Miller Electric MC-80 Owner's Manual
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Miller Electric MC-80 Owner's Manual

Miller Electric MC-80 Owner's Manual

Electric air-cooled plasma arc cutting (pac) torches
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Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
cover 5/94 – Ref. ST-800 895
OWNER'S
MANUAL
MC-80 And MC-80M
Air-Cooled Plasma Arc Cutting (PAC) Torches
Can Be Used For Plasma Arc Gouging (PAG)
80 Amperes, 120 Volts DC At 100% Duty Cycle
Safety Interlock Devices Shut Down Power Source
Hand-Held Torch Equipped With Either 25 Or 50 ft (7.6 Or 15.2 m) Cable
Machine-Held Torch Equipped With 50 ft (15.2 m) Cable
Fully Assembled And Supplied With Consumable Kit
1995 MILLER Electric Mfg. Co.
May 1995
Form: OM-1592A
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912
414-734-9821
PRINTED IN USA

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Summary of Contents for Miller Electric MC-80

  • Page 1 5/94 – Ref. ST-800 895 May 1995 MC-80 And MC-80M 1995 MILLER Electric Mfg. Co. Form: OM-1592A Give this manual to the operator. For help, call your distributor or: MILLER Electric Mfg. Co., P.O. Box 1079, Appleton, WI 54912 414-734-9821 PRINTED IN USA...
  • Page 2 ISO 9001 Quality System Standard. service information for your particular model are also provided. 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 or individual catalog sheets.
  • Page 3 PLASMA ARC CUTTING SAFETY PRECAUTIONS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In cutting, as in most jobs, exposure to certain hazards occurs. Cutting is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page.
  • Page 4 FUMES AND GASES can be hazardous to your health. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 1. Keep your head out of the fumes. Do not breathe the fumes. 2. If inside, ventilate the area and/or use exhaust at the arc to remove cutting fumes and gases.

  • Page 5: Table Of Contents

    ............. . . Figure 6-1. Torch, MC-80 (Hand-Held) Figure 6-2.

  • Page 7: Section 1 - Safety Information

    SECTION 1 – SAFETY INFORMATION Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Disconnect input power before installing or servicing.

  • Page 8: Duty Cycle

    Hand-Held Torch 2-1. Duty Cycle CAUTION CUTTING LONGER THAN RATED DUTY CYCLE can damage cutter and torch and void warranty. Do not cut at rated load longer than duty cycle of cutter (see cutter’s Owner’s Manual). Definition Duty Cycle is percentage of 10 minutes that cutter and torch can cut at rated load without overheating.

  • Page 9: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Installing Hand-Held Torch WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn Off cutter, and disconnect input power before installing torch. MOVING PARTS can cause injury. Keep away from moving parts. Significant DC voltage can remain on capacitors in cutter after unit is Off.

  • Page 10: Installing Machine-Held Torch And Remote Trigger Pendant

    3-2. Installing Machine-Held Torch And Remote Trigger Pendant WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn Off cutter, and disconnect input power before installing torch. MOVING PARTS can cause injury. Keep away from moving parts. Significant DC voltage can remain on capacitors in cutter after unit is Off.

  • Page 11: Section 4 - Operating The Torch

    SECTION 4 – OPERATING THE TORCH WARNING ELECTRIC SHOCK can kill. Always wear dry insulating gloves. Insulate yourself from work and ground. Do not touch live electrical parts. Keep all panels and covers securely in place. FUMES AND GASES can be hazardous to your health.
  • Page 12 CAUTION T I P AND EL ECT RO DE WEAR BEYO ND RE CO M M E NDE D VAL UE S or OP E RAT I O N WITHOUT TIP OR ELECTRODE can damage torch. Inspect cup, tip, and electrode before cutting or whenever cutting speed has been significantly reduced (see Section 5-2).
  • Page 13 Figure 4-2. Sequence Of Plasma Arc Cutting (PAC) CAUTION HITTING TORCH ON A HARD SURFACE to remove spatter can damage torch. Do not clean torch by hitting it against a hard surface. Hitting hard surfaces can damage torch parts and stop proper operation.

  • Page 14: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn Off cutter, and disconnect input power before inspecting, maintaining, or servicing. 5-1. Routine Maintenance Turn Off all power before maintaining. Each Use Check Tip Electrode, And Cup...

  • Page 15: Checking/Replacing Cup, Tip, And Electrode

    5-2. Checking/Replacing Cup, Tip, And Electrode CAUTION OVERTIGHTENING will strip threads. Do not overtighten electrode, tip, and cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Worn Figure 5-2. Checking/Replacing Cup, Tip, And Electrode T I P AND EL ECT RO DE WEAR BEYO ND RE CO M M E NDE D VAL UE S or OP E RAT I O N WITHOUT TIP OR ELECTRODE can damage...

  • Page 16: Troubleshooting

    5-3. Troubleshooting WARNING ELECTRIC SHOCK can kill. Do not touch live electrical parts. Turn Off cutter, and disconnect input power before inspecting, maintaining, or servicing. Trouble Cutter Gas/Torch trouble light On; cutter Power light Off; no cutting output. Unit pilots, but does not transfer. Sparks come out top of cut, or cut is not clean.

  • Page 17: Section 6 - Parts List

    SECTION 6 – PARTS LIST Item Part Figure 6-1. Torch, MC-80 (Hand-Held) ... . . 172 385 TORCH, body assembly (consisting of) ... . .

  • Page 18: Figure 6-3. Torch, Mc-80 (Machine-Held)

    Item Part Figure 6-3. Torch, MC-80 (Machine) ... . . 175 833 TORCH, body assembly (consisting of) ... . .
  • Page 19 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 20 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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