AirForce 500i Owner's Manual

8/6/2019 AirForce 500i Owner's Manual

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AirForce 500iAnd HP-50 Torch

Processes

Description

Air Plasma Cutting

Air Plasma Cutter

OM-243 974C 2010-04

File: Plasma Cutters


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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 dont have time to do

it any other way.

Thats 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 couldnt 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. Theyre just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owners 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.

Weve 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,

theres 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 inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Mil_Thank 200909


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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 SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers lis au coupage larc au plasma 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnementet la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Proposition californienne 65 Avertissements 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Principales normes de scurit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Informations relatives aux CEM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label 10. . . . . . . . . . . . . . . . . . . . . .

SECTION 4 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Duty Cycle And Overheating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Power Source Dimensions And Weight 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Torch Dimensions And Weight 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Connecting Gas/Air Supply 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting Work Clamp 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Electrical Service Guide For 240 VAC 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Extension Cord Data 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Connecting 1-Phase Input Power For 240 VAC 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Serial Number And Rating Label Location 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Connecting Input Power 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Generator Or Inverter Requirements 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Cable Management Strap 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14. Electrode Wrench 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Cutting Speed 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Trigger Safety Lock 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Plasma Cutting System Practices 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Sequence Of Cutting Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Sequence Of Cutting Using Stand-off Guide 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Sequence Of Piercing Operation 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 MAINTENANCE & TROUBLESHOOTING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Routine Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Overload Protection 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Checking Or Replacing Filter Element 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Status/Trouble Lights 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Checking Shield Cup Shutdown System 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Checking/Replacing Retaining Cup, Tip, And Electrode 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Torch And Work Cable Connections 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8. Troubleshooting Power Source 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9. Troubleshooting Torch 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 ELECTRICAL DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 PARTS LIST 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY


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OM-243 974 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGpom_201003

Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards 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! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Plasma Arc Cutting Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructionsto avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair 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, andhot equipment can cause fires and burns. Checkand 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 thisis 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 gothrough 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 cancause 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 unknownpaths 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, heavyshirt, 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 51Bfor hot work and have a fire watcher and extinguisher nearby.

Touching live electrical parts can cause fatal shocksor severe burns. The torch and work circuit areelectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. Plasma arc cutting requires

higher voltages than welding to start and maintain the arc (200 to 400volts dc are common), but may also use torches designed with safetyinterlock systems which turn off the machine when the shield cup isloosened or if tip touches electrode inside the nozzle. Incorrectlyinstalled 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 orcovers big enough to prevent any physical contact with the work orground.

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 CFR1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its OwnersManual and national, state, and local codes.

D Check and be sure that input power cord ground wire is properlyconnected to ground terminal in disconnect box or that cord plug isconnected to a properly grounded receptacle outlet always verifythe 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 metaland 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 damagedparts 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 Owners 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 aspractical.

D Insulate work clamp when not connected to workpiece to preventcontact with any metal object.


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OM-243 974 Page 2

SIGNIFICANT DC VOLTAGE exists ininverter 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 anyparts. Check capacitors according to instructions in Mainte-nance Section of Owners 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 whenpower is applied. Always wear a face shieldand 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.

DWear 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 fromentering ears.

Arc rays from the cutting process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin.

ARC RAYS can burn eyes and skin.

D Wear face protection (helmet or shield) with a proper shade of filterlenses to protect your face and eyes from arc rays and sparks whencutting or watching. ANSI Z49.1 (see Safety Standards) suggests aNo. 9 shade (with No. 8 as minimum) for all cutting currents lessthan 300 amperes. Z49.1 adds that lighter filter shades may be usedwhen 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 operators convenience.

D Wear approved safety glasses with side shields under your helmetor shield.

D Use protective screens or barriers to protect others from flash, glareand sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistantmaterial (leather, heavy cotton, or wool) and foot protection.

Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes Minimum Shade Number

Below 2020 40

40 60

60

100

#4#5

#6

#8

Prolonged noise from some cutting applications candamage hearing if levels exceed limits specified byOSHA (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. Breathingthese fumes and gases can be hazardous toyour 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 thearc 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 manufacturers instruction for metals to be cut, coatings,and cleaners.

D Work in a confined space only if it is well ventilated, or while wearingan air-supplied respirator. Fumes from cutting and oxygen depletioncan alter air quality causing injury or death. Be sure the breathing airis 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 formhighly toxic and irritating gases.

D Do not cut on coated metals, such as galvanized, lead, or cadmiumplated steel, unless the coating is removed from the cutting area, thearea is well ventilated, and while wearing an air-supplied respirator.The coatings and any metals containing these elements can give offtoxic fumes when cut.

D Do not cut containers with toxic or reactive materials inside orcontainers 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 seriousburns. The force of the arc adds greatly to the burnhazard. The intensely hot and powerful arc canquickly 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 pressingthe 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 Owners Manual.

Gas cylinders contain gas under high pressure. Ifdamaged, 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 themto a stationary support or equipment cylinder rack to prevent fallingor tipping.

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

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

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 associatedparts 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 inuse or connected for use.

D Use the right equipment, correct procedures, and sufficient numberof 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.


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OM-243 974 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 onequipment.

D To handle hot parts, use proper tools and/orwear heavy, insulated welding gloves andclothing to prevent burns.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guardsclosed and securely in place.

D Have only qualified persons remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owners

Manual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

D Use only genuine replacement parts from the manufacturer.

D Perform maintenance and service according to the OwnersManuals, industry standards, and national, state, and localcodes.

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or wearface shield.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect Implanted Medical Devices.

D Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

D Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.

D Reduce amperage (thickness) or reduce dutycycle before starting to cut again.

EXPLODING HYDROGEN hazard.

D When cutting aluminum underwater or with thewater 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 runninggear, 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 vehicleswhen working from an aerial location.

D Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94110) when manuallylifting heavy parts or equipment.

FIRE OR EXPLOSION hazard.

D Do not locate unit on, over, or near combustiblesurfaces.

D Do not install unit near flammables.

D Do not overload building wiring be sure power supply system isproperly 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 tostore, move, or ship PC boards.

H.F. RADIATION can cause interference.

D High frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications 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, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC CUTTING can cause interference.

D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch 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 electronicequipment.

D Be sure this cutting power source is installed and groundedaccording to this manual.

D If interference still occurs, the user must take extra measures suchas moving the machine, using shielded cables, using line filters, orshielding the work area.


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OM-243 974 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents are knownto 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 EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Weldingand 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,Chantil ly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum 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 HotWork, 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, andPart 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 Officesphonefor 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), 1600Clifton 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 electricand magnetic fields (EMF). Welding current creates an EMF field aroundthe welding circuit and welding equipment. EMF fields may interfere withsome medical implants, e.g. pacemakers. Protective measures for per-sons wearing medical implants have to be taken. For example, accessrestrictions for passersby or individual risk assessment for welders. Allwelders 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 acable cover.

2. Do not place your body between welding cables. Arrange cablesto 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 aspossible.

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 wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, 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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SECTION 2 CONSIGNES DE SCURIT LIRE AVANTUTILISATION

pom_201003fre

Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Signification des symboles

DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.

Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

NOTE Indique des dclarations pas en relation avec des blessurespersonnelles.

. Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGERDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECESCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers lis au coupage larc au plasma

Les symboles prsents ci-aprs sont utiliss tout au long duprsent manuel pour attirer votre attention et identifier les ris-ques de danger. Lorsque vous voyez un symbole, soyezvigilant et suivez les directives mentionnes afin dviter tout

danger. Les consignes de scurit prsentes ci-aprs nefont que rsumer linformation contenue dans les normes descurit numres la section 1-5. Veuillez lire et respectertoutes ces normes de scurit.

Linstallation, lutilisation, lentretien et les rparations ne doi-vent tre confis qu des personnes qualifies.

Au cours de lutilisation, tenir toute personne lcart et plusparticulirement les enfants.

LE COUPAGE prsente un risque defeu ou dexplosion.

Des particules de mtal chaud et des tincellespeuvent jaillir de la pice au moment du coupage.Les tincelles et le mtal chaud, la pice couper

chauffe et lquipement chaud peuvcnt causer unfeu ou des brlures. Avant de commencer travailler, assurez-vousque lendroit est scuritaire.

D Dplacez toute matire inflammable se trouvant lintrieur dunprimtre de 10,7 m (35 pi) de la pice couper. Si cela est impos-sible, vous devez les couvrir avec des housses approuves et bienajustes.

D Ne coupez pas dans un endroit o des tincelles pourraient attein-dre des matires inflammables.

D Protgezvous, ainsi que toute autre personne travaillant sur leslieux, contre les tincelles et le mtal chaud.

D Assurezvous quaucune tincelle ni particule de mtal ne peut seglisser dans de petites fissures ou tomber dans dautres pices.

D Afin dliminer tout risque de feu, soyez vigilant et gardez toujoursun extincteur la porte de la main.

D Si vous coupez sur un plafond, un plancher ou une cloison, soyezconscient que cela peut entraner un feu de lautre ct.

D Ne coupez pas sur un contenant ferm tel quun rservoir ou un bi-don.

D Fixez le cble de masse sur la pice couper, le plus prs possiblede la zone couper afin de prvenir que le courant de coupage neprenne une trajectoire inconnue ou longue et ne cause ainsi unedcharge lectrique, dtincelles ou un feu.

D Ne pas utiliser le coupeur plasma pour dgeler des conduites ge-les.

D Ne coupez jamais des contenants qui peuvent contenir des mati-res inflammables. Vous devez en premier lieu les vider et lesnettoyer convenablement.

D Ne coupez pas quand latmosphre peut contenir des poussires,gaz ou vapeurs (comme lessence) inflammables.

D Ne coupez pas dans un endroit o latmosphre risque de contenirde la poussire ou des vapeurs explosives.

D Ne coupez pas de bouteilles, de tuyaux ou de contenants pressuri-ss.

D Ne coupez pas de contenants qui ont dj reu des combustibles.

D Portez des vtements de protection exempts dhuile tels que desgants en cuir, une veste rsistante, des pantalons sans revers, desbottes et un casque.

D Ne placez pas le poste sur une surface combustible ou audessusde celleci.

D Une fois le travail achev, assurezvous quil ne reste aucune tra-ce dtincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

D Avant le coupage, retirez tout combustible de vos poches, parexemple un briquet au butane ou des allumettes.

Touching live electrical parts can cause fatal shocksor severe burns. The torch and work circuit areelectrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. Le coupage plasma ncessite

des tensions plus importantes que le soudage pour amorcer etmaintenir larc (200 400VDC est typique), mais peut tre utilis avecdes torches quipes de systmes de verrouillage de scurit quiarrtent la machine en cas de buse desserre ou si llectrode touchela tuyre.Incorrectly installed or improperly grounded equipment is ahazard.

UN CHOC LECTRIQUE peut tuer.

D Ne touchez pas aux pices lectriques sous tension.

D Portez des gants isolants et des vtements de protection secs etsans trous.

D Isolezvous de la pice couper et du sol en utilisant des housses

ou des tapis assez grands afin dviter tout contact physique avecla pice couper ou le sol.

D Ne touchez pas aux pices du chalumeau si vous tes en contactavec la pice couper ou le sol.

D Mettez lappareil hors tension avant deffectuer la vrification, lenettoyage ou le changement dune pice du chalumeau.

D Coupez lalimentation dentre avant dinstaller lappareil ou def-fectuer lentretien. Verrouillez ou tiquetez la sortie dalimentationselon la norme OSHA 29 CFR 1910.147 (reportezvous aux Prin-cipales normes de scurit).

D Installez le poste correctement et mettez-le la terre convenable-ment selon les consignes du manuel de loprateur et les normesnationales, provinciales et locales.


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D Assurezvous que le fil de terre du cordon dalimentation est cor-rectement reli la borne de terre dans la bote de coupure ou quela fiche du cordon est branche une prise correctement mise laterre vous devez toujours vrifier la mise la terre.

D Avant deffectuer les connexions dalimentation, vous devez relierle bon fil de terre.

D Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgezles contre les tincelles et les pices mtalliques chau-des.

D Vrifiez frquemment le cordon dalimentation afin de vous assurerquil nest pas altr ou nu, remplacezle immdiatement sil lest.

Un fil nu peut entraner la mort.D Lquipement doit tre hors tension lorsquil nest pas utilis.

D Vrifiez et remplacez les cosses du cble du chalumeau si ellessont uses ou altres.

D Le cble du chalumeau ne doit pas senrouler autour de votrecorps.

D Si les normes le stipulent, la pice couper doit tre mise la terre.

D Utilisez uniquement de lquipement en bonne condition. Rparezou remplacez immdiatement toute pice altre.

D Portez un harnais de scurit si vous devez travailler audessusdu sol.

D Assurezvous que tous les panneaux et couvercles sont correcte-ment en place.

D Nessayez pas daller lencontre des systmes de verrrouillagede scurit ou de les contourner.

