Manual Spectrum 375 CutMate

OM-2229
200 879D
May 2002
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum
375 CutMate
R
And ICE-27C Torch
And Non-CE Models
Visit our website at
www.MillerWelds.com
From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you dont have time to do
it 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 superior
quality. Like you, his customers couldnt afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
Weve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
theres a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Working as hard as you do

every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical

Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog orindividual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
OM-2229
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers lis au coupage larc au plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturers Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Specifications For Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Torch Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Connecting Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Installing Alternative Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System . . . . . . . . . .
5-3. Torch And Work Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Troubleshooting Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
1
1
1
3
4
4
5
5
5
7
8
8
9
9
10
10
11
11
11
12
12
13
14
15
15
16
17
17
18
18
19
20
20
21
22
23
24
25
26
28
Declaration of Conformity for

European Community (CE) Products
NOTE
This information is provided for units with CE certification (see rating label on unit).
Miller Electric Mfg. Co.
Manufacturers Name:
1635 W. Spencer Street

Appleton, WI 54914 USA
Manufacturers Address:
Declares that the product:
SPECTRUM 375 CutMateE
conforms to the following Directives and Standards:

Directives
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1989
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(September 1998 Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Plasma Cutting Systems for Manual Use: EN 50192: 1995
European Contact:
Telephone:
Fax:
dec_con1 1/96
Mr. Danilo Fedolfi, Managing Director

MILLER Europe S.r.l.
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98281-552
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

pom _nd_9/98
1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means Note; not safety related.
This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Plasma Arc Cutting Hazards

Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D
D
D
D
D
D
Y 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, and
hot equipment can cause fires and burns. Check
and be sure the area is safe before doing any cutting.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not cut where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this
is not possible, tightly cover them with approved covers.
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 practical to prevent cutting current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Never cut containers with potentially flammable materials inside
they must be emptied and properly cleaned first.
Do not cut in atmospheres containing explosive dust or vapors.
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.
ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but also uses torches designed with safety
interlock systems which turn off the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. Incorrectly
installed or improperly grounded equipment is a hazard.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
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 or
ground.
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 equipment. Lockout/tagout input power according to OSHA CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to its Owners
Manual and national, state, and local codes.
Check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet always verify
the supply ground.
When making input connections, attach proper grounding conductor first.
Frequently inspect input power cord for damage or bare wiring replace 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 as
practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
ELECTRIC SHOCK can kill.

SIGNIFICANT DC VOLTAGE exists on
internal parts of inverter power
sources AFTER the removal of input
power.
D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Maintenance Section of Owners Manual or Technical Manual before
touching any parts.
OM-2229 Page 1
EXPLODING PARTS can injure.

D On inverter power sources, failed parts can explode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.
D
D
D
D
FLYING SPARKS can cause injury.

D
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
D
D
D
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 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.
D
D
D
D
Wear face protection (helmet or shield) with correct shade of filter 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 operators convenience.
Wear approved safety glasses with side shields under your helmet
or shield.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
PLASMA ARC can cause injury.
D
D
D
D
D
D
D
Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes
Below 20
20 40
40 60
60 80
Minimum Shade Number

#4
#5
#6
#8
Gas cylinders contain gas under high pressure. If

damaged, a cylinder can explode. Since gas cylinders are normally part of metalworking processes,
be sure to treat them carefully.
D
D
D
D
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. Breathing
these fumes and gases can be hazardous to
your health.
D
Keep your head out of the fumes. Do not breathe the fumes.
OM-2229 Page 2
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.
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 trigger is pressed.
Wear proper flame-retardant clothing covering all exposed body areas.
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 disassembling torch or changing torch parts.
Use only torch(es) specified in the Owners Manual.
CYLINDERS can explode if damaged.
NOISE can damage hearing.

Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
If inside, ventilate the area and/or use exhaust at the arc to remove
cutting fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read 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 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.
Do not cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do 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 if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these
elements can give off toxic fumes when cut.
Do 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.
D
D
D
D
D
D
D
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flame, sparks, and arcs.
Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or 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 designed for the specific application; maintain them and associated
parts 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.
Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance

HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on torch.
MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FLYING METAL can injure eyes.

D Wear safety glasses with side shields or face
shield.
MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.
D Wearers should consult their doctor before going near plasma arc cutting operations.
OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.
D Reduce amperage (thickness) or reduce duty
cycle before starting to cut again.
EXPLODING HYDROGEN hazard.

D When cutting aluminum underwater or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the workpiece.
D See your cutting engineer and water table instructions for help.
FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift unit.
FIRE OR EXPLOSION hazard.

D Do not locate unit on, over, or near combustible
surfaces.
D Do not install unit near flammables.
D Do not overload building wiring be sure power supply system is
properly sized, rated, and protected to handle this unit.
STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.

D High frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment
at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC CUTTING can cause interference.

D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D To reduce possible interference, keep cables as short as possible,
close together, and down low, such as on the floor.
D Locate cutting operation 100 meters from any sensitive electronic
equipment.
D Be sure this cutting power source is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures such
as moving the machine, using shielded cables, using line filters, or
shielding the work area.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
OM-2229 Page 3
1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. EMF Information

Considerations About Welding Or Cutting And The Effects Of Low
Frequency Electric And Magnetic Fields
Welding or cutting current, as it flows through the welding or cutting
cables, will cause electromagnetic fields. There has been and still is
some concern about such fields. However, after examining more than
500 studies spanning 17 years of research, a special blue ribbon
committee of the National Research Council concluded that: The body
of evidence, in the committees judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a humanhealth hazard. However, studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic
fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
OM-2229 Page 4
1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep cutting power source and cables as far away from operator
as practical.
5. Connect work clamp to workpiece as close to the cut as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

pom_nd_fre_9/98
1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procdure
prsente des risques de danger ! Ceux-ci sont identifis
par des symboles adjacents aux directives.
Y Identifie un message de scurit particulier.
. Signifie NOTA ; nest pas relatif la scurit.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger relis aux CHOCS LECTRIQUES, aux PICES EN MOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connatre les mesures prendre pour viter tout danger.
1-2. Dangers lis au coupage larc au plasma

