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Miller ICE-12C Owner's Manual
Miller ICE-12C Owner's Manual

Miller ICE-12C Owner's Manual

Air-cooled torches for plasma arc cutting

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OWNER'S MANUAL
ICE-12C, ICE-25C, ICE-25CX, ICE-27C, ICE-27T
ICE-40C, ICE-50C, ICE-50CM, ICE-55C, ICE-55CM, ICE-80C, ICE-80CM,
ICE-80CX, ICE-80CXM, ICE-80T, ICE-80TM, ICE-100T, And ICE-100TM Torches
1.
Specifications
Air-cooled torches for plasma arc cutting (PAC)
12 A model: 12 A at 35% duty cycle;
25 A model: 25 A at 35% duty cycle;
27 A model: 27 A at 35% duty cycle;
40 A model: 40 A at 50% duty cycle;
50 A models: 50 A at 60% duty cycle;
55 A model: 55 A at 60% duty cycle;
80 A model: 80 A at 50% duty cycle
100 A model: 100 A at 80% duty cycle
12 A model equipped with 20 ft (6.1 m) cable
25 A model equipped with 15 ft (4.6 m) cable; available with optional 25 ft (7.6 m) cable
27 A model equipped with 20 ft (6.1 m) cable;
40 A model equipped with 25 ft (7.6m) cable; available with optional 50 ft (15.2 m) cable
50 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable
55 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable
80 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable
100 A model equipped with 25 ft (7.6 m) cable; available with optional 50 ft (15.2 m) cable
Use air or nitrogen plasma gas:
12 A model: 1 CFM (28.3 L/min) at 40 PSI (276 kPa);
25 A model: 4.5 CFM (129 L/min) at 60 PSI (414 kPa);
27 A model : 4.5 CFM (129 L/min) at 60 PSI (414 kPa);
40 A model: 6 CFM (170 L/min) at 75 PSI (517 kPa);
50 A model: 5.3 CFM (152 L/min) at 70 PSI (482 kPa);
55 A model: 6 CFM (172 L/min) at 70 PSI (482 kPa);
80 A (C, CM, CX, and CXM) model: 7.2 CFM (207 L/min) at 80 PSI (551 kPa)
80 A (T and TM) model: 7.8 CFM (221 L/min) at 70 PSI (482 kPa)
100 A model: 9.2 CFM (260 L/min) at 75 PSI (517 kPa)
Safety interlock devices shut down power source
12 A, 27 A, 40 A, 50 A, 55 A, 80 A and 100 A models have safety trigger guard
Gear rack pitch for 50 A, 55 A, 80 A and 100A machine-held models: 32
Cutting capacity for mild steel:
12 A model − up to 3/16 in (5 mm) at 12 A;
25 A model − up to 3/8 in (10 mm) at 25 A;
27 A model − up to 3/8 in (10 mm) at 27 A;
40 A model − up to 1/2 in (12.7 mm) at 40 A;
50 A model − up to 7/8 in (22 mm) at 50 A;
55 A model - up to 1 in (25.4 mm) at 55 A;
80 A model − up to 1-1/4 in (32 mm) at 80 A
100 A model − up to 1-1/2 in (38 mm) at 100 A
OM-1593
Use above FORM number when ordering extra manuals.
2007−08
176 877T
©
2007 MILLER Electric Mfg. Co.

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Summary of Contents for Miller ICE-12C

  • Page 1 OM-1593 176 877T Use above FORM number when ordering extra manuals. 2007−08 ICE-12C, ICE-25C, ICE-25CX, ICE-27C, ICE-27T ICE-40C, ICE-50C, ICE-50CM, ICE-55C, ICE-55CM, ICE-80C, ICE-80CM, ICE-80CX, ICE-80CXM, ICE-80T, ICE-80TM, ICE-100T, And ICE-100TM Torches Specifications Air-cooled torches for plasma arc cutting (PAC) 12 A model: 12 A at 35% duty cycle;...
  • Page 2: Safety Symbol Definitions

    Safety Symbol Definitions DANGER! − Indicates a hazardous situation which, if not Wear safety glasses with side shields. avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, Cutting processes cause flying pieces of metal and could result in death or serious injury.
  • Page 3 Installing 12 Ampere Torch And Work Cable, And Using Trigger Safety Lock If torch or work cable needs to be removed or replaced, proceed as follows: Turn power Off, disconnect input power plug from receptacle. Remove wrapper from unit. Torch Connections Remove existing torch cable from unit.
  • Page 4 Installing 25 Ampere Torch And Work Cable Turn Off power source, and disconnect input power plug from receptacle before installing torch and work cable. Remove top and screws holding front panel in place. Without discon- necting any plugs, move front panel to allow access.
  • Page 5 Installing 27 Ampere (ICE-27C) Torch And Work Cable, And Using Trigger Safety Lock If torch or work cable needs to be removed or replaced, proceed as follows: Turn power Off, disconnect input power plug from receptacle. Remove wrapper from unit. Torch Connections Remove existing torch cable from unit.
  • Page 6 Installing 27 Ampere (ICE-27T) Torch And Work Cable, And Using Trigger Safety Lock Check voltage according to Owner’s Manual, and be sure voltage is near zero before touching any parts. If torch or work cable needs to be removed or replaced, proceed as follows: Turn power Off, and disconnect input power plug from receptacle.
  • Page 7 Installing 40 Ampere Torch And Work Cable If torch or work cable needs to be removed back of strain relief. Strain Relief or replaced, proceed as follows: Remove nut, located inside of unit, from Slide torch cable, connector, and plugs back of strain relief.
  • Page 8 Installing 50 Ampere, 55 Ampere or 80 Ampere Torch And Using Trigger Safety Lock Turn Off power source, and disconnect input power plug The 50 ampere torch is shown in the illustrations below. from receptacle before The procedure for the 55 ampere and 80 ampere installing torch.
  • Page 9 10. Installing Either 80 Ampere Or 100 Ampere T/TM Torch Turn off power source and disconnect input power. Torch Connector Quick Connect Collar Nipple Receptacle Securing Pin To connect torch: Push torch connector onto receptacle and quick connect until collar secures nipple. Rotate securing pin to lock connector to unit.
  • Page 10 11. Sequence Of Operation For 12 Ampere Torch EXAMPLE Of Cutting Operation Moisture from the compressor will form in the air line and at the torch. It will be normal to sometimes see moisture come out the end of the torch. The pilot arc starts immediately when trigger is pressed.
  • Page 11 12. Sequence Of Operation For 27 Ampere Torch EXAMPLE Of Cutting Operation The pilot arc starts immediately when trigger is pressed. Place tip on work for drag cutting. Raise trigger lock and press After cutting arc starts, slowly trigger. Pilot arc starts. start moving torch across metal.
  • Page 12 13. Sequence Of Operation For 25, 40, 50, 55, 80, And 100 Ampere Torches NOTICE − Having pilot arc turn On and Off repeatedly, Inspect shield cup, tip, and electrode for wear be- such as during the cutting of chain fence, will shorten tip, fore cutting or whenever cutting speed has been electrode and torch life.
  • Page 13: Routine Maintenance

    14. Routine Maintenance Turn Off power source 25 ampere torch is shown. and disconnect Maintenance schedule for input power plug 50 and 80 ampere torches is the same. before maintaining. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Each...
  • Page 14 16. Checking/Replacing Retaining Cup, Tip, And Electrode For 12 And 27 Ampere Torch Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch with- out a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE −...
  • Page 15 17. Checking/Replacing Retaining Cup, Tip, And Electrode For 25, 40, 50, And 55 Ampere Torches Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE −...
  • Page 16 18. Checking/Replacing Retaining Cup, Tip, And Electrode For 80 Ampere (C/CM) Torch Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch with- out a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE −...
  • Page 17 19. Checking/Replacing Retaining Cup, Tip, And Electrode For 80 Ampere (CX/CXM/ T/TM, And 100 T/TM) Torch Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch with- out a tip or electrode in place. Be sure to use genuine replacement parts. NOTICE −...
  • Page 18 20. Troubleshooting For 12 Ampere Torch Torch travel speed too slow; increase travel speed (see Power Source Owner’s Does arc go Manual). Clean or replace See Power Source Owner’s torch consumables Manual. while cutting? necessary (see Section 16). Be sure work clamp is securely attached workpiece.
  • Page 19 21. Troubleshooting For 25, 27, 40, 50, 55, 80, And 100 Ampere Torches Trouble Remedy Power source Cup trouble light On; no Tighten cup onto torch and reset Power (see Section 15). cutting output. Check torch connections on power source. See power source Owner’s Manual. Sparks come out top of cut, or cut is not Torch travel speed too fast;...
  • Page 20: Parts Lists

    PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. ICE−12C Check before each use and hourly CONSUMABLES during operation. 206 304 206 304 Figure 22-2. Consumable Parts For ICE-12C OM-1593 Page 20...
  • Page 21 Item Part Description 183 428 Handle Assy, complete (1) 177 893 Leads, 15ft (1) 177 894 Leads, 25ft (1) 178 550 Main Body (1) 171 248 Push Button Switch (1) 169 231 Grease, silicone (1) 195 007 Torch, replacement 20ft (1) See Figure 22-4 for additional consumable parts.
  • Page 22 Item Part Description 183 427 Handle Assy, complete (1) 171 248 Push Button Switch (1) 205 881 Leads, 20ft (1) 203 119 Main Body (1) 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 195 007 Torch, replacement 20ft (1) See Figure 22-6 for additional...
  • Page 23 Item Part Description 183 427 Handle Assy, complete (1) 171 248 Push Button Switch (1) 203 120 Leads, 20ft (1) 203 119 Main Body (1) 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 195 014 Torch, replacement 20ft (1) See Figure 22-8 for additional...
  • Page 24 Item Part Description 183 427 Handle Assy, complete (1) 171 248 Push Button Switch (1) 228 405 Leads, 12 ft (1) 203 119 Main Body (1) 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 225 615 Torch, replacement 12 ft (1) See 22-10 for...
  • Page 25 Item Part Description 195 110 ICE-40C 25ft Torch 195 111 ICE-40C 50ft Torch 183 427 Handle Assy, complete (1) 192 059 Main Body (1) 209 298 Leads, 25ft (1) 209 299 Leads, 50ft (1) 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 171 248...
  • Page 26 Item Part Description 183 427 Handle Assy, complete (1) 171 248 Push Button Switch (1) 179 829 Leads, 25ft (1) 179 830 Leads, 50ft (1) 188 794 Main Body (1) 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly 169 231 Grease, silicone (1) 176 824...
  • Page 27 Item Part Description 192 050 Cup, shield (1) 169 232 O-Ring, 55A (1) 180 343 Main Body (1) 180 610 Position Sleeve (1) 180 342 Leads, 50ft (1) 180 605 Remote Pendent Control (1) 180 611 Torch Sleeve (1) 192 058 Shield, machine (1) 169 231 Grease, silicone (1)
  • Page 28 Item Part Description 183 427 Handle Assy, complete (1) 171 248 Push Button Switch (1) 192 062 Leads, 25ft (1) 192 063 Leads, 50ft (1) 192 059 Main Body (1) 202 932 Plunger Kit (for out-of-warranty torches) 185 833 Switch Assembly w/spring (1) 190 220 Spring, trigger assembly...
  • Page 29 Item Part Description 192 050 Cup, shield (1) 169 232 O-Ring, 55A (1) 192 060 Main Body (1) 180 610 Position Sleeve (1) 192 061 Leads, 50ft (1) 180 605 Remote Pendent Control (1) 198 643 Torch Sleeve (1) 192 058 Shield, machine (1) 198 644 Ring, retaining (1)
  • Page 30 Item Part Item Part Description Description 187 300 Handle (1) 196 415 Torch Lead, 25ft (1) 190 502 Boot (1) 196 416 Torch Lead, 50ft (1) 190 503 #6 x 5/8 Philips Screw, 190 497 Plug Assy, pan head (5) quick disconnect (1) 196 682 Trigger and Switch...
  • Page 31 Item Part Description 180 610 Sleeve, torch position (1) 196 417 Torch Lead, 50ft (1) 190 497 Plug Assy, quick disconnect (1) 187 305 O-Ring, quick disconnect (1) 190 498 Plug, 3-socket female (1) 187 299 Main Body (1) 177 902 O-Ring, silicon .864 x .070 (1) 190 499...
  • Page 32 Item Part Item Part Description Description 215 594 Handle w/Screws (1) 215 606 Clip, retaining (1) 215 478 Cup Switch Sensor Kit (1) 187 305 O-Ring, quick disconnect (2) 215 479 Torch Head Repair Kit (1) 212 735 O-Ring, main body (1) 185 833 Switch Assy w/Spring (1) 218 177...
  • Page 33 Item Part Description 215 607 Sleeve, torch position (1) 219 964 Torch Lead, 50ft (1) 218 177 Plug Assy, quick disconnect (1) 190 498 Plug, 3 socket female (1) 215 599 Torch Sleeve (1) 215 598 Main Body w/Switch (1) 187 305 O-ring, quick disconnect (2) 219 944...
  • Page 34 Standard Cutting Retaining Drag Shield Electrode Swirl Ring O−Ring 212 730 212 733 212 726 212 724 212 734 212 735 Shield Apply silicone grease (169 231) 212 732 (Machine before installing. Cutting) ICE−80T Retaining Drag Shield CONSUMABLES 212 730 212 733 212 725 CAUTION...
  • Page 35 Item Part Item Part Description Description 215 594 Handle w/Screws (1) 215 606 Clip, retaining (1) 215 478 Cup Switch Sensor Kit (1) 212 735 O-Ring, main body (1) 223 775 Torch Head Repair Kit (1) 169 231 Grease, silicon 185 833 Switch Assy w/Spring (1) 225 702...
  • Page 36 CAUTION FAILURE TO RE− PLACE WORN TIP OR ELECTRODE Drag Shield Retaining Cap Electrode Swirl Ring WILL RUIN TORCH AND VOID WARRANTY. Turn off power before checking torch parts. Check before each use and hourly 212 730 212 733 212 725 during operation.
  • Page 37 CAUTION Shield Sense Tab* Retaining Cap Electrode Swirl Ring FAILURE TO RE− PLACE WORN TIP OR ELECTRODE WILL RUIN TORCH AND VOID 212 732 212 733 212 725 WARRANTY. Turn off power before checking torch parts. 226 763 Check before each use and hourly during operation.
  • Page 38 Item Part See 22-30 for additional Description consumable parts. 215 607 Sleeve, torch position (1) 223 614 Torch Lead, 25ft (1) 223 615 Torch Lead, 50ft (1) 215 599 Torch Sleeve (1) 223 773 Main Body (1) 195 513 Remote Pendant Control (1) 215 478 Sup Sensor Switch Kit (1) 225 706...