Miller Electric Spectrum 1251 Owner's Manual
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Miller Electric Spectrum 1251 Owner's Manual

Miller Electric Spectrum 1251 Owner's Manual

Air plasma cutter and ice-100t/tm torch
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Visit our website at
www.MillerWelds.com
Spectrum 1251 And
ICE-100T/TM Torch
OM-201 872D
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
R
File: Plasma Cutters
2007−03

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Summary of Contents for Miller Electric Spectrum 1251

  • Page 1 Spectrum 1251 And ICE-100T/TM Torch Visit our website at www.MillerWelds.com OM-201 872D Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter File: Plasma Cutters 2007−03...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. 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 specification sheets.

  • Page 3: Table Of Contents

    ..............4-9. Connecting 3-Phase Input Power 4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant SECTION 5 − OPERATION .
  • Page 4 TABLE OF CONTENTS SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance ..............7-2.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • Page 6 EXPLODING PARTS can injure. 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. FLYING SPARKS can cause injury. Sparks and hot metal blow out from the cutting arc.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on torch. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from Global Engineering Docu-...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. 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.
  • Page 10 N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâ- chette est enfoncée. Le câble de masse doit être pincé correctement sur la pièce à cou- per, métal contre métal (et non de telle sorte qu’il puisse se détacher), ou sur la table de travail le plus près possible de la ligne de coupage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Les bouteilles ne doivent pas être près de la zone de coupage ni de tout autre circuit électrique. D Un contact électrique ne doit jamais se produire entre un chalumeau de plasma d’arc et une bouteille. D Ne coupez jamais sur une bouteille pressurisée − une explosion en résulterait.

  • Page 12: Principales Normes De Sécurité

    LE COUPAGE Ã L’ARC peut causer des interférence. D L’énergie électromagnétique peut gêner le fonction- nement d’appareils électroniques comme des ordi- nateurs et des robots. D Pour réduire la possibilité d’interférence, maintenir les câbles aussi courts que possible, les grouper, et les poser aussi bas que possible (ex.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperes Volts Protective Earth (Ground) Rated No Load Voltage (Average) Rated Maximum Supply Current 1max Degree Of Protection Maximum Effective 1eff Supply Current A complete Parts List is available at www.MillerWelds.com Plasma Arc Cutting (PAC) Increase Single Phase...

  • Page 14: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Specifications Amperes Input at Rated Load Output 60 Hz, Three-Phase* Duty Cycle 208 V 230 V 460 V 575 V *Power light will flash if torch trigger is pressed when unit is connected to single-phase input power indicating an incorrect power condition. Amperes Input at Rated Load Output 50 Hz,...

  • Page 15: Duty Cycle And Overheating

    4-2. Duty Cycle and Overheating 208 Volts AC Three-Phase Input Power: 4 Minutes Cutting 230 Volts AC Three-Phase Input Power: 50% Duty Cycle 5 Minutes Cutting Overheating 4-3. Cutting Speed Rated Cutting Speed vs Material Type & Thickness 0.25” 0.375” 0.5”...

  • Page 16: Selecting A Location

    4-4. Selecting a Location Dimensions And Weight 95 lb (43 kg) w/Torch Movement Location 18 in (460 mm) OM-201 872 Page 12 A complete Parts List is available at www.MillerWelds.com 24 in (610 mm) 12-1/2 in (318 mm) Y Do not move or operate unit where it could tip.

  • Page 17: Connecting Work Clamp And Gas/Air Supply

    4-5. Connecting Work Clamp and Gas/Air Supply From Gas/Air Supply Rear of Unit 4-6. Connecting And Disconnecting Torch A complete Parts List is available at www.MillerWelds.com AIR/N 90-120 psi @ 9.2 CFM (260 L/min) minimum Tools Needed: 9/16 in Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as...

  • Page 18: Electrical Service Guide

    4-7. Electrical Service Guide CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of 50 or 60 Hz (+10%) power at +10% of 575V or −10% of 208V input voltage. Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a gener- ator with automatic idle device (that idles engine when no load is sensed) to supply input power to this plasma power source.

  • Page 19: Extension Cord Data

    4-8. Extension Cord Data NOTE When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle. Input Power Phase Input Voltage Hertz 208 V 230 V 460 V 575 V 400 V 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating”...

  • Page 20: Connecting 3-Phase Input Power

    4-9. Connecting 3-Phase Input Power Tools Needed: 3/8 in 3/8 in OM-201 872 Page 16 A complete Parts List is available at www.MillerWelds.com = GND/PE Earth Ground Y Installation must meet all National and Local Codes − have only qualified persons make this...

