Miller Electric 280 NT Product specifications

For detailed specification sheets or to locate your
nearest Miller distributor, call:
w w w. M i l l e r We l d s . c o m
An Illinois Tool Works Company
©2003 Miller Electric Mfg Co.
August 2002
Table Of Contents
What Is Air Plasma?
Where Can I Use My Plasma Cutter?
Plasma — A Cut Above Oxyfuel
What To Look For In A Plasma Cutter
Operating A Plasma Arc For Cutting
Spectrum® Series Air Plasma
Cutting Systems
Spectrum® Product Specifications
Cutting Guide
Your Personal Guide To
Plasma Cutters
The air plasma arc process provides good quality
cutting at very high speeds for a much lower cost than
other cutting methods. Plasma arc also offers quality
gouging and piercing capabilities. Miller Electric Mfg. Co.,
a leading worldwide manufacturer of welding and
cutting power sources, has designed this handy
reference guide to assist you in making an informed
buying decision.
What Is Air Plasma?
Plasma arc cutting is a process where an open
arc, much like in TIG welding, can be constricted by
passing through a small nozzle, or orifice, from the
electrode to the workpiece. The gas used, typically air,
combines with an electrical current to create a high
temperature plasma arc. When placed in contact with
an electrically conductive material, the arc passes
through the metal, melting a thin area. The force of the
arc pushes the molten metal through the workpiece
and severs the material.
Where Can I Use
My Plasma Cutter?
Since the plasma process is capable of cutting
metals ranging from thin gauge aluminum to 1-1/2 in
stainless and carbon
steel, it can be used in
many applications,
including stack cutting,
beveling, shape cutting,
gouging, and piercing.
These processes are
used in such industries
as metal fabrication,
construction, maintenance, automotive
repair, and metal art
and sculpting.
Plasma —
A Cut Above Oxyfuel
While oxyfuel has been the most common method
of cutting carbon steel in the past, plasma cutting
provides numerous advantages over oxyfuel. It cuts
faster; does not require a pre-heat cycle; produces a
small and more precise kerf width (the width of the cut);
and has a smaller heat-affected zone, which prevents
the surrounding area from warping or damaging paint.
In addition, the plasma process cuts any type of
electrically conductive metal (the oxyfuel process
cannot cut stainless steel or aluminum). Plasma cutting
is a cleaner, less expensive and more convenient
method of metal cutting because clean, dry air is used
for most plasma cutting applications.
What To Look For
In A Plasma Cutter
When purchasing a plasma cutting unit there are
several features to consider before making your buying
decision. However, the performance of the machine
and its ease-of-use greatly outweigh any other factors.
A. True Blue® Warranty. For highly engineered
plasma products, you
need a manufacturer
who will stand behind
them. Miller backs all
of its power sources with the most comprehensive
coverage in the industry. The Spectrum Series has a
three-year warranty on the power source, parts and
labor. Original rectifier parts have a five-year
warranty and the ICE torches supplied with each
Spectrum have a one-year parts and labor warranty.
B. Input Power. When selecting a plasma cutter, it
is important to note the input power available where
the plasma cutting is going to take place. For an onsite solution, the Spectrum 2050 cuts up to 5/8 in. steel
when powered by any Miller generator providing
8,000 watts or more auxiliary power.
Miller also makes hooking up your plasma cutter
easy with two innovative input power technologies:
Output Voltage
Primary Input Voltage
Auto-Line™, featured exclusively in the Spectrum 2050,
allows direct connection to ANY primary power level:
50 or 60 Hz, single- or three-phase, 208 through 575 VAC.
Simply connect the power cord to the correct plug or
junction box and start cutting. Auto-Line lets you
plasma cut at any location, on any job site and in any
country without worrying about opening and manually
linking the machine or damaging the machine from
incorrect hookup.
Handles line power
fluctuations from 190 to
630 VAC during operation
without losing capacity.
(Single- or three-phase,
50 or 60 Hz)
Primary Input Voltage
Auto-Link® is featured in the Spectrum 3080. With this
technology, the machine’s circuitry senses the type
of incoming power (208 V, 230 V or 460 V) and automatically configures (or “links”) to provide the correct
output voltage. This is unlike many competitive systems,
which can only operate at a single voltage level or
require the operator to remove the cover of the machine
and manually link wires to switch between voltages.
Output Voltage
Auto-Link automatically
links to primary voltage
being used. (208 V, 230 V
or 460 V, single- or threephase)
C. Cutting Capability and Speed. Determine
the type and thickness of metal you are cutting and
your desired cutting speed. Then compare your needs
to the cutting capacity and cutting speed of the machine
you are considering. While there is no standard for
cutting speeds in the industry, Miller qualifies its cuts
by three standards:
Rated Cutting Capacity
10 inches per minute (minimum speed at which an operator
achieves a smooth, steady cut using a hand-held torch).
