverseur peut exploser ou faire exploser d autres pi ces Pour entretenir les inverseurs toujours porter un masque protecteur et un v tement man ches longues D LES TINCELLES VOLANTES ris quent de provoquer des blessures Le coupage plasma produit des tincelles et projec tions de m tal tr s haute temp rature Lorsque la pi ce refroidit du laitier peut se former a e Portez une visi re ou des lunettes de s curit avec des crans la t raux approuv es e Portez des v tements de protection ad quats afin de prot ger vo tre peau OM 228 305 Page 6 e Ayez recours des prot ge tympans ou un serre t te ignifuges afin d viter que les tincelles n entrent dans vos oreilles LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Les rayons d arc provenant du proc d de coupage produisent des rayons visibles et invisibles intenses ultraviolets et infrarouges qui peuvent entrainer des br lures aux yeux et la peau e lorsque vous coupez ou regardez quelqu un couper portez un casque de soudage approuv muni de verres filtrants appropri La norme ANSI Z49 1 reportez vous aux Principales normes de s curit sugg re d utiliser un filtre de teinte no 9 no 8 tant le minimum pour tout travail de coupage fai
33. g nitales ou autres probl mes de procr ation OM 228 305 Page 8 Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres proble mes de procr ation Se laver les mains apr s manipulation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Recommended Practices for Plasma Arc Cutting American Welding Society Standard AWS C5 2 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Interne
34. i 621 to 827 kPa pressure Gas Air Inlet Opening 2 Hose 3 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 4 Air Filter Regulator Adjust gas air pressure according to Section 5 1 802 787 A Ref 801 319 C Ref 804 486 A OM 228 305 Page 13 4 7 Connecting Work Clamp 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible 802 463 A Check input voltage available at site 1 Changeover Switch Switch is accessible through slot in rear panel 2 Changeover Switch Label Look at label to find correct switch position A Be sure input power connection meets all applicable national regional and local electrical codes 3 Grounded 120 VAC Receptacle A To use rated output see specifications connect the unit to an individual branch circuit capable of carrying the effective eff current for the output being used The unit must have a properly sized plug installed and the circuit must be protected by properly sized fuses or cir cuit breakers A 120 volt 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required See Section 4 1 4 Plug From Unit Connect plug to receptacle If an extension cord is necessary select a cord of 12 AWG
35. in d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main e Si vous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entrainer un feu de l autre cote e Ne coupez pas sur un contenant ferm tel qu un r servoir ou un bi don e Fixez le c ble de masse sur la pi ce couper le plus pr s possible de la zone couper afin de pr venir que le courant de coupage ne prenne une trajectoire inconnue ou longue et ne cause ainsi une d charge lectrique d tincelles ou un feu e Ne pas utiliser le coupeur plasma pour d geler des conduites ge l es e Necoupez jamais des contenants qui peuvent contenir des matie res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement e Ne coupez pas quand l atmosph re peut contenir des poussi res gaz ou vapeurs comme l essence inflammables e Ne coupez pas dans un endroit o l atmosph re risque de contenir de la poussi re ou des vapeurs explosives e Ne coupez pas de bouteilles de tuyaux ou de contenants pressuri s s Ne coupez pas de contenants qui ont d ja recu des combustibles Portez des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque e Ne placez pas le poste sur une surface combustible ou au dessus de celle ci e Une fois le travail achev assurez vous qu il
36. ive materials they must be emptied and properly cleaned first PLASMA ARC can cause injury The heat from the plasma arc can cause serious burns The force of the arc adds greatly to the burn hazard The intensely hot and powerful arc can quickly cut through gloves and tissue e Keep away from the torch tip Do not grip material near the cutting path The pilot arc can cause burns keep away from torch tip when trig ger is pressed e Wear proper flame retardant clothing covering all exposed body ar eas e Pointtorch away from your body and toward work when pressing the torch trigger pilot arc comes on immediately e Turn off power source and disconnect input power before disas sembling torch or changing torch parts e Use only torch es specified in the Owner s Manual CYLINDERS can explode if damaged Gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylin ders are normally part of metalworking processes be sure to treat them carefully e Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flame sparks and arcs e Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping e Keep cylinders away from any cutting or other electrical circuits Never allow electrical contact between a plasma arc torch and a cylinder Never cut on
