Issued Oct. 2013 • Index No. PC/9.

6
™

Spectrum 625 X-TREME ® Air Plasma Cutting

and Gouging

Industrial Process Cutting Capability Required Input

Applications Air Plasma Cutting and Gouging Rated: 5/8 in. (16 mm) Pressure/Flow
Quick Maintenance
Rated Output Weight
6 SCFM (170 L/min.)
Light Construction at 90 PSI minimum
Specs Prototyping 40 A at 140 VDC, 50% Duty Cycle With 12-ft. hand-held torch: 21 lb. (9.5 kg) (621 kPa), 120 PSI
Body Shops 27 A at 91 VDC, 20% Duty Cycle With 20-ft. hand-held torch: 23 lb. (10.4 kg) maximum (828 kPa)
Fabrication With 25-ft. machine torch: 24 lb. (10.7 kg)

X-TREME Versatility — Auto-Line™ circuitry automatically Comes complete with:

connects to 120–240 VAC, single-phase power, 60 Hz, XT40 hand-held torch with 12-ft. (3.7 m)
without making internal changes. (Output amperage is or 20-ft. (6.1 m) cable; or XT40M long
automatically reduced to 27 A for 120 V input.) body or short body machine torch with
25-ft. (7.6 m) cable. Torches include a
X-TREME Protection — X-CASE™ complete set of 40 A consumables
provides ultimate protection and Heavy-duty work clamp and flexible
additional space for MVP adapters, cable with quick connect
consumable box, gloves, and eye X-CASE™ provides protection during
protection, etc. transport and storage
X-TREME Portability — at just 12-ft. (3.7 m) power cord with 240 V
21 pounds the shoulder strap L6-30P twist lock plug for MVP™ adapters
allows the end user to easily MVP™ adapters with 240 V, 50A (6-50P)
move from location to location. plug and 120 V, 15 A (5-15P) plug
Shoulder strap
Auto postflow calculates the Consumables box with 2 electrodes,
optimum length of postflow time 2 tips (40 A), 1 tip (30 A), drag shield
to optimize consumable life and (30 A), deflector, and air fitting
eliminate excessive air usage. Machine torch packages include 20-ft.
(6.1 m) automation control cable,
Heavy-duty work clamp shield sense tab, and a front panel with
with flexible cable built-in remote control cable receptacle
and quick connect. for remote trigger, ok-to-move signal,
and voltage sensing
LVC™ line voltage
compensation provides
peak performance power under MVP™ adapters allow connection
variable conditions (187–264 V) for to 120 or 240 V receptacles
steady cuts and cleaner ending cuts. without tools — choose the
adapter cord with the right plug
Auto-Refire™ technology controls the that fits the receptacle and connect it to the
pilot arc when cutting expanded metal NEW! Ultra-Quick Connect™ XT40 power cord with the L6-30R twist lock.
or multiple pieces of metal. The pilot torch with an ergonomic handle to
arc will switch in and out as fast as help prevent operator fatigue and a LED indicators for power, pressure, cup and
needed when cutting expanded metal flexible cable that makes maneuvering temperature allow faster troubleshooting,
and provides maximum power for easier (see page 4 for more detail). eliminating unnecessary downtime.
cutting thicker metal—all automatically!
NEW! Now available with XT40M long body or Automatic air regulation compensates for
No need for manual re-triggering.
short body machine torches (see page 4). input pressure variation to provide constant
Can be powered by any Miller engine recommended torch pressure for optimum
drive with generator power (e.g. Bobcat™) cutting performance.
or equivalent equipment. See page 3 for
Automatic gouging consumable detection
engine drive compatibility.
adjusts gas pressure to optimize performance,
eliminating the need for a manual regulator.
Power source is warranted for 3 years, parts and labor.
XT torch is warranted for 1 year, parts only.

