Miller Electric AUTO ARC QUICK CUT 5000 User manual

AUTO
ARC)~
January
1989
FORM:OM.143
527
Effe
ctlve
Wit ii
Seria
No. JJ5I
8269
MODEL: QUICK
CUTTM
5000
OWNERS.
MANUAL
IMPORTANT: Read
and
understand
the entire
contents
of
this
manual,
with
special emphasis
on
the
safety
material
throughout
the
manual,
before
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.,
Company
installing, operating,
or
maintaining
this
equipment.
This unit and
these
instructions
are
for
use
only
by
persons
trained and
experienced
in the
safe
P0
Box
1079
Appleton,
WI
54912 USA
operation
of
welding
equipment.
Do
not
allow
untrained
persons
to
install,
Tel.
414-734-9821
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
TC-125
647
PRINTED
IN
U.S.A.

ERRATA
SHEET
After
this
manual
was
printed,
refinements
In
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
In
this
manual.
Add
the
following
CAUTION at
the
beginning
ot
Sections
2-4
and
3-2,
and
also
before
Step
2
of
Section
5-1.
CAUTION:
INCORRECT
PLASMA
GAS
can
cause
torch and
power
source
damage.
A~

Use
only
air
or
nitrogen
for
the
plasma
gas
supply.

Do not
use
any
other
gas
or
combination
of
gases.
AMENDMENT
TO
SECTION
2
-
INTRODUCTION
Amend
Table
2-1.
Specifications
Table
2-1.
SpecifIcations
Rated
Output
At
40%
Duty
Cycle
30
Amperes
At
120
Volts
DC
Maximum
Open-
~
370
Volts
DC
input
At
Rated
Load
Output
50/60
HZ
Sin~–hase
Plasma
Gas
Air
Or
Nitrogen
Onl~
Weight
Amperes
At
115V
I
230V
I
38 33
KVA
7.6
KW
4.6
Flow/Pressure
2.8
CFM
(79
L/min.)
At
50
PSI
(345
kPa)
Net
52 lbs.
(24
kg)
Ship
56
lbs.
(25
kg)
Add
Section
2-5.
Cutting
Speed
(Chart
2-1)
The
cutting
speed
chart
enables
the
operator
to
determine
the
maximum
cutting
speed
for various thickness
of
mrld
steel
within
the
capabilities
of the
power
source.
The
curve
indicates
the
proper
speeds
at
which
cutting
may
be
dcne.
although
the
speeds
indicated
may
not be achieved
instantaneously.
Cutting
may
have
to
begin
at
a
slower
speed
w~trt
an
increase
in
speed
until
the
optimum
speed
is
reached.
Cutting
at
speeds
above the
proper
speeds
shown
by
the
curve
will
cause
rapid
erosion
of
the
tip
and electrode
and
should be
avoided.

Do not
exceed
indicated
cutting speeds.
CAUTION:
EXCEEDING RECOMMENDED
CUTTING
SPEEDS
will
cause
rapid
erosion of
the
tip
and
electrode.
Add
Chart 2-1.
Cutting
Speed
Chart
2-1.
CuttIng Speed
z
z
z
d
LU
0,
0
30
(0.8)
3/8
.I0(2.~1
.20(~.I)
.30(7.61 .i.0(I0.2)
PLATE
THIC~(NESS.
IN.
(MM)
90
(2.31
80
(1.5)
I,
I
I
I
20 12
3/18
1/4
(CAGe)
I
~
ll~
~
SB.lr
~

AMENDMENT
TO
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
Amend
Section
6-5C.
OVERLOAD
PROTECTION: Air
Pressure Switch
C.
Air
Pressure
Switch
To
prevent
damage
to
the
torch
due
to
insufficient
air
pressure,
this
unit is
protected by
air
pressure
switch
S5
located
in
the
air
pressure/regulator.
Should
air
pressure
drop
below
a
preset
value,
S5
would
close,
the
READY
light
would
turn
ott,
and
the unit
would be
completely
inoperative.
Should
the
READY
light
be
turned
on,
check
airfilterlregulator
and
air
compressor
(see
Table
6-2.
Troubleshooting).
Add
Section
6-9.
SHIELD
CUP
DETECTOR
PIN
INSPECTION
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live electrical
parts.

Turn
of
f
power
source,
and
remove
input
power plug
from
receptacle
before
inspecting, maintaining.
or
servicing.
HOT
SURFACES
can
cause
severe
burns.

