Miller KB070482 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
cover 7/93 – ST-137 990-A PRINTED IN USA
1993 MILLER Electric Mfg. Co.
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
November 1993 Form: OM-812A
Effective With Serial No. KB070482
Air
Compressor Module
For Use With Spectrum
250 Series Plasma
Cutting Power Sources
2.8
CFM (79 L/min), 50 PSI (345 kP
A) Maximum Continuous
Pressure
230
V
olts AC, 50 Amperes, Single-Phase Input Power
Equipped With 230 V
olts AC Auxiliary Power Receptacle
Overload And Overheating Protection
ACM-1
OM-812A
- 1
1/93
TABLE OF CONTENTS
Section No. Page No.
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1.
. . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS
2-1. Description 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION
3-1. Location 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Input And Output Connections 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. 230V 50A Receptacle Specifications 2.
. . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION
4 – OPERA
TOR CONTROLS
4-1. Power Switch/Circuit Breaker 3.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance 3.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Thermal Protection 4.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAM
Diagram 6-1. Circuit Diagram For Air Compressor Module 5.
. . . . . . . . . . . . . .
SECTION 7 – PARTS LIST
Figure 7-1. Complete Assembly 6.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF CHARTS AND TABLES
Table 2-1. Specifications 1.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5-1. Maintenance Schedule 4.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5-2. Troubleshooting 4.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-812 Page 1
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY
A. General
Information
presented in this manual and on various
la
-
bels,
tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and trou-
bleshooting
which should
be read, understood, and fol
-
lowed for the safe and effective use of this equipment.
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be
installed, operated, and maintained only by qualified
persons
in accordance with
this manual and all applica
-
ble
codes such as, but not limited to, those listed at the
end
of
Plasma Arc Cutting Safety Precautions in plasma
cutting power source Owner’s Manual.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
CAUTION statements identify procedures or
practices
which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT
statements identify special instructions
necessary
for the most efficient operation of this equip
-
ment.
SECTION 2 – SPECIFICATIONS
Table 2-1. Specifications
Rated Output Of The
Receptacle At
100% Duty Cycle
Input At Max. Compressor Load
And Max. Receptacle Load
Maximum
Continuous
Flow/Pressure
Weight
Net Ship
47.4 Amps
At
230 Volts AC
2.8 CFM
(79L/Min.)
At 50 PSI
(345 kPa)
45 lbs.
(20.4 kg)
47.5 lbs.
(21.5 kg)
60 Hz Single-Phase AC
50 Amps
At
230 Volts AC
SA-137 990-A
*Add 2-1/2 in. (63.5 mm) For Height Of Handle.
10
in.
(254 mm)
12-1/2 in.*
(318 mm)
15 in.
(381 mm)
Figure 2-1. Overall Dimensions
OM-812 Page 2
2-1. DESCRIPTION
This unit has been specifically designed to provide the
proper
amount of air
pressure to operate the Spectrum
250
plasma cutting
machine. This unit can also be used
for other purposes that require the use of an air com-
pressor such as inflating tires, cleaning parts, etc.
SECTION 3 – INSTALLATION
WARNING: ELECTRIC SHOCK can kill.
•
Do not touch live electrical parts.
•
Shut down unit and power source, and dis-
connect input power employing lockout/tag-
ging
procedures before inspecting or installing.
Lockout/tagging procedures consist of remov-
ing plug from receptacle
,
padlocking line dis-
connect switch in open position, removing
fuses
from fuse box, or shutting of
f and red-tag
-
ging circuit breaker or other disconnecting
de
-
vice.
3-1. LOCATION
WARNING:
FIRE OR
EXPLOSION can result
from placing unit on or over combustible
surfaces; RESTRICTED AIRFLOW can
cause
overheating and possible damage
to
internal parts.
•
Do
not locate unit over combustible
surfaces.
•
Maintain
at least 6 inches (152 mm) of unre
-
stricted
space on all sides of unit, and keep un
-
derside free of obstructions.
•
Do
not place any
filtering device over the in
-
take air passages that provide airflow for cool-
ing this unit.
Warranty
is void if any type of filtering device is
used at intake air passages.
Figure 2-1 gives overall dimensions of the unit.
The service life and efficiency of this unit are reduced
when the unit is subjected to high levels of dust, dirt,
moisture, corrosive vapors, and extreme heat.
3-2. INPUT AND OUTPUT CONNECTIONS
Make all connections according to Figure 3-1.