Y Les symboles prsents ci-aprs sont utiliss tout au long du
prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnes afin dviter tout
danger. Les consignes de scurit prsentes ci-aprs ne font
que rsumer linformation contenue dans les normes de scurit numres la section 1-5. Veuillez lire et respecter toutes
ces normes de scurit.
Y Linstallation, lutilisation, lentretien et les rparations ne
doivent tre confis qu des personnes qualifies.
Y Au cours de lutilisation, tenir toute personne lcart et plus
particulirement les enfants.
LE COUPAGE prsente un risque de

feu ou dexplosion.
Des particules de mtal chaud et des tincelles
peuvent jaillir de la pice au moment du coupage.
Les tincelles et le mtal chaud, la pice couper
chauffe et lquipement chaud peuvcnt causer un
feu ou des brlures. Avant de commencer travailler, assurezvous
que lendroit est scuritaire.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Protgezvous, ainsi que toute autre personne travaillant sur les

lieux, contre les tincelles et le mtal chaud.
Ne coupez pas dans un endroit o des tincelles pourraient atteindre des matires inflammables.
Dplacez toute matire inflammable se trouvant lintrieur dun
primtre de 10,7 m (35 pi) de la pice couper. Si cela est impossible, vous devez les couvrir avec des housses approuves et bien
ajustes.
Assurezvous quaucune tincelle ni particule de mtal ne peut se
glisser dans de petites fissures ou tomber dans dautres pices.
Afin dliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur la porte de la main.
Si vous coupez sur un plafond, un plancher ou une cloison, soyez
conscient que cela peut entraner un feu de lautre ct.
Ne coupez pas sur un contenant ferm tel quun rservoir ou un bidon.
Fixez le cble de masse sur la pice couper, le plus prs possible
de la zone couper afin de prvenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une dcharge lectrique ou un feu.
Ne coupez jamais des contenants qui peuvent contenir des matires inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.
Ne coupez pas dans un endroit o latmosphre risque de contenir
de la poussire ou des vapeurs explosives.
Ne coupez pas de bouteilles, de tuyaux ou de contenants pressuriss.
Ne coupez pas de contenants qui ont dj reu des combustibles.
Portez des vtements de protection exempts dhuile tels que des
gants en cuir, une veste rsistante, des pantalons sans revers, des
bottes et un casque.
Ne placez pas le poste sur une surface combustible ou audessus
de celleci.
Avant le coupage, retirez tout combustible de vos poches, par
exemple un briquet au butane ou des allumettes.
UNE DCHARGE LECTRIQUE peut

entraner la mort.
Le fait de toucher une pice lectrique sous
tension peut donner une dcharge fatale ou entraner des brlures graves. Le chalumeau et le circuit
de masse sont automatiquement actifs lorsque le
poste est sous tension. Lalimentation dentre et les circuits internes
de lappareil le sont galement. Le coupage au plasma darc exige des
tensions plus leves que le soudage pour amorcer et maintenir larc
(souvent de 200 400 V CC), cest pourquoi on fait appel des
chalumeaux conus avec un systme de verrouillage scuritaire qui
met lappareil hors tension lorsque la capsule antifeu est desserre
ou si le tube touche llectrode lintrieur de la buse. Un poste
incorrectement install ou inadquatement mis la terre constitue un
danger.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Ne touchez pas aux pices lectriques sous tension.

Portez des gants isolants et des vtements de protection secs et
sans trous.
Isolezvous de la pice couper et du sol en utilisant des housses
ou des tapis assez grands afin dviter tout contact physique avec
la pice couper ou le sol.
Ne touchez pas aux pices du chalumeau si vous tes en contact
avec la pice couper ou le sol.
Mettez lappareil hors tension avant deffectuer la vrification, le
nettoyage ou le changement dune pice du chalumeau.
Coupez lalimentation dentre avant dinstaller lappareil ou deffectuer lentretien. Verrouillez ou tiquetez la sortie dalimentation
selon la norme OSHA 29 CFR 1910.147 (reportezvous aux Principales normes de scurit).
Installez le poste correctement et mettezle la terre convenablement selon les consignes du manuel de loprateur et les normes
nationales, provinciales et locales.
Assurezvous que le fil de terre du cordon dalimentation est correctement reli la borne de terre dans la bote de coupure ou que
la fiche du cordon est branche une prise correctement mise la
terre vous devez toujours vrifier la mise la terre.
Avant deffectuer les connexions dalimentation, vous devez relier
le bon fil de terre.
Vrifiez frquemment le cordon dalimentation afin de vous assurer
quil 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 elles
sont uses ou altres.
Le cble du chalumeau ne doit pas senrouler autour de votre corps.
Si les normes le stipulent, la pice couper doit tre mise la terre.
Utilisez uniquement de lquipement en bonne condition. Rparez
ou remplacez immdiatement toute pice altre.
Portez un harnais de scurit si vous devez travailler audessus du
sol.
Assurezvous que tous les panneaux et couvercles sont correctement en place.
Nessayez pas daller lencontre des systmes de verrrouillage
de scurit ou de les contourner.
Utilisez uniquement le ou les chalumeaux recommands dans le
manuel de loprateur.
Napprochez pas le tube du chalumeau et larc pilote lorsque la gchette est enfonce.
Le cble de masse doit tre pinc correctement sur la pice couper, mtal contre mtal (et non de telle sorte quil puisse se
dtacher), ou sur la table de travail le plus prs possible de la ligne
de coupage.
OM-2229 Page 5
Isoler la pince de masse quand pas mis la pice pour viter le

contact avec tout objet mtallique.
Il y a DU COURANT CONTINU IMPORTANT dans

les convertisseurs aprs la suppression de lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique, et dcharger les condensateurs dalimentation selon les instructions
indiques dans la partie entretien avant de toucher les pices.
Tableau 1. Protection des yeux pour le coupage au plasma darc

Intensit de courant en ampres
Filtre de teinte (minimum)
Moins de 20
20 40
40 60
60 80
no. 4
no. 5
no. 6
no. 8
LE BRUIT peut endommager loue.

DCHARGES LECTRIQUES potentiellement mortelles.
Les pices internes des sources dalimentation de linverseur ont DES
CHARGES C.C. SIGNIFICATIVES
mme APRS coupure du courant
dalimentation.
D Mettre lunit hors tension, mesurer la tension des condensateurs
dentre et sassurer quelle est pratiquement nulle avant de toucher lune quelconque des pices. Mesurer cette tension conformment aux directives nonces la section Entretien du manuel de
lutilisateur ou du manuel technique avant de toucher lune quelconque des pices.
Risque de blessure en cas

DEXPLOSION DES PICES.
D Mise sous tension, toute pice dfectueuse des
sources dalimentation de linverseur peut exploser ou faire exploser dautres pices. Pour entretenir les inverseurs, toujours porter un masque
protecteur et un vtement manches longues.
LES TINCELLES VOLANTES risquent de provoquer des blessures.

Le coupage plasma produit des tincelles et projections de
mtal trs haute temprature. Lorsque la pice refroidit,
du laitier peut se former.
D Portez une visire ou des lunettes de scurit avec des crans latraux approuves.
D Portez des vtements de protection adquats afin de protger votre
peau.
D Ayez recours des protgetympans ou un serrette ignifuges afin
dviter que les tincelles nentrent dans vos oreilles.
LES RAYONS DARC peuvent entraner des brlures aux yeux et la

peau.
Les rayons darc provenant du procd de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraner des brlures aux yeux et la
peau.
D Lorsque vous coupez ou regardez quelquun couper, portez un masque ou un cran facial avec le filtre appropri. La norme ANSI Z49.1
(reportezvous aux Principales normes de scurit) suggre dutiliser
un filtre de teinte nd 9 (nd 8 tant le minimum) pour tout travail de coupage faisant appel un courant de moins de 300 A. On mentionne
galement dans la norme Z49.1 quun filtre plus faible 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.
D Porter des lunettes de scurit coques latrales sous votre casque
ou cran facial.
D Ayez recours des crans protecteurs ou des rideaux pour protger
les autres contre les rayonnements et les blouissements; prvenez
toute personne sur les lieux de ne pas regarder larc.
D Portez des vtements confectionns avec des matires rsistantes
et ignifuges (cuir et laine) et des bottes de protection.
OM-2229 Page 6
Certaines applications de coupage produisent un bruit

constant, ce qui peut endommager loue si le niveau
sonore dpasse les limites permises par lOSHA (reportezvous aux Principales normes de scurit).
D Utilisez des protgetympans ou un serrette antibruit si le niveau

sonore est lev.
D Prvenez toute personne sur les lieux du danger reli au bruit.
LES FUMES ET LES GAZ peuvent

tre dangereux.
Le coupage produit des vapeurs et des gaz. Respirer
ces vapeurs et ces gaz peut tre dangereux pour la
sant.
D Ne mettez pas votre tte audessus des vapeurs. Ne respirez pas ces
vapeurs.
D Si vous tes lintrieur au moment du coupage, ventilez la pice ou
ayez recours une ventilation aspirante installe prs de larc pour
vacuer les vapeurs et les gaz.
D Si la ventilation est mdiocre, utilisez un respirateur antivapeurs
approuv.
D Veuillez lire le Material Safety Data Sheets (MSDS) et les instructions
du fabricant pour obtenir plus de renseignements sur les mtaux
couper, les enrobages et les nettoyants.
D Travaillez dans un espace restreint uniquement sil est bien ventil ou
si vous portez un respirateur antivapeurs. Les vapeurs causes par
le coupage et lpuisement de loxygne peuvent altrer la qualit de
lair et entraner des blessures ou la mort. Assurezvous que lair ambiant est sain pour la sant.
D Ne coupez pas dans un endroit prs doprations de dcapage, de
nettoyage ou de vaporisation. La chaleur et les rayons darc peuvent
ragir avec les vapeurs et former des gaz hautement toxiques et irritants.
D Ne coupez pas des mtaux enrobs tels que des mtaux galvaniss,
contenant du plomb ou de lacier plaqu au cadmium, moins que
lenrobage ne soit t de la surface du mtal couper, que lendroit o
vous travaillez ne soit bien ventil, ou, si ncessaire, que vous ne portiez un respirateur antivapeurs. Les enrobages ou tous mtaux qui
contiennent ces lments peuvent crer des vapeurs toxiques sils
sont coups.
D Ne coupez pas de contenants qui renferment ou ont renferms des
matires toxiques ou ractives vous devez en premier lieu les vider
et les nettoyer convenablement.
LE PLASMA DARC peut entraner

des blessures.
La chaleur dgage par le plasma darc peut entraner de
srieuses brlures. La force de larc est un facteur qui
sajoute au danger de brlures. La chaleur intense et la
puissance de larc peuvent rapidement passer au travers
de gants et de tissus.
D Napprochez pas le tube du chalumeau.

D Ne saisissez pas la pice couper prs de la ligne de coupage.
D Larc pilote peut causer des brlures napprochez pas le tube du chalumeau lorsque vous avez appuy sur le gchette.
D Portez des vtements de protection adquats qui recouvrent tout votre corps.
D Ne pointez pas le chalumeau en direction de votre corps ni de la pice
couper lorsque vous appuyez sur la gchette larc pilote sallume
automatiquement.
D Mettez lalimentation hors tension et dbranchez le cordon dalimentation avant de dmonter le chalumeau ou de changer une pice du
chalumeau.
D Utilisez uniquement le ou les chalumeaux recommands dans le manuel de loprateur.
LES BOUTEILLES peuvent exploser

si elles sont endommages.
Les bouteilles de gaz contiennent du gaz sous haute
pression. Si une bouteille est endommage, elle peut
exploser. Puisque les bouteilles de gaz font habituellement
partie dun processus de travail des mtaux, assurezvous
de les manipuler correctement.
D Protgez les bouteilles de gaz comprim contre la chaleur excessive,

les chocs mcaniques, le laitier, la flamme, les tincelles et larc.
D Installez et attachez les bouteilles dans la position verticale laide
dune chane, sur un support stationnaire ou un chssis portebouteille afin de prvenir quelles ne tombent ou ne basculent.
D Les bouteilles ne doivent pas tre prs de la zone de coupage ni de

tout autre circuit lectrique.
D Un contact lectrique ne doit jamais se produire entre un chalumeau
de plasma darc et une bouteille.
D Ne coupez jamais sur une bouteille pressurise une explosion en
rsulterait.
D Utilisez uniquement des bouteilles de gaz, des dtendeurs, des
boyaux et des raccords conus pour lapplication dtermine. Gardezles, ainsi que toute autre pice associe, en bonne condition.
D Dtournez votre visage du dtendeurrgulateur lorsque vous ouvrez
la soupape de la bouteille.
D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque
vous utilisez la bouteille ou quelle est relie pour usage ultrieur.
D Lisez et suivez les instructions sur les bouteilles de gaz comprim,
lquipement connexe et le dpliant P1 de la CGA mentionn dans
les Principales normes de scurit.
1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance
DES PIECES CHAUDES peuvent provoquer des brlures graves.
D
D
Ne pas toucher des parties chaudes mains nues.

Laisser refroidir avant dintervenir sur la torche.
DES ORGANES MOBILES peuvent

provoquer des blessures.
D
D
Sabstenir de toucher des organes mobiles tels que

des ventilateurs.
Maintenir ferms et verrouills les portes, panneaux,
recouvrements et dispositifs de protection.
DES PARTICULES VOLANTES

peuvent blesser les yeux.
D
Porter des lunettes de scurit avec protections latrales ou frontales.
LES CHAMPS MAGNTIQUES peuvent affecter les stimulateurs cardiaques.

D
D
Prvoir une priode de refroidissement; respecter le

cycle opratoire nominal.
Rduire lamprage (paisseur) avant de continuer
couper ou rduire le facteur de marche.
Danger DEXPLOSION
DHYDROGNE.
D
D
Lors du coupage daluminium partiellement ou totalement immerg dans leau, de lhydrogne libre peut
saccumuler sous la pice.
Consultez votre ingnieur de coupage et les instructions de la table de coupage.
LA CHUTE DE LAPPAREIL peut

blesser.
D
D
D
D
Utiliser lanneau de levage uniquement pour soulever

lappareil, NON PAS les chariot, les bouteilles de gaz
ou tout autre accessoire.
Utiliser un engin dune capacit approprie pour soulever lappareil.
Ne pas placer lappareil sur, au-dessus ou proximit

de surfaces infllammables.
Ne pas installer lappareil proximit de produits inflammables
D Ne pas surcharger linstallation lectrique sassurer que

lalimentation est correctement dimensionn et protg avant de
mettre lappareil en service.
LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprims.

D
D
Etablir la connexion avec la barrette de terre avant 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 FRQUENCE (H.F.) risque de provoquer

des interfrences.
D
Porteurs de stimulateur cardiaque, restez distance.

Les porteurs sont pris de consulter leur mdecin
avant dapprocher les oprations de coupage
plasma.
LEMPLOI EXCESSIF peut

SURCHAUFFER LQUIPEMENT.
D
Risque DINCENDIE OU
DEXPLOSION.
Le Rayonnement haute frequence (H.F.) peut provoquer des interfrences avec les quipements de radionavigation et de communication, les services de
scurit et les ordinateurs.
D Demander seulement des personnes qualifies familiarises avec

des quipements lectroniques de faire fonctionner linstallation.
D Lutilisateur est tenu de faire corriger rapidement par un lectricien
qualifi les interfrences rsultant de linstallation.
D Si le FCC signale des interfrences, arrter immdiatement lappareil.
D Effectuer rgulirement le contrle et lentretien de linstallation.
D Maintenir soigneusement ferms les portes et les panneaux des sources de haute frquence, maintenir les clateurs une distance
correcte et utiliser une terre et et un blindage pour rduire les interfrences ventuelles.
LE COUPAGE LARC peut causer

des interfrence.
D
Lnergie lectromagntique peut gner le fonctionnement dappareils lectroniques comme des ordinateurs et des robots.
D Pour rduire la possibilit dinterfrence, maintenir les cbles aussi

courts que possible, les grouper, et les poser aussi bas que possible
(ex. par terre).
D Veiller couper une distance de 100 mtres de tout quipement
lectronique sensible.
D Sassurer que la source de coupage est correctement branche et
mise la terre.
D Si linterfrence persiste, lutilisateur doit prendre des mesures supplmentaires comme carter la machine, utiliser des cbles blinds
de des filtres, ou boucler la zone de travail.
D En utilisant des fourches de levage pour dplacer lunit, sassurer

que les fourches sont suffisamment longues pour dpasser du ct
oppos de lappareil.
OM-2229 Page 7
1-4. Principales normes de scurit

Safety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Rgles de scurit en soudage, coupage et procds connexes, norme
CSA W117.2, de lAssociation canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs lectromagntiques

Donnes sur le soudage lectrique et sur les effets, pour lorganisme,
des champs magntiques basse frquence
Le courant de soudage ou de coupage passant dans les cbles de puissance cre des causera des champs lectromagntiques. Il y a eu et
il y a encore un certain souci propos de tels champs. Cependant,
aprs avoir examin plus de 500 tudes qui ont t faites pendant une
priode de recherche de 17 ans, un comit spcial ruban bleu du National Research Council a conclu: Laccumulation de preuves, suivant le
jugement du comit, na pas dmontr que lexposition aux champs magntiques et champs lectriques haute frquence reprsente un
risque la sant humaine. Toutefois, des tudes sont toujours en cours
et les preuves continuent tre examines. En attendant que les
conclusions finales de la recherche soient tablies, il vous serait souhaitable de rduire votre exposition aux champs lectromagntiques
pendant le soudage ou le coupage.
2
3
Afin de rduire les champs lectromagntiques dans lenvironnement

de travail, respecter les consignes suivantes :
OM-2229 Page 8
4
5
Garder les cbles ensembles en les torsadant ou en les

attachant avec du ruban adhsif.
Mettre tous les cbles du ct oppos de loprateur.
Ne pas courber pas et ne pas entourer pas les cbles autour de
vous.
Garder le poste de soudage et les cbles le plus loin possible de
vous.
Relier la pince de masse le plus prs possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :

Les consignes mentionnes prcdemment font partie de celles destines aux personnes ayant recours un stimulateur cardiaque. Veuillez
consulter votre mdecin pour obtenir plus de dtails.
SECTION 2 DEFINITIONS
2-1. Warning Label Definitions
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1
1.2
1
1.1
1.2
1.3
1.3
2
2.1
2.1
2.2
2.3
2.2
2.3
3
3.1
3.2
3.1
3.3
3.2
3.3
4
4.2
4.1
4.3
4
4.1
4.2
4.3
5.1
+
6
5.1
7
S-179 219
Cutting sparks can cause

explosion or fire.
Keep flammables away from
cutting. Do not cut near
flammables.
Cutting sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not cut on drums or any
closed containers.
The plasma arc can cause
injury and burns.
Turn off power before
disassembling torch.
Do not grip material near
cutting path.
Wear complete body
protection.
Electric shock from torch or
wiring can kill.
Wear dry insulating gloves.
Do not wear wet or damaged
gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing cutting fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or cutting.
Do not remove or paint over
(cover) the label.
9/01
OM-2229 Page 9
2-2. Manufacturers Rating Label For CE Products

STOCK NO.
SERIAL NO.
XXX04XXXXXXXXXX
EN50199
XXX03XXX
EN50192
14A/92V 27A/92V
X@40
35%
60%
100%
I2
27A
92V
14A
92V
U0
288V
U2
1
5060 Hz
S1
3.1KVA
COS
U 1 = 115V
U 1 = 230V
= .99
= 27A
I1
max
I1
m ax =13A
I 1 e ff =
I 1 e ff=
16A
7.8A
Protected By Patent #
4,791,268 4,861,962 5,120,930,
5,132,512 5,310,988 5,597,497,
5,620,617 5,900,169 6,051,804,
6,153,851. And other U.S.
Patents Pending.
IP23C
203 892
S and CE markings only apply when the torch is used with shielded parts: retaining cup (197 567) and drag shield (196 929).
2-3. Symbols And Definitions
A
V
U0
Amperes
Plasma Arc Cutting

(PAC)
Adjust Air/Gas
Pressure
Low Air Pressure

Light
Volts
Increase
No Do Not Do
This
Temperature
Protective Earth
(Ground)
Single Phase
Constant Current
Voltage Input
On
Off
Percent
Direct Current
Conventional Load
Voltage
Line Connection
Duty Cycle
Single Phase
Static Frequency
ConverterTransformerRectifier
Rated No Load
Voltage (Average)
I1max
Rated Maximum
Supply Current
IP
I1eff
Degree Of
Protection
Maximum Effective
Supply Current
OM-2229 Page 10
U1
I2
Primary Voltage
Rated Welding
Current
Loose Shield Cup
U2
X
Input
Hz
Hertz
SECTION 3 INSTALLATION
3-1. Specifications
NOTE
If the unit is operated from a 30* ampere, 115 volt circuit or a 15** ampere, 230 volt
circuit, a different input power plug must be installed on the power cord. See
Section 3-9 for instructions.
*A 30 ampere branch circuit is recommended for maximum performance. Performance on a 20 ampere branch service may be limited due to the circuit
breaker or line fuse. Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse.
**A 15 ampere branch circuit is recommended for maximum performance. Performance on a 10 ampere branch service may be limited due to the circuit
breaker or line fuse. Reducing unit output amperage will minimize circuit breaker tripping or blowing a line fuse.
A. Non-CE Model
Amperes Input at
Rated Output,
60 Hz, Single-Phase
Rated Output
115 V
(+15%)
230 V
(+15%)
115 V
KVA/KW
230 V
KVA/KW
Plasma
Gas
27 A at 92 Volts DC At
35% Duty Cycle
28 max;
0.30*
14 max;
0.13*
3.32 KVA
3.25 KW
3.25 KVA
3.19 KW
Air Or
Nitrogen
Only
Plasma
Gas Flow/
Pressure
4.5 CFM
(129 L/min)
At 60 PSI
(414 kPa)
Rated
Cutting
Capacity
at 10 IPM
Max
OCV
3/8 in
(10 mm)
288 Volts
DC
Rated
Cutting
Capacity
at 10 IPM
Max
OCV
3/8 in
(10 mm)
288 Volts
DC
*While idling
B. CE Model
Amperes Input at
Rated Output,
50 Hz, Single-Phase
Rated Output
115 V
(+15%)
230 V
(+15%)
115 V
KVA/KW
230 V
KVA/KW
Plasma
Gas
27 A at 92 Volts DC At
35% Duty Cycle
27 max;
0.33*
13 max;
0.17*
3.11 KVA
3.09 KW
3.04 KVA
3.04 KW
Air Or
Nitrogen
Only
Plasma
Gas Flow/
Pressure
4.5 CFM
(129 L/min)
At 60 PSI
(414 kPa)
*While idling
3-2. Specifications For Torch

Air-cooled torch for plasma arc cutting (PAC)
35% duty cycle
Safety interlock devices shut down power source
Safety trigger guard
Cutting capacity: see Section 3-1
OM-2229 Page 11
3-3. Duty Cycle And Overheating

For Units Connected to a 115 Volt Circuit
or a 230 Volt Circuit:
35% Duty Cycle At 27 amperes, 92 volts dc
35% duty cycle
3-1/2 Minutes Cutting
6-1/2 Minutes Resting
Duty Cycle is percentage of 10 minutes that unit can cut at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, Temperature
trouble light goes On, and cooling
fan runs. Wait fifteen minutes for
unit to cool or temperature light to
go off. Reduce amperage or duty
cycle before cutting or gouging.
Y Exceeding duty cycle can
damage unit and void
warranty.
Overheating
0
15
OR
Reduce Duty Cycle
Minutes
sduty1 5/95 / 802 784-B
3-4. Torch Dimensions And Weight
1 in
(25 mm)
3.0 lb (1.4 kg)
OM-2229 Page 12
8-3/8 in
(213 mm)
1-3/8 in
(35 mm)
Ref. 802 877
3-5. Selecting A Location

8-1/2 in
(216 mm)
Dimensions And Weight
12-5/16 in*
(313 mm)
49 lb (22.2 kg)
not including torch
*Add 13/16 in (21 mm) for handle.
16 in
(406 mm)
Movement
Lifting Handle
Use handle to lift unit.

2
2
3
4
Location And Airflow
INPUT
SERIAL NO.
HERTZ
X@40
I2
U2
35%
27A
92V
U0
288V
1
COS = .99
5060Hz
S1
U1= 115V I1max= 27A I1 eff= 16A
U1= 230V I1 max=13A I1 eff= 7.8A
3.1KV
A
IP23C
60%
14A
92V
120 VAC Receptacle

230 VAC Receptacle
Locate unit near correct input

power supply.
14A/92V 27A/92V
LR5071
NRTL/C
5
6
EN50199 EN50192
STOCK NO.
Plate Label (Non-CE Model)

Plate Label (CE Model)
Use label to determine input power

needs.
3
STOCKNO. XXX04XXXXXXXXXX
SERIAL
NO. XXX03XXX
VOLTS
AMPERES
KW
PHASE
Hand Cart
Use cart or similar device to move

unit.
100%
Y Special installation may be

required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
Section 20.
Protected By Patent #
4,791,268 4,861,962 5,120,930,
5,132,512 5,310,988 5,597,497,
5,620,617 5,900,169 6,051,804,
6,153,851. And other U.S.
Patents Pending.
EVIDENCE OF LABEL TAMPERING VOIDS WARRANTY
10 in
(254 mm)
10 in
(254 mm)
loc_2 3/96 - Ref. 802 784-B / 802 785-A / 802 786-A / 203 892
OM-2229 Page 13
3-6. Connecting Gas/Air Supply

