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Transcript of Spectrum 375 X-TREME And XT30 Torch - TS … Spectrum 375 X-treme... · Spectrum 375 X-TREME And...

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    Processes

    Description

    Air Plasma Cuttingand Gouging

    Air Plasma Cutter

    OM-253 555A 201108

    Spectrum 375 X-TREMEAnd XT30 Torch

    File: Plasma CuttersVisit our website atwww.MillerWelds.com

    EN

    GL

    ISH

  • Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual specification sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller, or visit us atwww.MillerWelds.com on the web.

    Thank you and congratulations on choosing Miller. Now you can getthe job done and get it done right. We know you dont have time to doit 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 superiorquality. Like you, his customers couldnt afford anything less. Millerproducts had to be more than the best they could be. They had to be thebest you could buy.

    Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

    This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. Theywill help you protect yourself against potential hazards on the worksite.

    Weve made installation and operation quickand easy. With Miller you can count on yearsof reliable service with proper maintenance.And if for some reason the unit needs repair,theres a Troubleshooting section that willhelp you figure out what the problem is. Theparts list will then help you to decide theexact part you may need to fix the problem.Warranty and service information for yourparticular model are also provided.

    Miller is the first weldingequipment 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

  • 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 fonctionnement

    et 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 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 4 SPECIFICATIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Unit Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Torch Dimensions And Weight 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Duty Cycle And Overheating 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 5 INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Serial Number And Rating Label Location 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Selecting A Location 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Connecting Gas/Air Supply 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Connecting Work Clamp 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Electrical Service Guide 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Extension Cord Data 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. MultiVoltage Plug (MVP) Connection 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8. Connecting 120 Volt Input Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9. Connecting 240 Volt Input Power 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 6 OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Cutting Speed 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Trigger Safety Lock 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4. Plasma Cutting System Practices 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5. Sequence Of Cutting Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6. Sequence Of Piercing Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 7 MAINTENANCE & TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Overload Protection 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Wrapper Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Checking Or Replacing Filter Element 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5. Status/Trouble Lights 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6. Checking Shield Cup Shutdown System 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7. Checking/Replacing Retaining Cup, Tip, And Electrode 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8. Troubleshooting Power Source 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9. Troubleshooting Torch 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 8 ELECTRICAL DIAGRAM 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 9 PARTS LIST 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY

  • OM-253 555 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.

    Remove all flammables within 35 ft (10.7 m) of the cutting arc. If thisis not possible, tightly cover them with approved covers.

    Do not cut where flying sparks can strike flammable material. Protect yourself and others from flying sparks and hot metal. Be alert that sparks and hot materials from cutting can easily go

    through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that cutting on a ceiling, floor, bulkhead, or partition can

    cause fire on the hidden side. Do not cut on closed containers such as tanks or drums. 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.

    Do not use plasma cutter to thaw frozen pipes. Never cut containers with potentially flammable materials inside

    they must be emptied and properly cleaned first.

    Do not cut where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

    Do not cut pressurized cylinders, pipes, or vessels. Do not cut containers that have held combustibles. Wear oil-free protective garments such as leather gloves, heavy

    shirt, cuffless trousers, high shoes, and a cap. Do not locate unit on or over combustible surfaces. Remove any combustibles, such as a butane lighter or matches,

    from your person before doing any cutting.

    After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.

    Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

    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.

    Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or

    covers big enough to prevent any physical contact with the work orground.

    Do not touch torch parts if in contact with the work or ground. Turn off power before checking, cleaning, or changing torch parts. Disconnect input power before installing or servicing this equip-

    ment. Lockout/tagout input power according to OSHA CFR1910.147 (see Safety Standards).

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

    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.

    When making input connections, attach proper grounding conduc-tor first.

    Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

    Frequently inspect input power cord for damage or bare wiring re-place cord immediately if damaged bare wiring can kill.

    Turn off all equipment when not in use. Inspect and replace any worn or damaged torch cable leads. Do not wrap torch cable around your body. Ground the workpiece to a good electrical (earth) ground if required

    by codes. Use only well-maintained equipment. Repair or replace damaged

    parts at once. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Do not bypass or try to defeat the safety interlock systems. Use only torch(es) specified in Owners Manual. Keep away from torch tip and pilot arc when trigger is pressed. Clamp work cable with good metal-to-metal contact to workpiece

    (not piece that will fall away) or worktable as near the cut aspractical.

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

  • OM-253 555 Page 2

    SIGNIFICANT DC VOLTAGE exists ininverter power sources AFTER the re-moval of input power.

    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 beforetouching any parts.

    ELECTRIC SHOCK can kill.

    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.

    Wear approved face shield or safety goggles with side shields. Wear proper body protection to protect skin. Wear flame-resistant ear plugs or ear muffs to prevent sparks from

    entering 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.

    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 casewith low current cutting, the shades suggested in Table 1 are pro-vided for the operators convenience.

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

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

    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 NumberBelow 2020 4040 6060 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.

    Use approved ear plugs or ear muffs if noise level is high. 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.

    Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the

    arc to remove cutting fumes and gases. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDSs)

    and the manufacturers instruction for metals to be cut, coatings,and cleaners.

    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.

    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.

    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.

    Do not cut containers with toxic or reactive materials inside orcontainers that have held toxic or reactive materials they must beemptied 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.

    Keep away from the torch tip. Do not grip material near the cutting path. The pilot arc can cause burns keep away from torch tip when trig-

    ger is pressed. Wear proper flame-retardant clothing covering all exposed body ar-

    eas. Point torch away from your body and toward work when pressing

    the torch trigger pilot arc comes on immediately. Turn off power source and disconnect input power before disas-

    sembling torch or changing torch parts. 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.

    Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flame, sparks, and arcs.

    Install and secure cylinders in an upright position by chaining themto a stationary support or equipment cylinder rack to prevent fallingor tipping.

    Keep cylinders away from any cutting or other electrical circuits. Never allow electrical contact between a plasma arc torch and a

    cylinder. Never cut on a pressurized cylinder explosion will result. Use only correct gas cylinders, regulators, hoses, and fittings de-

    signed for the specific application; maintain them and associatedparts in good condition.

    Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in

    use or connected for use.

    Use the right equipment, correct procedures, and sufficient numberof persons to lift and move cylinders.

    Read and follow instructions on compressed gas cylinders, asso-ciated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.

  • OM-253 555 Page 3

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

    HOT PARTS can burn.

    Do not touch hot parts bare handed. Allow cooling period before working on

    equipment. To handle hot parts, use proper tools and/or

    wear heavy, insulated welding gloves andclothing to prevent burns.

    MOVING PARTS can injure.

    Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards

    closed and securely in place.

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

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

    READ INSTRUCTIONS.

    Read and follow all labels and the OwnersManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

    Use only genuine replacement parts from the manufacturer.

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

    FLYING METAL or DIRT can injure eyes.

    Wear safety glasses with side shields or wearface shield.

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

    Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

    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.

    Allow cooling period; follow rated duty cycle. Reduce amperage (thickness) or reduce duty

    cycle before starting to cut again.

    EXPLODING HYDROGEN hazard.

    When cutting aluminum underwater or with thewater touching the underside of the aluminum,free hydrogen gas may collect under the work-piece.

    See your cutting engineer and water table instructions for help.

    FALLING EQUIPMENT can injure.

    Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

    Use equipment of adequate capacity to lift unit.

    If using lift forks to move unit, be sure forks are long enough to ex-tend beyond opposite side of unit.

    Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

    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.

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

    Do not install unit near flammables.

    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.

    Put on grounded wrist strap BEFORE handlingboards or parts.

    Use proper static-proof bags and boxes tostore, move, or ship PC boards.

    H.F. RADIATION can cause interference.

    High frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

    Have only qualified persons familiar with elec-tronic equipment perform this installation.

    The user is responsible for having a qualified electrician promptlycorrect any interference problem resulting from the installation.

    If notified by the FCC about interference, stop using the equipmentat once.

    Have the installation regularly checked and maintained.

    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.

    Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

    To reduce possible interference, keep cables as short as possible,close together, and down low, such as on the floor.

    Locate cutting operation 100 meters from any sensitive electronicequipment.

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

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

  • OM-253 555 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 otherreproductive 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, andother 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,Chantilly, 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.

  • OM-253 555 Page 5

    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 toutdanger. 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 couperchauffe et lquipement chaud peuvcnt causer un

    feu ou des brlures. Avant de commencer travailler, assurez-vousque lendroit est scuritaire.

    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.

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

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

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

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

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

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

    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.

