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OM-217 168 808F
October 1998
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum 1000 And 1250
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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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Plasma Arc Cutting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . .
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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 &1250 conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Electromagneti
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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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Do not bypass or try to defeat the safety interlock systems. Keep your head out of the fumes. Do not breathe the fumes. Use only torch(es) specified in Owner’s Manual. If inside, ventilate the area and/or use exhaust at the arc to remove cutting fumes and gases. Keep away from torch tip and pilot arc when trigger is pressed. If ventilation is poor, use an approved air-supplied respirator. Clamp work cable with good metal-to-metal contact to workpiece (not piece that will fall away)
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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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1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- dent of Documents, U.S. Government Printing Office, Washington, D.C. Code for Safety in Welding and Cutting, CSA Standard W1
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION pom_fre _nd_4/97 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 l
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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, Afin de réduire les champs électromagnétiques dans l’environnement des champs magnétiques basse fréquence de travail, respecter les consignes suivantes : L’extrait suivant est tiré des conclusions générales du document intitulé 1 Garder les câbles ensembles en les torsadant ou en les Biological Effects of Power Frequency Electric & Magnetic Fields – attachant avec du ruban ad
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SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! 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 1 1.1 1.2 1.3 nearby, and have a watchperson ready to use it. 1.3 Do not cut on drums or any closed containers. 2 The plasma arc can cause injury and burns. 2.1 Turn off power before disassembling to
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Warning! 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 must match. 2 Read Owner’s Manual and inside labels for connection points and procedures. 3 Move jumper links as shown on inside label to match voltage at job site. ? 1 2 V 3
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2-2. Manufacturer’s Rating Label For CE Products Match label to one on unit. See Section 3-4. 100 Ampere Model 70 Ampere Model 3 3 EN 60974-1 EN 60974-1 30A/120V 100A/120V 30A/120V 70A/120V X 80% 100% X 100% I 100A 80A I 70A 2 2 U = 270V U = 270V 0 0 U 120V 120V U 120V 2 2 U V I U V I 1 1 1 1 3 3 220V 78A 64A 220V 57A 380V 45A 37A 33A 380V 415V 41A 34A 30A 415V 50 Hz 50 Hz Drawing # IP 21S IP 21S S-174 462-A S-174 463-A OM-217 Page 11
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2-3. Symbols And Definitions Some symbols are found only on CE products. NOTE Plasma Arc Cutting Amperes Trigger Hold On Trigger Hold Off (PAC) A Continuous Pilot Volts Pilot/Pulse Starting Pulse V Arc No – Do Not Do Output Increase Temperature This Protective Earth Three Phase High Frequency Input (Ground) On Off Percent Direct Current Rated No Load Conventional Load Primary Voltage Line Connection U Voltage (Average) U Voltage U 0 1 2 Three Phase Rated Welding Transformer Primary Current Duty
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3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- 70 Ampere Models: 100% Duty Cycle At 70 Amperes utes that unit can cut at rated load without overheating. 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 Continuous Welding cycle before cutting or gouging. Exceeding duty cycle can 100 Ampere Models: 80% Duty Cycle At 100 A
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3-4. Selecting A Location 1 Lift Hook Install lift hooks using supplied bolts. Tighten to 25 ft/lb (34 N·m). Movement 2 Spreader Bar (Not Supplied) 3 Lifting Cable (Not Supplied) If lifting unit, use spreader and 3 cable. 2 4 Lifting Eye 5 Lifting Forks If using lifting forks, extend forks 1 beyond opposite side of unit. 4 6 Rating Label (Non CE Models Only) 7 Rating Label (CE Models Only, See Section 2-2) Use rating label to determine input OR power needs. 5 8 Plate Label (CE Models Only) 9 Li
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3-5. Dimensions And Weight Dimensions Height 37-1/4 in (946 mm) A Width 22-3/4 in (578 mm) B Length 20 in (508 mm) C 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 17-11/16 (449 mm) F 5-5/8 (143 mm) F G 1-1/8 (29 mm) Bottom Front H 7/16 in (11 mm) Dia H ST-159 464-B G G Weight 405 lbs (184 kg) 3-6. Tipping Be careful when placing or moving unit over uneven surfaces. OM-217 Page 15
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3-7. Connecting Work Clamp And Gas/Air Supply 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- 1 gen gas. Do not use any other gas or combination of gases. 2 Air Filter/Regulator 3 Gas/Air Inlet Opening 4 Hose 5 Teflon Tape Obtain hose with 5/8-18 right-hand thread fitting. Wrap threads with teflon tape, and install fitting in From Gas/Air Supply opening. Ad