D Utilisez uniquement le ou les chalumeaux recommands dans lemanuel de loprateur.

D Napprochez pas le tube du chalumeau et larc pilote lorsque la g-chette est enfonce.

D Le cble de masse doit tre pinc correctement sur la pice cou-per, mtal contre mtal (et non de telle sorte quil puisse sedtacher), ou sur la table de travail le plus prs possible de la lignede coupage.

D Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

DCHARGES LECTRIQUES poten-tiellement mortelles.

Il reste une TENSION DC NON

NGLIGEABLE dans les sources desoudage onduleur UNE FOISlalimentation coupe.

D Mettre lunit hors tension, mesurer la tension des condensa-teurs dentre et sassurer quelle est pratiquement nulle avantde toucher lune quelconque des pices. Mesurer cette tensionconformment aux directives nonces la section Entretien dumanuel de lutilisateur ou du manuel technique avant de toucher lune quelconque des pices.

Risque de blessure en casDEXPLOSION DES PICES.

D Mise sous tension, toute pice dfectueusedes sources dalimentation de linverseur peutexploser ou faire exploser dautres pices.

Pour entretenir les inverseurs, toujours porterun masque protecteur et un vtement man-ches longues.

Le coupage plasma produit des tincelles et projec-tions de mtal trs haute temprature. Lorsque lapice refroidit, du laitier peut se former.

LES TINCELLES PROJETESpeuvent provoquer des blessures.

D Portez une visire ou des lunettes de scurit avec des crans la-traux approuves.

D Portez des vtements de protection adquats afin de protger vo-tre peau.

D Ayez recours des protgetympans ou un serrette ignifugesafin dviter que les tincelles nentrent dans vos oreilles.

Les rayons darc provenant du procd de coupageproduisent des rayons visibles et invisibles intenses(ultraviolets et infrarouges) qui peuvent entranerdes brlures aux yeux et la peau.

LES RAYONS DARC peuvent entra-ner des brlures aux yeux et la peau.

D Une protection faciale (casque ou masque) avec des lunettes filt-rantes de teinte adquate est indispensable pour protger levisage et les yeux des rayonnements de larc et des tincellespendant la dcoupe ou en regardant simplement ANSI Z49.1 (re-portezvous aux Principales normes de scurit) suggredutiliser un filtre de teinte nd 9 (nd 8 tant le minimum) pour touttravail de coupage faisant appel un courant de moins de 300 A.On mentionne galement dans la norme Z49.1 quun filtre plus fai-ble peut tre utilis lorsque larc est cach par la pice couper.Comme cela est habituellement le cas pour les travaux de coupage faible courant, les teintes numres au tableau 1 sont fournies titre dinformation pour loprateur.

D Porter des lunettes de scurit coques latrales sous votre cas-que ou cran facial.

D Ayez recours des crans protecteurs ou des rideaux pour pro-tger les autres contre les rayonnements, les tincelles et lesblouissements; prvenez toute personne sur les lieux de ne pasregarder larc.

D Portez des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

Tableau 1. Protection des yeux pour le coupage au plasma darc

Intensit de courant en ampres Filtre de teinte (minimum)

Moins de 20 no. 4

20 40 no. 5

40 60 no. 6

60 100 no. 8

Certaines applications de coupage produisent unbruit constant, ce qui peut endommager loue si le

niveau sonore dpasse les limites permises parlOSHA (reportezvous aux Principales normes de

scurit).

LE BRUIT peut endommager loue.

D Utilisez des protgetympans ou un serrette antibruit si le ni-veau sonore est lev.

D Prvenez toute personne sur les lieux du danger reli au bruit.

LES FUMES ET LES GAZ peuventtre dangereux.Le coupage produit des vapeurs et des gaz.Respirer ces vapeurs et ces gaz peut tredangereux pour la sant.

D Ne mettez pas votre tte audessus des vapeurs. Ne respirez pasces vapeurs.

D Si vous tes lintrieur au moment du coupage, ventilez la pice

ou ayez recours une ventilation aspirante installe prs de larcpour vacuer les vapeurs et les gaz.

D Si la ventilation est mdiocre, utilisez un respirateur antivapeursapprouv.

D Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgrais-seurs.

D Travaillez dans un espace restreint uniquement sil est bien ventilou si vous portez un respirateur antivapeurs. Les vapeurs cau-ses par le coupage et lpuisement de loxygne peuvent altrer laqualit de lair et entraner des blessures ou la mort. Assurezvousque lair ambiant est sain pour la sant.


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D Ne coupez pas dans un endroit prs doprations de dcapage, denettoyage ou de vaporisation. La chaleur et les rayons darc peu-vent ragir avec les vapeurs et former des gaz hautement toxiqueset irritants.

D Ne coupez pas des mtaux enrobs tels que des mtaux galvani-ss, contenant du plomb ou de lacier plaqu au cadmium, moinsque lenrobage ne soit t de la surface du mtal couper, que len-droit o vous travaillez ne soit bien ventil, ou que vous ne portiezun respirateur antivapeurs. Les enrobages ou tous mtaux quicontiennent ces lments peuvent crer des vapeurs toxiques silssont coups.

D Ne coupez pas de contenants qui renferment ou ont renferms des

matires toxiques ou ractives

vous devez en premier lieu les vi-der et les nettoyer convenablement.

LARC PLASMA peut provoquer desblessures.

La chaleur dgage par le plasma darc peutentraner de srieuses brlures. La force de larc estun facteur qui sajoute au danger de brlures. Lachaleur intense et la puissance de larc peuvent

rapidement passer au travers de gants et de tissus.

D Napprochez pas le tube du chalumeau.

D Ne saisissez pas la pice couper prs de la ligne de coupage.

D Larc pilote peut causer des brlures napprochez pas le tube duchalumeau lorsque vous avez appuy sur le gchette.

D Portez des vtements de protection adquats qui recouvrent toutvotre corps.

D Ne pointez pas le chalumeau en direction de votre corps ni de lapice couper lorsque vous appuyez sur la gchette larc pilotesallume automatiquement.

D Mettez lalimentation hors tension et dbranchez le cordon dali-mentation avant de dmonter le chalumeau ou de changer unepice du chalumeau.

D Utilisez uniquement le ou les chalumeaux recommands dans lemanuel de loprateur.

Les bouteilles de gaz contiennent du gaz sous hautepression. Si une bouteille est endommage, ellepeut exploser. Puisque les bouteilles de gaz fonthabituellementpartie dun processus de travail des

mtaux, assurezvous de les manipuler correctement.

LES BOUTEILLES peuvent explosersi elles sont endommages.

D Protgez les bouteilles de gaz comprim contre la chaleur excessi-ve, les chocs mcaniques, des dommages physiques, le laitier, laflamme, les tincelles et larc.

D Installez et attachez les bouteilles dans la position verticale laidedune chane, sur un support stationnaire ou un chssis porte

bou-

teille afin de prvenir quelles ne tombent ou ne basculent.

D Les bouteilles ne doivent pas tre prs de la zone de coupage ni detout autre circuit lectrique.

D Un contact lectrique ne doit jamais se produire entre un chalu-meau de plasma darc et une bouteille.

D Ne coupez jamais sur une bouteille pressurise une explosion enrsulterait.

D Utilisez uniquement des bouteilles de gaz, des dtendeurs, desboyaux et des raccords conus pour lapplication dtermine. Gar-dezles, ainsi que toute autre pice associe, en bonne condition.

D Dtournez votre visage du dtendeurrgulateur lorsque vous ou-vrez la soupape de la bouteille.

D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque

vous utilisez la bouteille ou quelle est relie pour usage ultrieur.D Utiliser les quipements corrects, les bonnes procdures et suffi-

samment de personnes pour soulever et dplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scu-rit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnementet la maintenance

LES PICES CHAUDES peuvent

provoquer des brlures.D Ne pas toucher des parties chaudes mains

nues.

D Prvoir une priode de refroidissement avantdutiliser lquipement.

D Ne pas toucher aux pices chaudes, utiliser les outils recom-mands et porter des gants de soudage et des vtements paispour viter les brlures.

Les PICES MOBILES peuventprovoquer des blessures.

D Sabstenir de toucher des organes mobiles telsque des ventilateurs.

D Maintenir ferms et verrouills les portes, pan-

neaux, recouvrements et dispositifs de protec-tion.

D Lorsque cela est ncessaire pour des travaux dentretien et dedpannage, faire retirer les portes, panneaux, recouvrementsou dispositifs de protection uniquement par du personnel qua-lifi.

D Remettre les portes, panneaux, recouvrements ou dispositifs deprotection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur lestiquettes et le Mode demploi avant linstal-lation, lutilisation ou lentretien de lappareil.Lire les informations de scurit au dbut dumanuel et dans chaque section.

D Nutiliser que les pices de rechange recommandes par leconstructeur.

D Effectuer lentretien en respectant les manuels dutilisation, lesnormes industrielles et les codes nationaux, dtat et locaux.

DES PIECES DE METAL ou DES SA-LETES peuvent provoquer des bles-sures dans les yeux.

D Porter des lunettes de scurit avec crans latraux ou un cran

facial.


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Les CHAMPS LECTROMAGNTIQUES (CEM)peuvent affecter les implants mdicaux.

D Les porteurs de stimulateurs cardiaqueset autres implants mdicaux doivent rester distance.

D Les porteurs dimplants mdicaux doivent consulterleur mdecin et le fabricant du dispositif avant de sapprocherde la zone o se droule du soudage larc, du soudagepar points, du gougeage, de la dcoupe plasmaou une opration de chauffage par induction.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.

D Prvoir une priode de refroidissement; re-specter le cycle opratoire nominal.

D Rduire lamprage (paisseur) avant de con-tinuer couper ou rduire le facteur de marche.

Danger DEXPLOSIONDHYDROGNE.

D Lors du coupage daluminium partiellement outotalement immerg dans leau, de lhydrognelibre peut saccumuler sous la pice.

D Consultez votre ingnieur de coupage et les instructions de la

table de coupage.

LA CHUTE DE LQUIPEMENT peutprovoquer des blessures.

D Utiliser lanneau de levage uniquement poursoulever lappareil, NON PAS les chariot, lesbouteilles de gaz ou tout autre accessoire.

D Utiliser un engin dune capacit appropriepour soulever lappareil.

D En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

D Tenir lquipement (cbles et cordons) distance des vhiculesmobiles lors de toute opration en hauteur.

D Suivre les consignes du Manuel des applications pour lquationde levage NIOSH rvise (Publication N94110) lors du levagemanuelle de pices ou quipements lourds.

Risque DINCENDIE OUDEXPLOSION.

D Ne pas placer lappareil sur, au-dessus ou proximit de surfaces infllammables.

D Ne pas installer lappareil proximit de pro-duits inflammables

D Ne pas surcharger linstallation lectrique sassurer que lalimen-tation est correctement dimensionn et protg avant de mettrelappareil en service.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

D Etablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

D Utiliser des pochettes et des botes antistatiques pour stocker,dplacer ou expdier des cartes PC.

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences.

D Le Rayonnement haute frequence (H.F.) peutprovoquer des interfrences avec les quipe-ments de radionavigation et de communica-tion, les services de scurit et les ordinateurs.

D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-tion.

D Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences rsultant de linstallation.

D Si le FCC signale des interfrences, arrter immdiatement lappa-reil.

D Effectuer rgulirement le contrle et lentretien de linstallation.

D Maintenir soigneusement ferms les portes et les panneaux dessources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et et un blindage pour rduire lesinterfrences ventuelles.

LE COUPAGE LARC peut causerdes interfrence.

D Lnergie lectromagntique peut gner lefonctionnement dappareils lectroniquescomme des ordinateurs et des robots.

D Pour rduire la possibilit dinterfrence, maintenir les cbles aussicourts que possible, les grouper, et les poser aussi bas que possi-ble (ex. par terre).

D Veiller couper une distance de 100 mtres de tout quipementlectronique sensible.

D Sassurer que la source de coupage est correctement branche etmise la terre.

D Si linterfrence persiste, lutilisateur doit prendre des mesuressupplmentaires comme carter la machine, utiliser des cblesblinds de des filtres, ou boucler la zone de travail.


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2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

Ce produit contient des produits chimiques, compris du

plomb, dont ltat de Californie reconnat quils provoquentdes cancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs

manipulation.

Ce produit contient des lments chimiques, dont le plomb,reconnus par ltat de Californie pour leur caractre

cancrogne ainsi que provoquant des malformationscongnitales ou autres problmes de procration. Se laver les

mains aprs toute manipulation.

Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

Pour les moteurs diesel :

Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.

