Miller KG042026 Owner's manual

Miller
Brand
Miller
Model
KG042026
Category
Welding System
Type
Owner's manual

This manual is also suitable for

cover 5/94 − ST-801 302-B PRINTED IN USA
1996 MILLER Electric Mfg. Co.
Air Plasma Cutting System: Power Source, Torch, And Air Regulator
For Plasma Arc Cutting (PAC)
20 Amperes At 35% Duty Cycle With 115 VAC Input Power, 20 Ampere Input Circuit,
25 Amperes At 35% Duty Cycle With 115 VAC Input Power, 30 Ampere Input Circuit,
25 Amperes At 35% Duty Cycle With 230 VAC Input Power;
Cuts Up To 3/8 in (10 mm) Mild Steel, Stainless, And Aluminum
Uses Single-Phase, 60 Hz Input Power
Overload And Overheating Protection; Diagnostic Lights
Cuts All Metals
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
September 1996 Form: OM-2210
Effective With Serial No. KG042026
Spectrum 300
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sr2 11/92
PLASMA ARC CUTTING SAFETY PRECAUTIONS
WARNING
PROTECT YOURSELF AND 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 information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
PLASMA ARC CUTTING can be hazardous.
CUTTING can cause fire or explosion.
Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and burns. Check and
be sure the area is safe before doing any cutting.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not cut where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the cutting arc. If
this is not possible, tightly cover them with approved covers.
4. Be alert that sparks and hot materials from cutting can easily go
through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that cutting on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
7. Do not cut on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the cutting area as
practical to prevent cutting current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Never cut containers with potentially flammable materials inside
− they must be emptied and properly cleaned first.
10. Do not cut in atmospheres containing explosive dust or vapors.
11. Do not cut pressurized cylinders, pipes, or vessels.
12. Do not cut containers that have held combustibles.
13. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
14. Do not locate unit on or over combustible surfaces.
15. Remove any combustibles, such as a butane lighter or matches,
from your person before doing any cutting.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. Plasma arc cutting requires
higher voltages than welding to start and maintain the
arc (200 to 400 volts dc are common), but also uses torches designed
with safety interlock systems which turn off the machine when the
shield cup is loosened or if tip touches electrode inside the nozzle.
Incorrectly installed or improperly grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
4. Do not touch torch parts if in contact with the work or ground.
5. Turn off power before checking, cleaning, or changing torch
parts.
6. Disconnect input power before installing or servicing this
equipment. Lockout/tagout input power according to OSHA CFR
1910.147 (see Safety Standards).
7. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
8. Check and be sure that input power cord ground wire is properly
connected to ground terminal in disconnect box or that cord plug
is connected to a properly grounded receptacle outlet − always
verify the supply ground.
9. When making input connections, attach proper grounding
conductor first.
10. Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
11. Turn off all equipment when not in use.
12. Inspect and replace any worn or damaged torch cable leads.
13. Do not wrap torch cable around your body.
14. Ground the workpiece to a good electrical (earth) ground if
required by codes.
15. Use only well-maintained equipment. Repair or replace
damaged parts at once.
16. Wear a safety harness if working above floor level.
17. Keep all panels and covers securely in place.
18. Do not bypass or try to defeat the safety interlock systems.
19. Use only torch(es) specified in Owner’s Manual.
20. Keep away from torch tip and pilot arc when trigger is pressed.
21. 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.
ARC RAYS can burn eyes and skin.
Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin.
1. Wear face protection (helmet or shield) with correct shade of filter
to protect your face and eyes when cutting or watching. ANSI
Z49.1 (see Safety Standards) suggests a No. 9 shade (with No. 8
as minimum) for all cutting currents less than 300 amperes.
Z49.1 adds that lighter filter shades may be used when the arc is
hidden by the workpiece. As this is normally the case with low
current cutting, the shades suggested in Table 1 are provided for
the operator’s convenience.
2. Wear approved safety glasses with side shields.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
NOISE can damage hearing.
Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
1. Use approved ear plugs or ear muffs if noise level is high.
2. Warn others nearby about noise hazard.
Table 1. Eye Protection For Plasma Arc Cutting
Current Level In Amperes Minimum Shade Number
Below 20
20 − 40
40 − 60
60 − 80
#4
#5
#6
#8
sr2 11/92
FUMES AND GASES can be hazardous
to your health.
Cutting produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove cutting fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals to be cut, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Fumes from cutting and
oxygen depletion can alter air quality causing injury or death. Be
sure the breathing air is safe.
6. Do not cut in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not cut on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
cutting area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes when cut.
8. Do not cut containers with toxic or reactive materials inside or
containers that have held toxic or reactive materials − they must
be emptied and properly cleaned first.
PLASMA ARC can cause injury.
The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.
1. Keep away from the torch tip.
2. Do not grip material near the cutting path.
3. The pilot arc can cause burns − keep away from torch tip when
trigger is pressed.
4. Wear proper flame-retardant clothing covering all exposed body
areas.
5. Point torch away from your body and toward work when pressing
the torch trigger − pilot arc comes on immediately.
6. Turn off power source and disconnect input power before
disassembling torch or changing torch parts.
7. Use only torch(es) specified in the Owner’s Manual.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
1. Wear approved face shield or safety goggles with side shields.
2. Wear proper body protection to protect skin.
3. Wear flame-resistant ear plugs or ear muffs to prevent sparks
from entering ears.
CYLINDERS can explode if damaged.
Gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders
are normally part of metalworking processes, be sure
to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flame, sparks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to
prevent falling or tipping.
3. Keep cylinders away from any cutting or other electrical circuits.
4. Never allow electrical contact between a plasma arc torch and a
cylinder.
5. Never cut on a pressurized cylinder − explosion will result.
6. Use only correct gas cylinders, regulators, hoses, and fittings
designed for the specific application; maintain them and
associated parts in good condition.
7. Turn face away from valve outlet when opening cylinder valve.
8. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
9. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
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.
Recommended Practices for Plasma Arc Cutting, American Welding
Society Standard AWS C5.2, from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
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 American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
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OM-2210 − 9/96
EMF INFORMATION
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Cutting Speed 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Selecting A Location And Moving Power Source 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Connecting Gas/Air Supply 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting Input Power 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Torch And Work Cable Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Troubleshooting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-1. Main Asembly 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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OM-2210 Page 1
SECTION 1 − SAFETY INFORMATION
mod1.1 2/93
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And
Result
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each
symbol shown.
7 NOTE
Special instructions for best
operation − not related to safety.
2
NOTE
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
5
4
6
7
1 2
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
3
Turn Off switch when using high frequency.
Figure 1-1. Safety Information
SECTION 2 − SPECIFICATIONS
Table 2-1. Power Source
Specification Description
Type Of Output Direct Current, Straight Polarity (Electrode Negative)
Rated Output 20 Amperes, 89 Volts DC At 35% Duty Cycle With 115 VAC Input Power, 20 Ampere Input Circuit
25 Amperes, 89 Volts DC At 35% Duty Cycle With 115 VAC Input Power, 30 Ampere Input Circuit
25 Amperes, 89 Volts DC At 35% Duty Cycle With 230 VAC Input Power
Type Of Input Power Single-Phase; 115 Or 230 Volts AC; 60 Hz
Input Amperes At Rated Output 26 A At 115 V, 17 A At 230 V
Input Amperes While Idling 0.4 A At 115 V, 0.2 A At 230 V
KVA/KW Used At Rated Output 3.1/2.4 At 115 V, 4.0/3.1 At 230 V
KVA/KW Used While Idling 0.05/0.04 (Both Voltages)
Max. Open-Circuit Voltage 265 Volts DC
Rated Cutting Capacity At 10 IPM (See
Figure 2-1)
1/4 in (6 mm) at 115 V, 5/16 in (8 mm) At 230 V
Plasma Gas Air Or Nitrogen Only
Plasma Gas Flow/Pressure 4.5 CFM (129 L/min) At 60 PSI (414 kPa)
Overall Dimensions (With Handle) Width: 18 in (457 mm); Height: 17 in (432 mm); Depth: 6-3/4 in (171 mm)
Weight (Not Including Torch) Net: 42 lb (19.1 kg); Ship: 47 lb (21.4 kg)
OM-2210 Page 2
2-1. Cutting Speed
CAUTION
EXCEEDING RECOMMENDED CUTTING SPEEDS will cause rapid erosion of the tip and electrode.
• Do not exceed indicated cutting speeds.
ST-179 507
The cutting speed curve shows the
recommended maximum cutting
speed capabilities of the power
source and torch for mild steel of
various thickness.
Recommended production cutting speed vs. material thickness is
approximately 10 ipm at 5/16 in mild steel thickness at max setting.
Figure 2-1. Cutting Speed
2-2. Duty Cycle
CAUTION
CUTTING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.
• Do not cut at rated load longer than shown below.
warn7.1 8/93
Duty Cycle is percentage of 10
minutes that unit can cut at
rated load without overheating.
sb1.4* 8/93
0
10
Minutes
115 VAC Input Power: 35% Duty Cycle At 20 Amperes, 20 Ampere Input Circuit
Definition
3-1/2 Minutes Cutting 6-1/2 Minutes Resting
115 VAC Input Power: 35% Duty Cycle At 25 Amperes, 30 Ampere Input Circuit
230 VAC Input Power: 35% Duty Cycle At 25 Amperes
Figure 2-2. Duty Cycle
OM-2210 Page 3
SECTION 3 − INSTALLATION
3-1. Selecting A Location And Moving Power Source
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power plug from receptacle
BEFORE moving power source.
FIRE OR EXPLOSION can result from
placing unit on, over, or near
combustible surfaces.
• Do not locate unit on, over, or near combustible
surfaces.
• Do not install unit near flammables.
BLOCKED AIRFLOW causes
overheating and possible damage to
unit.
• Do not block or filter airflow.
Warranty is void if any type of filter is used.
FUMES can be hazardous; LACK OF
FRESH AIR AND PROPER
VENTILATION can be harmful.
• Do not breathe cutting fumes.
• Place unit only where there is a good fresh air supply
and proper ventilation.
FALLING EQUIPMENT can cause
serious personal injury and equipment
damage.
• Use handle to lift unit.
• Have persons of adequate physical strength lift unit.
• Move unit with hand cart or similar device.
WARNING
swarn11.1* 3/93
ST-801 303-B / ST-801 319-B
1 Lifting Handle
Use lifting handle to lift unit.
2 Hand Cart
Use cart or similar device to move
unit from place to place.
3 115 Or 230 VAC Receptacle
Locate unit near correct input pow-
er supply.
1
2
Movement
Location And Airflow
10 in
(254 mm)
10 in
(254 mm)
3
Special installation may be required
where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
Figure 3-1. Movement And Location Of Power Source
OM-2210 Page 4
3-2. Connecting Gas/Air Supply
INCORRECT PLASMA GAS can cause torch and power source damage.
• Use only air or nitrogen for the plasma gas.
• Do not use any other gas or combination of gases.
CAUTION
1 Air Filter/Regulator
2 Gas/Air Inlet Opening
3 Hose
4 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
supply.
Adjust gas/air pressure according
to Figure 4-5.
Ref. ST-801 306-B
Tools Needed:
1-1/8, 5/8 in
From Gas/Air Supply
2
Use only clean and dry gas/air with 70 to
150 psi (483 to 1034 kPa) pressure.
1
3
4
Figure 3-2. Connecting Gas/Air Supply
3-3. Connecting Input Power
WARNING
ELECTRIC SHOCK can kill; INCORRECT INPUT VOLTAGE can damage unit.
• Do not touch live electrical parts.
• Turn Off power source, and remove input power plug from receptacle before inspecting or installing.
• Have only qualified persons install unit.
• Installation must meet National Electrical Code and all other codes.
swarn3.1* 2/93
A. Setting Input Voltage Selector Switch
ssb5.1* 2/92 − ST-801 304-B
The Input Voltage Selector switch
allows operation on different line
voltages.
Check input voltage available at
site.
1 Input Voltage Selector Switch
Switch is accessible through slot in
rear panel.
2 Changeover Switch Label
Look at label to find correct switch
position.
Move switch to match input voltage.
For example, use 115 volts position
when 115 volts input power is avail-
able.Tools Needed:
Rear Of Unit
1
115V 230V
Ref. S-176 481
2
Input Voltage Selector
Figure 3-3. Setting Input Voltage Selector Switch
OM-2210 Page 5
B. Installing Alternative Plug
1 Supplied 115 VAC Plug
Cut cord close to plug.
2 Alternative PLug (230 VAC
Plug Shown)
3 Load 1 (Brass) Terminal
4 Load 2 (Brass) Terminal
5 Ground (Green) Terminal
6 Outer Shell
7 Cord Grip
Strip cord jacket back enough to
separate conductors. Strip conduc-
tors enough to make good contact
with plug terminals. Make plug con-
nections and reinstall outer shell
and cord grip. Tighten assembly
screws onto shell. Do not overtigh-
ten.
Ref. ST-801 305-A / ST-801 611
This procedure is necessary if the unit is to be connected to a 230
VAC receptacle, or to a 115 VAC receptacle that requires a plug that
is different from the supplied plug.
Tools Needed:
1
6
7
2
3
4
5
Figure 3-4. Installing Alternative Plug
C. Connecting Input Power
1 115 Or 230 VAC Plug (115
VAC Shown)
2 115 Or 230 VAC Receptacle
(115 VAC Shown)
Be sure unit is set up for proper in-
put power according to Figure 3-3
and Figure 3-4.
To use maximum output, an individ-
ual branch circuit capable of carry-
ing 26 amperes, 115 VAC at 35%
duty cycle; or 17 amperes, 230 VAC
at 35% duty cycle, and protected by
fuses or circuit breakers is re-
quired.
Connect input power plug to proper
receptacle. Be sure receptacle can
handle load.
ST-801 319-B
1
2
Be sure input power connection meets all applicable
national, regional, and local electrical codes.
Figure 3-5. Input Power Connections
OM-2210 Page 6
SECTION 4 − OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Always wear dry insulating gloves.
• Insulate yourself from work and ground.
• Do not touch live electrical parts.
• Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous
to your health.
• Keep your head out of the fumes.
• Ventilate area, or use breathing device.
• Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material cut.
CUTTING can cause fire or explosion.
• Do not cut near flammable material.
• Provide protection from flying sparks.
• Watch for fire; keep extinguisher nearby.
• Do not locate unit over combustible surfaces.
• Do not cut on closed containers.
• Allow work and equipment to cool before handling.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
• Wear face protection with correct shade of filter.
• Wear correct eye, ear, and body protection.
MOVING PARTS can cause injury.
• Keep away from moving parts.
• Keep all doors, panels, covers, and guards closed
and securely in place.
See Safety Precautions at beginning of manual for ba-
sic cutting safety information.
swarn6.1* 10/91
ST-801 302-B
1 Output Control
2 Ready Light, Power Light,
Trouble Lights (See Section
5-2A)
3 Power Switch
1
2
3
Figure 4-1. Controls
Wear the following while cutting:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet
4 Face Shield
Wear either helmet or face shield
with correct shade of filter (See
ANSI Z49.1).
5 Ear Muffs
Wear approved ear muffs or ear
plugs if noise exposure exceeds
OSHA limits.
sb3.1* 1/94
12
3 4
5
OR
Figure 4-2. Safety Equipment
OM-2210 Page 7
1 Work Clamp
2 Workpiece
Connect work clamp to a clean,
paint-free location on workpiece, as
close to cutting area as possible.
Ref. ST-091 547-C
1
2
Figure 4-3. Work Clamp
Ref. ST-174 716
1 Output Control
Use control to select cutting output
in amperes. Gas/air automatically
flows at the set pressure.
Use Gas/Air Set area of control
range for setting gas/air pressure
(see Figure 4-5).
If 20-25 amperes of cutting output is
used with 115 VAC input power, and
the overload protection on the input
power circuit frequently opens, ei-
ther reduce the cutting output and/
or the cut time or find more ade-
quate power (see Table 2-1).
1
Figure 4-4. Output Control
Place controls in positions shown to
adjust air pressure. Only gas/air cir-
cuit is activated when the Power
switch is turned On with Output
Control in Gas/Air Set position.
1 Air Filter/Regulator
2 Pressure Adjustment Knob
Lift knob and turn to adjust pres-
sure. Push knob down to lock in set-
ting. Place output control in desired
cutting output.
Ref. ST-801 306-B
1
Set Controls
Turn On Gas/Air Supply
Set To
60 PSI
Adjust Pressure
Amperage To
Begin Cutting
Requires 70−150 PSI
(414 kPa)
Select Desired
2
2
(483−1034 kPa) Supply
Figure 4-5. Setting Gas/Air Pressure
OM-2210 Page 8
1 Ready Light
Use light to tell if unit is ready for
operation.
Ready light comes on when Power
switch is placed in On position, indi-
cating that all safety shutdown sys-
tems are okay.
If Ready light does not come on,
check Trouble Lights (see Section
5-2B).
If Ready light is On and unit does
not operate, check and clean or re-
place worn consumables as neces-
sary.
1
Figure 4-6. Ready Light
1 Power Switch
Use switch to turn unit On and Off.
2 Power Light
Power switch comes On when
Power switch is placed in On
position.
1
Always turn unit Off when checking
or changing consumables.
2
Figure 4-7. Power Switch And Power Light
OM-2210 Page 9
HITTING TORCH ON A HARD SURFACE to remove
spatter can damage torch.
• Do not clean torch by hitting it against a hard surface.
• Hitting hard surfaces can damage torch parts and stop proper
operation.
TIP AND ELECTRODE WEAR BEYOND
RECOMMENDED VALUES or OPERATION
WITHOUT TIP OR ELECTRODE can damage torch.
• Inspect shield cup, tip, and electrode before cutting or whenever
cutting speed has been significantly reduced (see torch Owner’s
Manual).
• Do not operate torch without a tip or electrode in place.
CAUTION
Press trigger. Pilot arc starts.
After cutting arc starts, slowly
start moving torch across metal.
Adjust torch speed so
sparks go thru metal and
out bottom of cut.
Pause briefly at end of
cut before releasing trigger.
Postflow continues for approx. 20 to 30 seconds
after releasing trigger; cutting arc
can be instantly restarted during postflow
Install &
Connect
Equipment
Check Torch
(See Torch
Owner’s Manual)
Check Gas/Air
Pressure
(See Figure 4-5)
Set
Controls
Begin
Cutting
EXAMPLE Of Cutting Operation
ST-161 698-B
Turn On
Power Source
Put On Personal
Safety
Equipment
by pressing trigger.
The pilot arc starts immediately when
trigger is pressed.
Place torch tip on edge of metal.
Figure 4-8. Sequence Of Plasma Arc Cutting (PAC)
OM-2210 Page 10
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off power source, and remove input power plug
from receptacle before inspecting, maintaining, or
servicing.
HOT PARTS can cause severe burns.
• Allow cooling period before maintaining or servicing.
MOVING PARTS can cause injury.
• Keep away from moving parts.
STATIC ELECTRICITY can damage
parts on circuit boards.
• Put on grounded wrist strap BEFORE handling
boards or parts.
Maintenance to be performed only by qualified persons.
WARNING
swarn8.1* 2/93
5-1. Routine Maintenance
See
Section
4
OR
During Heavy Service,
Clean Monthly
Blow Out
Or
Vacuum
Inside
− −
Turn Off all power before maintaining.