3-3. 230V 50A RECEPTACLE SPECIFICATIONS
(Figure 4-1)
Receptacle RC1 provides 50 amperes of 230 volts ac
60
Hz
single-phase power to operate the Spectrum 250
plasma cutter.
IMPORTANT:
Connect the fitting to the
Air Filter/Regulator using joint compound or
teflon tape BEFORE connecting air hose
fitting.
Air Hose
Connect The Air Hose T
o The Air
Filter/Regulator Input Connection
On The Spectrum 250D As Shown.
Connect The Input
Power Plug From The
Spectrum Unit T
o The 230V
50A Receptacle As Shown.
Front Of ACM-1
Connect Input Power Plug
T
o A 230 V
olts AC 50A
Single-Phase Receptacle.
SA-138 297-A
Figure 3-1. Input And Output Connections
OM-812 Page 3
SECTION 4 – OPERATOR CONTROLS
Handle
Input Power Plug
Power Switch/
Circuit Breaker
230V 50A
Receptacle RC1
Air Hose
SA-137 990-A
(see Section 3-3)
Figure 4-1. Operator Controls
4-1.
POWER SWITCH/CIRCUIT BREAKER
V
POWER
CAUTION: RESETTING TRIPPED POWER
SWITCH/BREAKER
without correcting prob
-
lem can cause damage to this unit.
•
Do
not reset tripped POWER
switch/breaker
.
Check
all
possible causes for the switch/breaker
to
trip such
as a short, or excessive current draw
from the device connected to receptacle RC-1
etc., before resetting.
Placing
the Power Switch/Circuit Breaker S1 in the ON
position
energizes the unit and provides power to recep
-
tacle
RC1. Placing the Power Switch/Circuit Breaker
S1
in the OFF position turns off the unit and discontinues
the power to receptacle RC1.
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
5-1. ROUTINE MAINTENANCE (Table 5-1)
IMPORTANT:
Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when
necessary
. See Parts List for part number of
pre
-
cautionary labels.
WARNING: ELECTRIC SHOCK can kill.
•
Do not touch live electrical parts.
•
Turn off unit, and remove input power plug
from
receptacle before inspecting, maintaining,
or servicing.
HOT SURFACES can cause severe burns.
•
Allow cooling period before servicing.
Maintenance to be performed only by qualified
persons.
A. Air Compressor Fan
This
unit’
s compressor is equipped with an exhaust
fan
and
relies on forced draft for adequate cooling. The fan/
compressor
motor is manufactured with lifetime
sealed
bearings and requires no maintenance.
B. Internal Cleaning
WARNING: Read and follow safety informa-
tion
at beginning of entire Section 5-1 before
proceeding.
Every
six months blow out or
vacuum dust and dirt from
the
inside of the unit. Remove the outer enclosure, and
use a clean, dry airstream or vacuum suction for the
cleaning
operation. If dusty or dirty conditions are pres
-
ent, clean the unit monthly.
OM-812 Page 4
Table 5-1. Maintenance Schedule
Frequency*
Maintenance
Every day. Units in heavy service environ-
ments:
Check
and clean air filter in back of
unit (see Section 5-1C).
Every month. Check
hoses for cracks
and leaks.
Clean air filter in back of unit (see
Section 5-1C).
Units in heavy service environ-
ments:
Check labels and clean internal
parts.
Every
6
months.
Check all labels (see
IMPOR
TANT
block, Section 5-1). Clean internal
parts (see Section 5-1B).
*Frequency of service is based on units operated 40
hours per week. Increase frequency of maintenance if
usage exceeds 40 hours per week.
C. Air Filter Cleaning
CAUTION:
Do not operate unit without air fil
-
ter element in place.
Locate
air filter at back of unit and
proceed with cleaning
filter element as follows:
1. Remove air filter element.
2. Wash in water and detergent solution, and
squeeze until all dirt is removed.
3. Wrap
in clean cloth and squeeze until completely
dry.
4. Place element back in filter.
5-2. THERMAL PROTECTION
This
unit is equipped with thermal protection. If the mo
-
tor
overheats, the unit will shut down. The unit will auto
-
matically reset itself after an adequate cooling period.
5-3. TROUBLESHOOTING (Table 5-2)
WARNING: ELECTRIC SHOCK can kill.
•
Do not touch live electrical parts
•
Turn off unit, and remove input power plug
from receptacle before inspecting, maintaining
or servicing.