2-5. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 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 EngineeringDocuments (tlphone : 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 GlobalEngineering Documents (tlphone: 1-877-413-5184, site internet :www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire ProtectionAssociation, Quincy, MA 02269 (tlphone : 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 (tlphone : 703-788-2700, site Internet :www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, de Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone :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 (tlphone : 212-642-4900,site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association,Quincy, MA 02269 (tlphone : 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, andPart 1926, Subpart J, de U.S. Government Printing Office, Superinten-dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(tlphone : 1-866-512-1800) (il y a 10 bureaux rgionauxle tlphonede la rgion 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), 1600Clifton Rd, Atlanta, GA 30333(tlphone: 1-800-232-4636, site internet : www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant lectrique qui traverse tout conducteur gnre des champslectromagntiques (CEM) certains endroits. Le courant de soudagecre un CEM autour du circuit et du matriel de soudage. Les CEMpeuvent crer des interfrences avec certains implants mdicauxcomme des stimulateurs cardiaques. Des mesures de protection pourles porteurs dimplants mdicaux doivent tre prises: par exemple, desrestrictions daccs pour les passants ou une valuation individuelledes risques pour les soudeurs. Tous les soudeurs doivent appliquer lesprocdures suivantes pour minimiser lexposition aux CEM provenantdu circuit de soudage:

1. Rassembler les cbles en les torsadant ou en les attachant avecdu ruban adhsif ou avec une housse.

2. Ne pas se tenir au milieu des cbles de soudage. Disposer lescbles dun ct et distance de loprateur.

3. Ne pas courber et ne pas entourer les cbles autour de votrecorps.

4. Maintenir la tte et le torse aussi loin que possible du matriel ducircuit de soudage.

5. Connecter la pince sur la pice aussi prs que possible de lasoudure.

6. Ne pas travailler proximit dune source de soudage, nisasseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou ledvidoir.

En ce qui concerne les implants mdicaux :Les porteurs dimplants doivent dabord consulter leur mdecin avant desapprocher des oprations de soudage larc, de soudage par points,de gougeage, du coupage plasma ou de chauffage par induction. Si le

mdecin approuve, il est recommand de suivre les procdures prc-dentes.


14/40

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

OM-243 974 Page 10

SECTION 3 DEFINITIONS

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

A Amperes Plasma Arc Cutting(PAC) Adjust Air/GasPressure Low Air PressureLightV Volts Increase No Do Not DoThis Temperature

Protective Earth(Ground)

Single Phase Constant Current Voltage Input

On Off Percent Direct Current

U0 Rated No LoadVoltage (Average) U1 Primary Voltage U2Conventional Load

VoltageLine Connection

I1max Rated MaximumSupply Current I2Rated Welding

Current X Duty CycleSingle Phase

Static FrequencyConverter-

Transformer-Rectifier

IP Degree OfProtection Loose Shield Cup Input Hz Hertz

I1eff Maximum EffectiveSupply Current pf power factor SSuitable for Some

HazardousLocations

S1Power Rating,

Product Of VoltageAnd Current (KVA)


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OM-243 974 Page 11

SECTION 4 INSTALLATION

4-1. Specifications

Power Supply

Input

Rated AC phase (PH) and line frequency (Hz) 1 PH 60 Hz

Rated Input Voltage (U1) and rated Input Current (I1)and I1 eff at rated output. I1 eff used to determinepower cord rating

Volts AC RMS (U1) Amps RMS (I1) I1 eff

120 (20 A) at 20% Duty Cycle 28.8 12.9

120 (15 A) at 35% Duty Cycle 20.6 12.2

240 at 35% Duty Cycle 13.9 8.3

Power Factor/KVA/KW at Rated Output

Volts AC RMS (U1) Power Factor KVA/KW

120 Volts (20 A) 0.93 3.4/3.2

120 Volts (15 A) 0.92 2.5/2.3

240 Volts 0.91 3.3/3.0

Peak KW at Arc Stretch 5.4 kW at U1 = 240 Volts

Output

Rated Open Circuit Voltage (U0) Type 400 Volts DC/Electrode Negative

Output Characteristic Constant Current

Output Current Range 14-27 A

Output Current and Voltage Rating at Rated InputVoltage (I2 and U2 at U1)

Amps DC (I2) Volts DC (U2) Volts AC (U1)

27 A 91 Volts DC 240 Volts

27 A 91 Volts DC 120 Volts (20 A)

20 A 88 Volts DC 120 Volts (15 A)

Duty Cycle at 1045 F (405 C) at rated conditions (U1, I1,U2, I2) based on a 10 minute period

Duty Cycle % Amps DC (I2) Volts AC RMS (U1)

35 27 A 240 Volts

20 27 A 120 Volts (20 A)

35 20 A 120 Volts (15 A)

General

Operating Temperature 5 to 104 F (15 to 40 C)

IP Code Degree of protection provided by enclosure

IP23CS

IP International Protection

2 No ingress of foreign objects 12.5 mm (0.5 in.)

3 No harmful ingress spraying water

C AC line circuits protected against ingress of tool2.5 mm dia x 100 mm long (0.1 in. x 4 in.)

S Fan stationary during water test

Toppling or tilting Up to 15 incline

Gas Type Air or Nitrogen

Gas Quality Clean, moisture-free, oil-free

Gas Inlet Pressure and Flow 3.0 SCFM (85 L/min) 90 PSI (621 kPa)Min

120 PSI (827 kPa)Max

Gas Filtering Particulates to 5 microns

Torch

Mild Steel capacities (see Section 5-2 for cuttingspeeds vs material type and thickness)

Rated Capacity (edge start) 3/8 in. at 14 ipm (356 mm/min)*

Sever Cut Capacity (edge start) 5/8 in.

Pierce Capacity 5/16 in.

*Travel speeds are approximately 80% of maximum.


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OM-243 974 Page 12

4-2. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-utes that unit can cut at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, Temperaturetrouble light goes On, and coolingfan runs. Wait fifteen minutes forunit to cool or temperature light togo off. Reduce amperage or dutycycle before cutting or gouging.

NOTICE Exceeding duty cyclecan damage unit and void warranty.

Overheating

sduty1 5/95 / Ref. 244 405-A

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

35% duty cycle

For Units Connected to a 120 Volt Circuitor a 240 Volt Circuit:

35% Duty Cycle At 27 amperes, 92 volts DC

0

15

Minutes

A

OR

Reduce Duty Cycle

14-1/4 in.(362 mm)

4-3. Power Source Dimensions And Weight

loc_2 3/96 - Ref. 244 405-A

8-1/4 in.(210 mm)

11-1/4 in.(286 mm)

Dimensions And Weight

29 lb (13.2 kg)including torch

! Do not move or operate unitwhere it could tip.

4-4. Torch Dimensions And Weight

Ref. 801 397-A3.0 lb (1.4 kg)

1 in.(25mm)

8-3/8 in.

(213 mm)

1-3/8 in.(35 mm)


17/40


18/40


OM-243 974 Page 14

4-7. Electrical Service Guide For 240 VAC

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

60 HzSinglePhase

Input Voltage (V) 240

Input Amperes (A) At Rated Output 13.9

Max Recommended Standard Fuse Rating In Amperes1

Time-Delay Fuses 2 15

Normal Operating Fuses 3 20

Min Input Conductor Size In AWG 4 14

Max Recommended Input Conductor Length In Feet (Meters)92

(28)

Min Grounding Conductor Size In AWG 4 14

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 Table310.16. 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.

4-8. Extension Cord Data

. When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.

Input VoltageInput Power

Phase Hertz Conductor Size Max. Cord Length

120 V 1 60 14 AWG 22 ft (7 m)

240 V 1 60 14 AWG 92 ft (28 m)


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OM-243 974 Page 15

4-9. Connecting 1-Phase Input Power For 240 VAC

803 766-B / Ref. 802 443-A

! Installation must meet allNational and Local Codes haveonly qualified persons make thisinstallation.

! Disconnect and lockout/tagoutinput power before connectinginput conductors from unit.

! Always connect green or green/yellow conductor to supply

grounding terminal first, and neverto a line terminal.

1 Black And White Input Conductor(L1 And L2)

2 Green Or Green/Yellow GroundingConductor

3 Input Power Cord.

4 Disconnect Device (switch shown inthe OFF position)

5 Disconnect Device GroundingTerminal

6 Disconnect Device Line Terminals

Connect green or green/yellow groundingconductor to disconnect device groundingterminal first.

Connect input conductors L1 and L2 todisconnect device line terminals.

7 Over-Current Protection

Select type and size of over-currentprotection using Section 4-7 (fuseddisconnect switch shown).

8 Receptacle (NEMA 6-50R)Customer Supplied

Close and secure door on disconnectdevice. Remove lockout/tagout device,and place switch in the On position.

4

3

L1

L2

1

=GND/PE Earth Ground

2

1

5

6

7

Tools Needed:

L1L2

240 VAC, 1

8


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OM-243 974 Page 16

4-10. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or ratedoutput. For future reference, write serial number in space provided on back cover of this manual.

4-11. Connecting Input Power

! Installation must meet all Nationaland Local Codes have onlyqualified persons make thisinstallation.

! Special installation may be requiredwhere gasoline or volatile liquidsare present see NEC Article 511 orCEC Section 20.

. The Auto-Line circuitry in this unitautomatically links the power source to

the primary voltage being applied,either 115 or 230 VAC.

For 120 volts AC input power, a 15 or 20ampere individual branch circuit protected

by time-delay fuses or circuit breaker isrequired. For 240 volts AC input power, seeSection 4-7.

1 Power Cord Connector

2 Plug NEMA Type 515P

3 Receptacle NEMA Type 515R(Customer Supplied)

4 Plug NEMA Type 650P

5 Receptacle NEMA Type 650R(Customer Supplied)

Select plug for power supply receptacleavailable at site. Install plug onto powercord adapter. As threaded collar is tight-ened, push plug onto adapter until collar iscompletely tight.

Connect plug to receptacle.

18 in.(460 mm)

Ref. 244 423-A / Ref. 804 504-A

32

1

4 5

! Do Not cut off power cord connector and rewire. The power cordconnector and plugs will work with standard NEMA receptacles.Modifying power cord, connector, and plugs will void productwarranty.

18 in.(460 mm)


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OM-243 974 Page 17

4-12. Generator Or Inverter Requirements

. Generator or inverter operation varies by manufacturer. The power light on the cutter will flash and the unit will not provide output if input voltagedrops below 92 volts AC (see Section4-1).

Minimum auxiliary powerrequirement at rated cuttingcapacity [3/8 in. (9.5 mm) mild steel]is 6 KW continuous/6.5 KW peak at120 volts AC.

! Engine Control Switch must be set at RUNposition not RUN/IDLE. ! Set generator Fine Adjustment Controlto 10 for maximum auxiliary power.

Generator settings, if applicable.

4-13. Cable Management Strap

244 413-A / 244 412-A

1 Cable Management Strap

Coil cables together and secure tounit using the cable managementstrap.

1

1


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OM-243 974 Page 18

4-14. Electrode Wrench

244 412-A / Ref. 804 885-A

1 Cable Management Strap

2 Electrode Wrench

The electrode wrench is fastened tothe cable management strap.

2

1


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OM-243 974 Page 19

SECTION 5 OPERATION

5-1. Controls

1 Output Control

Use control to set cutting output.

If 22-27 amperes of cutting output is used

with 120 VAC input power, and the overloadprotection on the input power circuit fre-

quently opens, either reduce the cutting out-put and/or the cut time or find more adequate

power (see Section 4-1).

2 Power Light

3 Trouble Lights (See Section 6-4)

243 000-A

20

2714

2417

120V 20A MVP

5/8" SEVER CUT (STEEL)

1/4" STAINLESS

1/4" ALUMINUM

1/4" GALVANIZED

1/8" BRASS1/8" COPPER

V POWER

PRESSURE

ON

OFF

V

3/8 CLEAN CUT (STEEL)

CUTS:

240V 50A MVP

120V 15A MVP

CUP

TEMP

1

3

2


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OM-243 974 Page 20

5-2. Cutting Speed

Recommended Cut Speeds At 27 Amperes Output

Mild Steel

Thickness Recommended Cut Speeds*

Inches mm ipm mm/min

16 ga 1.5 192 4,877

1/8 3.2 71 1,808

1/4 6.4 25 630

3/8 9.5 14 345

1/2 12.7 6 163

*Recommended Cut Speed is approximately 80% of maximum.

. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

Recommended Cut Speeds At 20 Amperes Output

Mild Steel

Thickness Recommended Cut Speeds*

Inches mm ipm mm/min

16 ga 1.5 134 3,414

1/8 3.2 44 1,118

1/4 6.4 16 406

3/8 9.5 8 203

*Recommended Cut Speed is approximately 80% of maximum.

. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

5-3. Trigger Safety Lock

1 Trigger

Ref. 804 848-A

1

Trigger LockedWhen Button Is InForward Position(Left And Right Side)

Slide Button BackTo Unlock Trigger(Either Left OrRight Side)

1


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OM-243 974 Page 21

Ref 803 915-A / Ref. 804 848-A

5-4. Plasma Cutting System Practices

Pulling rather than pushing the torchmakes cutting easier. Use a proper guide

or template for accurate cutting operations.

