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Hobart Welding Products 700I Welder User Manual

1. Sequence Of Cutting Using Stand off Guide Sequence Of Piercing Operation SECTION 6 MAINTENANCE amp TROUBLESHOOTING 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 Routine Maintenance Js hr pter RR Sr Re rh X ae ela RR gig a ARa Checking Or Replacing Filter Element Status Trouble Lights 4n pn nci peer RAG ea LYRA ane RPG DETUR Checking Shield Cup Shutdown System Checking Replacing Retaining Cup Tip And Electrode Torch Work Cable Connections Troubleshooting Power Source 2 Troubleshooting Torch e Rodeo epe ne eod Ro RON Tap SECTION 7 ELECTRICAL DIAGRAM SECTION 8 PARTS WARRANTY O1 O1 0 snr 5250 2 On 10 A o SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 2010 03 A Protect yourself a
2. 1 d Rated Input Voltage U4 and rated Input VetsACRMS U AmpsRMS heff Current 1 and I eff at rated output I4 eff used Power Factor KVA KW at Rated Output Rated Open Circuit Voltage U0 Type 400 Volts DC Electrode Negative Output Current Range 20 40 Amps DC b Volts DC Us puree Output Current and Voltage Rating at Rated Input Voltage Ip and U3 at U4 140 Volts DC 208 Volts 40A 140 Volts DC 230 Volts Volts AC RMS U1 Duty Cycle Amps DC 15 Duty Cycle at 104 F 40 C at rated conditions U4 11 U2 15 based on a 10 minute period Operating Temperature 5 to 104 F 15 to 40 C m exe camem E 2 No ingress of foreign objects gt 12 5 mm IP Code Degree of protection provided by 0 5 in enclosure 3 No harmful ingress spraying water EE C AC line circuits protected against ingress of tool gt 2 5 mm dia x 100 mm long 0 1 in x 4 in a 57022080 Gas Inlet Flow and Pressure 4 8 SCFM 85 L min ine Pe Gas Filtering Particulates to 5 microns Torch Mild Steel capacities see Section 5 2 for ee cutting speeds vs material type and thickness Sever Cut Capacity edge start Travel speeds are approximately 80 of maximum OM 244 013 Page 11 5 A complete Parts List is available at www MillerWelds com 4 2 Duty Cycle And Overheating
3. For Units Connected to a 208 Volt Circuit or a 230 Volt Circuit 50 Duty Cycle At 40 amperes 140 volts DC 34 5 Minutes Cutting 50 dutycycle 2 5 Minutes Resting 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 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 NOTICE Exceeding duty cycle can damage unit and void warranty Overheating Reduce Duty Cycle sduty1 5 95 Ref 244 405 A Dimensions And Weight 31 4 Ib 14 2 kg including torch 286 mm 14 1 4 in 362 mm loc 2 3 96 Ref 244 405 A 1 3 8 in 3 0 Ib 1 4 kg 85 mm Ref 801 397 A OM 244 013 Page 12 A complete Parts List is available at www MillerWelds com 4 5 Selecting A Location see NEC Article 511 or CEC Section 20 4 A y 4 Special installation may be 4 required where gasoline volatile liquids are present A Do not move or operate unit where it could tip loc_2 3 96 Ref 244 405 A 4 6 Connecting Gas Air Supply Use only clean dry air with 90 to 120 psi 621 to 827 kPa pressure 1 Gas Air Inlet Opening 2 Hose 3 Teflon Tape
4. 1 32 in 1 mm 1 16 in 2 mm maximum pit depth depending on acceptable cut quality Lightly tighten electrode using electrode wrench 15 20 1 7 2 3 Nm 4 Opening Remove tip Check tip and replace if open ing is deformed or 5096 oversize If inside of tip is not clean and bright clean with steel wool Be sure to remove any pieces of steel wool afterwards 5 Electrode Check electrode If center has a pit more than a 1 16 in 2 mm deep remove and re place electrode Ref 804 851 A 6 Swirl Ring Remove swirl ring Check ring and replace if side holes are plugged Carefully reassemble parts in reverse order 7 Stand off Guide Placing the stand off guide on the end of the torch provides an optional method of maintaining a 1 16 in 1 6 mm gap between tip and workpiece OM 244 013 Page 28 A complete Parts List is available at www MillerWelds com 6 6 Torch And Work Cable Connections A Turn power Off and F s 210 disconnect input power plug gt from receptacle Check to see that all diagnostic LED s have stopped flashing before removing wrapper from unit If torch or work cable needs to be removed or replaced proceed as follows 1 Power Source Remove wrapper from unit LS Torch Connections ye Remove existing torch cable from unit 2 Strain Relief 3 Torch Cable 1 Insert strain relief on end of cab
5. 244 013 2010 04 Je ZN 5565 Air Plasma Cuttin Description Air Plasma Cutter WELDERS AirForce 700i And HP 70 Torch SED www HobartWelders com OWNER S MANUAL File Plasma Cutters From Miller to You 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 superior quality Like you his customers couldn t afford anything less Miller products had to be more than the best they could be They had to be the best you could buy Today the people that build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 T 1 2 PEENI This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick and easy With Miller you can count on years 90 0001 of reliable service with proper maintenance And if for some reason t
6. A Disconnect power Maintain more often during severe conditions before maintaining Sy 1 Check Change Clean Replace Reference E To be done by Factory Authorized Service Agent Each Section 4 1 Use 6 5 Gas Air Pressure Torch Tip Electrode And Shield Cup met 9 Section 6 4 Shield Cup Shutdown System FO W 26 E el Every X Damaged Or Unreadable Q Air Filter Regulator Cracked Parts Gas Air Hose Section 6 2 3 Labels 8 Months 2 ON 92 X Torch Body Cable Every 6 Months Q Inside Unit OM 244 013 Page 25 A complete Parts List is available at www MillerWelds com 6 2 Checking Or Replacing Filter Element T ap C LE Glas LE aco 1515 d A O H 5 16 in HH LI A Turn power and disconnect input power plug from receptacle Check to see that all diagnostic LED s have stopped flashing before removing wrapper from unit Turn power Off and disconnect input power plug from receptacle Remove wrappe
7. Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan LA CHUTE DE L EQUIPEMENT peut ce correcte et utiliser une terre et et un blindage pour r duire les provoquer des blessures interf rences ventuelles LE COUPAGE A L ARC peut causer des interf rence e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariot les poutellles de gaz Cutout aire accessoire e L nergie lectromagn tique peut g ner le Utiliser un engin d une capacit appropri e fonctionnement d appareils lectroniques pour soulever l appareil comme des ordinateurs et des robots e utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules e mobiles lors de toute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds 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 Veiller couper une distance de 100 m tres de tout quipement lectronique sensible e S assurer que la source de coupa
8. 3 2 ELK VR2 HT c12 c1 9 8 7 CNDB MM TE 4 v 4 J 9 5 7 o o o O o LA c 1 2 3 27 OA DA 4 4 20 a a a N 51 5109 38 2 1 OA S 8 a T1 PRI SPLICE OUTPUT INDUCTOR 244 011 B OM 244 013 Page 33 SECTION 8 PARTS LIST 8 1 Recommended Spare Parts FAILURE TO REPLACE WORN TIP OR ELECTRODE WILL DAMAGE TORCH AND VOID WARRANTY e Turn off power before checking torch parts e Check before each use and hourly during operation e Torque electrode lightly w small wrench 15 20 in lbs HP 70 CONSUMABLE KITS 770 654 0 Electrode Retaining Cup Swirl Ring O Ring 243016 A 770 655 243 016 Figure 8 1 Consumable Parts For HP 70 Item Dia Part No Mkgs No Description Quantity Recommended Spare Parts JI ade eds duce t oa 244 122 TORCH HP 70 16 4ft 5 m hand held replacement 1 EP 208 820 CLAMP work 1 COMM m 770 654 CONSUMABLE KIT tip electrode 2 ee eee 770 655 CONSUMABLE KIT cup swirl ring O ring 1 a eee Be ose a eee 227 877 FILTER air element 1 eet 232257 sac CABLE aad i eat 1 M 233 321 STAND OFF GUI
9. Be sure work clamp is securely attached to workpiece Make sure tip is on or near 1 16 in 1 6 mm to 1 8 in 3 2 mm workpiece See Section 5 6 Clean or replace torch consumables as necessary see Section 6 5 Sparks come out top of cut or cut is not clean Torch travel speed too fast reduce travel speed see Section 5 2 Clean or replace torch consumables as necessary see Section 6 5 Be sure work clamp is securely attached to workpiece Unit not capable of cutting metals thicker than rating see Section 5 2 Trouble lights are on unit has no cutting output Check torch consumables Check for gas air flow at torch Check air supply connection and pressure to unit and torch Reset unit Power switch Have Factory Authorized Service Agent check torch and connections inside unit OM 244 013 Page 31 SECTION 7 ELECTRICAL DIAGRAM 70 CONNECTOR AND PLUG RC 0 SCREW CONNECTION RC 9 BOLT THRU CONNECTION RC OM 244 013 Page 32 Figure 7 1 Circuit Diagram amp WARNING e Do not touch live electrical parts D e Disconnect input power or stop engine before servicing Do not operate with covers removed ELECTRIC Have only qualified persons install SHOCK HAZARD use or se
10. properly sized rated and protected to handle this unit STATIC ESD can damage PC boards 2 r e Puton grounded wrist strap BEFORE handling 7 boards or parts e Use proper static proof bags and boxes to store move or ship PC boards H F RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with elec tronic equipment perform this installation The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If 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 oc
11. 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 Risque de blessure en cas D EXPLOSION DES PIECES 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 LES TINCELLES PROJETEES peuvent 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 N 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 244 013 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 9 ner des br lures aux yeux et la peau Les rayons 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 Une
12. Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before 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 S CURIT LIRE AVANT UTILISATION pom_2010 03fre A Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Signification des symboles A A NOTE Indique des d clarations pas en relation avec des blessures personnelles 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 gt Indique des instructions sp cifiques i 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 a
13. National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org 1 6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may interfere with some medical implants e g pacemakers Protective measures for per sons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assessment for welders All welders should use the following procedures in order to minimize expos ure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body OM 244 013 Page 4 For Gasoline Engines A Engine exhaust contains chemicals known to the State o
14. O B at a Miller authorized service facility as determined by Miller 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 MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY 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 MILLER 15 EXCLUDED AND DISCLAIMED BY MILLER 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 X 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
15. Supply Connecting Work Clamp INA tetes anes Electrical Service Guide 22552285 annee tana Extension Cord Data s oir rte os re da oa oes PERPE RU E le dad ER NR e Serial Number And Rating Label Location esse Connecting 1 Phase Input Power 240 Wiring Optional 240 Volt Plug 119 172 For Connection To Bobcat Trailblazer Or Champion 10 000 Installing Alternative Cable Management Strap Electrode Wrench Ert recon pP Red urnes EO ALORS eo V d SECTION 5 OPERATION rene nid 5 1 5 2 5 3 5 4 5 5 5 6 5 7 Controls aan M RE Main ain a eder Mild Steel Recommended Cut Speed Trigger Safety Lock nana Stetina wee Pp etae dos PR XX Ga actuals E iae Plasma Cutting System Practices Sequence Of Cutting Operation
16. body ar eas e Point torch 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 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 instruction
17. les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qua lifi Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l instal lation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux DES PIECES DE METAL ou DES SA E AP LETES peuvent provoquer des bles sures dans les yeux e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 244 013 Page 7 Les CHAMPS ELECTROMAGNETIQUES LES CHARGES ELECTROSTATI peuvent affecter les implants m dicaux QUES peuvent endommager les cir e Les porteurs de stimulateurs cardiaques So Sor nes et autres implants m dicaux doivent rester gt gt a distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone o se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma
18. metal end of cut before and out bottom of cut releasing trigger The pilot arc starts immediately when trigger is pressed I cutting arc starts slowly move torch across metal 017070 7400000 a Torch air cooling postflow continues after releasing trigger Postflow must finish before trigger will pilot arc Ref 804 848 A OM 244 013 Page 23 A complete Parts List is available at www MillerWelds com 5 7 Sequence Of Piercing Operation 3 2 A A The pilot arc starts immediately when trigger is pressed NER 7 Connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Hold torch at an angle to the workpiece Slide trigger lock back Press trigger Pilot arc starts Move torch to upright Maintain torch position Release trigger Postflow cooling position 90 to surface and continue cutting continues after releasing trigger Start cutting when arc Postflow must finish before pierces workpiece trigger will restart pilot arc Ref 803 640 A 801 400 B OM 244 013 Page 24 A complete Parts List is available at www MillerWelds com SECTION 6 MAINTENANCE 8 TROUBLESHOOTING 6 1 Routine Maintenance P3 CIO w 1 NN ne
19. 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 pi ce couper doit tre mise la terre Utilisez uniquement de l quipement en bonne condition R parez ou remplacez imm diatement toute pi ce alt r e Portez un harnais de s curit si vous devez travailler au dessus du sol 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 ga chette est enfonc e Le c ble de masse doit tre pinc correctement sur la pi ce 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 pi ce pour viter le contact avec tout objet m tallique DECHARGES ELECTRIQUES poten tiellement mortelles Il reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur UNE FOIS l alimentation coup e e Mettre l unit hors tension mesurer la tension des condensa
20. ni de la pi ce couper lorsque vous appuyez sur la g chette 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 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 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 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 Installez et attachez les bouteilles dans la position verticale l aide d une chaine sur un support stationnaire ou un ch ssis porte bou teille afin de pr venir qu elles ne tombent ou ne basculent Les bouteilles ne doivent pas tre pr s de la zone de coupage ni de tout autre circuit lectrique Un contact lectrique ne doit jamais se produire entre un chalu meau de plasma d arc et une bouteille Ne coupez jamais sur une bouteille pressuris e une explosion en r sulterait Utilisez uniquement des bouteilles de gaz des d tendeurs des boyaux et des raccords con us pour l application d termi
21. protection faciale casque ou masque avec des lunettes filt rantes de teinte ad quate est indispensable pour prot ger le visage et les yeux des rayonnements de l arc et des tincelles pendant la d coupe ou en regardant simplement ANSI 249 1 re portez 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 faisant appel un courant de moins de 300 A On mentionne galement dans la norme Z49 1 qu un filtre plus fai ble peut tre utilis lorsque l arc est cach par la pi ce couper Comme cela est habituellement le cas pour les travaux de coupage faible courant les teintes num r es au tableau 1 sont fournies titre d information pour l op rateur e Porter des lunettes de s curit coques lat rales sous votre cas que ou cran facial 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 60 100 no 8 n LE BRUIT peut endommager l ouie Cer
22. 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 reactive materials they must be emptied and properly cleaned first PLASMA ARC can injure 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
23. 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 miller warr 2010 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you 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 Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller 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 ORIGINAL INSTRUCTIONS PRINTED IN USA O 2010 Miller Electric Mfg Co 2010 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 Intern
24. D Ref 244 405 A OM 244 013 Page 16 5 A complete Parts List is available at www MillerWelds com 4 13 Installing Alternative Plug This procedure is necessary if the unit is to be connected 1 Supplied 230 VAC Plug er to a 208 230 VAC receptacle that requires a plug that is Cut cord close to plug different from the supplied plug VERUM 2 Alternative Plug 230 VAC Plug Shown 2 3 Input Black Lead 2 2 Brass Terminal 5 4 Input White Lead 3 Brass Terminal D ae EN 5 Ground Green Terminal 1 6 Outer Shell 3 7 Cord Grip Strip cord jacket back enough to 5 Separate conductors Strip conductors enough to make good contact with plug terminals Make plug connections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not 2 overtighten p 4 14 Cable Management Strap A ESS Tools Needed Ref 801 305 801 611 1 Cable Management Strap Coil cables together and secure to unit using the cable management strap 244 413 A 244 412 A 244 013 Page 17 4 15 Electrode Wrench 5 A complete Parts List is available at www MillerWelds com a 1 Management Strap 2 Electrode Wrench The electrode wrench is fastened to the cable management strap 244 412 A Ref 804 885 A OM 244 013 Page 18 A complete Parts List i
25. DE HP 25 50 70 PLASMA TORCH 1 233 046 WRENCH electrode 1 245 993 detect leads 1 A complete Parts List is available on line at www Miller Welds com 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 244 013 Page 34 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives you Service You 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 of the distributor and Miller is there to help you every step of the way Q Minier Effective January 1 2010 Equipment with a serial number preface of MA or newer This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material a
26. ISATION 2 1 2 2 2 3 2 4 2 5 2 6 Signification des symboles Dangers li s au coupage l arc au plasma Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance dae b Proposition californienne 65 Avertissements Principales normes de s curit Informations relatives aux SECTION 3 DEFINITIONS 444 4444 sise 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label SECTION 4 INSTALLATION 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 Specifications RIVA RAT E ARE Y IN ACUDIR ONERE RCRUM Duty Cycle And Overheating Power Source Dimensions And Weight Torch Dimensions And Weight eL ee ee RE C Res agree Selecting A Location Connecting Gas Air
27. Max Recommended Standard Fuse Rating In Amperes 1 Time Delay Fuses 2 40 35 Normal Operating Fuses 3 50 45 Min Input Conductor Size In AWG 4 3 10 Max Recommended Input Conductor Length In Feet Meters 24 80 Min Grounding Conductor Size In AWG 4 10 10 Reference 2008 National Electrical Code NEC including article 630 1 If a circuit breaker is used in place of a fuse choose a circuit breaker with time current curves comparable to the recommended fuse 2 Time Delay fuses are UL class RK5 See UL 248 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amps and UL class 65 amps and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements 4 9 Extension Cord Data gt When calculating max cord length remember to include conductor length from line disconnect device to input power receptacle Input Power Fuse Size Or Input Voltage Phase Circuit Breaker Rating Conductor Size Max Cord Length Time Delay 40 A Time Delay 35A 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class 65 amp
28. NSI Standard Z87 1 de American National Standards Institute 25 West 43rd Street New York NY 10036 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 Quincy MA 02269 t l phone 1 800 344 3555 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 phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 t l phone 1 800 232 4636 site internet www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter l
29. 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 3 From Gas Air Supply Tools Needed lt 9 16 in Ref 244 423 A 4 7 Connecting Work Clamp 3 1 Do not connect work clamp to the portion of the workpiece that will fall when cut 2 1 Work Clamp 2 Workpiece Connect work clamp to a clean paint free location on workpiece as 2 close to cutting area as possible Ref 803 915 A OM 244 013 Page 13 5 A complete Parts List is available at www MillerWelds com 4 8 Electrical Service Guide A Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source NOTICE INCORRECT INPUT POWER can damage this welding power source This welding power source requires a CONTINUOUS supply of input power at rated frequency 10 and voltage 10 Phase to ground voltage shall not exceed 10 of rated input voltage Do not use genera tor with automatic idle device that idles engine when no load is sensed to supply input power to this welding power source 60 Hz Single Phase Input Voltage V 208 230 Input Amperes A At Rated Output 33 30
30. 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 FALLING EQUIPMENT can injure e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories 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 Keep equipment cables and cords away from moving vehicles when working from an aerial location Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manually lifting heavy parts or equipment 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
31. aient 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 Afin d liminer tout risque de feu soyez vigilant et gardez toujours un extincteur la port e de la main e Sivous coupez sur un plafond un plancher ou une cloison soyez conscient que cela peut entrainer un feu de l autre c t Necoupez 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 Ne coupez jamais des contenants qui peuvent contenir des mati res inflammables Vous devez en premier lieu les vider et les nettoyer convenablement e Necoupez pas quand l atmosph re peut contenir des poussi res gaz ou vapeurs comme l essence inflammables e coupez pas dans un endroit o l atmosph re risque de contenir de la poussi re ou des vapeurs explosives Necoupez pas de bouteilles de tuyaux ou de contenants pressuri S s Ne coupez pas de contenants qui ont d j recu
32. akers Do not oversize or by pass them e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 518 for hot work and have a fire watcher and extinguisher nearby EF Indicates special instructions A i 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 M 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 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 installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e 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 i
33. and above OM 244 013 Page 14 A complete Parts List is available at www MillerWelds com 4 10 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back Use rating label to determine input power requirements and or rated output For future reference write serial number in space provided on back cover of this manual 4 11 Connecting 1 Phase Input Power For 240 VAC A Installati t t Il 2 ar National and Local Codes have only qualified persons make this installation A Disconnect and lockout tagout input power before connecting input conductors from unit GND PE Earth Ground A Always connect green or green yellow conductor to supply grounding terminal first and never toa line terminal 1 Black And White Input Conductor L1 And L2 2 Green Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 7 Over Current Protection Select type and size of over curren
34. ant 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 nettoyage 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 244 013 Page 5 Assurez vous que le fil de terre du cordon d alimentation est rectement reli la borne de terre dans la bo te de coupure ou que la fiche du cordon est branch e a une prise correctement mise a la terre vous devez toujours v rifier la mise la terre e Avantd effectuer les connexions d alimentation vous devez relier le bon fil de terre 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 entrainer la
35. ational FAX 920 735 4125 For International Locations Visit www MillerWelds com 2 Miller
36. cked Slide Button Back When Button Is In To Unlock Trigger Forward Position Either Left Or Left And Right Side Right Side Ref 804 848 A OM 244 013 Page 20 5 4 Plasma Cutting System Practices A complete Parts List is available at www MillerWelds com A The pilot arc starts immediately when trigger is pressed V Always connect work clamp to a clean paint free location on workpiece as close to cutting area as possible Do not connect work clamp to the portion of the workpiece that will fall when cut gt Maintain approximately 90 angle to the workpiece surface for proper cutting results TN DO NOT put pressure on shield when drag cutting instead slide shield along the surface for proper cutting results 3 we DO NOT start pilot arc without cutting as this shortens the life of the tip and electrode 00 9 Sparks should pass through the workpiece and out the bottom when cutting Pulling rather than pushing the torch makes cutting easier Use a proper guide or template for accurate cutting operations If sparks flare back from surface this usually is an indication that travel speed is too fast Ref 803 915 A Ref 804 848 A OM 244 013 Page 21 A complete Parts List is available at www MillerWelds com 5 5 Sequence O
37. components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than Miller 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 MILLER 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 Miller s option 1 repair or 2 replacement or where authorized in writing by Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Miller 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 Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F
38. covers Do not cut where flying sparks can strike flammable 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 Useonly correct fuses or circuit bre
39. curs the user must take extra measures such as moving the machine using shielded cables using line filters or shielding the work area OM 244 013 Page 3 1 4 California Proposition 65 Warnings A 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 A 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 A This product contains chemicals including lead known to the state of California to cause cancer birth defects or other reproductive harm Wash hands after use 1 5 Principal Safety Standards Safety Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Recommended Practices for Plasma Arc Cutting and Gouging Ameri can Welding Society Standard AWS C5 2 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from
40. 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 Ne placez pas le poste sur une surface combustible ou au dessus de celle ci e Unefois le travail achev assurez vous qu il 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 1 UN CHOC ELECTRIQUE 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 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 utilis
41. ead bundle Tools Needed C 38i Reinstall wrapper Ref 804 887 A 244 409 A Ref 244 405 A OM 244 013 Page 29 5 A complete Parts List is available at www MillerWelds com 6 7 Troubleshooting Power Source 3 9 39 2 WS amp di Trouble Remedy No pilot arc difficulty in establishing an arc Clean or replace worn consumables as necessary see torch Owner s Manual Check for damaged torch or torch cable see torch Owner s Manual No cutting output Power light off status lights off fan motor FM does not run Place Power switch in On position Place line disconnect device in On position see Section 4 11 Check line fuse s and replace if needed or reset circuit breakers see Section 4 11 Pilot arc working no cutting output Power light on status lights off fan motor running Be sure work clamp is connected Clean or replace worn consumables as necessary see torch Owner s Manual No gas air flow Power light on status lights off fan motor running Have Factory Authorized Service Agent check for proper torch connections Check operation of gas valve AS1 and check gas air system for leaks Check filter element see Section 6 2 Pressure status light On Check for sufficient gas air supply pressure see Section 4 1 Check for dirty air filter and replace if necessary see manufacturer s instructio
42. eur 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 244 013 Page 9 A complete Parts List is available at www MillerWelds com SECTION 3 DEFINITIONS 3 1 Symbols And Definitions For Nameplate And Serial Number Rating Label Plasma Arc Cutting CF Adjust Air Gas Low Air Pressure IN A Amperes Pressure Light V Volts Increase Noz SM Do E Temperature Protective Earth D Ground 1 Single Phase Constant Current 67 Voltage Input Q Off Percent Direct Current Rated No Load U Primary Voltage Conventional Load 1 io Line Connection Voltage Average Voltage Single Phase Static Frequency Rated Maximum Rated Welding Duty Cycle Converter 1 Supply Current 2 Current Transformer Rectifier Degree Of y H Protection a Loose Shield Cup 6 Input 2 Hertz Suitable for Some Power Rating ff rip ld pf power factor Hazardous S Product Of Voltage PPly Locations 1 And Current KVA OM 244 013 Page 10 A complete Parts List is available at www MillerWelds com SECTION 4 INSTALLATION 4 1 Specifications Power Supply Rated AC phase PH and line frequency Hz
43. f California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 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 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website 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 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the weld ing circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6
44. f Cutting Operation 7 EXAMPLE Of Cutting Operation 30 M 2 9 F A Ar A The pilot arc starts immediately Q KT when trigger is pressed m gt 3 Place tip near work Slide trigger lock back After cutting arc Keep tip 1 16 from Press trigger Pilot arc starts starts slowly work for max cutting move torch speed and tip life across metal D as dm Torch air cooling postflow Adjust speed so Pause briefly at continues after releasing trigger sparks go thru metal out boton of cut end of cut before Postflow must finish before releasing trigger trigger will restart pilot arc 804 848 A OM 244 013 Page 22 5 6 Sequence Of Cutting Using Stand off Guide A complete Parts List is available at www MillerWelds com EXAMPLE Of Cutting Using Stand off Guide Stand off Guide Installation Split section 1 to bottom 1161 AX in 1 6 mm 11142 Place stand off guide on work Stand off Slide trigger lock back guide provides 1 16 in 1 6 mm gap Press trigger Pilot arc starts between tip and workpiece imm AN I FA Adjust speed so Pause briefly at sparks go thru
45. fin d viter le danger 2 2 Dangers li s au coupage l arc au plasma A 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 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 A L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne a l cart et plus particuli rementles 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 pi ce couper Si cela est impos sible vous devez les couvrir avec des housses approuv es et bien ajust es Necoupez pas dans un endroit des tincelles pourr
46. ge est correctement branch e et mise la terre e Si linterf rence persiste l utilisateur doit prendre des mesures 4 Risque D INCENDIE OU suppl mentaires comme carter la machine utiliser des c bles h D EXPLOSION blind s de des filtres ou boucler la zone de travail Ne pas placer sur au dessus ou a proximit de surfaces infllammables e Ne pas installer l appareil proximit de pro duits inflammables e pas surcharger l installation lectrique s assurer que tation est correctement dimensionn et prot g avant de mettre l appareil en service OM 244 013 Page 8 2 4 Proposition californienne 65 Avertissements A 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 A Ce produit contient des produits chimiques compris du plomb dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation Ce produit contient des l ments chimiques dont le plomb reconnus par l tat de Californie pour leur caract re 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Pr