HOT SURFACES can cause severe burns.
•
Allow cooling period before servicing.
Troubleshooting to be performed only by quali-
fied persons.
It
is assumed that the unit was properly installed accord
-
ing to Section 3 of this manual, the operator is familiar
with the function of controls, and the unit was working
properly until trouble developed.
The
following table is designed to diagnose and provide
remedies for some of the troubles that may develop in
this
unit. Use this table in conjunction with the circuit dia
-
gram while performing troubleshooting procedures. If
the trouble is not remedied after performing these pro-
cedures, contact the nearest Factory Authorized Ser-
vice Station/Service Distributor. In all cases of equip-
ment
malfunction, strictly follow the manufacturer
’
s pro
-
cedures and instructions.
Table 5-2. Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
Unit completely inoperative. Power Switch/Circuit Breaker
S1.
Reset S1 (see CAUTION in Section 4-1).
Check and replace S1 if necessary.
Unit slowly loses air pressure. Loose hose fitting connec-
tions.
Check and tighten loose connections.
Air hose. Check and replace hose.
O-ring on air cylinder. Check and replace o-ring.
Check valve. Check and replace check valve.
OM-812 Page 5
SECTION 6 – ELECTRICAL DIAGRAM
Circuit Diagram No. SA-137 385
Diagram 6-1. Circuit Diagram For Air Compressor Module
OM-812 Page 6
SECTION 7 – PARTS LIST
Figure 7-1. Complete Assembly
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
17
20
21
22
24
25
26
27
28
29
30
31
32
SC-137 989
20
5
4
23
OM-812 Page 7
Description Quantity
Part
No.
Dia.
Mkgs.
Figure 7-1. Complete Assembly
Item
No.
1 137 173 WRAPPER 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 137 172 BRACKET, mtg handle 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 137 171 TUBING, handle 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 146 329 HOSE, rbr x .312 ID x .562 OD (order by ft) 1ft.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 010 323 CLAMP, hose .250–.625 clp dia 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 146 320 AIR COMPRESSOR, (consisting of) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 146 960 FITTING, brs barbed M 5/16tbg x 1/4NPT 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 MOUNT, air compressor (included w/compressor) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 140 863 FIL
TER CAP
, w/element 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 137 162 CABLE, pwr 8ft 8–10ga 3/c 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 S1 022 374
CIRCUIT BREAKER, 2P50A 250V
1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 022 376 BRACKET, mtg breaker 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 RC1 137 176 RECEPTACLE, str grd 2P3W 50A 250VAC 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 137 170 BRACKET, mtg bottle 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 137 182 CYLINDER, air 2.906 dia x 7.375 lg 1.000-12 thd 38c 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 137 181 O-RING, .875 ID x 1.062 OD x .093 nprn 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 137 166 FITTING, coupler air 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 010 493 BUSHING, snap-in nyl .625 ID x .875 mtg hole 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 S2 137 178 SWITCH, pressure air 80–100 lb 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 071 270 FITTING, pipe brs tee st 1/4NPT 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 010 830 FITTING, pipe brs nipple hex 1/4NPT 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 137 163 HOSE, air output (consisting of) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 105 HOSE, nprn brd No 1 x .312 ID (order by ft) 15ft.
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
057 173 FITTING, hose brs ferrule .550 ID x .718L 2.
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
039 599 FITTING, brs barbed M 5/16tbg x 1/4NPT 1.
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
059 202 FITTING, hose brs barbed nipple 5/16tbg 1.
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 606 FITTING, hose brs nut .625-18 RH 1.
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 010 678 FITTING, pipe brs elb st 1/4NPT LH 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 146 330 VALVE, check air 500PSI 1/4FNPT inlet 1/4MNPT 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 039 599 FITTING, brs barbed M 5/16tbg x 1/4NPT 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 025 590 MOUNT, resilient 4.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 146 317 BRACKET, mtg fitting tee 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 +146 321 CASE SECTION, front/bottom/rear 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 057 357 BUSHING, snap-in nyl .937 ID x 1.125 mtg hole 2.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 137 260 LABEL, warning electric shock can kill 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 NAMEPLATE, (order by model and serial number) 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 137 180 CLAMP, stl cush .875 dia x .343 mtg hole 1.
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 604 FITTING, hose brs bushing 1/4NPT 1.
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE T
O PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT P
ARTS.
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
Miller KB070482 Owner's manual
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- Owner's manual
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