Miller OM-182 User manual

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our
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OM-182
702A
June 1997
Eff. w/Serial
Number KH387456
Processes
Air
Plasma
Cutting
and
Gouging
Description
Miller
The
Power
fBlue.
Air
Plasma
Cutter
FILE
COPY
~ETUR~3
TO
~
Spectrumfi
300
(50/60
Hz)
OWNERS
MANUAL

From
Miller
to
You
Thank
you
and
congratulations
on
choosing
Miller.
Now
you
can
get
the
job
done
and
get
it done
right.
We
know
you
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
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
call
1-800-4-A-Miller.
4k1IiIIW
I
REGISTERED
SYSTEM
Miller Is tIe first
welding equip
menttunutacturorlntbeU.S.A.te
Is
registered
to
Ike
ISO
9001
Quality System
Standard.
.me
~
~
~,
~1~Th1~ 1~ftflfl~~
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Working
as
lard
as
yen
I,.
every
power
source
trim
Miller is
lacked
ly
the
most
lasslo-troe
warranty
I. the
buslooss.
f/IA
Miller
heThwer9fBhse~

Call
1
-800-4-A-MILLER
for
your
local
Miller
dlslributor.
Your
distributor
gives
you
Service
You
always
get
the
fast,
reliable
response you
need. Most
replacement
parts
can
be in
your
hands in 24 hours.
Support
Need
fast
answers
to
the
tough welding questions?
Contact
your
distributor.
The
expertise
of the
distributor
and Miller is
there
to
help
you, every
step
of the
way.
Miller offers
a
Technical
Manual which
provides
more
detailed
service
and
parts
information for
your
unit. To obtain
a
Technical
Manual,
contact
your
local
distributor. Your
distributor
can
also
supply
you
with
Welding
Process
Manuals
such
as
SMAW,
GTAW,
GMAW,
and GMAW-P.
For
practical
information
on
welding,
process
applica
tions,
and Miller
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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
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTILISATION
5
1-1.
Signification
des
symboles
5
1-2.
Dangers
lies
au
coupage
a
Iarc
au
plasma
5
1-3.
Dangers
supplØmentaires
en
relation
avec
Iinstallation,
le fonctionnement
et
Ia
maintenance
7
1-4.
Principales
normes
de
sØcurit~
7
1-5.
Information
sur
los
champs
ØlectromagnØtiques
8
SECTION
2
-
INSTALLATION
9
2-1.
Specifications
9
2-2.
Symbols
And
Definitions
9
2-3.
Cutting
Speed
9
2-4.
Duty Cycle
And
Overheating
10
2-5.
Selecting
A
Location
11
2-6.
Connecting
Work
Clamp
And
Gas/Air
Supply
12
2-7.
Connecting
Input
Power 12
SECTION 3-OPERATION
13
3-1.
Controls
13
SECTION
4-
MAINTENANCE &
TROUBLESHOOTING
14
4-1.
Routine
Maintenance
14
4-2.
Overload Protection:
Trouble
Lights
&
Checking
Shield
Cup
Shutdown
System
15
4-3.
Torch
And Work
Cable Connections
16
4-4.
Troubleshooting
17
SECTION
5-
ELECTRICAL
DIAGRAM
SECTION
6-
PARTS LIST
.20
WARRANTY

SECTION
1
-
SAFETY PRECAUTIONS
-
READ
BEFORE
USING
1-1
Symbol
Usage
Means
Warning!
Watch
Out! There
are
possible

hazards with this
procedure!
The
possible
hazards
are
shown in the
adjoining
symbols.
porn
_nd_5/97
1-2
Plasma
Arc
Cutting
Hazards
A
The
symbols
shown
below
are
used
throughout
this manual
to
call
attention
to
and
identify possible
hazards.
When
you
see
the
symbol,
watch
out,
and follow the
related
instructions
to
avoid the hazard.
The
safety
Information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found in
the
Safety
Standards listed
in
Section
1-4.
Read and
follow
all
Safety
Standards.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this unit.
A
During operation,
keep
everybody,
especially
children,
away.
w
i
iriG
can cause
fire
or
explosion
Hot
metal
and
sparks
blow
out
from
the
cutting
arc.
The
flying
sparks
and hot
metal,
hot
workpiece,
and
hot
equipment
can cause
fires
and bums.
Check
and
be
sure
the
area
is
safe
before
doing
any
cutting.

Protect
yourself
and
others
from
flying
sparks
and hot metal.

Do
not
cut
where
flying
sparks
can
strike
flammable
material.

Remove
all
flammables
within 35
ft
(10.7
m)
of the
cutting
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.

Be
alert
that
sparks
and
hot materials
from
cutting
can
easily
go
through
small cracks and
openings
to
adjacent
areas.

Watch
br
fire,
and
keep
a
fire
extinguisher
nearby.

Be
aware
that
cutting
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the hidden
side.

Do
not
cut
on
closed
containers such
as
tanks
or
drums.

Connect
work cable
to
the work
as
close
to
the
cutting
area
as
practical
to
prevent
cutting
current
from
traveling long, possibly
unknown
paths
and
causing
electric shock
and
fire hazards.

Never
cut
containers with
potentially
flammable
materials inside

they
must
be
emptied
and
properly
cleaned
first.

Do
not cut
in
atmospheres
containing
explosive
dust
or
vapors.

Do
not cut
pressurized
cylinders,
pipes,
or
vessels.

Do
not cut
containers
that have held combustibles.

Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.

Do
not
locate
unit
on
or
over
combustible surfaces.

Remove
any
combustibles,
such
as a
butane
lighter
or
matches,
from
your
person
before
doing
any
cutting.

7
ELECTRIC SHOCK
can~
kill
~ki~,
I
Touching
live
electrical
parts
can
cause
fatal
I
shocks
or
severe
burns. The
torch and
work circuit
are
electrically
live whenever the
output
is
on.
The
_J
input
power
circuit
and machine
internal circuits
are
also
live
when
power
is
on.
Plasma
arc
cutting
requires
higher
voltages
than
welding
to start
and
maintain the
arc
(200
to
400 volts dc
are
common),
but also
uses
torches
designed
with
safety
interlock
systems
which
turn
off the
machine when
the
shield
cup
is
loosened
or
if
tip
touches
electrode
inside the nozzle.
Incorrectly
installed
or
improperly grounded
equipment
is
a
hazard.
~
~

Do
not
touch
live electrical
parts.

Wear
dry,
hole-free
insulating gloves
and
body
protection.

Insulate
yourself
from work and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the work
or
ground.

Do
not
touch
torch
parts
if
in
contact
with the work
or
ground.

Turn
off
power
before
checking,
cleaning,
or
changing
torch
parts.

Disconnect
input
power
before
installing
or
servicing
this
equip
ment.
Lockout/tagout
input
power
according
to
OSHA
CFR
191
0.147
(see
Safety
Standards).

Properly
install and
ground
this
equipment
according
to
its Own
ers
Manual
and
national,
state,
and local codes.

Check and
be
sure
that
input
power
cord
ground
wire is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly grounded receptacle
outlet

always
verify
the
supply ground.

When
making
input
connections,
attach
proper
grounding
con
ductor
first.

Frequently inspect
input
power
cord for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.

Turn
off all
equipment
when
not
in
use.

Inspect
and
replace
any
worn or
damaged
torch cable leads.

Do
not
wrap
torch
cable around
your
body.

Ground the
workpiece
to
a
good
electrical
(earth)
ground
if
re
quired
by
codes.

Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.

Wear
a
safety
harness
if
working
above floor level.

Keep
all
panels
and
covers
securely
in
place.

Do
not
bypass
or
try
to
defeat
the
safety
interlock
systems.

Use
only
torch(es)
specified
in
Owners
Manual.

Keep
away
from
torch
tip
and
pilot
arc
when
trigger
is
pressed.

Clamp
work
cable
with
good
metal-to-metal
contact to
workpiece
(not piece
that
will
fall
away)
or
worktable
as near
the
cut
as
practical.

Insulate work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
SIGNIFICANT
DC VOLTAGE
exists after
removal of
input
power
on
inverters.

Turn
OFF
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
a
A
Marks
a
special
safety
message.
~
Means
Note;
not
safety
related.
This
group
of
symbols
means
Warning!
Watch Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and related instructions below
for
necessary
actions
to
avoid
the hazards.
OM-1
82702
Page
1