Miller Electric Spectrum 1000 Owner's Manual
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Miller Electric Spectrum 1000 Owner's Manual

Air plasma cutter
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www.MillerWelds.com
Spectrum 1000 And 1250
OM-217
October 1998
Processes
Description
Air Plasma Cutter
R
168 808F
Air Plasma Cutting
and Gouging

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Summary of Contents for Miller Electric Spectrum 1000

  • Page 1 Spectrum 1000 And 1250 Visit our website at www.MillerWelds.com OM-217 October 1998 Processes Air Plasma Cutting and Gouging Description Air Plasma Cutter 168 808F...
  • Page 2 ISO 9001 Quality service information for your particular model System Standard. 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 catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ..............1-2.
  • Page 4 Declaration of Conformity For European Community (CE) Products NOTE This information is provided for units with CE certification (see rating label on unit.) Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Spectrum 1000 &1250...

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

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE 1-1. Symbol Usage Means Warning! Watch 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. 1-2.

  • Page 6: Arc Rays Can Burn Eyes And Skin

    Do not bypass or try to defeat the safety interlock systems. Use only torch(es) specified in Owner’s Manual. Keep away from torch tip and pilot arc when trigger is pressed. Clamp work cable with good metal-to-metal contact to workpiece (not piece that will fall away) or worktable as near the cut as practical.

  • 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. MOVING PARTS can cause injury. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place.

  • Page 8: Principal Safety Standards

    1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superinten- dent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT 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. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la gâchette est enfoncée. D Le câble de masse doit être pincé correctement sur la pièce à couper, 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

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance DES PIECES CHAUDES peuvent pro- voquer des brûlures 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.

  • Page 12: Information Sur Les Champs Électromagnétiques

    1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence L’extrait suivant est tiré des conclusions générales du document intitulé Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA–BP–E–53 (Washington DC : U.S.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 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.
  • Page 14 Í Í Í Í Í Í OM-217 Page 10 Í Í Í Í Í Í Í Í Í – 70 psi 4.8 bar 483 kPa S-175 971 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.

  • Page 15: Manufacturer's Rating Label For Ce Products

    2-2. Manufacturer’s Rating Label For CE Products Match label to one on unit. See Section 3-4. 100 Ampere Model EN 60974-1 30A/120V 100A = 270V 120V 220V 380V 415V 50 Hz IP 21S 100A/120V 100% = 270V 120V 220V 380V 415V 50 Hz S-174 462-A...

  • Page 16: Symbols And Definitions

    2-3. Symbols And Definitions NOTE Some symbols are found only on CE products. Amperes Volts Output Protective Earth (Ground) Rated No Load Voltage (Average) Primary Current Degree Of Protection Air/Gas Pressure Adjustment Adjust Air/Gas Pressure SECTION 3 – INSTALLATION 3-1. Specifications Amperes Input at Rated Output, Model/ 50 or 60 Hz, Three-Phase...

  • Page 17: Duty Cycle And Overheating

    3-2. Duty Cycle And Overheating 70 Ampere Models: 100% Duty Cycle At 70 Amperes 100 Ampere Models: 80% Duty Cycle At 100 Amperes 8 Minutes Welding Overheating 3-3. Cutting Speed 70 Ampere Model Continuous Welding 2 Minutes Resting Minutes Duty Cycle is percentage of 10 min- utes that unit can cut at rated load without overheating.

  • Page 18: Selecting A Location

    3-4. Selecting A Location Movement Location And Airflow OM-217 Page 14 18 in (460 18 in (460 Lift Hook Install lift hooks using supplied bolts. Tighten to 25 ft/lb (34 N·m). Spreader Bar (Not Supplied) Lifting Cable (Not Supplied) If lifting unit, use spreader and cable.

  • Page 19: Dimensions And Weight

    3-5. Dimensions And Weight Bottom Front 3-6. Tipping ST-159 464-B Dimensions Height 37-1/4 in (946 mm) Width 22-3/4 in (578 mm) Length 20 in (508 mm) 22-1/16 in (560 mm) 21-1/32 in (210 mm) 1-1/32 in (26 mm) 18-13/16 in (478 mm) 17-11/16 (449 mm) 5-5/8 (143 mm) 1-1/8 (29 mm)

  • Page 20: Connecting Work Clamp And Gas/Air Supply

    3-7. Connecting Work Clamp And Gas/Air Supply Tools Needed: 5/8, 1-1/8 in OM-217 Page 16 From Gas/Air Supply 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.

  • Page 21: Remote Control Connections

    3-8. Remote Control Connections Torch Switch N.O. Output Sensor Command Ref. Remote Jumper Common Panel Signal Ground S-169 259 Tools Needed: 3/8 in Black White +10 Volts DC (Brown) Wiper (Red) GND (Green) Y Turn Off power before instal- ling remote control. Remove left side panel.

  • Page 22: Electrical Service Guide

    3-9. Electrical Service Guide 60 Hertz Models Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1993 National Electrical Code (NEC) 50 Hertz Models Input Voltage...

  • Page 23: Placing Jumper Links And Connecting Input Power

    3-10. Placing Jumper Links And Connecting Input Power 220 VOLTS 200 VOLTS 230 VOLTS Connect GND/PE Conductor First L3 (W) L2 (V) L1 (U) Tools Needed: 3/8, 7/12, 1/2 in 380 VOLTS 230 VOLTS 460 VOLTS GND/PE Earth Ground L1 (U) L2 (V) Connect GND/PE L3 (W) Conductor First...

  • Page 24: Section 4 - Operation

    SECTION 4 – OPERATION 4-1. Controls Setting Gas/Air Pressure Pilot Light Power Switch Output Control Use control to set cutting output. For non-shielded cutting, use a 1/8 in (3 mm) standoff distance between torch tip and workpiece. Set/Run Switch Place switch up to safely adjust gas/air pres- sure.

  • Page 25: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Check Torch Tip, Electrode, And Shield Cup Y Disconnect power before maintaining. Each Use Every Week Check Shield Cup Shutdown System 3 Months Replace Unreadable Labels Clean And Tighten Weld Terminals Adjust Replace Spark...

  • Page 26: Overload Protection: Fuses

    5-2. Overload Protection: Fuses Tools Needed: 3/8 in OM-217 Page 22 Y Turn Off power and discon- nect input power before checking fuses. Remove left side panel. Main Fuse F1 F1 protects control transformer T2 from overload. If F1 opens, the power source shuts down.

  • Page 27: Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System

    5-3. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System Checking Torch Shield Cup Shutdown System If certain problems occur, the Ready light goes off, a trouble light comes on, and output stops. Gas/Air Or Shield Cup Light Lights if low gas/air pressure oc- curs, if shield cup is loose, or if o- ring is defective.

  • Page 28: Adjusting Spark Gap

    5-4. Adjusting Spark Gap Tools Needed: 3/8 in 5/32 in 0.030 in (0.762 mm) OM-217 Page 24 Y Turn Off power before ad- justing spark gap. Remove left side panel. Tungsten End Of Point Replace point if tungsten end dis- appears;...

  • Page 29: Torch And Work Cable Connections

    5-5. Torch And Work Cable Connections Torch Switch N.O. Output Sensor Command Ref. Remote Jumper Com- Panel Signal Ground S-169 259 Tools Needed: 1/2 in Hand-Held Torch Side View 3/8 in Y Turn Off power before re- moving side panel. If torch or work cable needs to be removed or replaced, remove left side panel, and proceed as follows:...

  • Page 30: Troubleshooting

    5-6. Troubleshooting Trouble 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 3-10). Check line fuse(s) and replace if needed or reset circuit breakers (see Section 3-10). Check main fuse F1 and replace if needed (see Section 5-2).
  • Page 31 Trouble Temperature Trouble light on; Ready Thermostat TP1 and/or TP2 open (overheating). Allow fan to run; the thermostat closes when the unit has light off. cooled (see Section 3-2). Have Factory Authorized Service Agent check timer/control board PC1. No high gas/air flow (cutting air), or de- Check for sufficient gas/air supply pressure and correct gas/air pressure adjustment (see Section 4-1).

  • Page 32: Section 6 - Electrical Diagrams

    SECTION 6 – ELECTRICAL DIAGRAMS SC-183 062-A Figure 6-1. Circuit Diagram For 60 Hertz Power Sources OM-217 Page 28...
  • Page 33 SC-176 919-A Figure 6-2. Circuit Diagram For 50 Hertz Power Sources OM-217 Page 29...

  • Page 34: Section 7 - Hf In Plasma Cutting

    SECTION 7 – HF IN PLASMA CUTTING 7-1. High Frequency In Plasma Arc Cutting (PAC) É É É É É É É É É É É É É É É É É É É É É É É É É É É É...

  • Page 35: Correct Installation

    7-3. Correct Installation A. Worksite Requirements 50 ft (15 m) Ground All Metal Objects And All Wiring In Cutting Zone Using #12 AWG Wire Plasma Arc Cutting Source Ground metal machine case, line disconnect device, input supply, and workpiece (if required).

  • Page 36: Section 8 - Parts List

    SECTION 8 – PARTS LIST Hardware is common and not available unless listed. ST-800 934–B Figure 8-1. Main Assembly OM-217 Page 32...
  • Page 37 Replace Coils at Factory or Authorized Factory Service Station Item Dia. Part Mkgs....015 531 ....132 940 .
  • Page 38 Item Dia. Part Mkgs....010 296 ..AS1-3 ..003 538 ..VR2-5,7,8 186 491 .
  • Page 39 Hardware is common and not available unless listed. Item Dia. Part Mkgs....... .
  • Page 40 Item Dia. Part Mkgs..PLG1 . . . 081 379 ....081 378 .
  • Page 41 Item Dia. Part Mkgs..R2,3 ..126 736 ... . *604 259 ....070 404 .
  • Page 42 Item Dia. Part Mkgs. 169 882 ....125 689 ....169 883 .
  • Page 43 Notes OM-217 Page 39...
  • Page 44 Notes OM-217 Page 40...
  • Page 45 Notes OM-217 Page 41...
  • Page 46 Notes OM-217 Page 42...
  • Page 47 LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.
  • Page 48 Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 1999 Miller Electric Mfg. Co. 9/98 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA &...

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Spectrum 1250rSpectrum 1250

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