Maximum Quality Cutting Capacity
Good-quality cut achieved at lower speeds.
Sever Cut Capacity
Maximum cut achieved in ideal conditions.
The output power needed from a plasma cutting
machine depends primarily on the thickness and type
of material you need to cut. Cutting speed makes a
significant difference in production time and operator
comfort. For example, Miller’s Spectrum® 375 CutMate™
provides 27 amps of output power and cuts metal up
to 3/8 in. thick at approximately 8 inches per minute
while drag cutting. If a more powerful machine is
necessary, the Spectrum 1250 provides 100 amps of
cutting output and can cut metal up to 1-1/2 in. thick
at approximately 8 inches per minute.
D. Air Requirement. All Miller air plasma cutting
machines require a clean, dry air supply. Check the
required PSI needed for each machine. A filter and
dryer are recommended for all applications.
The Spectrum Thunder (see page 10) comes
complete with a built-in piston-driven compressor
which provides the exact amount of air needed for
cutting. No external air hook-up is needed.
E. Durable Torch. While the type of torch depends
on the application, it is always best to purchase a
heavy-duty torch. With each Spectrum unit, Miller
supplies a rugged ICE torch with an epoxy cup that
outlives typical ceramic parts and is virtually
unbreakable. There are two different types of torches
available: hand-held or machine-held. Miller’s
machine-held torches are designed with a 1-3/8 in.
diameter fitting that is perfect for an automation or
clamp-type setup.
The Miller ICE torch also provides a drag shield
that attaches to the cup and holds the tip 1/16 to 1/8 in.
off of the workpiece. This permits the operator to drag
the torch on the workpiece while cutting at full output,
which increases operator comfort and makes template
cutting easier. Drag shields work with the flow
dynamics of the torch to provide better cooling of the
consumable parts for longer parts life.
F. High-Frequency Starts. High frequency (HF)
can interfere with controls or computers, so look for a
plasma cutting unit that starts without high frequency
if the plasma cutter is placed near equipment with
computer controls. To avoid this problem, Miller
provides contact start without high frequency in most
of its torches.
G. Postflow Cooling Circuit. To extend the life of
consumables and reduce the cost of replacing them,
the postflow circuit cools the consumables and torch
with postflow air after you release the trigger. Miller
units are available with postflow cooling circuits.
H. User-friendly Front Panel. Look for a machine
with easy-to-use and easy-to-understand controls,
including troubleshooting diagnostic lights. In addition,
some machines provide a built-in consumable
compartment conveniently mounted on the front
panel to make consumables readily available for
replacing while cutting.
60 PSI
Status and Troubleshooting Lights
Power Switch
Output Control
Gas/Air Pressure Gauge
Gas/Air Pressure Adjustment Control
I. Portability. Weight and size are important if there
is a need for portability. There are many handportable units available that weigh less than 75 lb.,
including the Spectrum Thunder, the Spectrum 375
CutMate, the Spectrum 625, the Spectrum 2050, and
the Spectrum 3080. Miller also offers compatible
running gears for some larger, heavier machines.
J. Built-in Gas/Air Filter/Regulator. A regulator
positioned on the outside of the unit is vulnerable to
damage during transportation, but the Spectrum
Series’ regulators are protected inside the power sources.
The Spectrum Series also has a standard air connection
on the back panel for easy gas or air hook-up.
Operating A Plasma
Arc For Cutting
Begin cutting by placing the torch as close as
possible to the edge of the base metal. Pull the trigger
to initiate the preflow air; the pilot arc will then light,
followed by the cutting arc. Wait for the arc to penetrate
through the bottom of the workpiece. Start moving the
torch slowly forward, perpendicular to the workpiece.
Watch sparks leaving the bottom of the workpiece to
judge speed. If the sparks are not visible at the bottom
of the plate, you have not penetrated the metal. This is
because your travel speed is too fast or you have
insufficient output amperage.
At the end of a cut, angle the torch slightly or
pause briefly to completely finish the cut. If the system
provides a postflow circuit, the postflow air will
continue for a short period of time after the trigger is
released to cool the torch and consumable parts,
however, cutting can be resumed immediately.
To maximize cutting speeds, it is recommended
to turn your power source to full output for all
material thicknesses.
Proper Safety Procedures
Safety procedures must be closely followed in any
application of the plasma cutting machine. Be aware
of potential hazards involved with the process including,
high voltages, noise, temperatures, flammable materials,
fumes, ultraviolet radiation and molten metal. Proper
welding clothing should be worn, as well as shaded
eye protection, as specified by the manufacturer. As
with all industrial products, read the owner’s manual
for proper safety procedures.
