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Miller Electric 188 036G manual

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Table of contents for the manual

  • Page 1

    Visit our website at www.M il ler Weld s.c om OM -2219 188 036G October 1999 Processes Processes Descrip tio n Air Plasma Cutting and Gouging Air Plasma Cutter Spectrum L ynx R[...]

  • Page 2

    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 or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

  • Page 3

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

  • Page 4

    [...]

  • Page 5

    OM-2219 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_9/98 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! Watch [...]

  • Page 6

    OM-2219 Page 2 D On inverter power sources, failed parts can ex- plode or cause other parts to explode when power is applied. Always wear a face shield and long sleeves when servicing inverters. EXPLODING P ARTS can injure. Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying metal. FL YING SP ARKS can cause injury[...]

  • Page 7

    OM-2219 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 [...]

  • Page 8

    OM-2219 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 [...]

  • Page 9

    OM-2219 Page 5 SECTION 1 – CONSIGNES DE S É CURIT É – LIRE A V ANT UTILISA TION pom_nd_fre_5/97 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[...]

  • Page 10

    OM-2219 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[...]

  • Page 11

    OM-2219 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 [...]

  • Page 12

    OM-2219 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for th[...]

  • Page 13

    OM-2219 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Rated Cutting Maximum Open- T ype of Output Plasma Gas Rated Output Rated Cutting Capacity Maximum Open- Circuit V oltage DC Direct Current, Straight 50 A @ 1 10 V olts DC, 0.7 in (16 mm) Direct Current, Straight Polarity (DCEN) Air Or Nitrogen Only 50 A @ 1 10 V olts DC, 50% Duty Cycl[...]

  • Page 14

    OM-2219 Page 10 2-4. Selecting A Location loc_2 3/96 - ST-801 976 1 Lifting Handles Use handles to lift unit. 2 Hand Cart Use cart or similar device to move unit. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 51 1 or CEC Section 20 . Dimensions And W eight 1 2 Y Do not move or operate unit[...]

  • Page 15

    OM-2219 Page 1 1 2-5. Connecting W ork Clamp And Gas/Air Supply Ref. 801 977-A 1 Work Clamp 2 W orkpiece W ork clamp cable is attached to front o f unit. Connect work clamp to a clean, paint-free location on work- piece, as close to cutting area as possible. . Use only clean, dry air with 90 to 150 psi pressure. 3 Gas/Air Inlet Opening 4 Hose 5 T e[...]

  • Page 16

    OM-2219 Page 12 SECTION 3 – OPERA TION If the welding generator includes a fine adjust control, be sure to set the control to maximum for full output control capacity . When using the Lynx, auxiliary power output is not available from the 120 or 240 V AC receptacles on the welding generator . NOTE 3-1. Controls Ref. ST -189 734 / Ref. 801 977 –[...]

  • Page 17

    OM-2219 Page 13 1 Output Control 2 Power Switch Place controls as indicated above. Only gas/ air circuit is activated when the Power switch is turned On with Output Control in Gas/Air Set position. 3 Gas/Air Pressure Adjustment Knob Pull knob and turn to adjust pressure. Push knob in to lock setting. Select desired cutting output with Output Contro[...]

  • Page 18

    OM-2219 Page 14 3-3. Sequence Of Operation Put On Personal Safety Equipment After cutting arc starts, slowly start moving torch across metal. Adjust torch speed so sparks go thru metal and out bottom of cut. Pause briefly at end of cut before releasing trigger . Install & Connect Equipment EXAMPLE Of Cutting Operation ST-801 400-A Press trigger[...]

  • Page 19

    OM-2219 Page 15 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. 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 Assembly Filt[...]

  • Page 20

    OM-2219 Page 16 4-2. Ground Fault Circuit Interrupter (GFCI) Ref. 801 977-A / Ref. 802 180-A 1 Ground Fault Circuit Interrupter GFCI 2 Spring-Loaded Door (Shown Open) GFCI provides ground fault protec- tion 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[...]

  • Page 21

    OM-2219 Page 17 4-3. T rouble Lights 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). Tur n power Of f, and check for prop- er gas/air pressure (see Section 3-2). 2 Cup Light Lights if shield cup is loose. T urn power Of f, and check shield cup connection (see torch Owner ’ s Manual). Power must be reset whenever the cup shu[...]

  • Page 22

    OM-2219 Page 18 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. 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, transfor[...]

  • Page 23

    OM-2219 Page 19 SECTION 5 – ELECTRICAL DIAGRAM 193 622 Figure 5-1. Circuit Diagram[...]

  • Page 24

    OM-2219 Page 20 SECTION 6 – P ARTS LIST . Hardware is common and not available unless listed. 802 180-C 1 2 3 4 6 7 8 9 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 48 49 50 5 47 53 54 51 51 52 57 55 55 56 19 Figure 6-1. Complete Assembly[...]

  • Page 25

    OM-2219 Page 21 Description Part No. Dia. Mkgs. Item No. Figure 6-1. Complete Assembly Quantity 1 187 782 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 126 416 HANDLE, molded 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 26

    OM-2219 Page 22 Description Part No. Dia. Mkgs. Item No. Figure 6-1. Complete Assembly (continued) Quantity 51 138 442 LABEL, caution falling equipment 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 178 739 FITTING, plastic straight fem 1/8 NPT 1 . . . . . . . . . . . . . . . . . . .[...]

  • Page 27

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y ou r distributor also gives you ... Service Y ou 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 [...]

  • Page 28

    PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 West Spencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Aut o-At t ended USA & C anada FAX: 920-735-4134 Int ernati onal F A X : 920-735-4125 European H eadqua rters – United[...]