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

Miller Spectrum 1000 Owner's Manual

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Read
and
safety blocks carefully.
Have oniy trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
cover
- ST-800
948-A
Miller
OWNER'S
MANUAL
Spectrum@
Air Plasma Cutting System: Power Source, Torch, And Air Regulator
For Plasma Arc Cutting (PAC) And Plasma Arc Gouging (PAG)
1000 Model: 70 Amperes DC At 100% Duty Cycle,
Cuts Up To I in (25 mm) Mild Steel, Stainless, And Aluminum
1250 Model: 100 Amperes OC At
Cuts up To 1-1/4 in (32 mm) Mild Steel, Stainless, And Aluminum
uses Three-Phase, 60 Hz Input Power
Overload And Overheating Protection; Diagnostic Lights
Cuts All Metals: Has Remote Controi And TIP Saver Capabilities
For Options And Accessories, See Rear Cover
follow
these
instructions
and
@ 1995 MILLER Ejectnc Mfg.co.
December 1995
Effective
With Serial
1000 And 1250
Duty cyc!e.
Give this manual to the operator.
all
For help, call your distributor
or: MILLER Electric Mfg. co., P.O. Box 1079,
Appleton, WI 54912
Form:
O.M-217B
No. KF959177
414-734-9821
PANTED
IN LSA

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Summary of Contents for Miller Spectrum 1000

