Miller Electric 188 036G Page 24 Owner'S Manual Download | Manualshive

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OM-2219 Page 20

SECTION 6 – PARTS LIST

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Hardware is common and
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Figure 6-1. Complete Assembly

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Summary of Contents for 188 036G

Page 1: ...Visit our website at www MillerWelds com OM 2219 188 036G October 1999 Processes Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter Spectrum Lynx R ...

Page 2: ...value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit...

Page 3: ...ION 9 2 1 Specifications 9 2 2 Duty Cycle And Overheating 9 2 3 Cutting Speed 9 2 4 Selecting A Location 10 2 5 Connecting Work Clamp And Gas Air Supply 11 2 6 Connecting Input Power 11 SECTION 3 OPERATION 12 3 1 Controls 12 3 2 Setting Gas Air Pressure 13 3 3 Sequence Of Operation 14 SECTION 4 MAINTENANCE TROUBLESHOOTING 15 4 1 Routine Maintenance 15 4 2 Ground Fault Circuit Interrupter GFCI 16 4...

Page 4: ......

Page 5: ...n cause fatal shocks or severe burns The torch and work circuit are 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 machi...

Page 6: ...ed respirator Fumes from cutting and oxygen deple tion can alter air quality causing injury or death Be sure the breathing air is safe D Do not cut in locations near degreasing cleaning or spraying oper ations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases D Do not cut on coated metals such as galvanized lead or cadmium plated steel unless the coating ...

Page 7: ... not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit STATIC ESD can damage PC boards D Put on grounded wrist strap BEFORE handling boards or parts D Use proper static proof bags and boxes to store move or ship PC boards H F RADIATION can cause interference D High frequency H F can interfere with radio navigation safety services compute...

Page 8: ... 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 EMF Information Considerations About Welding Or Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Welding or cutting current as it flows through the welding or cutting cables will cause electromagnetic fields There has been and still is some con...

Page 9: ...nts qui ont déjà reçu des combustibles D Portez des vêtements de protection exempts d huile tels que des gants en cuir une veste résistante des pantalons sans revers des bottes et un casque D Ne placez pas le poste sur une surface combustible ou au dessus de celle ci D Avant le coupage retirez tout combustible de vos poches par exemple un briquet au butane ou des allumettes Le fait de toucher à un...

Page 10: ...aterial Safety Data Sheets MSDS et les instructions du fabricant pour obtenir plus de renseignements sur les métaux à couper les enrobages et les nettoyants D Travaillez dans un espace restreint uniquement s il est bien ventilé ou si vous portez un respirateur anti vapeurs Les vapeurs causées par le cou page et l épuisement de l oxygène peuvent altérer la qualité de l air et entraîner des blessure...

Page 11: ...taller l appareil à proximité de produits in flammables D Ne pas surcharger l installation électrique s assurer que l alimentation est correctement dimensionné et protégé avant de mettre l appareil en service LES CHARGES ÉLECTROSTATI QUES peuvent endommager les cir cuits imprimés D Etablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces D Utiliser des pochettes e...

Page 12: ...gnétiques basse fréquence Le courant de soudage ou de coupage passant dans les câbles de puis sance crée des causera des champs électromagnétiques Il y a eu et il y a encore un certain souci à propos de tels champs Cependant après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans un comité spécial ruban bleu du Natio nal Research Council a conclu L accu...

Page 13: ...it and void war ranty 50 Duty Cycle Overheating 0 15 A OR Reduce Duty Cycle Minutes duty1 4 95 5 Minutes Cutting 5 Minutes Resting 2 3 Cutting Speed The cutting speed curve shows the recommended maximum cutting speed capabilities of the power source and torch for mild steel of various thickness Y Exceeding recommended cutting speeds will cause rapid erosion of the tip and electrode ST 191 605 Cutt...

Page 14: ...d Cart Use cart or similar device to move unit Y Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Dimensions And Weight 1 2 Y Do not move or operate unit where it could tip Movement 24 in 610 mm 17 in 432 mm 12 1 2 in 318 mm 47 lb 21 4 kg 1 ...

Page 15: ...nal or apply pipe sealant and install fitting in opening Route hose to gas air supply Adjust gas air pressure according to Section 3 2 Tools Needed 5 8 1 1 8 in 3 1 2 4 5 From Gas Air Supply 2 6 Connecting Input Power Do not attempt to connect this unit to anything other than a Miller engine driven welding generator with the proper receptacle installed 1 Spectrum Lynx 2 Power Plug 3 Engine Driven ...