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

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

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

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

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

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

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

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

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

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

    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.

    Ne touchez pas aux pices lectriques sous tension.

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

    Isolezvous de la pice couper et du sol en utilisant des houssesou des tapis assez grands afin dviter tout contact physique avecla pice couper ou le sol.

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

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

    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).

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

    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.

  • OM-253 555 Page 6

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

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

    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.

    Lquipement doit tre hors tension lorsquil nest pas utilis.

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

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

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

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

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

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

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

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

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

    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.

    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 NONNGLIGEABLE dans les sources desoudage onduleur UNE FOISlalimentation coupe.

    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.

    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.

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

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

    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.

    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 n 9 (n 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.

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

    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.

    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. 420 40 no. 540 60 no. 6

    60 100 no. 8

    Certaines applications de coupage produisent unbruit constant, ce qui peut endommager loue si leniveau sonore dpasse les limites permises parlOSHA (reportezvous aux Principales normes de

    scurit).

    LE BRUIT peut endommager loue.

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

    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.

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

    Si vous tes lintrieur au moment du coupage, ventilez la piceou ayez recours une ventilation aspirante installe prs de larcpour vacuer les vapeurs et les gaz.

    Si la ventilation est mdiocre, utilisez un respirateur antivapeursapprouv.

    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.

    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.

  • OM-253 555 Page 7

    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.

    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.

    Ne coupez pas de contenants qui renferment ou ont renferms desmatires 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.

    Napprochez pas le tube du chalumeau.

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

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

    Portez des vtements de protection adquats qui recouvrent toutvotre corps.

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

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

    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 fonthabituellement partie dun processus de travail des

    mtaux, assurezvous de les manipuler correctement.

    LES BOUTEILLES peuvent explosersi elles sont endommages.

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

    Installez et attachez les bouteilles dans la position verticale laidedune chane, sur un support stationnaire ou un chssis portebou-teille afin de prvenir quelles ne tombent ou ne basculent.

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

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

    Ne coupez jamais sur une bouteille pressurise une explosion enrsulterait.

    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.

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

    Le couvercle du dtendeur doit toujours tre en place, sauf lorsquevous utilisez la bouteille ou quelle est relie pour usage ultrieur.

    Utiliser les quipements corrects, les bonnes procdures et suffi-samment de personnes pour soulever et dplacer les bouteilles.

    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 peuventprovoquer des brlures.

    Ne pas toucher des parties chaudes mainsnues.

    Prvoir une priode de refroidissement avantdutiliser lquipement.

    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.

    Sabstenir de toucher des organes mobiles telsque des ventilateurs.

    Maintenir ferms et verrouills les portes, pan-neaux, recouvrements et dispositifs de protec-tion.

    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.

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

    LIRE LES INSTRUCTIONS.

    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.

    Nutiliser que les pices de rechange recommandes par leconstructeur.

    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.

    Porter des lunettes de scurit avec crans latraux ou un cranfacial.

  • OM-253 555 Page 8

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

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

    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.

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

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

    Danger DEXPLOSIONDHYDROGNE.

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

    Consultez votre ingnieur de coupage et les instructions de latable de coupage.

    LA CHUTE DE LQUIPEMENT peutprovoquer des blessures.

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

    Utiliser un engin dune capacit appropriepour soulever lappareil.

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

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

    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.

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

    Ne pas installer lappareil proximit de pro-duits inflammables

    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.

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

    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.

    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.

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

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

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

    Effectuer rgulirement le contrle et lentretien de linstallation.

    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.

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

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

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

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

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

  • OM-253 555 Page 9

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

    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 lesmains 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 Weldingand 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 rgionaux le 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 lemdecin approuve, il est recommand de suivre les procdures prc-dentes.

