Miller HJ000000 Owner's manual

Brand: Miller

Model: HJ000000

Category: Welding System

Type: Owner's manual

This manual is also suitable for

OWNER’S MANUAL

 1997 MILLER Electric Mfg. Co.

March 1997 FORM: OM-184 290

ICE-102 And ICE-102M Torches

1. Specifications

Air/nitrogen-cooled torches for plasma arc cutting (PAC)

100 A at 80% duty cycle; 80 A at 100% duty cycle

Equipped with 50 ft (15.2 m) cable

Shield Gas: Air, Nitrogen, Or Carbon Dioxide; see power source Owner’s Manual for pressure and flow rate information

Cutting Gas: Air, Nitrogen, Or Argon/Hydrogen; see power source Owner’s Manual for pressure and flow rate information

Safety interlock device shuts down power source if cup is removed or tip and electrode are shorted together

Gear rack pitch for machine-held model: 32

Cutting Capacity: 1-1/4 in (32 mm) at 10 in (254 mm) per minute

2. Dimensions And Weights

Ref. ST-800 713 / ST-800 712-A

Hand-Held Torch

12 lb (5.4 kg) With 30 ft (9.1 m) Cable

17 lb (7.7 kg) With 50 ft (15.2 m) Cable

Machine-Held Torch

14 lb (6.3 kg) With 30 ft (9.1 m) Cable

21 lb (9.5 kg) With 50 ft (15.2 m) Cable

28 lb (12.7 kg) With 75 ft (22.9 m) Cable

1-1/8 in

(29 mm)

10 in

(254 mm)

2-1/4 in

(57 mm)

1-3/16 in

(30 mm)

14-3/8 in

(365 mm)

1-3/8 in

(35 mm)

OM-184 290 Page 2

3. Safety Symbol Definitions

Warning! Watch Out! There are possible hazards as

shown in the adjoining symbols.

Static electricity can damage parts on circuit boards. Put

on grounded wrist strap before touching circuit board.

Beware of electric shock from the cutting torch or wiring.

Touching the cutting torch while in contact with the work

or ground can cause electric shock. Always wear dry

gloves. Keep all panels and covers closed.

Have only trained and qualified persons install, operate,

or service this unit. Call your distributor if you do not

understand the directions. For CUTTING SAFETY and

EMF information, read power source Manual.

Cutting sparks can cause fire or explosion. Move flam-

mables away. Do not cut on closed tanks or barrels –

they can explode. Clean tanks or barrels properly.

Beware of moving parts. Keep guards and panels in

place, covers closed, and hands away from moving

parts.

Arc rays can burn eyes and skin – wear face protection

(helmet or face shield) with correct shade of filter, and

cover exposed skin with nonflammable clothing.

Breathing cutting fumes and gases can harm your

health. Cutting requires good ventilation. If ventilation is

impossible, such as when cutting in a confined space,

use an air-supplied respirator.

Hot parts can cause burns. Cutting makes parts very hot

– let them cool before touching.

The plasma arc can cause injury. The intense heat of the

arc or pilot arc can cause serious burns. Keep away

from the torch tip when the trigger is pressed. Do not

grip material near the cutting path.

Allow cooling period. Reduce current or reduce duty

cycle before starting to cut again. Follow rated duty

cycle.

Prolonged noise from some cutting applications can

damage hearing. Use approved ear plugs or ear muffs if

noise level is high.

Wear safety glasses with side shields. Cutting processes cause flying pieces of metal and

sparks. Wear a face shield.

Exploding Hydrogen Hazard! When cutting aluminum

underwater or with the water touching the underside of

the aluminum, free hydrogen gas may collect under the

workpiece. See your cutting engineer and water table

instructions for help.

8 Minutes Cutting 2 Minutes Resting

4. Duty Cycle And Overheating

Duty Cycle is percentage of 10

minutes that unit can cut at rated

load without overheating.

Y Exceeding duty cycle can

damage unit and void

warranty.

80% Duty Cycle At 100 Amperes

Overheating

Reduce Duty Cycle

Minutes

sduty1 5/95

Continuous Cutting

100% Duty Cycle At 80 Amperes

OM-184 290 Page 3

5. Installing Torch And Work Cable

Y Turn Off unit and disconnect

input power before remov-

ing side panel.

If torch or work cable needs to be

removed or replaced, remove left

side panel, and proceed as follows:

1 Work Cable

2 Work (+) Output Terminal

3 Torch Cable

4 Torch (–) And Gas/Air Output

Connector

5 Pilot Cable

6 Pilot (+) Output Terminal

7 Cup Safety Hose

8 Cup Safety Push-In Connec-

tor (Mounted On Rear Panel)

Connect cables as shown.

