Miller - Plasma Cutting Guide

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:15 AM Page 1
SIZE
M
MATTER
Big Cutting Power
in a Small Package
When Size Does Matter, look to Miller Spectrum Plasma
Cutters for the right portable package to fit your needs
MillerWelds.com/SizeMatters
For detailed specification sheets or to locate your
nearest Miller distributor, call:
1-800-4-A-Miller
(1-800-426-4553)
Or visit
Plasma
MillerWelds.com
Cutting
Guide
An Illinois Tool Works Company
©2009 Miller Electric Mfg Co.
MillerWelds.com
July 2009

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 3
Miller Makes A Full Line Of Plasma
Cutting Equipment To Meet All Your Needs.
For more information, video clips, animated
descriptions, and specification sheets for products visit
MillerWelds.com
NEW!
NEW!
Table Of Contents
Page
Spectrum® Product Specifications
1
What Is Plasma Cutting And Its Advantages?
2
What Should I Look For In A Plasma Cutter?
3
How Do I Use My Plasma Cutter?
7
Cutting Guide For Plasma Cutting
With Engine Drive Welder/Generators
8
For more information on our full line of plasma cutters,
visit MillerWelds.com

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 5
eight
Product
W
50 lb.
(22.7 kg)
56.5 lb.
(25.6 kg)
18 lb.
(8.2 kg)
21 lb.
(10 kg)
52 lb.
(24 kg)
875®
Spectrum Output
Amp Setting
45 A
45 A
50 A
60 A
Spectrum
Recommended
Generator Power*
2500 watts
4000 watts
4000 watts
8000 watts
10,000 watts
Steel
Quality Cut
1/2"
1/2"
5/8"
7/8"
Aluminum
1/16 in.
(1.6 mm)
1/4 in.
(6.4 mm)
1/4 in.
(6.4 mm)
3/8 in.
(9.5 mm)
5/8 in.
(15.9 mm)
™
Spectrum Output
Amp Setting
40 A (240 V)
40 A (240 V)
40 A (240 V)
40 A (240 V)
625 X-TREME®
Stainless Steel
1/8 in.
(3.2 mm)
3/8 in.
(9.5 mm)
3/8 in.
(9.5 mm)
1/2 in.
(13 mm)
7/8 in.
(22 mm)
Rated Cutting Thickness**
Spectrum
Steel
Quality Cut
5/8"
5/8"
5/8"
5/8"
What do you need to cut?
Mild Steel
1/8 in.
(3.2 mm)
3/8 in.
(9.5 mm)
3/8 in.
(9.5 mm)
5/8 in.
(15.9 mm)
7/8 in.
(22 mm)
elder/Generators
™
AC
A plug)
A plug)
A plug)
A plug)
AC
,
, full KV
, full KV
, full KV
, full KV
Input Power
120 V
115 or 230 V
240 V
120 V (20 A), or
120 V (15 A)
208/230 V
208–230 V
Spectrum Output
Amp Setting
27 A (240 V
27 A (240 V
27 A (240 V
27 A (240 V
375 and 375 X-TREME®
,
Spectrum
Steel
Quality Cut
3/8"
3/8"
3/8"
3/8"
Spectrum Cutting On Engine Driven W
Generator
Power
11 kW
10.5 kW
12 kW
20 kW
(optional)
elder Generator usage.
Rated Output
12 amps at 110 volts DC,
35% duty cycle
27 amps at 90 volts DC,
35% duty cycle
27 amps at 92 volts DC, 35% duty cycle
27 amps at 92 volts DC, 20% duty cycle
20 amps at 88 volts DC, 35% duty cycle
40 amps at 140 volts DC,
50% duty cycle
60 amps at 140 volts DC,
50% duty cycle for 230 V
40% duty cycle for 208 V
Product Specifications®
for more information on our full line of plasma cutters.
®
®
cing capacity is approximately one half the rated cutting thickness.
™
elders
125C
375
375
PRO 300
um
®
®
®
™
302 & 275 DC
elds.com
500 CC/CV
Spectrum
Spectrum
250, ®
225 NT
304/
®
for specific Miller W
™
™
™
Plasma
Cutting Product
Spectrum
Spectrum
Spectrum
X-TREME
NEW!
625 X-TREME
NEW!
875
MillerW
1-Phase
Cutting Guide
Engine Driven W
Bobcat
T
railblazer
Bobcat
PipePro
Big Blue
Spectr
Visit
*See pg 8
**Recommended pier
8
1

