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— answers from the official manualAnswers from the official manual.
Common questions
Common Questions
9 totalHow do I change the consumables for the Spectrum 875 torch?
Consumable kit includes items such as electrodes (electrode installation not detailed in this sample), tips, drag shield, deflector, o-ring, swirl ring, retaining cup, gouge tip, and gouge shield. Refer to manual or technical guide for specific assembly steps.
What safety glasses shading level should be used with the Spectrum 875?
Safety Glasses (shade 5 lenses) are recommended for use with the Spectrum® 875, available in black frame, blue frame, or orange frame options.
What is the piercing capacity of the Spectrum 875?
The maximum piercing capacity is approximately 7/16 inch (11 mm), while a recommended cut thickness up to 3/4 inch can be achieved with smooth and steady travel.
Can I use the Spectrum 875 on both single-phase and three-phase power?
Yes, the Spectrum® 875 Auto-Line model is designed to automatically connect to any primary input voltage from 208–575 volts single- or three-phase.
What automation kits are available for the Spectrum 875?
Automation kits can be ordered separately and include necessary components such as an internal remote harness, CNC signal cable, voltage sensing signal wire assembly, and shield sense tab.
What is the duty cycle for the Spectrum 875 when powered by a two-phase system?
Rated: 208 V–40% Duty Cycle, 230 V: 50% Duty Cycle.
Full Manual
4 pages
Issued Feb. 2019 • Index No. PC/9.8
and GougingSpectrum®
875/875 Auto-Line™
Air Plasma Cutting
Industrial Applications
Rated Input 875: 208 or 230 V, 1-phase 875 Auto-Line: 208–575 V, 1- or 3-phase Rated Output at 104°F (40°C) 875/875 Auto-Line: 1-phase: 60 A at 140 VDC,
Cutting Capability
Required Input Pressure/Flow 6.75 cfm (191 L/min.) at 90 psi minimum (621 kPa), 120 psi maximum (828 kPa)
Rated: 7/8 in. (22.2 mm) Sever: 1-1/4 in. (32 mm)
Construction Maintenance/repair Fabrication
System Net Weight 875: with 20 ft. torch: 49 lb. (22.2 kg)
Quick Specs
Process Air plasma cutting and gouging
208 V: 40% duty cycle, 230 V: 40% duty cycle
with 50 ft. torch: 58 lb. (26.3 kg)
875 Auto-Line: 3-phase: 60 A at 140 VDC, 208 V: 40% duty cycle 230–380 V: 50% duty cycle 380–575 V: 60% duty cycle
875 Auto-Line with hand-held torch:
with 20 ft. torch: 54 lb. (24.5 kg) with 50 ft. torch: 63 lb. (28.6 kg) 875 Auto-Line with machine torch: with 25 ft. torch: 56 lb. (25.4 kg) with 50 ft. torch: 63 lb. (28.6 kg)
See page 2 for 100% duty cycle ratings
875 Auto-Line™ unit automatically connects to any primary input voltage from 208–575 volts single- or three-phase, 50 or 60 Hz.
Comes complete with: XT60 hand-held torch with 20 ft. (6 m) or 50 ft. (15.2 m) cable OR XT60M long body machine torch with 25 ft. (7.6 m) or 50 ft. (15.2 m) cable — torches include a complete set of 60 A consumables Heavy-duty work clamp and flexible cable with quick connect 10 ft. (3 m) power cord Extra consumables Machine torch packages include corresponding automation kit
LVC™ line voltage compensation provides peak performance power under variable conditions (power fluctuations up to ±15 percent) for steady cuts and cleaner ending cuts.
Consumables storage compartment provides convenient access to consumables and parts.
Heavy-duty work clamp with flexible cable and quick connect.
Wind Tunnel Technology™ prevents abrasive dust and particles from damaging internal components.
Auto-Refire™ technologyprovides ultimate customer convenience by automatically controlling the pilot arc when cutting expanded metal or multiple pieces of metal. The pilot arc will switch in and out as fast as needed when cutting expanded metal and provides maximum power for cutting thicker metal—all automatically! No need for manual re-triggering which reduces user hand fatigue.