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    OM-253 555 Page 10

    SECTION 3 DEFINITIONS

    3-1. Symbols And Definitions

    A Amperes Plasma Arc Cutting(PAC) Adjust Air/GasPressure Low Air PressureLight

    V Volts IncreaseNo Do Not Do

    This 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

    Voltage Line Connection

    I1max Rated MaximumSupply Current I2Rated Welding Or

    Cutting 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-253 555 Page 11

    SECTION 4 SPECIFICATIONS

    4-1. Unit Specifications

    Power Supply

    Input

    Rated AC Phase and line frequency (Hz) 1 Phase 50 / 60 Hz Rated Input Voltage (U1) and rated Input Current (I1)and I1 eff at rated output. I1 eff used to determine powercord rating

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

    120 VAC, 1Phase (20 A) 25.6 11.4

    120 VAC, 1Phase (15 A) 18.1 10.7

    240 VAC, 1Phase 13.6 8.1

    Power Factor/kVA/kW at Rated Output Volts AC RMS (U1) Power Factor kVA/kW

    120 VAC, 1Phase (20 A) 0.982 3.08 / 3.03

    120 VAC, 1Phase (15 A) 0.983 2.19 / 2.15

    240 VAC, 1Phase 0.995 3.31 / 3.29

    Peak kW at Arc Stretch kW 7.0

    Output

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

    Output Characteristic Constant Current

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

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

    120 VAC, 1Phase (20A) 27 A 91 V

    120 VAC, 1Phase (15 A) 20 A 88 V

    240 VAC, 1Phase 30 A 92 V

    Output Current Range 15 30 A Duty Cycle at 104F (40C) and Rated Conditions(U1, I1, U2, I2) based on a 10 minute period

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

    120 VAC, 1Phase (20A) 27 A 20%

    120 VAC, 1Phase (15 A) 20 A 35%

    240 VAC, 1Phase 30 A 35%

    240 VAC, 1Phase 22 A 100%

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    OM-253 555 Page 12

    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 sprayingwater

    C AC line circuits protectedagainst ingress of tool . 2.5 mm

    dia x 100 mm long (0.1 in. x 4 in.)

    S Fan stationary during watertest

    Toppling or tilting Up to 15 incline

    Torch The XT30 torch is intended for handheld use only. The torch conforms to IEC 60974-7 when used with the Spectrum 375X-TREME. Do not use this torch in combination with any other machines.

    Gas Type Air or Nitrogen

    Gas QualityClean, moisturefree,

    oilfree

    Gas Inlet Flow and Pressure 5.0 SCFM (142 L/min)90 PSI (621 kPa)

    Min120 PSI (827 kPa)

    Max

    Gas Filtering Particulates to 5 microns

    Mild Steel capacities (see Section 6-2 for cutting speeds vs material type and thickness)

    Cooling Method Air Duty Cycle of Torch 100% at 30 Amps Rating of Electrical Controls (Trigger) 30 VDC at .1 Amps

    Rating of Electrical Controls (Cup) 30 VDC at 1 Amp

    Approved Systems Spectrum 375 X-TREME w/XT30torch

    Trigger Protection Safety trigger guard

    Safety Devices Safety interlock devices shutdown power source

    Rated Capacity (edge start) 3/8 in. at 18 ipm (457 mm/min)*

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

    Pierce Capacity 3/16 in. *Travel speeds are approximately 80% of maximum.

    Dimensions 13-1/8 in. (333 mm) L5-1/2 in. (140 mm) W

    9 in. (229 mm) H

    Weight 18 lb (8.2 kg) including torch

    Requirements for the torch connection Use only compressed air which is free from dirt, oil, and water. Ensure that the connections are properly assigned and tighened. For torch replacement, see Miller torch manual Part No. OM-1593 Ensure correct air pressure (flow pressure) and airflow (volume) are set. Insufficient airflow can lead to the torch overheating.

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    OM-253 555 Page 13

    4-2. Torch Dimensions And Weight

    Ref. 253 554-A

    2.2 lb (1.0 kg)

    1-3/16 in.(30 mm)

    8-3/4 in.(222 mm)

    1-1/2 in.(38 mm)

    4-3. Duty Cycle And Overheating

    Duty Cycle is percentage of 10minutes that unit can cut at ratedload without 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. 804 503-A

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

    35% duty cycle

    0

    15

    Minutes

    A

    ORReduce Duty Cycle

    2 Minutes Cutting 8 Minutes Resting

    20% duty cycle

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    OM-253 555 Page 14

    SECTION 5 INSTALLATION5-1. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on the bottom. 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.

    5-2. Selecting A Location

    loc_2 3/96 - Ref. ST-151 556 / Ref. 804 503-A

    1 Line Disconnect Device

    Locate unit near correct inputpower supply.

    Locate unit at least 18 in. (460 mm)away from a wall or otherobstruction to allow adequateclearance for cooling air flow.

    ! Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

    Location

    1

    18 in.(460 mm)

    18 in.(460 mm)

    ! Do not move or operateunit where it could tip.

    5-3. Connecting Gas/Air Supply

    Ref. 251 808-A

    Use only clean, dry air with 90to 120 psi (621 to 827 kPa)pressure.

    1 Gas/Air Inlet Opening

    2 Hose

    3 Teflon Tape

    Obtain hose with 1/4 NPT right-hand thread fitting. Wrap threadswith teflon tape (optional) or applypipe sealant, and install fitting inopening. Route hose to gas/airsupply.

    Tools Needed:

    9/16 in.

    3From Gas/Air

    Supply

    1

    2

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    OM-253 555 Page 15

    5-4. Connecting Work Clamp

    Ref. 803 640-A

    1 Work Clamp

    2 Workpiece

    Connect work clamp to a clean,paint-free location on workpiece, asclose to cutting area as possible.

    1

    2

    5-5. Electrical Service Guide

    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.

    NOTICE Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual inputvoltage is outside this range, output may not be be available.

    50/60 Hz Single Phase

    Input Voltage (V) 120 240

    Input Amperes (A) At Rated Output

    A 15 or 20ampere individual

    branch circuitprotected by

    time-delay fusesor circuit breaker

    is required.See Section 4-1

    14

    Max Recommended Standard Fuse Rating In Amperes 1

    Time-Delay Fuses 2 15

    Normal Operating Fuses 3 25

    Min Input Conductor Size In AWG 4 14

    Max Recommended Input Conductor Length In Feet (Meters)96

    (29)

    Min Grounding Conductor Size In AWG 4 14

    Elec Serv 201104

    Reference: 2011 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 Table

    310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cablerequirements.

    5-6. Extension Cord Data

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

    Single Phase AC

    Input Voltage

    Conductor Size AWG (mm2)*

    6 (13.3) 8 (8.4) 10 (5.3) 12 (3.3) 14 (2.1)

    Maximum Allowable Cord Length in ft (m)

    120 175 (53) 110 (33) 70 (21) 44 (13) 28 (9)

    240 700 (213) 440 (134) 277 (84) 175 (53) 110 (33)

    *Conductor size is based on maximum 3% voltage drop

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    OM-253 555 Page 16

    5-7. MultiVoltage Plug (MVP) Connection

    Selecting Plug

    1 Power Cord Connector FromWelding Power Source

    Select plug for power supply receptacleavailable at site. Not all plugs shown areprovided as standard with unit.

    2 Plug NEMA Type 515P

    3 Receptacle NEMA Type 515R(Customer Supplied)

    4 Plug NEMA Type 520P (Optional)

    5 Receptacle NEMA Type 520R(Customer Supplied)

    6 Plug NEMA Type 650P

    7 Receptacle NEMA Type 650R(Customer Supplied)

    ! Follow electrical service guide for240 VAC in Section 5-5. Do not useplug rating to size branch circuitprotection.

    Connecting Plug To Power Cord

    Align arrow on plug with arrow on powercord connector. Push together.

    Tighten threaded collar. As threaded collaris tightened, push plug onto adapter untilcollar is completely tight.

    Connect plug to receptacle.

    MVP Plug1 201010 / Ref. 803 812-C

    ! Do not cut off power cord connec-tor and rewire. The power cordconnector and plugs will workwith standard NEMA receptacles.Modifying power cord, connector,and plugs will void product war-ranty.

    3

    2

    7

    4

    5

    6

    1

    Selecting Plug

    Connecting Plug To Power Cord

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    OM-253 555 Page 17

    Input6 201103 Ref. 253 558-A

    5-8. Connecting 120 Volt Input Power

    1

    ! Installation must meet all National andLocal Codes have only qualifiedpersons make this installation.

    See rating label on unit and check input voltageavailable at site.

    The Auto-Line circuitry in this unit automati-cally links the power source to the primaryvoltage being applied, either 120 or 240VAC.

    For 120 volts AC input power, a 15 or 20 ampereindividual branch circuit protected by time-delayfuses or circuit breaker is required.

    1 Multi-Voltage Plug And Power CordConnector (NEMA Type 515P PlugShown)

    For multivoltage plug connections, see Section5-7.

    2 Receptacle NEMA Type 515R(Customer Supplied)

    2

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    OM-253 555 Page 18

    5-9. Connecting 240 Volt Input Power

    Input6 201103 803 766-B / Ref. 802 443-A /Ref. 251 808-A

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

    ! Disconnect and lockout/tagoutinput power before connectinginput power cord to receptacle.

    ! Always connect green or green/yellow conductor to supplygrounding terminal first, and neverto a line terminal.

    See rating label on unit and check inputvoltage available at site.

    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 5-5 (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.

    The Auto-Line circuitry in this unitautomatically links the power sourceto the primary voltage being applied,either 120 or 240 VAC.

    9 Multi-Voltage Plug And Power CordConnector (NEMA Type 650P PlugShown)

    For multivoltage plug connections, seeSection 5-7.

    4

    3

    L1L2

    1

    =GND/PE Earth Ground

    2

    1

    5

    6

    7

    Tools Needed:

    L1L2

    240 VAC, 1

    89

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    OM-253 555 Page 19

    SECTION 6 OPERATION6-1. 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 7-5)

    253 014-A

    3

    12

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    OM-253 555 Page 20

    6-2. Cutting Speed

    Recommended Cut Speeds At 30 Amperes Output

    Mild Steel

    Thickness Recommended Cut Speeds*

    Inches mm ipm mm/min

    12 ga 2.8 104.8 2,662

    1/8 3.2 98.4 2,499

    3/16 4.8 63.2 1,605

    1/4 6.4 36.0 914

    3/8 9.5 18.4 467

    1/2 12.7 10.4 264

    5/8 15.9 6.4 163

    *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 27 Amperes Output

    Mild Steel

    Thickness Recommended Cut Speeds*

    Inches mm ipm mm/min

    12 ga 2.8 115.0 2,921

    1/8 3.2 88.0 2,235

    3/16 4.8 50.4 1,280

    1/4 6.4 28.0 711

    3/8 9.5 15.2 386

    1/2 12.7 8.0 203

    5/8 15.9 4.8 123

    *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

    1/16 1.6 158.4 4,014

    1/8 3.2 49.6 1,260

    3/16 4.8 32.8 833

    1/4 6.4 16.8 427

    5/16 7.9 8.0 203

    3/8 9.5 6.4 163

    *Recommended Cut Speed is approximately 80% of maximum.

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

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    OM-253 555 Page 21

    6-3. Trigger Safety Lock

    Trigger Locked Trigger Unlocked

    1 Trigger

    Ref. 253554-A

    1

    Ref. 254 087-A

    6-4. Plasma Cutting System Practices

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

    or template for accurate cutting operations.

    ! The pilot arc starts immediatelywhen trigger is pressed.

    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 orgouging as this shortens the service life

    of the nozzle and electrode.

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

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

    speed is too fast or amperage is set too low.

    When doing extended (non-shielded)cutting, maintain approximately 1/16 in.standoff between electrode and surface.

    1/16 in.(1.6 mm)

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

    the surface for proper cutting results.

    Wt

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    OM-253 555 Page 22

    out bottom of cut.

    Ref. 254 087-A

    6-5. Sequence Of Cutting Operation

    After cutting arc starts, slowlystart moving torch across metal.

    Adjust torch speed sosparks go thru metal and

    Pause briefly at end ofcut before releasing trigger.

    Raise trigger lock and presstrigger. Pilot arc starts.

    Postflow continues for approx. 20 secondsafter releasing trigger; cutting arc can be

    instantly restarted during postflow by raisingtrigger lock and pressing trigger.

    ! The pilot arc starts immediatelywhen trigger is pressed.

    For standard (shielded) cutting, place drag shield on edgeof metal. For extended (non-shielded) cutting, use 1/8 in.

    (3.2 mm) standoff distance (dragging tip will reduce tip life).

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

    area as possible.

    90

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    OM-253 555 Page 23

    Ref. 254 087-A

    6-6. Sequence Of Piercing Operation

    Maintain approximately 90 torchposition to surface, and continue

    cutting.

    Release trigger. Postflow continues forapprox. 20 seconds after releasing trigger;

    arc can be instantly restarted during postflowby raising trigger lock and pressing trigger.

    ! The pilot arc starts immediatelywhen trigger is pressed.

    Hold torch at approximately 45to the workpiece. Raise triggerlock and press trigger. Pilot arc

    starts.

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

    area as possible.