9 Terminal Strip 1T

10 Connection Label

11 Torch Switch Leads

For hand-held torches, refer to la-

bel to connect leads. Reinstall side

panel.

12 Nut

13 Hose Clamp

For machine-held torches, tighten

nut and clamp to secure cables.

See Section 6 for remote control

connections.

Tools Needed:

Ref. ST-801 662 / ST-801 664-A

3/8 in

1/2 in

Hand-Held Torch

Panel

N.O.

Output

Sensor

Command

Ref.

Remote

Jumper

Common

Torch

Switch

S-169 259

Signal

Ground

Machine-Held Torch

OM-184 290 Page 4

Panel

6. Remote Control Connections For Machine-Held Torches

Ref. ST-801 662 / Ref. ST-150 802-A

Y Turn Off unit and disconnect

input power before instal-

ling remote control.

Remove left side panel.

1 Terminal Strip 1T

2 Connection Label

. Lead colors shown match

those of Remote Pendant

Control supplied with

machine-held torches.

Route leads through hole below

torch and work cable access holes.

Refer to connection label and

make connections as follows:

Torch On/Off Connections:

3 Remote On/Off Switch

Connect switch leads to terminals

3 and 4 as shown. Switch closure

starts cutting arc.

Output Control Connections:

4 Jumper Link

For remote output control, remove

jumper link between terminals 9

and 10, and reinstall between ter-

minals 8 and 9 as shown. This dis-

ables front panel Output Control

and enables remote output control.

5 Remote Output Control

Connect control leads to terminals

7, 8, and 11 as shown.

Output Sensor Connections:

6 Output Sensor Terminals

Terminals 5 and 6 connect to inter-

nal, normally-open contacts which

close when cutting output is pres-

ent. For example, use signal to

start automatic fixture.

Reinstall side panel.

Tools Needed:

3/8 in

S-169 259

N.O.

Output

Sensor

Command

Ref.

Remote

Jumper

Common

Signal

Ground

Torch

Switch

+10 Volts DC

(Brown)

Black

White

Wiper (Red)

GND (Green)

OM-184 290 Page 5

7. Sequence Of Operation For Plasma Arc Cutting

Put On Personal

Safety

Equipment

Install &

Connect

Equipment

Check Torch Tip,

Electrode, And

Retaining Cup

Check Gas/Air

Pressure And

Adjust Flows

Set

Controls

Begin

Cutting

Turn On

Power Source

Do not clean torch by hitting it against

a hard surface. Hitting hard surfaces

can damage torch parts and stop

proper operation.

Inspect shield cup, tip, and electrode for

wear before cutting or whenever cutting

speed has been significantly reduced

(see Section 10). Do not operate torch

without a tip or proper electrode in place.

Press trigger. After 2 seconds of

preflow, pilot arc starts.

After cutting arc starts, slowly

start moving torch across metal.

Adjust torch speed so

sparks go thru metal and

out bottom of cut.

Pause briefly at end of

cut before releasing trigger.

EXAMPLE Of Cutting Operation

ST-161 698-A

Postflow continues for approximately

5 seconds after releasing trigger,

cutting arc can be instantly restarted

during postflow by pressing trigger.

Place drag shield on edge of

metal, or allow correct stand-off

distance. For machine shield, use

1/8-3/16 in (3-5 mm) stand-off.

Warning! Exploding Hydrogen Hazard! When cutting aluminum underwater or with the water touching the un-

derside of the aluminum, free hydrogen gas may collect under the workpiece. Detonation of the hydrogen gas

may occur while plasma cutting under these conditions. An effective means of eliminating the possibility of

hydrogen detonation is to install an aeration manifold on the floor of the water table. See your cutting engineer

or distributor for assistance.

OM-184 290 Page 6

8. Routine Maintenance

Y Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Each Use

Check Torch

Tip, Electrode,

And Shield Cup

Check Gas/Air

Pressure

Every Week

Check Shield Cup

Shutdown System

3 Months

Replace

Cracked

Parts

Gas/Air Hose

Torch Body, Cable

Tape Torn Outer

Covering

9. Shield Cup Shutdown System

1 Torch Shield Cup

Turn Power On and loosen shield

cup. If shutdown system works

properly, Ready light on power

source goes off and Gas/Air Or

Shield Cup light comes on. If not,

turn power Off and check for prop-

er gas/air pressure (see power

source Owner’s Manual), blocked

or leaking hose, or loose shield cup

(see Section 10).

