Miller SPECTRUM 750 User manual

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.
AM~o~pud..co~y
installing, operating,
or
maintaining
this
equipment.
This
unit and these
instructions
are
for
use
only by
persons
trained
and
experienced In
the safe
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
fuily
understand these instructions.
Miller
February
1990
FORM: OM-2201A
Effective
With
Serial
No.
KA780044
MODEL:
Spectrum1M
750
SB-134
696
PRINTED
IN
U.S.A

ui
LIMITED WARRANTY
EFFECTIVE: FEBRUARY
1,
1990
This
warranty
supersedes
all
previous
MILLER
warranties and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
lE
LIMITED WARRANTY

Subject
to
the
terms
and
conditions
hereof,
Miller Electric
Mtg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that all
new
and unused
Equipment
fur
nished
by
Miller
is
free
from defect
in
workmanship
and
material
as
of
the
time and
place
of
delivery by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and other items
are
sold
subject
to
the warranties
of
their
respective
manufacturers,
if
any.
All
engines
are warran
tied
by
their
manufacturer
fortwo
years
from date
of
original
pur
chase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
Millers
warranty
does not
apply
to
components
having
normal useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire includ
ing
nozzles
and nozzle
insulators where
failure
does
not
result
from
defect
in
workmanship
or
material.
Millershall
be
required
to
honor
warranty
claims
on
warranted
Equipment
in
the
event
of failure
resulting
from
a
defect
within
the
following periods
from the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and torches
.. .
90
days
5.
All
other
Millermatic
Feeders
1
year
6.
Replacement
or
repair parts,
exclusive of labor
60
days
7.
Batteries
6
months
provided
that
Miller
is
notified
in
writing
within
thirty (30) days
of
the date
of
such
failure.
As
a
matter
of
general policy
only,
Miller
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
Millers
breach of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive remedies
therefore
shall
be,
at
Millers
option
(1)
repairor
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service station
or
(4)
payment
of orcredit for the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at Customers
risk
and
expense.
MILLERs
option
of
repairor
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB. at
a
MILLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be allowed.
Upon receipt
of
notice
of
apparent
defect
or failure,
Miller shall instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be followed.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN
AND
ANY IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND ANY
REMEDY
FOR BREACH
OF CONTRACT
WHICH,
BUT FOR THIS PRO
VISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION OF
LAW,
CUSTOM OF
TRADE
OR COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF MERCHAN
TABILITY
OR OF
FITNESS FOR PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY AND
ALL
EQUIPMENT FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT AS EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE USE AND MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS OR
CON
SUMER
USE.
MILLERS WARRANTIES DO NOT EXTEND
TO,
AND
NO
RESELLER IS AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
5.

ERRATA
SHEET
June
3,
1991
FORM:
OM-2201A
AMENDMENT TO SECTION
5
OPERATOR CONTROLS
Amend Section
5-4.
TEST/RUN
SWITCH
a
AMENDMENT
TO
SECTION
6
SEOUENCE
OF
OPERATION
Add Section
6-4.
PLASMA
ARC
GOUGING
(PAG)
a
1.
Install and
connect
unit
according
to
Section
4.
a
2.
Wear
dry
insulating gloves
and
clothing.
3.
Connect
work
clamp
to
clean,
bare metal
at
workpiece.
4.
Place the
TEST/GOUGE/RUN
switch
in the
TEST
position.
a
After this manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
In
this
manual.
The
TEST/GOUGE/RUN
switch
provides
a means
for
adjusting
the air
filter/regulator
without
energizing
the
cutting
circuit.
Placing
the
TEST/GOUGE/RUN
switch
in
the
TEST
position
energizes
the air
solenoids
allowing
the
air
filter/regulator
to
be
properly
set to
64
psi (4.3
bars).
Placing
the
TEST/GOUGE/RUN
switch
in
the
GOUGE
position
provides
gas/air
to
the torch
for
normal
gouging
operations
when
the
torch switch
is
pressed.
Placing
the
TEST/GOUGE/RUN
switch
in
the
RUN
position provides
gas/air
to
the
torch
for normal
cutting
operations
when the
torch
switch
is
pressed.
CAUTION:
CUTTING
WHEN
THE
GAS/AIR
SWITCH
IS
IN
GOUGE POSITION
will
damage
torch.