  • Page 21: Connecting To Miller Welder/Generator With A Three-Phase Ac Power Plant

    4-10. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant Three-Phase Power Connection Y Close panel opening if no connections are made to generator. Remove plug before inserting leads. Reinstall bushing. Rear Of Panel 240V Output Volts Amps KVA/KW...

  • Page 22: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls Gas/Air Pressure Gauge Gas/Air Pressure Control Output Control Use control to select cutting output in am- peres. Gas/air automatically flows at the set pressure. OM-201 872 Page 18 A complete Parts List is available at www.MillerWelds.com Use Gas/Air Set area of control range for set- ting gas/air pressure (see Section 5-2).

  • Page 23: Setting Gas/Air Pressure

    5-2. Setting Gas/Air Pressure Setting Gas/Air Pressure Unit Requires 90-120 PSI (621-827 kPa) Supply At 9.2 CFM (260 L/min) Minimum Flow Rate Turn On Gas/Air Supply. Power Switch On. 5-3. Trigger Safety Lock Trigger Locked A complete Parts List is available at www.MillerWelds.com AIR/N 90-120 psi Power Switch...

  • Page 24: Plasma Cutting System Practices

    5-4. Plasma Cutting System Practices Always connect work clamp to a clean, paint-free location on metal workpiece, as close to cutting area as possible. Maintain approximately a 90 angle to the workpiece surface for proper cutting results. 1/8 in (3.2 mm) When doing non-shielded cutting, maintain approximately 1/8 in standoff between electrode and surface.

  • Page 25: Sequence Of Cutting Operation

    5-5. Sequence Of Cutting Operation Connect work clamp to a clean, paint-free location on metal workpiece, as close to cutting area as possible. For standard (shielded) cutting, place drag shield on edge of metal. For non-shielded cutting, use 1/8 in (3.2 mm) standoff distance (dragging tip will reduce tip life).

  • Page 26: Sequence Of Gouging Operation

    5-6. Sequence Of Gouging Operation Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. Hold torch at approximately 45 angle to workpiece. OM-201 872 Page 22 A complete Parts List is available at www.MillerWelds.com Set air pressure to 60 PSI (414 kPa) for gouging.

  • Page 27: Sequence Of Piercing Operation

    5-7. Sequence Of Piercing Operation Connect work clamp to a Set air pressure to 75 PSI clean, paint-free location (517 kPa) for cutting. on workpiece, as close to cutting area as possible. Rotate torch to upright position approximately 90 to surface. When arc has pierced through workpiece, start cutting.

  • Page 28: Section 6 − Mechanized Operation

    RMT2 receptacle on Control board PC1. RMT2 receptacle on Control board PC1. NOTE: The Spectrum 1251 is shipped from the factory with the plug connected to RMT1 (dry contacts). To power a relay or isolated input module with +24 volts dc on black lead (socket 2) and circuit common on green lead (socket 4), see Section 6-4 or 6-5.

  • Page 29: Volts Dc Hot Contacts For Relay Operation

    6-4. +24 Volts DC Hot Contacts For Relay Operation Remote Control Cable +24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated. Tools Needed: 5/16 in A complete Parts List is available at www.MillerWelds.com White Black +24 VDC...

  • Page 30: Volts Dc Hot Contacts For Isolated Input Module Operation

    6-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation Remote Control Cable Tools Needed: 5/16 in OM-201 872 Page 26 A complete Parts List is available at www.MillerWelds.com White Black +24 VDC Green − +24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated.

  • Page 31: Dry Contacts Using An External Power Supply For Relay Operation

    6-6. Dry Contacts Using An External Power Supply For Relay Operation Remote Control Cable +24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated. Tools Needed: 5/16 in A complete Parts List is available at www.MillerWelds.com White Green Black...

  • Page 32: Dry Contacts Using An External Power Supply For Isolated Input Module Operation

    6-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation Remote Control Cable +24 volts dc will activate relay coil after unit is triggered and the cutting arc is initiated. Tools Needed: 5/16 in OM-201 872 Page 28 A complete Parts List is available at www.MillerWelds.com White Green...

  • Page 33: Remote Voltage Sense Connection

    6-8. Remote Voltage Sense Connection Tools Needed: 15/16 in 5/16 in 6-9. Shield Sense Tab A complete Parts List is available at www.MillerWelds.com Y Turn off and disconnect input power. Remote voltage sense is an arc voltage output signal for automatic torch height adjustment.

