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May 1995 Form: OM-1592A
OWNER’S
MANUAL
MC-80 And MC-80M
Air-Cooled Plasma Arc Cutting (PAC) Torches
Can Be Used For Plasma Arc Gouging (PAG)
80 Amperes, 120 Volts DC At 100% Duty Cycle
Safety Interlock Devices Shut Down Power Source
Hand-Held Torch Equipped With Either 25 Or 50 ft (7.6 Or 15.2 m) Cable
Machine-Held Torch Equipped With 50 ft (15.2 m) Cable
Fully Assembled And Supplied With Consumable Kit
Read and follow these instructions and all Give this manual to the operator.
safety blocks ca
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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 bu
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PLASMA ARC CUTTING SAFETY PRECAUTIONS PLASMA ARC CUTTING can be hazardous. WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In cutting, as in most jobs, exposure to certain hazards occurs. Cutting is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page. Re
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5. Work in a confined space only if it is well ventilated, or while FUMES AND GASES can be hazardous wearing an air-supplied respirator. Fumes from cutting and to your health. oxygen depletion can alter air quality causing injury or death. Be Cutting produces fumes and gases. Breathing these sure the breathing air is safe. fumes and gases can be hazardous to your health. 6. Do not cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapo
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EMF INFORMATION Considerations About Welding And The Effects Of Low Frequency Electric And NOTE Magnetic Fields The following is a quotation from the General Conclusions Section of To reduce magnetic fields in the workplace, use the following procedures: the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – 1. Keep cables close together by twisting or taping them. Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Print
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SECTION 1 – SAFETY INFORMATION mod1.1 2/93 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. 1 Safety Alert Symbol 2 Signal Word 1 2 2 WARNING means possible death or serious injury can happen. WARNING CAUTION 3 CAUTION means possible minor ELECTRIC SHOCK can kill. MOVING PARTS can injure. injury or equipment damage can happen. • Do not touch live electrical parts. • Keep away from moving parts. 4 •Disconnect inpu
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Inches Millimeters Hand-Held Torch A 10-1/2 267 B 1-3/8 35 A C 1-1/4 32 D 1-5/16 33 E 13-11/16 348 B Machine-Held Torch D C E Ref. ST-800 895 / Ref. ST-801 208 Figure 2-1. Overall Dimensions 2-1. Duty Cycle CAUTION CUTTING LONGER THAN RATED DUTY CYCLE can damage cutter and torch and void warranty. • Do not cut at rated load longer than duty cycle of cutter (see cutter’s Owner’s Manual). miscwarn3.1 9/93 Definition 100% Duty Cycle At 80 Amperes 0 Duty Cycle is percentage of 10 10 minutes that cut
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SECTION 3 – INSTALLATION 3-1. Installing Hand-Held Torch WARNING ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns. • Do not touch live electrical parts. • Allow cooling period before maintaining or servicing. • Turn Off cutter, and disconnect input power before installing torch. MOVING PARTS can cause injury. • Keep away from moving parts. swarn8.1* 10/91 Turn Off cutter and remove input Significant DC voltage can remain on capacitors in cutter power. Remove top of cutter case. after un
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3-2. Installing Machine-Held Torch And Remote Trigger Pendant WARNING ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns. • Do not touch live electrical parts. • Allow cooling period before maintaining or servicing. • Turn Off cutter, and disconnect input power before installing torch. MOVING PARTS can cause injury. • Keep away from moving parts. swarn8.1* 10/91 Machine-held torches require a Significant DC voltage can remain on capacitors in cutter customer-supplied external switch after
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SECTION 4 – OPERATING THE TORCH WARNING ELECTRIC SHOCK can kill. CUTTING can cause fire or explosion. • Always wear dry insulating gloves. • Do not cut near flammable material. • Insulate yourself from work and ground. • Provide protection from flying sparks. • Do not touch live electrical parts. • Watch for fire; keep extinguisher nearby. • Keep all panels and covers securely in place. • Do not locate unit over combustible surfaces. FUMES AND GASES can be hazardous • Do not cut on closed contai
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CAUTION TIP AND ELECTRODE WEAR BEYOND HITTING TORCH ON A HARD SURFACE to RECOMMENDED VALUES or OPERATION remove spatter can damage torch. WITHOUT TIP OR ELECTRODE can damage • Do not clean torch by hitting it against a hard surface. torch. • Hitting hard surfaces can damage torch parts and stop proper • Inspect cup, tip, and electrode before cutting or whenever cutting operation. speed has been significantly reduced (see Section 5-2). HAVING PILOT ARC TURN ON AND OFF • Do not operate torch witho
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Figure 4-2. Sequence Of Plasma Arc Cutting (PAC) CAUTION HITTING TORCH ON A HARD SURFACE to remove TIP AND ELECTRODE WEAR BEYOND spatter can damage torch. RECOMMENDED VALUES or OPERATION WITHOUT TIP OR ELECTRODE can damage torch. • Do not clean torch by hitting it against a hard surface. • Inspect cup, tip, and electrode before cutting or whenever cutting • Hitting hard surfaces can damage torch parts and stop proper speed has been significantly reduced. operation. • Do not operate torch without
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SECTION 5 – MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns. • Do not touch live electrical parts. • Allow cooling period before maintaining or servicing. • Turn Off cutter, and disconnect input power before inspecting, maintaining, or servicing. Maintenance to be performed only by qualified persons. swarn8.1* 2/93 5-1. Routine Maintenance Turn Off all power before maintaining. 3 Months Tape Each Use Torn Outer Covering Check Tip – – Electrode, Se
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5-2. Checking/Replacing Cup, Tip, And Electrode CAUTION OVERTIGHTENING will strip threads. TIP AND ELECTRODE WEAR BEYOND RECOMMENDED VALUES or OPERATION • Do not overtighten electrode, tip, and cup during assembly. WITHOUT TIP OR ELECTRODE can damage • Do not cross-thread parts causing stripping. torch. • Use care during torch assembly and parts replacement. • Inspect cup, tip, and electrode before cutting or whenever cutting speed has been significantly reduced. • Do not operate torch without a
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5-3. Troubleshooting WARNING ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns. • Do not touch live electrical parts. • Allow cooling period before maintaining or servicing. • Turn Off cutter, and disconnect input power before inspecting, maintaining, or servicing. Troubleshooting to be performed only by qualified persons. swarn8.1* 2/93 Table 5-1. Cutting Trouble Trouble Remedy Section Cutter Gas/Torch trouble light On; cutter Check for properly installed torch tip. Check for blocked ho
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SECTION 6 – PARTS LIST Item Part No. No. Description Quantity Figure 6-1. Torch, MC-80 (Hand-Held) . . . 1 . . . . . . . . . . 172 385 . . TORCH, body assembly (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . 172 384 . . . . TORCH, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . 172 382 . . . . TRIGGER, switch . . . . . . . . . . . . . . . . . .
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Item Part No. No. Description Quantity Figure 6-3. Torch, MC-80 (Machine) . . . 1 . . . . . . . . . . 175 833 . . TORCH, body assembly (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . 175 829 . . . . TORCH HEAD, (Includes Item 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . 175 830 . . . . HANDLE ASSEMBLY, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY – Subject to the terms and conditions Call * APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment
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Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment
