Miller Electric ICE-100TM User manual

Brand: Miller Electric

Model: ICE-100TM

Category: Welding System

Type: User manual

Spectrum 1251 And

ICE-100T/TM Torch

Processes

Description

Air Plasma Cutting

and Gouging

Air Plasma Cutter

OM-201 872D 2007−03

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 9001:2000 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 4/05

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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers liés au coupage à l’arc au plasma 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

et la maintenance 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Symbols And Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Duty Cycle and Overheating 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Cutting Speed 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Selecting a Location 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Connecting Work Clamp and Gas/Air Supply 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting And Disconnecting Torch 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Electrical Service Guide 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Extension Cord Data 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Connecting 3-Phase Input Power 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant 17 . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Setting Gas/Air Pressure 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Trigger Safety Lock 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Plasma Cutting System Practices 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Sequence Of Cutting Operation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Sequence Of Gouging Operation 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Sequence Of Piercing Operation 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Consumables Storage Compartment 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MECHANIZED OPERATION 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. ICE-100TM Mounting Position 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Remote Control Receptacle 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Remote Control Cable Functions 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. +24 Volts DC Hot Contacts For Relay Operation 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Dry Contacts Using An External Power Supply For Relay Operation 27 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation 28 . . . . . . . . . . . . .

6-8. Remote Voltage Sense Connection 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Shield Sense Tab 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10. Cut Charts 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Trouble Lights 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Checking Shield Cup Shutdown System 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Checking/Replacing Retaining Cup, Tip, And Electrode 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Checking Or Replacing Filter Element 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Troubleshooting Power Source 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Troubleshooting Torch 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAM 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES

PARTS LIST − www.MillerWelds.com

WARRANTY

OM-201 872 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

pom _4/05

Y Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Plasma Arc Cutting Hazards

Y 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 Safe-

ty Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y 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 in atmospheres containing explosive dust or vapors.

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 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 also uses 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 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.

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.

OM-201 872 Page 2

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 cause injury.

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 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 provided for the operator’s conve-

nience.

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 − 80

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 cause injury.

The heat from the plasma arc can cause serious

burns. The force of the arc adds greatly to the burn

hazard. The intensely hot and powerful arc can

quickly cut through gloves and tissue.

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-201 872 Page 3

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

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on torch.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

MOVING PARTS can cause injury.

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 as

necessary.

D Reinstall doors, panels, covers, or guards

when maintenance is finished and before re-

connecting input power.

READ INSTRUCTIONS.

D Read Owner’s Manual before using or servic-

ing unit.

D Use only genuine Miller/Hobart replacement

parts.

FLYING METAL can injure eyes.

D Wear safety glasses with side shields or face

shield.

MAGNETIC FIELDS can affect pacemakers

D Pacemaker wearers keep away.

D Wearers should consult their doctor before go-

ing near plasma arc cutting 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 UNIT can cause injury.

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.

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.

1-4. California Proposition 65 Warnings

Y 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.)

Y 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.

For Gasoline Engines:

Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

Y Diesel engine exhaust and some of its constituents are known

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

other reproductive harm.

OM-201 872 Page 4

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, American Welding

Society Standard AWS C5.2, from Global Engineering Documents

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

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from Global Engineering Docu-

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

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

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

1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:

617−770−3000, 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 (there

are 10 Regional Offices−−phone for Region 5, Chicago, is

312−353−2220, website: www.osha.gov).

1-6. EMF Information

Considerations About Welding Or Cutting And The Effects Of Low

Frequency Electric And Magnetic Fields

Welding or cutting current, as it flows through the welding or cutting

cables, will cause electromagnetic fields. There has been and still is

some concern about such fields. However, after examining more than

500 studies spanning 17 years of research, a special blue ribbon

committee of the National Research Council concluded that: “The body

of evidence, in the committee’s judgment, has not demonstrated that

exposure to power-frequency electric and magnetic fields is a human-

health hazard.” However, studies are still going forth and evidence

continues to be examined. Until the final conclusions of the research are

reached, you may wish to minimize your exposure to electromagnetic

fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following proce-

dures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep cutting power source and cables as far away from operator

as practical.

5. Connect work clamp to workpiece as close to the cut as possible.

About Pacemakers:

Pacemaker wearers consult your doctor before welding/cutting or going

near welding/cutting operations. If cleared by your doctor, then following

the above procedures is recommended.

Page is loading ...

OM-201 872 Page 8

LE COUPAGE Ã L’ARC peut causer

des interférence.

D L’énergie électromagnétique peut gêner le fonction-

nement d’appareils électroniques comme des ordi-

nateurs et des robots.

D Pour réduire la possibilité d’interférence, maintenir les câbles aussi

courts que possible, les grouper, et les poser aussi bas que possible

(ex. par terre).

D Veiller à couper à une distance de 100 mètres de tout équipement

électronique sensible.

D S’assurer que la source de coupage est correctement branchée et

mise à la terre.

D Si l’interférence persiste, l’utilisateur doit prendre des mesures sup-

plémentaires comme écarter la machine, utiliser des câbles blindés

de des filtres, ou boucler la zone de travail.

2-4. 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

Internet : www.global.ihs.com).

Recommended Practices for Plasma Arc Cutting, American Welding

Society Standard AWS C5.2, de Global Engineering Documents (télé-

phone : 1-877-413-5184, site Internet : www.global.ihs.com).

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society de Global Engineering Documents

(téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101

(téléphone : 617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a

10 bureaux régionaux−−le téléphone de la région 5, Chicago, est

312-353-2220, site Internet : www.osha.gov).

2-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Le courant de soudage ou de coupage passant dans les câbles de puis-

sance crée des causera des champs électromagnétiques. Il y a eu et

il y a encore un certain souci à propos de tels champs. Cependant,

après avoir examiné plus de 500 études qui ont été faites pendant une

période de recherche de 17 ans, un comité spécial ruban bleu du Natio-

nal Research Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs ma-

gnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les

conclusions finales de la recherche soient établies, il vous serait sou-

haitable de réduire votre exposition aux champs électromagnétiques

pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

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

vous.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les porteurs de stimulateur cardiaque doivent consulter leur médecin

avant de souder/couper ou d’approcher des opérations de soudage/

couper. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

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

OM-201 872 Page 9

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

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)

Primary Voltage

Conventional Load

Voltage

Line Connection

1max

Rated Maximum

Supply Current

Rated Welding

Current

Duty Cycle

1/3 f1

Single Phase Or

Three Phase Static

Frequency

Converter-

Transformer-

Rectifier

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-201 872 Page 10

SECTION 4 − INSTALLATION

4-1. Specifications

Amperes Input at Rated Load

Output 60 Hz, Three-Phase*

Rated

Type of

Plasma

Rated

Maximum

Open-

Duty Cycle

Rated

Output

Type of

Output

Plasma

Gas

Rated

Cutting

Capacity

Maximum

Open-

Circuit

40% 50% 80% 80%

Output

Gas

Cutting

Capacity

Circuit

Voltage DC

208 V 230 V 460 V 575 V KVA KW

Voltage DC

55 49 24 19 19.1 18.2

100 A @

160 Volts

Direct

Current,

Straight

Polarity

(DCEN)

9.2 CFM

(261

L/min) At

75 PSI

(517 kPa)

Air Or

Nitrogen

Only

1.25 in

(32 mm)

At 12 IPM

(305 mm/min)

265

*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition.

Amperes Input

at Rated Load

Output 50 Hz,

Three-Phase*

Rated

Output

Type of

Output

Plasma

Gas

Rated Cutting

Capacity

Maximum

Open-Circuit

Voltage DC

400 V KVA KW

Voltage DC

28 19.2 18.3

100 A @ 160

Volts DC, 80%

Duty Cycle

Direct Current,

Straight Polarity

(DCEN)

9.2 CFM

(261 L/min) At

75 PSI (517

kPa) Air Or

Nitrogen Only

1.25 in

(32 mm)

At 12 IPM

(305 mm/min)

265

*Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition..

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

OM-201 872 Page 11

4-2. Duty Cycle and Overheating

Duty Cycle is percentage of 10

minutes that unit can cut at rated

load without overheating.

If unit overheats, output stops, and

cooling fan runs. Wait fifteen min-

utes for unit to cool. Reduce amper-

age or duty cycle before cutting.

Y Exceeding duty cycle can

damage unit and void war-

ranty.

Overheating

Reduce Duty Cycle

Minutes

duty1 4/95

230 Volts AC Three-Phase Input Power:

50% Duty Cycle

208 Volts AC Three-Phase Input Power:

40% Duty Cycle

380-575 Volts AC Three-Phase Input Power:

80% Duty Cycle

5 Minutes Cutting 5 Minutes Resting 8 Minutes Cutting 2 Minutes Resting

4 Minutes Cutting 6 Minutes Resting

4-3. Cutting Speed

The cutting speed curve shows the

rated cutting speed capabilities of

the power source and torch for mild

steel, stainless steel, and aluminum

of various thicknesses.

Y Exceeding recommended

cutting speeds will cause

rapid erosion of the tip and

electrode.

Rated Cutting Speed vs Material Type & Thickness

100

110

120

130

140

150

160

170

0.25” 0.375” 0.5” 0.625” 0.75” 1” 1.25”

Material Thickness (Inches)

Cutting Speed (Inches per Minute)

Aluminum Stainless Steel Mi ld St eel

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

OM-201 872 Page 12

4-4. Selecting a Location

loc_2 3/96 - Ref. 151 556 / 802 183

1 Lifting Handles

Use handles to lift unit.

2 Hand Cart

Use cart or similar device to move

unit.

3 Line Disconnect Device

Locate unit near correct input

power supply.

Y Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

24 in

(610 mm)

17 in

(432 mm)

12-1/2 in

(318 mm)

Movement

Y Do not move or operate unit

where it could tip.

Location

Dimensions And Weight

18 in

(460 mm)

18 in

(460 mm)

95 lb (43 kg) w/Torch

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

OM-201 872 Page 13

4-5. Connecting Work Clamp and Gas/Air Supply

1 Work Clamp

2 Workpiece

Connect work clamp to a clean,

paint-free location on workpiece, as

close to cutting area as possible.

. Use only clean, dry air with 90

to 120 psi (621 to 827 kPa)

pressure @ 9.2 CFM

(260L/min) minimum.

3 Gas/Air Filter Inlet Opening

4 Hose

. Hose must have a minimum

inside diameter of 3/8 in

(9.5 mm).

5 Teflon Tape

Obtain hose with 1/4 NPT right-

hand thread fitting. Wrap threads

with teflon tape (optional) or apply

pipe sealant, and install fitting in

opening. Route hose to gas/air

supply.

Adjust gas/air pressure according

to Section 5-2.

Tools Needed:

9/16 in

Ref. 803 640-A / Ref. 192 441 / Ref. 804 026-A

Rear of Unit

From

Gas/Air

Supply

AIR/N

90-120

psi

@ 9.2 CFM

(260 L/min)

minimum

4-6. Connecting And Disconnecting Torch

Y Turn off power source and

disconnect input power.

1 Torch Connector

2 Quick Connect Collar

3 Nipple

4 Receptacle

5 Securing Pin

To connect torch:

Push torch connector onto

receptacle and quick connect until

collar secures nipple.

Rotate securing pin to lock

connector to unit.

To disconnect torch:

Rotate securing pin to unlock

connector from unit.

Push quick connect collar back

towards unit to release nipple, and

pull torch connector away from unit.

804 055-A

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

OM-201 872 Page 14

4-7. Electrical Service Guide

Y CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding power

source requires a CONTINUOUS supply of 50 or 60 Hz (+10%) power at +10% of 575V or −10% of 208V

input voltage. Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a gener-

ator with automatic idle device (that idles engine when no load is sensed) to supply input power to this

plasma power source.

60 Hz Three Phase

Input Voltage 208 230 460 575

Input Amperes At Rated Output 55 49 24 19

Max Recommended Standard Fuse Rating In Amperes

Time-Delay

60 60 30 20

Normal Operating

80 70 35 30

Min Input Conductor Size In AWG

8 8 10 12

Max Recommended Input Conductor Length In Feet (Meters)

(27)

108

(33)

284

(87)

268

(82)

Min Grounding Conductor Size In AWG

8 8 10 12

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Consult factory for circuit breaker applications.

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 “H” ( 65 amp 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.

50 Hz Three Phase

Input Voltage 400

Input Amperes At Rated Output 28

Max Recommended Standard Fuse Rating In Amperes

Time-Delay

Normal Operating

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

155

(47)

Min Grounding Conductor Size In AWG

Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Consult factory for circuit breaker applications.

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 “H” ( 65 amp 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.

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

OM-201 872 Page 15

4-8. Extension Cord Data

When calculating max. cord length, remember to include conductor length from

line disconnect device to input power receptacle.

NOTE

Input Voltage

Input Power

Phase

Hertz

Fuse Size Or

Circuit Breaker Rating

Conductor Size Max. Cord Length

208 V 3 60

Time-Delay

60 A

Normal Operating

80 A

8 AWG 89 ft (27 m)

230 V 3 60

Time-Delay

60 A

Normal Operating

70 A

8 AWG 108 ft (33 m)

460 V 3 60

Time-Delay

30 A

Normal Operating

35 A

10 AWG 284 ft (87 m)

575 V 3 60

Time-Delay

20 A

Normal Operating

30 A

12 AWG 268 ft (82 m)

400 V 3 50

Time-Delay

25 A

Normal Operating

35 A

12 AWG 155 ft (47 m)

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 “H” ( 65 amp and

above).

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

OM-201 872 Page 16

4-9. Connecting 3-Phase Input Power

803 766-A / 802 183

Y Installation must meet all National

and Local Codes − have only

qualified persons make this

installation.

