Download Miller MTTF-2525W Specifications

FORM: OM-1 568
March 1988
Effective With
Millerfi
Style
No. JJ-23
MODEL
MTTF-251 2W
MTTF-2525W
FILE COPY
RETURN TO FOLDER
OWNERS
IMPORTANT
MANUAL
Read and understand the entire contents of this manual.
special emphasis on the safety material throughout the manual,
before installing, operating, or maintaining this equipment. This unit and
these instructions are for use only by persons trained and experienced in
the safe operation of welding equipment. Do not allow untrained persons
with
to
fully
PRINTED IN U.S.A.
Mfg.Co.
AM~1e,G~PUd.COmPW~Y
P0. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
maintain this unit. Contact your distributor if you
understand these instructions.
install, operate,
do not
Miller Electric
or
ADDI11ONAL COPY PRICE 35 CENTS
.
LIMITED WARRANTY
EFFECTIVE: FEBRUARY 16. 1988
supersedes
This warranty
all previous MILLER warranties and
LIMITED WARRANTY
warrants
to
-
Miller Electric
tions hereof,
Subject to the terms
Mfg. Co., Appleton,
its Distributor/Dealer that all
new
is
and condi-
Wisconsin
and unused
Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
,,~
~
.
~
have
~
normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
a
two year
Except
as
specified below, Millers warranty does
to components
f~
f~
~
7V~
~J
not result
warranty,
no
other guarantees
or warranties
expressed
or
implied.
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option (1) repair or (2) replacement
or, where authorized in
the reasonable cost of
writing by Miller in appropriate cases, (3)
repair or replacement at an authorized
Miller seivice station
(4) payment of
or
or
credit for the purchase
price (less reasonable depreciation based upon actual-use; upon
risk and expense. MILLERs
return of the goods at Customers
option of repair or replacement will be F.O.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instnict the claimant on the warranty
claim procedures to be followed.
having
from defect in
workmanship
or
material.
Miller shall be required to honor-warranty claims
Equipment in the event of failure resulting from
ranted
within the
apply
not
exclusive with
following periods from
original user:
the date of
on
a
war-
defect
delivery of Equip-
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA
T1ON AS TO PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ment to the
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
Lt~
1. Arc welders, p~er sour~, robots, and components
Load banks
2.
~
3.
Originalmainpowerrectifiers
1 year only)
(labor
All welding guns, feeder/guns
1 year
1 year
CLUDED AND DISCLAIMED BY MILLER.
3years
EXCEPT
-
~~)
4.
~
5. All other Millermatic Feeders
~
r~
f4
6.
or
1 year
repair parts, exclusive
of labor
7. Batteries
a
writing
within
60 days
thirty (30) days
of general policy only, Miller may honor claims
by the original user within the foregoing periods.
matter
submitted
..
6 months
provided that Miller is notified in
of the date of such failure.
As
(1
Replacement
90 days
and torches
~
._-,,,
-....~
J_
AS EXPRESSLY PROVIDED
MILLER
ARE
PRODUCTS
WRITING,
BY
MILLER
INTENDED
IN
FOR
PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
IN
EXPERIENCED
THE
USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
ULTIMATE
MILLERS
WARRANTIES TO, ANY CONSUMER.
.
-..
.
.
.-
.-
SECTION 1
UNSAFE PROCEDURES OR PRAC-
WARNING:
TICES
-
can cause
personal injury
serious
death.
or
SAFETY RULES
PROTECT EYES AND
1 -3.
SKIN
FROM
ARC
RAYS; PROTECT EARS FROM NOISE
Read, understand, and follow ALL of these safeLy
rules before
installing, operating,
or
servicing
this
equipment.
Be
sure
that all end
users
of this equipment, the
Arc rays from the welding process produce intense heat
and strong ultraviolet rays that can burn eyes and skin.
Noise from some processes can damage hearing.
operator and helpers, read and understand these
safety rules.
1
a welding helmet fitted with a proper filter
lens (see ANSI Z49.1 for detailed information).
a.
Wear
b.
Use
1. PREVENT ELECTRIC SHOCK
-
a.
Do not touch live electrical parts.
b.
Do not work in wet
or
c.
Wear dry insulating
gloves
damp
1
body protection.
and
screens
c.
Wear protective
d.
Always
work
areas.
protective
others from flash and
Touching live electrical parts can cause severe burns to
the body or fatal shock. Severity of electrical shock is
determined by the path and amount of current through
the body. Therefore:
-
4.
wear
barriers to protect
or
glare.
clothing and foot protection.
safety glasses
or
safety goggles in
a
area.
