Miller KG042026 Owner's manual

Brand: Miller

Model: KG042026

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Spectrum 300

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

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.

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

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

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

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.

Movement

Location And Airflow

10 in

(254 mm)

10 in

(254 mm)

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

Use only clean and dry gas/air with 70 to

150 psi (483 to 1034 kPa) pressure.

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

115V 230V

Ref. S-176 481

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:

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

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

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

3 4

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

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).

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

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

(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.

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.

Always turn unit Off when checking

or changing consumables.

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

During Heavy Service,

Clean Monthly

Blow Out

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

Figure 5-2. Trouble Lights

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

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:

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

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Miller KG042026 Owner's manual

Brand: Miller

Model: KG042026

Category: Welding System

Type: Owner's manual

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