Do
not
cut
when
in
GOUGE
position.

Use
GOUGE
position
for
gouging
only.
The
GOUGE
position
provides
an
inadequate
supply
of
airflow
for
cooling
during
cutting.
IMPORTANT:
For
gouging
operations,
install
a
G
style
gouging
tip
in
the
torch.
Follow
the instructions
in
the torch
Owner~s
Manual.
WARNING: Read and follow
safety
information
at
beginning
of
entire
Section
6
before
proceeding.
CAUTION:
TIP
AND
ELECTRODE
WEAR
BEYOND
RECOMMENDED
VALUES
or
OPERATION
WITHOUT
TIP
OR
ELECTRODE
in
place
can
damage
torch.

Inspect
shield
cup,
tip,
and electrode before each
use,
hourly
during
operation,
or
whenever
cutting
speed
has been
significantly
reduced
(see
Torch
Owners
Manual).

Do
not
operate
torch
without
a
tip
or
electrode
in
place.
IMPORTANT:
For
gouging
operations,
install
a
G
style
gouging
tip
in
the
torch.
Follow
the instructions
in
the torch
Owners
Manual.
5.
Place the
POWER
switch
in
the
ON
position.
The
POWER
light
will
come
on.
CAUTION:
INCORRECT
PLASMA GAS
can cause
torch
and
power
source
damage.

Use
only
air
or
nitrogen
for
the
plasma
gas
supply.

Do
not
use
any
other
gas
or
combination of
gases.

6. Turn
on
gas/air
supply
at
the
source,
and
adjust
air
filter/regulator
to
64
psi
(4.3
bars)
while
observing
air
pressure
gauge
on
rear
of
unit.
For
proper
regulation,
the
recommended
output
from
the
gas/air
supply
should
provide
a
minimum
of 80
psi
(5.5 bars)
and
a
maximum
of
150
psi
(10.3
bars).
Make
pressure
adjustment
according
to
Figure
4-4
as
follows:
a.
Loosen
locking
screw
in
center
of
air
filter/regulator
adjustment
knob.
b.
Turn
air
filter/regulator
adjustment
knob clockwise
to
increase
pressure
setting
and counterclockwise
to
decrease
pressure
setting.
c.
Tighten
locking
screw.
7.
Place
the
THICKNESS
OUTPUT
CONTROL
in
the desired
position
(see
Section
5-3).
8.
Place
the
TEST/GOUGE/RUN
switch
in
the
GOUGE
position.
The
READY
light
will
come
on
indicating
that
the
unit is
ready
for
operation.
a
CAUTION: CUTTING
WHEN THE
GAS/AIR
SWITCH
IS
IN
GOUGE
POSITION
will
damage
torch.

Do
not
Cut
when
in
GOUGE
position.

Use
GOUGE
position
for
gouging
only.
The
GOUGE
position
provides
an
inadequate
supply
of airflow
for
Cooling
during
Cutting.
9.
Wear
safety goggles
with
correct
filter
shade
according
to
ANSI
Z49.1.
10.
Place
tip
of torch
on
metal
to
be
gouged
at
approximately
a
40
angle
to
the line
of
travel
and
press
torch switch.
There
will
be
approximately
2
seconds of
preflow
air followed
by
approximately
2-1/2
seconds
of
pilot
arc.
If
the
gouge
arc
is
not
started
within
the
2-1/2
seconds
of
pilot
arc,
the
pilot
arc
will
stop.
The
torch
switch
will have
to
be
released,
and the
startup
procedure repeated.
11.
Once
gouging
arc
starts,
establish
an
arc
length
of
approximately
ito
1-1/2
in.
(25mm
to
38mm),
and
slowly
and
smoothly begin
moving
torch
across
material.
12.
Adjust
torch
speed
and
angle
for
desired
depth
of
groove
and
so
that
sparks
are
directed
away
from
the
operator.
Do
not
attempt
to
remove
too
much
metal
in
one
pass.
Additional
passes
can
be made
to
achieve the desired
depth.
13. Pause
briefly
at
end
of
gouge,
and then
release
torch
switch.
Postflow
gas/air
will
flow
for
approximately
20
seconds
to
cool the torch.
If
another
gouge
is
started
before
postflow
ends,
the
arc
will
start
immediately.
AMENDMENT
TO
SECTION 8-
ELECTRICAL
DIAGRAMS
Amend
Diagram
8-1.
Circuit
Diagram
For
Power
Source
(see
Page
3
on
this
Errata
Sheet)
Amend
Diagram
8-3.
Wiring
Diagram
For Power
Source
(see
Pages
4
and
5
on
this
Errata
Sheet)
Add
Diagram
8-8A.
Circuit
Diagram
For Trouble
Light
Board
PC4
(see
Page
6
on
this
Errata
Sheet)
Amend
Diagram
8-8B
on
this
Errata
Sheet. Circuit
Diagram
For
Trouble
Light
Board
PC4
(see
Page
6
on
this Errata
Sheet)
OM-2201A
Page
2

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With
Serial
No. KB058453
OM-2201A
Page
6

AMENDMENT
TO SECTION
10
PARTS LIST
Amend
Parts List
as
follows:
Dia.
Part
Replaced
**
Mkgs.
No. With
Description
Quantity
39-12 T2
Added
130 534
TRANSFORMER,
kVA
1/3 24-18-230/460/575
1
39-16
Ti
132 879
140 276
TRANSFORMER,
pwr
main
200/230/460
(Eff
w/KA885936)
(consisting
of)
1
140 084
COIL,
pri/sec
200/230/460
center
&
RH
2
140
083
.
COIL,
pri/sec
200/230/460
LH
1
39-16
Ti
Added
136 200
TRANSFORMER,
pwr
main
230/460/575
(consisting
of)
1
39-17
135 984
.
COIL,
pri/sec
230/460/575
center
&
RH
2
39-18
135 983
COIL,
pri/sec
230/460/575
LH
1
39-37 Zi
132 943
135
860
STABILIZER,
(Prior
to
KA834898)
1
39-37
Zi
135 860 137 762
STABILIZER,
(Eff
w/KA834898
thru
KA873919)
1
39-37
Zi
137 762 139
709
STABILIZER,
(Eff
w/KA873920
thru
KA885935))
1
39-37
139709
140 118
STABILIZER,
(Effw/KA885936)
1
39-
132463
132463
SLEEVE,
(APT
7000)
1
39-
132657
132657
GUIDE,
(APT 7000)
2
39-
Added
132
658
GUIDE,
stand-off
(APT 5000)
2
39-
Added
138
755
TIP,
gouge
GH
(Eff
w/KA880002
thru
KB079750)
5
39-
138
755
143 983
TIP,
gouge
70A
(Eff
w/KB079751)
5
41-3
089 085
089
085
SWITCH,
(qty
chg
deleted
S4) (Effw/KA880002)
1
41-4
098
691 115 443
STAND-OFF,
No. 6-32
x
.750
(Eff w/KB058453)
2
41-6
PC4
125 057
135 748
CIRCUIT
CARD,
display
(Prior
to
KB058453)
1
41-6
PC4
135 748 143
514
CIRCUIT
CARD,
display
(Eff w/KB058453)
1
41-17
PCi
127
184
136687
CIRCUITCARDASSEMBLY,
regulator
1
41-22
126 696
138 377
PANEL,
front
(Eff w/KA880002)
1
41-
S4
Added
088409
SWITCH,
tgl
DPDT
i5A
125VAC
(Effw/KA880002)
1
41-26
124 729
136 156
LABEL,
precautionary
plasma
cutting
1
42-
R65
108
442
RESISTOR,
MF
.25W 392 ohm
1
45-
VR5O
081 632 083 772
IC,
linear
7815
1
47-
024
103
BLANK,
snap
in
nyl
.750
mtg
hole
1
48-2
C4,14
128 256 142
133
CAPACITOR
2
~First
digit
represents
page
no

digits following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING REPLACEMENT
PARTS.
OM-2201
A
Page
7