Maintain approximately a 90 angle to theworkpiece surface for proper cutting results.

Always connect work clamp to a clean,paint-free location on workpiece, as close to

cutting area as possible.

90

DO NOT start pilot arc without cutting as thisshortens the life of the tip and electrode.

Sparks should pass through the workpieceand out the bottom when cutting.

If sparks flare back from surface, thisusually is an indication that travel

speed is too fast.

DO NOT put pressure on shield whendrag cutting; instead, slide shield along

the surface for proper cutting results.

Wt

. Do not connect work clamp to the portionof the workpiece that will fall when cut.

! The pilot arc starts immediatelywhen trigger is pressed.


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OM-243 974 Page 22

804 848-A

5-5. Sequence Of Cutting Operation

EXAMPLE Of Cutting Operation

Place tip near work.

. Keep tip 1/16 in. fromwork for max cutting

speed and tip life.

Slide trigger lock back.Press trigger. Pilot arc starts. After cutting arc

starts, slowlymove torch

across metal.

Adjust speed sosparks go thru metaland out bottom of cut.

Pause briefly atend of cut beforereleasing trigger.

Torch air cooling (postflow)continues after releasing trigger.

. Postflow must finish beforetrigger will restart pilot arc.



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OM-243 974 Page 23

Ref. 804 848-A

5-6. Sequence Of Cutting Using Stand-off Guide

EXAMPLE Of Cutting Using Stand-off Guide

Place stand-off guide on work. Stand-offguide provides 1/16 in. (1.6 mm) gapbetween tip and workpiece.

Slide trigger lock back.Press trigger. Pilot arc starts. After cutting arcstarts, slowlymove torch

across metal.

Adjust speed sosparks go thru metaland out bottom of cut.

Pause briefly atend of cut beforereleasing trigger.

Torch air cooling (postflow)continues after releasing trigger.


1/16 in.(1.6 mm)


Split sectionto bottom

Stand-off GuideInstallation


28/40


OM-243 974 Page 24

Ref. 803 640-A / 801 400-B

5-7. Sequence Of Piercing Operation

Connect work clamp to a clean, paint-freelocation on workpiece, as close to cutting

area as possible.

Hold torch at anangle tothe workpiece. Slide trigger

lock back. Press trigger.Pilot arc starts.

Move torch to uprightposition 90 to surface.Start cutting when arc

pierces workpiece.

Maintain torch positionand continue cutting.

Release trigger. Postflow coolingcontinues after releasing trigger.




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OM-243 974 Page 25

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. Routine Maintenance

! Disconnect powerbefore maintaining.

. Maintain more oftenduring severe conditions.

n = Check Z = Change ~ = Clean l = Replace* To be done by Factory Authorized Service Agent

Reference

EachUse

Section 4-1,4-5

n Gas/Air Pressure n Torch Tip, Electrode,And Shield Cup

EveryWeek

Section 6-5

n Shield Cup ShutdownSystem

Every3Months

Section 6-3,8

l Damaged Or UnreadableLabels

~ Air Filter/Regulator l Cracked Parts nl Gas/Air Hose

nl Torch Body, Cable

Every6

Months

OR

~ Inside Unit

6-2. Overload Protection

Ref. 244 411-A

1 Supplementary Protector CB1

CB1 protects unit from overload. IfCB1 opens, unit shuts down.

Reset supplementary protector.

1


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OM-243 974 Page 26

6-3. Checking Or Replacing Filter Element

! Turn power Off, anddisconnect input power plugfrom receptacle. Check tosee that all diagnostic LEDshave stopped flashingbefore removing wrapperfrom unit.

Turn power Off, and disconnectinput power plug from receptacle.

Remove wrapper from unit.1 Filter Base

2 Filter

3 Filter Cup

Unscrew filter cup from base.

Remove cup.

Unscrew filter element from base.

Check filter element for dirt andmoisture, and replace if necessary.

Be sure that all parts are clean anddry.

Reinstall filter element, and securefilter cup.

Reinstall wrapper.

244 407-A / Ref. 805 211-A

1

2

3

Tools Needed:

5/16 in.


31/40


OM-243 974 Page 27

6-4. Status/Trouble Lights

. Diffculty establishing a pilot arc may indicate consumables need to be cleaned or replaced.

V REWOP

ERUSSERP

PUC

PMET

Light Condition Status/Possible Cause

Power On Input power is okay.

Pressure/Cup/TempOff When Power light is on, system is normal if these lights

are off.

Power Flashing rate is steady. Input power below 92 volts AC or above 276 volts AC.

Pressure On No or low [below 50 psi (345 kPa)] input pressure.

PressureFlashing rate is steady. Regulated pressure in the unit is low. Check torch for

leaks. Check input pressure to unit is between 90 to 120psi (621 to 827 kPa).

Cup On Torch cup is loose or off. Once cup is tightened, unitpower must be cycled off and back on again.

CupFlashing rate is steady. No pilot arc was established. Check consumables or

torch.

TemperatureOn Power source overheated (see Section 4-2). Stop cutting

and allow unit to cool down.

TemperatureOn (indefinitely) Power source temperature sensors may have failed or

ambient temperature is below -31 F (-35 C).

For system troubleshooting see Section 6-8 and Section 6-9.

6-5. Checking Shield Cup Shutdown System

1 Torch Shield Cup

Turn Power On and loosen shieldcup. If shutdown system worksproperly, Cup light comes on. If not,immediately turn Off power andhave Factory Authorized Service

Agent check unit.

If system works properly, retightencup and reset power.

Ref. 801 300-A

1

. Power must be reset whenever the cup shutdown system is activated.Alwaysturn Off power when changing orchecking consumables. Do NOT over-tighten torch shield cup. Gently fingertighten cup onto torch.


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OM-243 974 Page 28

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

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

Ref. 804 851-A

Turn Off power source.1 Shield Cup

Remove shield cup. Check cup for cracks,and replace if necessary.

2 O-Ring

Check O-ring for cracks or worn spots andreplace, if necessary.

3 Tip

4 OpeningRemove tip. Check tip, and replace if open-ing is deformed or 50% oversize. If inside oftip is not clean and bright, clean with steelwool. Be sure to remove any pieces of steelwool afterwards.

5 Electrode

Check electrode. If center has a pit morethan a 1/16 in. (2 mm) deep, remove and re-place electrode.

6 Swirl RingRemove swirl ring. Check ring, and replaceif side holes are plugged.

Carefully reassemble parts in reverse order.

