Spectrum875auto Lineandice 60ttmtrch (Ma240476p)

TM-242 880B 2011−07
Eff. w/ Serial No. MA240476P

Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum 875 Auto-Line

R
And ICE-60T/TM Torch
File: Plasma Cutters
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www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3-4. Torch Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-5. System Dimensions, Weight, And Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3-6. Connecting Work Clamp and Gas/Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-7. Connecting And Disconnecting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-8. Connecting And Disconnecting Work Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-9. Power Cable Management Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-10. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-12. Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-13. Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-14. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-15. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat,
Trailblazer Or Hobart Champion 10,000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-16. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant . . . . . . . . . . . . . . . . . . . 16
3-17. Generator Settings For Plasma Cutter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2. Trigger Safety Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3. Plasma Cutting System Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-4. Sequence Of Cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-5. Sequence Of Gouging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-6. Sequence Of Piercing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-7. Cutting Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-8. Consumables Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 5 − MECHANIZED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-1. ICE-60TM Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-2. Remote Control Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-3. Remote Control Cable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-4. +24 Volts DC Hot Contacts For Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-6. Dry Contacts Using An External Power Supply For Relay Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation . . . . . . . . . . . . . 28
5-8. Remote Voltage Sense Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-9. Shield Sense Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-10. Cut Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 6 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
TABLE OF CONTENTS
SECTION 7 − PRE-POWER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7-1. Checking Unit Before Applying Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-2. Tools Needed For Troubleshooting And Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-3. Wrapper Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7-4. DC Bus Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7-5. Checking Primary Interconnect Circuit Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7-6. Checking Control Circuit Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7-7. Checking Secondary Interconnect Circuit Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-8. Flyback Power Supply Circuit Board PC3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 8 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-1. Status/Trouble Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8-3. Troubleshooting Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-4. Control/LED/POT Circuit Board PC1 LED Locations (Use With Section 8-5) . . . . . . . . . . . . . . . . . . . . 48
8-5. Diagnostic LED’s On Power Control Board PC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8-6. Secondary Interconnect Circuit Board PC4 LED Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8-7. Diagnostic LED On Secondary Interconnect Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8-8. Troubleshooting Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8-9. Control/LED/POT Circuit Board PC1 Testing Information (Use With Section 8-10) . . . . . . . . . . . . . . . 52
8-10. Control/LED/POT Circuit Board PC1 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8-11. Primary Interconnect Circuit Board PC2 Testing Information
(Use With Section 8-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8-12. Primary Interconnect Circuit Board PC2 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8-13. Flyback Power Supply Circuit Board PC3 Testing Information
(Use With Section 8-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8-14. Flyback Power Supply Circuit Board PC3 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8-15. Secondary Interconnect Circuit Board PC4 Testing Information
(Use With Section 8-16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8-16. Secondary Interconnect Circuit Board PC4 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8-17. Pressure Switch Circuit Board PC5 Testing Information
(Use With Section 8-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8-18. Pressure Switch Circuit Board PC5 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8-19. Filter Circuit Board PC6 Testing Information (Use With Section 8-20) . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8-20. Filter Circuit Board PC6 Test Point Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 9 − DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-1. Safety Precautions For Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-2. Wrapper Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9-3. Front And Rear Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9-4. Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9-5. Filter Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9-6. Control Circuit Board PC1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9-7. Disconnecting Magnetics Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9-8. Current Transformer CT Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9-9. Windtunnel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SECTION 10 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-2. Checking Shield Cup Shutdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-3. Checking/Replacing Retaining Cup, Tip, And Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10-4. Checking Or Replacing Filter Element (Part No. 227 877) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage

OM-242 880A - 2010−02, safety_ptm 2010−03
DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual STATIC (ESD) can damage PC boards.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Put on grounded wrist strap BEFORE handling
to avoid the hazard. boards or parts.
D Use proper static-proof bags to store, move, or
Only qualified persons should service, test, maintain, and
ship PC boards.
repair this unit.
During servicing, keep everybody, especially children, away. FIRE OR EXPLOSION hazard.
D Do not place unit on, over, or near combustible
ELECTRIC SHOCK can kill. surfaces.
D Do not touch live electrical parts. D Do not service unit near flammables.
D Turn OFF power source, and disconnect and
lockout input power using line disconnect FLYING METAL or DIRT can injure eyes.
switch, circuit breakers, or by removing plug
from receptacle before servicing unless the D Wear safety glasses with side shields or face
procedure specifically requires an energized shield during servicing.
unit. D Be careful not to short metal tools, parts, or
D Insulate yourself from ground by standing or working on dry insu- wires together during testing and servicing.
lating mats big enough to prevent contact with the ground.
D Do not leave live unit unattended. HOT PARTS can burn.
D If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job. D Do not touch hot parts bare handed.
D When testing a live unit, use the one-hand method. Do not put D Allow cooling period before working on equip-
both hands inside unit. Keep one hand free. ment.
D To handle hot parts, use proper tools and/or
D Do not touch torch parts if in contact with the work or ground.
wear heavy, insulated welding gloves and
D Turn off power before checking, cleaning, or changing torch
clothing to prevent burns.
parts.
D Do not bypass or try to defeat the safety interlock systems. EXPLODING PARTS can injure.
D Use only torch(es) specified in Owner’s Manual.
D Point torch away from your body and toward workpiece when D Failed parts can explode or cause other parts to
pressing the torch trigger − pilot arc comes on immediately. explode when power is applied to inverters.
D The pilot arc can cause burns − keep away from torch tip when D Always wear a face shield and long sleeves
trigger is pressed. when servicing inverters.
D Disconnect input power conductors from deenergized supply line
BEFORE moving power source. SHOCK HAZARD from testing.
D Turn Off power source before making or chang-
SIGNIFICANT DC VOLTAGE exists in inverter welding meter lead connections.
ing power sources AFTER removal of input power. D Use at least one meter lead that has a self-
retaining spring clip such as an alligator clip.
D Turn Off inverter, disconnect input power, and discharge input ca-
pacitors according to instructions in Troubleshooting Section D Read instructions for test equipment.
before touching any parts.
Spectrum 875 Auto-Line TM-242 880 Page 1

H.F. RADIATION can cause interference. CUTTING can cause fire or explosion.
D High-frequency (H.F.) can interfere with radio D Protect yourself and others from flying sparks
navigation, safety services, computers, and and hot metal.
communications equipment. D Do not cut where flying sparks can strike flam-
D Have only qualified persons familiar with electronic equipment mable material.
install, test, and service H.F. producing units. D If test cuts are required, follow Safety Precautions in Owner’s
D The user is responsible for having a qualified electrician promptly Manual and on safety label(s).
correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep NOISE can damage hearing.
spark gaps at correct setting, and use grounding and shielding to
Prolonged noise from some cutting applications can
minimize the possibility of interference. damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).
FALLING EQUIPMENT can injure.
D Use approved ear plugs or ear muffs if noise level is high.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories. D Warn others nearby about noise hazard.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to OVERUSE can cause OVERHEATING.
extend beyond opposite side of unit.
D Follow the guidelines in the Applications Manual for the Revised D Allow cooling period; follow rated duty cycle.
NIOSH Lifting Equation (Publication No. 94−110) when manu- D Reduce amperage (thickness) or reduce duty
ally lifting heavy parts or equipment. cycle before starting to cut again.
D Do not block or filter airflow to unit.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted READ INSTRUCTIONS.
Medical Devices should keep away from serv-
icing areas until consulting their doctor and the D Use Testing Booklet (Part No. 150 853) when
device manufacturer. servicing this unit.
D Consult the Owner’s Manual for welding safety
MOVING PARTS can injure. precautions.
D Use only genuine replacement parts from the manufacturer.
D Keep away from moving parts such as fans. D Read and follow all labels and the Technical Manual carefully be-
D Have only qualified people remove doors, pan- fore installing, operating, or servicing unit. Read the safety in-
els, covers, or guards for maintenance and formation at the beginning of the manual and in each section.
troubleshooting as necessary.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Reinstall doors, panels, covers, or guards when servicing is
finished.
1-3. California Proposition 65 Warnings

For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling. defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
TM-242 880 Page 2 Spectrum 875 Auto-Line

1-4. EMF Information
Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, access restrictions for passers−by or individual risk assess-
ment for welders. All welders should use the following procedures in 6. Do not work next to, sit or lean on the welding power source.
order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
1. Keep cables close together by twisting or taping them, or using a feeder.
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

SECTION 2 − DEFINITIONS
2-1. Symbols And Definitions For Nameplate And Serial Number/Rating Label
A Amperes
Plasma Arc Cutting
(PAC)
Adjust Air/Gas
Pressure
Low Air Pressure
Light
V Volts Increase
No − Do Not Do
This
Temperature
Protective Earth
Single Phase Constant Current Voltage Input
(Ground)
On Off Percent Direct Current
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional Load
Voltage
Line Connection
Single Phase
I1max I2 X
Static Frequency
Rated Maximum Rated Welding Or
Duty Cycle Converter-
Supply Current Cutting Current
Transformer-
Rectifier
IP Degree Of
Protection
Loose Shield Cup Input Hz Hertz
I1eff pf S1
Suitable for Some Power Rating,
Maximum Effective
Supply Current
power factor
S Hazardous
Locations
Product Of Voltage
And Current (kVA)

SECTION 3 − INSTALLATION
3-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the bottom. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
3-2. Specifications
Power Supply
Input
Rated AC Phase and line frequency (Hz) 1 − 3−Phase 50 / 60 Hz −−
Rated Input Voltage (U1) and rated Input Current (I1)
and I1 eff at rated output. I1 eff used to determine Volts AC RMS − (U1) Amps RMS − (I1) I1 eff
power cord rating
208 VAC 1−Phase 47.4 30
230 VAC 1−Phase 42.2 26.7
208 VAC 3−Phase 27.5 19.4
230 VAC 3−Phase 25 17.7
380 VAC 3−Phase 15 11.6
460 VAC 3−Phase 12.4 9.6
575 VAC 3−Phase 9.8 7.6
Power Factor/kVA/kW at Rated Output Volts AC RMS − (U1) Power Factor kVA/kW
208 VAC 1−Phase 0.98 9.9 / 9.7
230 VAC 1−Phase 0.98 9.7 / 9.6
208 VAC 3−Phase 0.95 9.9 / 9.5
230 VAC 3−Phase 0.95 9.9 / 9.5
380 VAC 3−Phase 0.95 9.9 / 9.4
460 VAC 3−Phase 0.95 9.9 / 9.4
575 VAC 3−Phase 0.95 9.8 / 9.3
Peak kW at Arc Stretch 15.5 kW −− −−
Output
Rated Open Circuit Voltage (U0) Type 400 Volts DC/Electrode Negative −− −−
Output Characteristic Constant Current −− −−
Rated Output Current (I2) 60 A −− −−
Rated Output Voltage (U2) 140 Volts DC −− −−
Output Current Range 20 − 60 A −− −−
Duty Cycle at 104°F (405C) and Rated Conditions (U1, Volts AC RMS −
Duty Cycle % Amps DC − (I2)
I1, U2, I2) based on a 10 minute period (U1)
208−230 VAC
40 60 A
1−Phase
208−230 VAC
50 60 A
3−Phase
380−575 VAC
60 60 A
3−Phase
208−230 VAC
100 50 A
1−Phase
208−575 VAC
100 50 A
3−Phase

General
Operating Temperature 5° to 104° F (−15° to 40° C) −− −−
IP Code − Degree of protection provided by enclosure IP23CS −− −−
IP − International Protection −− −−
2 − No ingress of foreign objects
≥12.5 mm (0.5 in.)
−− −−
3 − No harmful ingress spraying
water
−− −−
C − AC line circuits protected
against ingress of tool . 2.5 mm −− −−
dia x 100 mm long (0.1 in. x 4 in.)
S − Fan stationary during water
test
−− −−
Toppling or tilting Up to 15° incline −− −−
Gas Type Air or Nitrogen −− −−
Clean, moisture−free,
Gas Quality
oil−free
−− −−
90 PSI (621 kPa) 120 PSI (827 kPa)
Gas Inlet Flow and Pressure 6.75 SCFM (191 L/min)
Min Max
Gas Filtering Particulates to 5 microns −− −−
Torch
Mild Steel capacities (see Section for cutting speeds vs material type and thickness)
Rated Capacity (edge start) 7/8 in. at 10 ipm (254 mm/min)* −− −−
Sever Cut Capacity (edge start) 1−1/4 in. −− −−
Pierce Capacity 7/16 in. −− −−
*Travel speeds are approximately 80% of maximum.
3-3. Duty Cycle And Overheating

40% Duty Cycle Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating. Duty
cycle is based on an ambient tem-
perature of 104° F (40° C).
4 Minutes Cutting 6 Minutes Resting If unit overheats, output stops,
temperature status light
illuminates, and cooling fan runs.
50% Duty Cycle
Wait fifteen minutes for unit to cool
or temperature light to go off.
Reduce amperage or duty cycle
before cutting or gouging.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
5 Minutes Cutting 5 Minutes Resting
60% Duty Cycle
6 Minutes Welding 4 Minutes Resting

Overheating
15
OR
Minutes Reduce Duty Cycle
Duty1 4/95 − Ref. 805 159-A

3-4. Torch Dimensions
8-27/32 in. (225 mm)
Hand-Held Torch
1-1/2 in (38 mm)

4 in. (100 mm)
2-5/16 in. (58 mm)
1-1/16 in. (27 mm)

Machine Torch 15-9/32 in. (388 mm)
2-9/64 in. (54 mm)
1-1/16 in. (27 mm)
Gear rack 32 pitch

1/8 in. (3.2 mm) width 1-3/8 in. (35 mm)
1/8 in. (3.2 mm) height
8 in. (202 mm)
3-5. System Dimensions, Weight, And Movement

! Do not move or operate unit
where it could tip.
18-1/2 in. (470

mm)
13-1/2 in. (343

mm)
Unit Dimensions And Weight

47 lb (21.3 kg)
Torch Weight
Hand-Held: 20 ft (6.1 m) 6 lb (2.7 kg)
Hand-Held: 50 ft (15.2 m) 12-3/4 lb (5.8 kg)
Machine: 25 ft (7.6 m) 8 lb (3.6 kg)
Machine: 50 ft (15.2 m) 13-1/2 lb (6.1 kg)
Work Cable Weight
8-3/4 in. (222 mm)
20 ft (6.1 m) 3-1/2 lb (1.6 kg)
50 ft (15.2 m) 7-1/2 lb (3.4 kg)
loc_2 3/96 - Ref. 805 159-A

3-6. Connecting Work Clamp and Gas/Air Supply
1 Work Clamp
1
2 Workpiece
. Connect work clamp to portion
of workpiece that does not fall
away after being cut.
Connect work clamp to a clean,
paint-free location on workpiece, as
2
close to cutting area as possible.
. Use only clean, dry air with 90

to 120 psi (621 to 827 kPa)
pressure @ 6.75 CFM
AIR/N2 (191L/min) minimum.
90-120 psi . Use filter kit 300 491 or 228 926

where conditions at the work-
@ 6.75 CFM site allow moisture, oil or other
particulates into the air line.
5
3
(191 L/min) 3 Gas/Air Filter Inlet Opening
minimum 4 Hose
. Hose must have a minimum

inside diameter of 3/8 in
(9.5 mm).
5 Teflon Tape
Obtain hose with 1/4 NPT right-
4
hand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
From opening. Route hose to gas/air
Gas/Air supply.
Supply
NOTICE − Exceeding input
pressure rating of 120 PSI (827
Rear of Unit kPa) can damage unit.
Tools Needed:
9/16 in.
Ref. 803 640-A / Ref. 192 441 / Ref. 805 160-A

3-7. Connecting And Disconnecting Torch
! Turn off power source and
disconnect input power.
1 Torch Connector
2 Quick Connect Collar
2 3 Nipple
1
3 4 Receptacle
5 Securing Pin
To connect torch:
Push torch connector onto
receptacle and quick connect until
collar secures nipple.
4 Rotate securing pin clockwise to
lock connector to unit.
5
To disconnect torch:
Rotate securing pin counterclock-
wise to unlock connector from unit.
Push quick connect collar back
towards unit to release nipple, and
pull torch connector away from unit.
. Use supplied hook and loop

strap to manage torch and
work cables.
805 161-A
3-8. Connecting And Disconnecting Work Cable

1 Work Cable Receptacle
2 Work Cable Plug
To connect plug, align key with
receptacle keyway and insert into
receptacle. Rotate plug clockwise
(hand tight only) to secure in
receptacle.
To disconnect plug, rotate counter-
clockwise until key aligns with key-
way and pull plug from receptacle.
. Use supplied hook and loop

strap to manage torch and
work cables.
Ref. 805 161-A / Ref. 803 475-G

3-9. Power Cable Management Strap
1 Power Cable Management
Strap
Coil power cable and secure to unit
using the power cable management
strap.
Ref. 805 275-A
3-10. Selecting a Location

1 Lifting Handle
Use handle to lift unit.
1
2 Line Disconnect Device
! Do not move or operate Locate unit near correct input
unit where it could tip. power supply.
Locate unit at least 18 in. (460 mm)
away from a wall or other obstuction
to allow adequate clearance for
cooling air flow.
! Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Location
2
18 in.
(460 mm)
18 in.
(460 mm)
loc_2 3/96 - Ref. ST-151 556 / Ref. 805 159

3-11. Electrical Service Guide
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
. Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage
is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
Single-Phase
Input Voltage (V) 208 230
Input Amperes (A) At Rated Output 48 42
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 50 50
Normal Operating Fuses 3 70 60
Min Input Conductor Size In AWG/Kcmil 4 10 10
55 68
Max Recommended Input Conductor Length In Feet (Meters)
(17) (21)
Min Grounding Conductor Size In AWG/Kcmil 4 10 10
Three-Phase
Input Voltage (V) 208 230 380 460 575
Input Amperes (A) At Rated Output 27 25 15 12 10
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 30 30 15 15 10
Normal Operating Fuses 3 40 35 20 20 15
Min Input Conductor Size In AWG/Kcmil 4 12 12 14 14 14
68 83 148 216 341
Max Recommended Input Conductor Length In Feet (Meters)
(21) (25) (45) (66) (104)
Min Grounding Conductor Size In AWG/Kcmil 4 12 12 14 14 14
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

3-12. Extension Cord Data
. When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.
Input Power Fuse Size Or
Input Voltage Phase Hertz Circuit Breaker Rating Conductor Size Max. Cord Length
Time-Delay 2 50 A
208 V 1 50/60 10 AWG 55 ft (17 m)
Normal Operating 3 70 A
Time-Delay 2 50 A
230 V 1 50/60 10 AWG 67 ft (21 m)
208 V 3 50/60 Time-Delay 2 30 A 12 AWG 68 ft (21 m)





2 “Time-Delay” fuses are UL class “RK5” .

3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Notes

3-13. Connecting 1-Phase Input Power
Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
Disconnect and lockout/tagout in-

put power before connecting input
conductors from unit.
1 Always connect green or green/

yellow conductor to supply
grounding terminal first, and never
to a line terminal.
8 =GND/PE Earth Ground NOTICE − The Auto-Line circuitry in this
unit automatically adapts the power
source to the primary voltage being ap-
10 plied. Check input voltage available at site.
This unit can be connected to any input
power between 208 and 230 VAC without
removing cover to relink the power
source.
7
1 Black And White Input Conductor
(L1 And L2)
9
2 Red Input Conductor
3 Green Or Green/Yellow Grounding
L1 Conductor
1 4 Insulation Sleeving
L2
3 5 Electrical Tape
Insulate and isolate red conductor as
shown.
6 Input Power Cord.
6 7 Disconnect Device (switch shown in
the OFF position)
8 Disconnect Device Grounding
Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
10 Over-Current Protection
Select type and size of over-current
protection using Section 3-11 (fused dis-
connect switch shown).
1 Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
2
3
6
4
5
Tools Needed:
input1 20008−01 − 803 766-C / 805 159

3-14. Connecting 3-Phase Input Power
Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
Disconnect and lockout/tagout in-

put power before connecting input
3 conductors from unit.
Always connect green or green/
yellow conductor to supply
= GND/PE Earth Ground grounding terminal first, and never
to a line terminal.
NOTICE − The Auto-Line circuitry in this
4 unit automatically adapts the power
source to the primary voltage being ap-
plied. Check input voltage available at site.
This unit can be connected to any input
power between 208 and 575 VAC without
7 removing cover to relink the power
source.
For Three-Phase Operation
1 Input Power Cord.
2 Disconnect Device (switch shown in
2 the OFF position)
3 Green Or Green/Yellow Grounding
Conductor
4 Disconnect Device Grounding
Terminal
5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
L1 Connect green or green/yellow grounding
3 5 conductor to disconnect device grounding
L2 terminal first.
6 L3 Connect input conductors L1, L2, and L3

to disconnect device line terminals.
7 Over-Current Protection
Select type and size of over-current
protection using Section 3-11 (fused dis-
connect switch shown).
Close and secure door on disconnect
1 device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
input2 2008−01 − 803 766-C / 805 159

3-15. Wiring Optional 240 Volt Plug (119 172) For Connection To Miller Bobcat,
Trailblazer Or Hobart Champion 10,000
Check input voltage available at the
power supply.
. The Auto-LineE circuitry in this

unit automatically adapts the
power source to the 240 volts,
2 single-phase, 50 or 60 Hz
3 3 primary voltage from the power
4 4 supply.
7
1 Input And Grounding
Conductors
2 Plug Wired for 240 V, 2-Wire
240V Load
5
3 Neutral (Brass) Terminal And
6 Prong (Not Used)
6 5
11 Plug Front 4 Load 1 (Brass)Terminal And
View Prong
5 Load 2 (Brass) Terminal And
Prong
6 Ground (Brass) Terminal And
Prong
7 Black And White Input Con-
ductors
8 Red Input Conductor
7 9 Insulation Sleeving
10 Electrical Tape
11 Green Or Green/Yellow
8 Ground Conductor
11
Insulate and isolate red conductor
1 Green Or as shown.
Green/Yellow
! Always connect green or
green/yellow wire to ground
1 9 terminal, never to a load
terminal. Connect black (L1)
10 and white (L2) wires to load
terminals.
Tools Needed:
3/16 in.
Ref. 120 813-D / Ref. 805 161-A

3-16. Connecting To Miller Welder/Generator With A Three-Phase AC Power Plant
Three-Phase Generator Power
! Stop engine.
! Power and weld outputs are
live at the same time. Discon-
Three-Phase Power Connection nect or insulate unused
cables.
. Have qualified person install ac-

! Close panel opening cording to circuit diagram and
if no connections are Generator Power Guidelines
made to generator. (see generator Owner’s Manual).
Remove generator power panel
mounting screws. Tilt panel forward.
1 Circuit Breaker CB7
2 Lead 93
3 Lead 92
4 Lead 91
Remove plug 5 Lead 42 (Circuit Grounding
before inserting Lead)
leads. Reinstall
6 Lead 90 (Neutral)
bushing.
7 Isolated Neutral Terminal
Rear Of Panel 3 8 Jumper Lead 42
4 9 Grounding Terminal
91 92 93
2 Jumper 42 is connected to lead 90 at
5 factory. Jumper 42 may be discon-
1 nected from neutral to meet applica-
ble electrical codes.
11 Lead 42 connects to front panel
6 Ground stud.
10 Power Cord
9 11 Circuit Breaker CB7 User
Terminals
. Circuit breaker CB7 protects

