Miller Electric APT-1000 User manual

June
1989
FORM:
129
326
I
OWN
ERS
MANUAL
AUTO
ARC
MILLER
ELECTRIC
MFG.
CO~

718 S. BOUNDS
ST.
P.O. Box 1079

APPLETON.
WI
54912
USA
ADDITIONAL
COPY
PRICE
35
CENTS
MODEL
IMPORTANT Read and
understand
the entire
contents
of
this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment. This
unit
and
these
Instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand these
instructions.
APT-i
000
NWSA
CODE
NO. 4579
PRINTED
IN
U.S.A.

~--~-
-~-.
ONE YEAR
LIMITED WARRANTY
COVERAGE

Miller
Electric
Mfg.
Co.
warrants
to
the
buyer
who
purchases
this Auto
Arc
Welder
(Welder)
for
personal,
family
orhousehold
purposes
(Consumer)
thatthis
Welderwill
be free from defects
in
material
and
workmanship
fora
period
of
one
year from
the
date of
purchase.
This
warranty
covers
only
the
original
purchaser
of this Welder. Miller Electric
does
not
authorize
any
party,
including
its
authorized
distributors,
to
offer
any
other
warranty
on
behalf of Miller
Electric.
Upon expiration
of the
warranty
period,
Miller
Electric
shall
have
no
further
liabil
ity
related
to
the
Welder,
except
on
warranty
claims
made du
ring
the
warranty
period.
THIS
WARRANTY IS
OFFERED
IN LIEU OF
ANY OTHER
EXPRESS
WARRANTY;
AND,
EXCEPT TO
THE
EXTENT
PROHIBITED
BY
APPLICABLE
LAW,
THE DURATION
OF
ALL IMPLIED
WARRANTIES,
INCLUDING BUT
NOT
LIMITED TO THE
IMPLIED
WARRANTIES
OF
MERCHAN
TABILITY
AND
FITNESS FORA PARTICULAR
PURPOSE,
IS
LIMITED TO
THE DURATION OF THIS
WARRANTY.
Some
states do
not
allow limitations
on
how
long
an
implied
warranty
lasts,
so
the
above
limitation
may
not
apply
to
you.
This
warranty
gives
you
specific
legal rights,
and
you may
also
have other
rights
which
vary
from
state to
state.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components having
normal useful
life
of less than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
parts
that
come
in
contact with
the
welding
wire
including
nozzles and
nozzle
insulators
where failure does
not
result
from
defect in
workmanship
or
material.
Miller
shall
be
required
to
honor
warranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1. Arc
welders,
power
sources,
and
components
...
1
year
2.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
3. All welding
guns,
feeder/guns
and
torches
90
days
4.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
WHAT
IS NOT
COVEREDThis
warranty
does
not
extnd
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in-
warranty
repair
by
anyone
except
Miller
Electric.
Further,
this
warranty
only
extends
to those
purchasing
the
Welder
for
per
sonal,
family
or
household
purposes.
Commercial
and
indus
trial
users
are
given
a
different
warranty.
REMEDY FOR
DEFECTIVE
WELDER

Upon receipt
of
any
defective
Welder,
Miller Electric
will,
at its
option,
repair
or re
place
the
defective
Welder
at
its~xpense,
refund
or
credit the
purchase price (less
reasonable
depreciation
based
on
actual
use),
or
reimburse
the Consumer
for the
cost
of
repair
or re
placement
at
an
approved
Miller Electric
warranty
station,
pro
vided that
the
purchaser
of that Welder
has followed the
proce
dure for
obtaining
warranty
performance
set forth below. The
Welder
so
repaired
or
used
as a
replacementwill
be
shipped
to
the
purchaser
of
the defective
Welder,
with
transportation
charges prepaid
to
any
destination
in the continental
United
States
(transportation
charges
on
shipments
to
Alaska
or
Hawaii will be
paid
only
to
the
nearest
port
of
export).
THE PURCHASERS REMEDIES
FOR A
DEFECTIVE
WELDER,
TO
THE EXTENT
PERMITTED BY
APPLICABLE
LAW,
ARE
LIMITED
TO THE REMEDY
PROVIDED
BY THIS
WARRANTY:
AND,
TO
THE
EXTENT
ENFORCEABLE
UNDER APPLICABLE
LAW,
MILLER ELECTRIC
SHALL IN
NO
EVENT BE
LIABLE
FOR
CONSEQUENTIAL,
INCIDEN
TAL OR SPECIAL DAMAGES
ARISING
OUT OF THE
USE
OF,
OR INABILITY TO
USE,
THE
WELDER,
WHETHER
BASED
ON
BREACH OF
THIS
WARRANTY,
MILLER
ELECTRICS NEGLIGENCE
OR
OTHER
TORT,
OR ON ANY
THEORY
OF
STRICT LIABILITY.
Some
states
do
not
allow
the exclusion
or
limitation of
conse
quential
or
incidental
damages,
so
the
above
limitations
may
not
apply
to
you.
PROCEDURE
FOR
OBTAINING
WARRANTY
PERFORM
ANCE
As
soon
as
any
defect in
a
Welder
becomes
known,
the
pur
chaser of
the
Welder
must,
within
thirty
(30)
days,
notify
an
approved Warranty
Station
or
Miller
Electric
in
writing
of
the
defect. The
purchaser
must
then,
within
the
one
year
warranty
period,
return the
Welder
to
Miller
Electric
at
the
following
ad
dress:
Miller Electric
Mfg.
Co.
1635
W.
Spencer
St.
P.0
Box
1079
Appleton,
Wisconsin
54912
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
must
be
prepaid.
_
__
I

RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record the Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit. The
infor
claims for
loss
or
damage
with the
delivering
carrier.
mation
is located
on
the data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
________________________________________
ers
Transportation
Department.
Senal
or
Style
No.
_________________________
When
requesting
information
about
this
equipment,
al
ways
provide
the Model
Description
and
Serial
or
Style
Date
of
Purchase
__________________________
Number.
TABLE
OF
CONTENTS
.
Section
No.
Page
No.
SECTION
1

SAFETY
RULES
1-1.
Prevent Electric
Shock
1
1-2.
Prevent Fires
And
Burns
1
1-3.
Provide
Protection
From
Fumes And
Gases
I
1-4.
Protect
Eyes
And
Skin
From
Arc
Rays;
Protect Ears
From
Noise
.
~ 2
1-5.
Protect
Compressed
Gas
Cylinders
2
1-6.
Provide
Proper
Equipment
Maintenance
2
1-7..
Additional
Safety
Information
2
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
General
Information And
Safety
3
2-2.
Safety
Alert
Symbol
And
Signal
Words
3
SECTION
3
SPECIFICATIONS
3-1.
Duty
Cycle
4
3-2.
Description
4
SECTION
4INSTALLATiON
4-1.
Removing
Torch
4
4-2.
Installing
Torch
4
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Plasma
Arc
Cutting
(PAC)
7
5-2.
Cutting
Problems
And
Recommendations
7
5-3.
Shutting
Down
7
SECTION
6
MAINTENANCE
6-1.
Routine
Maintenance
7
6-2.
Shield
Cup,
Tip,
And
Electrode
Inspection
And
Replacement
8

Section
No
Page
No.
SECTION
7

PARTS
LIST
Figure
7-1.
Torch,
APT-i 000
9
LIST OF
CHARTS
AND
TABLES
Table
3-1.
Specifications
3
Table
6-1.
Maintenance
Schedule
8

SECTION
1
-
SAFETY RULES
a
WARNING: UNSAFE
PROCEDURES
OR
e.
Whenever
possible,
cut
over
a
water
table
or
PRACTiCES
can cause
serious
personal
in-
worktable
designed
to
minimize
sparks
and
I
ir~
Jury
or
death and
cause
fires,
hazards.

Read,
understand,
and
follow
ALL
of
these
f.
Cutting
aluminum
plate
on
a
water
table
may
safety
rules
before
installing,
operating,
or
seri
icing
this
equipment.
cause
hydrogen
detonation
beneath
the
workpiece.
Contact
equipment
manufacturer

Be
sure
that
all end
users
of
this
equipment,
i
for
recommended
practices
for
cutting
alumi
the
operator
and
helpers,
read and
understand
num.
these
safety
rules.
.
.
.
I

In
addition,
be
sure
that
all
users
of
this
equip-
g.
Do
not
cut
pressunzed
lines,
pipes,
or
c
ntain
ment
read
and
follow
the
in
formation
in
this
ers.
ri~g
has
entire Owners ManuaL
h.
Do
not
cut
electrical
conduit
unless
all
w
been
removed.
1-1.
PREVENT
ELECTRIC SHOCK
i.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Touching
live electrical
parts
can
cause
severe
burns
to
the
body
or
fatal shock.
Severity
of
electrical
shock is de-
j.
For
additional
information,
refer
to
N
FPA
Stan
termined
by
the
path
and
amount
of
current
through
the
dard
51 B
listed
in
Section
1-7.
body.
Therefore:
1-3.
PROVIDE
PROTECTION
FROM
FUMES
AND
a.
Do
not
touch
live
electrical.parts.
GASES
b.
Do
not
work in
wet
or
damp
areas.
Breathing
cutting
fumes
and
gases
can
be
hazardous
to
your
health.
c.
Wear
dry insulating gloves
and
body
protection.
a.
Keep
your
head
out
of
the
fumes.
d.
Disconnectallpowerbeforeinstallingorservic-
b.
Use
adequate
ventilation
in
the
work
area
to
ing
this
equipment.
keep
fumes
and
gases
from
your
breathin~
e.
Turn
off
all
equipment
when
not
in
use.
zone
and the
general
work
area.
I.
Properly
install and
ground
thecutting
power
c.
If
ventilation
is
inadequate,
use an
approved
-
source
according
to
its
Owners
Manual
and
all
breathing
device.
applicable
codes.
d.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and the
manufacturers
instructions
for
any
g.
Do
not
use
worn or
damaged
cables
or
cables
materials
cut.
that
are
too
small
or
poorly
spliced.
e.
Do
not
cut
containers
or materials
which
have
h.
Do
not
wrap
cables
around
your
body.
held
or
been
in
contact
with
hazardous
sub
i.
Turnoff
the
power
source
before
touching
torch
stances
unless
they
are
property
cleaned
and
tip
or
removing
any
torch
parts.
prepared
according
to
AWS
standard
F4.1
listed
in
Section
1-7.
j.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged parts
at
once.
f.
Do
not
cut
painted,
plated,
or
coated
parts
unless
special
ventilation
is
provided
to
remove
1-2.
PREVENT
FIRES
AND
BURNS
highly
toxic
fumes
or
gases.
The
flying
sparks
and
hot
metal,
hot
workpiece,
and
hot
g.
Be
aware
that
cutting
containers,
such
as
bar-
equipment
can
cause
fires
and
bums.
rels,
tanks,
and
pipes
can
result in
explosions,
fire,
or
poisonous
fumes.
Therefore,
cut
con-
a.
Do
not cut
where
flying
sparks
can strike
f
lam-
tainers
only
after
they
have
been
properly
mable
material.
cleaned
and
prepared
according
to
AWS
stan
b.
Remove
allflammables
from
the
work
area,
or
dard F4.1
listed
in
Section
1-7.
move
work
to
a
different
lOcation free
of
com-
h.
Be
aware
that
vapors
from
chlorinated
solvents
bustible material,
such
as
trichloroethylene
and
perchloro
c. Protect
yourself
and
others
from
flying
sparks
ethylene
can
be
decomposed
by
the
heat
and
and hot
metal.
light
rays
from
the
arc
to
form
Phosgene,
a
highly
toxic
gas,
as
well
as
other
lung
and
eye
d.
Wear
correct
eye,
face,
and
body
protection
in
irritating
products.
Therefore,
DO NOT
CUT
the
work
area.
where
solvent
vapors
can
be
drawn
into
the
cut-
129
326
Page
1