Each Use
Check
Torch Tip,
Electrode,
And Shield
Cup
Check
Shield Cup
Shutdown
System
Every Week
5-2
Check
Gas/Air
Pressure
Tape Torn
Outer
Covering
− −
Replace
Unreadable
Labels
3 Months
Clean
And
Tighten
Torch
Connections
Torch Body
Gas/Air Hose
Torch Cable
− −
Replace
Cracked
Parts
3 Months
Service
Air Filter/
Regulator
Torch
Manual
Regulator
Manual
6 Months
− −
Figure 5-1. Maintenance Schedule
OM-2210 Page 11
5-2. Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
If certain problems occur, the
Ready light goes off, a trouble light
comes on, and output stops.
1 Pressure Light
Lights if gas/air pressure is below
40 PSI (276 kPa).
Turn power Off, and check for prop-
er gas/air pressure (see
Figure 4-5).
2 Cup Light
Lights if shield cup is loose.
Turn power Off, and check shield
cup connection (see torch Owner’s
Manual). Power must be reset
whenever the cup shutdown is
activated.
Check shield cup shutdown system
once a week (see Figure 5-4).
3 Temperature Light
Lights if power source overheats
(see Figure 5-3).
Ref. ST-174 716
1
2
3
Figure 5-2. Trouble Lights
0
15
minutes
When overheated, thermostat(s)
open, output stops, and cooling
fan keeps running.
Let fan run for
15 minutes.
When Ready light comes back
on, start cutting.
ssb10.1* 1/94 − ST-801 302-B
Figure 5-3. Overheating Protection
1 Torch Shield Cup
Turn Power On and loosen shield
cup. If shutdown system works
properly, Ready light goes off and
Cup light comes on. If not, turn pow-
er Off and check for proper gas/air
pressure (see Figure 4-5), blocked
or leaking hose, or loose shield cup
(see torch Owner’s Manual).
If system works properly, retighten
cup and reset power.
Ref. ST-801 300-A
1
Power must be reset whenever the cup shutdown system is activated. Al-
ways turn Off power when changing or checking consumables.
Figure 5-4. Checking Shield Cup Shutdown System
OM-2210 Page 12
5-3. Torch And Work Cable Connections
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
ST-801 423 / Ref. ST-801 300-B
If torch or work cable needs to be
removed or replaced, proceed as
follows:
Turn power Off, and disconnect in-
put power plug from receptacle.
Remove top and screws holding
front panel in place. Without discon-
necting any plugs, move front panel
to allow access.
Torch Connections
1 Strain Relief Clamp
2 Torch Cable
Insert cable through strain relief
clamp.
3 Gas Connector
4 Gas Valve
Install gas connector onto gas
valve.
5 Plug PLG18
6 Safety Control Board PC2
7 Receptacle RC18
Connect PLG18 to RC18. Route
leads along existing lead bundle.
8 Female Friction Terminals
9 Male Friction Terminal
10 Power Control Board PC1
11 Receptacle RC4
Connect female terminals to leads
23 and 24 from RC4 (connect to
either lead). Connect male terminal
to lead 25 from RC4. Route leads
as shown.
Work Cable Connections
12 Strain Relief Clamp
Insert work clamp lead through
strain relief clamp.
13 Receptacle RC6
Connect work clamp lead to lead 20
from RC6 (leads not shown). Route
leads along existing lead bundle.
5/8 in
Tools Needed:
1
4
3
12
2
5
9
8
11
13
6
7
10
Figure 5-5. Torch And Work Cable Connections
OM-2210 Page 13
5-4. Troubleshooting
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off power source, and disconnect input power
plug from receptacle before inspecting, maintaining,
or servicing.
HOT PARTS can cause severe burns.
• Allow cooling period before servicing.
MOVING PARTS can cause injury.
• Keep away from moving parts.
STATIC ELECTRICITY can damage
parts on circuit boards.
• Put on grounded wrist strap BEFORE handling
boards or parts.
Troubleshooting to be performed only by qualified
persons.
WARNING
swarn8.1* 2/93
Table 5-1. Cutting Power Source Trouble
Trouble Remedy Section
No pilot arc; difficulty in establishing an
arc.
Clean or replace worn consumables as necessary. See torch Own-
er’s Manual.
− −
Check for damaged torch or torch cable. See torch Owner’s
Manual.
