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OM-2219 188 036G
October 1999
P Pr ro ocesses cesses
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum Lynx
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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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_9/98 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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If inside, ventilate the area and/or use exhaust at the arc to remove EXPLODING PARTS can injure. cutting fumes and gases. If ventilation is poor, use an approved air-supplied respirator. On inverter power sources, failed parts can ex- Read the Material Safety Data Sheets (MSDSs) and the manufac- plode or cause other parts to explode when turer’s instruction for metals to be cut, coatings, and cleaners. power is applied. Always wear a face shield Work in a confined space only if it is
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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_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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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Rated Cutting Rated Cutting Maximum Open- Maximum Open- Type of Output Plasma Gas Rated Output Capacity Circuit Voltage DC Direct Direct Current, Straight Current, Straight 50 A @ 1 50 A @ 110 V 10 Vo ollt ts s D DC C, , 0.7 in (16 mm) 0.7 in (16 mm) Air Or Nitrogen Only 350 Polarity (DCEN) 50% Duty Cycle At 10 IPM 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can cut at rated load without overheating. If unit ov
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2-4. Selecting A Location 1 Lifting Handles Use handles to lift unit. 2 Hand Cart 24 in Use cart or similar device to move (610 mm) Dimensions And Weight unit. 47 lb (21.4 kg) Special installation may be required where gasoline or volatile liquids are present – 17 in see NEC Article 511 or CEC (432 mm) Section 20. 12-1/2 in (318 mm) Movement 1 Do not move or operate unit where it could tip. 1 2 loc_2 3/96 - ST-801 976 OM-2219 Page 10
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2-5. Connecting Work Clamp And Gas/Air Supply 1 Work Clamp 2 Workpiece 1 Work clamp cable is attached to front of unit. Connect work clamp to a clean, paint-free location on work- piece, 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 right- hand thread fitting. Wrap threads with teflon tape (optional) or apply pipe sealant, and install fitting in opening. Route hose to gas/air su
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SECTION 3 – OPERATION If the welding generator includes a fine adjust control, be sure to set the NOTE 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 5 2 6 7 8 9 Rear of Unit Ref. ST-189 734 / Ref. 801 977–A 1 Gas/Air Pressure Gauge Saver position in most applications to length- Power light comes On when Power switch is en the life of the torch and
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3-2. Setting Gas/Air Pressure 1 3 2 Rear of Unit Setting Gas/Air Pressure Ref. 801 977-A / Ref. ST-801 976 Place Output Control in Gas/Air Set Position Requires Power Switch On 90–150 PSI Supply Set To 70 PSI Select Desired Set Controls Turn On Gas/Air Supply Adjust Pressure Amperage To Be- On Unit gin Cutting 1 Output Control air circuit is activated when the Power switch Pull knob and turn to adjust pressure. Push is turned On with Output Control in Gas/Air knob in to lock setting. 2 Power Sw
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3-3. 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 Welding Equipment E
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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 Service Air Replace Filter/Regulator Unreadable Assembly Filter Labels Replace Tape Torn Outer Cracked Covering Or Parts Replace Cable Check Check Torch Gas/Air Hose Body 6 Months Blow Out Or OR Vacuum Inside OM-2219
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4-2. Ground Fault Circuit Interrupter (GFCI) 1 Ground Fault Circuit Interrupter GFCI Press button to reset circuit breaker. If the GFCI opens, check 2 Spring-Loaded Door (Shown power cord for damage. If the GFCI continues to open, contact Open) a Factory Authorized Service Agent. 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. To Test the GFCI: Prepare machin