10 single-phase receptacle RC5
and the load wires from overload.
! Close panel If CB7 opens, all three-phase
opening if no generator output stops and the
8 connections receptacle does not work.
are made to
generator.
240V
Connect user-supplied ring lug to
7 green (ground) lead. Connect ring
120V 1-Phase lug on end of green (ground) lead
120V to grounding terminal (9).
240V Connect black, white, and red
240V 3-Phase leads to circuit breaker CB7 user
240V
terminals (11).
Reinstall power panel.
AC Single Three
Output Phase Phase
1 3 93
Volts 120/240 240
Amps 50 48 91
KVA/KW 12 20
Tools Needed: Frequency 60 Hz 90
Engine Speed 1850 RPM
Lead 42 connects to GROUND stud on
92
front of unit.
Jumper 42 is connected to 90 at factory.
Ref. 197 399 / 802 332-B

3-17. Generator Settings For Plasma Cutter Operation
! Engine Control Switch must be set at ! Set generator Fine Adjustment Control to 10
“RUN” position − not “RUN/IDLE”. for maximum auxiliary power, if applicable.
. The peak kW at arc stretch of this plasma power source is

15.5 kW. Reducing output to 45 amps may be necessary
to operate the unit using a 10 kW generator.
Ref. 803 222
Notes

SECTION 4 − OPERATION
4-1. Controls
40
V POWER
30 50
ON P R E S S UR E
3 C UP
V
20 TE M P
A 60
OFF
C UT GOUGE
2
4
Ref. 234 155-A
1 Output Control 4 Cut/Gouge Switch . Use only clean, dry air with 90 to 120 psi
Use control to set cutting output. Place switch in appropriate position for de- (621 to 827 kPa) pressure. Prevent
2 Status Lights (See Section 8-1) sired process. Unit will automatically regu- moisture from entering air supply at
3 Power Switch late pressure to 70 psi (483 kPa) for cutting extreme cold temperatures.
and 60 psi (413 kPa) for gouging. Pilot cur-
. The fan will operate for approximately 10 rent is automatically increased in gouge
. Use filter kit 300 491 or 228 926 where
seconds after power switch is placed in mode to provide better gouging starts. conditions at the worksite allow mois-
the Off position to reduce DC bus ture, oil or other particulates into the air
voltage. line.

4-2. Trigger Safety Lock
1 Trigger
Trigger Locked Trigger Unlocked

801 397-A
4-3. Plasma Cutting System Practices
! The pilot arc starts immediately

when trigger is pressed.
CUT GOUGE
Always connect work clamp to a clean, . Set switch to either cut or gouge DO NOT start pilot arc without cutting or
paint-free location on workpiece, as close to depending on desired process. gouging as this shortens the service life
cutting area as possible. of the nozzle and electrode.
. Connect work clamp to portion of workpiece

that does not fall away after being cut.
90°
Maintain approximately a 90° angle to the Sparks should pass through the workpiece If sparks flare back from surface, this
workpiece surface for proper cutting results. and out the bottom when cutting. usually is an indication that either travel
speed is too fast or amperage is set too low.
Wt
1/8 in
(3.2 mm)
When doing extended (non-shielded) DO NOT put pressure on shield when Pulling rather than pushing the torch
cutting, maintain approximately 1/8 in drag cutting; instead, slide shield along makes cutting easier. Use a proper guide
standoff between tip and surface. the surface for proper cutting results. or template for accurate cutting operations.
. For more information, go to MillerWelds.com.

Ref. 803 640-A / 801 400-B / Ref. 802 878

4-4. Sequence Of Cutting Operation
CUT GOUGE
Connect work clamp to a clean, paint-free . Unit automatically regulates pressure to 70 psi
location on workpiece, as close to cutting (483 kPa) for cutting.
area as possible.
90°
For standard (shielded) cutting, place drag shield Raise trigger lock and press trigger. Pilot After cutting arc starts, slowly
on edge of metal. For extended (non-shielded) arc starts and will go out after 3 seconds start moving torch across metal.
cutting, use 1/8 in (3.2 mm) standoff distance if cutting arc is not established.
(dragging tip will reduce tip life).
Adjust torch speed so Pause briefly at end of Postflow continues after releasing trigger;
sparks go thru metal and cut before releasing trigger. cutting arc can be instantly restarted during
out bottom of cut. postflow by raising trigger lock and pressing
trigger.
. For more information, go to MillerWelds.com.

Ref. 803 640-A / 801 400-B

4-5. Sequence Of Gouging Operation
CUT GOUGE
. Unit automatically regulates pressure to 60 psi

Connect work clamp to a clean, paint-free (413 kPa) for gouging.
location on workpiece, as close to cutting
area as possible.
455
Hold torch at approximately Raise trigger lock and press trigger. Pilot Release trigger. Postflow continues after
45° angle to workpiece. arc starts and will go out after 3 seconds if releasing trigger; arc can be instantly
gouging arc is not established. Move tip to restarted during postflow by raising trigger
within approximately 3/16 in (4.8 mm). Start lock and pressing trigger.
gouging across workpiece surface. Maintain
approximately a 45° angle to surface.
Ref. 803 640-A / 801 400-B

4-6. Sequence Of Piercing Operation
. Recommended maximum piercing
capacity is 7/16 in (11 mm).
CUT GOUGE
. Unit automatically regulates pressure

to 70 psi (483 kPa) for cutting.
Connect work clamp to a clean, Hold torch at an angle to the workpiece.
paint-free location on workpiece, as Raise trigger lock and press trigger. Pilot
close to cutting area as possible. arc starts and will go out after 3 seconds
if cutting arc is not established.
. Connect work clamp to portion of
workpiece that does not fall away after
being cut.
90° 90°
Rotate torch to upright position Maintain approximately 90° torch Release trigger. Postflow continues after
approximately 90° to surface. position to surface, and continue releasing trigger; arc can be instantly
When arc has pierced through cutting. restarted during postflow by raising trigger
workpiece, start cutting. lock and pressing trigger.
. For more information, go to MillerWelds.com and click on Resources/Improving Your Skills.
Ref. 803 640-A / 801 400-B

4-7. Cutting Speed
Mild Steel
Material Thickness Recommended Cut Speeds
Arc Current
Inches mm IPM mm/min
1/4 6.4 86 2184
3/8 9.5 41 1041
1/2 12.7 27 686
60
5/8 15.9 20 512
3/4 19.1 14 363
7/8 22.2 10 254
Stainless
Arc Current
1/4 6.4 72 1829
3/8 9.5 34 864
1/2 12.7 23 584
60
5/8 15.9 17 429
3/4 19.0 12 297
7/8 22.2 9 222
Aluminum
Arc Current
1/4 6.4 94 2388
3/8 9.5 48 1219
60
1/2 12.7 30 762
5/8 15.9 21 545
. Recommended cut speed is approximately 80% of maximum.

. Recommended maximum piercing capacity is 7/16 in (11 mm).
4-8. Consumables Storage Compartment
1 Consumables Storage
Compartment
This compartment provides
convenient access to consumables
and parts.
Rear of Unit Ref. 805 160-A

SECTION 5 − MECHANIZED OPERATION
5-1. ICE-60TM Mounting Position
1 ICE-60TM Machine Torch
2 Square
Use a square to align torch perpen-
dicular to the work surface.
1 2
90°
5-2. Remote Control Receptacle

. Remote trigger will only oper-
ate with a machine torch in-
stalled. Remote trigger is dis-
abled when a handheld torch is
1 installed.
1 Remote Control Receptacle
RC61
RC61 provides remote arc start
inputs when using the ICE-60TM
3 2 1 machine torch. Connect supplied
remote control cable or remote
7 6 5 4
pendant control to receptacle on
rear panel. See Section 5-3 for
11 10 9 8 remote control cable input and
output functions.
14 13 12
243 336-A
5-3. Remote Control Cable Functions
Function Lead Socket Lead Information
White 1 White and red leads connect to a set of customer-supplied remote contacts to
Remote Start provide a remote trigger input signal to RC61 sockets 1 and 5 for the remote
Red 5 start function.
Black 2 Black and green leads connect to a customer-supplied machine torch drive
device. Normally open contacts close after arc start to provide an output
signal to begin machine torch movement. These contacts can be either dry
(RMT1) or hot [RMT2 (+24 volts dc)] depending on plug position at RMT1 or
Okay To Move RMT2 receptacle on Control board PC1.
Green 4 NOTE: The Spectrum 875 Auto-Line with factory-installed machine torch is
shipped from the factory with the plug connected to RMT1 (dry contacts). To
power a relay or isolated input module with +24 volts DC on black lead (socket
2) and circuit common on green lead (socket 4), see Section 5-4 or 5-5.
Noise Suppression Shielding 3 Chassis ground.

5-4. +24 Volts DC Hot Contacts For Relay Operation
Remove wrapper (see Section 7-3).
Control board PC1 can supply +24
volts DC from receptacle RMT2 to
2 3 operate a customer-supplied relay
for the Okay To Move signal.
1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RMT2
4 Receptacle RC61
Move plug from RMT1 into
receptacle RMT2 on PC1. Be
sure remote control cable plug is
connected to RC61 on rear of
1 unit.
If voltage sensing is required, see
Section 5-8.
Install wrapper on unit.
Required Items:
Customer-supplied 24 volts DC re-
lay coil with resistance greater than
240 ohms.
Suppression diode (1A, 100V) such
as type IN4002 through IN4004
across relay coil.
. Machine torch equipped

plasma cutter is shipped from
the factory with plug connected
4 to receptacle RMT1 (dry
contacts).
White
Remote
Red Start
Black +24 VDC
Green
+
Relay Okay To
Relay Move
Contacts
Remote Control Cable
Tools Needed:
−
Torx 25
. +24 volts DC will activate relay coil after unit is triggered and
the cutting arc is initiated.
243 336-A / 804 041-A

5-5. +24 Volts DC Hot Contacts For Isolated Input Module Operation
Control board PC1 can supply +24
volts DC from receptacle RMT2 to
2 3 operate a customer-supplied
isolated input module for the Okay
To Move signal.
1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RMT2
4 Receptacle RC61
Move plug from RMT1 into
1
receptacle RMT2 on PC1. Be
sure remote control cable plug is
connected to RC61 on rear of
unit.
Section 5-8.
Required Items:
Customer-supplied isolated input
module.
. Machine torch equipped

plasma cutter is shipped from
the factory with plug connected
4 to receptacle RMT1 (dry
contacts).
White
Remote
Red Start
Black +24 VDC
Green
Okay To
Output Move
−
Tools Needed:
Torx 25
the cutting arc is initiated. 243 336-A / 804 041-A

5-6. Dry Contacts Using An External Power Supply For Relay Operation
Control board PC1 can provide dry
contacts from receptacle RMT1 to
2 operate a customer-supplied relay
using an external power supply for
the Okay To Move signal.
1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RC61
Machine torch equipped units are
shipped from factory with plug con-
1 nected to receptacle RMT1.
Be sure that remote control cable
plug is connected to RC61 on rear
of unit.
Section 5-8.
Required Items:
Customer-supplied +24 volts DC
power supply.
24 volts DC relay coil with resist-
ance greater than 240 ohms.
Suppression diode (1A, 100V) such
3 as type IN4002 through IN4004
across relay coil.
White
Remote
Red Start
Green
Black
+
+24 VDC
Power
Supply
−
Relay Okay To
Relay Move
Contacts
Tools Needed:
Torx 25
243 336-A / 804 041-A

5-7. Dry Contacts Using An External Power Supply For Isolated Input Module Operation
Control board PC1 can provide dry
2 contacts from receptacle RMT1 to
operate a customer-supplied
isolated input module using an
external power supply for the Okay
To Move signal.
1 Control Board PC1
2 Receptacle RMT1
3 Receptacle RC61
Unit is shipped from factory with
1 plug connected to receptacle
RMT1.
Be sure that remote control cable
plug is connected to RC61 on rear
of unit.
Section 5-8.
Required Items:
Customer-supplied +24 volts DC
power supply.
Isolated input module.
White
Remote
Red Start
Green
Black
+
+24 VDC
Power
Supply
−
Tools Needed: Output Okay To

Move
Torx 25
804 041-A

5-8. Remote Voltage Sense Connection
Remote voltage sense is an arc
voltage output signal for automatic
torch height adjustment.
1 Snap-in Blank
1 2 Secondary Interconnect
Board PC4
3 Receptacle RC48
Remove snap-in blank from rear
panel.
Route plug end of cable through
opening in rear panel.
Route plug end of cable over to
PC4.
Allowing adequate slack inside the
machine, secure cable and strain
relief by snapping strain relief into
opening in rear panel.
Connect plug to RC48 on PC4.
Cut off crimped terminals on lead
ends, and connect lead 1 to +volts
DC (electrode) and lead 2 to −volts
DC (work) on customer-supplied
voltage sense device.
Tools Needed:
Torx 25
2
Ref. 804 041-A / 243 336-A
5-9. Shield Sense Tab

. Shield sense tab is located in
the consumable storage box
on left side of unit wrapper.
Shield sense tab is included

only with units originally sold
with machine torches.
Shield sense tab provides feedback to a

compatible torch height controller before
starting the cutting process. Place the shield
sense tab between the cup and shield.

5-10. Cut Charts
60 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts.
Shield Sense Tab* Retaining Cap Tip Electrode Swirl Ring ICE-60TM Torch
212 732 212 733 219 676 212 724 212 734
226 763
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel
Pierce Material Thickness Maximum Cut Speeds Optimum Cut Speeds

Arc Current Arc Voltage Delay Inches mm IPM mm/min IPM mm/min
136 16 Ga 1.5 627 15926 502 12751
0
136 10 Ga 3.4 266 6756 213 5405
138 0.25 1/4 6.4 131 3327 85 2163
60 141 0.75 3/8 9.5 63 1600 41 1041
143 1.50 1/2 12.7 44 1118 29 726
147 5/8 15.9 31 787 20 508
153 3/4 19.0 22 559 14 356
Stainless

134 0 16 Ga 1.5 625 15875 406 10312
136 0.25 10 Ga 3.4 244 6198 159 4039
139 0.50 1/4 6.4 112 2845 73 1849
60 145 0.75 3/8 9.5 53 1346 34 864
145 2.00 1/2 12.7 36 914 23 594
149 5/8 15.9 26 660 17 432
154 3/4 19.0 18 457 12 305
Aluminum

135 0 1/16 1.6 666 16916 433 10998
138 1/8 3.2 400 10160 260 6604
0.25
139 1/4 6.4 147 3734 96 2427
60
146 0.75 3/8 9.5 74 1880 48 1219
147 1.50 1/2 12.7 51 1295 30 762
153 5/8 15.9 33 838 21 533
Without concern for cut appearance, the fastest speed for cutting material is the maximum cut speed. For better cut angle, less dross, and cut surface
appearance, use the optimum cut speed. The values in the cut charts are basic starting points and each application may require some adjustment to
achieve the best cut characteristics.

40 Amp Machine Torch Shielded Consumables
The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch and workpiece for all cuts.
Shield Sense Tab* Retaining Cap Tip Electrode Swirl Ring ICE-60TM Torch
212 732 212 733 212 725 212 724 212 734
226 763
*Shield sense tab 226 763 provides feedback to a compatible torch height controller before starting the cutting process.
. Shield sense tab is located in the consumable storage box on left side of unit wrapper.
Mild Steel

147 26 Ga 0.5 638 16205 415 10541
148 22 Ga 0.8 500 12700 325 8255
25 0
149 18 Ga 1.3 312 7925 203 5156
152 16 Ga 1.5 176 4470 114 2896
144 0.25 14 Ga 1.9 640 16256 221 5613
146 0.50 10 Ga 3.4 152 3861 99 2510
40
147 0.75 3/16 4.7 97 2464 63 1600
149 1.00 1/4 6.4 73 1854 47 1205
Stainless

139 26 Ga 0.5 631 16027 410 10414
25 0
139 22 Ga 0.8 496 12598 322 8179
142 18 Ga 1.3 592 15037 335 8509
143 0.25 16 Ga 1.5 374 9500 243 6172
143 14 Ga 1.9 224 5690 146 3698
40
147 0.50 10 Ga 3.4 107 2718 70 1778
149 0.75 3/16 4.7 67 1702 44 1118
149 1.00 1/4 6.4 48 1219 31 792
Aluminum

150 1/32 0.8 610 15494 397 10084
25 0
151 1/16 1.5 188 4775 122 3104
146 0.25 3/32 2.4 293 7442 190 4826
40 149 0.50 1/8 3.2 276 2010 179 4557
150 1.00 1/4 6.4 78 1981 51 1288

40 Amp Machine Torch Extended Consumables
The following cut charts are based on a distance of 1/16 in. (1.5 mm) between torch tip and workpiece for all cuts.
Deflector Retaining Cap Tip Electrode Swirl Ring ICE-60TM Torch
212 736 212 733 212 729 212 724 212 734
Mild Steel

125 26 ga 0.5 550 13970 353 8966
128 22 ga 0.8 484 12294 315 8001
25 0
128 18 ga 1.3 232 5893 151 3830
130 16 Ga 1.5 167 4242 109 2757
40 129 0.25 14 Ga 1.9 336 8534 218 5547
Stainless

127 26 ga 0.5 561 14249 365 9271
25 0
127 22 ga 0.8 453 11506 295 7493
123 18 Ga 1.3 500 12700 325 8255
40 127 0.25 16 GA 1.5 365 9271 237 6026
128 14 GA 1.9 220 5588 143 3632
Aluminum

125 1/32 0.8 564 14326 366 9296
25 0
127 1/16 1.5 236 5994 153 3886
40 127 0.25 3/32 2.4 268 6807 174 4425

Notes

SECTION 6 − THEORY OF OPERATION
1
1 Power Switch S1
Provides on/off control of power to Input Power Power Switch S1
primary interconnect board PC2 Cord
2 Filter Board PC6
8
Provides primary line signal filtering 208-575 VAC
Single- Or 2
3 Primary Interconnect Board Main
Three-Phase Transformer T1
PC2 Line Input Filter Board PC6
Provides electrical connections for Power
the following: Current
Transformer
S Input rectifier/boost IGBT CT1
module PM1 and thermistor 3
S Inverter module PM2 and Primary Interconnect

thermistor Board PC2
S Input inductor L1
S Main Transformer T1
Input Rectifier/Boost
S Bus capacitors that store IGBT Module PM1
approximately 445 VDC for use
in controlling the output
Thermistor
S Provides a path for +15 VDC 7
from the flyback board PC3 to
control board PC1 Power
4 Inverter Module PM2 Control
S Provides a path for the Board PC1
fan-on-demand signal from
control board PC1 Input
Inductor L1
S Provides a path for PWM signal Thermistor
to proportional valve.
4 Input Inductor
DC Bus
Stores energy in order to control
Capacitors
boost voltage across bus
capacitors and power factor
corrects the line draw.
5 Flyback Board PC3
Provides ±15 and +25 VDC for fan
motor, control circuits, safety
circuits, and proportional valve.
5
6 Fan Motor FM1
Provides cooling of internal com- 6 Flyback Board PC3
ponents. Fan turns on when unit re-
quires cooling. Fan Motor
FM1
7 Control Board PC1
Receives inputs from the following:
S LED/Pot Board PC1
S Air/Gas Sensor 9
S Torch Proportional Valve
S Four Thermistors
Air Valve
S Primary Interconnect Board 10
PC2 Dump Valve
LED/Pot Board PC1
S Secondary Interconnect Board
PC4 Pressure
Switch
Supplies control for the following:
S Fan Motor FM1 Pressure
S Input Rectifier/Boost IGBT Transducer
Module PM1
S Inverter Module PM2
11
S Proportional Valve
Cut/Gouge
Switch S2

8 Main Transformer T1
CT1 provides primary transformer
current feedback
Supplies power for cutting circuit
12
and isolated output from line power
Secondary Interconnect 9 Proportional Valve
Board PC4
Provides the following:
Output Rectifier/Pilot S Approximately 70 psi air/gas
13 IGBT Module PM3 for cutting and 60 psi air/gas for
Pilot Lead (+) gouging
Output
Thermistor
Inductor L3 S Opens dump valve briefly to
purge line during retriggering of
Thermistor Electrode torch
Voltage Sense
RT1 Leads (−) S Pressure switch closes at
40 psi supplying a pressure
okay signal to PC1
S Pressure transducer monitors
pressure so PC1 can regulate
pressure
10 LED/Pot Board PC1
Provides an interface to the
Power operator. LED’s indicate unit status.
Control Potentiometer provides amperage
Board PC1 control of output current supplied to
the torch
11 Cut/Gouge Switch S2
Controls pilot current to 17 amperes
for Cut and 25 amperes for Gouge.
Also controls pressure and dis-
ables pilot arc control
12 Secondary Interconnect
Board PC4
Provides electrical connections for
the following:
S Torch
S Work clamp
S Output rectifier/pilot IGBT
module PM3
S Output inductor L3
RMT1 and RMT2 on PC1 Torch Trigger
for automation interface Circuit 14 S LEM2 for current control
(remote trigger and okay
S LEM3 for transfer detection
to move)
Cup Safety S Voltage sense for automation
Circuit interface
13 Output Inductor L3
Directly connected to torch elec-
15 trode.. L3 sustains/smooths output
amperage
Work Cable And Clamp (+) Workpiece (+) 14 Torch
Receives input signals from the
following:
S Output rectifier PM3
S Supplies 17 to 25 amperes for
AC Or DC Control Circuits pilot arc and 20 to 60 amperes
for cutting
1φ Power S Proportional valve supplies
air/gas for cutting and gouging
15 Workpiece
Cutting And Pilot Current Circuits
Metal to be cut provides a path for
Gas/Air cutting current

PRE-POWER CHECKS
SECTION 7 − PRE-POWER TROUBLESHOOTING

7-1. Checking Unit Before Applying Power
. Use MILLER Testing Booklet (Part No. 150 853) when serv-
icing this unit.
. See Section 8-8 for test points and values and appropriate
Parts Section for parts location.
. See the Miller Extranet for service memos that may aid in the
repair of this product.
! Turn off power, and disconnect input power plug from receptacle before working on unit.
! Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing wrapper.
! Check DC bus voltage according to Section 7-4 after removing wrapper.
! Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.
7-2. Tools Needed For Troubleshooting And Servicing
13 mm, 13/16 in.
Torx 25

PRE-POWER CHECKS
7-3. Wrapper Removal/Installation
! Turn off power, and
4 disconnect input power plug
from receptacle or turn off
and lockout/tagout line dis-
1 connect device before
working on unit.
3
! Significant DC voltage can
2 remain on capacitors after
unit is Off. Check to see that
front panel lights (LED’s)
have stopped flashing and
are off before removing
wrapper.
1 Wrapper
2 Front Bezel
3 Rear Bezel
4 Torx Screw (Fine Thread)
Remove 13 screws from wrapper,
and front and rear bezels as shown.
Spread open tops of front and rear
bezels.
1 Compartment Opening
3 2
Be sure that opening clears the
storage compartment. Lift wrapper
off unit.
. When installing wrapper, front

and rear wrapper flanges must
be on outside of front and rear
portion of metal chassis.
Tools Needed:
Torx 25
Ref. 805 209-A / Ref. 249 823-A1

PRE-POWER CHECKS
7-4. DC Bus Voltage Check
! Turn Off power source, and
remain on capacitors after
unit is Off. Always check the
voltage as shown to be sure
the input capacitors have
Backside Of Primary Interconnect Circuit Board PC2 discharged before working
on unit.
1 Remove wrapper from unit (see
Section 7-3).
1 Circuit Board PC2
2 Bus Capacitors C8, C9, C11,
C12
! Check DC bus voltage before
2 servicing. Set multimeter to
read DC voltage. Check
voltage at each individual
capacitor (C8, C9, C11, and
C12). Voltage should read 5
volts DC or less.
. If the capacitor voltage does

not drop to near zero after
several minutes, use a bleeder
resistor of between 200 and
500 ohms, at least 10 watts,
and #16 AWG 600 volts ac in-
sulation rated wire to discharge
the capacitor(s).
3 Typical Bleeder Resistor
An example of a typical bleeder
resistor is shown on this page.
Proceed with job inside unit.
Reinstall wrapper when finished.
Typical Bleeder Resistor

200 to 500 ohm, 10 watt
wire wound resistor
Tools Needed: #16 AWG 600 Volts AC

Insulation Rating
Torx 25
234 176-E / Ref. 249 823-A1

PRE-POWER CHECKS
Notes

PRE-POWER CHECKS
7-5. Checking Primary Interconnect Circuit Board PC2
! Read and follow safety information in
Section 7-1 before proceeding.
Backside Of Primary
Interconnect Circuit
Board PC2
LINPUT PTC1
PTC2
XFMR1
LSNUB
LTAP
Line 2
Line 3 Capacitor C12 Positive
Line 1
Capacitor C8
Negative
C_STORE
SNUBBER C_SNUB
TAP
C_SNUB
SNUBbER
SNUB TAP
SNUB
RETURN XFMR2
RETURN
Diode D6
Diode D7
234 176-E / Ref. 249 823-A1
Precharge Thermistors On Primary Interconnect Circuit Board PC2

1. Measure across PTC1 and look for a reading of less than 50 ohms.
2. Measure across PTC2 and look for a reading of less than 50 ohms.
3. Measure across C12 positive to RC27 pin 1 and look for a reading of less than 1 ohm.