PREVENT FIRES AND BURNS
The hot
workpiece, hot equipment, other hot metal,
arc sparks can cause fires and burns.
spatter, and
d.
Disconnect all power before
ing this equipment.
installing
equipment when
or
servic
a.
Wear correct eye, face, and body
the work area.
b.
Allow work and
Turn off all
f.
Properly install and ground the welding power
Manual and all
source according to its Owners
codes.
applicable
c.
Do not weld
cables
d.
Watch for fire, and keep
h.
i.
Do not use worn
that are too small
or
or
in
not in use.
e.
g.
protection
damaged cables
poorly spliced.
Do not wrap cables around your
Do not touch electrode and any
or circuit at the same time.
or
equipment
to cool
before handl
ing.
near
combustible material.
a
fire extinguisher
near
by.
body.
e.
grounded object
For additional information, refer to NFPA Stan
dard 51 B, Fire Prevention in Use of Cutting and
Welding Processes, available from the National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
j.
only well-maintained equipment. Repair
replace damaged parts at once.
Use
or
1 -5. PROTECT COMPRESSED GAS CYLINDERS
PROTECTION
1 -2.
PROVIDE
AND GASES
FROM
FUMES
Since gas cylinders
are
normally part of the welding
carefully.
pro
cess, be sure to treat them
Breathing welding
to your
fumes and gases
can
be hazardous
health.
a.
Protect
compressed
gas
cylinders from excessive
heat, mechanical shocks, and
a.
Keep
b.
Use
b.
adequate ventilation
in the work
keep fumes and gases from
and the
general
work
your
area
breathing
to
If ventilation
is
Install and secure cylinders so that they cannot
fall or tip over by fastening them to a mounting
bracket, wall,
zone
or
other stationary support.
area.
c.
c.
arcs.
your head out of the fumes.
inadequate,
use
an
approved
Keep cylinders
away from any
welding
or
other
electrical circuits.
breathing device.
d.
d.
Read the Material
Safety Data Sheets (MSDSs)
the manufacturers
materials used.
and
instructions
for
Never allow
a
welding
electrode to touch any
cylinder.
any
OM-1 568
Page
1
1
6.
PROVIDE
S ITU ATIO N S
PROTECTION
-
FOR
SPECIAL
1 -8. ADDITIONAL SAFETY INFORMATION
information on safe practices for setting up
operating electric welding and cutting equipment
and on good working habits, ask your welding equip
ment supplier. The following publications, which are
available from the American Welding Society, 550
For
Do not weld or cut containers or materials which
have held or been in contact with hazardous
substances unless they are properly cleaned and
a.
inspected.
more
and
N.W. LeJuene Rd., Miami, FL 33126,
b.
Do not weld
or
cut
toxic fumes
or
gases.
painted or plated parts unless
special ventilation is provided to remove highly
are
recommend
ed to you:
a.
Safety
in
Welding and Cutting
-
AWS Z49.1
(ANSI)
Since welding
c.
pacemaker
affect pacemakers, keep all
of the work area. Have
doctor before coming near a
can
wearers out
them consult
a
b.
Recommended Safe Practices for Gas-Shielded
AWS A6.1
Arc Welding
-
welding operation.
c.
1 -7.
PROVIDE
MAINTENANCE
PROPER
EQUIPMENT
-
Improperly maintained equipment can result in poor
most importantly it can cause physical injury
or death through fires or electrical shock. Therefore:
work, but
Always have qualified personnel perform the in
stallation, troubleshooting, and maintenance
work. Do not perform any electrical work unless
you are fully qualified.
a.
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances
AWS F4.1
d.
NFPA Standard 51 B, Fire Prevention in Use of
Cutting and Welding Processes, available from
the National Fire Protection Association, Bat
terymarch Park, Quincy, MA 02269.
e.
NFPA Standard
70, National
available
the
from
National
Electrical Code,
Fire Protection
Association, Batterymarch Park, Quincy, MA
b.
a
performing any maintenance work inside
power supply, disconnect the power supply
form the electrical power
source.
c.
Maintain cables, grounding wire, connections,
power cord, and power supply in safe working
order. Do not operate any equipment in ques
tionable condition.
d.
Do not abuse any
f.
ANSI Standard Z87.1, Safe Practice for Oc
cupation and Educational Eye and Face Protec
tion, available from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
g.
OSHA Standard 29 CFR, Part 1910, Subpart Q,
Welding, Cutting, and Brazing, available from
the Superintendent of Documents, U.S. Govern
ment Printing Office, Washington, DC 20402.
h.
CSA Standard W117.2, Code
for Safety in
Welding and Cutting, available from the Cana
dian Standards Association, 178 Rexdale Blvd.,
Rexdale, Ontario, Canada M9W 1 R3.
i.
See also the Standards Booklet Index in the
welding power source Owners Manual.
accessories.
Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles,
oil or grease, corrosive atmospheres, and incle
equipment
or
ment weather.
e.
Keep all safety devices, guards, panels, and
covers in position and in good repair.
f.
Use
OM-1568
02269.
Before
equipment for its intended
modify it in any manner.
Page 2
purpose. Do not
SECTION 2
INTRODUCTION
-
Ampere Rating
Model
Duty Cycle
Size
DCEN; ACHF
250 Amperes
With Argon
Torch
Cooling
Length
Body
Method
12.5 ft.
Length:
(3.8 m)
9.5 in. (241.0 mm)
Handle Diameter:
0.75 in. (19.0 mm)
Cable
Capacity
MTTF-2512
.020 thru 5/32 in.
(0.5 thru 4.0 mm)
MTTF-2525
25 ft.
Figure 2
-
5.0
1.
1. DUTY CYCLE
The duty cycle of a welding
torch is the percentage of a ten minute period that a
torch can be operated at a given load. This torch is rated
-
1
Water
Wel ~ ht
-
-
100% duty cycle using argon shielding gas. This
that the torch can be operated at rated load con
ditions continuously.
at
means
Ship
2 lbs.
2 lbs.
(0.9 kg)
(0.9 kg)
3 lbs.
(1.4 kg)
(1.4 kg)
(0.94 1/mm)
(140 g)
oz.
Net
qt/min
Weight:
(7.6 m)
.
2
Coolant
Flow
Rate
Tungsten
at
100%
3 lbs.
Specifications
carefully followed could result
in serious
personal injury
loss of life.
or
CAUTION
statements include
and maintenance
procedures
or
carefully followed could result
or damage to this equipment.
installation, operation,
practices which if not
personal injury
in minor
~~UU~L
EXCEEDING
THE
RATED
AMPERAGE and duty cycle can result in damage
to the torch.
Do not exceed rated amperage and
stated in Figure 2-1.
duty cycle
A third
signal word, IMPORTANT highlights instruc
special emphasis to obtain the most
efficient operation of this equipment.
_______________
tions which need
3. RECEIVING
HANDLING
2
Before installing
this equipment, clean all packing material from around
the unit, and carefully inspect for any damage that may
-
2 -2. GENERAL INFORMATION AND SAFETY
A.
General
Information
presented
in this manual and
on
various
labels, tags, and plates on the unit pertains to equip
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equip
ment.
B.
Safety
The
installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
lading will be furnished by the manufacturer on request
if occasion to file claim arises.
requesting information concerning this equip
ment, it is essential that Model Description and Style
Numbers of the equipment be supplied. The style
number is located on a label under the torch handle.
When
2
This torch is specifically for
with the Gas Tungsten Arc Welding (GTAW) pro
cess. The alphanumeric model designation refers to the
M
the end of Section 1
T
Rules.
F
Safety
specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
different levels of hazard.
instructions
____________
___________
-
following:
T
Safety
4. DESCRIPTION
-
use
persons in accordance with this manual and all ap
plicable codes such as, but not limited to, those listed at
-
-
-
-
-
-
25
12
25
W
Miller
TIG/GTAW
Torch
Flex Loc Head
-
-
-
-
Ampere Rating: 250 Amperes
12.5 ft. (3.8 m) Cable
25 ft. (7.6 m) Cable
Water-Cooled
include installation, operation,
procedures or practices which if not
WARNING
____________statements
and maintenance
OM-1568 Page3
SECTION 3
-
Flex Loc Head
INSTALLATION
Short
Backc.p
Handle
0-ring
/
1
Cup
Tungsten
Electrode
r
Notches indicate
left-hand
Hose
threaded coolant
fitting
0
RequIred Consumable. and Accessories
Welding Equipment Supplier
Power Cable/Coolant-Out
Hose
Obtaln from
Power Cable
Adapter
Figure
ELECTRIC SHOCK
WARNING:
can
3
-
1. Torch
kill.
Components
5.
Do not touch live electrical parts.
Shut down we/ding power source and disconnect
employing lockout/tagging pro
installing torch.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
input
Install properly prepared tungsten electrode (see
Section 5-4) through front of collet body to posi
tion electrode tip outside cup rim. Securely
tighten backcap.
power
cedures
before
To
readjust electrode,
-
1. TORCH BODY
Torch
Body Assembly
as
follows:
1.
Install collet body into torch head
heat shield is in place.
2.
Install cup onto collet body.
Flex Loc Head
Adjust the flex
making
sure
Adjustment (Figures 3-1, 3-2,
backcap and install standard collet, slot
ted end first, through back of torch body into
collet body. If using reverse collet, install collet
with slotted end toward backcap.
bc head
as
position
within its
follows:
1.
Hold head adjusting stem in place, and rotate
head clockwise one full turn.
2.
Push head into torch
body until adjusting
stem
freely.
Remove
3.
Loosely install backcap and 0-ring (supplied
backcap) onto torch head.
OM-1568 Page 4
on
Rotate head and
in
4.
4.
application.
to
The flex bc head can be locked in any
360 degree rotation (Figure 3-1).
turns
3.
according
and 3-3)
The torch body is shipped requiring consumables and
accessories indicated in Figure 3-1: cup, collet body,
collet, power cable adapter and tungsten electrode.
Assemble torch body
backcap.
(Figure 3-1)
B.
A.
loosen
IMPORTANT As a general rule, electrode extension
should equal electrode diameter; but exact electrode ex
tension may vary
3
TB-120 888
same
Hold
adjusting
adjusting
stem in
counterclockwise until
simultaneously
angle is attained.
stem
direction until desired
place, and
secure.
rotate head
3 -3. COOLANT REQUIREMENTS
freezing conditions may be encountered, mix
coolant according to the manufacturers recommenda
tions for the ambient temperature encountered.
Where
INCORRECT COOLANT LEVEL
system and torch.
Maintain correct coolant level at all times.
CAUTION
can
_______
damage
TA-120 998
cooant
This torch is rated at a 1 qt./min (0.94 I/mm) coolant
flow rate. Changes in flow rate may effect operating
temperature of torch. Maintain proper flow
rate at all
times.
Figure 3
-
2. Clockwise Head Adjustment
3 -4. GAS HOSE CONNECTIONS
3-4)
-
The gas hose has
a
(Figures 3-1 and
5/8-18 male, right-hand fit
ting (Figure 3-1).
To install gas hose, connect gas hose fitting to gas valve
outlet. Connect gas hose (extra hose not supplied) from
gas valve inlet to regulator/flowmeter (Figure 3-4).
If power source is equipped with a gas valve, use valve
control gas postflow time, or the length of time gas
to
flows after the arc is extinguished. Insufficient gas
postf low time results in an oxidized (black) electrode
surface. If an oxidized electrode were used, the black
surface would contaminate the weld and
direction.
cause
poor
arc
TA-120 998
Figure 3
-
IMPORTANT: As
CONNECTIONS
a general rule, allow 10 seconds
posiflow time per 100 amperes of weld current
before closing valve.
Tungsten Arc
damage torch.
3 -5. POWER CABLE ADAPTER CONNECTION
(Figures 3-1 and 3-4) The power cable adapter has
both a 5/8-18 and 7/8-14 female, notched, left-hand
3. Counterclockwise Head Adjustment
_______
gas
3 -2. COOLANT HOSES
(Figures 3-1 and 3-4)
AND
CAUTION OVERHEATING
_________
Gas
Welding (GTAW) torch can
If using recirculating coolant system,
do not make
connections from the coolant system to water
valve; instead, make connections directly from the
coolant system to torch hoses.
If receptacle is available on power source, connect
coolant supply/pump power cord to power source
-
fitting (Figure 3-1).
Install power cable
The coolant-in hose has
hand
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect
a
5/8-18 male, notched, left-
To install coolant hose, connect coolant-in hose
to coolant supply outlet (Figure 3-4).
B.
employing lockout/tagging pro
installing torch.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
power
cedures
fitting (Figure 3-1).
follows (Figure 3-4):
WARNING
input
Coolant-In Hose
as
_________
receptacle.
A.
adapter
before
fitting
1.
Install power cable/coolant-out hose fitting into
power cable adapter (see Section 3-2B).
2.
Connect power cable adapter to weld output ter
minal.
Power Cable/Coolant-Out Hose
The power cable/coolant-out hose has
notched, left-hand fitting (Figure 3-1).
a
7/8-14 male,
install power cable/coolant-out hose, connect
cable/coolant-out fitting into power cable
adapter. Connect coolant hose (extra hose not sup
plied) from power cable adapter to coolant return fitting
To
power
(Figure 3-4).
OM-1568 Page 5
Regulator! Flowmeter
Torch
Coolant Return
Coolant
Out
Coolant In
4
Work
Clamp
Gas
Cylinder
TA-120 870
Figure 3
-
SECTION
ELECTRIC SHOCK
WARNING
4. GTAW Torch Connection
4
-
SEQUENCE OF OPERATION
kill.
can
With
5.
Set power
6.
Wear
Do not touch live electrical parts.
covers
and
in
handle
place
open gas
while
ARC RAYS, SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
Ventilate to keep from breathing fumes and gases.
If ventilation is inadequate,
use
approved
breathing apparatus.
HOT METAL, SPAUER, AND SLAG
and burns.
regulator/flowmeter valve closed,
cylinder valve.
4.
_________
Keep all
operating.
Diagram
can cause
for desired
welding
amperage.
dry insulating clothing and gloves and
welding helmet with proper filter lens according
to
ANSI Z49.1.
7.
Energize welding
8.
Set gas flow to desired level
power source.
(requires
open gas
valve).
fire
IMPORTANT
Watch for fire.
source
Purge
gas hose to clear hose of air,
______________
Have
a
fire
extinquisher nearby,
and know how to
moisture,
or
any other contaminants. Allow gas to flow
2 to 3 minutes
use.
Allow work and
equipment
9.
MAGNETIC FIELDS FROM HIGH CURRENTS can
affect pacemaker operation.
Wearers should consult with their doctor before
See Section 1
mation.
-
arc
torch; 5
to
6 seconds thereafter.
to cool before handl
ing.
going near
operations.
on new
welding, gouging,
or
spot welding
Safety Rules for additional safety infor
Begin welding.
4 -2. SHUTI1NG DOWN
1.
Stop welding.
a general rule, allow 10 seconds of
time
postflow
per 100 amperes of weld current
gas
before closing valve.
IMPORTANT: As
4-1. GAS TUNGSTEN ARC WELDING (GTAW)
1.
Install and connect torch according to Section 3.
2.
Make
sure
backup and all gas connections
are
2.
Turn off
3.
Turn off the
their
welding
power
shielding
source.
gas and coolant
supplies
at
sources.
securely tightened.
HIGH
CONCENTRATION
SHIELDING GAS can harm health or kill.
Shut off gas supply when not in use.
~r~ti~U~E
3.
OM-1568
Turn
Page
6
on
coolant supply.
OF
SECTION 5
-
MAINTENANCE
1. INSPECTION AND
UPKEEP
Usage and
shop conditions will determine frequency and type of
maintenance required. Perform inspections, once a
Inspect cables for breaks in insulation, and
week.
all connections
5
-
WARNING
ELECTRIC
SHOCK can kill; HOT
SURFACES can cause severe burns.
Do not touch live electrical parts.
Shut down welding power source before working
on
torch
from
welding
power source
before inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
clean and
ensure
tight. Repair
cables if insulation breaks are present.
connections at each inspection.
or
that
replace
Clean
and
tighten
5
-
PREPARING
4.
TUNGSTEN
ELECTRODES
(Figure 5-1)
injure personnel,
Inspect torch for broken areas, cracks and loose
parts; tighten, repair and replace as required.
2.
Remove grease and dirt from components, and
moisture from electrical parts and cables.
5 -2. TORCH BODY MAINTENANCE
(Figure 3-1)
ELECTRIC
SHOCK can kill; HOT
burns.
Do not touch live electrical parts.
Shut down welding power source before working
on torch.
Disconnect torch from welding power source
WARNING
_________
SURFACES
before
Allow
HOT FLYING METAL PARTICLES can
start fires, and damage equip
ment; TUNGSTEN CONTAMINATION can lower
weld quality.
Shape tungsten electrode only with properly
guarded grinder in a safe location wearing proper
face, hand, and body protection.
Do not use same wheel for any other job or the
CAUTION
_________
1.
can cause severe
inspecting, maintaining, or servicing.
cooling period before servicing.
tungsten will become contaminated.
Tungsten electrode shaping should be done on a fine
grit, hard abrasive wheel. Since tungsten is harder than
most grinding wheels, causing the tungsten to be chip
ped away rather than cut away, the grinding marks
should run lengthwise with the electrode.
For additional
quest
Arc
a
information, see your distributor or re
factory on the Gas Tungsten
handbook from
Welding (GTAW)
process.
a
week inspect condition of torch body
a
are
torch.
Disconnect
Once
Power Cable/Coolant-Out
C.
-
com
ponents.
TUNGSTEN PREPARATION: IDEAL
Replace cup, heat shield, backcap, and 0-rings if crack
ed. Maintain tight fit of torch components to ensure
good weld quality.
Stable Arc
Straight
5 -3. INSPECTING HOSES, CONNECTIONS AND
CABLES
ELECTRIC SHOCK
WARNING
can
Groun~,~~::~
Fiat (the Die. of thIs
Flat Governs
Amperage Capacity)
kill.
_________
Do not touch live electrical parts.
Shut down welding power source and disconnect
input
power employing lockout/tagging
pro
cedures before inspecting, maintaining, or ser
vicing.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
TUNGSTEN PREPARATION: WRONG
Arc Wander
Point
Radial Ground
Once
A.
a
week
inspect hoses and connections.
Figure 5
Coolant-In
Inspect coolant-in hose for breaks and clogs. Keep
nections clean and tight to prevent coolant leaks.
B.
TA-120 630
-
1.
Tungsten Preparation
con
Gas
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
OM-1 568
Page 7
Table 5
Electrode Diameter
-
1.
Tungsten Size Chart
Amperage Range
Tungsten
Electrode
Straight Polarity
.020
5-20
15-80
70-150
1/16
3/32
1/8
5/32
-
Gas Type
Electrode Positive!
Reverse Polarity
Negative/
(Green Band)
.040
Polarity
DC-Argon
DC-Argon
Pure
-
*
~
10-20
15-30
25-40
40-55
125-225
225-360
360-450
AC-Argon
Using High
Frequency
.
5-20
10-60
50-100
100-160
150-210
200-275
2% Thorium
Alloyed Tungsten
(Red Band)
*
15-40
25-85
50-160
135-235
250-400
400-500
10-20
15-30
25-40
40-55
.020
.040
*
*
15-35
*
*
20-80
1/16
3/32
1/8
5/32
*
*
*
*
*
*
*
*
50-150
130-250
225-360
300-450
.020
.040
1/16
3/32
1/8
5/32
*
15-35
20-80
50-150
130-250
225-360
300-450
Zirconium Alloyed
Tungsten
(Brown_Band)
*NOT RECOMMENDED
The figures are intended as a guide, and are a composite of recommendations
from American Welding Society and electrode manufacturers.
11
3
2
1~
-
r
I
~~22
TA-120 868
Figure
OM-1568
Page
8
A
-
Complete
Torch
Assembly
Item
No.
Miller
Stock No.
Figure
Miller
Model No.
A
Complete
7
5
5
118 526
115256
116 203
116260
tll.9 914
t119 915
FL3L
300HS
01-0009
300R
3GHS
3GHSLD
8
9
9
9
10
11
12
13
14
14
15
16
17
18
18
19
20
21
22
23
23
Torch
Quantity
Assembly
TUNGSTEN, electrode (consult your welding supply distributor)
1
2
3
4
5
6
Description
116 259
t116 258
t116 257
116260
116 204
116217
300S
300M
300L
300R
FLWB
01-0002
117585
116 267
116 268
116 512
116 266
116 269
116 232
116 233
116269
116236
118 512
ti 16 228
116231
116 230
212AH
225AH
CUP (see Figure B)
COLLET BODY (see Figure B)
3 SERIES HEAD (consisting of)
.
.
1
1
.HEATSHIELD,std
HEADADJUSTMENTSTEM(consistingof)
1
.0-RING
1
SHIELD, small dia gas lens
HEAT SHIELD, large dia gas lens
HEAT
1
1
COLLET (see Figure B)
BACKCAP, short (consisting of)
BACKCAP, medium (consisting of)
1
BACKCAP, long (consisting of)
1
.0-RING
FLEX LOC TORCH BODY
1
(consisting of)
1
1
.0-RING
HANDLE
GAS HOSE, 12-1/2 ft (consisting of)
GAS HOSE, 25 ft (consisting of)
HOSE, black 1/8 ID (order by ft as reqd.)
GAS NUT
HOSE FITTING
WATER HOSE, 12-1 /2ft (consisting of)
WATER HOSE, 25ft (consisting of)
.HOSEFITTING
.WATER NUT
HOSE, black 1/8 ID (order by ft as reqd)
POWER CABLE ADAPTER
2
POWERCABLE,12-1/2ft
POWER CABLE, 25 ft
1
1
1
1
.
2AN
3HF
212WH
225WH
3HF
2WN
.
1
.
1
1
1
1
1
.
2PCA
212PC
225PC
1
1
tOptional Parts
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 568
Page 9
Orif ce
Cup
1/4 5/16 3/8
7/16
3/16 1/4 5/16
20 -425 375- 0 4C532 1 6378 7C532 1 6384 4CB532 1 63 0
1/8 (3.2) 150-325 2 0-350 4C415 1 637 7C418 1 638 4CB415 1 6359
3/32 (2.41 10 -235 150.250 4C3 2 1 6376 7C3 2 1 6382 4CB3 2 1 6358
1/16 (1.6) 50.150 70-150 4C1 6 1 6375 7C1 6 1 6381 4CB1 6 1 8357
.040 (1.0) 10.80 15.80 4C40 1 6374 7C40 1 6380 4CB40 1 6356
.020 (0.5) 5-20 5-20 4C20 1 637 7C20 1 6379 4CB20 1)53 5
3/8 1/4
5/16 3/8 7/16
1/2 5/8
Ran., Cal er 7C.SX
~)
0
,.SUOATFRNED
Adeptr. Bode CB.XS
Cable Sho.5~Csti.s
I
Lw.
Short IS..
I
Duty Using eodn.
When
4I3HS Shield
COL.SX
etc
iie
No.
U.n Hae, Stonk
Conlic,. Coi.Unet
25%
By
R.don. R.tlng Shorn
III
in.
Power
A
Require
Standr c~i.~ 3c.x Bone., Cnli.1 lc.x
Also
Diametr
Tungsten
Torches
SELCTOR Coled
PARTS
Water
And
Cable
CONSUMABLE Compsite
Flea
8TANDRLEOHFS
L.na(h
Body
Standr ColIc, 3ce.x
~_yr~ s
SrnukNo.1625 Standr Oa.Ln. 30L.SX u.,Skield
30 HS Shield
L.nalk
30H5
U.. Haul
U..
514
115
No.
No.
ModeiNo. StockN. Mode)No. StockN. Mode) StockN.
)2C4) (2C5)
(2C4L) )2C5L( )2A4) (2A5( )2A6) )2A7)
Stock/Mde) 1639)2C 16340)2C7 ~E 16327 16329)CL
)Short( Ceramic
Range
1-7/8
~ :
1-5/32
-Long
Amperag Co)etS r) Coiet(Rnr)
337 338
328
310 311 312 313
116 116
116
116 118 116 116
Long
Body
Cup,
Col el
A)umina Log
No.
INDCATE USAGE
AREAS
,
No.
1634(2A8) 1635)2A0 Mode) StockN. Stock/Mde 1983C 1985)2AG6
Body-Shrt Cup,A)rona
(~
SHADE
(2AG7)
894
896
119
119
RECOMND
Chart
Refrnce
Coi et
Cup, 15/32
Lens
Gas
Cros
No.
Slo k bra. 0.. 3OL Use H. , Slouk
And
5/16
1/2 5/8 3/4 1/4
3/8
3/8
1/4
7/16
1/2 5/8 3/4
1/4
5/16 318 7/16
1/2
1 /16 3/4
7/8
1
1/4
5/16 3/8 7/16
1/2
Parts
1 /16
3/4
I
20 -425 375- 0
JTorche. 1/8 (3.2) 150-3251 20-350 3C418
366
~.
3C8532 116
3651
7C418 3CB418
Torch 3/32 (2.4) 10 -2351 50-2501 3C3 2 7C3 2 3CB3 2
3C532 7C532
16389702 16380I24 16324
I
I
I
1
I
Complet 1/16 (1.6) 50-150 70-150
I
J
I
16
Required .020
I
3d
0.5) 5-20 5-20
ni
3C20 1 63 7 7C20 1 6379
Lgth.(
Col et
Diametr Range (Standr) (Revrse)
Tungetn Amperage CaDet Co)lel
Cotlet.
(
(SId.
Body
Co)iet
903
119
Stock/Md.)
i3C6) )3C7) )3CS)
B
119
Figure
1 9 28
3GL40 1 9 27
3GUO 1 9 26
350
11
116
1
1 6351 1 6352
1
Ceramic Long c
Cup. 1-27/3
)3C4L1 (3C5L
)3A5i )3A6)
343 344
331
116
No.
Mode) StockN .
No.
)3CG6) )3CG7) )3CG8) )3CG1 ) )3CG12) )3CG14( 13CG16)
1635C0) 16354)C2 16345)CL 1634)C7L t1630)A4i 1632 163)A7 1634(A8 1635)A0 163)A2 Stock/Mde 1917) 19 8) 1921 1923
Ceramic .GaLens ~ 3CG1I
A)umina
Ceramic
1.27/3
3-7/3
BodySt.Lgh 1.5/8 1./8
116 116
Long
Long
Cup,
Cup,
Gas
919 920
922
119 119
119
Long
Co( et
Lens
Consumable
-
902
3GL1
I
)mmi~
ACHF DCSP No.
SModel tockN. StockN. MNo.ode) No.Stock No.
Body
119
16
3CB20 361118
Mode)No.