Allow
cooling
period
before
servicing.
Each
time the
shield
cup
is
removed
from
the
torch,
check that
the shield
cup
detector
pins
move
freely.
If
there
is
diii
around
the
pins,
clean
pins
with
electrical
contact
cleaner,
and
recheck
lorfree movement,
lilt
becomes
necessary
to
replace
the
torch
body
or
pin
assembly,
contact
the
nearest
Factory
Authorized
Service Station.
AMENDMENT
TO
SECTION
7- ELECTRICAL
DIAGRAMS
Amend
Diagram
7-1.
Circuit
Diagram
(see
Page
3
on
this Errata
Sheet)
Add
Diagram
7-2.
Circuit
Diagram
For Driver
Board
PC2
(see
Page
4
on
this
Errata
Sheet)
Add
Diagram
7-3.
Circuit
Diagram
For
Transformer
Control
Board
PC3
(see
Page
5
on
this
Errata
Sheet)
Add
Diagram
7-4.
Circuit
Diagram
For
Filter
Board PC4
(see
Page
5
on
this
Errata
Sheet)
Add
Diagram
7-5. Circuit
Diagram
For
High
Frequency
Board PC5
(see
Page
6
on
this
Errata
Sheet)
AMENDMENT
TO
SECTION
9-
PARTS LIST
Amend
Parts
List
as
follows:
Dia.
Part
Replaced
Mkgs
No.
With
Description
OU3r~V
25-31
125 125
Deleted
Item
not
available
as an
assembly
25-35
125
126
Deleted
Item
not available
as
an
assembly
25-36
125
114
Deleted
Item
not
available
as
an
assembly
25-38
125
123
Deleted
Item
not available
as
an
assembly
25-39
125
121
Deleted
Item not
available
as an
assembly
25-
125
030
126
797
TORCH.
APT-3000
27-1
iT
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
PIN
KIT,
(consisting
of)
130 031 INSULATING COVER
130032
SCREW
First
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER WHEN
ORDERING
REPLACEMENT
PARTS
OM-296
Page
2

Circuit
Diagram
No.
SC125
063-B
~
i~i~
PS
TMI
~
ii
A
~
~
~
!f!
!
~
~11D~

-.0
9
PS

,
IT
Diagram
7-1.
Circuit
Diagram

0
-o
lQ
Circuit
Diagram
No.
SC-i
29
644
DIagram
7-2.
Circuit
Diagram
For
Driver
Board
PC2

CN2
-3
CN9-
I
CN3
-3
CN4
-3
CN5-3
CN2-
I
CN3-
I
CN4-
I
CN5-
I
CN6
-3
CNI
-f
CNI -3
CN8-
I
CN8-2
CN7-
I
CN7-3
CN6-
I
Circuit
Diagram
No.
SA-1
29 636
Diagram
7-3.
CircuIt
Diagram
For Power
Distribution
Board
PC3
3<
Ri
>2
C2 L2
C3
Cl
4
CN
I
CNS
3
CN3
7
5
3
Circuit
Diagram
No.
SA-129
638
L7
L8
Diagram
7-4.
CircuIt
Diagram
For
Filter
Board
PC4
OM
Y~...
~e
5

4
1B2
Circuit
Diagram
No. SA1
29
639
DIagram
7-5.
CircuIt
Diagram
For
High
Frequency
Board
PC5
ct4I
3
c~ C6
EI(
OTB?
OM-296
Page
6

TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY RULES
1-1.
Introduction
1
1-2.
General
Precautions
1
1-3.
Arc
Welding
4
1-4.
Standards
Booklet
Index
5
SECTION
2-INTRODUCTION
2-1.
Duty
Cycle
7
2-2.
General
Information
And
Safety
7
2-3.
Receiving-Handling
8
2-4.
Description
8
SECTION
3INSTALLATION
3-1.
Location
8
3-2.
Air
Filter/Regulator
Installation
And
Connections
8
3-3.
Input
Voltage
Changeover
Switch
9
3-4.
Electrical
Input
Connections
9
SECTION
4-
OPERATOR
CONTROLS
4-1.
Power
Switch/Breaker
And
Power On
Light
11
4-2.
Ready
Light
11
4-3.
Metal
Switch
11
4-4.
Thickness Control
11
4-5.
Gas/Air
Switch
11
4-6.
Trigger
Hold
Switch
11
SECTION
5-
SEQUENCE OF OPERATION
5-1.
Plasma
Arc
Cutting
(PAC)
12
5-2.
Cutting
Problems And
Recommendations
13
5-3.
Shutting
Down
13
SECTION
6-
MAINTENANCE &
TROUBLESHOOTING
6-1.
Routine
Maintenance
13
6-2.
Shield
Cup.
Tip,
And
Electrode
Inspection
And
Replacement
14
6-3.
Torch
And
Work Lead
Inspection
And
Connections
15
6-4.
Spark
Gap
16
6-5.
Overload
Protection
16
6-6.
Safety
Shutdown Devices
16
6-7. Circuit
Board
Handling
Precautions
17
6-8.
Troubleshooting
17
SECTION
7-
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
19

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
29
30
31
Table
2-1.
Specifications
Table
6-1.
Maintenance
Schedule
Table
6-2.
Troubleshooting
Section
No.
SECTION
8-
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 Of
Plasma
Arc
Cutting
(PAC)
Power
Sources
8-7.
Installation Guidelines
Checklist
SECTION
9
PARTS
LIST
Page
No.
20
20
21
21
21
22
23
LIST
OF CHARTS AND
TABLES
7
13
18