PRE-POWER CHECKS
Power Module 1 (PM1)
Input rectifier diodes (diode test) look for a diode drop of 0.200 to 0.900 volts.
Positive Meter Lead Negative Meter Lead

C8 Negative (−) Line 1
Line 1 LINPUT
Line 2 LINPUT
Line 3 LINPUT
Boost IGBT (diode test) look for a diode drop of 0.200 to 0.900 volts.
C8 Negative (−) LTAP

Snubber diodes (diode test) look for a diode drop of 0.200 to 0.900 volts.
C_STORE C12 Positive (+)
LTAP C_SNUB
C_SNUB C_STORE
L_SNUB C_STORE
Inverter IGBTs (diode test) look for a diode drop of 0.200 to 0.900 volts.
C8 Negative (−) XFMR 2
XFMR2 C12 Positive (+)

Snubber diodes (diode test) look for a diode drop of 0.200 to 0.900 volts.
Snub Return XFMR2
Snub Return Snubber Tap

Inverter gate drives (ohm test), unplug RC22 from PC2.
1. Measure across D6 and look for a resistance of 47k ohms.
2. Measure across D7 and look for a resistance of 47k ohms.

PRE-POWER CHECKS
7-6. Checking Control Circuit Board PC1
Control Circuit Board PC1

AUX PM2 SEC PM1
RC12
RMT1 RMT2
242 087-D
Check machine thermal protection (ohms test).
RC12 AUX
5.3k ohms at room temperature
RC12 PM2
RC12 SEC
700 ohms at room temperature
RC12 PM1

PRE-POWER CHECKS
7-7. Checking Secondary Interconnect Circuit Board PC4
Secondary interconnect
Circuit Board PC4
L2−1
PM3
PILOT AC_2
AC_1
WORK
234 142-G

Output rectifier diodes (diode test) look for a diode drop of 0.200 to 0.900 volts.
AC1 WORK
AC2 WORK
L2_1 AC1
L2_1 AC2
Output rectifier diodes reverse resistance test (ohms position on meter) resistance should be more than 5k ohms.
WORK AC1
WORK AC2
AC1 L2_1
AC2 L2_1
Pilot IGBT (diode test) look for a diode drop of 0.200 to 0.900 volts.
PILOT WORK

PRE-POWER CHECKS
7-8. Flyback Power Supply Circuit Board PC3

Diode D7
Anode
U1 Pin2
(Tab)
234 180-D / Ref. 249 823-A1
Flyback Power Supply Circuit Board PC3

Unplug RC31, RC32, RC33, and RC34. Perform diode test and look for a diode drop of 0.200 to 0.900 volts. Reconnect plugs after
testing.
U1 Pin 2 (Tab) RC32-3

D7 Anode RC34-1
RC34-5 D7 Anode

Always check unit before applying power (see Sections 7-1 thru 8-6).
SECTION 8 − TROUBLESHOOTING
8-1. Status/Trouble Lights
V POWER
PRESSURE
CUP
TEMP
Light Condition Status/Possible Cause

Power On Input power is okay.
Off When Power light is on, system is normal if these lights
Pressure/Cup/Temp
are off.
Flashing rate is steady for 15 seconds or until torch trigger Input power was above 300 volts AC or below 156 volts
Power
is pressed again, whichever comes first. AC, but has returned to normal.
Repetitive flashing rate of two quick cycles, then a one Input power is above 300 volts AC or below 156 volts AC.
second pause.
Precharge resistors have overheated due to multiple on/
off cycles. Allow unit to cool.
Power
An internal current latch has activated with three
consecutive trigger pull events. There is an internal LED
on PC1 that will stay lit once the system is latched off due
to current latch. Check for failed output rectifier.
Pressure On No or low [below 40 psi (276 kPa)] input pressure.
Flashing rate is steady for 15 seconds or until torch trigger Regulated pressure in the unit is low, but has returned to
Pressure
is pressed again, whichever comes first. normal.
Repetitive flashing rate of two quick cycles, then a one Regulated pressure in the unit is high or malfunctioning
Pressure
second pause for a 15 second period. pressure transducer.
On Torch cup is loose or off. Once cup is finger tightened, unit
Cup
power must be cycled off and back on again.
Flashing rate is steady for 15 seconds or until torch trigger No arc was established. Plasma system failed to strike an
Cup
is pressed again, whichever comes first. arc. No pilot current detected (failed to strike).
Repetitive flashing rate of three quick cycles, then a one Consumables in torch failed to separate during pilot arc
Cup second pause for a 15 second period or until torch trigger possibly due to being stuck.
is pressed again, whichever comes first.
Temperature On Power source overheated.
On (indefinitely) Power source temperature sensors may have failed or
Temperature
ambient temperature is below -22° F (-30° C).
Flashing rate is steady (indefinitely). Power source temperature sensor provided inaccurate
Temperature readings, but returned to normal. Unit power must be
cycled off and back on again.
For system troubleshooting see Section 8-2 and Section 8-3.

8-2. Troubleshooting
. See Section 8-8 for test points and values
and Section 12 and following for parts
location.
. Use Miller Testing Booklet (Part No. 150

853) when servicing this unit.
. See the Miller Extranet for service memos

that may aid in the repair of this product.
Trouble Remedy
No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see Section 10-3).
arc.
Check for damaged torch or torch cable.
Check position of cut/gouge switch. If using cutting consumables, be sure that switch is in the CUT
position. If using gouging consumables, be sure that switch is in the GOUGE position.
No cutting output; Power light off; status Place Power switch in On position.
lights off; fan motor FM does not run.
Place line disconnect device in On position (see Section 3-13 or 3-14).
Check line fuse(s) and replace if needed or reset circuit breakers (see Section 3-13 or 3-14).
Pilot arc working; no cutting output; Be sure work clamp is connected to a clean, rust-free workpiece.
Power light on; status lights off; fan
motor running. Check for correct torch standoff distance (see Section 4-3).
Check for overtightened retaining cup.
Clean or replace worn consumables as necessary (see Section 10-3).
No gas/air flow; Power light on; status Check for proper torch connections. Check operation of gas valve AS1, and check gas/air system for
lights off; fan motor running. leaks. Check filter element (see Section 10-4).
Pressure status light On. Check for sufficient gas/air supply pressure (see Section 3-6).
Check for dirty air filter and replace, if necessary (see Section 10-4).
Check air lines for leaks.
Cup status light On. Check torch shield cup (see Section 10-2). Reset power switch.
Temperature status light On. Unit overheating (see Section 3-3). Allow fan to run; the Trouble light goes out when the unit has cooled.
Temperature status light On indefinitely. Power source temperature sensors may have failed or ambient temperature is below −22° F (−30° C).
Operate unit in a warmer ambient temperature.
Temperature status light flashing rate Power source temperature sensor(s) provided inaccurate feedback, but have returned to normal. Unit
steady (indefinitely). power must be cycled off and back on again.
Power light flashing steady for 15 Input power was above 300 volts AC or below 156 volts AC, but has returned to normal. Have a qualified
seconds or until torch trigger is pressed, technician check input line power at idle and while cutting.
whichever happens first.
Power light is flashes at a rate of two Input power is above 300 volts AC or below 156 volts AC. Have a qualified technician check input power
quick cycles and then a one second at idle and while cutting.
pause.
Pre-charge PTC’s are overheated. Allow 15 minutes for unit to cool.
Pressure status light flashes at a rate of Unit regulated pressure is too high. Check for input pressure between 90-120 PSI (see Section 3-6).
two quick flashes and then a one second Malfunctioning pressure transducer if unit has not been triggered.
pause for a duration of 15 seconds.
Pressure status light flashes steady for Regulated pressure is too low. Check torch for leaks. Check for input pressure between 90-120 PSI
15 seconds or until torch trigger is during cutting (see Section 3-6).
pressed, whichever happens first.
Cup status light flashes steady for 15 System failed to strike an arc. Power source failed to deliver current to the output. Check continuity of
seconds or until torch trigger is pressed, torch connections (pilot lead and electrode lead).
whichever happens first.
Cup status light flashes at a rate of two The power source failed to maintain a pilot arc. Try a different set of torch consumables (tip and electrode).
quick cycles and then a one second Check for input pressure between 90-120 PSI.
pause for 15 seconds or until torch trig-
ger is pressed, whichever comes first.

Trouble Remedy
Cup status light flashes at a rate of three Power source detected that tip and electrode failed to separate when gas valve turned on. Check that
quick cycles and then a one second cup is not too tight (finger tight only). Check for correct torch consumables. Check for gas flow through
pause for 15 seconds or until torch trig- the torch head.
ger is pressed, whichever comes first.
Short tip life. Check and clean drag shield of any slag, particles, and debris.
Check position of cut/gouge switch. Place switch in correct position to match the process.
Check input air pressure.
Check that compressed air is clean, dry and oil-free. Use filter kit 300 491 or 228 926, if necessary.
Maintain 1/8 in (3.2 mm) standoff for extended tip cutting over 40 amps. Do not drag tip on workpiece.
Current latch. A mismatch between the Check for failed output rectifiers.
ratio of primary current in the main
transformer and measured load current. Check for failed components in the inverter control or drive.
Check for an extreme voltage imbalance between main bus capacitors.
Check for a failed output current sensor.
Check for a failed primary current sensor.
8-3. Troubleshooting Torch
Trouble Remedy
Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 4-4).
Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece.
Arc goes out while cutting. Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece.
Make sure drag shield is on the workpiece or the extended tip is 1/16 in. (1.6 mm) to 1/8 in. (3.2 mm) from
workpiece while cutting (see Section 4-4).
On thin metal, check travel speed. Constant travel speed must be maintained when cutting thin material.
Check that compressed air is clean, dry and oil-free. Use filter kit 300491 or 228926, if necessary.
Check retaining cup. DO NOT overtighen cup, hand-tighten only.
Sparks come out top of cut or cut is not Torch travel speed too fast; reduce travel speed (see Section 4-4).
clean.
Be sure work clamp is securely attached to a clean, paint-free, rust-free workpiece.
Unit not capable of cutting metals thicker than rating (see Section 3-2) or faster than shown in Section 4-7.

