Miller Electric Spectrum 1250R manuale d’uso

Visit our website at www.MillerW elds.com Processes Descrip tio n Air Plasma Cutting and Gouging Air Plasma Cutter OM -217 168 808F October 1998 Spectrum 1000 And 1250 R[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor call 1-800-4-A-Miller . Thank you and congratulations on choosing Miller [...]

T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Plasma Arc Cutting Hazards 1 . . . . . . . . . . . . . . . . . . . . [...]

dec_con1 10/95 Declaration of Conformity For European Community (CE) Products This information is provided for units with CE certification (see rating label on unit.) NOTE Manufacturer ’ s Name: Miller Electric Mfg. Co. Manufacturer ’ s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Spectrum  1000 &125[...]

OM-217 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_5/97 1-1. Symbol Usage Means W arning! W atch 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 W arning! Watc[...]

OM-217 Page 2 D Do not bypass or try to defeat the safety interlock systems. D Use only torch(es) specified in Owner ’ s Manual. D Keep away from torch tip and pilot arc when trigger is pressed. D Clamp work cable with good metal-to-metal contact to workpiece (not piece that will fall away) or worktable as near the cut as practical. D Insulate wo[...]

OM-217 Page 3 1-3. Additional Symbols for Installation, Operation, and Maintenance HOT P ARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. MOVING P ARTS can cause injury . D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in p[...]

OM-217 Page 4 1-4. Principal Safety Standards Safety in Welding and Cutting , ANSI Standard Z49.1, from American W elding Society , 550 N.W . LeJeune Rd, Miami FL 33126 Safety and Health Standards , OSHA 29 CFR 1910, from Superinten- dent o f Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Practices for Plasma Arc C[...]

OM-217 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION pom_fre _nd_4/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particuli[...]

OM-217 Page 6 D N ’ approchez pas le tube du chalumeau et l ’ arc pilote lorsque la g â chette est enfonc é e. D Le c â ble de masse doit ê tre pinc é correctement sur la pi è ce à couper , m é tal contre m é tal (et non de telle sorte qu ’ il puisse se d é tacher), ou sur la table de travail le plus pr è s possible de la ligne de [...]

OM-217 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro- voquer des br û lures graves. D Ne pas toucher des parties chaudes à mains nues. D Laisser refroidir avant d ’ intervenir sur la torche. DES ORGANES MOBILES peuvent provoquer des blessures. D S ?[...]

OM-217 Page 8 1-5. Information sur les champs é lectromagn é tiques Donn é es sur le soudage é lectrique et sur les effets, pour l ’ organisme, des champs magn é tiques basse fr é quence L ’ extrait suivant est tir é des conclusions g é n é rales du document intitul é Biological Effects of Power Frequency Electric & Magnetic Field[...]

OM-217 Page 9 SECTION 2 – DEFINITIONS 2-1. W arning Label Definitions W arning! Watch Out! There are possible hazards as shown by the symbols. 1 Cutting sparks can cause explosion or fire. 1.1 Keep flammables away from cutting. Do not cut near flammables. 1.2 Cutting sparks can cause fires. Have a fire extinguisher nearby , and have a watchperson[...]

OM-217 Page 10 W arning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner ’ s Manual before working on this machine. 1 Consult rating label for input power requirements, and check power available at the job site – they mus[...]

OM-217 Page 1 1 2-2. Manufacturer ’ s Rating Label For CE Products Drawing # Match label to one on unit. See Section 3-4. S-174 462-A 3 EN 60974-1 X 80% 100% 30A/120V 100A/120V U 0 = 270V I 2 100A 80A U 2 120V 120V 78A 64A IP 21S 50 Hz U 1 V 220V I 1 45A 37A 380V 41A 34A 415V 3 S-174 463-A 3 EN 60974-1 X 100% 30A/120V 70A/120V U 0 = 270V I 2 70A [...]

OM-217 Page 12 2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE A Amperes Plasma Arc Cutting (P AC) T rigger Hold On T rigger Hold Of f V V olts Pilot/Pulse Starting Continuous Pilot Arc Pulse Output Increase No – Do Not Do This T emperature Protective Earth (Ground) Three Phase High Frequency Input On Of f Percent Di[...]

OM-217 Page 13 Continuous W elding 8 Minutes W elding 2 Minutes Resting 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min - utes that unit can cut at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, T emperature trouble light goes On, and cooling fan runs. Wait fifteen minutes for unit to cool o[...]

OM-217 Page 14 3-4. Selecting A Location 1 Lift Hook Install lift hooks using supplied bolts. T ighten to 25 ft/lb (34 N · m). 2 Spreader Bar (Not Supplied) 3 Lifting Cable (Not Supplied) If lifting unit, use spreader and cable. 4 Lifting Eye 5 Lifting Forks If using lifting forks, extend forks beyond opposite side of unit. 6 Rating Label (Non CE [...]

OM-217 Page 15 3-5. Dimensions And Weight Dimensions Height 37-1/4 in (946 mm) A Width 22-3/4 in (578 mm) B C Length 20 in (508 mm) C A 22-1/16 in (560 mm) B 21-1/32 in (210 mm) D C 1-1/32 in (26 mm) E D 18-13/16 in (478 mm) E 17-1 1/16 (449 mm) F 5-5/8 (143 mm) F G 1-1/8 (29 mm) H ST-159 464-B G Bottom Front H 7/16 in (1 1 mm) Dia G W eight 405 lb[...]

OM-217 Page 16 3-7. Connecting W ork Clamp And Gas/Air Supply ST-800 958 / ST -800 701 / S-0818 1 Work Cable Connect work cable to supplied clamp as shown. Connect work clamp to a clean lo- cation on workpiece, as close to cutting area as possible. . Use only clean, dry air or nitro- gen gas. Do not use any other gas or combination of gases. 2 Air [...]

OM-217 Page 17 Panel 3-8. Remote Control Connections Ref. ST-159 466-C / Ref. ST -150 802-A Y T urn Off power before instal- ling remote control. Remove left side panel. 1 T erminal Strip 1T 2 Connection Label . Lead colors shown match those o f Remote Pendant Con- trol supplied with machine-held torches. Route leads through hole below torch and wo[...]

OM-217 Page 18 3-9. Electrical Service Guide 60 Hertz Models 70 Ampere Model 100 Ampere Model Input V oltage 230 460 575 200 230 460 575 Input Amperes At Rated Output 54 27 22 85 74 37 30 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 80 40 30 125 125 60 45 Min Input Conductor Size In A WG/Kcmil 6 10 10 4 4 8 10 Max Recommended [...]

OM-217 Page 19 3-10. Placing Jumper Links And Connecting Input Power Ref. ST-800 718 Check input voltage available at site. 1 Jumper Link Label Check label – only one is on unit. 2 Jumper Links Move jumper links to match input voltage. 3 Input And Grounding Conductors Select size and length using Sec- tion 3-9. 4 Line Disconnect Device Select typ[...]

OM-217 Page 20 SECTION 4 – OPERA TION 4-1. Controls Ref. ST-159 465-A / ST -800 701 / S-0818 1 2 3 4 5 6 7 8 1 Pilot Light 2 Power Switch 3 Output Control Use control to set cutting output. Fo r non-shielded cutting, use a 1/8 in (3 mm) standof f distance between torch tip and workpiece. 4 Set/Run Switch Place switch up to safely adjust gas/air p[...]

OM-217 Page 21 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. Each Use Check T orch T ip, Electrode, And Shield Cup Check Gas/Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service A i r Filter/Regulator Replace Unread[...]

OM-217 Page 22 5-2. Overload Protection: Fuses Y T urn Off power and discon- nect input power before checking fuses. Remove left side panel. 1 Main Fuse F1 F1 protects control transformer T2 from overload. If F1 opens, the power source shuts down. 2 Timer/Control Board PC1 3 PC1 Fuse F1 4 PC1 Fuse F2 5 PC1 Fuse F4 6 Isolator/Filter Board PC5 7 PC5 [...]

OM-217 Page 23 5-3. Overload Protection: T rouble Lights & Checking Shield Cup Shutdown System If certain problems occur , the Ready light goes off, a trouble light comes on, and output stops. 1 Gas/Air Or Shield Cup Light Lights if low gas/air pressure oc- curs, if shield cup is loose, or if o- ring is defective. T urn power Of f, and check sh[...]

OM-217 Page 24 5-4. Adjusting Spark Gap Y T urn Off power before ad- justing spark gap. Remove left side panel. 1 Tungsten End Of Point Replace point if tungsten end dis- appears; do not clean or dress tungsten. 2 Spark Gap Normal spark gap is 0.030 in (0.762 mm). If adjustment is needed, proceed as follows: 3 Adjustment Screw Loosen screw . Place [...]

OM-217 Page 25 1T 5-5. T orch And Work Cable Connections Y T urn Off power before re- moving side panel. If torch or work cable needs to be removed or replaced, remove left side panel, and proceed as follows: 1 Work Cable 2 W ork (+) Output T erminal 3 T orch Cable 4 Pilot Cable 5 T orch ( – ) And Gas/Air Output Connector 6 Pilot (+) Output T erm[...]

OM-217 Page 26 5-6. T roubleshooting T rouble Remedy No cutting output; Power light of f; T rouble lights of f; Ready light o f f; fan mo- tor FM does not run. Place Power switch in On position. Place line disconnect device in On position (see Section 3-10). Check line fuse(s) and replace if needed or reset circuit breakers (see Section 3-10). Chec[...]

OM-217 Page 27 T rouble Remedy T emperature T rouble light on ; Ready light of f. Thermostat TP1 and/or TP2 open (overheating). Allow fan to run; the thermostat closes when the unit has cooled (see Section 3-2). Have Factory Authorized Service Agent check timer/control board PC1. No high gas/air flow (cutting air), or de- creased cutting ability . [...]

OM-217 Page 28 SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For 60 Hertz Power Sources SC-183 062-A[...]

OM-217 Page 29 Figure 6-2. Circuit Diagram For 50 Hertz Power Sources SC-176 919-A[...]

OM-217 Page 30 SECTION 7 – HF IN PLASMA CUTTING 7-1. High Frequency In Plasma Arc Cutting (P AC) high_freq2 4/95 – S-0753 1 Plasma Arc T orch 2 High-Frequency V oltage Used inside torch to ionize gap between electrode and tip to help start the pilot arc. 3 Electrode 4 Pilot Arc 5T i p 6 Shield Cup 1 3 5 4 6 2 W ork Plasma Arc Cutting (P AC) 7-2[...]

OM-217 Page 31 7-3. Correct Installation A. Worksite Requirements 1 Plasma Arc Cutting Source Ground metal machine case, line disconnect device, input supply , and workpiece (if required). 2 Center Point Of Cutting Zone Midpoint between high-frequency source and cutting torch. 3 Cutting Zone A circle 50 ft (15 m) from center point in all directions[...]

OM-217 Page 32 SECTION 8 – P ARTS LIST 1 Figure 8-1. Main Assembly ST-800 934 – B 3 2 4 5 6 7 8 Fig 8-4 9 10 11 12 13 14 15 16 17 18 19 Fig 8-3 22 21 20 34 33 32 31 30 29 28 27 26 25 23 24 35 36 37 Fig 8-2 38 39 . Hardware is common and not available unless listed.[...]

OM-217 Page 33 Replace Coils at Factory or Authorized Factory Service Station Description Quantity Part No. Dia. Mkgs. Figure 8-1. Main Assembly Item No. 1 015 531 HOOK, lift 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 132 940 P ANEL, side LH 1[...]

OM-217 Page 34 Description Quantity Part No. Dia. Mkgs. Figure 8-1. Main Assembly Item No. 24 010 296 FITTING, hose brs elb M 1/4NPT x .625-18RH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 AS1-3 003 538 V AL VE, 1 15V AC 2 way 1/4 IPS port 1/8orf 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-217 Page 35 1 Figure 8-2. Panel, Front w/Components 2 3 4 5 7 6 8 9 11 12 13 10 14 15 17 16 18 19 20 21 22 23 24 ST-800 935-A . Hardware is common and not available unless listed. Description Quantity Part No. Dia. Mkgs. Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 37) Item No. 1 NAMEPLA TE, (order by model and serial number) 1 . . . . . [...]

OM-217 Page 36 Description Quantity Part No. Dia. Mkgs. Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 37) Item No. PLG1 081 379 CONNECTOR, rect 12skt plug Amp 1-87159-2 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 081 378 CONNECTOR, rect skt 22-18ga Amp 102100-2 12 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-217 Page 37 Description Quantity Part No. Dia. Mkgs. Figure 8-3. Panel, Rear w/Components (Fig 8-1 Item 19) Item No. 1 R2,3 126 736 RESIST OR, WW fxd 375W 20-161 ohm dual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 F1 *604 259 FUSE, crtg 3A 600V one time 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-217 Page 38 Description Quantity Part No. Dia. Mkgs. Figure 8-4. HF Panel (Fig 8-1 Item 8) 169 882 Item No. 1 125 689 FITTING, pipe brs adapter bhd .562-18 x .750-16 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 169 883 STRIP , mtg torch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-217 Page 39 Notes[...]

OM-217 Page 40 Notes[...]

OM-217 Page 41 Notes[...]

OM-217 Page 42 Notes[...]

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 W ARRANTY – Subject to the terms and conditions below , Miller Electric Mfg. Co., Appleton, Wisconsin, warra[...]

PRINTED IN USA  1999 Miller Electric Mfg. Co. 9/98 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West S pencer St reet Applet on, WI 5 4914 USA International He adquarte rs – USA USA Phone: 920-735-4505 Auto-At t ended USA & Canada F AX : 920-735-4134 Int ernati onal F A X : 920-735-4125 European Headqua rters – Unit[...]