Instruction/ maintenance manual of the product ICE-27T Miller Electric
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Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM-225 216F 2007−03 Spectrum 375 X-TREME And ICE-27T T orch R File: Plasma Cutters V isit our website at www.
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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-225 216 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _4/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
OM-225 216 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 P ARTS can injure. Sparks and hot metal blow out from the cutting arc .
OM-225 216 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance HOT P ARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. D T o handle hot parts, use proper tools and/or wear heavy , insulated welding gloves and clothing to prevent burns.
OM-225 216 Page 4 1-5. Principal Safety Standards Safety i n W elding, 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 A WS C5.
OM-225 216 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom_fre 4/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-225 216 Page 6 D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée. D Le câble de masse doit être pincé correctement sur la pièce à cou- per , métal contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table de travail le plus près possible de la ligne de coupage.
OM-225 216 Page 7 D Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique. D Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille. D Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait.
OM-225 216 Page 8 LE COUP AGE 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.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperes Increase Power Light Low Air Pressure Light Loose Shield Cup Light T emperature Light On Of f SECTION 4 − INST ALLA TION 4-1.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 10 4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min - utes that unit can cut at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, T emperature trouble light goes On, and cooling fan runs.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 1 1 4-6. Connecting Gas/Air Supply 804 505-A . Use only clean, dry air with 90 to 120 psi (621 to 827 kPa) pressure. 1 Gas/Air Inlet Opening 2 Hose 3 T eflon T a pe Obtain hose with 1/4 NPT right- hand thread fitting.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 12 4-8. Electrical Service Guide For 240 V AC Y CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of 60 Hz ( + 10%) power at + 10% of rated input voltage.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 13 4-10. Connecting 1-Phase Input Power For 240 V AC 803 766-B / Ref. 802 443-A Y Install ation must meet all National a nd Local Codes − have only qualifie d persons make this installation.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 14 4-1 1. Connecting Input Power Y Install ation must meet all N ational and Local Codes − have only qualified per s ons m a ke this installation.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 15 SECTION 5 − OPERA TION 5-1. Controls 1 Output Control Use control to set cutting output.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 16 5-2. Cutting Speed Recommended Cut Speeds At 27 Amperes Output Thickness Recommended Cut Speeds* Inches mm ipm mm/min Mild Steel 16 ga 1.5 188 4,775 Mild Steel 3/16 4.8 40 1,016 1/4 6.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 17 out bottom of cut. Ref. 802 878 5-4. Sequence Of Operation After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and Pause briefly at end of cut before releasing trigger .
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 18 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 19 6-3. W rapper Removal Ref. 804 505-A Y T urn off power , and disconnect input power plug from receptacle before working on unit. Y Significant DC voltage can remain o n capacitors after unit is Off.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 20 6-4. DC Bus V oltage Check Y T urn Off welding power source, and disconnect input power . Y Significant DC voltage can remain on capacitors after unit i s Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 21 6-5. Checking Or Replacing Filter Element Y Check DC bus voltage according to Section 6-4 , and be sure voltage is near zero before touching any parts. T urn power Of f, and disconnect input power plug from receptacle.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 22 6-6. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System 1 Power Light Light is steady if input power is okay . Light flashes for the following conditions: a If input power is 120 volts ac, but power supply is less than 92 volts ac.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 23 6-7. Checking/Replacing Retaining Cup, Tip, And Electrode Overtightening will strip threads. Do not overtighten retaining cup during assembly . Do not cross-thread parts causing stripping.
. A complete Parts List is available at www .MillerW elds.com OM-225 216 Page 24 6-8. T orch And Work Cable Connections Y Check DC bus voltage according to Section 6-4 , and be sure voltage is near zero before touching any parts.
OM-225 216 Page 25 Notes.
OM-225 216 Page 26 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram.
OM-225 216 Page 27 224 682-B.
OM-225 216 Page 28 SECTION 8 − P ARTS LIST 8-1. Recommended Spare Parts Description Part No. Dia. Mkgs. Item No. Recommended Spare Parts Quanti ty 225970 PLUG KIT ,ADAPTER (1 15V/15A) (230V/50A) (including) 1 . . . . . . . . . . . . . . . . . . . . .
OM-225 216 Page 29 1 183 42 7 Handle Assy , complete (1) 2 171 248 Push Button Switch (1) 3 228 405 Leads, 12 ft (1) 4 203 1 19 Main Body (1) 5 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 225 615 T orch, replacement 12 ft (1) See Figure 8-1 for additional consumable parts.
Notes.
Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007−01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquart.
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If you already are a holder of Miller Electric ICE-27T, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric ICE-27T.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric ICE-27T. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric ICE-27T along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