37. lammable material e Protect yourself and others from flying sparks and hot metal Be alert that sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that cutting on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not cut on closed containers such as tanks or drums e Connect work cable to the work as close to the cutting area as prac tical to prevent cutting current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use plasma cutter to thaw frozen pipes e Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first e Do not cut where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline e Do not cut pressurized cylinders pipes or vessels Do not cut containers that have held combustibles Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Do not locate unit on or over combustible surfaces Remove any combustibles such as a butane lighter or matches from your person before doing any cutting e After completion of work inspect area to ensure it is free of sparks glowing embers and flames e Use only correct fuses or circuit breakers Do not oversize or by pass them e Follow
38. les ms m m mimi ome BEE 8 BE HE Recommended Cut Speed is approximately 80 of maximum 7 Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20 5 3 Trigger Safety Lock 1 Trigger Trigger Locked Trigger Unlocked 802 877 OM 228 305 Page 17 5 4 Sequence Of Operation EXAMPLE Of Cutting Operation A The pilot arc starts immediately when trigger is pressed Place tip on work for drag cutting or for Raise trigger lock and press After cutting arc starts slowly maximum cutting speed and tip life use a trigger Pilot arc starts start moving torch across metal standoff distance of 1 16 in 1 6 mm to 1 8 in 3 2 mm dragging tip will reduce tip life Adjust torch speed so Pause briefly at end of Postflow continues for 20 seconds after sparks go thru metal and cut before releasing trigger releasing trigger cutting arc can be instantly out bottom of cut restarted during postflow by raising trigger lock and pressing trigger Ref 802 878 OM 228 305 Page 18 SECTION 6 MAINTENANCE 8 TROUBLESHOOTING 6 1 Routine Maintenance A Disconnect power Maintain more often before maintaining during severe conditions Y Check Change Clean x Replace Reference To be done by Factory Authorized Service Agent Each A Section 4 6 Use 6 4 y Gas Air Pressure Y Torch Tip Electrode And Shield Cup vH
39. lney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com 1 6 EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current as it flows through the welding or cutting cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following proce dures OM 228 305 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association S
40. n injure eyes e Wear safety glasses with side shields or wear face shield MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away e Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce amperage thickness or reduce duty cycle before starting to cut again EXPLODING HYDROGEN hazard e When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the work piece e See your cutting engineer and water table instructions for help Operation And Maintenance MIX FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift unit e f using lift forks to move unit be sure forks are long enough to ex tend beyond opposite side of unit FIRE OR EXPLOSION hazard e Do not locate unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit STATIC ESD can damage PC boar
41. n running Check Power switch S1 and relay CR2 and thermistor R1 on PC2 Replace PC2 if R1 or CR2 are not functioning correctly Yes Reset Power switch S1 Is P liah Yes and verify line power flashing an voltage see Section 4 1 Check relay CR2 thermistor R1 on PC2 and Control board PC1 No Is Cup Status Yes Check torch consumables light On or Reset Power switch S1 flashing No Is Temp Status Yes If unit is overheated wait light On while fan cools down unit temperature No Turn Output control fully counterclockwise see Section 5 1 Check for gas air flow at torch Check Control board PCI pressure switch S3 gauge air filter valve AS1 and air supply connection to unit and torch Is Pressure Status light On or flashing Press torch trigger and check if pilot arc ignites Check torch consumables Does pilot arc Check torch connections ignite air filter pressure switch S3 valve AS1 air supply connection to unit torch and PC1 Yes Place torch near workpiece and check if pilot arc umps or transfers to workpiece Check work clamp connection Check Control board PC1 and connections and torch and its connections Does pilot arc transfer to workpiece Yes Check all connections Check main transformer T1 Check boost inductor L1 and buck inductor L2 Return to beginning of chart Servicing procedure to be performed o
42. nly by authorized Service Station OM 228 305 Page 23 6 6 Troubleshooting Torch A r NAN of Does arc go on and off while cutting Torch travel speed too slow increase travel speed see Section 5 2 Clean or replace torch consumables __ Go to Section 6 5 as necessary see Section 6 4 Be sure work clamp is securely attached to workpiece Be sure work clamp is securely attached to work Does arc go out piece Make sure tip is on or 1 16 in 1 1 while cutting in 32 a E 2 Go to Section 6 5 Section 5 4 Clean or replace torch consumables as necessary see Section 6 4 Torch travel speed too fast reduce travel speed see Section 4 1 Clean or Do sparks come replace torch consumables out of top of cut as necessary see Section or cut is not 6 4 Be sure work clamp is clean securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 4 1 Check torch shield cup see Section 6 2 reset unit Power switch Check torch Go to Section 6 5 and connections inside unit Is Trouble light On unit has no cutting output Go to Section 6 5 Servicing procedure to be performed only by authorized Service Station OM 228 305 Page 24 SECTION 7 ELECTRICAL DIAGRAM INPUT POWER doo W Hl oL dl db dlLOL 16 76 C 000904 2 20VAC ee 2 c RC4 5 PUR Z lt lt Ro4 2 20VAC
43. ntion to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The torch and work circuit are electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on Plasma arc cutting requires follow all Safety Standards Only qualified persons should install operate maintain and repair this unit higher voltages than welding to start and maintain the arc 200 to 400 volts dc are common but may also use torches designed with safety interlock systems which turn off the machine when the shield cup is loosened or if tip touches electrode inside the nozzle Incorrectly During operation keep everybody especially children away CUTTING can cause fire or explosion Hot metal and sparks blow out from the cutting arc The flying sparks and hot metal hot workpiece and hot equipment can cause fires and burns Check and be sure the area is safe before doing any cutting e Remove all flammables within 35 ft 10 7 m of the cutting arc If this is not possible tightly cover them with approved covers Do not cut where flying sparks can strike f
44. oivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induction Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 228 305 Page 9 3 1 SECTION 3 DEFINITIONS Symbols And Definitions For Nameplate And Serial Number Rating Label A LE Plasma Arc Cutting S N Adjust Air Gas Low Air Pressure Petes V PAC Pressure Light V Volts Increase N nor e o E Temperature Protective Earth l D Ground 1 ENG Single Phase N Constant Current Lv Voltage Input On O Off o6 Percent Direct Current Rated No Load U Primary Voltage U Conventional Load e Line Connection Voltage Average Voltage Single Phase Rated Maximum Rated Welding X E _ Static Frequency max Supply Current Current Duty Cycle SALIS A Transformer 2 Rectifier Converter Degree Of H D Protection Er Loose Shield Cup Input Z Hertz Waman Eiee f IS Suitable for Some Power Rating power factor Hazardous S Product Of Voltage 1eff Uppy ent D Locations 1 And Current KVA OM 228 305 Page 10 SECTION 4 INSTALLATION 4 1 Specifications C7 If the unit is operated from a 30 ampere 115 volt circuit 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
45. ore performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION pom2007 04fre Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Signification des symboles DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles E Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger 2 2 Dangers li s au coupage l arc au plasma Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les
46. our soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Laisser refroidir avant d intervenir sur la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures DES ORGANES MOBILES peuvent provoquer des blessures mii FE AJ e S abstenirde toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remetire les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e Nutiliser que les pieces de rechange recom mand es par le constructeur DES PIECES DE ME
47. pcre wx daria ube 9 2 0 Iniormallon EME uoce seta eee ER We nos rr ea pa Mi RE 9 SECTION 3 DEFINITIONS out A AA dee eodd 10 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label 10 DE CTION INSTAELEALTION 2 besito mice el 11 251 Speeilicall ns res Eee ash 11 4 2 SBEechcallons For Torch ino stare mid tee Rime Score kind nase as sus Rene dre u 11 4 3 Duty Cycle And Overheating s ote ka a o RI a ala Ee BEY 11 4 4 Torch Dimensions ANG Weight su ades kd ated Riad chow Rene mind Bees whee ERAS ated ene po ke 12 LS A A LOCATION suos d Rae clos hx Rd ated Bune thew bee tamed dicm sre id ERES eine cock hee 12 4 6 Connecting Gas Air SUDDDXd eine ch os bd wie eme thee bes iex rada eine whew hea 13 2 7 Connecting Work CAMP cria nee en 14 4 8 Connecting Input PO WE sumas nn ne na e aa 14 4 9 Installing Alternative Plug es A AA AAA Inu i 15 SECTION 5 OPERATION sis au zu sanidad cria AA Issa Ed 16 Ors CONTO M T M M A e 16 0 2 A O 17 D 3 110 0 Sale V LOCK uscar pa EEEE ved Da ie Reg de ie rd dea na atin ee REOR 17 5 4 Sequence OF Operon socias chet pene aa Oe er P Od Re Re elt Oe bane ee dre c eee 18 SECTION 6 MAINTENANCE amp TROUBLESHOOTING 19 6216 RoulneMalblelatiGe dde Sea SAT pa Baud eer Oe Ser d uar Serer eee 19 6 2 Overload Protection Trouble Lights amp
48. re mise a la terre Utilisez uniquement de l quipement en bonne condition R parez ou remplacez imm diatement toute pi ce alt r e e Portez un harnais de s curit si vous devez travailler au dessus du sol e Assurez vous que tous les panneaux et couvercles sont correcte ment en place e N essayez pas d aller l encontre des syst mes de verrrouillage de s curit ou de les contourner e Utilisez uniquement le ou les chalumeaux recommand s dans le manuel de l op rateur e N approchez pas le tube du chalumeau et l arc pilote lorsque la g chette est enfonc e e Lecable de masse doit tre pinc correctement sur la piece cou per m tal contre m tal et non de telle sorte qu il puisse se d tacher ou sur la table de travail le plus pr s possible de la ligne de coupage e isoler la pince de masse quand pas mis la piece pour viter le contact avec tout objet m tallique e D CHARGES LECTRIQUES poten tiellement mortelles Il y a DES CHARGES DC SIGNIFICATI VES dans le poste de soudage inver seur m me APRES coupure du cou rant d alimentation e Mettre l unit hors tension mesurer la tension des condensa teurs d entr e et s assurer qu elle est pratiquement nulle avant de toucher l une quelconque des pi ces Mesurer cette tension conform ment aux directives nonc es la section Entretien du manuel de l utilisateur ou du manuel technique avant de toucher l une quelconque des pi c
49. red to original customer Distributor Address City State Zip Resources Avallable Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2007 01
50. requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not touch torch parts if in contact with the work or ground Turn off power before checking cleaning or changing torch parts Disconnect input power before installing or servicing this equip ment Lockout tagout input power according to OSHA CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet always verify the supply ground When making input connections attach proper grounding conduc tor first Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring re place cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Inspect and replace any worn or damaged torch cable leads Do not wrap torch cable around your body
51. sant appel un courant de moins de 300 A On mentionne galement dans la norme Z49 1 qu un filtre plus faible peut tre utilis lorsque l arc est cach par la pi ce couper Comme cela est habituellement le cas pour les tra vaux de coupage faible courant les teintes num r es au tableau 1 sont fournies titre d information pour l op rateur Porter des lunettes de s curit coques lat rales sous votre cas que ou cran facial e Ayez recours des crans protecteurs ou des rideaux pour pro t ger les autres contre les rayonnements les tincelles et les blouissements pr venez toute personne sur les lieux de ne pas regarder l arc Portez des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection Tableau 1 Protection des yeux pour le coupage au plasma d arc Intensit de courant en amp res Filtre de teinte minimum Moins de 20 no 4 20 40 no 5 40 60 no 6 60 80 no 8 LE BRUIT peut endommager l ouie n Certaines applications de coupage produisent un bruit constant ce qui peut endommager l ou e si le niveau sonore d passe les limites permises par l OSHA reportez vous aux Principales normes de s curit e Utilisez des prot ge tympans ou un serre t te antibruit si le ni veau sonore est lev e Pr venez toute personne sur les lieux du danger reli au bruit LES FUM ES ET LES GAZ peuvent
52. t Lights if power source overheats or when ambient temperature is below 35 C 31 F see Section 4 3 4 Torch Shield Cup Turn Power On and loosen shield cup If shutdown system works properly Ready light goes off and Cup light comes on If not turn power Off and check for proper gas air pressure see Section 4 1 blocked or leaking hose or loose shield cup see torch Owner s Manual If system works properly retighten cup and reset power Ref 200 808 Ref 802 877 6 3 Torch And Work Cable Connections If torch or work cable needs to be removed or replaced proceed as follows Turn power Off and disconnect input power plug from receptacle Remove wrapper from unit Torch Connections Remove existing torch cable from unit 1 Strain Relief 2 Torch Cable Insert cable through strain relief Slide strain relief nut onto torch cable but do not tighten 3 Air Line Connector Insert air line connector into solenoid fitting 4 Plug PLG1 Receptacle RC1 Connect PLG1 from torch to receptacle RC1 on end of wiring harness connected to circuit board PC1 5 Ring Terminal And TORCH RED Terminal Connect ring terminal on end of red leads to TORCH RED terminal 6 Ring Terminal And TORCH WHITE Terminal Connect ring terminal on end of white leads to TORCH WHITE terminal daa E mE cr 77g e s a E ids Hin E or 4 rd a CEL E i B fe gebe len RPC Redi ue E o a
53. t www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 telephone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apres avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques a haute fr quence repr sente un risque a la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent a tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes L
54. t bien ventil ou que vous ne portiez un respirateur anti vapeurs Les enrobages ou tous m taux qui contiennentces l ments peuvent cr er des vapeurs toxiques s ils sont coup s e Ne coupez pas de contenants qui renferment ou ont renferm s des mati res toxiques ou r actives vous devez en premier lieu les vi der et les nettoyer convenablement LE PLASMA D ARC peut entrainer des blessures La chaleur d gag e par le plasma d arc peut entrainer de s rieuses br lures La force de l arc est un facteur qui s ajoute au danger de br lures La chaleur intense et la puissance de l arc peuvent rapidement passer au travers de gants et de tissus N approchez pas le tube du chalumeau Ne saisissez pas la pi ce couper pr s de la ligne de coupage L arc pilote peut causer des br lures n approchez pas le tube du chalumeau lorsque vous avez appuy sur le g chette e Portez des v tements de protection ad quats qui recouvrent tout votre corps e Ne pointez pas le chalumeau en direction de votre corps ni de la pi ce couper lorsque vous appuyez sur la gachette l arc pilote s allume automatiquement e Mettez l alimentation hors tension et d branchez le cordon d ali mentation avant de d monter le chalumeau ou de changer une pi ce du chalumeau e Utilisez uniquement le ou les chalumeaux recommand s dans le manuel de l op rateur LES BOUTEILLES peuvent exploser si elles sont endommag es Les bouteilles
55. tandards Sales 5060 Mississauga Ontario Canada L4W 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 web site www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Re gion 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep cutting power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the cut as possible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer bef
56. uired when ordering parts from your local distributor OM 228 305 Page 27 Part E No 183 427 171 248 203 120 203 119 185 833 Description Handle Assy complete 1 Push Button Switch 1 Leads 20ft 1 Main Body 1 Switch Assembly w spring 1 Spring trigger assembly Grease silicone 1 Torch replacement 20ft 1 190 220 169 231 195 014 See Figure 8 3 for additional consumable parts Figure 8 2 Torch ICE 27C ICE 27C Auto Arc Consumables i FAILURE TO RE PLACE WORN TIP O ring OR ELECTRODE OR 2 pkg OPERATION WITH 181336 OUT THEM will ruin Electrode a Swirl Ring torch 5 pkg A 203493 e Turn off power before 181332 checking torch parts ini ae e Check before each a 5 peo use ans hourly during 203495 181333 operation 203 492 203 492 Figure 8 3 Consumable Parts For ICE 27C To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 228 305 Page 28 Notes Notes Warranty Effective January 1 2007 Equipment with a serial number preface of LH or newer This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below warrants to its original retail purchaser
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