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OM-1572A August 1993
Processes
Air Plasma Cutting
and Gouging
Description
Air-Cooled Plasma Arc Cutting (PAC)
Torch
APT-1000 Torch
Visit our website at
www.MillerWelds.com
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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 injury or equipment damage can ELECTRIC SHOCK can kill. MOVING PARTS can injure. happen. • Do not touch live electrical parts. • Keep away from moving parts. 4 •Disconnect inpu
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2-1. Duty Cycle CAUTION EXCEEDING DUTY CYCLE RATINGS will damage power source and torch. • Do not exceed indicated duty cycles. warn7.1* 2/92 Duty cycle is how long the torch and power source can operate within a ten minute period without causing overheating or damage. This torch is rated at 60% duty cycle when operated at 10 amperes, allowing cutting 6 minutes out of 10. If the cutting amperes decrease, the duty cycle increases. SECTION 3 – INSTALLATION WARNING ELECTRIC SHOCK can kill. • Do not
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3-2. Installing Torch READ SAFETY BLOCK at start of WARNING Section 3 before proceeding. A. Installing Torch In Standard Power Source Turn Off power source, and disconnect input power plug. Re- move wrapper. 1 Torch Cable 2 Front Panel Opening 1 234 3 Pilot Arc/Shield Cup Detector S-137 691 Lead 1 6 4 Shield Cup Detector Lead 2 7 5 Torch Switch Leads 3 and 4 3 Route cable and leads through front panel opening. 4 6 Terminal Strip 1T 7 Connection Label Connect cable to air/torch (–) out- put conne
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B. Installing Torch In Inverter Power Source Turn Off power source, and disconnect input power plug. Open lower front access door. Label is located under 1 Access Door terminal strip. 2 Strain Relief Clamp 3 Torch Cable 12 34 6 4 Torch (–) And Air/Gas Output S-137 691 Connector Connect torch cable as shown. 5 5 Terminal Strip1T 6 Connection Label 1 4 7 Pilot Arc/Shield Cup Detector Lead 1 7 8 Shield Cup Detector Lead 2 8 9 Torch Switch Leads 3 And 4 Refer to label and connect leads as 9 shown. I
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1 Insulating Gloves 2 Safety Glasses With Side Shields 12 3 4 5 3 Welding Helmet 4 Face Shield Wear dry insulating gloves, safety glasses with side shields, and a welding helmet or face shield with a 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 10/91 Figure 4-1. Safety Equipment CAUTION HITTING TORCH ON A HARD SURFACE to TIP AND ELECTRODE WEAR BEYOND remove spatter can damage torch. RECOMMENDED VALUES or O
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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 power source, 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 Check Covering Torch Tip, – –
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5-2. Checking Detector Pins And Checking/Replacing Shield Cup, Tip, And Electrode CAUTION OVERTIGHTENING will strip threads. TIP AND ELECTRODE WEAR BEYOND RECOMMENDED VALUES or OPERATION • Do not overtighten electrode, tip, and shield 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 shield cup, tip, and electrode before cutting or whenever cutting speed has been signifi
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Figure 5-2. Checking Detector Pins And Checking/Replacing Shield Cup, Tip, And Electrode 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 power source, 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 Sparks
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SECTION 6 – PARTS LIST 5 4 3 1 2 6 15 14 13 12 78 11 9 10 ST-124 813-A Figure 6-1. Torch, APT-1000 Item Part No. No. Description Quantity Figure 6-1. Torch, Model APT-1000 126 796 . . . 1 . . . 131 190 . . TORCH BODY KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . 131 184 . . . . DETECTIVE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 3 . . . 12
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Notes
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Notes
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Notes
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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