. Use only clean, dry air with 70
to 150 psi (483 to 1034 kPa)
pressure.
Gas/Air Inlet Opening
Hose
Teflon Tape
Obtain hose with 1/4 NPT righthand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.
Tools Needed:
5/8, 1-1/8 in
4
1
3
From Gas/Air
Supply
Air Filter/Regulator
Adjust gas/air pressure according

to Section 4-1.
2
4
802 787-A / Ref. 801 319-C / Ref. 802 784-B
OM-2229 Page 14
3-7. Connecting Work Clamp

1
2
Work Clamp
Workpiece
Connect work clamp to a clean,

paint-free location on workpiece, as
close to cutting area as possible.
2
802 463-A
3-8. Connecting Input Power

Check input voltage available at
site.
1
Changeover Switch
Switch is accessible through slot in

rear panel.
2
Changeover Switch Label
Look at label to find correct switch

position.
Y Be sure input power
connection
meets
all
applicable
national,
regional, and local electrical
codes.
3
2
3
4
5
6
Grounded 120 VAC

Receptacle
Y To use rated output (see

specifications), connect the
unit to an individual branch
circuit capable of carrying
the effective (eff) current for
the output being used. The
unit must have a properly
sized plug installed and the
circuit must be protected by
properly sized fuses or circuit breakers.
A 120 volt, 20 ampere (minimum)
individual branch circuit protected
by time-delay fuses or circuit
breaker is required (see Section
3-1).
4
Plug From Unit
Select extension cord of 12 AWG

for up to 53 ft (16 m).
5
Grounded 230 VAC

Receptacle
A 230 volt, 10 ampere (minimum)

individual branch circuit protected
by time-delay fuses or circuit
breaker is required (see Section
3-1).
6
Plug From Unit (Customer

Supplied)
Select extension cord of 14 AWG

for up to 133 ft (41 m).
Y Special installation may be
required where gasoline or
volatile liquids are present
see NEC Article 511 or CEC
Section 20.
Ref. 802 787-A / 802 786-A
OM-2229 Page 15
3-9. Installing Alternative Plug

This procedure is necessary if the unit is to be connected to a 230
VAC receptacle, or to a 115 VAC receptacle that requires a plug that
is different from the supplied plug.
See Section 3-8 for instructions on setting changeover switch for

proper voltage.
Alternative PLug (230 VAC

Plug Shown)
Load 1 (Brass) Terminal
Load 2 (Brass) Terminal
3
6
1
7
4
5
Tools Needed:
Supplied 115 VAC Plug
Cut cord close to plug.
Ground (Green) Terminal
Outer Shell
Cord Grip
Strip cord jacket back enough to

separate conductors. Strip conductors enough to make good contact
with plug terminals. Make plug connections and reinstall outer shell and
cord grip. Tighten assembly screws
onto shell. Do not overtighten.
Ref. 801 305-A / 801 611
OM-2229 Page 16
SECTION 4 OPERATION
4-1. Controls
ON
OFF
PRESSURE
60 PSI
20
24
16
27
Set To
60 PSI (414 kPa)
Setting Gas/Air Pressure

1
20
20
24
16
27
Output Control
Use control to set cutting output.

Place control in Gas/Air Set position to safely
adjust gas/air pressure. Only gas/air circuit
is activated.
If 22-27 amperes of cutting output is used
with 115 VAC input power, and the overload
protection on the input power circuit frequently opens, either reduce the cutting out-
24
16
Requires
70-150 PSI
(483-1034 kPa)
Supply
27
put and/or the cut time or find more adequate

power (see Section 3-1).
2
Trouble Lights (See Section 5-2)
Power Light
Power Switch
Setting Gas/Air Pressure

5
Air Filter/Regulator
Pressure Adjustment Knob
Place Output control in Gas/Air position and

turn on gas/air supply. Lift knob and turn to
adjust pressure. Push knob down to lock in
setting.
Place Output control in desired cutting
output.
. At ambient temperatures below 55 C

(235 F), readjustment of gas/air
pressure regulator may be necessary.
Ref. 200 808 / Ref. 802 784
OM-2229 Page 17
4-2. Cutting Speed

The cutting speed curves show the
recommended maximum cutting
speed capabilities of the power
source and torch for mild steel of
various thickness.
Cut at speeds below the lines
shown to avoid poor cuts and torch
wear.
wmdesign
4-3. Trigger Safety Lock

1
Trigger
Trigger Locked
Trigger Unlocked
802 877
OM-2229 Page 18
4-4. Sequence Of Operation
EXAMPLE Of Cutting Operation
The pilot arc starts immediately when trigger is pressed.
Place tip on work for drag cutting or for

maximum cutting speed and tip life, use a
standoff distance of 1/16 in (1.6 mm) to 1/8
in (3.2 mm) (dragging tip will reduce tip life).
Adjust torch speed so

sparks go thru metal and
out bottom of cut.
Raise trigger lock and press

trigger. Pilot arc starts.
Pause briefly at end of

cut before releasing trigger.
After cutting arc starts, slowly

start moving torch across metal.
Postflow continues for 20 seconds after

releasing trigger; cutting arc can be instantly
restarted during postflow by raising trigger
lock and pressing trigger.
Ref. 802 878
OM-2229 Page 19
SECTION 5 MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
Each Use
Check
Torch Tip,
Electrode,
And Shield
Cup
Check
Gas/Air
Pressure
Every Week
Check
Shield Cup
Shutdown
System
3 Months
Replace
Damaged Or
Unreadable
Labels
Service
Air Filter/
Regulator
Replace
Cracked
Parts
Torch Body, Cable
Gas/Air Hose
Tape Torn
Outer
Covering
6 Months
Blow Out Or
Vacuum Inside
OM-2229 Page 20
5-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System
If certain problems occur, the
Ready light goes off, a trouble light
comes on, and output stops.
1
1
2
Pressure Light
Lights if gas/air pressure is below

40 PSI (276 kPa).
Turn power Off, and check for
proper gas/air pressure (see
Section 4-1).
A flashing Pressure light indicates
that gas/air system may be set too
low, faulty, leaking or has a flow restriction (see Section 5-5).
2
Cup Light
Lights if shield cup is loose.

Turn power Off, and check shield
cup connection (see torch Owners
Manual). Power must be reset
whenever the cup shutdown is
activated.
Checking Torch Shield Cup Shutdown System
Power must be reset whenever the cup shutdown system is activated.

Always turn Off power when changing or checking consumables.
A flashing Cup light indicates that

the torch consumables are stuck or
worn and should be inspected and/
or replaced (see Section 5-4).
Check shield cup shutdown system
once a week.
3
Temperature Light
Lights if power source overheats or

when ambient temperature is below
35 C (31 F) (see Section 3-3).
4
Torch Shield Cup
Turn Power On and loosen shield

cup. If shutdown system works
properly, Ready light goes off and
Cup light comes on. If not, turn
power Off and check for proper
gas/air pressure (see Section 3-1),
blocked or leaking hose, or loose
shield cup (see torch Owners
Manual).
If system works properly, retighten
cup and reset power.
Ref. 200 808 / Ref. 802 877
OM-2229 Page 21
5-3. Torch And Work Cable Connections

If torch or work cable needs to be
removed or replaced, proceed as
follows:
5
4
Turn power Off, and disconnect

input power plug from receptacle.
Remove wrapper from unit.
Torch Connections
Remove existing torch cable from

unit.
1
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.
2
Plug PLG1/Receptacle RC1
Connect PLG1 from torch to

receptacle RC1 on end of wiring
harness connected to circuit board
PC1.
Ring Terminal And Terminal

PILOT
Connect ring terminal on end of red

leads to PILOT terminal.
Ring Terminal And Terminal

L2RED
Connect ring terminal on end of

white leads to L2RED terminal.
Tighten strain relief nut.
Tighten strain relief around cable.
Work Cable Connections
Remove existing work cable from
unit.
7
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 PC1. Route
lead along torch lead bundle.
Tools Needed:
1/4 in
OM-2229 Page 22
Ref. 802 854 / Ref. 802 860 / 200 173-A
5-4. Checking/Replacing Retaining Cup, Tip, And Electrode

Overtightening will strip threads. Do not overtighten retaining cup during
assembly. Do not cross-thread parts causing stripping. Use care during torch
assembly and parts replacement.
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.
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
6
Make sure swirl ring is clean of any
debris and no holes are obstructed.
4
3
New
1/16 in
(2 mm)
Pit
New
Worn
Worn
802 465
Turn Off power source.

1 Shield Cup
2 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.
3 Tip
4 Opening
Remove tip. Check tip, and replace if opening is deformed or 50% oversize. If inside of
tip is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards.
5 Electrode
Check electrode. If center has a pit more
than a 1/16 in (2 mm) deep, remove and replace electrode.
6 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-2229 Page 23
5-5. Troubleshooting Power Source
Is input power
connected to
correct line
voltage?
No
Connect unit to proper input

voltage (see Section 3-8).
Yes
Check torch consumables.

Reset Power switch S1.
Yes
If unit is overheated, wait

while fan cools down unit
temperature.
No
Yes
Is Changeover
switch S2 in
the 115V or
230V position?
Is Cup Status
light On or
flashing?
No
Place Changeover switch in

proper position for input
Is Temp Status
light On?
No
Yes
Does the breaker

trip when unit is set
on 115V?
Yes
Turn down output current.

(see Section 4-1).
Yes
No
No
Is Power switch
S1 in the On
position?
Is Pressure Status
light On or flashing?
*
Turn Output control
fully counterclockwise (see
Section 4-1). Check for
gas/air flow at torch. Check
Control
board
PC1,
pressure switch S3 (gauge),
air filter, valve AS1, and air
supply connection to unit
and torch.
No
Place Power switch in the

On position. (see Section
4-1).
Does pilot arc

ignite?
No
Press torch trigger and

check if pilot arc ignites.
Check torch consumables.
*Check torch connections,
air filter, pressure switch S3,
valve AS1, air supply
connection to unit, torch,
and PC1.
Yes
Yes
Is the cooling
fan running?
No
*
Check Power switch S1 and
relay CR2 and thermistor R1
on PC2. Replace PC2 if R1
or CR2 are not functioning
correctly.
Does pilot arc

transfer
to
workpiece?
No
Place torch near workpiece

and check if pilot arc jumps
or transfers to workpiece.
Check
work
clamp
connection. *Check Control
board PC1 and connections,
and torch and its connections.
Yes
Yes
*
Is Power light
flashing?
No
OM-2229 Page 24
Yes
Reset Power switch S1

and verify line power
Check
relay
CR2,
thermistor R1 on PC2,
and Control board PC1.
Check all connections,

Check main transformer T1,
Check boost inductor L1
and buck inductor L2.
Return to beginning of chart.
*Servicing procedure to be
performed only by authorized
Service Station.
5-6. Troubleshooting Torch
Does arc go
on and off
while cutting?
Yes
Torch travel speed too slow;

increase travel speed (see
Section 4-2). Clean or
replace torch consumables
as necessary (see Section
5-4). Be sure work clamp is
securely
attached
to
workpiece.
Go to Section 5-5.
No
Does arc go out

while cutting?
Yes
Be sure work clamp is

securely attached to workpiece. Make sure tip is on or
near, 1/16 in (1.6 mm) to 1/8
in (3.2 mm) workpiece (see
5-4).
Go to Section 5-5.
No
Do sparks come
out of top of cut;
or cut is not
clean?
Yes
Torch travel speed too fast;

reduce travel speed (see
5-4). Be sure work clamp is
securely
attached
to
workpiece. Unit not capable
of cutting metals thicker
than rating (see Section
3-1).
No
Is Trouble light
On; unit has no
cutting output?
Yes
Check torch shield cup (see

Section 5-2); reset unit
Power switch. *Check torch
and connections inside unit.
Go to Section 5-5.
No
Go to Section 5-5.
*Servicing procedure to be performed
only by authorized Service Station.
OM-2229 Page 25
SECTION 6 ELECTRICAL DIAGRAM
200 809-B
Figure 6-1. Circuit Diagram

OM-2229 Page 26
Notes
OM-2229 Page 27
SECTION 7 PARTS LIST

. Hardware is common and
not available unless listed.
2
1
6
7
8
9
26
25
24
10
23
22
11
21
20
12
19
13
18
14
17
16
15
802 805-A
Figure 7-1. Main Assembly