7 Stand-off Guide

Placing the stand-off guide on the end ofthe torch provides an optional method ofmaintaining a 1/16 in. (1.6 mm) gapbetween tip and workpiece.

Make sure this area is clean of

any debris.

Make sure swirl ring is clean of anydebris and no holes areobstructed.

New

Worn

*1/32 in. (1 mm) 1/16 in. (2 mm)maximum pit depth depending on

acceptable cut quality.

43

6

1

Replace tip if opening isdeformed or 50% oversized.

2

. Lightly tighten electrodeusing electrode wrench(15-20 in.lb (1.7-2.3 NVm).

7

! Turn Off power source before checking torch parts.

! Overtightening will strip threads. Do not overtighten retaining cup duringassembly. Do not cross-thread parts causing stripping. Use care duringtorch assembly and parts replacement.

! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantlyreduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.

New

Worn

5

*PitDepth

ElectrodeWrench


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OM-243 974 Page 29

6-7. Torch And Work Cable Connections

! Turn power Off, anddisconnect input power plugfrom receptacle. Check tosee that all diagnostic LEDshave stopped flashingbefore removing wrapperfrom unit.

If torch or work cable needs to beremoved or replaced, proceed asfollows:

1 Power Source

Remove wrapper from unit.

Torch Connections

Remove existing torch cable fromunit.

2 Strain Relief

3 Torch Cable

Insert strain relief on end of cablethrough front panel opening. Slidestrain relief nut onto torch cable, butdo not tighten.

4 Air Line Connector

Insert air line into solenoid fitting.5 Plug PLG1/Receptacle RC1

Connect PLG1 from torch toreceptacle RC1 on end of wiringharness connected to circuit boardPC1.

Route torch white and red leadsand work black lead throughsleeving the same way as the unitwas originally.

6 Ring Terminal And TORCHWHITE Terminal

Connect ring terminal on end oftorch white lead to TORCH WHITEterminal.

7 Ring Terminal And TORCHRED Terminal

Connect ring terminal on end oftorch red lead to TORCH REDterminal.

Tighten strain relief screw.

Work Cable Connections

Remove existing work cable fromunit.

8 Strain Relief

Loosen strain relief screw.

. Be sure to allow some workcable slack inside the unit.

Insert strain relief on end of cablethrough front panel opening. Slidestrain relief nut onto work cable andsecure strain relief to front panel.

9 Work Lead Ring Terminal AndWORK BLACK Terminal

Connect ring terminal on end ofwork clamp lead to terminal labeledWORK BLACK. Route lead alongtorch lead bundle.

Reinstall wrapper.Tools Needed:

Ref. 804 887-A / 244 410-A / Ref. 244 405-A

3/8 in.

1

2

7 9

3

2

5

6 7

45

8

6


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OM-243 974 Page 30

6-8. Troubleshooting Power Source

Trouble Remedy

No pilot arc; difficulty in establishing anarc.

Clean or replace worn consumables as necessary (see torch Owners Manual).

Check for damaged torch or torch cable (see torch Owners Manual).

No cutting output; Power light off; statuslights off; fan motor FM does not run.

Place Power switch in On position.

Place line disconnect device in On position (see Section 4-9).

Check line fuse(s) and replace if needed or reset circuit breakers (see Section 4-9).

Pilot arc working; no cutting output;Power light on; status lights off; fanmotor running.

Be sure work clamp is connected.

Clean or replace worn consumables as necessary (see torch Owners Manual).

No gas/air flow; Power light on; statuslights off; fan motor running.

Have Factory Authorized Service Agent check for proper torch connections. Check operation of gasvalve AS1, and check gas/air system for leaks. Check filter element (see Section 6-3).

Pressure status l ight On. Check for sufficient gas/air supply pressure (see Section 4-5).

Check for dirty air filter and replace, if necessary (see manufacturers instructions).

Check air lines for leaks.

Have Factory Authorized Service Agent check pressure switch and control board.

Cup status light On. Check torch shield cup (see Section 6-5). Reset power switch.

Have Factory Authorized Service Agent check torch.

Temperature status lightOn. Unit overheating. Allow fan to run; the Trouble light goes out when the unit has cooled.

Have Factory Authorized Service Agent check control board.

Status lights not working. Have Factory Authorized Service Agent check unit.

Power light flashing, status lights off. Reset power switch. Have qualified technician check input line power.

Pressure status light flashes. Unit lost pressure (momentarily) while cutting. Check air line for leaks.

Cup status light flashes. Unit lost output while attempting to cut or pilot. Check consumables and torch for wear.

Short tip life. Check and clean drag shield of any slag, particles, and debris.

Check input air pressure.


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OM-243 974 Page 31

6-9. Troubleshooting Torch

Trouble Remedy

Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 5-2). Clean or replace torch consumablesas necessary (see Section 6-6). Be sure work clamp is securely attached to workpiece.

Arc goes out while cutting. Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in. (1.6 mm) to1/8 in. (3.2 mm)] workpiece (see Section 5-6). Clean or replace torch consumables as necessary (seeSection 6-6).

Sparks come out top of cut or cut is notclean.

Torch travel speed too fast; reduce travel speed (see Section 5-2). Clean or replace torch consumablesas necessary (see Section 6-6). Be sure work clamp is securely attached to workpiece. Unit not capableof cutting metals thicker than rating (see Section 4-1).

Trouble lights are on; unit has no cuttingoutput.

Check torch consumables. Check for gas/air flow at torch. Check air supply connection and pressure tounit and torch. Reset unit Power switch. Have Factory Authorized Service Agent check torch andconnections inside unit.


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OM-243 974 Page 32

SECTION 7 ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram


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OM-243 974 Page 33

243 971-B


38/40

OM-243 974 Page 34

SECTION 8 PARTS LIST

8-1. Recommended Spare Parts

243 015-B

CAUTION

S

S

S

Turnoffpowerbeforecheckingtorchparts.Checkbeforeeachuseandhourlyduringoperation.Torqueelectrodelightlyw/smallwrench(1520in.lbs.)

FAILURETOREPLACEWORNTIPORELECTRODEWILLDAMAGETORCHANDVOIDWARRANTY.

HP-50CONSUMABLEKITS

243015-B

RetainingCup

Tip Electrode

SwirlRingO-Ring

770496

770653

Figure 8-1. Consumable Parts For HP50

DescriptionPartNo.ItemNo.

Recommended Spare Parts

QuantityDia.Mkgs.

244 121 TORCH, HP-50 16.4ft (5 m) hand held (replacement) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 820 CLAMP, work 1. . . . . . . . . . . . . . . . . .