OM-2248 213 990G 2010−07 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter Spectrum 125C R And ICE-12C Torch Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom_2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. 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.
ELECTRIC SHOCK can kill. FUMES AND GASES can be hazardous. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input power. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any parts.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can burn. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MOVING PARTS can injure. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
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 & 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.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_2010−04fre Se protéger et protéger 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’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
D Assurez−vous que le fil de terre du cordon d’alimentation est correctement relié à la borne de terre dans la boîte de coupure ou que la fiche du cordon est branchée à une prise correctement mise à la terre − vous devez toujours vérifier la mise à la terre. D Avant d’effectuer les connexions d’alimentation, vous devez relier le bon fil de terre. D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.
D Ne coupez pas dans un endroit près d’opérations de décapage, de nettoyage ou de vaporisation. La chaleur et les rayons d’arc peuvent réagir avec les vapeurs et former des gaz hautement toxiques et irritants. D Ne coupez pas des métaux enrobés tels que des métaux galvanisés, contenant du plomb ou de l’acier plaqué au cadmium, à moins que l’enrobage ne soit ôté de la surface du métal à couper, que l’endroit où vous travaillez ne soit bien ventilé, ou que vous ne portiez un respirateur anti−vapeurs.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.
2-4. Proposition californienne 65 Avertissements cancérogène ainsi que provoquant des malformations congénitales ou autres problèmes de procréation. Se laver les mains après toute manipulation. Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.
. A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1.
. A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Specifications Primary Volts Primary Amperes 120 20.32 (0.25*) Primary Service (Recommended) 20A Secondary Volts (DC) Secondary Amperes 110 12 KW 2.01 KVA 2.44 Rated Cutting Capacity 0.25 in (6.4 mm) At 6 IPM (2.5 mm/s) Power Factor Max** OCV (DC) 0.82 375 *While idling **10% High line condition 4-2.
. A complete Parts List is available at www.MillerWelds.com 4-4. 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. 4-5. Selecting A Location 6-3/4 in. (171 mm) Dimensions And Weight 17 in. (432 mm) 31 lb (14 kg) 18 in.
. A complete Parts List is available at www.MillerWelds.com 4-6. Torch Dimensions And Weight 8-3/8 in. (213 mm) 1 in. (25 mm) 1-3/8 in. (35 mm) 3.0 lb (1.4 kg) Ref. 801 397-A 4-7. Connecting Work Clamp . Do not connect work clamp to the portion of the workpiece that will fall when cut. 1 1 2 Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 Ref 803 915-A 4-8.
. A complete Parts List is available at www.MillerWelds.com 4-10. Connecting Input Power Check input voltage available at site. 1 Grounded Receptacle A 120 volts AC, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required (see Section 4-8). 120 V 20 A Receptacle 2 Plug From Unit Connect plug to receptacle. For extension cord data, see Section 4-9.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 2 1 3 4 Ref. 245 701-A 1 Power Switch The cooling fan will run for a few seconds after the power switch is placed in the OFF position in order to discharge internal circuitry. 2 Power Light Use light to tell if unit is energized and ready to operate. Light blinks if input power is not within specified range . 3 Cup Light Light comes on if cup is removed from torch.
. A complete Parts List is available at www.MillerWelds.com 5-2. Cutting Speed . Recommended production cutting speed vs. material thickness is approximately 10 ipm at 1/8 in (3.2 mm) mild steel thickness at max setting. The cutting speed curve shows the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness. The best cut quality is achieved by cutting near the chart line. Cutting below the line (too slow) will result in excess dross.
. A complete Parts List is available at www.MillerWelds.com 5-4. Sequence Of Operation . Moisture from the compressor will form in the air line and at EXAMPLE Of Cutting Operation the torch. It will be normal to sometimes see moisture come out the end of the torch. ! The pilot arc starts immediately when trigger is pressed. For shielded cutting, place drag shield on edge of metal. For non-shielded cutting, use 1/8 in. (3.2 mm) standoff distance (dragging tip will reduce tip life).
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. . Maintain more often during severe conditions.
. A complete Parts List is available at www.MillerWelds.com 6-2. Overload Protection: Trouble Light And Checking Shield Cup Shutdown System 1 1 2 3 Power Light Light is steady if input power is okay. Light flashes if input power is less than 92 volts AC or greater than 136 volts AC. Light stops flashing 15 seconds after condition is corrected or when torch trigger is pressed. 4 If certain problems occur, the trouble light comes on, and output stops. 2 Cup Light Lights if shield cup is loose/off.
. A complete Parts List is available at www.MillerWelds.com 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. 4 6 8 7 5 1 Strain Relief 2 Torch Cable Insert cable through strain relief. Slide strain relief nut onto torch cable, but do not tighten.
. A complete Parts List is available at www.MillerWelds.com 6-4. Checking/Replacing Retaining Cup, Tip, And Electrode ! ! Overtightening will strip threads. Do not overtighten retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place.
. A complete Parts List is available at www.MillerWelds.com 6-5. Compressor Filter Cleaning And Replacement ! Turn Off power source, and disconnect input power. 1 2 Power Source Compressor Filter Remove wrapper from unit. Unscrew filter from compressor. 1 2 Clean debris from filter surface or replace filter, if necessary. . Do not overtighten filter. Screw filter back into compressor. Tighten 1 full turn past hand tight. Reinstall wrapper. Tools Needed: 5/16 in. 5/8 in.
. A complete Parts List is available at www.MillerWelds.com 6-6. Troubleshooting Power Source Is input power connected to correct line voltage? No Connect unit to proper input voltage. (see Section 4-10). Are Power and Temp lights flashing? Yes * The compressor current limit was exceeded either above or below its operating range (see Section 6-2). Yes No Is Power switch in the On position? No Place Power switch in the On position. (see Section 5-1).
. A complete Parts List is available at www.MillerWelds.com 6-7. Troubleshooting Torch Does arc go on and off while cutting? Yes Torch travel speed too slow; increase travel speed (see Section 5-2). Clean or replace torch consumables as necessary (see Section 6-4). Be sure work clamp is securely attached to workpiece. Go to Section 6-6. Be sure work clamp is securely attached to workpiece. Make sure drag shield contacts metal while cutting.
SECTION 7 − ELECTRICAL DIAGRAM 245 705-A Figure 7-1.
SECTION 8 − PARTS LIST 8-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts ................... ................... ................... ................... 245 728 208 820 232 015 247 327 .. .. .. .. KIT, ICE-12C torch 20 ft handheld (replacement) . . . . . . . . . . . . . . . . . . . . CLAMP, work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER, air intake compressor 1/8 NPT . . . . . . .
1 Item Part No. No. 2 3 6 5 4 1 183 427 2 3 4 5 6 171 248 248 174 196 930 196 932 185 833 190 220 169 231 245 728 Description Handle Assy, left and right w/screws (1) Pushbutton Switch (1) Leads, 20ft (1) Label, ICE-12C (1) Main Body (1) Switch Assy w/Spring (1) Spring, trigger assy (1) Grease, silicone (1) Torch, replacement (1) 1 Figure 8-2.
Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.
Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
Notes
Effective January 1, 2010 (Equipment with a serial number preface of MA or newer) 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.
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 Miller Electric Mfg. Co.