    Rotate torch to upright positionapproximately 90 to surface.When arc has pierced through

    workpiece, start cutting.

    90 90

    45

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    OM-253 555 Page 24

    SECTION 7 MAINTENANCE & TROUBLESHOOTING

    7-1. Routine Maintenance

    ! Disconnect power before maintaining.

    Maintain more oftenduring severe conditions.

    = Check = Change = Clean = Replace* To be done by Factory Authorized Service Agent

    Reference

    EachUse

    Section 5-3,7-7

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

    EveryWeek Section 7-6

    Shield Cup ShutdownSystem

    Every3Months

    Section 7-4,9

    Damaged Or UnreadableLabels

    Air Filter/Regulator Cracked Parts Gas/Air Hose

    Torch Body, Cable

    Every6Months

    OR

    Inside Unit

    7-2. Overload Protection

    Ref. 251 808-A

    1 Supplementary Protector CB1

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

    Reset supplementary protector.1

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    OM-253 555 Page 25

    7-3. Wrapper Removal

    Ref. 251 808-A

    ! Turn off power, anddisconnect input power plugfrom receptacle or turn off andlockout/tagout line discon-nect device before working onunit.

    ! Significant DC voltage canremain on capacitors after unitis Off. Check to see that frontpanel lights (LEDs) havestopped flashing and are offbefore removing wrapper.

    1 Wrapper

    2 Torx Screws (Fine Thread)

    Remove Torx screws and slidewrapper off.

    Torx 25

    Tools Needed:

    1

    2

    Notes

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    OM-253 555 Page 26

    7-4. Checking Or Replacing Filter Element

    ! Significant DC voltage canremain on capacitors afterunit is Off. Check to see thatfront panel lights (LEDs)have stopped flashing andare off before removingwrapper.

    Turn power Off, and disconnectinput power plug from receptacle.Remove wrapper from unit (seeSection 7-3).

    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.

    Ref. 251 808-A / Ref. 804 506-B

    1

    2

    3

    Torx 25

    Tools Needed:

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    OM-253 555 Page 27

    7-5. Status/Trouble Lights

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

    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.

    PowerFlashing rate is steady for 15 seconds or until torch triggeris pressed again, whichever comes first.

    Input power below 88 volts AC, but has returned tonormal.

    PowerRepetitive flashing rate of two quick cycles, then a onesecond pause.

    Input power is below 88 volts AC.

    Pressure On No or low [below 40 psi (276 kPa)] input pressure.

    PressureFlashing rate is steady for 15 seconds or until torch triggeris pressed again, whichever comes first.

    Regulated pressure in the unit is low. Check torch forleaks. Check input pressure to unit is between 90 to 120psi (621 to 827 kPa).

    PressureRepetitive flashing rate of two quick cycles, then a onesecond pause for a 15 second period.

    Regulated pressure in the unit is high. Check input pressureto unit is between 90 to 120 psi (621 to 827 kPa).

    CupOn Torch cup is loose or off. Once cup is tightened, unit

    power must be cycled off and back on again.

    CupFlashing rate is steady for 15 seconds or until torch triggeris pressed again, whichever comes first.

    No arc was established. Check consumables or torch.

    CupRepetitive flashing rate of two quick cycles, then a onesecond pause for a 15 second period or until torch triggeris pressed again, whichever comes first.

    No pilot arc established possibly due to a loss of current.Check consumables.

    CupRepetitive flashing rate of three quick cycles, then a onesecond pause for a 15 second period or until torch triggeris pressed again, whichever comes first.

    Consumables in torch failed to separate during pilot arcpossibly due to being stuck. Check consumables.

    TemperatureOn Power source overheated (see Section 4-3). Stop cutting

    and allow unit to cool down.

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

    ambient temperature is below -22 F (-30 C).

    Temperature

    Flashing rate is steady (indefinitely). Power source temperature sensor provided inaccuratereadings, but returned to normal. Unit power must becycled off and back on again.

    Stalled or locked fan. Clean or replace as needed.

    For system troubleshooting see Section 7-8 and Section 7-9.

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    OM-253 555 Page 28

    7-6. Checking Shield Cup Shutdown System

    Ref. 253 554-A

    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 ServiceAgent check unit.

    If system works properly, retightencup and reset power.

    1

    Power must be reset whenever the cup shutdown systemis activated. Always turn Off power when changing orchecking consumables. Do NOT overtighten torchshield cup. Gently finger tighten cup onto torch.