ting atmosphere,
or
where
arc
rays
can
pene
trate
to
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
perchloro
ethylene.
i.
Do
not cut
in
a
confined
space
unless
it
is
being
well
ventilated
or,
if
necessary,
while
wearing
an
air-supplied respirator.
j.
Do
not cut
coated
metals
unless
the
coating
is
removed from
the
work
surface,
the
area
is
well
ventilated,
or,
it
necessary,
while
wearing
an
air-
supplied respirator.
1-4.
PROTECT
EYES
AND
SKIN FROM
ARC
RAYS;
PROTECT EARS
FROM
NOISE
Arc
rays
from
the
cutting
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise
from
some
cutting
processes
can
damage
hear
ing.
a.
Wear
a
welding
helmet
fitted
with
a
proper
filter
lens
or
a
face shield
with
correct
filter
shade
(see
ANSI
Z49.i and
ANSI
Z87.1 listed in
Sec
tiOn
1-7
for
detailed
information).
b.
Use
protective
screens or
barriers
to
protect
others
from
flash
and
glare.
c.
Wear
protective
clothing
and
foot
protection.
d.
Aiways
wear
safety
glasses
or
safety
goggles
in
a
work
area.
-
e.
Wear
proper
ear
protection.
1-5.
PROTECT
COMPRESSED GAS
CYLINDERS
Since
gas
cylinders
are
often
part
of
the
cutting
process,
be
sure
to
treat
them
carefully.
a.
Protect
compressed
gas
cylinders
from
exces
sive
heat,
mechanical
shocks,
and
arcs.
b.
Install
and
secure
cylinders
so
that
they
cannot
fall
or
tip
over
by
fastening
them
to
a
mounting
bracket,
wall,
or
other
stationary
support.
c.
Keep cylinders
away
from
any
cutting
or
other
electrical
circuits.
1-6.
PROVIDE
PROPER
EQUIPMENT
MAINTE
NANCE
Improperly
maintained
equipment
can
result in
poor
work,
but
most
importantly
it
can cause
physical
injury
or
death
through
fires
or
electrical
shock.
Therefore:
a.
Always
have
qualified
personnel
perform
the
installation,
troubleshooting,
and
maintenance
work.
Do
not
perform
any
electrical
work
unless
you
are
fully
qualified.
b.
Before
performing
any
maintenance
work
on a
torch
or
inside
a
power supply,
disconnect the
płwer
supply
from
the electrical
power
source.
c.
Maintainlorch
and
cables,
groundingwire,
con
nections,
power
cord,
and
power
supply
in
safe
working
order. Do
not
operate
any
equipment
in
questionable
condition.
d. Do
not
abuse
any
equipment
or
accessories.
Keep
equipment
away
from heat
sources
such
as
furnaces,
wet
conditions such
as
water
pud
dles,
oil
or
grease,
corrosive
atrT%~spheres,
and
inclement weather.
I
e.
Keep
all
safety
devices, handles,
guards,
pan
els,
and
covers
in
position
and in
good
repair.
f.
Use
equipment
for
its
intended purpose.
Do
not
modify
it
in
any
manner.
1-7.
ADDITIONAL
SAFETY
INFORMATION
For
more
information
on
safe
prac~ic~es
for
setting
up
and
operating
electric
cutting
equipment
and
on
good
work
ing
habits,
refer
to
the
latest
revisions
of
the
following.
standards,
and
comply
as
applicable.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING,
obtainable
from
the American
WeIdin~
Soci
ety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
OSHA,
SAFETY
AND HEALTH
STANDARDS,
29
CFR
1910,
obtainable from
the
Superintendent
of
Docu
ments,
U.S.
Government
Printin~
Office,
Washington,
D.C.
20402.
ANSI
Standard
Z87.1,
PRACTICE
FOR
OCCUPA
TIONAL
AND
EDUCATIONAL EYE
AND
FACE
PRO
TECTION,
obtainable
from the
american
National
Stan
dards
Institute,
1430
Broadway,
New
York,
NY
10018.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
ll4
THE
USE OF CUTTING
AND
WELDING
PROCESSES,
ob
tainable from
the
American National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
American
Welding Society
Standard
AWS
F4.1,
REC
OMMENDED SAFE
PRACTICES
FOR
THE PREPA
RATION
FOR
WELDING
AND
CUTTING OF
CON
TAINERS
THAT
HAVE HELD
HAZARDOUS SUB
STANCES,
obtainable
from
the American
Welding
Soci
ety,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
NFPA
Standard
70,
NATIbNAL
ELECTRICAL
CODE,
obtainable
from the
National
Fire
Protection
Associa
tion,
Batterymarch
Park,
Quincy,
MA
02269.
American
Welding Society
Standard
AWS
C5.2,
REC
OMMENDED
PRACTICES
FOR
PLASMA
ARC
CUT
TING,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd, Miami,
FL
33126.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES,
obtainable
from
the
National
Fire
Protec
tion
Association,
Batteryrnarch
Park,
Quincy,
MA
02269.
GSA
Standard
Wi
17.2,
CODE
FOR SAFETY
IN
WELD

ING
AND
CUTTING,
obtair~abIe
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
See
also
the
Standards
Booklet
Index
in
the
cutting
power
source
Owners
Manual.
129
326
Page
2

SECTION
2-
SAFETY
PRECAUTIONS
AND
SIGNAL WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
A.
General
The
following
safety
alert
symbol
and
signal
words
are
Information
presented
in
this
manual
and
on
various
Ia-
used
throughout
this
manual
to
call attention
to
and iden
bels,
tags,
and
plates
on
the unit
pertains
to
equipment
tify
different
levels
of
hazard and
special
instructions.
design,
installation,
operation,
maintenance,
and
P~
This
safety
alert
symbol
is used with
the
signal
troubleshooting
which
should be
read, understood,
and
~
words
WARNING
and
CAUTION
to
call
atten
followed forthe safe and effective
use
of this
equipment.
tion
to
the
safety
statements.
I
B.
Safety
WARNING
statements
identify
procedures
or
The
installation,
operation,
maintenance,
and trouble-
practices
which
must
be
followed
to
avoid
seri
shooting
of
plasma
arc
cutting equipment
requires
prac-
ous
personal injury
or
loss
of life.
tices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
CAUTION
statements
identify
procedures
or
installed,
operated,
and
maintained
only by
qualified
practices
which
must
be
followed
to
avoid minor
persons
in
accordance
with
this
manual
and
all
applica-
personal
injury
or
damage
to
this
equipment.
ble codes such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section 1

Safety
Rules and
Section 1

Safety
IMPORTANT
statements
identify
special
instructions
Rules For
Plasma
Arc
Cutting (PAC)
in
the
power
source
necessary
for
the
most
efficient
operation
of
this
equip-
Owners Manual.
ment.
SECTION
3SPECIFICATIONS
Table 3-1.
SpecIfIcations
Amperage
Rating
At 60%
Duty_Cycle
Cable
Length
Plasma Gas
Air
Coolina
Method
Weight
Net
Ship
10
Amperes
15 ~
(4.6m)
0.6CFM
(17
LJmin.)
At
35
PSI
(1242
kPa)
Air
.
3.5
lbs.
(1.6
kg)
4.5
lbs.
(2.0
kg)
80
5-1/4
In.
(136
mm)
rrn-ii
(4~
~n)
L_J
(23
mm)
Figure
3-1.
Overall
DImensIons
s-ova
129326
Page
3

3-1.
DUTY
CYCLE
The
duty
cycle
is the
percentage
of
a
ten
minute
period
that
the
torch
can
be
operated
at
a
given
load
without
overheating
and
damaging
the
torch.
The torch
is
rated
at
60
percent
duty
cycle;
therefore,
the
torch
can
be
op
erated
at
10
amperes
for
six
consecutive
minutes,
but it
must
operate
at
no
load
forthe
remaining
four
minutes
to
allow
for
proper
cooling.
4A
CAUTION:
EXCEEDiNG
THE RATED
AM
PERAGE
and
duty cycle
will
damage
the
torch.

Do
not
exceed
rated
amperage
and
dutycycle
stated/n
Table 3-1.
3-2.
DESCRIPTION
The
model
APT-i
000
torch is
designed specifically
for
the
Plasma
Arc
Cutting
(PAC)
process.
The torch
can
cut
through
all
metals
with
the
capacity
to cut
3/16
in.
(4.7
mm)
mild
steel.
The torch is
designed
to
protect
the
operatorfrom
touch
ing
live
internal torch
parts.
This
safety design
is
accom
plished by
means
Of
a
shield
cup
detector
circuit.
If
the
shield
cup
comes
loose
or
is
removed,
the
circuit
is
opened.
The torch is
equipped
with
two
shield
cup
detec
tor
leads
which
provide
a
safety
circuit
for
the
operator
when
they
are
property
connected
to
the
plasma
arc
cut
ting
power
source.
These
leads
are
connected
to two
pins
in
the
torch
head which
make
contact
with
the
shield
cup
thereby completing
the
safety
circuit
to
the
power
source.
The
power
source
must
be
designed
so
that
when this circuit
is
open
there
will
be
no
power
at
the
torch.
The
alphanumeric
model
designation
refers
to
the fol
lowing:
A-Air
P
-
Plasma
T-Torch
I
1000
-
Amperage Rating:
10
Amperes
Plasma is air
which
has
been
heated
to
an
extremely
high
temperature
and
ionized
so
that
the
air
becomes.
electrically
conductive.
The
electrode
is
located
inside
the
tip
of
the torch. The torch
tip
has
a
small
opening
(ori
fice)
which
constricts
the
arc.
The
compressed
air flows
through
the
arc
where it
is
heated to
the
plasma
tem
perature
range.
Since
the air
cannot
expand
due
to
the
constriction
of the
tip,
air
is
forced
through
the orifice and
emerges
in
the
form
of
a
highly
compressed
airstream.
The
heat
formed
by
the
arc
and
the
plasma
melts the
metal,
and
the
airstream
forces the molten
metal from
the
cut.
SECTION
4-
INSTALLATION
IMPORTANT: See
powersource
Owners
Manualforlo
cation
of
torch
connections.
4-1.
REMOVING TORCH
(FIgure
4-1)
To
remove
torch,
refer
to
Figure
4-1,
and
proceed
as
fol
WARNING:
ELECTRIC
SHOCK
can
kIll.

Do
not
touch
live
electrical
parts.

Turn
off
power
source,
and
remove
input
power
plug
from
receptacle
before
inspecting
or
installing.
MOVING
PARTS
can cause
serIous
Injury.

Keep
away
from
moving
parts.
HOT
SURFACES
can cause
severe
burns.

Allow
cooling
period
before
servicing.
1.
Open
lower
front
panel
access
door
or
remove
wrapper,
as
applicable.
2.
Loosen
strain
relief,
and
disconnect
torch
cable
from
air/torch
(-)
output
connector.
3.
Disconnect
pilot
arc/shield
cup
detector
lead
1
and
shield
cup
detector
lead
2
from
terminal
strip
iT.
4.
Disconnect
torch switch
leads
3
and
4
from
terminal
strip
1T.
5.
Remove
torch
cable
and
leads
from
power
source.
4-2.
INSTALLING
TORCH
(FIgure
4-1)
To
install
torch,
refer
to
Figure
4-1,
and
proceed
as
follows:

Turn off
power
source,
and
remove
input
power
plug
from
receptacle
before
inspecting
or
installing.
MOVING
PARTS
can
cause
serIous
Injury.

Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.

Allow
cooling period
before
servicing.
1.
Route
new
torch
cable
and
leads
through
strain
relief.
2.
Connect
torch
cable
to
air/torch
(-)
output
connector.
3.
Connect
pilot
arc/shield
cup
detector lead
ito termi
nal
1
on1T.
4.
Connect
shield
cup
detector
lead
2
to
terminal
2
on
iT.
5.
Connect
torch
switch lead
3
to
terminal
3
on
iT.
6.
Connect
torch
switch
lead
4
to
terminal
4
on
iT.
lows:
a
4A
WARNING:
ELECTRIC SHOCK
can
kIll.

Do
not touch
live
electrical
parts.
129
326
Page
4

7.
Secure
torch
cable and leads
in
strain
relief.
8.
Close
and
secure
lower front
panel
access
door
or
reinstall
and
secure
wrapper.
Torch
9.
Reconnect
power
source
input
power
plug
into
115
volts
ac
receptacle.
TC-124
813
2
Figure
4-1.
Torch
Connections
And
Parts
Torch
Body
Shield
Cup
lIp
Electrode
TIp
And
Electrode
Wrench
Torch
Handle
Pilot
Arc/Shield
Cup
Detector
Lead
1
Air/Torch
(),
Connector
Torch
Switch
Leads
3
And
4
129
326
Page
5

SECTION
5
SEQUENCE
OF
OPERATION
.
WARNING: PLASMA
ARC
CUTTING
can
be
hazardous;
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on
or
near
com
bustible
surfaces.

Only
qualified
persons
are
to
operate
this
equipment
according
to
all
codes and
em
ployers
safety practices.

Do
not
locate
unit
over
combustible
sur
faces.

Keep
children
away.
CUTTING
CONTAINERS,
such
as
bar
rels, tanks,
and
pipes,
can
result
In
ex
plosions,
fire,
or
poisonous
fumes.

Cut
containers
only
after
they
have
been
properly
cleaned
and
prepared.

Never
cut
pressurized
lines,
pipes,
or
containers.
ELECTRIC SHOCK
can
kill;
IMPROPER
AIRFLOW
AND
EXPOSURE TO ENVI
RONMENT
can
damage
internal
parts.

Do
not
touch
live
electrical
parts.

Keep
all
covers,
panels,
and
guards
se
curely
in
place.

Wear
dry insulating
gloves
and
body
pro
tection.

Do
not
use
cables
or
torch
with
damaged
insulation.

Turn
off
power
source,
and
remove
input
power
plug
from
receptacle
before
cleaning
slag
from
torch
tip
or
replacing
any
torch
parts.

Maintain
at
least 10
inches
(254
mm)
of
unrestricted
space
on
all
sides
of
power
source,
and
keep
underside
free
of
obstruc
tions.

Do
not
place
any filtering
device
over
the
intake
air
passages
of
the
power
source.
Warranty
is
void
if
the
power
source
is
oper
ated with
any
portion
of
the
outer
enclosure
removed.
FUMES
AND
GASES
can
seriously
harm
your
health.

Keep
your
head
out
of
any
fumes.

Ventilate
area,
or
use
approved
breath
ing
device.

Read
Material
Safety
Data
Sheets
(MSDSs)
and
manufacturers
instructions
for
any
materials
used.

When
possible
cut
over
a
water
table
or
work
table
designed
to
minimize
fumes,
gases,
and
sparks,
except
for
aluminum

see
next
statement.

Cutting
aluminum
on
a
water
table
may
cause
hydrogen
detonation beneath the
workpiece.
Contact
equipment
manufac
turer
for
recommended
pra
ctices
for
cutting
aluminum.
FLYING SPARKS
AND
HOT METAL
can
cause
fire
and burns.

Do
not cut
where
flying sparks
can
strike
flammable
materiaL
f
Protect
yourself
and
others
from
flying
sparks
and
hot metal.

Allow
work
and
equipment
to
cool before
handling.

Watch
for
fire,
and
keep
a
fire extin
guisher nearby.
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.

Wear
safety
goggles
with
correct
filter
shade.

Wear
a
face shield.

Cover
skin.

Protect
ears.
PILOT
ARC
can cause
burns..

Keep
torchtipawayfrompersonnel
when
switch
is
pressed.
CUTTING
WORKPIECE
ON CONCRETE
FLOOR
can
cause concrete
to
explode.

Do
not
place
workpiece
directly
on
con
Crete
floor.
HOT
METAL
SPARKS
will
mark
glass
and burn
trim.

Remove,
cover,
or
protect
any
glass
or
trim.
CUTTING
CURRENT
can
damage
vehi
cle
computer(s)
and other
electronic
components.

Disconnect
both
battery
cables
before
cutting
on
a
vehicle.

Place
work
clamp
as
close
to
the
cut
as
possible
to
avoid
long
electrical
paths.

Be
sure
torch
to
power
source as
well
as
lead
connections
to
work
clamp
are
clean
and
tight.

To minimize
risk,
disconnect
the
com
puter(s)
from
the
vehicle.
See
Section 1
-
Safety
Rules
and
Section
1

Safety
Rules
For
Plasma
Arc
Cutting
(PAC).in
the
power
source Owners
Manual
for
basic
safety
information.
a
129
326
Page
6

5-1.
PLASMA
ARC
CUTI1NG
(PAC)
4A
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
entire Section
5
before
proceeding.
1.
~Install
and
connect
torch
according
to
Section
4.
CAUTION:
TIP
AND
ELECTRODE
WEAR BE
YOND RECOMMENDED
VALUES
or
OPERA
TION WITHOUT
TIP
OR
ELECTRODE
can
damage
torch.

Inspect
shield
cup,
tip,
and
electrode before
cutting
or
whenever
cutting
speed
has
been
sig
nificantly
reduced
(see
Section
6-2).

Do
not
operate
torch
without
a
tip
or
electrode
in
place.
2.
Turn
on
air
supply
at
the
source,
if
applicable.
3.
Adjust
controls and
turn
on
power
source
according
to
power
source
Owners Manual.
4.
Wear
dry
insulating
gloves
and
clothing,
and
wear
goggles
with
correct
filter shade
according
to
ANSI Z49.1.
5.
Connect
work
clamp
to
clean
,
bare metal
at
workpiece.
6.
Place
tip
of
tOrch
at
edge
of
metal
to
be
cut with
hole
in
tip just
over
metal
edge.
7.
Press torch
switch.
8.
Once
arc
starts,
drag
tip
slowly
and
smoothly
across
material.
Adjust
torch
speed
so
that
sparks
are
di
rected
through
material
away
from
torch
tip. Proper
cutting speed
is
being
used when
sparks
go
out
bot
tom
of
cut.
9.
Pause
briefly
at
end
of
cut to
allow
metal
bridge
to
be
cut,
and
then
release
torch
switch.
IMPORTANT: The
torch
can
also
be
used to
pierce
the
material
to start
a
cut
away
from the metal
edge.
On
light
gauge
material,
there
will
be
little
or
no
additional
wear
on
tbrch
parts,
but
as
the
material
becomes
thicker,
the
wear
will increase
accordingly.
Always
pierce using
a
100
angle
to
the
material
so
that
molten
metal
will
be
blown
away
from the
torch
tip.
Molten
metal
blowing
back
onto
the
torch
tip
will
further
reduce the
tip
life.
Wear
a
face
shield
if
any
piercing
is
to
be
part
of
the
op
eration.
5-2.
CUTTING
PROBLEMS
AND
RECOMMENDA
TIONS
1.
If
sparks
come
out
top
of
cut
or
cut
is
not clean:
a.
The
torch
is
being
moved
too
fast;
slow
torch
travel.
b.
The
workpiece
being
Cut
is
too
thick.
c.
Tip
or
electrode
worn;
replace
tip
or
electrode
(see
Section
6-2).
2.
If
arc
goes
out
while
cutting:
a.
The
torch
was
lifted
too
far
from
workpiece;
place
torch
on
workpiece
while
cutting.
b.
Work
clamp
disconnected;
connect
work
clamp
to
clean,
bare metal
at
workpiece.
c.
See
power
source
Owners
Manual
for
addi
tional remedies.
3.
If
arc
goes
on/off
while
cutting:
a.
The
torch
is
being
moved
too
slowly;
increase
torch travel.
b.
lip
or
electrode
worn;
replace
tip
or
electrode
(see
Section
6-2).
c.
See
power
source
Owners
Manual
for
addi
tional remedies.
5-3.
SHUTTING DOWN
1.
Stop
cutting.
2.
Allow
power
source
to
idle for
1
to
2
minutes.
3.
Turn
off
power
source.
4.
Turn
off air
supply
at
the
source,
if
applicable.
SECTION
6-
MAINTENANCE
6-1.
ROUTINE
MAINTENANCE
(Table
6-1)
a
WARNING: ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Turn
off
power
source,
and
remove
input
power
plug
from
receptacle
before
inspecting,
maintaining,
or
servic,ng~
MOVING PARTS
can
cause
serious
Injury.

Keep
away
from
moving
parts.
HOT
SURFACES
can
cause severe
burns.

Allow
cooling
period
before
servicing.
A. Torch
Cable
And
Leads
a
WARNING:
Read
and
follow
safety
Informa
tion
at
beginning
of entire
Section
6-1 before
proceedIng.
Every
three
months,
inspect
cable, leads,
and torch for
breaks
in
insulation.
Repair
or
replace
cable,
leads,
and
torch
if
insulation breaks
are
present.
Clean
and
tighten
connections at
each
inspection.
B.
ShIeld
Cup
Detector CircuIt
Once
a
week,
check
the
shield
cup
detector
circuit
ac
cording
to
the
power
source
Owners
Manual.
129 326
Page
7

Table
6-1.
Maintenance Schedule
To
inspect
and
replace
torch
parts,
proceed
as
follows:
Frequency*
MaIntenance
Before
cutting
or
as
required.
Check
air
pressure
if
applicable
(see
power
source
Owners
Manual). Inspect
shield
cup,
tip,
and
electrode
(see
Section
6-2).
Every
week.
Check
shieldcup
detector
circuit
(see
power
source
Owners
Manual).
Every
month. Unit
in
heavy
service environ
ments:
Check
cable,
leads,
and
torch.
Every
3 months.
I
Check
cable,
leads,
and
torch
(see
Section
6-lA).
*
Frequency
of service is based
on
units
operated
40
hours
perweek.
Increase
frequency
of
maintenance
if
usage
exceeds 40
hours
per
week.
6-2.
SHIELD
CUP,
TIP,
AND
ELECTRODE
INSPEC
TION
AND
REPLACEMENT
(Figure
4-1
And
Figure
6-1)
A~
WARNING: ELECTRIC SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Turn off
power
source,
and
remove
input
power
plug
from
receptacle
before
inspecting,
maintaininQ,
or
servicing.
HOT
SURFACES
can
cause
severe
burns.

Allow
cooling
period
before
servicing.
1.
Turnoff
power
source,
and
remove
input
power
plug
from
receptacle.
2.
Remove and
inspect
shield
cup.
If
shield
cup
is
cracked
or
broken,
obtain
new
shield
cup.
3.
Using
a
clean,
dry
cloth,
wipe
off
contact
surface
on
shield
cup
(see
Figure
6-1).
Remove
tip
using
supplied
wrench.
Inspect
hole
in
tip
(see
Figure
6-1).
If
hole
in
tip
is
de
formed
or
50
percent
oversize,
replace
tip.
6.
inspect
end of
electrode
(see Figure
6-1).
If
erosion
depth
of
electrode exceeds
0.039 in.
(1.0
mm)
or
cross-channel is
worn
off,
remove
and
replace
elec
trode
using
supplied
wrench.
7.
Reinstall
and
secure
tip
and
shield
cup.
8.
Reconnect
power
source
input
power
plug
into
115
volts
ac
receptacle,
and
resume
operation.
Contact
Surface
a
CAUTION:
TIP
AND
ELECTRODE
WEAR BE
YOND
RECOMMENDED
VALUES
or
OPERA
TION
WITHOUT
TIP
OR
ELECTRODE
can
damage
torch.

Inspect
shield
cup,
tip,
and
electrode
before
cutting
or
whenever
cutting
speed
has
been
sig
nificantly
reduced
(see
Section
6-2).

Do
not
operate
torch
without
a
tip
or
electrode
in
place.

Be
sure
to
use
only
genuine
replacement
parts.

A
good practice
is
to
replace
both
the
tip
and
electrode
at
the
same
time.
.~O
039
In
(1.0
mm)
Figure
6-1.
Shield
Cup,.TIp,
And
Electrode
Inspection
4.
5.
Shield
Cup
~59
In.
(1
.5
mm
Cross
Channel
~
Worn
Electrode
S-0083
129326
Page
8

11
SECTION
7
PARTS
LIST
3
4
Figure
7-1.
Torch,
APT-i
000
TC-124
813

Figure
7-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
i25 014
Torch,
Model
APT-i000
125
265
128
845
128
844
128 843
128
846
125
270
125
078
125 079
125
273
125
269
125268
125
074
125
266
125 285
Quantity
2
1
14-
.
13
.6
9~
7
Item
No.
Part
No.
TORCH BODY
1
ELECTRODE
1
TIP
1
CUP
1
WRENCH
1
POWER CABLE
ASSEMBLY
1
PILOT
AND
DETECTIVE
LEAD
1
TORCH
SWITCH
LEAD
1
HOSE SHEATH
1
HEAT
SHRINKABLE
TUBE
1
SWITCHCOVER
1
TORCH SWITCH
I
TORCH
HANDLE
1
INSULATINGTUBE
1
129
326
Page
9