OM-2229 Page 28
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly

. . . 1 . . . . . . . . . . . . . 204 326 . . CONSUMABLE STORAGE BOX w/DOOR . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 202 108 . . LABEL, ICE-27C consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 089 899 . . LATCH, slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 196 851 . . LABEL, warning precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 195 585 . . HANDLE, carrying rubberized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . +206 442 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . L2 . . . . 200 816 . . INDUCTOR, buck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . L1 . . . . 200 815 . . INDUCTOR, boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . PC2 . . . 200 666 . . CIRCUIT CARD ASSY, primary change-over (non-CE) . . . . . . . . . . . . . . .
. . . 8 . . . . PC2 . . . 200 866 . . CIRCUIT CARD ASSY, primary change-over (CE) . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . 200 726 . . BRACKET, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . FM . . . . 195 610 . . FAN, muffin 115V 50/60HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . S1 . . . . . 124 511 . . SWITCH, power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 200 724 . . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 202 674 . . CABLE, power 10ft 14ga 3c (non-CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 202 714 . . CABLE, power 10ft 14ga 3c (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . +200 729 . . CASE SECTION, base/front/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 179 190 . . LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 204 255 . . FILTER, air w/fittings (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 200 878 . . . . FILTER, air 5 micron 1/4NPT ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 204 005 . . . . FITTING, elbow quick disconnect 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 010 830 . . . . FITTING, pipe adapter 1/4NPT x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 204 066 . . . . FITTING, extension M5 thread w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . AS1 . . . 204 254 . . VALVE, air w/fittings (non-CE) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . AS1 . . . 206 257 . . VALVE, air w/fittings (CE) (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 200 877 . . . . VALVE, 24VDC 3 way 1/8NPT (non-CE) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 206 000 . . . . VALVE, 24VDC 3 way 1/8NPT (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 204 003 . . . . FITTING, straight quick disconnect 1/8NPT . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . 200 728 . . BRACKET, mtg air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . 200 875 . . REGULATOR, air w/fittings (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . PC1 . . . 205 852 . . CIRCUIT CARD ASSY, control (non-CE) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . PC1 . . . 205 875 . . CIRCUIT CARD ASSY, control (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . 138 044 . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . 195 014 . . ICE-27C 20ft hand held (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 121 276 . . . . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . . 199 021 . . CABLE, work 15ft 12ga w/clamp (consisting of) . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 203 988 . . . . CLAMP, work 150A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 199 995 . . . . TIP, contact work clamp copper 150A . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . . 200 517 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . S3 . . . . 200 876 . . GAUGE, air w/pressure switch & fitting (consisting of) . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 204 012 . . . . FITTING, quick disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . T1 . . . . 208 825 . . TRANSFORMER, toroid main 60HZ 115/230V (non-CE) . . . . . . . . . . . . . .
. . . 25 . . . . . T1 . . . . 202 454 . . TRANSFORMER, toroid main 50HZ 115/230V (CE) . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . 181 708 . . GASKET, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
Optional
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2229 Page 29
1
2
Item Part
No. No.
1
2
3
4
5
183 427
171 248
203 120
203 119
185 833
190 220
169 231
195 014
Description
Handle Assy, complete (1)
Push Button Switch (1)
Leads, 20ft (1)
Main Body (1)
Switch Assembly
w/spring (1)
Spring, trigger assembly
Grease, silicone (1)
Torch, replacement 20ft (1)
1
4
See Figure 7-3 for

additional consumable parts.
Figure 7-2. Torch, ICE-27C
202 108-A
Figure 7-3. Consumable Parts For ICE-27C

To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2229 Page 30
Effective January 1, 2001

(Equipment with a serial number preface of LB or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
LIMITED WARRANTY Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts 3 Years Labor
*
*
2.
3 Years Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers

Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder

Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year whichever is greater.)
4.
6 Months Batteries
5.
90 Days Parts
*
*
MIG Guns/TIG Torches

Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Millers True Blue Limited Warranty shall not apply to:

1.
Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,

such as engines or trade accessories. These items are
covered by the manufacturers warranty, if any.
3.
Equipment that has been modified by any party other

than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE

AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customers risk and expense. Millers option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 10/01
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for:
Welding Supplies and Consumables

Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
European Headquarters
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during

shipment.
For assistance in filing or settling claims,

contact your distributor and/or equipment
manufacturers Transportation Department.
PRINTED IN USA
2002 Miller Electric Mfg. Co.
1/02

Manual Spectrum 375 CutMate

Uploaded by

Copyright:

Available Formats

Manual Spectrum 375 CutMate

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Spectrum 375 CutMate

Uploaded by

Copyright:

Available Formats

OM-2229

Air Plasma Cutter

And ICE-27C Torch

And Non-CE Models

Visit our website at

From Miller to You

Working as hard as you do

Miller offers a Technical

Miller Electric manufactures a full line

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of Conformity for

Miller Electric Mfg. Co.

1635 W. Spencer Street

Declares that the product:

SPECTRUM 375 CutMateE

conforms to the following Directives and Standards:

Mr. Danilo Fedolfi, Managing Director

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

. Means Note; not safety related.

This group of symbols means Warning! Watch Out! possible

1-2. Plasma Arc Cutting Hazards

Y During operation, keep everybody, especially children, away.

CUTTING can cause fire or explosion.

ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

EXPLODING PARTS can injure.

FLYING SPARKS can cause injury.

Wear approved face shield or safety goggles with side shields.

ARC RAYS can burn eyes and skin.

Wear face protection (helmet or shield) with correct shade of filter to

PLASMA ARC can cause injury.

Table 1. Eye Protection For Plasma Arc Cutting

Minimum Shade Number

Gas cylinders contain gas under high pressure. If

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

FUMES AND GASES can be hazardous.

The heat from the plasma arc can cause serious

CYLINDERS can explode if damaged.

NOISE can damage hearing.

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

MOVING PARTS can cause injury.

FLYING METAL can injure eyes.

MAGNETIC FIELDS can affect pacemakers.

OVERUSE can cause OVERHEATING.

EXPLODING HYDROGEN hazard.

FALLING UNIT can cause injury.

FIRE OR EXPLOSION hazard.

STATIC (ESD) can damage PC boards.

H.F. RADIATION can cause interference.

ARC CUTTING can cause interference.

1-4. Principal Safety Standards

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

1-5. EMF Information

1. Keep cables close together by twisting or taping them.

SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

1-1. Signification des symboles

. Signifie NOTA ; nest pas relatif la scurit.