    Notes

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

    OM-253 555 Page 29

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

    ! Overtightening will strip threads. Do not overtighten retainingcup during assembly. Do not cross-thread parts causingstripping. Use care during torch assembly and partsreplacement.

    ! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been signifi-cantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacementparts.

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

    Ref. 253554-A

    Turn Off power source.

    1 Shield Cup

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

    2 Tip

    3 Opening

    Remove 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.

    4 Electrode

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

    5 Swirl Ring

    Remove swirl ring. Check ring, and replaceif side holes are plugged.

    6 O-Ring

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

    Carefully reassemble parts in reverse order.

    Make sure this area isclean of any debris.

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

    ! Turn Off power source before checking torchparts.

    New

    Worn

    32

    5

    1

    6

    New

    Worn

    4

    1/32 in. (1 mm) to 1/16in. (2 mm) maximum pitdepth depending onacceptable cut quality

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

    OM-253 555 Page 30

    7-8. Troubleshooting Power Source

    Trouble Remedy

    No pilot arc; difficulty in establishing anarc.

    Clean or replace worn consumables as necessary (see Section 7-7).

    Check for damaged torch or torch cable.

    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 5-9).

    Check line fuse(s) and replace if needed or reset circuit breakers (see Section 5-9).

    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 Section 7-7).

    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 7-4).

    Pressure status light On. Check for sufficient gas/air supply pressure (see Section 5-3).

    Check for dirty air filter and replace, if necessary (see Section 7-4).

    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 7-6). Reset power switch.

    Have Factory Authorized Service Agent check torch.

    Temperature status light On. 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. If problem continues, 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.

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

    OM-253 555 Page 31

    7-9. Troubleshooting Torch

    Trouble Remedy

    Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 6-5). Clean or replace torch consumablesas necessary (see Section7-7). 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 6-4). Clean or replace torch consumables as necessary (seeSection 7-7).

    Sparks come out top of cut or cut is notclean.

    Torch travel speed too fast; reduce travel speed (see Section 6-4). Clean or replace torch consumablesas necessary (see Section 7-7). Be sure work clamp is securely attached to workpiece. Unit not capableof cutting metals thicker than rating (see Section 6-2).

    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.

    Notes

  • OM-253 555 Page 32

    SECTION 8 ELECTRICAL DIAGRAM

    Figure 8-1. Circuit Diagram

  • OM-253 555 Page 33

    254 176-A

  • OM-253 555 Page 34

    SECTION 9 PARTS LIST

    9-1. Recommended Spare Parts

    DescriptionPartNo.

    Dia.Mkgs.

    ItemNo.

    Recommended Spare Parts

    Quantity

    225970 Plug Kit, Adapter (115V/15A) (230V/50A) (including) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219261 Adapter, Power Cable 515P (115V/15A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219258 Adapter, Power Cable 650P (230V/50A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238486 Element, Filter Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249949 XT30, 12FT Hand Held (Replacement) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225916 Cable, Work 12 FT 8 GA W/Clamp Strain RLF & TERM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253524 LabeL, XT30 Consumables 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219259 Adapter, Power Cable 5-20P (115v/20A) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

    253 524-A

    253524-A

    CAUTION

    XT30 CONSUMABLES

    PLUG CONFIGURATIONSTO USE WITH THE BRANCH

    CIRCUITS SHOWN.

    15A MVP 120V219 261

    20A MVP 120V219 259

    50A MVP 240V219 258

    FAILURE TO REPLACE WORN TIP ORELECTRODE WILL DAMAGE TORCHAND VOID WARRANTY.

    Turn off power before checking torch parts.

    Check before each use and hourly during operation.

    DragShield249930

    Extended ConsumableShield Deflector

    249933

    RetainingCup

    249932 Tip249927

    Electrode249926

    Swirl Ring249931

    O-Ring249969

    Figure 9-1. Consumable Parts For XT30

    To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

  • OM-253 555 Page 35

    1 249 970 Torch Handle Kit (1)2 249 971 Torch Trigger

    Microswitch (1). . . . . . . . . . . . . . .3 249 957 Leads, 12 ft (1)4 252 938 Torch Body Kit (1)5 249 972 Torch Trigger Assembly

    w/Spring (1)252 951 Gre