  • Page 34: Cut Charts

    6-10. Cut Charts 100 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/8 in (3.2 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 219 687 219 684 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
  • Page 35 80 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 212 733 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
  • Page 36 60 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 212 733 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
  • Page 37 40 Amp Machine Torch Shielded Consumables The following cut charts are based on a distance of 1/16 in (1.6 mm) between torch and workpiece for all cuts. Shield Sense Tab* Retaining Cap 212 732 212 733 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
  • Page 38 100 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts. Deflector Retaining Cap 212 736 219 684 Mild Steel Pierce Pierce Arc Current Arc Voltage Arc Current Arc Voltage Delay Delay...
  • Page 39 80 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts. Deflector Retaining Cap 212 736 212 733 Mild Steel Pierce Pierce Arc Current Arc Voltage Arc Current Arc Voltage Delay Delay...
  • Page 40 60 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts. Deflector Retaining Cap 212 736 212 733 Mild Steel Pierce Pierce Arc Current Arc Voltage Arc Current Arc Voltage Delay Delay...
  • Page 41 40 Amp Machine Torch Extended Consumables The following cut charts are based on a distance of 3/16 in (4.8 mm) between torch tip and workpiece for all cuts. Deflector Retaining Cap 212 736 212 733 Mild Steel Pierce Pierce Arc Current Arc Voltage Arc Current Arc Voltage Delay Delay...

  • Page 42: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Each n Torch Tip, Electrode, n Gas/Air Pressure And Shield Cup Every Week Week n Shield Cup Shutdown System l Damaged Or Unreadable l Cracked Parts...

  • Page 43: Trouble Lights

    7-2. Trouble Lights Difficulty establishing pilot arc may indicate consumables need to be cleaned or replaced. 7-3. Checking Shield Cup Shutdown System A complete Parts List is available at www.MillerWelds.com Power must be reset whenever the cup shutdown system is activated. Always turn Off power when changing or checking consumables.

  • Page 44: Checking/Replacing Retaining Cup, Tip, And Electrode

    7-4. Checking/Replacing Retaining Cup, Tip, And Electrode Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts. A good practice is to replace both the tip and electrode at the same time.

  • Page 45: Checking Or Replacing Filter Element

    7-5. Checking Or Replacing Filter Element A complete Parts List is available at www.MillerWelds.com Latch Filter Cup Retaining Nut Filter Element Defuser Ring Filter Cap Slide latch down, and rotate filter cup approximately 1/4 turn. Remove cup. Remove retaining nut, element, and defuser ring.

  • Page 46: Troubleshooting Power Source

    7-6. Troubleshooting Power Source Trouble Clean or replace worn consumables as necessary (see torch Owner’s Manual). No pilot arc; difficulty in establishing an arc. arc. Check for damaged torch or torch cable (see torch Owner’s Manual). Check position of cut/gouge switch. If using cutting consumables, be sure that switch is in the CUT position.

  • Page 47: Troubleshooting Torch

    7-7. Troubleshooting Torch Trouble Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 5-5). Clean or replace torch consumables as necessary (see Section 7-4). Be sure work clamp is securely attached to workpiece. Arc goes out while cutting.

  • Page 48: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram For Power Source OM-201 872 Page 44...
  • Page 49 201 858-A OM-201 872 Page 45...

  • Page 50: Section 9 − Parts List

    SECTION 9 − PARTS LIST 9-1. Recommended Spare Parts Item Dia. Part Mkgs. Recommended Spare Parts ....224749 COVER ASSY (including) ....223835 .
  • Page 51 Drag Shield Retaining Cap 212 730 212 733 212 730 212 733 212 730 212 733 100A 219 685 219 684 Shield Retaining Cap 212 731 212 733 212 731 212 733 100A 212 731 219 684 Figure 9-2. Consumable Parts For ICE-100T To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts.
  • Page 52 Shield Sense Tab* Retaining Cap 212 732 212 733 226 763 212 732 212 733 226 763 212 732 212 733 226 763 100A 219 687 219 684 226 763 *Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process. Deflector Retaining Cap 212 736...
  • Page 53 Item Part Description 215 607 Sleeve, torch position (1) 223 614 Torch Lead, 25ft (1) 223 615 Torch Lead, 50ft (1) 215 599 Torch Sleeve (1) 223 773 Main Body w/Switch (1) 195 513 Remote Pendant Control (1) 215 478 Switch, cup sensor (1) 225 706 Torch, replacement 25ft (1)
  • Page 54 Notes...
  • Page 55 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 56: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2007 Miller Electric Mfg. Co. 2007−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

This manual is also suitable for:

Ice-100tIce-100tm

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