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 7
What Is Plasma Cutting?
How Do I Use
Plasma - the fourth state of matter - is an ionized
My Plasma Cutter?
gas that conducts electricity. Plasma is created by
Begin cutting by placing the torch as close as
adding energy to an electrically neutral gas. In this case,
possible to the edge of the base metal. Pull the trigger to
the gas is compressed air and the energy is electricity.
initiate the pilot arc. Move the torch near the workpiece to
The more electrical energy added, the hotter the plasma
initiate the cutting arc. Wait for the arc to penetrate
arc becomes. Plasma arc cutting machines control this
through the bottom of the workpiece. Start moving the
powerful energy by constricting the arc and forcing it
torch slowly, perpendicular to the workpiece. Watch
through a concentrated area (the nozzle). By increasing
sparks leaving the bottom of the workpiece to judge
air pressure and intensifying the arc with higher
your speed. If the sparks are not visible at the bottom of
amperage, the arc becomes hotter and more capable of
the plate, you have not penetrated the metal. This is
blasting through thicker metals and blowing away the
because your travel speed is too fast or you have
cuttings, with minimal cleanup required.
insufficient output amperage.
It is easy to learn and use the process. First time
At the end of a cut, angle the torch slightly or pause
users of the process can achieve good quality cuts after
briefly to completely finish the cut. Miller plasma systems
minutes of practice.
provide a post-flow circuit, the post-flow air will
continue for a short period of time after the trigger is
Plasma Advantages
released to cool the torch and consumable parts.
However, cutting can be resumed immediately.
Plasma provides numerous advantages over other
To maximize cutting speeds, it is recommended to
cutting processes. While there are many common
turn your power source to full output for all material
methods of cutting metal, the plasma process offers the
thicknesses.
following advantages:
• Cuts any type of electrically conductive metals
Proper Safety Procedures
including aluminum, copper, brass and stainless steel
Safety procedures must be closely followed in any
• Cuts faster — up to 130 in. per minute on 1/4 in. steel
application of a plasma cutter. Be aware of potential
• Does not require a pre-heat cycle which saves time
hazards involved with the process, including high
and is more convenient
voltages, noise, temperatures, flammable materials,
• Produces a small and more precise kerf (width of the
fumes, ultraviolet
cut) — great when precision matters
radiation, and
• Has a smaller heat affected zone which prevents the
molten metal.
area around the cut from warping and minimizes
Proper welding
paint damage
clothing should be
worn, as well as
• Provides gouging and piercing capabilities
shaded eye
Sawing or chopping can take a long time and will
protection, as
typically leave a rough edge — plasma cutting is fast,
specified by the
clean, and leaves a nice straight edge. It is also a less
manufacturer. As
expensive and more convenient method for cutting
with all industrial
than many other processes because compressed air is
products, read the
typically available in most applications via shop or
owner’s manual for
portable compressors.
proper safety
procedures.
2
7

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 9
What Should I Look For
More Power
In A Plasma Cutter?
Look for a plasma cutter that offers superb cutter
When you are considering a plasma cutter there are
performance at lower operating costs and purchase price.
several features to keep in mind. However, portability and
Many Miller plasma cutters offer similar cutting speeds
performance, ease-of-use and reliability greatly outweigh
as higher amperage competitor models by more
other factors.
efficiently using power in the cutting arc to deliver faster
cutting speeds at lower output amperages. Therefore
Portability & Performance
drawing less power from the wall.
Size and Weight
Reliability
Size and weight are important if there is a need for
moving your plasma cutter from location to location.
You want to find a plasma cutter that works in real
For example, the portable Spectrum 375 X-TREME and
world applications. At Miller, plasma units are shaked,
625 X-TREME that weigh only 18 lbs. and 21 lbs
baked, frozen and dropped. They are subjected to tests
respectively, yet are rated to cut 3/8 in. and 5/8 in.
that provide you with the security that your plasma
metal. There are many other hand-portable units
system will operate when and where you need it to.
available that weigh less than 55 lb., including Miller’s
Spectrum 125C, Spectrum 375, and Spectrum 875.
Get more PROOF at
Cutting Capability
MillerWelds.com/reliable
Determine the type and thickness of metal you need to
cut and your desired speed. Then compare your needs to
product specifications. Miller qualifies its cutting
capabilities by a rated cutting capacity at approximately
10 in. per minute. You can increase your speed by using a
machine with more amperage power. For example, a
Spectrum 375 cuts 3/8 in. steel at 10 in. per minute.; a
Spectrum 875 can cut that same material at 41 in. per
minute.
Rated Cutting Capacity
Approximately 10 in. per minute (minimum speed at which an operator
achieves a smooth, steady cut using a hand-held torch).
6
3

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 11
Duty Cycle Requirements
Input Power
Duty cycle is the number of minutes out of a 10-
Keep in mind the type of input power you have
minute period that a welder or plasma cutter can be
available or if you will be moving the plasma cutter from
operated at its rated capacity. For example, a 300-amp
job to job. All of Miller’s Spectrum units can be powered
welder with a 60% duty could operate at 300 amps for 6
from a generator with at least 10,000 watts of power,
minutes and then need to cool with its fan running for 4
such as Bobcat™ or Trailblazer®. Miller also offers
minutes. Miller rates its products, including its Spectrum
innovative input power technologies:
plasma cutters, at 104º F. Therefore, even in the hottest
environments your machine will run accurately
Auto-Line™, technology permits direct connection to
at its rated duty cycle.
almost any type of input power– 115-575 VAC (varies by
Air Requirement
product), 1- or 3-phase, 50 or 60 Hz. Simply connect the
power cord to the correct plug or junction box and start
All Miller air plasma cutting machines require a
cutting. Auto-Line technology allows the plasma power
clean, dry air supply. Check the required PSI for each
source to draw fewer amps and provides exceptional
machine. Also, a filter and dryer are recommended for all
electrical efficiency. This technology allows you to cut at
applications. Miller’s Spectrum 125C comes complete
any location, at any job site, and in any country without
with a built-in piston driven compressor which provides
the exact amount of air needed for cutting.
User-Friendly Front Panel
ne™
Look for a machine with easy-to-use controls with
uto-Li
less need for manual adjustment. Many Miller Plasma
A
Handles line power fluctuations from
systems offer intelligent design which eliminates the
190 to 630 VAC during operation
need for pressure knobs and gauges. Miller’s Automatic
without losing capacity. (Single- or
three-phase, 50 or 60 Hz)
Air Regulation , Automatic Consumable Detection and
Auto-Refire technology make set-up and cutting easy.
Miller’s exclusive multi-
Diagnostic lights that aid in troubleshooting are time
voltage plug (MVP™) on the
saving and convenient.
Spectrum 375 X-TREME
allows connection to 115 or
230 V receptacles without
tools — choose the plug that
fits the receptacle and
connect it to the power cord.
1.
True Blue® Warranty
2.
Look for a manufacturer to stand behind its
product so you have
the confidence that
your purchase will
last. Miller provides
its True Blue® 3-year
Warranty on its entire family of Spectrum plasma cutter
power sources, parts and labor. The supplied ICE torches
1. Status and Troubleshooting Lights
are backed by a one-year parts and labor guarantee.
2. Output Control
4
5

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 11
Duty Cycle Requirements
Input Power
Duty cycle is the number of minutes out of a 10-
Keep in mind the type of input power you have
minute period that a welder or plasma cutter can be
available or if you will be moving the plasma cutter from
operated at its rated capacity. For example, a 300-amp
job to job. All of Miller’s Spectrum units can be powered
welder with a 60% duty could operate at 300 amps for 6
from a generator with at least 10,000 watts of power,
minutes and then need to cool with its fan running for 4
such as Bobcat™ or Trailblazer®. Miller also offers
minutes. Miller rates its products, including its Spectrum
innovative input power technologies:
plasma cutters, at 104º F. Therefore, even in the hottest
environments your machine will run accurately
Auto-Line™, technology permits direct connection to
at its rated duty cycle.
almost any type of input power– 115-575 VAC (varies by
Air Requirement
product), 1- or 3-phase, 50 or 60 Hz. Simply connect the
power cord to the correct plug or junction box and start
All Miller air plasma cutting machines require a
cutting. Auto-Line technology allows the plasma power
clean, dry air supply. Check the required PSI for each
source to draw fewer amps and provides exceptional
machine. Also, a filter and dryer are recommended for all
electrical efficiency. This technology allows you to cut at
applications. Miller’s Spectrum 125C comes complete
any location, at any job site, and in any country without
with a built-in piston driven compressor which provides
the exact amount of air needed for cutting.
User-Friendly Front Panel
ne™
Look for a machine with easy-to-use controls with
uto-Li
less need for manual adjustment. Many Miller Plasma
A
Handles line power fluctuations from
systems offer intelligent design which eliminates the
190 to 630 VAC during operation
need for pressure knobs and gauges. Miller’s Automatic
without losing capacity. (Single- or
three-phase, 50 or 60 Hz)
Air Regulation , Automatic Consumable Detection and
Auto-Refire technology make set-up and cutting easy.
Miller’s exclusive multi-
Diagnostic lights that aid in troubleshooting are time
voltage plug (MVP™) on the
saving and convenient.
Spectrum 375 X-TREME
allows connection to 115 or
230 V receptacles without
tools — choose the plug that
fits the receptacle and
connect it to the power cord.
1.
True Blue® Warranty
2.
Look for a manufacturer to stand behind its
product so you have
the confidence that
your purchase will
last. Miller provides
its True Blue® 3-year
Warranty on its entire family of Spectrum plasma cutter
power sources, parts and labor. The supplied ICE torches
1. Status and Troubleshooting Lights
are backed by a one-year parts and labor guarantee.
2. Output Control
4
5

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 9
What Should I Look For
More Power
In A Plasma Cutter?
Look for a plasma cutter that offers superb cutter
When you are considering a plasma cutter there are
performance at lower operating costs and purchase price.
several features to keep in mind. However, portability and
Many Miller plasma cutters offer similar cutting speeds
performance, ease-of-use and reliability greatly outweigh
as higher amperage competitor models by more
other factors.
efficiently using power in the cutting arc to deliver faster
cutting speeds at lower output amperages. Therefore
Portability & Performance
drawing less power from the wall.
Size and Weight
Reliability
Size and weight are important if there is a need for
moving your plasma cutter from location to location.
You want to find a plasma cutter that works in real
For example, the portable Spectrum 375 X-TREME and
world applications. At Miller, plasma units are shaked,
625 X-TREME that weigh only 18 lbs. and 21 lbs
baked, frozen and dropped. They are subjected to tests
respecitively, yet are rated to cut 3/8 in. and 5/8 in.
that provide you with the security that your plasma
metal. There are many other hand-portable units
system will operate when and where you need it to.
available that weigh less than 55 lb., including Miller’s
Spectrum 125C, Spectrum 375, and Spectrum 875.
Get more PROOF at
Cutting Capability
MillerWelds.com/reliable
Determine the type and thickness of metal you need to
cut and your desired speed. Then compare your needs to
product specifications. Miller qualifies its cutting
capabilities by a rated cutting capacity at approximately
10 in. per minute. You can increase your speed by using a
machine with more amperage power. For example, a
Spectrum 375 cuts 3/8 in. steel at 10 in. per minute.; a
Spectrum 875 can cut that same material at 41 in. per
minute.
Rated Cutting Capacity
Approximately 10 in. per minute (minimum speed at which an operator
achieves a smooth, steady cut using a hand-held torch).
6
3

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 7
What Is Plasma Cutting?
How Do I Use
Plasma - the fourth state of matter - is an ionized
My Plasma Cutter?
gas that conducts electricity. Plasma is created by
Begin cutting by placing the torch as close as
adding energy to an electrically neutral gas. In this case,
possible to the edge of the base metal. Pull the trigger to
the gas is compressed air and the energy is electricity.
initiate the pilot arc. Move the torch near the workpiece to
The more electrical energy added, the hotter the plasma
initiate the cutting arc. Wait for the arc to penetrate
arc becomes. Plasma arc cutting machines control this
through the bottom of the workpiece. Start moving the
powerful energy by constricting the arc and forcing it
torch slowly, perpendicular to the workpiece. Watch
through a concentrated area (the nozzle). By increasing
sparks leaving the bottom of the workpiece to judge
air pressure and intensifying the arc with higher
your speed. If the sparks are not visible at the bottom of
amperage, the arc becomes hotter and more capable of
the plate, you have not penetrated the metal. This is
blasting through thicker metals and blowing away the
because your travel speed is too fast or you have
cuttings, with minimal cleanup required.
insufficient output amperage.
It is easy to learn and use the process. First time
At the end of a cut, angle the torch slightly or pause
users of the process can achieve good quality cuts after
briefly to completely finish the cut. Miller plasma systems
minutes of practice.
provide a post-flow circuit, the post-flow air will
continue for a short period of time after the trigger is
Plasma Advantages
released to cool the torch and consumable parts.
However, cutting can be resumed immediately.
Plasma provides numerous advantages over other
To maximize cutting speeds, it is recommended to
cutting processes. While there are many common
turn your power source to full output for all material
methods of cutting metal, the plasma process offers the
thicknesses.
following advantages:
• Cuts any type of electrically conductive metals
Proper Safety Procedures
including aluminum, copper, brass and stainless steel
Safety procedures must be closely followed in any
• Cuts faster — up to 130 in. per minute on 1/4 in. steel
application of a plasma cutter. Be aware of potential
• Does not require a pre-heat cycle which saves time
hazards involved with the process, including high
and is more convenient
voltages, noise, temperatures, flammable materials,
• Produces a small and more precise kerf (width of the
fumes, ultraviolet
cut) — great when precision matters
radiation, and
• Has a smaller heat affected zone which prevents the
molten metal.
area around the cut from warping and minimizes
Proper welding
paint damage
clothing should be
worn, as well as
• Provides gouging and piercing capabilities
shaded eye
Sawing or chopping can take a long time and will
protection, as
typically leave a rough edge — plasma cutting is fast,
specified by the
clean, and leaves a nice straight edge. It is also a less
manufacturer. As
expensive and more convenient method for cutting
with all industrial
than many other processes because compressed air is
products, read the
typically available in most applications via shop or
owner’s manual for
portable compressors.
proper safety
procedures.
2
7

---

A Plasma Cutting Guide 6-09:doc 8/7/2009 10:16 AM Page 5
eight
Product
W
50 lb.
(22.7 kg)
56.5 lb.
(25.6 kg)
18 lb.
(8.2 kg)
21 lb.
(10 kg)
52 lb.
(24 kg)
875®
Spectrum Output
Amp Setting
45 A
45 A
50 A
60 A
Spectrum
Recommended
Generator Power*
2500 watts
4000 watts
4000 watts
8000 watts
10,000 watts
Steel
Quality Cut
1/2"
1/2"
5/8"
7/8"
Aluminum
1/16 in.
(1.6 mm)
1/4 in.
(6.4 mm)
1/4 in.
(6.4 mm)
3/8 in.
(9.5 mm)
5/8 in.
(15.9 mm)
™
Spectrum Output
Amp Setting
40 A (240 V)
40 A (240 V)
40 A (240 V)
40 A (240 V)
625 X-TREME®
Stainless Steel
1/8 in.
(3.2 mm)
3/8 in.
(9.5 mm)
3/8 in.
(9.5 mm)
1/2 in.
(13 mm)
7/8 in.
(22 mm)
Rated Cutting Thickness**
Spectrum
Steel
Quality Cut
5/8"
5/8"
5/8"
5/8"
What do you need to cut?
Mild Steel
1/8 in.
(3.2 mm)
3/8 in.
(9.5 mm)
3/8 in.
(9.5 mm)
5/8 in.
(15.9 mm)
7/8 in.
(22 mm)
elder/Generators
™
AC
A plug)
A plug)
A plug)
A plug)
AC
,
, full KV
, full KV
, full KV
, full KV
Input Power
120 V
115 or 230 V
240 V
120 V (20 A), or
120 V (15 A)
208/230 V
208–230 V
Spectrum Output
Amp Setting
27 A (240 V
27 A (240 V
27 A (240 V
27 A (240 V
375 and 375 X-TREME®
,
Spectrum
Steel
Quality Cut
3/8"
3/8"
3/8"
3/8"
Spectrum Cutting On Engine Driven W
Generator
Power
11 kW
10.5 kW
12 kW
20 kW
(optional)
elder Generator usage.
Rated Output
12 amps at 110 volts DC,
35% duty cycle
27 amps at 90 volts DC,
35% duty cycle
27 amps at 92 volts DC, 35% duty cycle
27 amps at 92 volts DC, 20% duty cycle
20 amps at 88 volts DC, 35% duty cycle
40 amps at 140 volts DC,
50% duty cycle
60 amps at 140 volts DC,
50% duty cycle for 230 V
40% duty cycle for 208 V
Product Specifications®
for more information on our full line of plasma cutters.
®
®
cing capacity is approximately one half the rated cutting thickness.
™
elders
125C
375
375
PRO 300
um
®
®
®
™
302 & 275 DC
elds.com
500 CC/CV
Spectrum
Spectrum
250, ®
225 NT
304/
®
for specific Miller W
™
™
™
Plasma
Cutting Product
Spectrum
Spectrum
Spectrum
X-TREME
NEW!
625 X-TREME
NEW!
875
MillerW
1-Phase
Cutting Guide
Engine Driven W
Bobcat
T
railblazer
Bobcat
PipePro
Big Blue
Spectr
Visit
*See pg 8
**Recommended pier
8
1

---