Miller Electric 1251, ICE-100T manual Exploding Parts can injure, Flying Sparks can cause injury

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EXPLODING PARTS can injure.

DOn inverter power sources, failed parts can ex- plode or cause other parts to explode when

power is applied. Always wear a face shield and long sleeves when servicing inverters.

FLYING SPARKS can cause injury.

Sparks and hot metal blow out from the cutting arc.

Chipping and grinding cause flying metal.

DWear approved face shield or safety goggles with side shields.

DWear proper body protection to protect skin.

DWear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears.

ARC RAYS can burn eyes and skin.

Arc rays from the cutting process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

DWear face protection (helmet or shield) with a proper shade of filter lenses to protect your face and eyes when cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a No. 9 shade (with No. 8 as minimum) for all cutting currents less than 300 amperes. Z49.1 adds that lighter filter shades may be used when the arc is hidden by the workpiece. As this is normally the case with low current cutting, the shades suggested in Table 1 are provided for the operator’s conve- nience.

DWear approved safety glasses with side shields under your helmet or shield.

DUse protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.

DWear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes

Minimum Shade Number

Below 20

#4

20 − 40

#5

40 − 60

#6

60 − 80

#8

NOISE can damage hearing.

Prolonged noise from some cutting applications can damage hearing if levels exceed limits specified by OSHA (see Safety Standards).

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

DWarn others nearby about noise hazard.

FUMES AND GASES can be hazardous.

Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

DKeep your head out of the fumes. Do not breathe the fumes.

DIf inside, ventilate the area and/or use local forced ventilation at the arc to remove cutting fumes and gases.

DIf ventilation is poor, wear an approved air-supplied respirator.

DRead and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals to be cut, coatings, and cleaners.

DWork in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Fumes from cutting and oxygen depletion can alter air quality causing injury or death. Be sure the breathing air is safe.

DDo not cut in locations near degreasing, cleaning, or spraying oper- ations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

DDo not cut on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the cutting area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes when cut.

DDo not cut containers with toxic or reactive materials inside or containers that have held toxic or reactive materials − they must be emptied and properly cleaned first.

PLASMA ARC can cause injury.

The heat from the plasma arc can cause serious burns. The force of the arc adds greatly to the burn hazard. The intensely hot and powerful arc can quickly cut through gloves and tissue.

DKeep away from the torch tip.

DDo not grip material near the cutting path.

DThe pilot arc can cause burns − keep away from torch tip when trig- ger is pressed.

DWear proper flame-retardant clothing covering all exposed body ar- eas.

DPoint torch away from your body and toward work when pressing the torch trigger − pilot arc comes on immediately.

DTurn off power source and disconnect input power before disas- sembling torch or changing torch parts.

DUse only torch(es) specified in the Owner’s Manual.

CYLINDERS can explode if damaged.

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylin- ders are normally part of metalworking processes, be sure to treat them carefully.

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

DInstall and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

DKeep cylinders away from any cutting or other electrical circuits.

DNever allow electrical contact between a plasma arc torch and a cylinder.

DNever cut on a pressurized cylinder − explosion will result.

DUse only correct gas cylinders, regulators, hoses, and fittings de- signed for the specific application; maintain them and associated parts in good condition.

DTurn face away from valve outlet when opening cylinder valve.

DKeep protective cap in place over valve except when cylinder is in use or connected for use.

DUse the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.

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

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Contents Description OM-201 872DProcesses File Plasma CuttersFrom Miller to You Table of Contents − Maintenance & Troubleshooting Plasma Arc Cutting Hazards Symbol UsageMarks a special safety message Cutting can cause fire or explosionARC Rays can burn eyes and skin Exploding Parts can injureFlying Sparks can cause injury Noise can damage hearingCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort Signification des symbolesLE Coupage présente un risque de feu ou d’explosion Identifie un message de sécurité particulierLES Fumées ET LES GAZ peuvent être dangereux Risque de blessure en casLE Bruit peut endommager l’ouïe LE Plasma D’ARC peut entraîner des blessuresLA Chute DE L’APPAREIL peut blesser DES Pieces Chaudes peuvent pro- voquer des brûlures gravesDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OULE Coupage à L’ARC peut causer des interférence Principales normes de sécuritéInformation sur les champs électromagnétiques Consignes relatives aux stimulateurs cardiaquesI1max Symbols And Definitions− Definitions 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 TorchHz Three Phase Electrical Service GuideHz Three Phase Input Voltage 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 Setting Gas/Air PressureTrigger Safety Lock 90-120 psiMaintain approximately a 90 angle to Pilot arc starts immediately when trigger is pressedPlasma Cutting System Practices 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 Compartment− Mechanized Operation Remote Control ReceptacleRemote Control Cable Functions ICE-100TM Mounting Position+24 Volts DC Hot Contacts For Relay Operation Turn off and disconnect input powerRemote Control Cable Okay To Move 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 Mild Steel Cut ChartsAmp Machine Torch Shielded Consumables Stainless388 486 140089 105 12.7 524 991353 15,926 502 12,751706 600464 16,256 221835 15,037 335Amp Machine Torch Extended Consumables Deflector Retaining Cap Tip Electrode Swirl RingArc Voltage 140 556 120 160 064 10612.7 397 863 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 RemedyArc goes on and off while cutting Troubleshooting TorchClean Arc goes out while cutting− Electrical Diagram Circuit Diagram For Power Source201 858-A Recommended Spare Parts − Parts ListRecommended Spare Parts 215 606 Clip, retaining60A Drag Shield40A RingShield Sense Tab* Retaining Cap Tip Electrode 80A RingDeflector Retaining Cap Tip 804 036-A Page Service Your distributor also givesSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s

ICE-100T, 1251, ICE-100TM specifications

Miller Electric has long been a trusted name in the welding industry, and their range of inverter-powered welding machines continues to set benchmarks for performance and reliability. Among their most notable offerings are the ICE-100TM, 1251, and ICE-100T models, which have been engineered to meet the demands of both professional and DIY welders.

The ICE-100TM is particularly celebrated for its cutting-edge technology that maximizes efficiency and versatility. This machine features an advanced inverter design that allows for a compact form factor while maintaining high output performance. The ICE-100TM is capable of both MIG and TIG welding, making it a dual-purpose device that can handle a variety of materials, including steel, aluminum, and stainless steel. With precise control over heat input and an adjustable arc, welders can easily tailor their settings for different applications.

The 1251 model builds upon the foundation of the ICE-100TM, introducing a host of enhancements that improve user experience. With a more robust power output, the 1251 can handle thicker materials with ease, while its intuitive interface allows for quick adjustments, ensuring optimal performance in diverse welding conditions. This model also integrates advanced safety features like thermal overload protection, safeguarding both the machine and the user during intensive projects.

The ICE-100T is another standout model, designed for those who prioritize portability without sacrificing power. Weighing significantly less than traditional welding machines, the ICE-100T is engineered for ease of transport and convenience on the job site. Its user-friendly controls make it ideal for welders of all skill levels, while its durable design ensures that it can withstand tough working environments.

All three models incorporate Miller Electric's proprietary Auto-Set technology. This feature automatically regulates parameters such as voltage and wire feed speed based on the material being welded, minimizing the setup time and enhancing overall weld quality.

In terms of characteristics, these machines boast a rugged construction designed for long-lasting performance. Their compact designs coupled with lightweight materials facilitate mobility, making them suitable for fieldwork as well as workshop settings. Additionally, their low energy consumption aligns with modern sustainability practices, making them not only efficient but environmentally friendly.

In summary, the Miller Electric ICE-100TM, 1251, and ICE-100T welding machines represent the forefront of welding technology with their innovative features, adaptability, and reliable performance. These models offer a compelling choice for professional welders and hobbyists alike, ensuring they can tackle a wide range of welding tasks with confidence and efficiency.
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