Fan-On-Demand™ cooling system operates only when needed. In dirty or dusty environments, this feature reduces the amount of airborne dust/dirt pulled through the unit.
Auto postflow calculates the length of postflow time based on the amount of cutting time to optimize consumable life and eliminate excessive air usage.
Starts without high-frequency so it will not interfere with or damage controls or computers.
Ultra-Quick Connect™ XT60 torch with an ergonomic handle to help prevent operator fatigue and a flexible cable that makes maneuvering easier (see page 4 for more detail).
Automatic air regulation. For end user convenience, the unit has no pressure gauge or manual regulator knob. The unit auto matically adjusts the air pressure to the torch for optimum cutting and gouging. No adjustments necessary.
Can be powered by Miller engine drives with generator power. See page 2 for engine drive compatibility and recommended settings.
Also available with an XT60M long body machine torch. Short body machine torch can only be ordered separately (see page 4).
Automation kits and accessories are available. See page 3 for more information.
Power source is warranted for three years, parts and labor. XT torch is warranted for one year, parts only.
Miller Electric Mfg. LLC
An ITW Welding Company 1635 West Spencer Street P.O. Box 1079 Appleton, WI 54912-1079 USA
MillerWelds.comEquipment Sales US and Canada
Phone: 866-931-9730 FAX: 800-637-2315 International Phone: 920-735-4554 International FAX: 920-735-4125
Specifications (Subject to change without notice.)
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Non-Auto-Line model is 1-phase only.
|Model|Rated Output at 104°F (40°C)*|Amps Input at Rated Output, 50/60 Hz|Max. OpenCircuit Voltage|Plasma Gas|Dimensions|Net Weight| |---|---|---|---|---|---|---| |875|1-phase: 60 A at 140 VDC, 208 V: 40% duty cycle 230 V: 50% duty cycle|208 V: 47 KVA: 9.9 230 V: 42 KW: 9.8|400 VDC
|Air or nitrogen only|H: 13.5 in
(343 mm) W: 8.75 in
(222 mm) D: 18.5 in
(470 mm)|With hand-held torch* 20 ft. (6.1 m): 49 lb. (22.2 kg) 50 ft. (15.2 m): 58 lb. (26.3 kg) With machine torch** 25 ft. (7.6 m): 51 lb. (23.1 kg)| |875 Auto-Line™|1-phase: 60 A at 140 VDC, 208 V: 40% duty cycle 230 V: 40% duty cycle 230 V: 100% duty cycle at 50 A|208 V: 47.4 KVA: 9.9 230 V: 42.2 KW: 9.7|400 VDC|Air or nitrogen only|H: 13.5 in
(343 mm) W: 8.75 in
(222 mm) D: 18.5 in
(470 mm)|With hand-held torch* 20 ft. (6.1 m): 54 lb. (24.5 kg) 50 ft. (15.2 m): 63 lb. (28.6 kg) With machine torch** 25 ft. (7.6 m): 56 lb. (25.4 kg) 50 ft. (15.2 m): 63 lb. (28.6 kg)| |875 Auto-Line™|3-phase: 60 A at 140 VDC, 208 V: 40% duty cycle 230–380 V: 50% duty cycle 380–575 V: 60% duty cycle 380–575 V: 100% duty cycle at 50 A|208 V: 27.5 KVA: 9.9 230 V: 25 KW: 9.4 380 V: 15 460 V: 12.4 575 V: 9.8|400 VDC|Air or nitrogen only|H: 13.5 in
(343 mm) W: 8.75 in
(222 mm) D: 18.5 in
(470 mm)|With hand-held torch* 20 ft. (6.1 m): 54 lb. (24.5 kg) 50 ft. (15.2 m): 63 lb. (28.6 kg) With machine torch** 25 ft. (7.6 m): 56 lb. (25.4 kg) 50 ft. (15.2 m): 63 lb. (28.6 kg)|
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
Mild Steel Cutting Capability (Thickness to scale.)