  • Page 1 Have oniy trained and qualified persons For help, call your distributor install, operate, or service this unit. or: MILLER Electric Mfg. co., P.O. Box 1079, Call your distributor if you do not understand Appleton, WI 54912 414-734-9821 the directions.
  • Page 2 WARRANTY Effective January 1, 1995 (Equipment with a serial number preface of "KD" or newer) ThiS *nited warvantysupersedes ad previous MILLER warranties and iS extiusive Withno other guarantees or warranties expressed or LIMITED WARRANTY the terms aneeortditions bébw. MILLER Electnc 90 Days —...
  • Page 3 PLASMA CUTTING SAFETY PRECAUTIONS WARNING PLASMA CUTTING be hazardous. PROTECT YOURSELF OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In cutting, as in most jobs, exposure to certain hazards occurs. Cutting is safe when precautions are taken. The safety informationgivenbelowis only a summaryof the morecompletesafetyinformationthat wiltbe foundin the Safety Standards listed on the next page.
  • Page 4 Work in a confined space only if it is well ventilated, or while FUMES GASES can be hazardous wearing an air-supplied respirator. Fumes from cutting and to your health. 0)0tgendepletion can alterair quality causing injury or death. Be Cutting produces fumes and gases. Breathing these sure the breathing air is safe.
  • Page 5 INFORMATION Considerations About Welding And The Effects Of Low Frequency Electric And NOTE Magnetic Fields The following is a quotation from the General Conclusions Section To reduce magnetic fields in the workplace, use the following procedures: of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency...
  • Page 7 SECTION 1 - SAFETY INFORMATION modi.1293 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. Safety Alert Symbol Signal Word WARNING means possible death or serious injury can happen. WARNING CAUTION CAUTION means possible minor...
  • Page 8 Cutting Speed 2-1. CAUTION EXCEEDING RECOMMENDED CUTTING SPEEDS will cause rapid erosion of the tip and electrode. • Do not exceed indicated cutting speeds. The cutting speed cunte shows the recommended maximum cutting Cut on or below curves shown. Cutting above speed capabilities of the power this line may result in lowered cut quali$•' a nd source...
  • Page 9 SECTION 3 - INSTALLATION WARNING HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers, and communications equipment. • Have only qualified person familiar with electronic equipment perform this installation. • Read and follow entire Secüon 7 for proper location and installation requirements for high-frequency equipment before installing unit.
  • Page 10 NOTE Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc. Inches Millimeters 37-1/4 22-3/4 22-1/16 21-1/32 1-1/32 18-13/16 17-11/16 5-5/8 1-1/8 7/16 Dia. 11 Dia. 6 Holes 6 Holes Bottom Front ST-I SS 464-8 Figure 3-2. Overall Dimensions And Base Mounting Hole Layout 3-2.
  • Page 11 Remote Control Connections 3-4. WARNING ELECTRIC SHOCK kill. • Do not touch live electrical parts. • Turn Off power source, and disconnect input power before making remote connections or installing torch. swam3.1• Tum Off power source and discon- nect input power. Remove Eefiside panel.
  • Page 12 3-5. Connecting Input Power WARNING ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Turn Off power source, and disconnect input power before inspecting or installing. • Have only qualified persons install unit. • Installation must meet National Electrical Code and all other...
  • Page 13 Connecting Input Power Have only qualified persons make this installation. Remove top cover and right side panel. Line Disconnect Device Of Proper Rating Input Conductors Grounding Conductor Select size and length using Table3-1. Conductor rating must comply with national, state, and lo- cal electrical codes.
  • Page 14 Table 3-1. Electrical Service Requirements* 70 Ampere Model 100 Ampere Model Input Voltage Input Amperes At Rated Output Recommended Standard Fuse Or Cir- cuit Breaker Rating In Amperesl Input Conductor Size In AWG/Kcmi12 Max Input Conductor Length In Feet 226 (69) 418 (127) 653 (199) 160 (49)
  • Page 15 Wear the following while cutting: Dry, Insulating Gloves Safety Glasses With Side Shields Welding Helmet Face Shield Wear either helmet or face shield with correct shade of filter (See ANSI Z49.1). Ear Muffs Wear approved ear muffs or ear plugs if noise exposure exceeds OSHA limits.
  • Page 16 Ready Light Use light to tell if unit is ready for operation. Ready light comes on when Power switch is placed in On position, in- dicating that all safety shutdown READY systerns are okay. If Ready light does not come on, check Trouble Lights (see Sectjon 5-23).
  • Page 17 Pilot Arc Control Switch Use switch to control pilot arc output. Place switch in the TIP Saver position to provide pulsed pilot arc PILOT ARC output for arc starting only. use the • KEEP FROM TOR* TIP. TIP Saver position whenever pos- •...
  • Page 18 CAUTION HITTING TORCH ON A HARD SURFACE to remove ELECTRODE WEAR BEYOND spatter can damage torch. RECOMMENDED VALUES OPERATION WITHOUT TIP OR ELECTRODE can damage torch. • Do not clean torch by hitting it against a hard surface. Inspect Shield cup, tip, and electrode before cutting or whenever •...
  • Page 19 CAUTION HITTING TORCH ON A HARD SURFACE to remove ELECTRODE WEAR BEYOND RECOMMENDED VALUES OPERATION spatter can damage torch. WITHOUT TIP OR ELECTRODE can damage torch. • Do not clean torch by hitting it against a hard surface. Inspect shield cup, tip, and electrode before cutting or whenever •...
  • Page 20 SECTION 5 - MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK kill. MOVING PARTS can cause injury. Do not touch live electrical parts. • Keep away from moving parts. • Turn Off powersource. and disconnect input power before inspecting, maintaining, or senticjng. STATIC ELECTRICITY can damage pans PARTS...
