Miller ICE-50 User manual

ICE-50, ICE-70, ICE-100,
ICE-70M, And ICE-100M
Processes
Description
Air Plasma Cutting
and Gouging
Air-Cooled Arc Plasma Cutting Torches
OM-1591 169 258B
December 1999
Visit our website at
www.MillerWelds.com

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. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s 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 couldn’t 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. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s 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. We’ve
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, there’s a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Milleroffers 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.

TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Plasma Arc Cutting Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance 2. . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Duty Cycle 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing 50 Ampere Torch 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing 70 Or 100 Ampere Torch 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Remote Control Connections For Machine-Held Torches 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATING THE TORCH 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Checking/Replacing Retaining Cup, Tip, And Electrode 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1591B

OM-1591 Page 1
SECTION 1 –SAFETY PRECAUTIONS - READ BEFORE USING
pom _nd_9/98
1-1. Symbol Usage
MeansWarning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
YMarks 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.
Consultsymbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Plasma Arc Cutting Hazards
YThe 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.
YOnly qualified persons should install, operate, maintain, and
repair this unit.
YDuring operation, keep everybody, especially children, away.
CUTTING can cause fire or explosion.
Hot metal and sparks blow out from the cutting arc.
Theflying 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.
DProtect yourself and others from flying sparks and hot metal.
DDo not cut where flying sparks can strike flammable material.
DRemoveall flammables within 35 ft (10.7 m) of the cutting arc. If this
is not possible, tightly cover them with approved covers.
DBe alert that sparks and hot materials from cutting can easily go
throughsmall cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
DDo not cut on closed containers such as tanks or drums.
DConnectwork cable to the work as close to the cutting area as prac-
tical to prevent cutting current from traveling long, possibly
unknownpaths and causing electric shock and fire hazards.
DNever cut containers with potentially flammable materials inside –
they must be emptied and properly cleaned first.
DDo not cut in atmospheres containing explosive dust or vapors.
DDo not cut pressurized cylinders, pipes, or vessels.
DDo not cut containers that have held combustibles.
DWear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
DDo not locate unit on or over combustible surfaces.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any cutting.
Touchinglive electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electricallylive whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
highervoltages 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
installedor improperly grounded equipment is a hazard.
ELECTRIC SHOCK can kill.
DDo not touch live electrical parts.
DWear dry, hole-free insulating gloves and body protection.
DInsulateyourself from work and ground using dry insulating mats or
covers big enough to prevent any physical contact with the work or
ground.
DDo not touch torch parts if in contact with the work or ground.
DTurn off power before checking, cleaning, or changing torch parts.
DDisconnect input power before installing or servicing this equip-
ment. Lockout/tagout input power according to OSHA CFR
1910.147(see Safety Standards).
DProperlyinstall and ground this equipment according to its Owner’s
Manualand national, state, and local codes.
DCheck and be sure that input power cord ground wire is properly
connectedto ground terminal in disconnect box or that cord plug is
connected to a properly grounded receptacle outlet –always verify
the supply ground.
DWhenmaking input connections, attach proper grounding conduc-
tor first.
DFrequentlyinspect input power cord for damage or bare wiring –re-
place cord immediately if damaged –bare wiring can kill.
DTurn off all equipment when not in use.
DInspect and replace any worn or damaged torch cable leads.
DDo not wrap torch cable around your body.
DGroundthe workpiece to a good electrical (earth) ground if required
by codes.
DUse only well-maintained equipment. Repair or replace damaged
parts at once.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DDo not bypass or try to defeat the safety interlock systems.
DUse only torch(es) specified in Owner’s Manual.
DKeep away from torch tip and pilot arc when trigger is pressed.
DClamp work cable with good metal-to-metal contact to workpiece
(not piece that will fall away) or worktable as near the cut as
practical.
DInsulatework clamp when not connected to workpiece to prevent
contact with any metal object.
SIGNIFICANT DC VOLTAGE exists on
internal parts of inverter power
sources AFTER the removal of input
power.
DTurn Off unit, disconnect input power, check voltage on input ca-
pacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Mainte-
nance Section of Owner’s Manual or Technical Manual before
touchingany parts.
ELECTRIC SHOCK can kill.

OM-1591 Page 2
DOn inverter power sources, failed parts can ex-
plode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.
EXPLODING PARTS can injure.
Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.
FLYING SPARKS can cause injury.
DWear approved face shield or safety goggles with side shields.
DWear proper body protection to protect skin.
DWear flame-resistant ear plugs or ear muffs to prevent sparks from
enteringears.
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.
ARC RAYS can burn eyes and skin.
DWear 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 mini-
mum) for all cutting currents less than 300 amperes. Z49.1 adds
thatlighter filter shades may be used when the arc is hidden by the
workpiece. As this is normally the case with low current cutting, the
shades suggested in Table 1 are provided for the operator’s conve-
nience.
DWear approved safety glasses with side shields under your helmet
or shield.
DUse protective screens or barriers to protect others from flash and
glare;warn others not to watch the arc.
DWear protective clothing made from durable, flame-resistant
material(leather and wool) and foot protection.
Table 1. Eye Protection For Plasma Arc Cutting
Current Level InAmperes Minimum Shade Number
Below 20
20 –40
40 –60
60 –80
#4
#5
#6
#8
Prolongednoise from some cutting applications can
damagehearing if levels exceed limits specified by
OSHA (see Safety Standards).
NOISE can damage hearing.
DUse approved ear plugs or ear muffs if noise level is high.
DWarn others nearby about noise hazard.
FUMES AND GASES can be hazardous.
Cutting produces fumes and gases. Breathing
these fumes and gases can be hazardous to
your health.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use exhaust at the arc to remove
cuttingfumes and gases.
DIf ventilation is poor, use an approved air-supplied respirator.
DRead the Material Safety Data Sheets (MSDSs) and the manufac-
turer’s instruction for metals to be cut, coatings, and cleaners.
DWork in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Fumes from cutting and oxygen deple-
tion can alter air quality causing injury or death. Be sure the
breathingair is safe.
DDo not cut in locations near degreasing, cleaning, or spraying oper-
ations.The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
DDo not cut on coated metals, such as galvanized, lead, or cadmium
platedsteel, unless the coating is removed from the cutting area,
the area is well ventilated, and if necessary, while wearing an air-
suppliedrespirator. The coatings and any metals containing these
elements can give off toxic fumes when cut.
DDo not cut containers with toxic or reactive materials inside or
containersthat have held toxic or reactive materials –they must be
emptiedand properly cleaned first.
PLASMA ARC can cause injury.
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.
DKeep away from the torch tip.
DDo not grip material near the cutting path.
DThe pilot arc can cause burns –keep away from torch tip when trig-
ger is pressed.
DWear proper flame-retardant clothing covering all exposed body ar-
eas.
DPoint torch away from your body and toward work when pressing
the torch trigger –pilot arc comes on immediately.
DTurn off power source and disconnect input power before disas-
semblingtorch or changing torch parts.
DUse only torch(es) specified in the Owner’s Manual.
Gas cylinders contain gas under high pressure. If
damaged,a cylinder can explode. Since gas cylin-
ders are normally part of metalworking processes,
be sure to treat them carefully.
CYLINDERS can explode if damaged.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flame, sparks, and arcs.
DInstalland secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
DKeep cylinders away from any cutting or other electrical circuits.
DNever allow electrical contact between a plasma arc torch and a
cylinder.
DNever cut on a pressurized cylinder –explosion will result.
DUse only correct gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated
parts in good condition.
DTurn face away from valve outlet when opening cylinder valve.
DKeepprotective cap in place over valve except when cylinder is in
use or connected for use.
DRead and follow instructions on compressed gas cylinders, asso-
ciated equipment, and CGA publication P-1 listed in Safety
Standards.

OM-1591 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
HOT PARTS can cause severe burns.
DDo not touch hot parts bare handed.
DAllow cooling period before working on torch.
MOVING PARTS can cause injury.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
FLYING METAL can injure eyes.
DWear safety glasses with side shields or face
shield.
MAGNETIC FIELDS can affect pacemakers.
DPacemaker wearers keep away.
DWearers should consult their doctor before go-
ing near plasma arc cutting operations.
OVERUSE can cause OVERHEATING.
DAllow cooling period; follow rated duty cycle.
DReduce amperage (thickness) or reduce duty
cycle before starting to cut again.
EXPLODING HYDROGEN hazard.
DWhencutting aluminum underwater or with the
water touching the underside of the aluminum,
free hydrogen gas may collect under the work-
piece.
DSee your cutting engineer and water table instructions for help.
FALLING UNIT can cause injury.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift unit.
DIf using lift forks to move unit, be sure forks are long enough to ex-
tendbeyond opposite side of unit.
FIRE OR EXPLOSION hazard.
DDo not locate unit on, over, or near combustible
surfaces.
DDo not install unit near flammables.
DDo 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.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
H.F. RADIATION can cause interference.
DHigh frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with elec-
tronic equipment perform this installation.
DThe user is responsible for having a qualified electrician promptly
correct any interference problem resulting from the installation.
DIf notified by the FCC about interference, stop using the equipment
at once.
DHave the installation regularly checked and maintained.
DKeep 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.
DElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
DTo reduce possible interference, keep cables as short as possible,
close together, and down low, such as on the floor.
DLocatecutting operation 100 meters from any sensitive electronic
equipment.
DBe sure this cutting power source is installed and grounded
accordingto this manual.
DIf interference still occurs, the user must take extra measures such
as moving the machine, using shielded cables, using line filters, or
shieldingthe work area.

OM-1591 Page 4
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
WeldingSociety, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
RecommendedPractices for Plasma Arc Cutting, American Welding
SocietyStandard AWS C5.2, from American Welding Society, 550 N.W.
LeJeuneRd, Miami, FL 33126
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, American
WeldingSociety Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
levard,Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, 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.
1-5. EMF Information
Considerations About Welding Or Cutting And The Effects Of Low
FrequencyElectric 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
committeeof the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposureto power-frequency electric and magnetic fields is a human-
health hazard.”However, studies are still going forth and evidence
continuesto 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 proce-
dures:
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 possi-
ble.
About Pacemakers:
Pacemakerwearers consult your doctor first. If cleared by your doctor,
thenfollowing the above procedures is recommended.

OM-1591 Page 5
SECTION 2 –SPECIFICATIONS
Table 2-1. Cutting Torch
Specification Description
CoolingMethod Air
Overall Dimensions See Figure 2-1
Cable Length 30 Or 50 ft (9.1 Or 15.2 m)
Plasma Gas Air Or Nitrogen
ICE-50 ICE-70 And 70M ICE-100 And 100M
Plasma Gas Flow/Pressure 4.7 CFM (135 L/min) At 60 PSI (413
kPa) 7 CFM (198 L/min) At 70 PSI (483 kPa) 7 CFM (198 L/min) At 70 PSI (483 kPa)
Ampere Rating Low Range: 35 Amperes At 100%
Duty Cycle; High Range: 55 Am-
peres At 60% Duty Cycle (See
Section2-1)
70 Amperes At 100% Duty Cycle
(See Section 2-1) 100 Amperes At 80% Duty Cycle (See Section 2-1)
Cutting Capacity UpTo 5/8 in (16 mm) Mild Steel And
Stainless; Up To 3/8 in (10 mm)
Aluminum
1 in (25 mm) Mild Steel, Stainless,
And Aluminum 1-1/4 in (32 mm) Mild Steel, Stainless, And Aluminum
Gear Rack Pitch
(Machine Torches Only) Not Applicable 32 32
Weight Net: 13-1/2 lb (6.1 kg) Net: 10-1/2 lb (4.7 kg) Net: 10-1/2 lb (4.7 kg)
ST-800 712-A
Inches Millimeters
A 10 254
B 1-1/8 29
C 2-1/4 57
D 1-3/16 30
E 1-3/8 35
F 14-3/8 365
F
D
E
Hand-Held
Torch Machine-Held
Torch
A
B
C
50 ampere model is available
as hand-held only.
Figure 2-1. Overall Dimensions

OM-1591 Page 6
2-1. Duty Cycle
Duty Cycle is percentage of 10
minutes that power source and
torch can cut at rated load
withoutoverheating.
sb1.4* 8/93
0
10
Minutes
Low Range:
100% Duty Cycle At 35 Amperes
Definition
High Range:
60% Duty Cycle At 55 Amperes
6 Minutes Cutting 4 Minutes RestingContinuous Cutting
ICE-70 And 70M Model:
100% Duty Cycle At 70 Amperes ICE-100 And 100M Model: 80% Duty Cycle At 100 Amperes
8 Minutes Cutting 2 Minutes RestingContinuous Cutting
ICE-50 Model:
Figure 2-2. Duty Cycle

OM-1591 Page 7
SECTION 3 –INSTALLATION
3-1. Installing ICE-50 Torch
ST-800 783 / ST-800 784 / ST-800 713
Turn Off power source and remove
inputpower. Remove left side panel.
1 Access Holes
Insert cables through access holes.
2 Work Cable
3 Work (+) Output Terminal
4 Torch Cable
5 Pilot/Air Safety Cable
6 Pilot (+) Output Terminal
7 Torch/Air Output Cable
8 Torch (–) And Gas/Air Output
Connector
Connect cables as shown.
9 Terminal Strip 1T
10 Torch Switch Leads
Connectone lead to each terminal of
1T.
Reinstall side panel.
1/2 in
3/8 in
Tools Needed:
Side View
1
2
7
8
10
9
3
5
6
4
10
7
5
Figure 3-1. Installing ICE-50 Torch Into Power Source

OM-1591 Page 8
3-2. Installing ICE-70, 70M, ICE-100, And 100M Torches
Turn Off power source and remove
input power. Remove left side
panel.
1 Access Holes
Insert cables through access holes
as shown.
2 Work Cable (Supplied With
Power Source)
3 Torch Cable
4 Torch (–) And Gas/Air Output
Connector
5 Pilot Cable
6 Pilot (+) Output Terminal
Connect cables as shown.
7 Terminal Strip 1T
8 Connection Label
9 Torch Switch Leads
For hand-held torches, refer to label
to connect leads. Reinstall side
panel.
10 Nut
11 Hose Clamp
For machine-held torches, tighten
nut and clamp to secure cables.
Machine torches require a custom-
er-supplied external switch or re-
mote pendant control connected
betweenterminals 3 and 4 (refer to
it’s Owner’s Manual).
1/2 in
3/8 in
Tools Needed:
8
9
4
6
532
Side View
1
2
3
4
5
6
7
8
9
10
11
Torch
Switch
N.O.
Output
Sensor
Command
Ref.
Remote
Jumper
Common
Panel
Signal
Ground
S-169 259
71
72
84
85
64
63
65
66
70
43
1T
Ref. ST-159 466-C / ST-800 702-B / ST-800 713
7
9
3
5
1
Machine-Held Torch
2
3
5
1
1110
Hand-Held Torch
OR
Figure 3-2. Installing ICE-70, 70M, ICE-100, And 100M Torches Into Power Source

OM-1591 Page 9
3-3. Remote Control Connections For Machine-Held Torches
Ref. ST-159 466-C / Ref. ST-150 802-A
Turn Off power source and discon-
nect input power. Remove left side
panel.
1 Terminal Strip 1T
2 Connection Label
Route leads through hole below
torch and work cable access holes.
Remove snap-in blank from hole,
as needed. Refer to connection la-
bel and use 1T to make remote con-
trol connections to power source as
follows:
Torch On/Off Connections:
3 Remote On/Off Switch
Connect black and white switch
leads to terminals 3 and 4 as
shown. Switch closure starts cut-
ting arc.
Output Control Connections:
4 Jumper Link
For remote output control, remove
jumper link between terminals 9
and 10, and reinstall between termi-
nals 8 and 9 as shown. This dis-
ables Output Control on front panel
of power source and enables re-
mote thickness control.
5 Remote Thickness Control
Potentiometer
Connectpotentiometer leads to ter-
minals7, 8, and 11 as shown.
Output Sensor Connections:
6 Output Sensor Terminals
Terminals 5 and 6 connect to inter-
nal, normally-open contacts which
close when cutting output is pres-
ent. For example, use signal to start
automaticfixture.
Reinstall side panel.
2
Tools Needed:
3/8 in
1
1
2
3
4
5
6
7
8
9
10
11
Torch
Switch
N.O.
Output
Sensor
Command
Ref.
Remote
Jumper
Common
Panel
Signal
Ground
S-169 259
71
72
84
85
64
63
65
66
70
43
1T
Wiper (Red)
GND (Green)
3
5
White
Black
4
6
+10
Volts DC
(Brown)
Figure 3-3. Remote Control Connections For Machine-Held Torches

OM-1591 Page 10
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.
•Keep your head out of the fumes.
•Ventilate area, or use breathing device.
•Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material cut.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
•Wear face protection with correct shade of filter.
•Wear correct eye, ear, and body protection.
CUTTING can cause fire or explosion.
•Do not cut near flammable material.
•Provide protection from flying sparks.
•Watch for fire; keep extinguisher nearby.
•Do not locate unit over combustible surfaces.
•Do not cut on closed containers.
•Allow work and equipment to cool before handling.
MOVING PARTS can cause injury.
•Keep away from moving parts.
•Keep all doors, panels, covers, and guards closed
and securely in place.
See Safety Precautions at beginning of manual for ba-
sic cutting safety information. swarn6.1* 10/91
Wear the following while cutting:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
4 Face Shield
Wear either helmet or face shield
with correct shade of filter (See
ANSI Z49.1).
5 Ear Muffs
Wear approved ear muffs or ear
plugs if noise exposure exceeds
OSHA limits.
sb3.1* 1/94
12
3 4
5
OR
Figure 4-1. Safety Equipment

OM-1591 Page 11
CAUTION
TIP AND ELECTRODE WEAR BEYOND
RECOMMENDED VALUES or OPERATION
WITHOUT TIP OR ELECTRODE can damage
torch.
•Inspect retaining cup, tip, and electrode before cutting or
whenever cutting speed has been significantly reduced (see
Section5-2).
•Do not operate torch without a tip or electrode in place.
INCORRECT PIERCING can damage torch.
•Whenpiercing (starting a cut away from metal edge) use a slight
standoff distance and hold torch at about 10°angle to prevent
sparks from reflecting back at torch.
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.
INCORRECT STANDOFF DISTANCE can damage
torch.
•For non-shielded cutting, always use a 1/8 in (3 mm) standoff
distance between torch tip and workpiece.
•For 50 ampere torch, always use standoff guide when cutting with
power source Range switch in High Range.
HAVING PILOT ARC TURN ON AND OFF
REPEATEDLY, such as during the cutting of chain
fence, will shorten tip, electrode, and torch life.
•Put a continuous piece of sheet metal under the fence to prevent
pilot arc from cycling on and off.
•Avoid constant starting and restarting of the arc.
Put On Personal
Safety
Equipment
Place drag shield on edge After cutting arc starts, slowly
start moving torch across metal.
Adjust torch speed so
sparks go thru metal and
out bottom of cut.
Pause briefly at end of
cut before releasing trigger.
of metal, or allow correct
standoff distance.
Install &
Connect
Equipment
EXAMPLE Of Cutting Operation
ST-161 698-A
Press trigger. After 2 seconds
of preflow, pilot arc starts.
Postflow continues for 20 seconds
after releasing trigger; cutting arc
can be instantly restarted during
postflow by pressing trigger.
Check Torch Tip,
Electrode, And
Retaining Cup
Check Gas/Air
Pressure Set Controls
Begin
Cutting
Turn On
Power Source
Figure 4-2. Sequence Of Plasma Arc Cutting (PAC)

OM-1591 Page 12
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.
TIP AND ELECTRODE WEAR BEYOND
RECOMMENDED VALUES or OPERATION
WITHOUT TIP OR ELECTRODE can damage torch.
•Inspect retaining cup, tip, and electrode before cutting or whenever
cutting speed has been significantly reduced.
•Do not operate torch without a tip or electrode in place.
•Use correct standoff distance.
•Do not cut with gouging tip.
CAUTION
Check Torch Tip,
Electrode, And
Retaining Cup
Install &
Connect
Equipment
Install
Gouging Tip Check Gas/Air Pressure Set Controls
Begin
Gouging
EXAMPLE Of Gouging Operation
Ref. ST-162 317-A / Ref. ST-161 876-B
Use approx. 1/8 in (3 mm)
standoff at about a 40°angle. Establish arc length of 1 to 1-1/2 in
(25 - 38 mm), and slowly
start moving torch across metal.
Adjust torch speed, arc length and angle as needed.
Direct sparks away from torch. Do not gouge too
deeply in one pass; make repeated passes if needed.
Release trigger. Postflow continues for approx.
20 to 30 seconds. Gouging arc can be instantly
restarted during postflow by pressing trigger.
Turn On
Power Source
Put On Personal
Safety
Equipment
Press trigger. After 2 seconds of
preflow, pilot arc starts.
Figure 4-3. Sequence Of Plasma Arc Gouging (PAG)

OM-1591 Page 13
SECTION 5 –MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
YTurn Off power source and
disconnect input power
before maintaining.
Turn Off all power before maintaining.
Each Use
Check Tip
Electrode,
And
Retaining
Cup
Check
Retaining
Cup
Shutdown
System
Every Week
Check
Gas/Air
Pressure
At Power
Source
Tape
Torn
Outer
Covering
––
Clean
And
Tighten
Torch
Connections
3-1, 3-2
Torch Body
Gas/Air Hose Torch Cable
––
Replace
Cracked
Parts
3 Months
Power
Source
Manual
See
Section
5-2
Power
Source
Manual Ref. ST-800 713
Figure 5-1. Maintenance Schedule

OM-1591 Page 14
5-2. Checking/Replacing Retaining Cup, Tip, And Electrode
CAUTION
OVERTIGHTENING will strip threads.
•Do not overtighten electrode, tip, and retaining cup during
assembly.
•Do not cross-thread parts causing stripping.
•Use care during torch assembly and parts replacement.
TIP AND ELECTRODE WEAR BEYOND
RECOMMENDED VALUES or OPERATION
WITHOUT TIP OR ELECTRODE can damage
torch.
•Inspect retaining cup, tip, and electrode before cutting or
whenevercutting 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.
Ref. ST-800 714-C / ST-800 726 / ST-801 139
Turn Off power source, and disconnect input
power.
1 Shield/Deflector
Remove shield/deflector. If necessary, clean
metal or other debris off shield/deflector. If
gas holes are blocked, clear by pushing pin
from outside the cup to inside.
2 Retaining Cup
Remove retaining cup. Check retaining cup
for cracks, and replace if necessary.
3Tip
4 Opening
Remove tip. Check tip, and replace if open-
ing 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 Swirl Ring
Remove swirl ring. Check ring, and replace
if side holes are plugged.
6 Electrode
Check electrode. If center has a pit more
thana 1/16 in (2 mm) deep, remove and re-
place electrode using supplied wrench. Do
not overtighten.
7 O-Ring
Check O-rings on torch. If needed, coat with
thin film of supplied lubricant. Replace if
damaged.
8 Standoff Guide
Remove excess slag buildup. Replace if
legs are deformed or melted.
Carefullyreassemble parts in reverse order.
Swirl ring must be installed with word “front”
facing away from torch body.
Threadsize for electrode for ICE-70, 70M,
ICE-100and 100M models:
7/16 - 28
New
Worn
4
5
6
3
New
Worn
1/16 in
(2 mm)
Pit
Tools Needed:
(Supplied)
7
The word “front”on
swirl ring must face
away from torch body.
Do not overtighten
electrode.
New
Worn
New
Worn
2
1
ICE-50 Model ICE-70, 70M, ICE-100, And 100M Models
6
1/16 in
(2 mm)
Pit
4
3
5
7
2
8
Figure 5-2. Checking/Replacing Retaining Cup, Tip, And Electrode

OM-1591 Page 15
5-3. Troubleshooting
Table 5-1. Cutting Trouble
Trouble Remedy Section
Powersource Torch-To-Tip Short trouble
lightOn; no cutting output. Check tip and electrode for a short. See also power source Owner’s Manual. 5-2
Check torch connections on power source terminal 1T. See power
source Owner’s Manual. 3-1, 3-2
Power source Gas/Air Or Shield Cup
troublelight On; no cutting output. Check o-ring, and lubricate if needed with supplied grease. Figure 6-3, Figure 6-4
Check for clean and sufficient gas/air supply pressure. See power
source Owner’s Manual. ––
Sparks come out top of cut, or cut is not
clean. Torch travel speed too fast; reduce travel speed. Figure 4-2
Check torch tip and electrode, and replace if necessary. 5-2
Metalbeing cut is too thick; increase power source output control
setting. See power source Owner’s Manual. ––
Be sure work clamp is securely attached. See power source Own-
er’s Manual. ––
Arc goes out while cutting. Make sure torch tip is not touching metal while cutting (above 40
amperesonly). Figure 4-2
Check torch tip and electrode, and replace if necessary. 5-2
Be sure work clamp is securely attached. See power source Own-
er’s Manual. ––
Arc goes on and off while cutting. Torch travel speed is too slow; increase travel speed. Figure 4-2
Check torch tip and electrode, and replace if necessary. 5-2
Be sure work clamp is securely attached. See power source Own-
er’s Manual. ––

OM-1591 Page 16
SECTION 6 –PARTS LIST
1
Figure 6-1. Torch, ICE-50/-70/-100
2
34
5
6
7
2
8
9
10 11
See Figure 6-3, Figure 6-4, or Figure 6-5 for additional
torch consumables and parts.
Description
Part
No.
Item
No. Figure 6-1. Torch, ICE-50/-70/-100 Quantity
1 171 258 TORCH, main body (ICE-50 model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 171 257 TORCH, main body (ICE-70/-100 models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 171 246 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 171 248 PUSHBUTTON, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
171 255 SPLICE, 22-18 butt N-insul connector 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 171 263 LEAD INSULATOR, 5/8PVC 3.5 in long (ICE-50 model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 171 252 TEFLON TUBE, 11/16 ID x .030W x 3.5 in long (ICE-70/-100 models) 1. . . . . . . . . . . . . . . . . . . .
5 171 260 LEAD INSULATOR, 7/16PVC 3 in long (ICE-50 model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 171 251 TEFLON TUBE, 9/16 ID x .030W x 2.5 in long (ICE-70/-100 models) 1. . . . . . . . . . . . . . . . . . . . .
6 171 259 BOOT, (ICE-50 model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 171 247 BOOT (ICE-70/-100 models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 171 256 HANDLE SCREW, No. 6 x 3/4ph 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 171 264 LEADS, 30ft (ICE-50 model) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 180 504 LEADS, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 180 507 LEADS, pilot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 180 506 LEADS, torch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 171 253 LEADS, 30ft (ICE-70/-100 models) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 180 504 LEADS, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 180 500 LEADS, pilot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 180 501 LEADS, torch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 171 265 LEADS, 50ft (ICE-50 model) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 180 505 LEADS, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 180 509 LEADS, pilot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 180 508 LEADS, torch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 171 254 LEADS, 50ft (ICE-70/-100 models) (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 180 505 LEADS, trigger 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 180 498 LEADS, pilot 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 180 499 LEADS, torch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .