OWNER S MANUAL Use above FORM number when ordering extra manuals.

Transcription

1 OWNER S MANUAL OM-9 8T Use above FORM number when ordering extra manuals ICE-C, ICE-C, ICE-CX, ICE-C, ICE-T ICE-0C, ICE-0C, ICE-0CM, ICE-C, ICE-CM, ICE-80C, ICE-80CM, ICE-80CX, ICE-80CXM, ICE-80T, ICE-80TM, ICE-00T, And ICE-00TM Torches. Specifications Air-cooled torches for plasma arc cutting (PAC) A model: A at % duty cycle; A model: A at % duty cycle; A model: A at % duty cycle; 0 A model: 0 A at 0% duty cycle; 0 A models: 0 A at 0% duty cycle; A model: A at 0% duty cycle; 80 A model: 80 A at 0% duty cycle 00 A model: 00 A at 80% duty cycle A model equipped with 0 ft (. m) cable A model equipped with ft (. m) cable; available with optional ft (. m) cable A model equipped with 0 ft (. m) cable; 0 A model equipped with ft (.m) cable; available with optional 0 ft (. m) cable 0 A model equipped with ft (. m) cable; available with optional 0 ft (. m) cable A model equipped with ft (. m) cable; available with optional 0 ft (. m) cable 80 A model equipped with ft (. m) cable; available with optional 0 ft (. m) cable 00 A model equipped with ft (. m) cable; available with optional 0 ft (. m) cable Use air or nitrogen plasma gas: A model: CFM (8. L/min) at 0 PSI ( kpa); A model:. CFM (9 L/min) at 0 PSI ( kpa); A model :. CFM (9 L/min) at 0 PSI ( kpa); 0 A model: CFM (0 L/min) at PSI ( kpa); 0 A model:. CFM ( L/min) at 0 PSI (8 kpa); A model: CFM ( L/min) at 0 PSI (8 kpa); 80 A (C, CM, CX, and CXM) model:. CFM (0 L/min) at 80 PSI ( kpa) 80 A (T and TM) model:.8 CFM ( L/min) at 0 PSI (8 kpa) 00 A model: 9. CFM (0 L/min) at PSI ( kpa) Safety interlock devices shut down power source A, A, 0 A, 0 A, A, 80 A and 00 A models have safety trigger guard Gear rack pitch for 0 A, A, 80 A and 00A machine-held models: Cutting capacity for mild steel: A model up to / in ( mm) at A; A model up to /8 in (0 mm) at A; A model up to /8 in (0 mm) at A; 0 A model up to / in (. mm) at 0 A; 0 A model up to /8 in ( mm) at 0 A; A model - up to in (. mm) at A; 80 A model up to -/ in ( mm) at 80 A 00 A model up to -/ in (8 mm) at 00 A 00 MILLER Electric Mfg. Co.

2 . Safety Symbol Definitions NOTICE DANGER! Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates statements not related to personal injury. Indicates special instructions. Wear safety glasses with side shields. Cutting processes cause flying pieces of metal and sparks. Wear a face shield. Static electricity can damage parts on circuit boards. Put on grounded wrist strap before touching circuit board. Beware of electric shock from the cutting torch or wiring. Touching the cutting torch while in contact with the work or ground can cause electric shock. Always wear dry gloves. Keep all panels and covers closed. Cutting sparks can cause fire or explosion. Move flammables away. Do not cut on closed tanks or barrels they can explode. Clean tanks or barrels properly. Have only trained and qualified persons install, operate, or service this unit. Call your distributor if you do not understand the directions. For CUTTING SAFETY and EMF information, read power source Manual. Beware of moving parts. Keep guards and panels in place, covers closed, and hands away from moving parts. Arc rays can burn eyes and skin wear face protection (helmet or face shield) with correct shade of filter, and cover exposed skin with nonflammable clothing. Hot parts can cause burns. Cutting makes parts very hot let them cool before touching. Allow cooling period. Reduce current or reduce duty cycle before starting to cut again. Follow rated duty cycle. Breathing cutting fumes and gases can harm your health. Cutting requires good ventilation. If ventilation is impossible, such as when cutting in a confined space, use an air-supplied respirator. The plasma arc can cause injury. The intense heat of the arc or pilot arc can cause serious burns. Keep away from the torch tip when the trigger is pressed. Do not grip material near the cutting path. Prolonged noise from some cutting applications can damage hearing. Use approved ear plugs or ear muffs if noise level is high.. Duty Cycle And Overheating Duty Cycle is percentage of 0 minutes that unit can cut at rated load without overheating. NOTICE Exceeding duty cycle can damage power source and torch and void warranty. Ampere Torch: % Duty Cycle At Amperes Ampere Torch: % Duty Cycle At Amperes Ampere Torch: % Duty Cycle At Amperes 0 Ampere Torch: 0% Duty Cycle At 0 Amperes Ampere Torch: 0% Duty Cycle At Amperes -/ Minutes Cutting -/ Minutes Resting Minutes Cutting Minutes Resting 0 Ampere Torch: 0% Duty Cycle At 0 Amperes 00 Ampere Torch: 80% Duty Cycle At 00 Amperes 80 Ampere Torch: 0% Duty Cycle At 80 Amperes Minutes Cutting Minutes Resting 8 Minutes Welding Minutes Resting rduty* /9 OM-9 Page