− −
Have Factory Authorized Service Agent check control relay CR6,
power control board PC1, safety control board PC2, gas valve
GS1, rectifier SR1, and check gas/air system for leaks.
− −
No cutting output; Power light off; Ready
light off; Trouble Lights off; fan motor
does not run.
Place Power switch in On position. Figure 4-7
Place line disconnect device in On position. 3-3C
Check line fuse(s) and replace if necessary or reset circuit
breakers.
3-3C
Have Factory Authorized Service Agent check power switch S1, in-
put voltage selector switch S2, input resistor R2, control relay CR6,
safety control board PC2, and transformer T1.
− −
No cutting output; Power light on; Ready
light on; Trouble Lights off; fan motor
running.
Be sure work clamp is connected. Figure 4-3
Clean or replace worn consumables as necessary. See torch Own-
er’s Manual.
− −
Have Factory Authorized Service Agent check contactor CR7, con-
trol relay CR6, safety control board PC2, input resistor R2, and
power control board PC1. Check for proper torch lead connections.
Check operation of gas valve GS1, and check gas/air system for
leaks.
− −
No cutting output; Power light on; Ready
light off; Trouble Lights off; fan motor
running.
Reset Power switch. Figure 5-4,
Figure 4-7
Have Factory Authorized Service Agent check safety control board
PC2.
− −
No control of output. Check position of input voltage selector switch S2. 3-3B
Have Factory Authorized Service Agent check power control board
PC1, and safety control board PC2.
− −
OM-2210 Page 14
Trouble Remedy Section
No gas/air flow; Power light on; Ready
light on; Trouble Lights off; fan motor
running.
Have Factory Authorized Service Agent check for proper torch con-
nections, and check power control board PC1. Check operation of
gas valve GS1, and check gas/air system for leaks.
− −
Pressure Trouble Light on; Ready light
off.
Check for correct gas/air pressure adjustment. Figure 4-5
Check for sufficient gas/air supply pressure. 3-2
Clean air filter/regulator filter. See instructions supplied with air fil-
ter/regulator.
− −
Cup Trouble Light on; Ready light off. Check torch shield cup. Figure 5-4
Have Factory Authorized Service Agent check for proper torch con-
nections, and check safety control board PC2.
− −
Temperature Trouble Light on; Ready
light off.
Thermostat TP1 open (overheating). Allow fan to run; the thermo-
stat closes when the unit has cooled.
5-2
Have Factory Authorized Service Agent check safety control board
PC2 and transformer T1.
− −
Fan motor does not run; Power light and
Ready light both on.
Have Factory Authorized Service Agent check fan motor
connections.
− −
Trouble Lights not working. Have Factory Authorized Service Agent check safety control board
PC2.
− −
Table 5-2. Cutting Process Trouble
Trouble Remedy Section
Sparks come out top of cut, or cut is not
clean.
Torch travel speed too fast; reduce travel speed. Figure 4-8,
Figure 2-1
Clean or replace worn consumables as necessary. See torch Own-
er’s Manual.
− −
Metal being cut is too thick; increase Output control setting. Figure 4-4,
Figure 2-1
Be sure work clamp is securely attached. Figure 4-3
Arc goes out while cutting. Make sure torch tip is contacting metal while cutting. Figure 4-8
Be sure work clamp is securely attached. Figure 4-3
Clean or replace worn consumables as necessary. See torch Own-
er’s Manual.
− −
Arc goes on and off while cutting. Torch travel speed is too slow; increase travel speed. Figure 4-8,
Figure 2-1
Clean or replace worn consumables as necessary. See torch Own-
er’s Manual.
− −
OM-2210 Page 15
SECTION 6 − ELECTRICAL DIAGRAM
SC-177 987-A
Figure 6-1. Circuit Diagram For Power Source
OM-2210 Page 16
SECTION 7 − PARTS LIST
Figure 7-1. Main Assembly
ST-801 412
1
2
3
9
8
7
6
4
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
5
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Miller KG042026 Owner's manual

Miller
Brand
Miller
Model
KG042026
Category
Welding System
Type
Owner's manual
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