Miller Electric 125C Owner's manual

Brand: Miller Electric

Model: 125C

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Spectrum 125C

And ICE-12C Torch

Processes

Description

Air Plasma Cutting

and Gouging

Air Plasma Cutter

OM-2248 213 990G

2010−07

File: Plasma Cutters

Visit our website at

www.MillerWelds.com

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 call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Now you can get

the job done and get it done right. We know you don’t have time to do

it any other way.

That’s why when Niels Miller first started building arc welders in 1929,

he made sure his products offered long-lasting value and 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.

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

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1..................................

1-1. Symbol Usage 1........................................................................

1-2. Plasma Arc Cutting Hazards 1............................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4.......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4......................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 1...........................

2-1. Signification des symboles 1.............................................................

2-2. Dangers liés au coupage à l’arc au plasma 1................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 3.....................................................................

2-4. Proposition californienne 65 Avertissements 5...............................................

2-5. Principales normes de sécurité 5..........................................................

2-6. Informations relatives aux CEM 5.........................................................

SECTION 3 − DEFINITIONS 6...................................................................

3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label 6......................

SECTION 4 − INSTALLATION 7..................................................................

4-1. Specifications 7........................................................................

4-2. Specifications For Torch 7................................................................

4-3. Duty Cycle And Overheating 7............................................................

4-4. Serial Number And Rating Label Location 8.................................................

4-5. Selecting A Location 8...................................................................

4-6. Torch Dimensions And Weight 9..........................................................

4-7. Connecting Work Clamp 9...............................................................

4-8. Electrical Service Guide For 120 VAC 9....................................................

4-9. Extension Cord Data 9..................................................................

4-10. Connecting Input Power 10................................................................

SECTION 5 − OPERATION 11....................................................................

5-1. Controls 11.............................................................................

5-2. Cutting Speed 12........................................................................

5-3. Trigger Safety Lock 12...................................................................

5-4. Sequence Of Operation 13................................................................

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 14...........................................

6-1. Routine Maintenance 14..................................................................

6-2. Overload Protection: Trouble Light And Checking Shield Cup Shutdown System 15.................

6-3. Torch And Work Cable Connections 16......................................................

6-4. Checking/Replacing Retaining Cup, Tip, And Electrode 17......................................

6-5. Compressor Filter Cleaning And Replacement 18.............................................

6-6. Troubleshooting Power Source 19..........................................................

6-7. Troubleshooting Torch 20.................................................................

SECTION 7 − ELECTRICAL DIAGRAM 21..........................................................

SECTION 8 − PARTS LIST 22.....................................................................

WARRANTY

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OM-2248 Page 1

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. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

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.

1-2. Plasma Arc Cutting Hazards

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.

Only qualified persons should install, operate, maintain, and

repair this unit.

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.

D Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this

is not possible, tightly cover them with approved covers.

D Do not cut where flying sparks can strike flammable material.

D Protect yourself and others from flying sparks and hot metal.

D Be alert that sparks and hot materials from cutting can easily go

through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that cutting on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not cut on closed containers such as tanks or drums.

D 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.

D Do not use plasma cutter to thaw frozen pipes.

D Never cut containers with potentially flammable materials inside −

they must be emptied and properly cleaned first.

D Do not cut where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Do not cut pressurized cylinders, pipes, or vessels.

D Do not cut containers that have held combustibles.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Do not locate unit on or over combustible surfaces.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any cutting.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

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.

ELECTRIC SHOCK can kill.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats or

covers big enough to prevent any physical contact with the work or

ground.

D Do not touch torch parts if in contact with the work or ground.

D Turn off power before checking, cleaning, or changing torch parts.

D Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA CFR

1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its Owner’s

Manual and national, state, and local codes.

D 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.

D When making input connections, attach proper grounding conduc-

tor first.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring − re-

place cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Inspect and replace any worn or damaged torch cable leads.

D Do not wrap torch cable around your body.

D Ground the workpiece to a good electrical (earth) ground if required

by codes.

D Use only well-maintained equipment. Repair or replace damaged

parts at once.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Do not bypass or try to defeat the safety interlock systems.

D Use only torch(es) specified in Owner’s Manual.

D Keep away from torch tip and pilot arc when trigger is pressed.

D Clamp work cable with good metal-to-metal contact to workpiece

(not piece that will fall away) or worktable as near the cut as

practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

OM-2248 Page 2

SIGNIFICANT DC VOLTAGE exists in

inverter power sources AFTER the re-

moval of input power.

D 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.

ELECTRIC SHOCK can kill.

D On inverter power sources, failed parts can ex-

plode or cause other parts to explode when

power is applied. Always wear a face shield

and long sleeves when servicing inverters.

EXPLODING PARTS can injure.

Sparks and hot metal blow out from the cutting arc.

Chipping and grinding cause flying metal.

FLYING SPARKS can injure.

D Wear approved face shield or safety goggles with side shields.

D Wear proper body protection to protect skin.

D Wear flame-resistant ear plugs or ear muffs to prevent sparks from

entering ears.

Arc rays from the cutting process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin.

ARC RAYS can burn eyes and skin.

D 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 Safety Standards) suggests a

No. 9 shade (with No. 8 as minimum) for all cutting currents less

than 300 amperes. Z49.1 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.

D Wear approved safety glasses with side shields under your helmet

or shield.

D Use protective screens or barriers to protect others from flash, glare

and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes Minimum Shade Number

Below 20

20 − 40

40 − 60

60 − 100

Prolonged noise from some cutting applications can

damage hearing if levels exceed limits specified by

OSHA (see Safety Standards).

NOISE can damage hearing.

D Use approved ear plugs or ear muffs if noise level is high.

D Warn others nearby about noise hazard.

FUMES AND GASES can be hazardous.

Cutting produces fumes and gases. Breathing

these fumes and gases can be hazardous to

your health.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove cutting fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.

D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instruction for metals to be cut, coatings,

and cleaners.

D 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.

D 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.

D 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.

D 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.

D Keep away from the torch tip.

D Do not grip material near the cutting path.

D The pilot arc can cause burns − keep away from torch tip when trig-

ger is pressed.

D Wear proper flame-retardant clothing covering all exposed body ar-

eas.

D Point torch away from your body and toward work when pressing

the torch trigger − pilot arc comes on immediately.

D Turn off power source and disconnect input power before disas-

sembling torch or changing torch parts.

D Use only torch(es) specified in the Owner’s Manual.

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.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flame, sparks, and arcs.

D Install and secure cylinders in an upright position by chaining them

to a stationary support or equipment cylinder rack to prevent falling

or tipping.

D Keep cylinders away from any cutting or other electrical circuits.

D Never allow electrical contact between a plasma arc torch and a

cylinder.

D Never cut on a pressurized cylinder − explosion will result.

D Use only correct gas cylinders, regulators, hoses, and fittings de-

signed for the specific application; maintain them and associated

parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient number

of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-2248 Page 3

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.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D 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.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local

codes.

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or wear

face shield.

ELECTRIC AND MAGNETIC FIELDS (EMF)

can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D 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.

D Allow cooling period; follow rated duty cycle.

D Reduce amperage (thickness) or reduce duty

cycle before starting to cut again.

EXPLODING HYDROGEN hazard.

D When cutting aluminum underwater or with the

water touching the underside of the aluminum,

free hydrogen gas may collect under the work-

piece.

D See your cutting engineer and water table instructions for help.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift unit.

D If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D 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.

D Do not locate unit on, over, or near combustible

surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

H.F. RADIATION can cause interference.

D High frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with elec-

tronic equipment perform this installation.

D The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the equipment

at once.

D Have the installation regularly checked and maintained.

D 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.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D To reduce possible interference, keep cables as short as possible,

close together, and down low, such as on the floor.

D Locate cutting operation 100 meters from any sensitive electronic

equipment.

D Be sure this cutting power source is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures such

as moving the machine, using shielded cables, using line filters, or

shielding the work area.

OM-2248 Page 4

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.

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.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting and Gouging, Ameri-

can Welding Society Standard AWS C5.2, from Global Engineering

Documents (phone: 1-877-413-5184, website: www.global.ihs.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.ihs.com).

National Electrical Code, NFPA Standard 70, from 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).

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).

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.

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. Do not work next to, sit or lean on the welding power source.

7. Do not 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.

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OM-2248 Page 5

2-4. Proposition californienne 65 Avertissements

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 mal-

formations congénitales et, dans certains cas, des cancers.

