OM-254 170B 2012−09 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter R Spectrum 625 X-TREME And XT40 Torch 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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom_2011-10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
ELECTRIC SHOCK can kill. FUMES AND GASES can be hazardous. SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input power. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is near zero (0) volts before touching any parts.
1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can burn. D Do not touch hot parts bare handed. D Allow cooling period before working on equipment. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MOVING PARTS can injure. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.
1-4. California Proposition 65 Warnings Welding or cutting equipment 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.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-5.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION pom_2011−10fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
D Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation selon la norme OSHA 29 CFR 1910.147 (reportez−vous aux Principales normes de sécurité). D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, départementales et locales.
D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce ou ayez recours à une ventilation aspirante installée près de l’arc pour évacuer les vapeurs et les gaz. D Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs approuvé. D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
LIRE LES INSTRUCTIONS. D Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section. D N’utiliser que les pièces de rechange recommandées par le constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.
2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.
SECTION 3 − DEFINITIONS 3-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 When power is applied failed parts can explode or cause other parts to explode. Safe26 2012−05 3-2.
. A complete Parts List is available at www.MillerWelds.com SECTION 4 − INSTALLATION 4-1. Specifications Power Supply Input Rated AC Phase and line frequency (Hz) Rated Input Voltage (U1) and rated Input Current (I1) and I1 eff at rated output. I1 eff used to determine power cord rating Power Factor/kVA/kW at Rated Output Peak kW at Arc Stretch 1 − Phase 60 Hz −− Volts AC RMS − (U1) Amps RMS − (I1) I1 eff 120 VAC, 1−Phase (20 A) 25.1 11.2 120 VAC, 1−Phase (15 A) 18.1 10.
. A complete Parts List is available at www.MillerWelds.com General Operating Temperature IP Code − Degree of protection provided by enclosure 5 to 104 F (−15 to 40 C) −− −− IP23CS** −− −− IP − International Protection −− −− 2 − No ingress of foreign objects 12.5 mm (0.5 in.) −− −− 3 − No harmful ingress spraying water −− −− C − AC line circuits protected against ingress of tool 2.5 mm dia x 100 mm long (0.1 in. x 4 in.
. A complete Parts List is available at www.MillerWelds.com 4-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. 20% duty cycle 2 Minutes Cutting 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.
. A complete Parts List is available at www.MillerWelds.com 4-5. Serial Number And Rating Label Location The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-6. Selecting A Location 1 Line Disconnect Device Locate unit near correct input power supply. ! Locate unit at least 18 in.
. A complete Parts List is available at www.MillerWelds.com 4-8. Connecting Work Clamp 1 2 1 Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 Ref. 803 640-A 4-9. Electrical Service Guide Elec Serv 2011−08 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard.
. A complete Parts List is available at www.MillerWelds.com 4-11. Multi−Voltage Plug Adapter (MVP) Connection Selecting Plug Adapter 1 2 3 4 5 ! 6 Do not cut off power cord connector and rewire. The power cord connector and plugs adapters will work with standard NEMA receptacles. Modifying power cord, connector, and plug adapter will void product warranty.
. A complete Parts List is available at www.MillerWelds.com 4-12. Connecting 120 Volt Input Power ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. See rating label on unit and check input voltage available at site. .
. A complete Parts List is available at www.MillerWelds.com 4-13. Connecting 1-Phase Input Power For 240 VAC 1 3 =GND/PE Earth Ground 7 2 4 L1 L2 5 6 1 8 L1 L2 9 240 VAC, 1 Tools Needed: Input6 2011−03 − 803 766-B / Ref. 254 665-A / Ref.
. A complete Parts List is available at www.MillerWelds.com 4-13. Connecting 1-Phase Input Power For 240 VAC (Continued) ! Installation must meet all National and Local Codes − have only qualified persons make this installation. See rating label on unit and check input voltage available at site. ! 1 Input Power Cord Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.
. A complete Parts List is available at www.MillerWelds.com SECTION 5 − OPERATION 5-1. Controls 2 1 25 V 30 POWER PRESSURE 3 20 CUP 35 30A TIP TEMP 120V 15A 120V 20A 50A 40A 240V TIP 30A A 15 40 253 015-A 1 Output Control Use control to set cutting output.
. A complete Parts List is available at www.MillerWelds.com 5-2. Mild Steel Recommended Cut Speed Recommended Cut Speeds At 40 Amperes Output Thickness Mild Steel Approximate Travel Speed* Inches mm IPM mm/min 1/8 3.2 156 3962 1/4 6.4 64 1626 3/8 9.5 36 914 1/2 12.7 22 559 5/8 15.9 13 330 *Recommended Cut Speed is approximately 80% of maximum. . Aluminum and stainless steel cut speeds at these thicknesses may be reduced as much as 30%.
. A complete Parts List is available at www.MillerWelds.com 5-4. Plasma Cutting System Practices ! The pilot arc starts immediately when trigger is pressed. DO NOT start pilot arc without cutting or gouging as this shortens the service life of the nozzle and electrode. Always connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 90 Maintain approximately a 90 angle to the workpiece surface for proper cutting results.
. A complete Parts List is available at www.MillerWelds.com 5-5. Sequence Of Cutting Operation 90 Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. ! For standard (shielded) cutting, place drag shield on edge of metal. For extended (non-shielded) cutting, use 1/8 in. (3.2 mm) standoff distance (dragging tip will reduce tip life). The pilot arc starts immediately when trigger is pressed. Raise trigger lock and press trigger. Pilot arc starts.
. A complete Parts List is available at www.MillerWelds.com 5-6. Sequence Of Gouging Operation Trigger pilot arc once before starting to gouge. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. ! The pilot arc starts immediately when trigger is pressed. 45 Hold torch at approximately 45 angle to workpiece. Raise trigger lock and press trigger. Pilot arc starts. Move tip to within approximately 3/16 in. (4.8 mm).
. A complete Parts List is available at www.MillerWelds.com 5-7. Sequence Of Piercing Operation ! The pilot arc starts immediately when trigger is pressed. 45 Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 90 Rotate torch to upright position approximately 90 to surface. When arc has pierced through workpiece, start cutting. Hold torch at approximately 45 to the workpiece. Raise trigger lock and press trigger. Pilot arc starts.
. A complete Parts List is available at www.MillerWelds.com SECTION 6 − MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Disconnect power before maintaining. . Maintain more often during severe conditions.
. A complete Parts List is available at www.MillerWelds.com 6-2. Wrapper Removal 2 1 ! Turn off power, and disconnect input power plug from receptacle before working on unit. Check to see that all diagnostic LEDs have stopped flashing before removing wrapper from unit. 1 2 Wrapper Torx Screws (Fine Thread) Remove Torx screws and slide wrapper off. Tools Needed: Torx 25 Ref.
. A complete Parts List is available at www.MillerWelds.com 6-3. Checking Or Replacing Filter Element ! Turn power Off, and disconnect input power plug from receptacle. Check to see that all diagnostic LEDs have stopped flashing before removing wrapper from unit. Remove wrapper from unit (see Section 6-2). 1 Filter Base 2 Filter 3 Filter Cup Unscrew filter cup from base. Remove cup. Unscrew filter element from base. Check filter element for dirt and moisture, and replace if necessary.
. A complete Parts List is available at www.MillerWelds.com 6-4. Status/Trouble Lights . Diffculty establishing a pilot arc may indicate consumables need to be cleaned or replaced. V POWER PRESSURE CUP TEMP Light Power Condition Status/Possible Cause On Input power is okay. Off When Power light is on, system is normal if these lights are off. Power Flashing rate is steady for 15 seconds or until torch trigger is pressed again, whichever comes first.
. A complete Parts List is available at www.MillerWelds.com 6-5. Checking Shield Cup Shutdown System . Power must be reset whenever the cup shutdown system is activated. Always turn Off power when changing or checking consumables. Do NOT overtighten torch shield cup. Gently finger tighten cup onto torch. 1 1 Torch Shield Cup Turn Power On and loosen shield cup. If shutdown system works properly, Cup light comes on. If not, immediately turn Off power and have Factory Authorized Service Agent check unit.
. A complete Parts List is available at www.MillerWelds.com 6-6. Checking/Replacing Retaining Cup, Tip, And Electrode ! ! Overtightening will strip threads. Do not overtighten retaining cup during assembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place.
. A complete Parts List is available at www.MillerWelds.com 6-7. Troubleshooting Power Source 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). No cutting output; Power light off; status Place Power switch in On position. lights off; fan motor FM does not run. Place line disconnect device in On position (see Section 4-13).
. A complete Parts List is available at www.MillerWelds.com 6-8. Troubleshooting Torch Trouble Remedy Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 5-5). Clean or replace torch consumables as necessary (see Section 6-6). Be sure work clamp is securely attached to workpiece. Arc goes out while cutting. Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in. (1.6 mm) to 1/8 in. (3.2 mm)] workpiece (see Section 5-4).
SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1.
254 445-A OM-254 170 Page 35
SECTION 8 − PARTS LIST 8-1. Recommended Spare Parts Item No. Dia. Mkgs. Part No. Description Quantity Recommended Spare Parts ................ ................ ................ ................ ................ ................ ................ ................ ................ 253008 254330 254328 238486 249951 249952 225916 254655 254331 . . Cord Set, 250V 6-30P 10ga 3/C 12 ft st jkt Locking . . . . . . . . . . . . . . . . . . . . . . . . Adapter, 5-15PXL630R . . . . . . . . . . . . . . . . . . . .
Item No. 1 Part No. Description 1 249 970 Torch Handle Kit (1) 2 249 971 Torch Trigger . . . . . . . . . . . . . . . Microswitch (1) 3 249 959 Leads, 12 ft (1) 3 249 960 Leads, 20 ft (1) 4 252 938 Torch Body Kit (1) 5 249 972 Torch Trigger Assembly w/Spring (1) 252 951 Grease, Silicone (1) 249 951 Torch, Replacement 12 ft (1) 249 952 Torch, Replacement 20 ft (1) 2 5 4 1 3 See Figure 8-1 for additional consumable parts. Figure 8-2. Torch, XT40 . A complete Parts List is available on-line at www.
Notes
Effective January 1, 2012 (Equipment with a serial number preface of MC or newer) 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. 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.
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 Contact 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 Service and Repair Miller Electric Mfg. Co.