8-4. Control/LED/POT Circuit Board PC1 LED Locations (Use With Section 8-5)
+15 +5 ! Measure voltage on input
1 VDC VDC capacitors according to
Latch LED LED Section 7-4, and be sure
LED
voltage is near zero before
touching any parts.
Trig
LED
Bus
Okay
LED
242 087-D
8-5. Diagnostic LED’s On Power Control Board PC1

LED Status Diagnosis
On Bus voltage is at least 873 VDC.
Bus Okay
Off Bus voltage is below 873 VDC.
On PC1 is receiving +15 VDC on RC7-3 from
RC7-2 through a closed trigger switch.
Trigger Off Check to see if +15 VDC LED is lit. If LED is

lit, check for +15 VDC at RC7-2. If voltage is
present, either the trigger is not closed or
there is an open lead in the trigger circuit.
On There has been three consecutive trigger
pulls in which the ratio of primary current draw
Latch to load current draw is out of range. Check for
failed output rectifier.
Off Current draw is normal.
On Flyback circuit is supplying +15 VDC to PC1.
+15 Volts DC
Off No +15 VDC supply received from PC3.
On There is +5 VDC generated on PC1 from the
+15 VDC supplied by PC3.
+5 Volts DC Off No +5 VDC being generated on PC1. Check
to see if the +15 VDC LED is lit. If LED is lit,
replace PC1.

8-6. Secondary Interconnect Circuit Board PC4 LED Location

Secondary interconnect
Circuit Board PC4
LED1
234 142-G
8-7. Diagnostic LED On Secondary Interconnect Board PC4

LED Status Diagnosis
On Pilot IGBT is receiving the gate signal.
LED1
Off There is no gate signal at the pilot IGBT.

8-8. Troubleshooting Circuit Diagram

! Check and make sure input capacitors are discharged according to
Section 8, and be sure voltage is near zero before touching any parts.
Voltage Readings
a) Tolerance − ±10% unless specified
b) Reference − single arrow: reference to
circuit common
(lead 42); double arrow: reference to
points indicated
c) Wiring Diagram − see Section 11
V1 +940 VDC
V2 +180 to 200 VDC when piloting
V3 +160 to 200 VDC when cutting, approx-
imately 360 VDC (400 VDC max) OCV
with tip and electrode removed from
torch and a jumper lead across RC16
pins 1 and 2 on PC1 (see Section 8-9
for RC16 location)
V4 +25 VDC when fan is running R1
V5 LED1 on when pilot IGBT is receiving a
gate signal from PC1
V6 Bus okay LED is on when bus is above
+873 VDC
V7 Trigger LED is on when +15 VDC
comes back from trigger on RC7-2
V8 Latch LED is on if primary and
secondary current is out of balance
V9 +5 VDC LED is on when +5 VDC R2
supply is present
V10 +15 VDC LED is on when +15 VDC
supply from PC3 is present
V1
V4
R6
Test Equipment Needed:

Resistance Values
b) Turn Off unit and disconnect input power
before checking resistance
R1,R2 Power switch off is open, on approx. 0 ohms
R3 No trigger is open, trigger is approx. 0 ohms
R4 Retaining cup off is open, consumables in
place and retaining cup on is approx. 0
ohms
R5 Consumables in place and air off is approx.
0 ohms, air on is open
R6 No air connected to unit is 15.5k ohms, air
connection is approx. 0 ohms
V5
LED1
V2, R5
V3
R3 R4
Bus Okay LED V6

Trigger LED V7
Latch LED V8
+5 VDC LED V9
+15 VDC LED V10
234 018-B

8-9. Control/LED/POT Circuit Board PC1 Testing Information (Use With Section 8-10)
! Measure voltage on input
capacitors according to
Section 7-4, and be sure
touching any parts.
Be sure plugs are secure before
testing. See Section 8-8 for specific
values during testing.
1 Control/LED/POT Circuit
+15 +5
Board PC1
VDC VDC
Latch
LED
LED LED . See Section 8-8 for detailed
LED information.
Trig
LED
Bus
Okay
LED
242 087-D

8-10. Control/LED/POT Circuit Board PC1 Test Point Values

PC1 Voltage Readings b) Reference − to circuit common (lead 43)
unless noted
Receptacle Pin Source Value
RC1 1 Output +5 VDC
2 Input Cut/Gouge switch return
RC2/RC13 1 Output +15 VDC
2 Input Panel reference 0 to +5 VDC, 0 = 20 A and +5 VDC = 60 A
3 Output +5 VDC reference
4 —— Not used
5 —— Ground
6 —— Cut/Gouge +5 VDC = Cut and 0 = Gouge
7 Output Power LED 0 = On and +15 VDC = Off
8 Output Temp LED 0 = On and +15 VDC = Off
9 Output Pressure LED 0 = On and +15 VDC = Off
10 Output Cup LED 0 = On and +15 VDC = Off
RC6 1 Output +5 VDC
2 Input + Pressure 1 mV per PSI reference to RC6 pin 3
3 Input − Pressure 1 mV per PSI reference to RC6 pin 2
4 —— Ground
RC7 1 Input +15 VDC with Cup switch closed and 0 with Cup switch open
2 Output +15 VDC from PC1
3 Input +15 VDC with trigger switch open and 0 with trigger switch closed
RC8 1 —— Thermistor 10k ohms at room temperature (plug disconnected), reference to RC8 pin 2
2 —— Thermistor 10k ohms at room temperature (plug disconnected), reference to RC8 pin 1
RC9 —— Output +5 VDC open and 0 closed, to pressure switch
RC9A —— —— Ground

RC10 1 Input +25 VDC from PC2
2 Input +15 VDC from PC2
4 Input −15 VDC from PC2
5 —— Ground
6 —— Ground
7 Input V−Bus scaled 1 V per 125.3 volts
8 Input V−Rectifier scaled 1 V per 200 volts
9 Output Fan On +15 VDC when fan is running
10 Output Gas PWM 0 = gas off and pulsed +5 VDC = gas on
11 Output Dump valve has brief voltage when valve is energized
12 —— Ground
13 Input Do Not Measure (transformer current feedback)
14 Input Do Not Measure (Input feedback)
15 Input PM1 thermistor 2.5 V at room temperature (25° C)
16 Input PM2 thermistor 2.5 V at room temperature (25° C)
17 Output Do Not Measure (boost drive)
18 Output Bus precharge 0 when bus is precharged and +25 VDC if relay is not energized
19 —— Ground
20 —— Ground
R C11 1 Output +15 VDC
2 —— Ground
3 Output −15 VDC
4 —— Ground
5 —— Ground
6 Input Secondary Thermistor +2.5 VDC at room temperature (25° C)
7 Output Pilot_Enable +5 VDC when off and 0 when on from PC4
8 Input VEW_Scaled +1 VDC per 100 V from PC4
9 Input Current feedback, 1 V per 12.8 A from PC4
10 Input Current transfer 0 to 5 A, 1 V per ampere, +5 VDC max from PC4

RC15 1 Output Highside_Gate Do not measure − high voltage present.
2 —— Not used
3 Output Snub1_Gate Do not measure − high voltage present.
4 Input Snub_Return Do not measure − high voltage present.
5 —— Not used
6 —— Not used
7 Input Highside_Return Do not measure − high voltage present.
8 —— Not used
9 Output Snub2_Gate Do not measure − high voltage present.
10 —— Not used
11 Output Lowside_Gate Do not measure − high voltage present.
12 Input Lowside_Return Do not measure − high voltage present.
RMT1 1 Output +5 VDC for trigger
2 —— Ground
3 Output Contact closure with arc transfer with respect to RMT4
4 Output Contact closure with arc transfer with respect to RMT3
RMT2 1 Output +5 VDC for trigger
2 —— Ground
3 Output +25 VDC with arc transfer, 0 VDC without arc transfer
4 Input Ground

8-11. Primary Interconnect Circuit Board PC2 Testing Information

(Use With Section 8-12)
touching any parts.
1 Primary Interconnect Circuit
Board PC2
234 176-E / Ref. 249 823-A1

8-12. Primary Interconnect Circuit Board PC2 Test Point Values

unless noted
RC21 1 Output +25 VDC
2 Output +15 VDC
3 Output +15 VDC
4 Output −15 VDC
5 —— Ground
6 —— Ground
7 Output V−Bus scaled 1 V per 125.3 volts
8 Output V−Rectifier scaled 1 V per 200 volts
9 Input Fan On +15 VDC when fan is running
10 Input Gas PWM 0 = gas off and pulsed +5 VDC = gas on
11 Input Dump valve has brief voltage when valve is energized
12 —— Ground
13 Output Do Not Measure (transformer current feedback)
14 Output Do Not Measure (Input feedback)
15 Output PM1 thermistor 2.5 V at room temperature (25° C)
16 Output PM2 thermistor 2.5 V at room temperature (25° C)
17 Input Do Not Measure (boost drive)
18 Input Bus precharge 0 when bus is precharged and +25 VDC if relay is not energized
19 —— Ground
20 —— Ground
RC22 1 Input Highside_Gate Do not measure − high voltage present.
2 —— Not used
3 Input Snub1_Gate Do not measure − high voltage present.
4 Output Snub_Return Do not measure − high voltage present.
5 —— Not used
6 —— Not used
7 Output Highside_Return Do not measure − high voltage present.
8 —— Not used
9 Input Snub2_Gate Do not measure − high voltage present.
10 —— Not used
11 Input Lowside_Gate Do not measure − high voltage present.
12 Output Lowside_Return Do not measure − high voltage present.

RC23 1 Input +25 VDC from PC3
3 Input −15 VDC from PC3
4 —— Ground
5 —— Ground
7 —— Ground
8 Output Fan_On +15 VDC when fan is on
9 Output Gas_PWM, 0 = gas off and pulsed +5 VDC = gas on
10 Output Dump valve has brief voltage when valve is energized
RC25 1 Output 208/230 VAC input power reference to RC25 pins 3 or 4
2 Output 208/230 VAC input power reference to RC25 pins 3 or 4
RC26 1 —— +Bus
2 —— MP
3 —— −Bus
RC27 1 Output + Bus +940 VDC reference to RC27 pin 5
2 —— Not used
3 —— Not used
4 Input +15 VDC reference to pin 5
5 Output − Rectifier/− Bus reference to RC27 pins 1 or 4
RC28 1 —— Do not measure − high voltage present.
2 —— Not used
3 —— Do not measure − high voltage present.

Notes

8-13. Flyback Power Supply Circuit Board PC3 Testing Information

touching any parts.
1 Flyback Power Supply Circuit
Board PC3
234 180-D / Ref. 249 823-A1

8-14. Flyback Power Supply Circuit Board PC3 Test Point Values
unless noted
RC31 1 Output +25 VDC
2 Output +15 VDC
3 Output −15 VDC
4 —— Ground
5 —— Ground
6 Output +15 VDC
7 —— Ground
8 Input Fan_On +15 VDC when fan is on
9 Input Gas_PWM, 0 = gas off and pulsed +5 VDC = gas on
10 Input Dump valve has brief voltage when valve is energized
RC32 1 Output +25 VDC for air valve
2 Output +25 VDC for dump valve
3 —— Air drive +9 to 25 VDC depending on input air pressure reference to RC32 pin 1
4 —— Dump drive +25 VDC pulsed briefly when dump valve is on reference to RC32 pin 2
RC33 1 Output +25 VDC for fan
2 —— Fan Off = 0 VDC and fan On = +25 VDC reference to RC33 pin 1
RC34 1 Input + Bus +445 VDC reference to RC27 pin 5
2 —— Not used
3 —— Not used
4 Output +15 VDC reference to RC27 pin 5
5 Input − Rectifier/− Bus reference to RC27 pins 1 or 4

8-15. Secondary Interconnect Circuit Board PC4 Testing Information

touching any parts.
1 values during testing.
1 Secondary interconnect
Circuit Board PC4
234 142-G

8-16. Secondary Interconnect Circuit Board PC4 Test Point Values

unless noted
RC41 1 —— Do not measure − high voltage present.
2 —— Not used
3 —— Do not measure − high voltage present.
RC42 1 —— +15 VDC from PC1
2 —— Ground
3 —— −15 VDC from PC1
4 —— Ground
5 —— Ground
6 Input Secondary Thermistor +2.5 VDC at 25° C
7 Input Pilot_Enable +5 when off and 0 when on
8 Output VEW_Scaled +1VDC per 100 V
9 Output Current feedback, 1 V per 12.8 A
10 Output Current transfer 0 to 5 A, 1 V per ampere, +5 max
RC45 1 —— +15 VDC referenced to RC45 pin 2
2 —— Pilot drive common
RC48 1 Output Raw arc voltage with respect to RC48-2 +160-+200 VDC while cutting (400 VDC max OCV)
2 Output Raw arc voltage with respect to RC48-1 +160-+200 VDC while cutting (400 VDC max OCV)

8-17. Pressure Switch Circuit Board PC5 Testing Information

1 touching any parts.
2 testing. See Section 8-8 for specific
1 Secondary interconnect
Circuit Board PC4
2 Receptacle RC1
Ref. 249 823-A1
8-18. Pressure Switch Circuit Board PC5 Test Point Values

unless noted
R C1 1 Input +5 VDC = open and 0 = closed
2 —— Ground

8-19. Filter Circuit Board PC6 Testing Information (Use With Section 8-20)
touching any parts.
1 Filter Circuit Board PC6
2 Receptacle RC61
3 Receptacle RC62
4 Line 1
5 Line 2
6 Line 3
8 7 5 4 1 7 Load 1
8 Load 2
3 9 Load 3
9 6
242 281-C / Ref. 249 823-A1

8-20. Filter Circuit Board PC6 Test Point Values

unless noted
RC61 —— —— Not used
RC62 —— —— Ground
Line 1 —— Input Input power 208-575 VAC with respect to Line 2 and/or Line 3
Load 1 —— Output Input power 208-575 VAC with respect to Load 2 and/or Load 3

SECTION 9 − DISASSEMBLY PROCEDURE
9-1. Safety Precautions For Disassembly
. Use MILLER Testing Booklet (Part No. 150 853) when

servicing this unit.
! Unplug unit before beginning disassembly procedure.