(Code de santé et de sécurité de Californie, chapitre 25249.5

et suivants)

Ce produit contient des produits chimiques, compris du

plomb, dont l’État de Californie reconnaît qu’ils provoquent

des cancers et des malformations congénitales ou autres

problèmes de procréation. Se laver les mains après

manipulation.

Ce produit contient des éléments chimiques, dont le plomb,

reconnus par l’État de Californie pour leur caractère

cancérogène ainsi que provoquant des malformations

congénitales ou autres problèmes de procréation. Se laver les

mains après toute manipulation.

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro-

duits chimiques dont l’État de Californie reconnaît qu’ils

provoquent des cancers et des malformations congénitales

ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de

leurs composants sont reconnus par l’État de Californie com-

me provoquant des cancers et des malformations

congénitales ou autres problèmes de procréation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 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 (téléphone : 1-877-413-5184, site internet :

www.global.ihs.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 (téléphone: 1-877-413-5184, site internet :

www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protection

Association, Quincy, MA 02269 (téléphone : 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 (téléphone : 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 (téléphone :

800-463-6727, site internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (téléphone : 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 (téléphone : 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

(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux −le téléphone

de la région 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

(téléphone: 1-800-232-4636, site internet : www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs

électromagnétiques (CEM) à certains endroits. Le courant de soudage

crée un CEM autour du circuit et du matériel de soudage. Les CEM

peuvent créer des interférences avec certains implants médicaux

comme des stimulateurs cardiaques. Des mesures de protection pour

les porteurs d’implants médicaux doivent être prises: par exemple, des

restrictions d’accès pour les passants ou une évaluation individuelle

des risques pour les soudeurs. Tous les soudeurs doivent appliquer les

procédures suivantes pour minimiser l’exposition aux CEM provenant

du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec

du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre

corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du

circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

6. Ne pas travailler à proximité 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

dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant de

s’approcher des opérations de soudage à l’arc, de soudage par points,

de gougeage, du coupage plasma ou de chauffage par induction. Si le

médecin approuve, il est recommandé de suivre les procédures précé-

dentes.

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 6

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label

Amperes

Plasma Arc Cutting

(PAC)

Adjust Air/Gas

Pressure

Low Air Pressure

Light

Volts Increase

No − Do Not Do

This

Temperature

Protective Earth

(Ground)

Single Phase Constant Current Voltage Input

On Off Percent Direct Current

Rated No Load

Voltage (Average) U

Primary Voltage

Conventional Load

Voltage

Line Connection

1max

Rated Maximum

Supply Current

Rated Welding

Current X

Duty Cycle

1 f1

Single Phase

Static Frequency

Transformer-

Rectifier-Converter

Degree Of

Protection

Loose Shield Cup Input

Hertz

1eff

Maximum Effective

Supply Current

power factor

Suitable for Some

Hazardous

Locations

Power Rating,

Product Of Voltage

And Current (KVA)

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 7

SECTION 4 − INSTALLATION

4-1. Specifications

Primary

Volts

Primary

Amperes

Primary Service

(Recommended)

Secondary

Volts (DC)

Secondary

Amperes

KW KVA

Rated

Cutting

Capacity

Power

Factor

Max**

OCV

(DC)

120

20.32

(0.25*)

20A 110 12 2.01 2.44

0.25 in

(6.4 mm)

At 6 IPM

(2.5 mm/s)

0.82 375

*While idling

**10% High line condition

4-2. Specifications For Torch

Air-cooled torch for plasma arc cutting (PAC)

35% duty cycle

Compressor output: 1.2 scfm (28.3 L/min) at 40 PSI (276 kPa) at 700 ft (213 m)

Safety interlock devices shut down power source

Safety trigger guard

Cutting capacity: see Section 4-1

4-3. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-

utes that unit can cut at rated load

without overheating.

If unit overheats, thermostat(s)

opens, output stops, 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 or gun and void

warranty.

Overheating

duty1 4/95

3-1/2 Minutes Cutting 6-1/2 Minutes Resting

Minutes

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 8

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.

18 in.

(457 mm)

4-5. Selecting A Location

loc_2 3/96

1 Lifting Handle

Use handle to lift unit.

2 Hand Cart

Use cart or similar device to move

unit.

3 120 VAC, 20 A Receptacle

Locate unit near correct input

power supply.

! Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

6-3/4 in.

(171 mm)

Movement

Location And Airflow

Dimensions And Weight

31 lb (14 kg)

10 in.

(254 mm)

10 in.

(254 mm)

17 in.

(432 mm)

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 9

4-6. Torch Dimensions And Weight

Ref. 801 397-A

3.0 lb (1.4 kg)

1 in.

(25 mm)

8-3/8 in.

(213 mm)

1-3/8 in.

(35 mm)

4-7. Connecting Work Clamp

Ref 803 915-A

. Do not connect work clamp to

the portion of the workpiece

that will fall when cut.

1 Work Clamp

2 Workpiece

Connect work clamp to a clean,

paint-free location on workpiece, as

close to cutting area as possible.

4-8. Electrical Service Guide For 120 VAC

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These

recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

50/60 Hz

Single

Phase

Input Voltage (V) 120

Input Amperes (A) At Rated Output 19

Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

(10)

Min Grounding Conductor Size In AWG

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 “H” ( 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

Input Voltage

Input Power

Phase

Hertz Conductor Size Max. Cord Length

120 V 1 50/60 12 AWG 50 ft (15 m)

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 10

4-10. Connecting Input Power

Ref. 802 460-B

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).

2 Plug From Unit

Connect plug to receptacle.

For extension cord data, see

Section 4-9.

! Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

120 V 20 A

Receptacle

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 11

SECTION 5 − OPERATION

5-1. Controls

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.

Once cup is reinstalled on torch, unit power

must be turned off and back on again.

4 Temp Light

Light comes on if unit overheats.

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 12

5-2. Cutting Speed

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. Cutting above the

line (too fast) will cause blowback

and lack of penetration.

. Recommended production cutting speed vs. material thickness is approximately

10 ipm at 1/8 in (3.2 mm) mild steel thickness at max setting.

5-3. Trigger Safety Lock

Trigger Locked Trigger Unlocked

1 Trigger

801 545-A

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 13

out bottom of cut.

801 400-A

5-4. Sequence Of Operation

After cutting arc starts, slowly

start moving torch across metal.

Adjust torch speed so

sparks go thru metal and

Pause briefly at end of

cut before releasing trigger.

EXAMPLE Of Cutting Operation

Raise trigger lock and press

trigger. Pilot arc starts.

Postflow continues after releasing trigger;

cutting arc can be instantly restarted during

postflow by raising trigger lock and pressing

trigger.

! 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).

. Moisture from the compressor will form in the air line and at

the torch. It will be normal to sometimes see moisture come

out the end of the torch.

As a convenience, the torch can be set up

with two cutting combinations, either drag

or non-shielded cutting. The torch comes

standard with drag cutting.

. Maximum performance on thicker materials can be obtained by using

non-shielded cutting with a 1/16 - 1/8 in (1.6 - 3.2 mm) standoff.

197 567

196 929

Use retaining cup (197 567) and drag

shield (196 929) to obtain a 1/16 in

(1.6 mm) standoff automatically. This

combination is designed to allow

dragging the torch directly on the

workpiece.

Use shields for ease of use when

cutting with a template, or when drag

cutting is preferred.

Drag Cutting

196 926

196 928

1/16-1/8 in

(1.6-3.2 mm)

standoff

workpiece

Use retaining cup (196 928) and hold a

1/16-1/8 in (1.6-3.2 mm) standoff between

the workpiece and cutting tip.

Use non-shielded when visually following

a line.

. This combination can be used for drag

cutting but does not provide optimum

cutting performance on thicker material.

Non-Shielded Cutting

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 14

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

n = Check Z = Change ~ = Clean l = Replace

* To be done by Factory Authorized Service Agent

Reference

Each

Use

n Torch Tip, Electrode,

And Shield Cup

Every

Week

n Shield Cup Shutdown

System

Every

Months

l Unreadable Labels nl Torch Body, Cable n Tape Torn Outer

Covering

nl Cracked Parts

Every

Months

nl Compressor Filter −

Clean With A Damp Cloth

Or Replace If Necessary

~ Inside Unit

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 15

6-2. Overload Protection: Trouble Light And Checking Shield Cup Shutdown System

1 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.

