Instruction/ maintenance manual of the product pmn Miller Electric
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OM-228 305D 2007−06 Auto Arc Quick Cut 4500 And Ice-27C T orch R ® For W arranty Claims And T echnical Support, Contact: Milweld Inc., National Distributor P .
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T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-228 305 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury .
OM-228 305 Page 2 SIGNIFICANT DC VOL T AGE exists in inverter power sources AFTER the re - moval of input power . D Turn Of f unit, disconnect input power , check voltage on input ca- pacitors, and be sure it is near zero (0) volts before touching any parts.
OM-228 305 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-228 305 Page 4 1-4. California Proposition 65 W arnings W elding 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.
OM-228 305 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION pom2007−04fre Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
OM-228 305 Page 6 D Assurez−vous que le fil de terre du cordon d’alimentation est cor- rectement relié à la borne de terre dans la boîte de coupure ou que la fiche du cordon est branchée à une prise correctement mise à la terre − vous devez toujours vérifier la mise à la terre.
OM-228 305 Page 7 D Ne coupez pas dans un endroit près d’opérations de décapage, de nettoyage ou d e vaporisation. La chaleur et les rayons d’arc peu- vent réagir avec les vapeurs et former des gaz hautement toxiques et irritants.
OM-228 305 Page 8 Danger D’EXPLOSION D’HYDROGÈNE. D Lors d u coupage d’aluminium partiellement ou totalement immergé dans l’eau, de l’hydrogène libre peut s’accumuler sous la pièce. D Consultez votre ingénieur de coupage et les instructions de la table de coupage.
OM-228 305 Page 9 2-5. P r inc ip al es n or m es d e sé cur it é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.
OM-228 305 Page 10 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label A Amperes Plasma Arc Cutting (P AC) Adjust Air/Gas Pressure Low Air Pressure Ligh.
OM-228 305 Page 1 1 SECTION 4 − INST ALLA TION 4-1. Specifications . If the unit is operated from a 30* ampere, 1 15 volt circuit or a 15** ampere, 230 volt circuit, a different input power plug must be installed on the power cord. See Section 4-9 for instructions.
OM-228 305 Page 12 4-4. T orch Dimensions And Weight Ref. 802 877 3.0 lb (1.4 kg) 1 in (25 mm) 8-3/8 in (213 mm) 1-3/8 in (35 mm) 4-5. Selecting A Location loc_2 3/96 - Ref. 804 486-A / 804 487-A / 804 488-A 1 Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart or similar device to move unit.
OM-228 305 Page 13 4-6. Connecting Gas/Air Supply 802 787-A / Ref. 801 319-C / Ref. 804 486-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 ap e Obtain hose with 1/4 NPT right- hand thread fitting.
OM-228 305 Page 14 4-7. Connecting W ork Clamp 802 463-A 1 Work Clamp 2 W orkpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 1 2 4-8. Connecting Input Power Ref. 802 787-A / 804 488-A Check input voltage available at site.
OM-228 305 Page 15 4-9. Installing Alternative Plug 1 Supplied 1 1 5 V AC Plug Cut cord close to plug. 2 Alternative PLug (230 V AC Plug Shown) 3 Load 1 (Brass) T erminal 4 Load 2 (Brass) T erminal 5 Ground (Green) T erminal 6 Outer Shell 7 Cord Grip Strip cord jacket back enough to separate conductors.
OM-228 305 Page 16 SECTION 5 − OPERA TION 5-1. Controls 1 42 3 ON OFF PRESSURE 60 PSI 5 6 24 27 20 16 24 27 20 16 1 24 27 20 16 Requires 90-120 PSI (621-827 kPa) Supply Setting Gas/Air Pressure 1 Output Control Use control to set cutting output. Place control in Gas/Air Set position to safely adjust gas/air pressure.
OM-228 305 Page 17 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 6.4 24 610 3/8 9.5 14 256 1/2 12.7 6 152 *Recommended Cut Speed is approximately 80% of maximum.
OM-228 305 Page 18 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 . EXAMPLE Of Cutting Operation Raise trigger lock and press trigger .
OM-228 305 Page 19 SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions .
OM-228 305 Page 20 6-2. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System If certain problems occur , the Ready light goes off, a trouble light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa).
OM-228 305 Page 21 6-3. T orch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: T urn power Of f, and disconnect input power plug from receptacle. Remove wrapper from unit. T orch Connections Remove existing torch cable from unit.
OM-228 305 Page 22 6-4. Checking/Replacing Retaining Cup, Tip, And Electrode ! Overtightening will strip threads. Do not overtighten retaining cup during assembly . Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement.
OM-228 305 Page 23 6-5. T roubleshooting Power Source Connect unit to proper input voltage (see Section 4-8). Ye s No Is input power connected to correct line voltage? Is Changeover switch S2 in the 1 15V or 230V position? Place Changeover switch i n proper position for input voltage (see Section 4-8).
OM-228 305 Page 24 6-6. T roubleshooting T orch T orch travel speed too slow; increase travel speed (see Section 5-2). Clean or replace torch consumables as necessary (see Section 6-4 ).
OM-228 305 Page 25 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Circuit Diagram 227 893-A.
OM-228 305 Page 26 SECTION 8 − P ARTS LIST . Hardware is common and not available unless listed. 804 490-B 13 18 16 4 5 1 2 26 6 25 24 22 20 19 21 7 8 9 10 11 12 15 23 3 17 14 Figure 8-1.
OM-228 305 Page 27 Figure 8-1. Main Assembly Diagram marking Item No. Part No. Description Quantit y 1 204 326 CONSUMABLE ST ORAGE BOX w/DOOR (including) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 089 899 LA TCH, slide 1 .
OM-228 305 Page 28 1 183 427 Handle Assy , complete (1) 2 171 248 Push Button Switch (1) 3 203 120 Leads, 20ft (1) 4 203 1 1 9 Main Body (1) 5 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 195 014 T orch, replacement 20ft (1) See Figure 8-3 for additional consumable parts.
Notes.
Notes.
Effective January 1, 2007 (Equipment with a serial number preface of “LH” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties express ed or implied.
PRINTED IN USA 2007−01 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip Please complete and retain with your personal records. Always provide Model Name and Serial/Style Number.
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