47. he unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the es d exact part you may need to fix the problem the ISO 9001 Quality System Warranty and service information for your Standard particular model are also provided REGISTERED QUALITY SYSTEM Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributor or service agency 1 800 4 A Miller or visit us at www Miller Welds com on the web Mill Mil Thank 2009 09 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 1 2 1 8 1 4 1 5 1 6 Symbol USage ee en ne ae Rc ee Plasma Arc Cutting Hazards 42222 Additional Symbols For Installation Operation And Maintenance California Proposition 65 Warnings Principal Safety Standards Information e s sania UO e e BRE SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTIL
48. ing or checking consumables Do NOT properly Cup light comes on If not overtighten torch shield cup Gently immediately turn Off power and finger tighten cup onto torch have Factory Authorized Service Agent check unit If system works properly retighten cup and reset power Ref 801 300 A OM 244 013 Page 27 A complete Parts List is available at www MillerWelds com 6 5 Checking Replacing Retaining Cup Tip And Electrode ay Overtightening will strip threads Do not overtighten retaining cup during assembly Do not cross thread parts causing stripping Use care during torch T F A assembly 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 A good practice is to replace both the tip and electrode at the same time A Turn Off power source before checking torch parts Make sure this area is clean of any debris Make sure swirl ring is clean of any are debris and holes obstructed Replace tip if opening is deformed or 5096 oversized Turn Off power source 1 Shield Cup Remove shield cup Check cup for cracks and replace if necessary 2 O Ring Check O ring for cracks or worn spots and replace if necessary 3 Tip
49. le through front panel opening Slide strain relief nut onto torch cable but do not tighten 4 Air Line Connector Insert air line into solenoid fitting Je Tee 5 Plug PLG4 Receptacle RC4 pr NZ Connect PLG4 from torch to 5 receptacle RC4 on end of wiring harness connected to circuit board PC1 Route torch white and red leads and work black lead through 0 sleeving the same way as the unit was originally 6 Ring Terminal And TORCH WHITE Terminal Connect ring terminal on end of torch white lead to TORCH WHITE terminal 7 Ring Terminal And TORCH RED Terminal Connect ring terminal on end of torch red lead to TORCH RED terminal Tighten strain relief screw Work Cable Connections Remove existing work cable from unit 8 Strain Relief Loosen strain relief screw Be sure to allow some work cable slack inside the unit Insert strain relief on end of cable through front panel opening Slide strain relief nut onto work cable and secure strain relief to front panel 9 Work Lead Ring Terminal And WORK BLACK Terminal Connect ring terminal on end of work clamp lead to terminal labeled WORK BLACK Route lead along torch l
50. must be cycled off and back on again C Flashing rate is steady for 15 seconds or until torch trigger No arc was established Check consumables or torch up is pressed again whichever comes first Repetitive flashing rate of two quick cycles then a one No pilot arc established possibly due to a loss of current Cup second pause for a 15 second period or until torch trigger Check consumables is pressed again whichever comes first Repetitive flashing rate of three quick cycles then a one Consumables in torch failed to separate during pilot arc second pause for a 15 second period or until torch trigger possibly due to being stuck Check consumables is pressed again whichever comes first T a On Power source overheated see Section 4 2 Stop cutting and allow unit to cool down T atir On indefinitely Power source temperature sensors may have failed or ambient temperature is below 22 F 30 Flashing rate is steady indefinitely Power source temperature sensor provided inaccurate Temperature readings but returned to normal Unit power must be cycled off and back on again For system troubleshooting see Section 6 7 and Section 6 8 6 4 Checking Shield Cup Shutdown System 4 19 gt ao Power must be reset whenever the cup 1 Torch Shield Cup 2 4 shutdown system is activated Always Turn Power On and loosen shield cup If shutdown system works turn Off power when chang
51. n e Gar dez les ainsi que toute autre pi ce associ e en bonne condition D tournez votre visage du d tendeur r gulateur lorsque vous ou vrez la soupape de la bouteille 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 Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles 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 LES 5 CHAUDES peuvent provoquer des br lures e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser l quipement 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 Les PIECES MOBILES peuvent provoquer des blessures CN 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 Lorsque cela est n cessaire pour des travaux d entretien et de d pannage faire retirer
52. nd others from injury read and follow these precautions 1 1 Symbol Usage A A NOTICE Indicates statements not related to personal injury 1 2 Plasma Arc Cutting Hazards 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 A The symbols shown below are used throughout this manual to call attention 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 follow all Safety Standards A Only qualified persons should install operate maintain and repair this unit A 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
53. nd workmanship at the time it is shipped by Miller 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 Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Miller must be notified in writing within thirty 30 days of such defect or failure at which time Miller will provide instructions on the warranty claim procedures to be followed Miller 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 a North American distributor or eighteen months after the equipment is shipped to an International distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules 2 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Water C