Mild Steel Recommended Cut Speed
|Thickness|Approximate Travel Speeds*| |---|---| |1/4 in. (6.4 mm)|105 ipm (2667 mm/min.)| |3/8 in. (9.5 mm)|54 ipm (1372 mm/min.)| |1/2 in. (12.7 mm)|34 ipm (864 mm/min.)| |5/8 in. (15.9 mm)|27 ipm (686 mm/min.)| |3/4 in. (19.0 mm)|18 ipm (457 mm/min.)| |7/8 in. (22.2 mm)|15 ipm (381 mm/min.)| |1 in. (25.4 mm)|10 ipm (254 mm/min.)|
Rated
7/8 in. (22.2 mm) at 15 ipm1/2 in. (12.7 mm) at 34 ipm
Note: Recommended maximum piercing capacity for hand-held and automated applications is 7/16 inch (11 mm). Maximum sever cut of 1-1/4 inches (32 mm) at 3 ipm. For aluminum and other metals with high thermal conductivity, cutting capabilities will be derated as much as 30%.
*Travel speeds are approximately 80% of maximum.
Rated cut capacity is based on traveling approximately 15 inches per minute to achieve a steady, precise cut. This is the key rating that should meet or exceed your typical cutting thickness requirements.
Control Panel
04
V REWOP ERUSSERP PUC PMET
0503
NO
| | |---| | |
V
02
06
A
FFO
EGUOGTUC
S ectrum 875P
DC Plasma Cutting System
Engine Drive Compatibility
|Engine-Driven Welder/Generator|Continuous Generator Power|Steel Quality Cut (approximate)|Spectrum Output Amp Setting (240 V full KVA adapter cord)| |---|---|---|---|
|Bobcat™ 225 and 250, 3 Phase and Trailblazer® Series|9,500 watts/10,500 watts|1/2 in.|45 A| |Big Blue® 400 Pro, 400 PipePro®, and 450 Duo CST™|10,000 watts|1/2 in.|45 A| |Big Blue® 500 Pro
|1-phase: 12,000 watts 3-phase: 20,000 watts|5/8 in.|50 A| |Big Blue® 600 Series and 800 Series|1-phase: 12,000 watts 3-phase: 20,000 watts|7/8 in.|50 A|
2
Genuine Miller
Accessories
®
Female Receptacle
Full KVA Adapter Cord 300517 Field NEMA 14-50P to NEMA 6-50R. Adapts engine drive 120/240 V plug to Spectrum® 240 V plug.
XT60 Consumable Kit 256033 Consumable kit includes 3 standard electrodes, 3 standard
tips, 1 drag shield, 1 deflector, 1 o-ring, 1 swirl ring, 1 retaining cup, 1 gouge tip, 1 gouge shield and silicone grease.
Plasma Standoff Roller Guide 253054 Helps maintain recom mended standoff distance to maximize cutting performance and improve tip life.
Plasma Circle-Cutting Guide 253055 Cut straight lines or circles up to 12-inch diameter with ease.
Suction/Magnetic Pivot Base 195979 Add this to your cutting guide for convenient attachment to all flat surfaces. The extended arm accommodates holes up to 30-inch diameter.
RTI Filter and Bracket 300491 Dryer will remove water, dirt and oil as small as one micron with 99.9 percent efficiency. Can be mounted on plasma cutter or on wall. Install as close as possible to point of air consumption.
RTI Replacement Filter Element 212771 For RTI filter 300491.
In-Line Air Filter Kit 228926 Mounts to the back of the Spectrum® 875 and 875 Auto-Line™. Includes male and female 1/4-inch NPT quick-disconnect fittings and hose for easy on/off connection. The
replaceable filter element filters to .85 microns for removal of 99.9 percent of water, dirt and oil.
In-Line Air Filter Replacement Element 228928 For in-line filter 228926.
Torch Cable Covers 239642 20 ft. (6.1 m)
Flexible Work Cable 234838 20 ft. (6.1 m) 234930 50 ft. (15.2 m) Work cable with quick
connect and heavy-duty clamp.
Safety Glasses (shade 5 lenses, recommended)
Form-fitting orbital eye coverage with increased comfort and style. Meets ANSI Z87.1 standards.
Automation Accessories
For Spectrum 875 (single-phase)
Automation Kit 301156 Kit for single-phase Spectrum 875 works with both XT60M long and short body machine torches to provide automation capabilities. Includes voltage sensing signal wire assembly for torch height control. Also includes the following components which can also be ordered separately:
External Reed Switch 190602 Provides dry contact closure for ok-to-move signal. (Not included with Automation Kit 301156.)
For Spectrum 875 Auto-Line
Automation Kit 301157 Kit for Spectrum 875 Auto-Line works with both XT60M long and short body machine torches to provide automation capabilities. Includes the following components which can also be ordered separately:
Note: Automation Kits are for upgrading hand-held torch packages to add machine torch capabilities. Machine torches are not included in Automation Kits and must be ordered separately. See back page to order machine torches.
3
XT60 and XT60M Replacement Torches and Consumables
XT60 Hand-Held Torch
XT60M Machine Torch
No-slip gripfor easy control and torch dexterity. Ergonomic designwith unique thumb guide and finger grip contours.
O-ring 263834 Swirl Ring 256028 Electrode 256026 Tip 249929 (60 A)
Trigger guard protects against inadvertent arc initiation.
Shield Sense Tab 263310 Included in Automation Kits, not included with torches.
80-degree handle provides natural arm and elbow positioning while cutting.
262643 (40 A)
Gouge Tip 249935 Retaining Cup 256029 Deflector 256030 Gouge Shield 256031 Drag Shield 256027
Robust tip front end design optimizes arc performance and tip life.
Laser-etched tip for easy identification. New retaining cup design provides increased cutting visibility and quick turn for easy consumable change. Strain relief is durable and
Machine Shield 265226
Note: Replacing drag shield with deflector offers improved arc visibility while maintaining 1/16-inch standoff. For gouging, replace the tip and drag shield with gouge tip and gouge shield. The rest of the XT60 consumables are common.
corrosion resistant, and more flexible cable has improved bend radius.
Note: The XT60M consumables are the same as the XT60 consumables, except for the machine shield.
Ordering Information
Power Source Stock No. Description Qty. Price
|Spectrum® 875 208/230 V, 1-phase
|907583
907583001
907583002
|With 20 ft. (6.1 m) XT60 hand-held torch With 50 ft. (15.2 m) XT60 hand-held torch With 25 ft. (7.6 m) XT60M long body machine torch| | | |---|---|---|---|---| |Spectrum® 875 Auto-Line™ 208–575 V, 1- or 3-phase|907584
907584001
907584002 907584004
|With 20 ft. (6.1 m) XT60 hand-held torch With 50 ft. (15.2 m) XT60 hand-held torch With 25 ft. (7.6 m) XT60M long body machine torch With 50 ft. (15.2 m) XT60M long body machine torch| | | |Replacement Torches and Consumables| |See above| | | |Accessories| | | | | |Automation Accessories| |See page 3 for kits and accessories| | | |Full KVA Adapter Cord|300517|Adapts engine drive 120/240 V plug to Spectrum
®
240 V plug| | | |XT60 Consumable Kit|256033| | | | |Plasma Standoff Roller Guide|253054| | | | |Plasma Circle-Cutting Guide|253055| | | | |Suction/Magnetic Pivot Base|195979| | | | |RTI Filter and Bracket|300491| | | | |RTI Filter Replacement Element|212771|For RTI filter 300491| | | |In-Line Air Filter Kit|228926| | | | |In-Line Air Filter Replacement Element|228928|For in-line filter 228926| | | |orch Cable Covers| |See page 3| | | |Flexible Work Cable w/Heavy-Duty Clamp
|234838 234930|20 ft. (6.1 m) cable with quick connect 50 ft. (15.2 m) cable with quick connect.| | | |Safety Glasses| |See page 3| | |
Date: Total Quoted Price:
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© 2019 Miller Electric Mfg. LLC