! Check bus voltage according to Section 7-4 after removing wrapper.
9-2. Wrapper Removal/Installation

4 disconnect input power plug
1 connect device before
working on unit.
3
2
front panel lights (LED’s)
wrapper.
1 Wrapper
2 Front Bezel
3 Rear Bezel
4 Torx Screw (Fine Thread)
Remove 13 screws from wrapper,
and front and rear bezels as shown.
Spread open tops of front and rear
bezels.
3 1 Compartment Opening
2
Be sure that opening clears the
storage compartment. Lift wrapper
off unit.
1
. When installing wrapper, front
and rear wrapper flanges must
be on outside of front and rear
portion of metal chassis.
Tools Needed:
#25 Torx
805 209-A / Ref. 249 823-A1

9-3. Front And Rear Panel Assembly Removal
! Read and follow safety infor-
mation in Section 9-1 before
proceeding with disassembly.
1 Front Panel
2 Rear Panel
3 T25 Torx Screws
Remove four screws.
Remove front and rear panel
1 assembly.
2
Tools Needed:
#25 Torx
Ref. 249 823-A3

9-4. Fan Removal
! Turn Off power source before
removing fan.
2 1 ! Significant DC voltage can
4 remain on capacitors after unit
is Off. Always check capacitors
according to Section 7-4 or to
be sure they have discharged
before working on unit.
Board PC3
2 Fan Harness
3 Receptacle RC33
Disconnect plug from RC33.
4 Air Filter
5 Drain Tube
Remove drain tube from notch in
windtunnel to prevent interference
during fan removal.
6 Locking Tabs
Push locking tabs out away from
edge of fan, and push fan out from
6 5 rear panel.
Once fan is clear of locking tabs, pull
3
out fan and guide harness through
hole in windtunnel to completely
remove fan.
Reverse steps to replace fan in unit.

9-5. Filter Assembly Removal
3 Remove rear panel according to
Section 9-3.
1 5/16 in Screws
Remove two screws.
2 Receptacle RC1
Mark and disconnect plug from RC1.
3 Receptacle RC6
Mark and disconnect plug from RC6.
4 Air/Gas Fitting
Front View Of PC1
6 5 Air/Gas Hose
2 Disconnect hose from fitting.
Board PC3
7 Receptacle RC32
Mark and disconnect plug from
RC32.
Remove filter assembly from unit.
Tools Needed:
5/16 in.

9-6. Control Circuit Board PC1 Removal
6 5
7
4
8 1 11
9 10
2
3
! Read and follow safety information Disconnect GND2 and GND3 leads from 9 Receptacle RC11
in Section 9-1 before proceeding PC4. Disconnect CHGND terminal and 10 Receptacle RC15
with disassembly. SGND terminal from PC1.
11 Locking Tabs
4 Receptacle RC10
1 Control Circuit Board PC1 5 Receptacle RC8 Mark and disconnect plugs from
receptacles.
6 Receptacle RC6
2 Secondary Interconnect Board PC4 Push up on tabs to release PC1.
7 Receptacle RC13
3 Ground Leads GND2 And GND3 8 Receptacle RC7 Remove PC1 from unit.

9-7. Disconnecting Magnetics Leads
Rotate Insulator Up
1
3
Tools Needed:
5/16 in., 3/8 in.
! Read and follow safety information 2 Primary Interconnect Circuit Board L2−1, L2−2, AC_1, and AC_2 on PC4.
in Section 9-1 before proceeding PC2 4 3/8 in Nuts
with disassembly.
3 5/16 in Nuts Mark leads, and remove four nuts from
1 Secondary Interconnect Circuit LINPUT, LTAP, XFMR1 and XFMR2 on
Board PC4 Mark leads, and remove four nuts from PC2.

9-8. Current Transformer CT Removal
1 Primary Interconnect Circuit
Board PC2
2 Current Transformer CT
3 Receptacle RC24
4 2 1 Disconnect plug from RC24.
4 Locking Tabs
Push out on tabs to release CT.
Remove CT from unit.
Ref. 249 823-A1

9-9. Windtunnel Removal
2
2
Tools Needed:
#25 Torx
Ref. 249 823-A2
! Read and follow safety information Remove ten screws. . Be sure that tabs are in locator slots in
in Section 9-1 before proceeding base when installing windtunnel.
with disassembly. Remove windtunnel from unit. Install windtunnel and secure with ten
screws.
1 Windtunnel
Replace malfunctioning magnetics Reverse the order of disassembly to
2 T25 Torx Screws assembly. re-assemble unit.

SECTION 10 − MAINTENANCE
10-1. Routine Maintenance
! Disconnect power . Maintain more often

before maintaining. during severe conditions.
n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent
Each
Use
n Torch Tip, Electrode, n Gas/Air Pressure
And Shield Cup
Every
Week
n Shield Cup Shutdown
System
Every l Damaged Or Unreadable l Cracked Parts ~ Air Filter/Regulator n Gas/Air Hose

3 Labels Assembly Filter
Months
n l Torch Body, Cable
Every OR
6
Months
~ Inside Unit
10-2. Checking Shield Cup Shutdown System

. Power must be reset whenever the cup shutdown system 1 Torch Shield Cup
is activated. Always turn Off power when changing or Turn Power On and loosen shield
checking consumables. Do NOT overtighten torch cup. If shutdown system works
shield cup. Gently finger tighten cup onto torch. properly, Cup light comes on. If not,
immediately turn Off power and
have Factory Authorized Service
Agent check unit.
1
If system works properly, retighten
cup and reset power.
. DO NOT overtighten torch

shield cup.
Ref. 801 300-A

10-3. Checking/Replacing Retaining Cup, Tip, And Electrode
Overtightening will strip threads. Do not overtighten electrode, tip,

and retaining cup during assembly. Do not cross-thread parts causing
stripping. Use care during torch assembly and parts replacement.
Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly
reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement parts.
. A good practice is to replace both the tip and electrode at the same time.
Turn Off power source before checking torch parts.
1/32 in. (1 mm) to 1/16

in. (2 mm) maximum pit
depth depending on
acceptable cut quality
5
Worn
New
Make sure this area is
clean of any debris.
3
Worn 8
7
New
4
6
Make sure this area is

clean of any debris.
804 056-A
! Turn Off power source. Remove tip. Check tip, and replace if open- Remove swirl ring. Check ring, and replace
ing is deformed or 50% oversize. If inside of if side holes are plugged.
1 Drag Shield tip is not clean and bright, clean with steel 7 O-Ring
Check this area for any debris or foreign wool. Be sure to remove any pieces of steel
material. Clean out if necessary. wool afterwards. Check O-rings on torch. If needed, coat with
thin film of silicone lubricant (part no.
2 Retaining Cup 5 Electrode 169 231). Replace if damaged.
Remove retaining cup. Check retaining cup Check electrode. Performance may
degrade if center has a pit more than a 1/32 8 Plunger Area
for cracks, and replace if necessary.
in. (1 mm) deep, remove and replace Check this area for any debris or foreign
3 Tip electrode. material. Clean out if necessary.
4 Opening 6 Swirl Ring Carefully reassemble parts in reverse order.

10-4. Checking Or Replacing Filter Element (Part No. 227 877)
disconnect input power plug
connect device before
working on unit.
1
front panel lights (LEDs)
wrapper.
Remove wrapper from unit (see
Section 7-3).
1 Rear Bezel
Remove rear bezel from unit.
2 Filter Bracket Screws
Remove filter bracket screws. Pull
filter bracket toward front of unit
until gas/air supply fitting is past
rear panel, and swing filter
assembly out to the side to allow
filter cup removal.
3 Filter Base
4 Filter Element
(Part No. 227877)
2 5 Filter Cup
Unscrew filter cup from base.
Remove cup.
Unscrew filter element from base.
Check filter element for dirt and
3 moisture, and replace if necessary.
Be sure that all parts are clean and
dry.
4
Reinstall filter element, and secure
filter cup.
Secure filter bracket to rear panel.
Reinstall wrapper and rear bezel.
5
Tools Needed:
5/16 in.
Ref. 249 823-A1

Notes

SECTION 11 − ELECTRICAL DIAGRAM
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit
inside machine case or contact distributor for more information.
The following is a list of all diagrams for models covered by this manual.
Model Serial Or Style Number Circuit Diagram Wiring Diagram
Spectrum 875 Auto-Line MA240476P and following 243 018-B ♦♦
♦♦ Not included in this manual

Figure 11-1. Circuit Diagram Eff w/MA240476P And Following
243 018-B

Notes

TM-242 880B 2011−07
Processes
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter
Spectrum 875 Auto-Line

R
And ICE-60T/TM Torch

Eff w/MA240476P And Following
For OM-242 880 Revision A And Following
File: Plasma Cutters
Visit our website at

www.MillerWelds.com
SECTION 12 − PARTS LIST
. Hardware is common and

not available unless listed.
57
3
2 56
4
55
13
1 5 15
9 17
12 14 16 52
11
6 19
7 8 18
10
12
44
53
48
47 43
42
41 11
40 58 10
46
45 50
38 51
21
18
20
37 39
49
36 22
34
35 24
23
23
54
33 27
29 28 25
26
32 30
31
247 688-A
Figure 12-1. Main Assembly