Spectrum® Series Air Plasma
Cutting Systems
When you need rugged cutting systems, look to the
Spectrum Series, which is ideal for cutting mild steel,
stainless steel and aluminum from gauge thickness to
1-1/4 in. Portable and industrial models are available to
fit the demands of your cutting application. In addition,
many of the Miller Spectrum products provide air
plasma arc gouging and excellent piercing capabilities.
Spectrum® Thunder™
The Spectrum Thunder boasts a
built-in piston-driven air compressor
giving it an “out of the box, ready to
cut” attitude. This economical unit
is capable of a maximum cut up to
1/4 in. steel. At about 43 lb., its
portability makes it an appealing
option for HVAC, sheet metal applications,
auto body repair, and the home hobbyist.
Spectrum® 375 CutMate™
The Spectrum 375 CutMate is an
economical plasma cutting system for
work on all conductive metals including
mild steel up to 3/8 in (9.5 mm),
aluminum to 1/4 in (6.4 mm), and
stainless steel to 5/16 in (8 mm) while
drag cutting. Stand-off cutting allows
you to cut 1/2 in (13 mm) mild steel.
Solid-state design and Miller’s reliable
technology packs a lot of performance
into a very portable, 49 lb (22 kg) package.
This versatile power source adapts to your shop or
work site by operating from either 115 or 230 volt AC
power. The CutMate is ideal for maintenance, light
construction, prototyping, body shops, fabrication
and HVAC ductwork.
NEW! Spectrum® 625
The Spectrum 625 is a dependable
plasma cutting system for applications
from maintenance to construction. The
Spectrum 625 provides up to a ½" rated
cut on mild steel and up to 3/8" on
aluminum. It is equipped with two
exclusive Miller features: Wind Tunnel
Technology™which prevents abrasive
dust and particles from damaging internal components
and Fan-on-Demand™, a cooling systems that only
operates when needed. It can also be powered by any
Miller generator with generator power output of 8 kW
or more providing up to a 5/8" cut. The Spectrum 625
packs a lot of performance into a portable, 57lb unit to
handle your plasma cutting needs.
Spectrum® 2050
The Spectrum 2050 is a
portable cutting and gouging
system with Auto-Line™,a Miller
feature that accepts any type of
input power from 208 to 575 VAC.
It can also be powered by any Miller
welding generator with generator
power output of 8 KW or more—
such as the Bobcat™ 225 NT, and
the Trailblazer® 280 NT (as well as
equivalent competitive equipment). The Spectrum
2050 weighs 70 lb., provides a cutting range of 20 to
55 amps and makes a quality cut on mild or stainless
steel up to 7/8 in. It is equipped with two exclusive
Miller features: Wind Tunnel Technology™ which
prevents abrasive dust and particles from damaging
internal components, and Fan-on-Demand™, a cooling
system that only operates when needed. Both features
increase productivity and energy efficiency, but more
importantly decrease service required for maintenance.
Spectrum® 3080
The portable 74 lb. Spectrum
3080 is equipped with Auto-Link ®, a
Miller technology that senses
the type of incoming power (208 V,
230 V or 460 V) and provides
correct output voltage automatically. The Spectrum 3080, featuring
Wind Tunnel Technology™ and
Fan-on-Demand™, provides 80
amps of power to cut mild steel and stainless steel
from gauge thickness up to 1-1/4 in. and aluminum
up to 7/8 in. Providing optimum peak power, the
Spectrum 3080 power source gives high quality cutting
performance and excellent gouging characteristics.
Spectrum® 1250
Miller’s highest powered plasma
cutter, the Spectrum 1250, is a heavyduty industrial air plasma cutting and
gouging system. It also operates on
three-phase power at 80 percent duty
cycle and has a rated cutting capacity
of 1-1/4 in. on mild or stainless steel
and 1 in. on aluminum.
Cutting Guide Suction/Magnetic Base
with Extension Arm
Add this to your Cutting Guide for a convenient
attachment to all flat surfaces. The extended arm
accommodates holes up to 30 inches in diameter.
Part #195 979
Circle Cutting Guides
Cuts straight lines or circles up to 12 inches in
diameter with ease. Fits ICE-12C, 25C, 27C, 50C,
55C and 80C torches.
Part #195 981
Standoff Roller Guide
Helps maintain
recommended standoff
distance when using
extended consumables.
Part #194 883
Plastic Consumables Box
Compartments for storing additional parts and accessories.
Part #127 493
#30 A Economy Running Gear and Cord Wrap
Economical running gear with angle for easy front
panel access provides storage for gloves and tools.
(Fits Spectrum® Thunder, 375 CutMate, 2050 and
3080, XMT ® 304, Maxstar ®, and Dynasty ).