If certain problems occur, the

trouble light comes on, and output

stops.

2 Cup Light

Lights if shield cup is loose/off.

Check shield cup shutdown system

as follows:

Turn power On and loosen shield

cup. If shutdown system works

properly, Cup light comes on. If

not, turn power Off and have a

factory authorized service agent

check unit.

If system works properly,

retighten cup. Power must be

reset whenever the cup

shutdown is activated.

Check shield cup shutdown

system once a week.

A flashing Cup light indicates that

the torch consumables are stuck

or worn and should be inspected

and/or replaced (see

Section 6-4).

3 Temp Light

Lights if power source overheats or

when ambient temperature is below

−40° C (−40° F). If unit overheats,

allow fan to cool unit for 15 minutes

(see Sections 4-3).

4 Power/Temp Lights

When both lights flash, the com-

pressor current limit was exceeded

either above or below its operating

range. The lights flash for 15 sec-

onds before the torch can be retrig-

gered. If this condition continues

during unit operation, have a facto-

ry authorized service agent check

unit.

5 Torch Shield Cup

Turn Power On and loosen shield

cup. If shutdown system works

properly, trouble light comes on. If

not, turn power Off and check for

loose shield cup.

Check consumables (see Section

6-4 and Parts List).

If system works properly, retighten

cup and reset power.

Ref. 245 701-A / Ref. 801 300-A

Checking Torch Shield Cup Shutdown System

. Power source Power switch must be reset whenever cup shutdown

system is activated. Always turn Off power source when changing or

checking consumables.

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 16

6-3. Torch And Work Cable Connections

If torch or work cable needs to be

removed or replaced, proceed as

follows:

Turn power Off, and disconnect

input power plug from receptacle.

Remove wrapper from unit.

Torch Connections

Remove existing torch cable from

unit.

1 Strain Relief

2 Torch Cable

Insert cable through strain relief.

Slide strain relief nut onto torch

cable, but do not tighten.

3 Air Line Connector

Install air line connector into torch

fitting.

4 Plug PLG4/Receptacle RC4

Connect PLG4 to receptacle RC4

on circuit board PC1.

5 Female And Male Friction

Terminal RC1/ELECT WHITE

Connect female friction terminal on

end of white leads to RC1/ELECT

WHITE.

6 Female And Male Friction

Terminal RC2/TIP RED

Connect female friction terminal on

end red leads to RC2/TIP RED.

Tighten strain relief nut.

Tighten strain relief around cable.

. Do not overtighten strain relief

onto torch cable.

Work Cable Connections

Remove existing work cable from

unit.

7 Work Cable Strain Relief

. Be sure to allow some work

cable slack inside the unit.

Insert work clamp lead and strain

relief, and install strain relief into

front panel.

8 Work Lead Male Friction

Terminal RC3/WORK BLACK

Connect work clamp lead to male

friction terminal labeled WORK on

circuit board PC1. Route lead along

torch lead bundle.

Tools Needed:

5/8 in.

Ref. 801 300-B

. A complete Parts List is available at www.MillerWelds.com

OM-2248 Page 17

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. Be sure to use genuine

replacement parts.

. A good practice is to replace both the tip and electrode at the same time.

802 465

Turn Off power source.

1 Shield Cup

2 O-Ring

Remove shield cup. Check cup for cracks,

and replace if necessary.

Check O-ring for cracks or worn spots, re-

place shield cup if necessary.

3Tip

4 Opening

Remove tip. Check tip, and replace if open-

ing is deformed or 50% 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.

6 Swirl Ring

7 O-Ring

Remove swirl ring. Check ring, and replace

if side holes are plugged.

Check O-ring for cracks or worn spots,

replace swirl ring if necessary.

8 O-Ring

Check O-ring for cracks or worn spots, and

replace if necessary.

Carefully reassemble parts in reverse order.

Make sure this area is clean of

any debris.

Make sure swirl ring is clean of any

debris and no holes are

obstructed.

! Turn Off power source before checking torch parts.

New

Worn

New

Worn

1/16 in

(2 mm)

Pit

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Miller Electric 125C Owner's manual

Brand: Miller Electric

Model: 125C

Category: Welding System

Type: Owner's manual

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