Miller Electric Mfg. Co. Equipment Sales US and Canada MillerWelds.com

An ITW Company Phone: 866-931-9730
1635 West Spencer Street FAX: 800-637-2315
P.O. Box 1079 International Phone: 920-735-4554
Appleton, WI 54912-1079 USA International FAX: 920-735-4125
 Specifications (Subject to change without notice.)
Amps Input at Rated Plasma
Input Power Rated Output Output, 60 Hz, 1-Phase KVA KW Gas Dimensions Net Weight with Torch*
240 V 40 A at 140 VDC, 50% Duty Cycle 27 6.4 6.3 Air or H: 9 in. (229 mm) With Hand-Held Torch
Nitrogen W: 5.5 in. (140 mm) 12 ft. (3.7 m): 21 lb. (9.5 kg)
120 V (20 A) 27 A at 91 VDC, 20% Duty Cycle 26 3.0 2.9 only D: 13.25 in. (337 mm) 20 ft. (6.1 m): 23 lb. (10.5 kg)
With Machine Torch
120 V (15 A) 20 A at 88 VDC, 35% Duty Cycle 18 2.2 2.1 25 ft. (7.6 m): 24 lb. (10.7 kg)

*Add 18 lb. (8.2 kg) for shipping weight. Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

Mild Steel Cutting Capability (Thickness to scale.)

Cutting at 40 Amps (240 V) Mild Steel Recommended Cut Speeds at 40 Amps
Thickness Approximate Travel Speeds*
1/8 in. (3.2 mm) 156 IPM (3963 mm/min.)
Rated 1/4 in. (6.4 mm) 64 IPM (1626 mm/min.)
3/8 in. (9.5 mm) 36 IPM (915 mm/min.)
1/4 in. (6.4 mm) at 64 IPM 5/8 in. (15.9 mm) at 13 IPM 1/2 in. (12.7 mm) 22 IPM (559 mm/min.)
5/8 in. (15.9 mm) 13 IPM (330 mm/min.)
Note: Recommended maximum piercing capacity for hand-held applications is 5/16 inch (7.9 mm).
*Travel speeds are approximately 80% of maximum.
Maximum sever cut of 7/8 inch (22.2 mm) at approximately 5 IPM.
For aluminum and other metals with high thermal conductivity, cutting capacities may be reduced as much as 30%.

Cutting at 27 Amps (120 V) Mild Steel Recommended Cut Speeds at 27 Amps

Output amperage is automatically reduced to 27 A for 120 V input. Thickness Approximate Travel Speeds*
12 ga. (2.8 mm) 115 IPM (2921 mm/min.)
1/8 in. (3.2 mm) 88 IPM (2235 mm/min.)
3/16 in. (4.8 mm) 50 IPM (1280 mm/min.)
Rated
1/4 in. (6.4 mm) 28 IPM (711 mm/min.)
1/8 in. (3.2 mm) at 88 IPM 3/8 in. (9.5 mm) at 15 IPM 3/8 in. (9.5 mm) 15 IPM (386 mm/min.)
1/2 in. (12.7 mm) 8 IPM (203 mm/min.)
Note: Recommended maximum piercing capacity for hand-held applications is 1/8 inch (3.2 mm).
5/8 in. (15.9 mm) 5 IPM (126 mm/min.)
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
1 25 30
POWER 4

PRESSURE 5
2 20 35
CUP 120V
30A 15A
TIP 120V
20A Automation Kit Panel
TEMP
3 40A
50A
15
A 40
TIP
240V
30A

SPectrum 625 X-TREME

TM

1. Output Control
DC Plasma Cutting System
2. Status and Troubleshooting Lights
3. Range for 30 A Tip, 120 V/15 A, 5-15P MVP™ Adapter
CNC
Control 6 4. Range for 30 A Tip, 120 V/20 A, 5-20P MVP™ Adapter
Option
5. Range for 40 A Tip, 240 V/30 A/50 A, 6-50P MVP™ Adapter
MILLER ELECTRIC MFG. CO.
6. CNC Automation Receptacle. This receptacle is installed
APPLETON, WI USA on panel in optional Automation Kit (page 3) or is
factory-installed in machine torch packages (page 4).