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-1. Main Assembly
. . . 1 . . . PC3 . . 234179 . . CIRCUIT CARD ASSY, FLYBACK PWR SUPPLY 875 AUTOLINE . . . . . . . . . 1
. . . 2 . . . . . . . . . . 243959 . . WINDTUNNEL, LH W/CMPNTS (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 235579 . . . . DOOR, CONSUMABLE STORAGE BOX W/LATCH . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . L2 . . 243337 . . INDUCTOR, DI/DT BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . L1 . . 243339 . . INDUCTOR, INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . T1 . . 242583 . . XFMR, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . L3 . . 245556 . . INDUCTOR, OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 237138 . . INSULATOR, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 234818 . . HEAT SINK, PRIMARY/SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . PM3 . . 247083 . . KIT, OUTPUT RECTIFIER/PILOT IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . PM2 . . 242877 . . KIT, INVERTER IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . PM1 . . 242878 . . KIT, INPUT RECTIFIER/BOOST IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . FM1 . . 246973 . . FAN, MUFFIN W/LEADS & GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . CT1 . . 236848 . . XFMR, CURRENT SENSING 200/1 W/6IN LEADS . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . R3 . . 238142 . . RESISTOR, WW FXD 50 W 25 OHM NI 5% . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 235573 . . WINDTUNNEL, HEAT SINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . +237137 . . INSULATOR, VALVE BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . PC1 . . 242085 . . CIRCUIT CARD ASSY, CNTRL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . PC2 . . 243979 . . KIT, PRIMARY INTRCNNCT BD ASSY,60AMP AUTOLINE . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 243613 . . CABLE, POWER 10 FT 8GA 4C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 604102 . . CONN, CLAMP CABLE 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 234806 . . PANEL, REAR PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . 249590 . . KIT, REPLACEMENT AIR FITTINGS (INCLUDING) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTG, PLSTC/BRS STRAIGHT QDISC 1/4RC METRIC X 8MM OD . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . FTG, AIR QUICK DISCONNECT FEMALE METRIC . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . 235580 . . RECEPTACLE, FASTENER QUARTER TURN STUD RIVETED . . . . . . . . . . 1
. . . 25 . . . . . . . . . . 237021 . . WASHER, INSULATOR KEYED TWIST LOCK RECEPTACLE . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . +234797 . . CASE SECTION, BASE/FRONT/REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 237020 . . INSULATOR, RECEPTACLE TWIST LOCK (MINI−DINSE TYPE) . . . . . . . . . 1
. . . 28 . . . . . . . . . . 234841 . . RECEPTACLE, TWIST LOCK BRASS FEM PANEL MTG (MINI DINSE) . . . 1
. . . 29 . . . . . . . . . . 234895 . . LEAD ASSY, ELECT (TORCH RECPT TO CNTRL/SECNDRY BDS) . . . . . . . 1
. . . 30 . . . . . . . . . . 234805 . . PANEL, FRONT PLASTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . 234838 . . CABLE, WORK 20 FT 6 GA W/MALE (DINSE TYPE)
CONN & CLAMP (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 213619 . . . . CLAMP, WORK 300 AMP STL CHROME PLD W/COP CONTACTS . . . . . 1
. . . . . . . . . . . . . . . . 213620 . . . . CONTACT TIP, WORK CLAMP 300AMP COPPER . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 127836 . . . . CONN, TW LK INSUL MALE(DINSE TYPE)25 SERIES . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 605520 . . . . STRIP, COP .010 X .750 XCOIL DEAD SOFT . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . 234930 . . CABLE, WORK 50 FT 6 GA W/MALE (DINSE TYPE)
CONN & CLAMP (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 213619 . . . . CLAMP, WORK 300 AMP STL CHROME PLD W/COP CONTACTS . . . . . 1
. . . . . . . . . . . . . . . . 213620 . . . . CONTACT TIP, WORK CLAMP 300AMP COPPER . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 127836 . . . . CONN, TW LK INSUL MALE(DINSE TYPE)25 SERIES . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 605520 . . . . STRIP, COP .010 X .750 XCOIL DEAD SOFT . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 234132 . . ICE− 60T, 20FT HAND HELD TORCH (REPLACEMENT) . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . 234134 . . ICE− 60T, 50FT HAND HELD TORCH (REPLACEMENT) . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . 234829 . . KIT, ICE− 60T QUICK DISCONNECT HOUSING
REPLACEMENT (W/O PINS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 174992 . . KNOB, POINTER .840 DIA X .250 ID W/SPRING CLIP−.21 . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . 238453 . . SWITCH, CUT/GOUGE W/LEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . 237141 . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . 238770 . . INSULATOR, SWITCH POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . S1 . . 245907 . . SWITCH ASSY, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . 237651 . . PLATE, COVER REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
Serial number is on rating card located on bottom (outside) of unit. Model number is on nameplate located on front of unit.
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.
Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 12-1. Main Assembly (Continued)
. . . 40 . . . PV1 . . 234169 . . VALVE ASSY, W/TRANSDUCER (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PC5 . . 241301 . . . . KIT, REPLACEMENT CIRCUIT CARD ASSY PRESSURE SWITCH . . . . . 1
. . . . . . . . . PS1 . . 236003 . . . . SENSOR, PRESSURE 0-100MV DC/0-100PSI . . . . . . . . . . . . . . . . . . . . . . . 1
................ 234837 . . . . FTG, PLSTC/BRS ELBOW QDISC 3/8 OD X 5/16 OD TBG . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . 236002 . . FILTER, AIR W/FTG & BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
................ 227877 . . FILTER, AIR ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . PC4 . . 249920 . . CIRCUIT CARD ASSY, INTRCNCTNG SECONDARY 60 A . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . 238275 . . BRACKET, RESISTOR SECONDARY SNUBBER . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . R2 . . 236234 . . RESISTOR, WW FXD 75 W 25 OHM NI 5%
W/LEADS (Prior to MB270125P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . R2 . . 251703 . . RESISTOR,WW FXD 50 W 25 OHM NI 5%
W/STAND-OFFS (Eff w/MB270125P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 245909 . . COVER ASSY (INCLUDING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . +234893 . . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . 234129 . . . . LABEL, WARNING PRECAUTIONARY PLASMA CUTTING EQUIP. . . . . . 1
. . . 47 . . . . . . . . . . 234130 . . . . LABEL, WARNING PRECAUTION PLASMA CTNG EQUIP SPANISH . . . 1
. . . 48 . . . . . . . . . . 208015 . . . . HANDLE, RUBBERIZED CARRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . 189784 . . . . INSULATOR, WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . 245901 . . . . CIRCUIT DIAGRAM SPECTRUM 875 AUTOLINE . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . 237017 . . LABEL, AIR PRESSURE 90−120PSI/621−827kPa . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . 208622 . . LABEL, WARN ELECT SHOCK/EXPLOD PARTS/DO NOT REMOVE . . . . . 1
. . . 53 . . . . . . . . . . 234843 . . LABEL, ICE− 60T CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . 237130 . . CLIP, GRD 250X032 FRICT TERM MALE W/.575 MTG HOLE . . . . . . . . . . . . 1
. . . 55 . . . PC6 . . 242280 . . CIRCUIT CARD ASSY,INPUT FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . 109056 . . CORE, FERRITE E 2.164 LG X 1.094 HIGH X .826 WIDE . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . 089899 . . LATCH, SLIDE FLUSH STYLE SERIES 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . 246287 . . REMOTE RECEPTICLE, W/LEADS 60AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
Serial number is on rating card located on bottom (outside) of unit. Model number is on nameplate located on front of unit.
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

StandardCutting
60A Retaining
DragShield Cup Tip Electrode SwirlRing O-Ring
212730 212733 219676 212724 212734 212735
Shield Applysilicone
212732 grease(169231)
(MachineCutting) beforeinstalling.
40A Retaining
DragShield Cup Tip
212730 212733 212725 ICE-60T
CONSUMABLES
ExtendedCutting
60A
Deflector
Retaining
Cup Tip
CAUTION
212736 212733 219682
FAILURETOREPLACE
WORNTIPOR
40A Retaining ELECTRODEMAY
Deflector Cup Tip
212736 212733 212729 DAMAGETORCHAND
VOIDWARRANTY.
S Turnoffpowerbefore
Gouging checkingtorchparts.
60A Retaining S Checkbeforeeachuseand
Shield Cup Tip
212731 212733 219680 hourlyduringoperation.
234843-B
CupInstallation:Donotovertighten—finger-tightonly.
234 843-B
Figure 12-2. Consumable Parts For ICE-60T
Replacement Parts. Model (located on nameplate on front of unit) and serial number (located on outside
bottom of plasma cutter base) is required when ordering parts from your local distributor.

Item Part Item Part
No. No. Description No. No. Description
1 215 594 Handle w/Screws (1) 9 215 606 Clip, retaining (1)
2 215 478 Kit, cup sensor (1) 10 212 735 O-Ring, main body (1)
3 215 479 Torch Head Repair Kit (1) 11 234 829 Kit, ICE 60T/TM quick connect w/wing
4 185 833 Switch Assy w/Spring (1) head fastener (1)
5 190 220 Trigger Spring (1) 169 231 Grease, silicon
6 215 592 Switch Trigger (1) 234 132 Torch, replacement 25ft (1)
7 215 477 Main Body (1) 234 134 Torch, replacement 50ft (1)
8 234 170 Torch Lead, replacement
w/quick disconnect 20ft (1)
8 234 171 Torch Lead, replacement 11
w/quick disconnect 50ft (1)
8
1 9
See Figure 12-2 for

additional consumable parts.
7 6
3 5
10
4 1
804 035-A
Figure 12-3. Torch, ICE-60T

Item Part See Figure 12-2 for
No. No. Description additional consumable parts.
1 215 607 Sleeve, Torch Position (1)

2 234 172 Torch Lead, Replacement W/QD 25 ft (1)
2 234 173 Torch Lead, Replacement W/QD 50 ft (1)
3 215 599 Torch Sleeve (1)
6
4 215 598 Main Body W/Switch (1)
5 195 513 Remote Pendant Control (1)
234 136 Torch, Replacement 25 ft (1)
234 138 Torch, Replacement 50 ft (1)
220 240 Cable, Remote Control Trigger 25 ft (1)
246 285 Cable, Remote Voltage Sense 26.5 ft (1)
6 234 829 Kit, Ice-60t/Tm QD W/Wing Head Fastener
7 215 606 Clip, Retaining
1
5
4
3
804 036-A
Figure 12-4. Torch, ICE-60TM

Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co.

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TM-242 880B 2011−07

Eff. w/ Serial No. MA240476P

Air Plasma Cutter

Spectrum 875 Auto-Line

And ICE-60T/TM Torch

File: Plasma Cutters

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SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 7 − PRE-POWER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

1-2. Arc Welding Hazards

Spectrum 875 Auto-Line TM-242 880 Page 1

1-3. California Proposition 65 Warnings

TM-242 880 Page 2 Spectrum 875 Auto-Line

Spectrum 875 Auto-Line TM-242 880 Page 3

On Off Percent Direct Current

TM-242 880 Page 4 Spectrum 875 Auto-Line

Spectrum 875 Auto-Line TM-242 880 Page 5

3-3. Duty Cycle And Overheating

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

Duty1 4/95 − Ref. 805 159-A

TM-242 880 Page 6 Spectrum 875 Auto-Line

1-1/2 in (38 mm)

2-5/16 in. (58 mm)

1-1/16 in. (27 mm)

2-9/64 in. (54 mm)

1-1/16 in. (27 mm)

Gear rack 32 pitch

3-5. System Dimensions, Weight, And Movement

18-1/2 in. (470

13-1/2 in. (343

Unit Dimensions And Weight

loc_2 3/96 - Ref. 805 159-A

Spectrum 875 Auto-Line TM-242 880 Page 7

. Use only clean, dry air with 90

90-120 psi . Use filter kit 300 491 or 228 926

. Hose must have a minimum

TM-242 880 Page 8 Spectrum 875 Auto-Line

. Use supplied hook and loop

3-8. Connecting And Disconnecting Work Cable

. Use supplied hook and loop

Ref. 805 161-A / Ref. 803 475-G

Spectrum 875 Auto-Line TM-242 880 Page 9

Ref. 805 275-A

3-10. Selecting a Location

loc_2 3/96 - Ref. ST-151 556 / Ref. 805 159

TM-242 880 Page 10 Spectrum 875 Auto-Line

Spectrum 875 Auto-Line TM-242 880 Page 11

208 V 3 50/60 Time-Delay 2 30 A 12 AWG 68 ft (21 m)

230 V 3 50/60 Time-Delay 2 30 A 12 AWG 83 ft (25 m)

380 V 3 50/60 Time-Delay 2 15 A 14 AWG 148 ft (45 m)

460 V 3 50/60 Time-Delay 2 15 A 14 AWG 216 ft (66 m)

575 V 3 50/60 Time-Delay 2 10 A 14 AWG 341 ft (104 m)

2 “Time-Delay” fuses are UL class “RK5” .

TM-242 880 Page 12 Spectrum 875 Auto-Line

Disconnect and lockout/tagout in-

1 Always connect green or green/

input1 20008−01 − 803 766-C / 805 159