Miller Electric 1251 manual Plasma Cutting System Practices, Maintain approximately a 90 angle to

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

5-4. Plasma Cutting System Practices

The pilot arc starts immediately when trigger is pressed.

Always connect work clamp to a clean, paint-free location on metal workpiece, as close to cutting area as possible.

90°

.Set correct air pressure for process: 75 PSI (517 kPa) for cutting,

60 PSI (414 kPa) for gouging.

DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle and electrode.

°

Sparks should pass through the workpiece

If sparks flare back from surface, this

Maintain approximately a 90 angle to the

and out the bottom when cutting.

usually is an indication that either travel

workpiece surface for proper cutting results.

 

 

speed is too fast, amperage is set too low,

 

 

or consumables are worn.

 

Wt

 

1/8 in

 

 

(3.2 mm)

 

 

When doing non-shielded cutting, maintain

DO NOT put pressure on shield when

Pulling rather than pushing the torch

approximately 1/8 in standoff between

drag cutting; instead, slide shield along

makes cutting easier. Use a proper guide

electrode and surface.

the surface for proper cutting results.

or template for accurate cutting operations.

 

 

Ref. 803 640-A / 801 400-B / Ref. 802 878

OM-201 872 Page 20

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Contents OM-201 872D ProcessesDescription File Plasma CuttersFrom Miller to You Table of Contents − Maintenance & Troubleshooting Symbol Usage Marks a special safety messagePlasma Arc Cutting Hazards Cutting can cause fire or explosionExploding Parts can injure Flying Sparks can cause injuryARC Rays can burn eyes and skin Noise can damage hearingCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers Signification des symboles LE Coupage présente un risque de feu ou d’explosionUNE Décharge Électrique peut entraîner la mort Identifie un message de sécurité particulierRisque de blessure en cas LE Bruit peut endommager l’ouïeLES Fumées ET LES GAZ peuvent être dangereux LE Plasma D’ARC peut entraîner des blessuresDES Pieces Chaudes peuvent pro- voquer des brûlures graves DES Organes Mobiles peuvent provoquer des blessuresLA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OUPrincipales normes de sécurité Information sur les champs électromagnétiquesLE Coupage à L’ARC peut causer des interférence Consignes relatives aux stimulateurs cardiaquesSymbols And Definitions − DefinitionsI1max I1eff− Installation SpecificationsDuty Cycle and Overheating Cutting SpeedDimensions And Weight Movement Do not move or operate unit where it could tipSelecting a Location Connecting Work Clamp and Gas/Air Supply Connecting And Disconnecting TorchElectrical Service Guide Hz Three Phase Input VoltageHz Three Phase Min Grounding Conductor Size In AWGExtension Cord Data Connecting 3-Phase Input Power = GND/PE Earth GroundThree-Phase Power Connection Reinstall power panelClose panel opening if no connections are made to generator Power Switch OM-201 872 − OperationControls Setting Gas/Air Pressure Trigger Safety LockSetting Gas/Air Pressure 90-120 psiPilot arc starts immediately when trigger is pressed Plasma Cutting System PracticesMaintain approximately a 90 angle to Workpiece surface for proper cutting resultsSequence Of Cutting Operation Sparks go thru metalSet Mode switch to Gouge Sequence Of Gouging OperationHold torch at approximately Angle to workpiece Sequence Of Piercing Operation Consumables Storage CompartmentRemote Control Receptacle Remote Control Cable Functions− Mechanized Operation ICE-100TM Mounting PositionTurn off and disconnect input power Remote Control Cable Okay To Move+24 Volts DC Hot Contacts For Relay Operation White Remote RedStart Black +24 VDC Green RelayRemote Start Output Input power Turn offWhite Red Green Black Remote Control Cable Remote Voltage Sense Connection Shield Sense TabTools Needed 15/16 Cut Charts Amp Machine Torch Shielded ConsumablesMild Steel Stainless486 140 089 105388 12.7 524 99115,926 502 12,751 706353 60016,256 221 835464 15,037 335Amp Machine Torch Extended Consumables Deflector Retaining Cap Tip Electrode Swirl RingArc Voltage 160 064 106 12.7 397 863140 556 120 12.7 032610 15,494 385 114 896214 435 135 057− Maintenance & Troubleshooting Routine MaintenanceTrouble Lights Checking Shield Cup Shutdown SystemTurn Off power source before checking torch parts Checking/Replacing Retaining Cup, Tip, And ElectrodeChecking Or Replacing Filter Element Troubleshooting Power Source Trouble RemedyTroubleshooting Torch CleanArc goes on and off while cutting Arc goes out while cutting− Electrical Diagram Circuit Diagram For Power Source201 858-A − Parts List Recommended Spare PartsRecommended Spare Parts 215 606 Clip, retainingDrag Shield 40A60A RingShield Sense Tab* Retaining Cap Tip Electrode 80A RingDeflector Retaining Cap Tip 804 036-A Page Service Your distributor also givesSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

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