And
.
904
I
16
I
Cup
3GL532
3GL418
3GL32
3GL532 1 9 31
3GL418 1 9 30
3GL3 2 1 9 29
__ _ j: / _ _ _
I
7C1 6 3C81
.040 1.0) 10-80 15-80 3C40 7C40 3CB40
I
Gee
~
Dl.mre, Lone XXX 3OHSLD Shield Stels
Orit ce 3/16 1/4 5/16 3/8 7/16
Cup
High 5/32 (4.0
With
To
~
16
No.
(m ) ACHF DCSP
~
-
5/16 3/8 7/16
4GL532 1 9 10
4GL418 1 9 09
4GL3 2 1 9 08
4GL1 1 9 07
4GL40 1 9 06
4GL20 1 9 05
5/32 4.0
Siru l Coi .l 4C-X
1/4
Cup,
is
Long
924 925
119 119
1932) 193)
1935)AG7 1937(AG) Stock/Mde) l3AG8LDi~)3AG12LD
)3AG6) )3AGS) No.Mode) No.Stock No.
936
934
119
911
119
119
913
119
~
A)umina Lens Long
Cup, -Get 1-5/8
Co)iol Dia. Aium ne
Lens
Gas
BodyLg. Cup,
.
0
U,0)
-V
0
CROSS REFERENCE TO
COMPETITIVE MODEL
MILLER
STOCK NO.
MILLER
MODEL NO.
COMPETITI VE
NO.
116367
116368
116369
116370
116371
116372
116379
116380
116381
116382
116383
116384
116361
116362
116363
116364
116365
116366
116347
116348
116349
116350
116351
116352
116353
116354
116343
116344
116345
116346
116330
116331
116332
116333
116334
116335
116336
119926
119927
119928
3C20
3C40
3C116
3C332
3C418
3C532
7C20
7C40
7C116
7C332
7C418
7C532
3CB20
3CB40
3CB116
3CB332
10N21
10N22
3A5
3A6
3A7
3A8
3A10
3A12
3GL20
3GL40
3GL116
119929
119930
119931
119917
119918
119919
119920
119921
119922
119923
119924
3GL332
3GL418
3GL532
3CG4
3CG5
3CG6
3CG7
3CG8
3CG11
3CG12
3CG14
MILLER
MODEL NO.
COMPETITIVE
NO.
119925
119932
119933
119934
119935
119936
119937
119902
119903
119904
119911
119912
119913
116373
116374
116375
116376
116377
116378
3CG16
3AG4
3AG5
3AG6
3AG7
3AG8
3AG11
3GLL332
3GLL418
3GLL532
3AG8LD
3AG1OLD
3AG12LD
4C20
4C40
4C116
4C332
4C418
4C532
N/A
54N18
116355
116356
116357
116358
116359
116360
116337
116338
116339
116340
116341
116342
116326
116327
116328
116329
116310
116311
116312
116313
116314
116315
119905
119906
119907
119908
119909
119910
119893
119894
119895
119896
4CB20
4CB40
4CB116
4CB332
4CB418
4CB532
2C4
2C5
2C6
2C7
2C8
2C10
2C3L
2C4L
2C5L
2C6L
2A4
2A5
2A6
2A7
2A8
2A10
MILLER
STOCK NO.
~
3CB418
3CB532
3C3
3C4
3C5
3C6
3C7
3C8
3C10
3C12
3C4L
3C5L
3C6L
3C7L
3A4
10N23
10N24
10N25
54N20
N/A
N/A
N/A
N/A
N/A
N/A
10N29
10N30
10N31
10N32
10N28
406488
N/A
105Z43
105Z42
105Z44
105Z45
08N78
08N79
08N80
12N03
105Z60
12N02
105Z61
10N50
10N49
10N48
10N47
10N46
10N45
10N44
45V29
45V24
45V25
45V26
45V27
45V28~
54N35
54N34
54N33
54N32
54N31
54N36
N/A
N/A
4GL20
4GL40
4GL116
4GL332
4GL418
4GL532
2AG4
2AG5
2AG6
2AG7
54N17
54N16
54N15
54N14
54N19
45V64
995795
45V63
57N74
53N88
53N87
N/A
10N225
10N23S
10N24S
10N25S
N/A
N/A
17CB20
17CB20
17CB20
17CB20
N/A
13N14
13N15
13N16
13N17
13N18
13N19
796F70
796F71
796F72
796F73
13N08
13N09
13N10
13N11
13N12
13N13
N/A
N/A
N/A
N/A
N/A
N/A
53N58
53N59
53N60
53N61
OM-1 568
Page
11