If system works properly, retighten

cup and turn Off power.

Ref. ST-800 713

The tight fit of the double O-ring seal

may make it difficult to turn shield cup.

Be sure to retighten cup completely.

Off

OM-184 290 Page 7

10. Checking/Replacing Retaining Cup, Tip, And Electrode

Overtightening will strip threads. Do not overtighten electrode and 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.

ST-801 811 / ST-800 726

Turn Off power source, and disconnect in-

put power.

1 Shield/Deflector

Remove shield/deflector. If necessary,

clean metal or other debris off shield/deflec-

tor. If gas holes are blocked, clear by push-

ing pin from outside the cup to inside.

2 Retaining Cup

Remove retaining cup. Check retaining cup

for cracks, and replace if necessary.

3Tip

Check O-ring on tip. Replace tip if O-ring is

damaged or tip is worn.

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 Swirl Ring

Remove swirl ring. Check ring, and replace

if side holes are plugged.

6 Electrode

Check electrode. If center has a pit more

than a 1/16 in (2 mm) deep, remove and re-

place electrode using supplied wrench. Do

not overtighten.

7 O-Rings

Check O-rings on torch. If needed, coat with

thin film of supplied lubricant. Replace if

damaged.

Carefully reassemble parts in reverse order.

Swirl ring must be installed with word “front”

facing away from torch body.

Thread size for electrode:

7/16 - 28

Turn Off power source before checking torch parts.

New

Worn

New

Worn

1/16 in

(2 mm)

Pit

The word “front” on

swirl ring must face

away from torch body.

Do not overtighten

electrode.

OM-184 290 Page 8

11. Troubleshooting

Trouble Remedy

Power source Torch-To-Tip trouble light

On; no cutting output.

Check to make sure torch electrode is not touching tip inside the torch (see Section 10).

Check torch connections on power source (see Section 5).

Power source Gas/Air Or Shield Cup

trouble light On; no cutting output.

Check shield cup and O-ring (see Section 10).

Check for sufficient gas/air supply pressure and correct gas/air pressure adjustment. See power source

Owner’s Manual.

Sparks come out top of cut, or cut is not

clean.

Torch travel speed too fast; reduce travel speed (see Section 7).

Clean or replace worn consumables as necessary (see Section 10).

Metal being cut is too thick; increase output control setting. See power source Owner’s Manual.

Be sure work clamp is securely attached. See power source Owner’s Manual.

Arc goes out while cutting. Make sure drag shield is contacting the workpiece or that proper stand-off is maintained (see

Section 7).

Be sure work clamp is securely attached. See power source Owner’s Manual.

Clean or replace worn consumables as necessary (see Section 10).

Arc goes on and off while cutting. Torch travel speed is too slow; increase travel speed (see Section 7).

Clean or replace worn consumables as necessary (see Section 10).

Be sure work clamp is securely attached. See power source Owner’s Manual.

OM-184 290 Page 9

12. Parts List

Description

Part

No.

Item

No.

Figure 12-1. Torch, ICE 102 Hand Held

Quantity

1 183 448 TORCH, main body 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 171 246 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 171 248 PUSHBUTTON, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171 255 SPLICE, 22-18 butt N-insul connector 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 171 263 LEAD INSULATOR, 5/8PVC 3.5 in long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 171 252 TEFLON TUBE, 11/16 ID x .030W x 3.5 in long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 171 260 LEAD INSULATOR, 7/16PVC 3 in long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 171 251 TEFLON TUBE, 9/16 ID x .030W x 2.5 in long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 171 259 BOOT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 171 247 BOOT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 171 256 HANDLE SCREW, No. 6 x 3/4ph 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 183 450 LEADS, 50ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 12-1. Torch, ICE 102

Figure 12-2. Torch, ICE 102M

ST-800 951-A

See Fig 12-3 for additional

Torch Consumables and Parts

Description

Part

No.

Item

No.

Figure 12-2. Torch, ICE 102M Machine

Quantity

1 183 449 TORCH, main body 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 171 241 TORCH ASSEMBLY, rack and sleeve (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 185 999 TORCH POSITION SLEEVE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 186 000 COLLAR, brass 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 186 001 LOCKING RING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 183 452 LEADS, 50ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 010 860 CLAMP, hose .750-1.750clp dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 170 993 COLLAR, brass 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 170 825 WASHER, shldr 1.251 ID x 1.750 OD x .125thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 010 907 NUT, 1.000-11 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 171 244 BLACK PVC, 5/8 ID x 3.5 long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .