OM-2210 176 876N April 2000 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter R Spectrum 300 And Non-CE Models Visit our website at www.MillerWelds.
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.
TABLE OF CONTENTS WARNING This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) OM-2210N SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of Conformity for European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y 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. 1-2.
FLYING SPARKS can cause injury. Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. D D D Wear approved face shield or safety goggles with side shields. Wear proper body protection to protect skin. Wear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears. ARC RAYS can burn eyes and skin. D D D D Arc rays from the cutting process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. FLYING METAL can injure eyes. D Wear safety glasses with side shields or face shield. MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away.
1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, from American Welding Society, 550 N.W.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION pom_nd_fre_5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité.
D D D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée. Le câble de masse doit être pincé correctement sur la pièce à couper, métal contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table de travail le plus près possible de la ligne de coupage. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance DES PIECES CHAUDES peuvent provoquer des brûlures graves. D D D D Ne pas toucher des parties chaudes à mains nues. Laisser refroidir avant d’intervenir sur la torche. DES ORGANES MOBILES peuvent provoquer des blessures. D Risque D’INCENDIE OU D’EXPLOSION. D D D D Porter des lunettes de sécurité avec protections latérales ou frontales. Porteurs de stimulateur cardiaque, restez à distance.
1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence 1 Le courant de soudage ou de coupage passant dans les câbles de puissance crée des causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs.
SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 1.1 1.2 1 1.1 1.2 1.3 1.3 2 2.1 2 2.1 2.2 2.3 2.2 2.3 3 3 3.1 3.2 3.1 3.3 3.2 3.3 4 4.2 4.1 4.3 4 4.1 4.2 5 4.3 5.1 + 6 + 5 + 5.1 7 + 6 7 S-179 219 Cutting sparks can cause explosion or fire. Keep flammables away from cutting. Do not cut near flammables. Cutting sparks can cause fires.
1 2 3 4 1 2 3 4 5 5 115V Warning! Watch Out! There are possible hazards as shown by the symbols. Incorrect voltage other than specified may damage unit (see Section 3-8). Read Owner’s Manual. Look at input power receptacle and plug, and be sure they match. Move switch to match input voltage. 230V S-176 481-A 4/96 2-2.
SECTION 3 – INSTALLATION 3-1. Specifications For Units Connected to a 20 Ampere, 115 Volt Circuit or a 10 Ampere, 230 Volt Circuit Amperes Input at Rated Output, 60 Hz, Single-Phase Rated Output 21 A at 88 Volts DC At 35% Duty Cycle 115 V 115 V KVA/KW 230 V 25.3 max; 15 eff 12.6 max; 7.5 eff 2.9 KVA 2.2 KW 230 V KVA/KW Plasma Gas 2.9 KVA 2.2 KW Air Or Nitrogen Only Plasma Gas Flow/ Pressure 4.
3-4. Duty Cycle And Overheating For Non-CE Model For Units Connected to a 20 Ampere, 115 Volt Circuit or a 10 Ampere, 230 Volt Circuit: Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. 35% Duty Cycle At 21 Amperes, 88 volts dc If unit overheats, thermostat(s) opens, output stops, Temperature trouble light goes On, and cooling fan runs. Wait fifteen minutes for unit to cool or temperature light to go off. Reduce amperage or duty cycle before cutting or gouging.
3-6. Selecting A Location 6-3/4 in (171 mm) Dimensions And Weight 42 lb (19.1 kg) 17 in (432 mm) 18 in (457 mm) Movement 1 Y Do not move or operate unit where it could tip. 1 Lifting Handle Use handle to lift unit. 2 Hand Cart Use cart or similar device to move unit. 2 3 Plate Label Use label to determine input power needs. 4 115 Or 230 VAC Receptacle Locate unit near correct input power supply.
3-7. Connecting Work Clamp And Gas/Air Supply 1 2 1 Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. . Use only clean, dry air with 70 to 150 psi (483 to 1034 kPa) pressure. 3 2 Air Filter/Regulator 4 Gas/Air Inlet Opening 5 Hose 6 Teflon Tape Obtain hose with 1/4 NPT righthand thread fitting. Wrap threads with teflon tape (optional) or apply pipe sealant, and install fitting in opening. Route hose to gas/air supply.
3-8. Setting Input Voltage Selector Switch And Connecting Input Power Check input voltage available at site. 1 Input Voltage Selector Switch Switch is accessible through slot in rear panel. 2 Changeover Switch Label Look at label to find correct switch position. 115V 230V Move switch to match input voltage. S-176 481-A 2 1 Rear Of Unit . If input voltage selector switch is set to a different voltage when unit is plugged in and turned on, the unit will go into a protective shutdown mode.
SECTION 4 – OPERATION 4-1. Controls 2 1 3 5 4 Setting Gas/Air Pressure 7 6 Set To 60 PSI (414 kPa) 1 Requires 70-150 PSI (483-1034 kPa) Supply 1 Output Control Use control to set cutting output. The yellow zone is for use on 20 A or greater primary circuits. Place control in Gas/Air Set position to safely adjust gas/air pressure. Only gas/air circuit is activated.
4-2. Cutting Speed The cutting speed curves show the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness. Recommended production cutting speed vs. material thickness is approximately 10 imp at 5/16 in mild steel thickness at max setting. Cut at speeds below the lines shown to avoid poor cuts and torch wear.
4-3. Sequence Of Operation Do not clean torch by hitting it against a hard surface. Hitting hard surfaces can damage torch parts and stop proper operation. Install & Connect Equipment Put On Personal Safety Equipment Check Torch (See Torch Owner’s Manual) Check Gas/Air Pressure (See Section 4-1) Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced (see torch Owner’s Manual). Do not operate torch without a tip or electrode in place.
SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
5-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System If certain problems occur, the Ready light goes off, a trouble light comes on, and output stops. 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). 1 Turn power Off, and check for proper gas/air pressure (see Section 4-1). 2 2 Cup Light Lights if shield cup is loose. Turn power Off, and check shield cup connection (see torch Owner’s Manual). Power must be reset whenever the cup shutdown is activated.
5-3. Torch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: Turn power Off, and disconnect input power plug from receptacle. Remove top and screws holding front panel in place. Without disconnecting any plugs, move front panel to allow access. Torch Connections 1 Strain Relief Clamp 2 Torch Cable Insert cable through strain relief clamp. 8 9 3 Gas Connector 4 Gas Valve Install gas connector onto gas valve.
5-4. Troubleshooting Trouble Remedy No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see torch Owner’s Manual). arc. Check for damaged torch or torch cable (see torch Owner’s Manual). Have Factory Authorized Service Agent check control relay CR6, power control board PC1, safety control board PC2, gas valve GS1, rectifier SR1, and check gas/air system for leaks. No cutting output; Power light off; Place Power switch in On position.
SECTION 6 – ELECTRICAL DIAGRAM SC-189 005-A Figure 6-1.
SECTION 7 – PARTS LIST . Hardware is common and not available unless listed. Figure 7-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Main Assembly . . . 1 . . . . . . . . . . . . . 183 161 . . . 2 . . . . . . . . . . . . . 175 145 . . . 3 . . . . . . . . . . . . . 175 366 . . . 4 . . . . . . . . . . . . . 188 961 . . . 5 . . . . . . . . . . . . . 174 668 . . . 6 . . . . . . . . . . . . . 176 518 . . . 7 . . . . . . . . . . . . . 176 517 . . . 8 . . . . . . . . . . . . . 602 963 . . . . . . . . . . . . . . . . . . . . 118 134 . . . 9 . . . . . . . . . . . . . 174 783 . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Main Assembly (Continued) . . . 38 . . . . . . . . . . . . +181 717 . . FRONT PANEL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 544 . . . . LINER, polycarbonate lens . . . . . . . . . . . . . . . . . . . . . . . .
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 guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
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.