3 . Installing Ampere Torch And Work Cable, And Using Trigger Safety Lock If torch or work cable needs to be removed or replaced, proceed as follows:! Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. 8 Torch Connections Remove existing torch cable from unit. Strain Relief Torch Cable Insert cable through strain relief. Slide strain relief nut onto torch cable, but do not tighten. Air Line Connector Install air line connector onto compressor fitting. Plug PLG/Receptacle RC Connect PLG to receptacle RC on circuit board PC. Female And Male Friction Terminal RC/ELECT WHITE Connect female friction terminal on end of white leads to RC/ELECT WHITE. Female And Male Friction Terminal RC/PILOT RED Connect female friction terminal on end red leads to RC/PILOT RED. Tighten strain relief nut. Tighten strain relief around cable. Work Cable Connections Remove existing work cable from unit. Strain Relief Be sure to allow some work cable slack inside the unit. Insert work clamp lead through strain relief, and install strain relief into front panel. 8 Work Lead Male Friction Terminal 8 Connect work clamp lead to male friction terminal labeled WORK LEAD on circuit board PC. Route lead along torch lead bundle. 9 Trigger 9 Tools Needed: Trigger Locked Trigger Unlocked /8 in Ref B / Ref. 80 / / 80 -A OM-9 Page

4 . Installing Ampere Torch And Work Cable! Turn Off power source, and disconnect input power plug from receptacle before installing torch and work cable. Remove top and screws holding front panel in place. Without disconnecting any plugs, move front panel to allow access Torch Connections Strain Relief Clamp Torch Cable Insert cable through strain relief clamp. Gas Connector Gas Valve Install gas connector onto gas valve. Plug PLG8 Safety Control Board PC 0 Receptacle RC8 Connect PLG8 to RC8. Route leads along existing lead bundle. 8 Female Friction Terminals 9 Male Friction Terminal 0 Power Control Board PC Receptacle RC Connect female terminals to leads and from RC (connect to either lead). Connect male terminal to lead from RC. Route leads as shown. Work Cable Connections Strain Relief Clamp Insert work clamp lead through strain relief clamp. Receptacle RC Connect work clamp lead to lead 0 from RC (leads not shown). Route leads along existing lead bundle. Tools Needed: /8 in 80 / Ref B OM-9 Page

5 . Installing Ampere (ICE-C) Torch And Work Cable, And Using Trigger Safety Lock If torch or work cable needs to be removed or replaced, proceed as follows: 8! Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. Torch Connections Remove existing torch cable from unit. Strain Relief Torch Cable Insert cable through strain relief. Slide strain relief nut onto torch cable, but do not tighten. Air Line Connector Insert air line connector into solenoid fitting. Plug PLG/Receptacle RC Connect PLG from torch to receptacle RC on end of wiring harness connected to circuit board PC. Ring Terminal And Terminal PILOT Connect ring terminal on end of red leads to PILOT terminal. Ring Terminal And Terminal L RED Connect ring terminal on end of white leads to L RED terminal. Tighten strain relief nut. Tighten strain relief around cable. Work Cable Connections Remove existing work cable from unit. Strain Relief Be sure to allow some work cable slack inside the unit. Insert work clamp lead through strain relief, and install strain relief into front panel. 8 8 Work Lead Ring Terminal Connect ring terminal on end of work clamp lead to terminal labeled WORK on circuit board PC. Route lead along torch lead bundle. 9 Trigger 9 Tools Needed: Trigger Locked Trigger Unlocked / in Ref / Ref / 00 -A / 80 8 OM-9 Page

6 . Installing Ampere (ICE-T) Torch And Work Cable, And Using Trigger Safety Lock! Check DC bus voltage according to Owner s Manual, and be sure voltage is near zero before touching any parts. 8 If torch or work cable needs to be removed or replaced, proceed as follows: Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit (see Owner s Manual). Torch Connections Remove existing torch cable from unit. Strain Relief Loosen strain relief screw. Torch Cable Insert cable through strain relief, but do not tighten. Air Line Connector Insert air line connector into solenoid fitting. Pull slightly on torch to set fitting. Plug PLG/Receptacle RC Connect PLG from torch to receptacle RC on end of wiring harness connected to circuit board PC. Ring Terminal And TORCH WHITE Terminal Connect ring terminal on end of white leads to TORCH WHITE terminal. Ring Terminal And TORCH RED Terminal Connect ring terminal on end of red leads to TORCH RED terminal. Tighten strain relief screw. Work Cable Connections Remove existing work cable from unit. Strain Relief Loosen strain relief screw. Be sure to allow some work cable slack inside the unit. 9 Insert work clamp lead through strain relief, but do not tighten. 8 Work Lead Ring Terminal And WORK BLACK Terminal Trigger Locked Trigger Unlocked Connect ring terminal on end of work clamp lead to terminal labeled WORK BLACK terminal. Route lead along torch lead bundle. Tighten strain relief screw. Reinstall wrapper. Tools Needed: 9 Trigger Torx / in Ref A / Ref / 80 8 OM-9 Page

7 8. Installing 0 Ampere Torch And Work Cable 8 If torch or work cable needs to be removed or replaced, proceed as follows:! Turn power Off, and disconnect input power plug from receptacle. Remove wrapper from unit. Torch Replacement Strain Relief Torch Cable Loosen outer strain relief pigtail so that torch cable can slide freely. Plug PLG/Receptacle RC Disconnect PLG from receptacle RC on Control board PC. Plug PLG/Receptacle RC Disconnect PLG from receptacle RC on Control board PC. Air Line Connector Push orange fitting inward toward air solenoid while pulling connector out of fitting. Remove nut, located inside of unit, from back of strain relief. Slide torch cable, connector, and plugs through nut and out of unit. Retain nut for use on replacement strain relief. Insert replacement cable with strain relief through opening where old cable and strain relief were removed. Slide strain relief nut over plugs, connector, and cable. Install nut onto strain relief, but do not tighten. Insert air line connector into solenoid fitting. Connect PLG to RC on Control board PC. Connect PLG to RC on Control board PC. Tighten strain relief nut. Tighten strain relief around cable. Work Cable Replacement Rubber Boot Work Cable Ring Terminal Slide rubber boot away from ring terminal connection on Control board PC. Remove hardware securing ring terminal to PC. 8 Strain Relief Remove nut, located inside of unit, from back of strain relief. Slide work cable through nut and out of unit. Retain nut for use on replacement strain relief. Slide rubber boot over ring terminal and off of work cable. Retain rubber boot for use on replacement work cable. Be sure to allow some work cable slack inside the unit. Insert replacement cable with strain relief through opening where old cable and strain relief were removed. Slide strain relief nut over ring terminal and cable. Install nut onto strain relief, but do not tighten. Route cable along bottom of unit and up to PC. Slide rubber boot over ring terminal and onto work clamp lead. Connect work cable ring terminal to terminal labeled WORK on circuit board PC. Torque to in lb ( N m). Slide boot over connection. Tighten strain relief nut. Tighten strain relief around cable. Tools Needed: /, /8 in 80 8 / 80 8 OM-9 Page

8 9. Installing 0 Ampere, Ampere or 80 Ampere Torch And Using Trigger Safety Lock The 0 ampere torch is shown in the illustrations below. The procedure for the ampere and 80 ampere torches is identical. The ampere torch can be used on a 0 ampere model power source. The 0 ampere torch cannot be used on a ampere model power source. The ampere power source has a special torch connection receptacle that prevents the 0 ampere torch from being connected.! Turn Off power source, and disconnect input power plug from receptacle before installing torch. Power Source Torch Connection Receptacle Plug Threaded Collar Keyway To connect to receptacle, align keyway, insert plug, and tighten threaded collar. Trigger NOTICE Be sure plug is correctly aligned before tightening collar to avoid cross-threading. Trigger Locked Trigger Unlocked 80 9-A / 80 -A OM-9 Page 8

9 0. Installing Either 80 Ampere Or 00 Ampere T/TM Torch! Turn off power source and disconnect input power. Torch Connector Quick Connect Collar Nipple Receptacle Securing Pin To connect torch: Push torch connector onto receptacle and quick connect until collar secures nipple. Rotate securing pin to lock connector to unit. To disconnect torch: Rotate securing pin to unlock connector from unit. Push quick connect collar back towards unit to release nipple, and pull torch connector away from unit A OM-9 Page 9

10 . Sequence Of Operation For Ampere Torch EXAMPLE Of Cutting Operation Moisture from the compressor will form in the air line and at the torch. It will be normal to sometimes see moisture come out the end of the torch.! The pilot arc starts immediately when trigger is pressed. For shielded cutting, place drag shield on edge of metal. For non-shielded cutting (non-ce only), use /8 in (. mm) standoff distance (dragging tip will reduce tip life). Raise trigger lock and press trigger. Pilot arc starts. After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and out bottom of cut. Pause briefly at end of cut before releasing trigger. Postflow continues for approx. seconds after releasing trigger; cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger A OM-9 Page 0

11 . Sequence Of Operation For Ampere Torch EXAMPLE Of Cutting Operation! The pilot arc starts immediately when trigger is pressed. Place tip on work for drag cutting. For maximum cutting speed and tip life, use a standoff distance of / in (. mm) to /8 in (. mm). Dragging tip will reduce tip life. Raise trigger lock and press trigger. Pilot arc starts. After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and out bottom of cut. Pause briefly at end of cut before releasing trigger. Postflow continues for 0 seconds after releasing trigger; cutting arc can be instantly restarted during postflow by raising trigger lock and pressing trigger. Ref OM-9 Page

12 . Sequence Of Operation For, 0, 0,, 80, And 00 Ampere Torches! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced (see Section ). Do not operate torch without a tip or electrode in place. NOTICE Do not clean torch by hitting it against a hard surface. Hitting hard surfaces can damage torch parts and stop proper operation. NOTICE Having pilot arc turn On and Off repeatedly, such as during the cutting of chain fence, will shorten tip, electrode and torch life. Put a continuous piece of sheet metal under the fence to prevent pilot arc from cycling On and Off. Avoid constant starting and restarting of arc. Install & Connect Equipment Put On Personal Safety Equipment Check Torch Tip, Electrode, And Retaining Cup Check Gas/Air Pressure Set Controls Turn On Power Source Begin Cutting EXAMPLE Of Cutting Operation! The pilot arc starts immediately when trigger is pressed. For ampere torch, place tip on edge of metal. For 0, 0, 80 and 00 ampere hand-held torches, place drag shield on edge of metal, or allow correct standoff distance approximately /8 in (. mm). Press trigger. Pilot arc starts. After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and out bottom of cut. Pause briefly at end of cut before releasing trigger. Postflow continues for approx. 0 to 0 seconds after releasing trigger; cutting arc can be instantly restarted during postflow by pressing trigger. 98-A OM-9 Page

13 . Routine Maintenance! Turn Off power source and disconnect input power plug before maintaining. ampere torch is shown. Maintenance schedule for 0 and 80 ampere torches is the same. = Check = Change = Clean = Replace * To be done by Factory Authorized Service Agent Reference Each Use Check Gas/Air Pressure Torch Tip, Electrode, And Shield Cup Every Week Shield Cup Shutdown System Every Months Cracked s Gas/Air Hose Torch Body, Cable Tape Torn Outer Covering. Shield Cup Shutdown System Power source Power switch must be reset whenever cup shutdown system is activated. Always turn Off power source when changing or checking consumables. Torch Shield Cup Turn Power On and loosen shield cup. If shutdown system works properly, Ready light on power source goes off and Cup light comes on. If not, turn power Off and check for proper gas/air pressure, blocked or leaking hose, or loose shield cup. If system works properly, retighten cup and reset power. Procedure applies to all torch models. Ref A / Ref A OM-9 Page

14 . Checking/Replacing Retaining Cup, Tip, And Electrode For And Ampere Torch! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE 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. A good practice is to replace both the tip and electrode at the same time.! Turn Off power source before checking torch parts. Make sure this area is clean of any debris. 8 Make sure swirl ring is clean of any debris and no holes are obstructed. New *Pit Depth New Worn */ in ( mm) / in ( mm) maximum pit depth depending on acceptable cut quality. Worn 80 Turn Off power source. Shield Cup O-Ring Remove shield cup. Check cup for cracks, and replace if necessary. Check O-ring for cracks or worn spots, replace shield cup if necessary. Tip Opening Remove tip. Check tip, and replace if opening is deformed or 0% oversize. If inside of tip is not clean and bright, clean with steel wool. Be sure to remove any pieces of steel wool afterwards. Electrode Check electrode. If center has a pit more than a / in ( mm) deep, remove and replace electrode. Swirl Ring O-Ring Remove swirl ring. Check ring, and replace if side holes are plugged. Check O-ring for cracks or worn spots, replace swirl ring if necessary. 8 O-Ring Check O-ring for cracks or worn spots, and replace if necessary. Carefully reassemble parts in reverse order. OM-9 Page

15 . Checking/Replacing Retaining Cup, Tip, And Electrode For, 0, 0, And Ampere Torches! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. A good practice is to replace both the tip and electrode at the same time.! Turn Off power source before checking torch parts. Ampere Model 0 Ampere and Ampere Models 8 Make sure this area is clean of any debris. 8 New *Pit Depth The word front on swirl ring must face away from torch body. Make sure swirl ring is clean of any debris and no holes are obstructed. New Worn *Pit Depth Worn */ in ( mm) / in ( mm) maximum pit depth depending on acceptable cut quality. New New Worn Worn Ref / 80 9 / Ref A / 80 0 Turn Off power source. Drag Shield Retaining Cup Remove retaining cup. Check retaining cup for cracks, and replace if necessary. Tip Opening Remove tip. Check tip, and replace if opening is deformed or 0% oversize. If inside of tip is not clean and bright, clean with steel wool. Be sure to remove any pieces of steel wool afterwards. Electrode Check electrode. If center has a pit more than a / in ( mm) deep, remove and replace electrode. Swirl Ring Remove swirl ring. Check ring, and replace if side holes are plugged. O-Ring Check O-rings on torch. If needed, coat with thin film of silicone lubricant (part no. 9 ). Replace if damaged. 8 Plunger Area Check this area for any debris or foreign material. Clean out if necessary. Carefully reassemble parts in reverse order. For the ampere model, swirl ring must be installed with word front facing away from torch body. OM-9 Page

16 8. Checking/Replacing Retaining Cup, Tip, And Electrode For 80 Ampere (C/CM) Torch! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. A good practice is to replace both the tip and electrode at the same time.! Turn Off power source before checking torch parts. 80 ampere model requires electrode wrench Make sure this area is clean of any debris. */ in ( mm) / in ( mm) maximum pit depth depending on acceptable cut quality. New *Pit Depth Make sure swirl ring is clean of any debris and no holes are obstructed. Worn New Worn 80 -A Turn Off power source. Drag Shield Retaining Cup Remove retaining cup. Check retaining cup for cracks, and replace if necessary. Tip Opening Remove tip. Check tip, and replace if opening is deformed or 0% oversize. If inside of tip is not clean and bright, clean with steel wool. Be sure to remove any pieces of steel wool afterwards. Electrode Check electrode. If center has a pit more than a / in ( mm) deep, remove and replace electrode. Swirl Ring Remove swirl ring. Check ring, and replace if side holes are plugged. O-Ring Check O-rings on torch. If needed, coat with thin film of silicone lubricant (part no. 9 ). Replace if damaged. 8 Torch Head Check this area for any debris or foreign material. Clean out if necessary. Carefully reassemble parts in reverse order. OM-9 Page

17 9. Checking/Replacing Retaining Cup, Tip, And Electrode For 80 Ampere (CX/CXM/ T/TM, And 00 T/TM) Torch! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. A good practice is to replace both the tip and electrode at the same time.! Turn Off power source before checking torch parts. / in ( mm) Pit Worn New Make sure this area is clean of any debris. Worn 8 New Make sure this area is clean of any debris A Turn Off power source. Drag Shield Check this area for any debris or foreign material. Clean out if necessary. Retaining Cup Remove retaining cup. Check retaining cup for cracks, and replace if necessary. Tip Opening Remove tip. Check tip, and replace if opening is deformed or 0% oversize. If inside of tip is not clean and bright, clean with steel wool. Be sure to remove any pieces of steel wool afterwards. Electrode Check electrode. If center has a pit more than a / in ( mm) deep, remove and replace electrode. Swirl Ring Remove swirl ring. Check ring, and replace if side holes are plugged. O-Ring Check O-rings on torch. If needed, coat with thin film of silicone lubricant (part no. 9 ). Replace if damaged. 8 Plunger Area Check this area for any debris or foreign material. Clean out if necessary. Carefully reassemble parts in reverse order. OM-9 Page

18 0. Troubleshooting For Ampere Torch Does arc go on and off while cutting? Yes Torch travel speed too slow; increase travel speed (see Power Source Owner s Manual). Clean or replace torch consumables as necessary (see Section ). Be sure work clamp is securely attached to workpiece. See Power Source Owner s Manual. No Does arc go out while cutting? Yes Be sure work clamp is securely attached to workpiece. Make sure drag shield contacts metal while cutting. Clean or replace torch consumables as necessary (see Section ). See Power Source Owner s Manual. No Do sparks come out of top of cut; or cut is not clean? No Yes Torch travel speed too fast; reduce travel speed (see Power Source Owner s Manual). Clean or replace torch consumables as necessary (see Section ). Be sure work clamp is securely attached to workpiece. Unit not capable of cutting metals thicker than rating (see Section ). Is Trouble light On; unit has no cutting output? Yes Check torch shield cup (see Section ); reset unit Power switch. *Check torch and connections inside unit. See Power Source Owner s Manual. No See Power Source Owner s Manual. *Servicing procedure to be performed only by authorized Service Station. OM-9 Page 8