#30 Economy Running Gear
Part #195 093
Spectrum® Product Specifications
Cutting Capacity
Cutting Product Rated Output
Input Power
Max. Quality
12 amps at 110 volts DC
120 V, 1-phase, 60 Hz
1/8 in. (3.2 mm)
3/16 in. (4.2 mm) 1/4 in. (6.4 mm)
12 ga.
(2.6 mm)
43 lb.
(18 kg)
375 CutMate™
27 amps at 90 volts DC,
35% duty cycle
115 or 230 VAC, 1-phase,
60 Hz
5/16 in.(8 mm)
3/8 in. (9.5 mm)*
3/8 in. (9.5 mm)
1/2 in.(13 mm)*
1/2 in.(13 mm)
5/8 in. (16 mm)*
3/16 in.
(5 mm)
49 lb.
(22 kg)
40 amps at 140 volts DC,
50% duty cycle
208/230 VAC, 1-phase,
50/60 Hz
1/2 in.(13 mm)
5/8 in. (16 mm)
7/8 in.(22 mm)
1/4 in.
(6.4 mm)
57 lb.
(26 kg)
55 amps at 140 volts DC,
60% duty cycle for 3-phase,
50% duty cycle for 1-phase
Auto-Line accepts input voltage
from 208 to 575 VAC, 1- and
3-phase capacities, 50/60 Hz
7/8 in. (22 mm)** 1 in. (25.4 mm)** 1-1/4 in. (32 mm)** 3/8 in.
(9.5 mm)
70 lb.
(32 kg)
80 amps at 140 volts DC,
60% duty cycle for 3-phase,
40% duty cycle for 1-phase
Auto-Link 230 or 460 1- and
3-phase capacities, 50/60 Hz
7/8 in. (22 mm)
1-1/4 in. (32 mm) 1-1/2 in. (38 mm)
1/2 in.
(13 mm)
74 lb.
(33.5 kg)
50 amps at 110 volts DC,
60% duty cycle
200/230/460 or 230/460/575 VAC,
1- or 3-phase, 50 or 60 Hz models
5/8 in. (16 mm)
3/4 in. (19 mm)
3/8 in.
(9.5 mm)
147 lb.
(67 kg)
100 amps at 120 volts DC,
80% duty cycle
200/230/460 or 230/460/575 VAC,
220/380/415 VAC, 3-phase,
50/60 Hz
1-1/4 in. (32 mm) 1-1/2 in. (38 mm) 1-3/4 in. (44 mm)
1 in.
(25 mm)
410 lb.
(186 kg)
*1/16 in standoff cutting.
**Using non-shielded consumables.
1 in. (25 mm)
Rated Cutting Capacity: 10 inches per minute (minimum speed at which an operator achieves a smooth, steady cut using a hand-held torch)
Maximum Quality Cutting Capacity: good quality cut achieved at lower speeds
Sever Cut Capacity: maximum cut achieved in ideal conditions
Cutting Guide Spectrum Cutting on Engine Driven Welders
For detailed literature, a full-line catalog or
to locate your nearest distributor,
call 1-800-4-A-MILLER (1-800-426-4553)
CutMate™ 375
Engine Driven Welders
Generator Steel
Quality Cut
Legend NT
5 kW
Bobcat® 225 NT
2050*/2050 (55A)
Spectrum Output
Amp Setting
Quality Cut
27 A (240 V, full KVA plug)
8 kW
27 A (240 V, full KVA plug)
8 kW
27 A (240 V, full KVA plug)
Bobcat 250 NT
10 kW
Trailblazer® 301 G
10 kW
10 kW
Spectrum Output
Amp Setting
Quality Cut
Spectrum Output
Amp Setting
30 A (240V)
40 A (240V)
45 A
40 A (240V)
45 A
27 A (240 V, full KVA plug)
40 A (240V)
27 A (240 V, full KVA plug)
40 A (240V)
50 A
27 A (240 V, full KVA plug)
40 A (240V)
50 A
12 kW
27 A (240 V, full KVA plug)
40 A (240V)
50 A
12 kW
27 A (240 V, full KVA plug)
40 A (240V)
55 A
Big 40 CAT CC/CV
15 kW
27 A (240 V, full KVA plug)
40 A (240V)
55 A
20 kW
27 A (240 V, full KVA plug)
40 A (240V)
55 A
Trailblazer 280 NT
Trailblazer DC
Trailblazer Pro 350
PipePro CC/CV
Big Blue 402 CC/CV
*Models manufactured after (and including) serial number KJ283702.
Note: LP powered machines need to be derated 15%.
while not
For detailed specification sheets or to locate your
nearest Miller distributor, call:
w w w. M i l l e r We l d s . c o m
An Illinois Tool Works Company
©2003 Miller Electric Mfg Co.