Page 16: ...e in Expanded Metal mode Place switch in Tip Saver position to provide pilot arc output for arc starting only Use Tip Saver position in most applications to length en the life of the torch and its consumables and to obtain maximum cutting performance Torch trigger must be reset after every cut while in Tip Saver mode 3 Output Control Use control to set cutting output Gas air automatically flows at...

Page 17: ...Knob Pull knob and turn to adjust pressure Push knob in to lock setting Select desired cutting output with Output Control 3 2 Setting Gas Air Pressure Ref 801 977 A Ref ST 801 976 1 Set Controls Turn On Gas Air Supply Adjust Pressure On Unit Select Desired Amperage To Be gin Cutting Set To 70 PSI Requires 90 150 PSI Supply Setting Gas Air Pressure Place Output Control in Gas Air Set Position Power...

Page 18: ...antly restarted during postflow by pressing trigger Check Torch Tip Electrode And Retaining Cup Check Gas Air Pressure Set Controls Begin Cutting Turn On Welding Generator The pilot arc starts immediately when trigger is pressed Place drag shield on edge of metal or allow correct standoff distance approximately 1 8 in 3 mm Do not clean torch by hitting it against a hard surface Hitting hard surfac...

Page 19: ...re conditions Each Use Check Torch Tip Electrode And Shield Cup Check Gas Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service Air Filter Regulator Assembly Filter Replace Unreadable Labels Tape Torn Outer Covering Or Replace Cable Replace Cracked Parts Check Gas Air Hose Check Torch Body 6 Months Blow Out Or Vacuum Inside OR ...

Page 20: ...nerator Consult a qualified elec trician If the GFCI trips by itself at anytime during use reset the GFCI and test it as explained above If the GFCI fails to reset properly DO NOT USE THE EQUIPMENT Unplug equipment or turn Off power at generator Consult a qualified elec trician 3 Fuse F1 0 5 A only Fuse F1 is part of the ground fault circuit interrupter If F1 opens check if work lead is properly c...

Page 21: ...eld cup If shutdown system works properly Ready light goes off and Cup light comes on If not immedi ately turn Off power and have Fac tory Authorized Service Agent check safety control board PC1 op eration If system works properly retighten cup and reset power 1 Power must be reset whenever the cup shutdown system is activated Always turn Off power when changing or checking consumables 4 5 Trouble...

Page 22: ...e Trouble light On Ready light off Check for correct gas air pressure adjustment see Section 3 2 Check for sufficient gas air supply pressure see Section 2 5 Check for dirty air filter regulator and clean if needed see manufacturer s instructions Check air lines for leaks Have Factory Authorized Service Agent check pressure switch S3 and safety control board PC1 Cup Trouble light On Ready light of...

Page 23: ...OM 2219 Page 19 SECTION 5 ELECTRICAL DIAGRAM 193 622 Figure 5 1 Circuit Diagram ...

Page 24: ... is common and not available unless listed 802 180 C 1 2 3 4 6 7 8 9 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 48 49 50 5 47 53 54 51 51 52 57 55 55 56 19 Figure 6 1 Complete Assembly ...

Page 25: ...NEL rear 1 23 184 934 COVER rcpt weatherproof 1 24 185 696 CABLE power 10 5ft 1 25 044 426 CONNECTOR clamp cable 690 1 070 1 26 S1 111 997 SWITCH rocker SPST 10A 250VAC 1 27 GFCI 172 072 SENSOR GFCI test reset 50A 1 28 R1 189 235 RESISTOR WW fxd 675W 3 ohm 1 096 864 WASHER 2 189 442 WASHER 1 29 107 347 SCREW 250 20 x 8 00 hex hd pln stl pld 1 30 SR1 SR2 179 682 RECTIFIER 2 31 189 718 HEAT SINK rec...

Page 26: ...ht fem 1 8 NPT 1 53 046 432 HOLDER fuse mintr 1 54 F1 012 653 FUSE mintr GL 5A 250V 1 55 VR1 VR2 178 739 VARISTOR 2 56 VR4 190 184 VARISTOR w terminals 1 57 C1 190 449 CAPACITOR ASSY 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor ...

Page 27: ...tting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Miller but manufactured by others such as engines or trade accessories The...

Page 28: ... complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Informati...

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