54. near the cut as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object OM 244 013 Page 1 ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the re moval of input power 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 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 FLYING SPARKS can injure 777 Sparks and hot metal blow out from the cutting arc 2 Chipping and grinding cause flying metal e Wear approved face shield or safety goggles with side shields Wear proper body protection to protect skin e Wear flame resistant ear plugs or ear muffs to prevent sparks from entering ears D 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 from arc rays and sparks when cutting or watching ANSI Z49 1 see Safe
55. ns Check air lines for leaks Have Factory Authorized Service Agent check pressure switch and control board Cup status light On Check torch shield cup see Section 6 4 Reset power switch Have Factory Authorized Service Agent check torch Temperature status light On Unit overheating Allow fan to run the Trouble light goes out when the unit has cooled Have Factory Authorized Service Agent check control board Status lights not working Have Factory Authorized Service Agent check unit Power light flashing status lights off Reset power switch Have qualified technician check input line power Pressure status light flashes Unit lost pressure momentarily while cutting Check air line for leaks Cup status light flashes Unit lost output while attempting to cut or pilot Check consumables and torch for wear Short tip life Check and clean drag shield of any slag particles and debris Check input air pressure OM 244 013 Page 30 A complete Parts List is available at www MillerWelds com 6 8 Troubleshooting Torch LIT DP ete Trouble Remedy Arc goes on and off while cutting Torch travel speed too slow increase travel speed see Section 5 2 Clean or replace torch consumables as necessary see Section 6 5 Be sure work clamp is securely attached to workpiece Arc goes out while cutting
56. nstalling or servicing this equip ment Lockout tagout input power according to OSHA CFR 1910 147 see Safety Standards e 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 e When making input connections attach proper grounding conduc tor first e Keep cords dry free of oil and grease and protected from hot metal and sparks e Frequently inspect input power cord for damage or bare wiring re place cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use e Inspect and replace any worn or damaged torch cable leads e Do not wrap torch cable around your body e Ground the workpiece to a good electrical earth ground if required by codes e Use only well maintained equipment Repair or replace damaged parts at once e Wear a safety harness if working above floor level e Keep all panels and covers securely in place e Do not bypass or try to defeat the safety interlock systems e Use only torch es specified in Owner s Manual e Keep away from torch tip and pilot arc when trigger is pressed e Clamp work cable with good metal to metal contact to workpiece not piece that will fall away or worktable as
57. ocesses ANSI Standard Z49 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 and Gouging Ameri can Welding Society Standard AWS C5 2 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site internet www global ins com National Electrical Code NFPA Standard 70 de National Fire Protection Association Quincy MA 02269 t l phone 1 800 344 3555 site Inter net www nfpa org et www sparky 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 t l phone 703 788 2700 site Internet www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 de Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS t l phone 800 463 6727 site internet www csa international org 2 6 Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec cer
58. oolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices QCoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors 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 Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HF Units ICE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Work Stations Weld Tables No Labor 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 0 x X 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Millers True Blue Limited Warranty shall not apply to 1 Consumable
59. ou une op ration de chauffage par induction L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT e Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes 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 LeRayonnement haute frequence H F peut e Pr voir une p riode de refroidissement re provoquer des interf rences avec les quipe specter le cycle op ratoire nominal ments de radio navigation et de communica MN tion les services de s curit et les ordinateurs e R duire l amp rage paisseur avant de con tinuer couper ou r duire le facteur de marche e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa Danger D EXPLOSION tion D HYDROGENE e L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Lors du coupage d aluminium partiellement ou e Sile FCC signale des interf rences arr ter imm diatement l appa totalementimmerg dans l eau de l hydrog ne reil libre peut s accumuler sous la pi ce e Consultez votre ing nieur de coupage et les instructions de la table de coupage Effectuer r guli rement le contr le et l entretien de l installation
60. r from unit 1 Filter Base 2 Filter 3 Filter Cup Unscrew filter cup from base Remove cup Unscrew filter element from base Check filter element for dirt and moisture and replace if necessary Be sure that all parts are clean and dry Reinstall filter element and secure filter cup Reinstall wrapper 244 408 A Ref 805 211 A OM 244 013 Page 26 A complete Parts List is available at www MillerWelds com 6 3 Status Trouble Lights Difficulty establishing a pilot arc may indicate consumables need to be cleaned or replaced n Input power is okay eee are oh T Hi ii Flashing rate is steady for 15 seconds or until torch trigger Input power below 156 volts AC but has returned to ower is pressed again whichever comes first normal Power Repetitive flashing rate of two quick cycles then a one Input power is below 156 volts AC second pause Flashing rate is steady for 15 seconds or until torch trigger Regulated pressure in the unit is low Check torch for Pressure is pressed again whichever comes first leaks Check input pressure to unit is between 90 to 120 psi 621 to 827 kPa Repetitive flashing rate of two quick cycles then a one Regulated pressure in the unit is high Check input pressure second pause for 15 second period to unit is between 90 to 120 psi 621 to 827 kPa Torch is loose or off Once cup is tightened unit Hp power
