OM-2219 188 036 July 1998 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter Spectrum Lynx R 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. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . .
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.
1-5. EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current, as it flows through the welding or cutting cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
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 − INSTALLATION 2-1. Specifications Type of Output Plasma Gas Rated Output Rated Cutting Capacity Maximum OpenCircuit Voltage DC Direct Current, Straight Polarity (DCEN) Air Or Nitrogen Only 50 A @ 110 Volts DC, 50% Duty Cycle 0.7 in (16 mm) At 10 IPM 350 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.
2-4. Selecting A Location 1 Lifting Handles Use handles to lift unit. 2 24 in (610 mm) Dimensions And Weight Hand Cart Use cart or similar device to move unit. 47 lb (21.4 kg) 17 in (432 mm) Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 12-1/2 in (318 mm) Movement 1 Y Do not move or operate unit where it could tip.
2-5. Connecting Work Clamp And Gas/Air Supply 1 2 1 Work Clamp Workpiece Work clamp cable is attached to front of unit. Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. 2 . Use only clean, dry air with 90 to 150 psi pressure. 3 Gas/Air Inlet Opening 4 Hose 5 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.
SECTION 3 − OPERATION NOTE Be sure to set the Bobcat fine adjust control to maximum for full output control capacity. When using the Lynx, auxiliary power output is not available from the 120 or 240 VAC receptacles on the welding generator. 3-1. Controls 1 4 3 2 5 6 7 8 9 Rear of Unit Ref. ST-189 734 / Ref. ST-801 977 1 Gas/Air Pressure Gauge 2 Pilot Arc Switch Use switch to control pilot arc. Place switch in Expanded Metal position for continuous pilot arc.
3-2. Setting Gas/Air Pressure 1 3 2 Rear of Unit Setting Gas/Air Pressure Place Output Control in Gas/Air Set Position Power Switch On Set Controls 1 Output Control 2 Power Switch Ref. ST-801 977 / Ref. ST-801 976 Requires 90−150 PSI Supply Turn On Gas/Air Supply Place controls as indicated above. Only gas/ Set To 70 PSI Adjust Pressure On Unit air circuit is activated when the Power switch is turned On with Output Control in Gas/Air Set position.
3-3. 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 Tip, Electrode, And Retaining Cup Check Gas/Air Pressure 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 4 − MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions.
4-2. Ground Fault Circuit Interrupter (GFCI) . Press button to reset circuit breaker. If the GFCI opens, check power cord for damage. If the GFCI continues to open, contact a Factory Authorized Service Agent. 1 2 Ground Fault Circuit Interrupter GFCI Spring-Loaded Door (Shown Open) GFCI provides ground fault protection for the input power connection. If a ground fault is detected, GFCI RESET button pops out and the unit will not function. Press button to reset.
4-3. Trouble Lights 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). Difficulty establishing pilot arc may indicate consumables need to be cleaned or replaced. Turn power Off, and check for proper gas/air pressure (see Section 3-2). 2 Cup Light Lights if shield cup is loose. 1 Turn power Off, and check shield cup connection (see torch Owner’s Manual). Power must be reset whenever the cup shutdown is activated. 2 Check shield cup shutdown system once a week (see Section 4-4).
Trouble Remedy No cutting output; Power light off; Place Power switch in On position. Trouble lights off; Ready light off; fan motor FM does not run. Reset welding generator circuit breaker CB1 and/or CB2. Check power plug connection at welding generator. Have Factory Authorized Service Agent check power switch S1, transformer T1, fan motor, and protection board PC4. Also have Agent check for chassis to electrode short. No cutting output; Power light on; Ready Be sure work clamp is connected.
SECTION 5 − ELECTRICAL DIAGRAM SC-182 691-B Figure 5-1.
26 SECTION 6 − PARTS LIST . Hardware is common and 18 33 34 32 16 9 7 48 53 52 1 54 2 44 46 47 49 45 50 51 56 3 55 4 5 43 54 42 38 55 40 6 39 16 8 10 41 9 10 36 37 35 11 10 12 13 15 57 14 31 17 20 19 21 22 23 30 29 24 28 25 27 not available unless listed. Figure 6-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly . . . 1 . . . . . . . . . . . . . . . . 187 782 . . . 2 . . . . . . . . . . . . . . . . 126 416 . . . 3 . . . . . . . . . . . . . . . . 126 415 . . . 4 . . . . . . . . . . . . . . . . 136 156 . . . 5 . . . . . . . . . . . . . . . . 188 943 . . . 6 . . . . . TP1 . . . . . . 006 334 . . . 7 . . . . . . . . . . . . . . . . 189 730 . . . 8 . . . . . CR5 . . . . . 006 393 . . . 9 . . . . . CR6 . . . . . 180 270 . . . 10 . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 6-1. Complete Assembly (continued) ... ... ... ... 54 55 56 57 . . . . . . . . . . . . . . . . 138 442 . . . . . . . . . . . . . . . . 182 696 . . . . . . . . . . . . . . . . 178 739 . . . . . . C1 . . . . . . 190 449 . . . LABEL, caution falling equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, plastic elbow 1/4 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Effective January 1, 1998 (Equipment with a serial number preface of “KJ” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co.
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 Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: To locate distributor nearest you call 1-800-4-A-Miller. Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co.
