Miller OM-182 User manual

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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

Spectrumﬁ

300

(50/60

Hz)

OWNERS

MANUAL

From

Miller

You

Thank

you

and

congratulations

choosing

Miller.

Now

you

can

get

the

job

done

and

get

done

right.

know

you

dont

have

time

any

other

way.

Thats

why

when

Niels

Miller

first

started

building

arc

welders

1929,

made

sure

his

products

offered

long-lasting

value

and

superior

quality.

you,

his

customers

couldnt

afford

anything

less.

Miller

products

had

than

the

best

they

could

be.

They

had

the

best

you

could

buy.

Today,

the

people

that

build

and

sell

Miller

products

continue

the

tradition.

Theyre

just

committed

providing

equipment

and

service

that

meets

the

high

standards

quality

and

value

established

1929.

This

Owners

Manual

designed

help

you

get

the

most

out

your

Miller

products.

Please

take

time

read

the

Safety

precautions.

They

will

help

you

protect

yourself

against

potential

hazards

the

worksite.

Weve

made

installation

and

operation

quick

and

easy.

With

Miller

you

can

count

years

reliable

service

with

proper

maintenance.

And

for

_______________

some

reason

the

unit

needs

repair,

theres

Troubleshooting

section

that

will

help

you

figure

out

what

the

problem

is.

The

parts

list

will

then

help

you

decide

which

exact

part

you

may

need

fix

the

problem.

Warranty

and

service

information

for

your

particular

model

are

also

provided.

Miller

Electric

manufactures

full

line

welders

and

welding

equipment.

For

information

other

quality

Miller

products,

contact

your

local

Miller

distributor

receive

the

latest

full

line

catalog

individual

catalog

sheets.

locate

your

nearest

distributor

call

1-800-4-A-Miller.

4k1IiIIW

REGISTERED

SYSTEM

Miller

tIe

first

welding

equip

menttunutacturorlntbeU.S.A.te

registered

Ike

ISO

9001

Quality

System

Standard.

.me

~1~Th1~

1~ftflfl~~

Working

lard

yen

I,.

every

power

source

trim

Miller

lacked

the

most

lasslo-troe

warranty

the

buslooss.

f/IA

Miller

heThwer9fBhse~

Call

-800-4-A-MILLER

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your

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Miller

dlslributor.

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distributor

gives

you

Service

You

always

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fast,

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response

you

need.

Most

replacement

parts

can

your

hands

hours.

Support

Need

fast

answers

the

tough

welding

questions?

Contact

your

distributor.

The

expertise

the

distributor

and

Miller

there

help

you,

every

step

the

way.

Miller

offers

Technical

Manual

which

provides

detailed

service

and

parts

information

for

your

unit.

obtain

Technical

Manual,

contact

your

local

distributor.

Your

distributor

can

also

supply

you

with

Welding

Process

Manuals

such

SMAW,

GTAW,

GMAW,

and

GMAW-P.

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TABLE

CONTENTS

SECTION

SAFETY

PRECAUTIONS

READ

BEFORE

USING

1-1.

Symbol

Usage

1-2.

Plasma

Arc

Cutting

Hazards

1-3.

Additional

Symbols

For

Installation,

Operation,

And

Maintenance

1-4.

Principal

Safety

Standards

1-5.

EMF

Information

SECTION

CONSIGNES

SECURITE

LIRE

AVANT

UTILISATION

1-1.

Signification

des

symboles

1-2.

Dangers

lies

coupage

Iarc

plasma

1-3.

Dangers

supplØmentaires

relation

avec

Iinstallation,

fonctionnement

maintenance

1-4.

Principales

normes

sØcurit~

1-5.

Information

sur

los

champs

ØlectromagnØtiques

SECTION

INSTALLATION

2-1.

Specifications

2-2.

Symbols

And

Definitions

2-3.

Cutting

Speed

2-4.

Duty

Cycle

And

Overheating

2-5.

Selecting

Location

2-6.

Connecting

Work

Clamp

And

Gas/Air

Supply

2-7.

Connecting

Input

Power

SECTION

3-OPERATION

3-1.

Controls

SECTION

MAINTENANCE &

TROUBLESHOOTING

4-1.

Routine

Maintenance

4-2.

Overload

Protection:

Trouble

Lights

Checking

Shield

Cup

Shutdown

System

4-3.

Torch

And

Work

Cable

Connections

4-4.

Troubleshooting

SECTION

ELECTRICAL

DIAGRAM

SECTION

PARTS

LIST

.20

WARRANTY

SECTION

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

the

adjoining

symbols.

porn

_nd_5/97

1-2

Plasma

Arc

Cutting

Hazards

The

symbols

shown

below

are

used

throughout

this

manual

call

attention

and

identify

possible

hazards.

When

you

see

the

symbol,

watch

out,

and

the

instructions

avoid

the hazard.

The

safety

Information

given

below

only

summary

the

complete

safety

information

found

the

Safety

Standards

listed

Section

1-4.

Read

and

all

Safety

Standards.

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

During

operation,

keep

everybody,

especially

children,

away.

iriG

can

cause

fire

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

sure

the

area

safe

before

doing

any

cutting.



Protect

yourself

and

others

from

flying

sparks

and

hot

metal.



not

cut

where

flying

sparks

can

strike

flammable

material.



Remove

all

flammables

within

(10.7

the

cutting

arc.

this

not

possible,

tightly

cover

them

with

approved

covers.



alert

that

sparks

and

hot materials

from

cutting

can

easily

through

small

cracks

and

openings

adjacent

areas.



Watch

fire,

and

keep

fire

extinguisher

nearby.



aware

that

cutting

ceiling,

floor,

bulkhead,

partition

can

cause

fire

the

hidden

side.



not

cut

closed

containers

such

tanks

drums.



Connect

work

cable

the

work

the

cutting

area

practical

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

emptied

and

properly

cleaned

first.



not

cut

atmospheres

containing

explosive

dust

vapors.



not

cut

pressurized

cylinders,

pipes,

vessels.



not

cut

containers

that

have

held

combustibles.



Wear

oil-free

protective

garments

such

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

cap.



not

locate

unit

over

combustible

surfaces.



Remove

any

combustibles,

such

butane

lighter

matches,

from

your

person

before

doing

any

cutting.



ELECTRIC

SHOCK

can~

kill

~ki~,

Touching

live

electrical

parts

can

cause

fatal

shocks

severe

burns.

The

torch

and

work

circuit

are

electrically

live

whenever

the

output

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

on.

Plasma

arc

cutting

requires

higher

voltages

than

welding

start

and

maintain

the

arc

(200

400

volts

are

common),

but

also

uses

torches

designed

with

safety

interlock

systems

which

turn

off

the

machine

when

the

shield

cup

loosened

tip

touches

electrode

inside

the

nozzle.

Incorrectly

installed

improperly

grounded

equipment

hazard.



not

touch

live

electrical

parts.



Wear

dry,

hole-free

insulating

gloves

and

body

protection.



Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

covers

big

enough

prevent

any

physical

contact

with

the

work

ground.



not

touch

torch

parts

contact

with

the

work

ground.



Turn

off

power

before

checking,

cleaning,

changing

torch

parts.



Disconnect

input

power

before

installing

servicing

this

equip

ment.

Lockout/tagout

input

power

according

OSHA

CFR

191

0.147

(see

Safety

Standards).



Properly

install

and

ground

this

equipment

according

its

Own

ers

Manual

and

national,

state,

and

local

codes.



Check

and

sure

that

input

power

cord

ground

wire

properly

connected

ground

terminal

disconnect

box

that

cord

plug

connected

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

bare

wiring



replace

cord

immediately

damaged



bare

wiring

can

kill.



Turn

off

all

equipment

when

not

use.



Inspect

and

replace

any

worn

damaged

torch

cable

leads.



not

wrap

torch

cable

around

your

body.



Ground

the

workpiece

good

electrical

(earth)

ground

quired

codes.



Use

only

well-maintained

equipment.

Repair

replace

damaged

parts

once.



Wear

safety

harness

working

above

floor

level.



Keep

all

panels

and

covers

securely

place.



not

bypass

try

defeat

the

safety

interlock

systems.



Use

only

torch(es)

specified

Owners

Manual.



Keep

away

from

torch

tip

and

pilot

arc

when

trigger

pressed.



Clamp

work

cable

with

good

metal-to-metal

contact

workpiece

(not

piece

that

will

fall

away)

worktable

as near

the

cut

practical.



Insulate

work

clamp

when

not

connected

workpiece

prevent

contact

with

any

metal

object.

SIGNIFICANT

VOLTAGE

exists

after

removal

input

power

inverters.



Turn

OFF

inverter,

disconnect

input

power,

and

discharge

input

capacitors

according

instructions

Maintenance

Section

before

touching

any

parts.

Marks

special

safety

message.

Means

Note;

not

safety

related.

This

group

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

instructions

below

for

necessary

actions

avoid

the

hazards.

OM-1

82702

Page

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