2
 Engine Drive Compatibility
Equipment Generator Power Steel Quality Cut (Approximate) Spectrum Output Amp Setting
Bobcat 225 and 250
™
11 kW 5/8 in. 40 A (240 V full KVA adapter cord)
®
Bobcat 250 with EFI, Trailblazer
™
12 kW 5/8 in. 40 A (240 V full KVA adapter cord)
Big Blue® 400 Pro 10 kW 5/8 in. 40 A (240 V full KVA adapter cord)
Big Blue® 500 Pro 15 kW 5/8 in. 40 A (240 V full KVA adapter cord)

Genuine Miller Accessories ®

Plasma Standoff
Roller Guide Torch Cable Covers
#253 054 #239 642 20 ft. (6.1 m)
Helps maintain #231 867 25 ft. (7.6 m)
recommended
standoff distance
to maximize cutting
performance and
improve tip life. Flexible Work Cable
with Heavy-Duty Clamp
Automation Kit #301 158
#263 799 12 ft. (3.7 m)
Includes front panel, remote control cable and
#263 800 20 ft. (6.1 m)
shield sense tab. Panel has built-in remote
12- or 20-ft. cable with
control cable receptacle for remote trigger,
quick connect.
ok-to-move signal, and voltage sensing. Only
available for Spectrum® 625 X-TREME™ models Safety Glasses
with quick-connect torch feature.
#235 662 Black, shade 3.0
X-CASE™ #300 184 Plasma Circle-Cutting Guide #253 055 #235 661 Blue, shade 3.0
Sturdy case provides Cut straight lines or circles up to 12-inch #235 663 Orng, shade 3.0
ultimate protection diameter with ease. #235 658 Black, shade 5.0
for transport and #235 657 Blue, shade 5.0
storage. Also features #235 659 Orng, shade 5.0
convenient top Form-fitting orbital eye coverage with increased
carrying handle and comfort and style. Choice of black, blue or
side recessed hand grips. Store the Spectrum
orange frame. Meets ANSI Z87.1 standards.
625 X-TREME, accessories and gear in this
generous case to be ready to go at any time. Suction/Magnetic Pivot Base #195 979
Dimensions (H x W x D): 13 x 10.5 x 30.625 in. Add this to your cutting guide for convenient MVP™ Adapters
(330 x 267 x 778 mm). attachment to all flat surfaces. The extended
arm accommodates holes up to 30-inch Order from Miller Service Parts.
diameter.

Female Receptacle In-Line Air Filter Kit #228 926 Female

Mounts to the back of the Receptacle

Adapter Cord, Full KVA #300 517 Field Spectrum® 375 X-TREME™,
NEMA 14-50P to NEMA 6-50R. Adapts engine 375, 625 X-TREME™, 875 and 875 #254 328 For connection to
drive 120/240 V plug to Spectrum® 240 V plug. Auto-Line™. Includes male and 6-50P receptacle
female 1/4-inch NPT quick
(240 V/50 A). Included with
disconnect fittings and hose for
Miller Service Parts Accessories machine.
easy on/off connection. The replaceable filter
element filters to .85 microns for removal of #254 330 For connection to
The following accessories must be ordered 99.9 percent of water, dirt and oil. 5-15P receptacle
from Miller Service Parts.
(120 V/15 A). Included with
In-Line Air Filter Replacement Element
XT40 Consumable Kit machine.
#228 928
#253 521
For in-line filter #228 926. #254 331 For connection to
Consumable kit
includes 5 electrodes, 5-20P receptacle
5 tips (40 A), 3 tips (30 A), (120 V/20 A). Optional.
1 drag shield (40 A),
1 drag shield (30 A),
1 deflector, 1 o-ring, 1 swirl ring, 1 retaining
cup, 1 gouge tip (40 A), 1 gouge shield and
silicone grease.

3
 XT40 and XT40M Replacement Torches and Consumables
XT40 Hand-Held Torch XT40M Machine Torch
#260 633 12 ft. (3.7 m) #259 305 25 ft. (7.6 m), long body
#260 635 20 ft. (6.1 m) #257 462 25 ft. (7.6 m), short body

No-slip grip for easy control and torch dexterity.

O-ring #249 969
Ergonomic design with unique thumb guide and
Swirl Ring #249 931
finger grip contours.
Electrode #249 926
Trigger guard protects against inadvertent arc Shield Sense
Tip #249 928 (40 A) initiation. Tab #263 310
#249 927 (30 A) Included in
80-degree handle provides natural arm and
Gouge Tip #249 934 elbow positioning while cutting. Automation Kit,
Retaining Cup #249 932 Robust tip front end design optimizes arc not included
performance and tip life. with torches.
Deflector #249 933
Gouge Shield #249 936 New retaining cup design provides increased
Drag Shield #251 960 (40 A) cutting visibility and quick turn for easy
#249 930 (30 A) consumable change.
Strain relief is durable and Machine
Laser-etched tip for easy identification. corrosion resistant, and Shield (40 A)
exclusive flexible cable #249 937
has improved bend radius.

Note: The XT40 can be configured for cutting at either 30 A or 40 A by installing the appropriate cutting tip and drag shield. Note: The XT40M consumables are
Replacing drag shield with deflector offers improved arc visibility while maintaining 1/16-inch standoff. For gouging, replace the same as the XT40 consumables,
the tip and drag shield with gouge tip and gouge shield. The rest of the XT40 consumables are common. except for the machine shield.

Ordering Information
Power Source Stock No. Description Qty. Price
Spectrum 625 X-TREME with X-CASE
® ™ ™
#907 579 With 12-ft. (3.7 m) XT40 hand-held torch and X-CASE ™

120 – 240 VAC, 60 Hz, 1-Phase #907 579 001 With 20-ft. (6.1 m) XT40 hand-held torch and X-CASE™
#907 579 002 With 25-ft. (7.6 m) XT40M long body machine torch and X-CASE™
#907 579 003 With 25-ft. (7.6 m) XT40M short body machine torch and X-CASE™
Replacement Torches and Consumables
XT40 Hand-Held Torch (See above) Order from Miller Service Parts
XT40M Machine Torch (See above) Order from Miller Service Parts
Consumables (See above) Order from Miller Service Parts
Accessories
Automation Kit #301 158 Cable kit for automation upgrade. Only for models with quick-connect torch
X-CASE™ (only) #300 184 Carrying case for Spectrum® 625 X-TREME™
Adapter Cord, Full KVA #300 517 Adapts engine drive 120/240 V plug to Spectrum® 240 V plug
XT40 Consumable Kit #253 521 See page 3 for contents. Order from Miller Service Parts
Plasma Standoff Roller Guide #253 054 Order from Miller Service Parts
Plasma Circle-Cutting Guide #253 055 Order from Miller Service Parts
Suction/Magnetic Pivot Base #195 979 Order from Miller Service Parts
In-Line Air Filter Kit #228 926 Order from Miller Service Parts
In-Line Air Filter Replacement Element #228 928 Order from Miller Service Parts
Torch Cable Covers #239 642 20 ft. (6.1 m). Order from Miller Service Parts
#231 867 25 ft. (7.6 m)
Flexible Work Cable w/Heavy-Duty Clamp #263 799 12-ft. (3.7 m) cable with quick connect. Order from Miller Service Parts
#263 800 20-ft. (6.1 m) cable with quick connect.
Safety Glasses See page 3. Order from Miller Service Parts
MVP™ Adapters See page 3. Order from Miller Service Parts

Date: Total Quoted Price:

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© 2013 Miller Electric Mfg. Co.