19 . Troubleshooting For,, 0, 0,, 80, And 00 Ampere Torches Trouble Power source Cup trouble light On; no cutting output. Remedy Tighten cup onto torch and reset Power (see Section ). Check torch connections on power source. See power source Owner s Manual. Sparks come out top of cut, or cut is not clean. Torch travel speed too fast; reduce travel speed (see Section ). Clean or replace worn consumables as necessary (see Section ). Metal being cut is too thick; increase output control setting. See power source Owner s Manual. Be sure work clamp is securely attached. See power source Owner s Manual. Arc goes out while cutting. Make sure torch tip is contacting metal while cutting. Be sure work clamp is securely attached. See power source Owner s Manual. Clean or replace worn consumables as necessary (see Section ). Arc goes on and off while cutting. Torch travel speed is too slow; increase travel speed (see Section ). Clean or replace worn consumables as necessary (see Section ). Be sure work clamp is securely attached. See power source Owner s Manual. OM-9 Page 9

20 . s Lists Item 8 Handle Assy, left and right w/screws () 8 Pushbutton Switch () 9 9 Leads, 0ft () 9 90 Label, ICE-C () 9 9 Main Body () 8 8 Switch Assy w/spring () 90 0 Spring, trigger assy () 9 Grease, silicone () 9 9 Torch, replacement 0ft () See Figure - for additional consumable parts. Figure -. Torch, ICE-C Drag Shield 999 Retaining Cup 9 Tip 99 Electrode 99 Swirl Ring 99 O Ring 99 Apply silicone grease(9) before installing. Retaining Cup 998 /8 (mm) stand off recommended ICE C CONSUMABLES CAUTION FAILURE TO RE PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation OM-9 Page 0 Figure -. Consumable s For ICE-C

21 Item 8 8 Handle Assy, complete () 89 Leads, ft () 89 Leads, ft () 8 0 Main Body () 8 Push Button Switch () 9 Grease, silicone () 9 00 Torch, replacement 0ft () See Figure - for additional consumable parts. Ref B Figure -. Torch, ICE-C O-ring 9 Electrode Swirl Ring 0809 Retaining Cup 0808 Tip Ref. 8 Figure -. Consumable s For ICE-C OM-9 Page

22 Item 8 Handle Assy, complete () 8 Push Button Switch () 0 88 Leads, 0ft () 0 9 Main Body () 8 8 Switch Assembly w/spring () 90 0 Spring, trigger assembly 9 Grease, silicone () 9 00 Torch, replacement 0ft () See Figure - for additional consumable parts. Ref B Figure -. Torch, ICE-CX ICE-CX Consumables Ref A Figure -. Consumable s For ICE-CX OM-9 Page

23 Item 8 Handle Assy, complete () 8 Push Button Switch () 0 0 Leads, 0ft () 0 9 Main Body () 8 8 Switch Assembly w/spring () 90 0 Spring, trigger assembly 9 Grease, silicone () 9 0 Torch, replacement 0ft () See Figure -8 for additional consumable parts. Figure -. Torch, ICE-C 0 08-A Figure -8. Consumable s For ICE-C OM-9 Page

24 Item 8 Handle Assy, complete () 8 Push Button Switch () 8 0 Leads, ft () 0 9 Main Body () 8 8 Switch Assembly w/spring () 90 0 Spring, trigger assembly 9 Grease, silicone () Torch, replacement ft () See -0 for additional consumable parts. Figure -9. Torch, ICE-T Retaining Cup Tip Electrode Swirl Ring O Ring 9 Drag Shield Retain Cup, Drag Shield Tip, Drag Shield ICE C/T CONSUMABLES CAUTION FAILURE TO RE PLACE WORN TIP OR ELECTRODE WILL DAMAGE TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation. 8 9 A 8 9-A OM-9 Page Figure -0. Consumable s For ICE-C/T

25 Item 9 0 ICE-0C ft Torch 9 ICE-0C 0ft Torch 8 Handle Assy, complete () 9 09 Main Body () Leads, ft () Leads, 0ft () 8 8 Switch Assembly w/spring () 90 0 Spring, trigger assembly 8 Push Button Switch () 9 Grease, silicone () See Figure - for additional consumable parts. Ref Figure -. Torch, ICE-0C For extended tip use, set Amperage control to. Drag Shield 0 Retaining Cup 9 00 Tip 0 Electrode 9 0 Swirl Ring 9 09 O Ring 9 Deflector 888 Shield 9 0 Retaining Cup 9 00 Retaining Cup 9 00 A Tip 9 0 Tip 0 Electrode 9 08 Electrode 9 0 Standard Cutting Extended Cutting Gouging Apply silicone grease (9 ) before installing. /8 (mm) stand off recommended CAUTION NOTE: Set air pressure to PSI for cutting or PSI for gouging. ICE 0C CONSUMABLES FAIL URE TO RE PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation. 0 8 A 0 8-A Figure -. Consumable s For ICE-0C OM-9 Page

26 Item 8 Handle Assy, complete () 8 Push Button Switch () 9 89 Leads, ft () 9 80 Leads, 0ft () 88 9 Main Body () 8 8 Switch Assembly w/spring () 90 0 Spring, trigger assembly 9 Grease, silicone () 8 Torch, replacement ft () 8 Torch, replacement 0ft () See Figure - for additional consumable parts. Figure -. Torch, ICE-0C Ref. S-80 8-C OM-9 Page Figure -. Consumable s For ICE-0C And 0CM

27 Item 9 00 Cup, shield () 9 O-Ring, A () 80 Main Body () 80 0 Position Sleeve () 80 Leads, 0ft () 80 0 Remote Pendent Control () 80 Torch Sleeve () Shield, machine () 9 Grease, silicone () 88 Torch, replacement 0ft () See Figure - for additional consumable parts. 8 Figure -. Torch, ICE-0CM OM-9 Page

28 Item 8 Handle Assy, complete () 8 Push Button Switch () 9 0 Leads, ft () 9 0 Leads, 0ft () 9 09 Main Body () 0 9 Plunger Kit (for out-of-warranty torches) 8 8 Switch Assembly w/spring () 90 0 Spring, trigger assembly 9 Grease, silicone () 9 Torch, replacement ft () 9 8 Torch, replacement 0ft () See Figure - for additional consumable parts. Figure -. Torch, ICE-C Ref. 9 -A Figure -. Consumable s For ICE-C And CM OM-9 Page 8

29 Item 9 00 Cup, shield () 9 O-Ring, A () 9 00 Main Body () 80 0 Position Sleeve () 9 0 Leads, 0ft () 80 0 Remote Pendent Control () 98 Torch Sleeve () Shield, machine () 9 98 Ring, retaining () 9 Grease, silicone () 9 9 Torch, replacement 0ft () 8 9 See Figure - for additional consumable parts. Figure -8. Torch, ICE-CM OM-9 Page 9

30 Item Item 8 00 Handle () 90 0 Boot () 90 0 # x /8 Philips Screw, pan head () 9 8 Trigger and Switch Replacement Kit () 90 0 spring () 8 0 Switch, cup sensor () 8 98 Main Body () 90 O-Ring, silicon.8 x.00 () 8 9 Torch Lead, ft () 8 9 Torch Lead, 0ft () Plug Assy, quick disconnect () 8 0 O-Ring, quick disconnect () Tubing, /8 in ID (in) () 90 0 Heatshrink / in ID (.in) () 80 Torch, replacement ft () 8 Torch, replacement 0ft () See Figure -0 for additional consumable parts. Older model torches using trigger 8 0 and pushbutton switch 8 should be updated using trigger and switch replacement kit 9 8. Figure -9. Torch, ICE-80C Electrode Wrench Ref. S-88 9-A OM-9 Page 0 Figure -0. Consumable s For ICE-80C And 80CM

31 Item See Figure -0 for additional consumable parts Sleeve, torch position () 9 Torch Lead, 0ft () 90 9 Plug Assy, quick disconnect () 8 0 O-Ring, quick disconnect () Plug, -socket female () 8 99 Main Body () 90 O-Ring, silicon.8 x.00 () Contact, cap-on sensor () Tubing, /8 in ID (in) () Heatshrink / in ID (.in) () 8 Torch, replacement 0ft () 8 8 Figure -. Torch, ICE-80CM OM-9 Page

32 Item Item 9 Handle w/screws () 8 Cup Switch Sensor Kit () 9 Torch Head Repair Kit () 8 8 Switch Assy w/spring () 90 0 Trigger Spring () 9 Switch Trigger () Main Body () 8 09 Torch Lead, ft () Torch Lead, 0ft () 9 0 Clip, retaining () O-Ring, quick disconnect () O-Ring, main body () 8 Plug Assy, quick disconnect () 9 Grease, silicon 00 Torch, replacement ft () 8 0 Torch, replacement 0ft () See Figure - for additional consumable parts. Figure -. Torch, ICE-80CX Standard Cutting Retaining Cup 0A Drag Shield 0 Tip Electrode Swirl Ring O Ring Shield 80A Drag Shield 0 (Machine Cutting) Retaining Cup Tip Apply silicone grease (9 ) before installing. ICE 80CX CONSUMABLES Extended Cutting Retaining Cup 0A Deflector 80A Deflector 80A Shield Retaining Cup Gouging Retaining Cup Tip 9 Tip 8 Tip CAUTION FAILURE TO RE PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation. 8 A 8 -A OM-9 Page Figure -. Consumable s For ICE-80CX