61. rvice this unit Sfin INPUT INDUCTOR e 8 nm N ay m GY T ZA ev 9 9 3162 6 5 TT GND6 6 5 GND1 gt GND5 RC2 RCI C31 21 NES EOS S1 cp 2 1 230V INPUT L2 o pci ei GND3 POWER amp PROCESS PCB END RCPT PLG FUNCTION RC1 021 POS 244 4 e RC2 C21 NEG T RC3 PLG3 PRESSURE SENSOR RC4 PLG4 TORCH PRESSURE SWITCH AIR VALVE RC12 PLG12 FAN REAR PANEL RC14 PGM U10 RC15 PLG15 T1 PRI RC16 POT LED RC17 PLG17 INPUT INDUCTOR RC18 NO STUFF RC19 PLG19 1 SEC RC29 PGM U25 Re 4 lt lt 12 2 9 L ZU cc RC12 3 a 55 ES 8880 L 12 4 NDA c ce cere yy VYYY 5 N NRE 3 999 amp HHS MENS Y al Sa S SERE NA 1 jq Fe ASI PRESSURE INPUT DRAIN TRANSDUCER TORCH NX Ze AIT VAVE Ps1 70 75 PSI AIR FILTER 00 4 8 SCFM pw i FRICTION LUG CONNECTION RC PRESSURE SWITCH SOLDERED IN ILEAD PROPORTIONAL VALVE 2 FRONT PANEL PCB RC20 PLG16 GND7 RC16 70 RC4 4 gt gt INVERTER Ecco BRN RT1 m T TRIGGER ELECTRODE 25 SPLICE WHT 4 29 1 YEL CUP DETECT 4 13 GRN D 1 13 gt REDS WHT FED PILOT 4 3 TE 2 CURRENT XFMR 200 1 WORK T5
62. s available at www MillerWelds com SECTION 5 OPERATION 5 1 Controls DRM wed T s 67 POWER d Oo 2 PRESSURE 95 3 O amp CUP E Temp CUTS 1 2 CLEAN CUT STEEL 3 8 ALUMINUM 3 8 GALVANIZED 1 4 BRASS 3 16 COPPER 7 8 SEVER CUT STEEL 3 8 STAINLESS ON O OFF 1 Output Control with 120 VAC input power and the overload protection on the input power circuit fre Use s t cutting output quently opens either reduce the cutting out If 22 27 amperes of cutting output is used put and or the cut time or find more adequate 243 013 A power see Section 4 1 2 Power Light 3 Trouble Lights See Section 6 4 OM 244 013 Page 19 5 A complete Parts List is available at www MillerWelds com 5 2 Mild Steel Recommended Cut Speed Aluminum and stainless steel cut speeds at these thicknesses may be reduced as much as 30 3 4 Travel speeds are approximately 80 if maximum The best cut quality is achieved by cutting near the table value Cutting below the value too slow will result in excess dross Cutting above the value too fast will cause blowback and lack of penetration 5 3 Trigger Safety Lock A 2 1 o 1 Trigger i 000 0 2 2 Trigger Lo
63. 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 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 droit o vous travaillez ne soit bien ventil ou que vous ne portiez un respirateur anti vapeurs Les enrobages ou tous m taux qui contiennent ces l ments peuvent cr er des vapeurs toxiques s ils sont coup s 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 L ARC PLASMA peut provoquer 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 Portez des v tements de protection ad quats qui recouvrent tout votre corps e Ne pointez pas le chalumeau en direction de votre corps
64. s 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 Operation And Maintenance HOT PARTS can burn Do not touch hot parts bare handed Allow cooling period before working on equipment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns 8 MOVING PARTS can injure Keep away from moving parts such as fans 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 and troubleshooting as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 7 FLYING METAL or DIRT can injure eyes Wear safety glasses with side shields or wear face shield ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e Wearers of
65. t NI protection using Section 4 8 fused 8 a disconnect switch shown IN 8 Receptacle NEMA 6 50R L2 L1 Customer Supplied amp Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 240 1 v Tools Needed 803 766 Ref 802 443 244 013 Page 15 L A complete Parts List is available at www MillerWelds com 4 12 Wiring Optional 240 Volt Plug 119 172 For Connection To Bobcat Trailblazer Or Champion 10 000 3 1 Input And Grounding Conductors 2 Plug Wired for 240 V 2 Wire Load 3 3 Neutral Brass Terminal And Prong Not Used 4 4 Load 1 Brass Terminal And Tools Needed Prong 5 Load 2 Brass Terminal And K Prong 5 AN 6 Ground Brass Terminal And 6 Prong Plug Front 7 Black And White Input View Conductors 8 Green Or Green Yellow Ground Conductor A Always connect green or green yellow wire to ground terminal never to a load terminal Connect black L1 and white L2 wires to load terminals Green Or Green Yellow A Engine Control Switch must be set at RUN A Set generator Fine Adjustment Control to 10 position not RUN IDLE for maximum auxiliary power if applicable or RUN IDLE 5 SET AT 10 FOR MAX AC POWER 10 FINE ADJUST Ref 120 813
66. taines applications de coupage produisent un bruit constant ce qui peut endommager l ouie si le niveau sonore d passe les limites permises par l OSHA reportez vous aux Principales normes de s curit 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 tre dangereux Le coupage produit des vapeurs et des gaz Respirer ces vapeurs et ces gaz peut tre dangereux pour la sant e Nemettez pas votre t te au dessus des vapeurs Ne respirez pas ces vapeurs 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 s es par le coupage et l puisement de 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
67. tains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage Informations relatives aux CEM 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne pas se tenir au milieu des c bles de soudage Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps canc rog ne ainsi que provoquant des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s toute manipulation Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation Safe Practice For Occupational And Educational Eye And Face Protec tion A
68. ty Standards suggests a No 9 shade with No 8 as minimum for all cutting currents less than 300 amperes 249 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 pro vided for the operator s convenience e Wear approved safety glasses with side shields under your helmet or shield 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 4 20 40 5 40 60 6 60 100 8 n NOISE can damage hearing Prolonged noise from some cutting applications can damage hearing if levels exceed limits specified by OSHA see Safety Standards e Use approved ear plugs or ear muffs if noise level is high e Warn others nearby about noise hazard OM 244 013 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

Hobart Welding Products 700I Welder User Manual

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