Y Disconnect and lockout/tagout

input power before connecting

input conductors from unit.

Y Always connect green or green/

yellow conductor to supply

grounding terminal first, and never

to a line terminal.

. The Auto-Line circuitry in this unit

automatically adapts the power

source to the primary voltage being

applied. Check input voltage available

at site. This unit can be connected to

any input power between 208 and 575

VAC without removing cover to relink

the power source.

1 Input Power Cord.

2 Disconnect Device (switch shown in

the OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding

Terminal

5 Input Conductors (L1, L2 And L3)

6 Disconnect Device Line Terminals

Connect green or green/yellow grounding

conductor to disconnect device grounding

terminal first.

Connect input conductors L1, L2, and L3

to disconnect device line terminals.

7 Over-Current Protection

Select type and size of over-current

protection using Section 4-7 (fused dis-

connect switch shown).

Close and secure door on disconnect

device. Remove lockout/tagout device,

and place switch in the On position.

= GND/PE Earth Ground

Tools Needed:

3/8 in

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

OM-201 872 Page 17

4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant

Ref. 197 399 / 802 332-B

Three-Phase Generator Power

Y Stop engine.

Y Power and weld outputs are

live at the same time. Discon-

nect or insulate unused

cables.

. Have qualified person install ac-

cording to circuit diagram and

Generator Power Guidelines

(see generator Owner’s Manual).

Remove generator power panel

mounting screws. Tilt panel forward.

1 Circuit Breaker CB7

2 Lead 93

3 Lead 92

4 Lead 91

5 Lead 42 (Circuit Grounding

Lead)

6 Lead 90 (Neutral)

7 Isolated Neutral Terminal

8 Jumper Lead 42

9 Grounding Terminal

Jumper 42 is connected to lead 90 at

factory. Jumper 42 may be discon-

nected from neutral to meet applica-

ble electrical codes.

Lead 42 connects to front panel

Ground stud.

10 Power Cord

11 Circuit Breaker CB7 User

Terminals

. Circuit breaker CB7 protects

single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all three-phase

generator output stops and the

receptacle does not work.

Connect user-supplied ring lug to

green (ground) lead. Connect ring

lug on end of green (ground) lead

to grounding terminal (9).

Connect black, white, and red

leads to circuit breaker CB7 user

terminals (11).

Reinstall power panel.

. Engine control must be set to

Run NOT Run/Idle to adequately

power the plasma cutter.

Tools Needed:

Volts

Amps

KVA/KW

Three

240

60 HzFrequency

Engine Speed 1850 RPM

Phase

Output

Lead 42 connects to GROUND stud on

front of unit.

Jumper 42 is connected to 90 at factory.

91 92 93

240V

3-Phase

Rear Of Panel

Three-Phase Power Connection

Y Close panel opening

if no connections are

made to generator.

Y Close panel

opening if no

connections

are made to

generator.

240V

Remove plug

before inserting

leads. Reinstall

bushing.

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

OM-201 872 Page 18

SECTION 5 − OPERATION

5-1. Controls

1 Gas/Air Pressure Gauge

2 Gas/Air Pressure Control

3 Output Control

Use control to select cutting output in am-

peres. Gas/air automatically flows at the set

pressure.

Use Gas/Air Set area of control range for set-

ting gas/air pressure (see Section 5-2).

4 Trouble Lights (see Section 7-2)

5 Power Light

6 Cut/Gouge Switch

Set pressure as indicated on nameplate for

appropriate switch position.

After the cutting arc goes out, the torch

will automatically re-ignite the pilot arc if

the trigger is held down.

7 Power Switch

201 853-A

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

OM-201 872 Page 19

5-2. Setting Gas/Air Pressure

Ref. 804 025-A / Ref. 804 026-A

Turn On Gas/Air Supply.

Power Switch On.

Place Output Control in

Gas/Air Set Position.

Pull knob and turn, set

pressure to 75 PSI

(517 kPa). Push knob in

to lock setting.

1 Power Switch

Setting Gas/Air Pressure

Unit Requires 90-120 PSI

(621-827 kPa) Supply At

9.2 CFM (260 L/min)

Minimum Flow Rate

Rear of Unit

2 Output Control 3 Gas/Air Pressure

Adjustment Knob

Select desired cutting

output with Output

Control.

AIR/N

90-120 psi

5-3. Trigger Safety Lock

1 Trigger

801 397-A

Trigger Locked Trigger Unlocked

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Miller Electric ICE-100TM User manual

Brand: Miller Electric

Model: ICE-100TM

Category: Welding System

Type: User manual

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Miller Electric ICE-100TM User manual

Miller Electric ICE-100TM User manual

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