33 Item 0 Sleeve, torch position () 9 9 Torch Lead, 0ft () 8 Plug Assy, quick disconnect () Plug, socket female () 99 Torch Sleeve () 98 Main Body w/switch () 8 0 O-ring, quick disconnect () 9 9 Torch, replacement 0ft () See Figure - for additional consumable parts. Figure -. Torch, ICE-80CXM Item Item 9 Handle w/screws () 8 Cup Switch Sensor Kit () 9 Torch Head Repair Kit () 8 8 Switch Assy w/spring () 90 0 Trigger Spring () 9 Switch Trigger () Main Body () 8 Torch Lead, ft () 8 Torch Lead, 0ft () 9 0 Clip, retaining () 0 O-Ring, main body () 9 Grease, silicon 9 Torch, replacement ft () 9 Torch, replacement 0ft () Wing Head / Turn Fastener () 9 8 See Figure - for additional consumable parts A Figure -. Torch, ICE-80T OM-9 Page

34 Standard Cutting Retaining Cup 80A Drag Shield 0 Tip Electrode Swirl Ring O Ring Shield 0A Drag Shield 0 (Machine Cutting) Retaining Cup Tip Apply silicone grease (9 ) before installing. ICE 80T CONSUMABLES Extended Cutting Retaining Cup 80A Deflector 0A Deflector 80A Shield Retaining Cup Gouging Retaining Cup Tip 8 Tip 9 Tip CAUTION FAILURE TO RE PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation. 0 B 0-B Figure -. Consumable s For ICE-80T Item See Figure - for additional consumable parts. 0 Sleeve, torch position () Torch Lead, ft () Torch Lead, 0ft () 99 Torch Sleeve () 98 Main Body () 9 Remote Pendant Control () 9 Torch, replacement ft () Torch, replacement 0ft () 0 0 Cable, remote control trigger ft () 0 Cable, remote voltage sense.ft () Wing Head / Turn Fastener () 8 Cup Switch Sensor Kit () 80 0-A OM-9 Page Figure -. Torch, ICE-80TM

35 Item Item 9 Handle w/screws () 8 Cup Switch Sensor Kit () Torch Head Repair Kit () 8 8 Switch Assy w/spring () 90 0 Trigger Spring () 9 Switch Trigger () Main Body () 8 Torch Lead, ft () 8 Torch Lead, 0ft () 9 0 Clip, retaining () 0 O-Ring, main body () 9 Grease, silicon 0 Torch, replacement ft () 0 Torch, replacement 0ft () Wing Head / Turn Fastener () 9 8 See - for additional consumable parts A Figure -8. Torch, ICE-00T OM-9 Page

36 CAUTION 0A Drag Shield 0 Retaining Cap Tip Electrode Swirl Ring FAILURE TO RE PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation. 0A 0 9 O-Ring 80A 0 00A Standard Cutting Shield Retaining Cap Tip Electrode Swirl Ring 0A A O-Ring 00A Gouging Ref. 0-B / Ref A OM-9 Page Figure -9. Consumable s For ICE-00T

37 Shield Sense Tab* Retaining Cap Tip Electrode Swirl Ring CAUTION 0A 0A FAILURE TO RE PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly during operation. 9 80A O-Ring 00A Machine Cutting *Shield sense tab provides feedback to a compatible torch height controller before starting the cutting process. Deflector Retaining Cap Tip Electrode Swirl Ring 0A 9 0A 9 8 O-Ring 80A 8 00A Extended Cutting Ref. 0-B / Ref A Figure -0. Consumable s For ICE-00TM OM-9 Page

38 Item See -0 for additional consumable parts. 0 Sleeve, torch position () Torch Lead, ft () Torch Lead, 0ft () 99 Torch Sleeve () Main Body () 9 Remote Pendant Control () 8 Sup Sensor Switch Kit () 0 Torch, replacement ft () 08 Torch, replacement 0ft () 0 0 Cable, remote control trigger ft () 0 Cable, remote voltage sense.ft () Wing Head / Turn Fastener () 80 0-A Figure -. Torch, ICE-00TM OM-9 Page 8