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OM-225A February 1998
Eff. w/Serial Number KG155768
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum 650 Cut Force
Visit our website at
www.MillerWelds.com
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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. Today, the people that bu
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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. Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Means “Note”; not safety related. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Plasma Arc
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Work in a confined space only if it is well ventilated, or while wearing FLYING SPARKS can cause injury. an air-supplied respirator. Fumes from cutting and oxygen deple- tion can alter air quality causing injury or death. Be sure the Sparks and hot metal blow out from the cutting arc. breathing air is safe. Chipping and grinding cause flying metal. Do not cut in locations near degreasing, cleaning, or spraying oper- ations. The heat and rays of the arc can react with vapors to form Wear ap
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1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can cause severe burns. FIRE OR EXPLOSION hazard. Do not touch hot parts bare handed. Do not locate unit on, over, or near combustible surfaces. Allow cooling period before working on torch. Do not install unit near flammables. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. MOVING PARTS can cause injury. Keep away from moving parts
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1-5. EMF Information Considerations About Welding Or Cutting And The Effects Of Low 1. Keep cables close together by twisting or taping them. Frequency Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding or cutting current, as it flows through the welding or cutting cables, will cause electromagnetic fields. There has been and still is 3. Do not coil or drape cables around your body. some concern about such fields. However, after examining more than 500
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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. Identifie un message de sécurité particulier. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des ris- ques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVE- Signifie NOTA ; n’est pas relatif à la
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N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est Ne mettez pas votre tête au–dessus des vapeurs. Ne respirez pas ces va- enfoncée. peurs. Le câble de masse doit être pincé correctement sur la pièce à couper, métal Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce ou ayez contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table recours à une ventilation aspirante installée près de l’arc pour évacuer les de travail le plus
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro- Risque D’INCENDIE OU voquer des brûlures graves. D’EXPLOSION. Ne pas toucher des parties chaudes à mains nues. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. Laisser refroidir avant d’intervenir sur la torche. Ne pas installer l’appareil à proximité de produits in- flammables DES ORGANES MOBILES peuvent Ne pas surcharger l
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1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, 1 Garder les câbles ensembles en les torsadant ou en les des champs magnétiques basse fréquence attachant avec du ruban adhésif. 2 Mettre tous les câbles du côté opposé de l’opérateur. Le courant de soudage ou de coupage passant dans les câbles de puis- sance crée des causera des champs électromagnétiques. Il y a eu et 3 Ne pas courber pas et ne pas entourer pas les câbles au
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SECTION 2 – INSTALLATION 2-1. Specifications Amperes Input Maximum Plasma Rated at Rated Load Open- Input Type of Plasma Gas Flow/ Cutting Rated Output Circuit Output Power Power Output Output Gas Gas Pressure Capacity Voltage 230 V 460 V KVA KW DC 50 A @ 110 Single- 48 24 11.2 7.0 Direct Volts DC, 50% 5.3 CFM Phase (0.4*) (0.2*) (0.2*) (0.1*) Duty Cycle Current, Air Or 5/8 in (152 L/min) (152 L/min) Straight Nitrogen (16 mm) At 340 At 70 PSI 50 A @ 110 Polarity Only 10 IPM 23.2 11.6 9.1 6.8 (4
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2-3. Cutting Speed The cutting speed curves show the recommended maximum cutting speed capabilities of the power Cutting speed is approximately 10 inches per source and torch for mild steel of minute at 5/8 in mild steel thickness at max setting. various thickness. Cut at speeds below the lines shown to avoid poor cuts and torch wear. ST-180 909 OM-225 Page 10
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2-4. Selecting A Location 19 in (483 mm) Dimensions And Weight 69 lb (31.3 kg) 17 in (432 mm) 10 in (254 mm) Movement 1 Lifting Handles Use handles to lift unit. 2 Hand Cart 1 Do not move or operate unit Use cart or similar device to move where it could tip. unit. 3 Rating Label Use rating label to determine input power needs. 2 4 Line Disconnect Device Locate unit near correct input power supply. 4 Special installation may be required where gasoline or volatile liquids are present – see NEC
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2-5. Connecting Work Clamp And Gas/Air Supply 1 Work Clamp 2 Workpiece Connect work clamp to a clean, paint-free location on workpiece, as 1 close to cutting area as possible. 2 3 Gas/Air Input (Female 1/4 NPT) 4 Quick Connect Gas Fitting 5 Standard Pipe Fitting (Male 1/4 Inch) Obtain desired fitting. Wrap threads with teflon tape or apply pipe seal- ant, and install fitting onto unit. 6 Hose Obtain suitable hose according to Use only clean, dry gas/air with 70 to 150 psi installed fitting, and
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2-7. Connecting Input Power Check input voltage available at site. 1 Input Voltage Selector Switch 2 Selector Switch Label Rotate switch to match input voltage. 3 Input And Grounding 230 460 Conductors 4 Line Disconnect Device See Section 2-6. 2 For single-phase operation: 5 Black And Brown Input Conductor 6 Blue Input Conductor 1 7 Insulation Sleeving 8 Electrical Tape Insulate and isolate blue conductor as shown. 3 1 4 4 L1 L1 L2 L2 L3 3 Always connect grounding 3 conductor first. = GND/PE 5
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SECTION 3 – OPERATION 3-1. Controls 123 4 5 Setting Gas/Air Pressure 5 40 30 7 6 50 Set To 1 70 PSI (482 kPa) 30 40 O I 50 Requires 70–150 PSI POWER (482–1034 kPa) Supply Select Desired Set Controls Turn On Gas/Air Supply Adjust Pressure Amperage To Be- gin Cutting ST-801 394 1 Power Switch whenever the torch parts are disassembled Gas/air automatically flows at the set while the unit is turned On. pressure. 2 Power Light Setting Gas/Air Pressure 3 Ready Light Power light comes On when Power swi
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3-2. Sequence Of Operation Do not clean torch by hitting it against a Inspect shield cup, tip, and electrode for hard surface. Hitting hard surfaces can wear before cutting or whenever cutting damage torch parts and stop proper opera- speed has been significantly reduced (see tion. torch Owner’s Manual). Do not operate torch without a tip or electrode in place. Install & Put On Personal Check Torch Tip, Check Gas/Air Set Turn On Connect Safety Electrode, And Pressure Controls Power Source Equipm
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SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. Each Use Check Torch Check Gas/Air Tip, Electrode, Pressure And Shield Cup Every Week Check Shield Cup Shutdown System 3 Months Replace Damaged Or Service Air Unreadable Filter/Regulator Labels Tape Torn Outer Replace Covering Or Cracked Replace Cable Parts Check Torch Check Body Gas/Air Hose 6 Months Blow Out Or Vacuum Inside OM-225 Page 16
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4-2. Trouble Lights 1 Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). Turn power Off, and check for prop- er gas/air pressure (see Section 2-5). 1 2 Cup Light Lights if shield cup is loose. 2 Turn power Off, and check shield cup connection (see torch Owner’s Manual). Power must be reset 3 whenever the cup shutdown is activated. Check shield cup shutdown system once a week (see Section 4-3). 3 Temperature Light Lights if power source overheats (see Section 2-2). 4-3. Checking
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4-4. 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). No cutting output; Power light off; Place Power switch in On position. Trouble lights off; Ready light off; fan mo- tor FM does not run. Place line disconnect device in On position (see Section 2-7). Check line fuse(s) and replace if needed or reset circuit breakers (see S