  • Page 21 5-2. Overload Protection READ SAFETY BLOCKS at start WARNING Section 5 before proceeding. Turn Off power source and discon- nect input power. Remove left side panel. Main Fuse Fuse Holder Fl protects control transformerT2 from overload. If Fl opens, the power source shuts down.
  • Page 22 Trouble Lights If certain problems occur, Ready light goes off , a trouble light comes on, and output stops Gas/Air Or Shield Cup Light Lights if iow gas/air pressure is sensed by pressure switch S2: if shield cup is loose, or if O-ring is defective.
  • Page 23 5-3. Adjusting Spark Gap READ SAFETY BLOCKS at start WARNING Section 5 before proceeding. Turn Off power source and discon- nect input power. Remove left side panel. Tungsten End Of Point Do not clean or dress tungsten. Replace point if tungsten end dis- appears.
  • Page 24 Torch Work Cable Connections READ SAFETY BLOCKS at start WARNING Section 5 before proceeding. If torch or work cable needs to be re- moved or replaced, proceed Tools Needed; follows: 1/2 in Turn Off power source and remove input power. Remove left side panel. Access Holes 3/8 in...
  • Page 25 Troubleshooting 5-5. WARNING MOVING PARTS can cause injury. ELECTRIC SHOCK can kill. • Keep away from moving parts. Do not touch live electrical parts. • Turn Offpower source, anddisconnect input power before inspecting, maintaining, or servicing. STATIC ELECTRICITY can damage parts HOT PARTS can cause severe...
  • Page 26 Section Remedy Trouble 5-2A Check fuses on timer/control board and isolator/filter board No gas/air flow; Power light on; Ready light off; Trouble Lights off: fan motor PC5. running. Check fuses on timer/control board and isolator/fitter board 5-2A No pilot arc or high frequency; difficulty in establishing an arc.
  • Page 27 Section Remedy Trouble Table 5-2. Cutting Process Trouble Section Remedy Trouble — -e Torch travel speed too fast; reduce travel speed. Figure 4-9, Sparks come out top of cut, or cut iS not Figure 4-10 clean. Check torch tip and electrode and replace if necessary. See torch Owner's Manual.
  • Page 28 NOTES OM-217 Page 22...
  • Page 29 SECTION 6 - ELECTRICAL DIAGRAMS < g;2-C < C2-F < cz-c C3-a CJ-A > < z:2-A æ.4-1 ca-T1 RZ-Y C3-a > < C4-2 Z4-B ITIelTlä C2-o CI-s SC-171 43±-B Figure 6-1. Circuit Diagram For Power Source OM-217 Page 23...
  • Page 30 PRIMARY Si-OWN W IRED3 230/460/575. PRIMARY COBNECTION CIÅCRAH OT'-ER PRIMARY ill" ÉÉääää RS I PLC 17 PLG16 TAP4 TAP2 0-ussls PILOT COIL COIL p I—69 PLGIO i tZvteu.E CHASSIS TORCH Figure 6•2- Wiring Diagram For Power Source OM-217 Page 24...
  • Page 31 3QAtÄ_Z- RC3,'PLGS RC2/PLG4 CR_G9-Z} vava g•zva 9tAtTPn RC2/PLG2 RCI 'PLCI s.uo.o•-a 64A1 IT-S' IT-6) FRONT .a:x RC'3-3) vava -tæJ eavn séz '.GIE€*R SPLICE RC2/PLG15 RCZ,'PLC RC3/PLG1 SD-169 875-A OM-217 Page 25...
  • Page 32 SECTION 7 - HF IN PLASMA CUTTING mod6-2• 4,93 WARNING HIGH-FREQU ENCY RADIATION can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified person familiar with electronic equipment perform this installation. • The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
  • Page 33 Cutting Zone 50 ft (15 m) 50 ft (15 m) Ground All Metal Objects And All Wiring In Cutting Zone Using AWG Wire Ground Workpiece If Required By Codes Nonmetal Building Metal Building 50755 Conduit Joint Bonding And Grounding Grounding Rod Plasma Arc Cutting Source Electrically join (bond) all conduit sections Ground...
  • Page 34 SECTION 8 - PARTS LIST ST-goo Figure 8-1. Main Assembly OM-217 Page 2B...
  • Page 35 Replace Coils at Factory or Authorized Factory Service Station Item Dia. Part Quantity Description Mkgs. Figure 8-1. Main Assembly HOOK, lift 015531 132 940 PANEL, side LH 168 943 COVER, top 168 942 PANEL, side RH BRACKET, mtg heatsink LH RECTIFIER, main (fig 8-5) BRACKET, mtg heatsink RH 126 701...
  • Page 36 S?-800 935-A Figure 8-2. Panel, Front wfComponents OM-217 Page 30...
  • Page 37 Item Dia. Part Description Quantity Mkgs. Figure 8-2. Panel, Front w/Components (Fig 8-1 Item 37) . NAMEPLATE, (order by model and serial number) LIGHT, ind grn lens 28V snap mtg . 125 521 . 089 085 ... SWITCH, SPST 20A 125VAC .. 115 443 STAND-OFF, 6-32 x .7504g CIRCUIT CARD, display...
  • Page 38 Item Dia. part Description Mkgs- Quantity Figure 8-3. Panel, Rear w/Components (Fig 8-1 Item 19) R2,3 ..126 736 RESISTOR, WW fxd 375W 20-161 ohm dual *604 259 ... FUSE, crtg 3A 600V one time HOLDER, fuse ctlg - BLADE, fan 14 in 3wg 23deg .375 bore CCW .
  • Page 39 Item Dia. part Quantity Description Mkgs. Figure 8-4. HF Panel (Fig 8-1 Item 8) 169 882 . FITTING, pipe brs adapter bhd .562-18 x .750-16 . 125 169 883 ... STRIP, mtg torch 605 884 NOT, sti hex jam .750-16 . .
  • Page 40 item Dia. Part Description Quantity Mkgs. Figure 8-5. Rectifier, Main (Fig 8-1 Item 6) POWER BLOCK, thyristor 55A 1200PlV SCRI-3 68 065 FOIL, interface heat transfer ..112 250 . HEAT SINK, rectifier . HEAT SINK, rect THERMOSTAT, NC . 07-12 127 082 CAPACITOR...
  • Page 41 Item Dia. Part Description Quantity Mkgs. Figure 8-6. Terminal Assembly, Pri 3Ph 3V (Fig 8-1 Item 17) NUT, brs hex 10-32 reg 601 835 TERMINAL BOARD, pri ..038 058 STUD, pri bd brs 10-32 x 1.375 . WASHER, flat brs 218 ID x .460 OD x .031thk . 010 913 ...
  • Page 42 OPTIONS ACCESSORIES provide portability- Torch cables MOTOR GUARD FILTER REPLACEMENT FILTER may be conveniently wrapped and ELEMENT (#042 306) (#042 312) stored on handle. This filter is equipped with a Carton of four filters for use with mounting bracket that allows PENDANT CONTROL (#042 585) motor guard air filter (#042 306).

This manual is also suitable for:

Spectrum 1250