Miller Electric AUTO ARC QUICK CUT 5000 User manual

AUTO

ARC)~

January

1989

FORM:OM.143

527

Effe

ctlve

Wit

Seria

No. JJ5I

8269

MODEL:

QUICK

CUTTM

5000

OWNERS.

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

this

manual,

with

special

emphasis

the

safety

material

throughout

the

manual,

before

MILLER

ELECTRIC

Mfg.

Co.

Miller

Group

Ltd.,

Company

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

Box

1079

Appleton,

54912

USA

operation

welding

equipment.

not

allow

untrained

persons

install,

Tel.

414-734-9821

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

TC-125

647

PRINTED

U.S.A.

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

Add

the

following

CAUTION

the

beginning

Sections

2-4

and

3-2,

and

also

before

Step

Section

5-1.

CAUTION:

INCORRECT

PLASMA

GAS

can

cause

torch

and

power

source

damage.



Use

only

air

nitrogen

for

the

plasma

gas

supply.



not

use

any

other

gas

combination

gases.

AMENDMENT

SECTION

INTRODUCTION

Amend

Table

2-1.

Specifications

Table

2-1.

SpecifIcations

Rated

Output

40%

Duty

Cycle

Amperes

120

Volts

Maximum

Open-

370

Volts

input

Rated

Load

Output

50/60

Sin~–hase

Plasma

Gas

Air

Nitrogen

Onl~

Weight

Amperes

115V

230V

38 33

KVA

7.6

4.6

Flow/Pressure

2.8

CFM

(79

L/min.)

PSI

(345

kPa)

Net

lbs.

(24

kg)

Ship

lbs.

(25

kg)

Add

Section

2-5.

Cutting

Speed

(Chart

2-1)

The

cutting

speed

chart

enables

the

operator

determine

the

maximum

cutting

speed

for

various

thickness

mrld

steel

within

the

capabilities

the

power

source.

The

curve

indicates

the

proper

speeds

which

cutting

may

dcne.

although

the

speeds

indicated

may

not

achieved

instantaneously.

Cutting

may

have

begin

slower

speed

w~trt

increase

speed

until

the

optimum

speed

reached.

Cutting

speeds

above

the

proper

speeds

shown

the

curve

will

cause

rapid

erosion

the

tip

and

electrode

and

should

avoided.



not

exceed

indicated

cutting

speeds.

CAUTION:

EXCEEDING

RECOMMENDED

CUTTING

SPEEDS

will

cause

rapid

erosion

the

tip

and

electrode.

Add

Chart

2-1.

Cutting

Speed

Chart

2-1.

CuttIng

Speed

(0.8)

3/8

.I0(2.~1

.20(~.I)

.30(7.61

.i.0(I0.2)

PLATE

THIC~(NESS.

IN.

(MM)

(2.31

(1.5)

3/18

1/4

(CAGe)

ll~

SB.lr

AMENDMENT

SECTION

MAINTENANCE

TROUBLESHOOTING

Amend

Section

6-5C.

OVERLOAD

PROTECTION:

Air

Pressure

Switch

Air

Pressure

Switch

prevent

damage

the

torch

due

insufficient

air

pressure,

this

unit

protected

air

pressure

switch

located

the

air

pressure/regulator.

Should

air

pressure

drop

below

preset

value,

would

close,

the

READY

light

would

turn

ott,

and

the

unit

would

completely

inoperative.

Should

the

READY

light

turned

on,

check

airfilterlregulator

and

air

compressor

(see

Table

6-2.

Troubleshooting).

Add

Section

6-9.

SHIELD

CUP

DETECTOR

INSPECTION

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Turn

power

source,

and

remove

input

power

plug

from

receptacle

before

inspecting,

maintaining.

servicing.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

servicing.

Each

time

the

shield

cup

removed

from

the

torch,

check

that

the

shield

cup

detector

pins

move

freely.

there

diii

around

the

pins,

clean

pins

with

electrical

contact

cleaner,

and

recheck

lorfree

movement,

lilt

becomes

necessary

replace

the

torch

body

assembly,

contact

the

nearest

Factory

Authorized

Service

Station.

AMENDMENT

SECTION

ELECTRICAL

DIAGRAMS

Amend

Diagram

7-1.

Circuit

Diagram

(see

Page

this

Errata

Sheet)

Add

Diagram

7-2.

Circuit

Diagram

For

Driver

Board

PC2

(see

Page

this

Errata

Sheet)

Add

Diagram

7-3.

Circuit

Diagram

For

Transformer

Control

Board

PC3

(see

Page

this

Errata

Sheet)

Add

Diagram

7-4.

Circuit

Diagram

For

Filter

Board

PC4

(see

Page

this

Errata

Sheet)

Add

Diagram

7-5.

Circuit

Diagram

For

High

Frequency

Board

PC5

(see

Page

this

Errata

Sheet)

AMENDMENT

SECTION

PARTS

LIST

Amend

Parts

List

follows:

Dia.

Part

Replaced

Mkgs

No.

With

Description

OU3r~V

25-31

125 125

Deleted

Item

not

available

assembly

25-35

125

126

Deleted

Item

not

available

assembly

25-36

125

114

Deleted

Item

not

available

assembly

25-38

125

123

Deleted

Item

not

available

assembly

25-39

125

121

Deleted

Item

not

available

assembly

25-

125

030

126

797

TORCH.

APT-3000

27-1

125

175

125

175

TERMINAL,

(addeddiamkg)

27-3

Torch

125

056

125

056

FITTING.

(added

dia

mkg)

27-13

Work

125181 125181

TERMINAL,(addeddiamkg)

31-4

125

068

130

286

TORCH

BODY,

(consisting

of)

(Eff

w/JK634462)

130

285

DETECTIVE

KIT,

(consisting

of)

130

031

INSULATING

COVER

130032

SCREW

First

digit

represents

page

digits

following

dash

represent

item

no.

SURE

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS

OM-296

Page

Circuit

Diagram

No.

SC125

063-B

~

i~i~

TMI

~

!f!

~11D~



-.0

PS



,

Diagram

7-1.

Circuit

Diagram

-o

Circuit

Diagram

No.

SC-i

644

DIagram

7-2.

Circuit

Diagram

For

Driver

Board

PC2

CN2

-3

CN9-

CN3

-3

CN4

-3

CN5-3

CN2-

CN3-

CN4-

CN5-

CN6

-3

CNI

-f

CNI

-3

CN8-

CN8-2

CN7-

CN7-3

CN6-

Circuit

Diagram

No.

SA-1

636

Diagram

7-3.

CircuIt

Diagram

For

Power

Distribution

Board

PC3

C2 L2

CNS

CN3

Circuit

Diagram

No.

SA-129

638

Diagram

7-4.

CircuIt

Diagram

For

Filter

Board

PC4

Y~...

1B2

Circuit

Diagram

No.

SA1

639

DIagram

7-5.

CircuIt

Diagram

For

High

Frequency

Board

PC5

ct4I

c~ C6

EI(

OTB?

OM-296

Page

TABLE

CONTENTS

Section

No.

Page

No.

SECTION

SAFETY

RULES

1-1.

Introduction

1-2.

General

Precautions

1-3.

Arc

Welding

1-4.

Standards

Booklet

Index

SECTION

2-INTRODUCTION

2-1.

Duty

Cycle

2-2.

General

Information

And

Safety

2-3.

Receiving-Handling

2-4.

Description

SECTION

3INSTALLATION

3-1.

Location

3-2.

Air

Filter/Regulator

Installation

And

Connections

3-3.

Input

Voltage

Changeover

Switch

3-4.

Electrical

Input

Connections

SECTION

OPERATOR

CONTROLS

4-1.

Power

Switch/Breaker

And

Power

Light

4-2.

Ready

Light

4-3.

Metal

Switch

4-4.

Thickness

Control

4-5.

Gas/Air

Switch

4-6.

Trigger

Hold

Switch

SECTION

SEQUENCE

OPERATION

5-1.

Plasma

Arc

Cutting

(PAC)

5-2.

Cutting

Problems

And

Recommendations

5-3.

Shutting

Down

SECTION

MAINTENANCE

TROUBLESHOOTING

6-1.

Routine

Maintenance

6-2.

Shield

Cup.

Tip,

And

Electrode

Inspection

And

Replacement

6-3.

Torch

And

Work

Lead

Inspection

And

Connections

6-4.

Spark

Gap

6-5.

Overload

Protection

6-6.

Safety

Shutdown

Devices

6-7.

Circuit

Board

Handling

Precautions

6-8.

Troubleshooting

SECTION

ELECTRICAL

DIAGRAMS

Diagram

7-1.

Circuit

Diagram

Figure

9-1.

Main

Assembly

Figure

9-2.

Capacitor

Assembly

Figure

9-3.

Terminal

Assembly,

Output

Figure

9-4.

Front

Panel

Assembly

Figure

9-5.

Pilot

Unit

Figure

9-6.

Rectifier

Assembly

Figure

9-7.

Torch,

Model

APT-3000

24262728

Table

2-1.

Specifications

Table

6-1.

Maintenance

Schedule

Table

6-2.

Troubleshooting

Section

No.

SECTION

PLASMA

ARC

CUTTING

(PAC)

INSTALLATION

GUIDELINES

8-1.

General

8-2.

Definitions

8-3.

High-Frequency

Radiation

8-4.

Location

8-5.

General

Installation

Procedures

8-6.

Guidelines

For

Installation

Plasma

Arc

Cutting

(PAC)

Power

Sources

8-7.

Installation

Guidelines

Checklist

SECTION

9

PARTS

LIST

Page

No.

LIST

CHARTS

AND

TABLES

Table of contents

Other Miller Electric Welding System manuals

Miller Electric

Miller Electric Big Blue 600D User manual

Miller Electric

Miller Electric Big Blue 401DX User manual

Miller Electric

Miller Electric UNITOR UWI 150 Auto-Line User manual

Miller Electric

Miller Electric Dynasty User manual

Miller Electric

Miller Electric MILLERMATIC 30A CONTROL/FEEDER User manual

Miller Electric

Miller Electric Millermatic 250X User manual

Miller Electric

Miller Electric MOG-Pak2 APR User manual

Miller Electric

Miller Electric SuitCase X-TREME 12VS User manual

Miller Electric

Miller Electric STR 450 CE User manual

Miller Electric

Miller Electric MMP User manual

Miller Electric

Miller Electric Maxstar 200 STR User manual

Miller Electric

Miller Electric Delta-Fab User manual

Miller Electric

Miller Electric RCCS-RJ User manual

Miller Electric

Miller Electric STARFIRE 1 User manual

Miller Electric

Miller Electric DVI-2 R User manual

Miller Electric

Miller Electric Spoolmatic 15A User manual

Miller Electric

Miller Electric Swingarc User manual

Miller Electric

Miller Electric APT-1000 User manual

Miller Electric

Miller Electric RCT-224 Trailer User manual

Miller Electric

Miller Electric 188 036G User manual

Miller Electric

Miller Electric SRS-1000A1 User manual

Miller Electric

Miller Electric Big Blue 400 PX User manual

Miller Electric

Miller Electric SRH-503 User manual

Miller Electric

Miller Electric SHOPMATE 300 DX User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual