Download Miller MTT-2512WV Specifications

March 1988
FORM: OM-1562
Effective With
Millerfi
OWNERS
MODEL
MTT-251 2W
MTT-2525W
MTT-251 2WV
MTT-2525WV
MANUAL
Read and understand the entire contents of both this
IMPORTANT:
manual and the power source manual used with this unit, with special
emphasis on the safety material throughout both manuals, before in-
stalling, operating,
instructions
safe
are
operation
not
maintaining
this
equipment. This unit and these
only by persons trained and experienced in the
welding equipment. Do not allow untrained persons to
for
of
install, operate,
or
or
Style No. JJ-20
use
Miller Electric
Mfg.Co.
C~r~o~
~o. Box 1079
Applelon, WI 54912 USA
Tel. 414-734-9821
maintain this unit. Contact your distributor if you do
fully understand these instructions.
PRINTED IN U.S.A.
ADDITION COPY PRICE 35 CENTS
EFFECTIVE: FEBRUARY 16, 1988
This warranty supersedes all
previous
LIMITED WARRANTY
hereof, Miller Electric
-
tions
warrants
to
MILLER warranties and is exclusive with
Subject to the terms
Mfg. Co., Appleton,
its Distributor/Dealer that all
new
and condiWisconsin
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
.
Œ~
have
~
a two
year warranty,
as specified below, Millers warranty does not apply
components having 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
Except
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 wTiting by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual-use) upon
,~t and expense. MILLERs
return of the goods as Customers
option of repair or replacen~itt wit) be F.O.B., Factory,. at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized ~ice
facility, therefore, no compensation for trarispo.latior. costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
to
wire
~
including
not result
nozzles and nozzle insulators where failure does
from detect in workmanship
or
required to honor warranty claims on warEquipment in the event of failure resulting from a detect
within the following periods from the date of delivery of Equipment to the original user:
ranted
k4
1. Arc welders, p~r sources, robots, and components
2. Load banks
3.
~
Original
main power rectifiers
(labor
1 year
4. All
4~
-
~
~,j
7.
Batteries
1 yser
1 year
or
days
1 year
repair parts, exclusive of labor
60 days
6 months
As
matter of
a
general policy only,
submitted by the original
Miller may honor claims
within the
user
WRITING,
AS EXPRESSLY PROVIDED
ARE
MILLER
PRODUCTS
PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
ULTIMATE
THE USE AND MAINTENANCE OF
EXPERIENCED
IN
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
MILLERS WARRANTiES TO, ANY CONSUMER.
foregoing periods.
-
.
,
.
,..
BY MILLER
IN
INTENDED
FOR
..
of the date of such failure.
!j~
fl
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT
90
provided that Miller is notified in writing within thirty (30) days
~
AS
3 years
5. All other Millermatic Feeders
Replacement
.
only)
welding guns, feeder/guns and torches
6.
WARRANTY, GUARANTY OR REPRESENTA
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
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
TION
material.
Miller shall be
~f
~
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED
...
.
SECTION 1
-
UNSAFE PROCEDURES OR PRAC-
WARNING
SAFETY RULES
1
3.
-
PROTECT EYES AND SKIN
FROM ARC
_________
serious personal injury or death.
Read, understand, and follow ALL of these safety
rules before installing, operating, or servicing this
TICES
can cause
equipment.
Be
sure
that all end
users
of this
equipment, the
RAYS; PROTECT EARS FROM NOISE
Arc rays from the welding process produce intense heat
and strong ultraviolet rays that can burn eyes and skin.
Noise from
some
processes
damage hearing.
can
operator and helpers, read and understand these
safety ru/es.
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
-
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
protective
a.
Do not touch live electrical parts.
b.
Do not work in wet
c.
Wear
d.
glare.
protective clothing and foot protection.
c.
Wear
d.
Always
or
damp
work
1
areas.
dry insulating gloves and body protection.
installing
Disconnect all power before
ing this equipment.
when not in
Turn off all
f.
Properly install and ground the welding power
Manual and all
source according to its Owners
applicable codes.
Do not
that
h.
i.
j.
are
equipment
use worn
or
too small
or
Do not touch electrode and any
or circuit at the same time.
or
a
arc
sparks
other hot metal,
equipment,
can cause
fires and burns.
a.
Wear correct eye, face, and body protection in
the work area.
b.
Allow work and
equipment
to
cool before handl
ing.
body.
combustible material.
c.
Do not weld
d.
Watch for fire, and keep
e.
near
a
fire extinguisher
near
For additional information, refer to NFPA Stan
dard 51 B, Fire Prevention in Use of Cutting and
Welding Processes,
grounded object
available from the National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
or
1
PROTECTION
safety goggles in
by.
only well-maintained equipment. Repair
replace damaged parts at once.
PROVIDE
AND GASES
or
4. PREVENT FIRES AND BURNS
-
The hot workpiece, hot
cables
Use
2.
safety glasses
use.
damaged cables
poorly spliced.
Do not wrap cables around your
wear
area.
servic
or
e.
g.
-
barriers to protect
or
body. Therefore:
spatter, and
1
screens
others from flash and
FROM
5. PROTECT COMPRESSED GAS CYLINDERS
-
FUMES
Since gas
cylinders
are
normally part of the welding
carefully.
pro
cess, be sure to treat them
Breathing welding fumes and gases
be hazardous
can
to your 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
If ventilation
breathing
is
zone
or
area.
inadequate,
use
an
approved
Keep cylinders away from
any
welding
or
other
electrical circuits.
device.
d.
d.
secure cylinders so that they cannot
tip over by fastening them to a mounting
bracket, wall, or other stationary support.
Install and
fall
to
c.
c.
arcs.
your head out of the fumes.
Read the Material Safety Data Sheets (MSDSs)
instructions for any
and the manufacturers
Never allow
a
welding electrode
to touch any
cylinder.
materials used.
OM-1562
Page
1
1
6.
PROVIDE
SITUATIONS
PROTECTION
-
FOR
SPECIAL
1 -8. ADDITIONAL SAFETY INFORMATION
For
a.
Do not weld or cut containers or materials which
have held or been in contact with hazardous
substances unless they are properly cleaned and
inspected.
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
more
and
N.W. LeJuene Rd., Miami, FL 33126,
b.
Do not weld or cut painted or plated parts unless
special ventilation is provided to remove highly
toxic fumes or gases.
are
recommend
ed to you:
a.
Safety
in
Welding and Cutting
-
AWS Z49.1
(ANSI)
c.
Since
welding
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.
PROVIDE
MAINTENANCE
1
-7.
Improperly
work, but
or
death
PROPER
EQUIPMENT
-
maintained equipment can result in poor
importantly it can cause physical injury
most
through
fires
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
Cutting
electrical shock. Therefore:
or
and
Prevention in Use of
Welding Processes, available from
Fire Protection Association, Bat
terymarch Park, Quincy, MA 02269.
the- National
a.
Always have qualified personnel perform the in
stallation,
troubleshooting, and maintenance
perform any electrical work unless
fully qualified.
work. Do not
you
are
e.
NFPA Standard 70, National Electrical Code,
available from the National Fire Protection
Association, Batterymarch Park, Quincy, MA
b.
Before
performing
power supply,
form the electrical power
a
c.
02269.
any maintenance work inside
disconnect the power supply
source.
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
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
equipment
accessories.
Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles,
oil or grease, corrosive atmospheres, and incle
ment weather.
or
ment
h.
Printing Office, Washington, DC 20402.
CSA Standard W117.2, Code
Welding
e.
Keep all safety devices, guards, panels, and
covers in position and in good repair.
f.
Use
equipment for its intended
modify it in any manner.
OM-1 562 Page 2
purpose. Do not
and
Cutting,
for Safety in
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.
SECTION 2
-
INTRODUCTION
Ampere Rating
at
Tungsten
100% Duty Cycle
Size
Cable
Torch
Cooling
DCEN; ACHF
Capacity
Length
Body
Method
Model
.020 thru
1/8 in.
250 Amperes
With Argon
MTT2525W
12.5 ft.
(190.5 mm)
(3.8 m)
Handle Diameter:
25 ft.
(7.6 ml
MTT2525WV
Figure 2
-
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
at 100% duty cycle using argon shielding gas. This
means that the torch can be operated at rated load con
2
-
-
ditions
Water
0.75 in.
(19.0 mm)
(0.5 thru
3.2 mm)
continuously.
Weight
Net
S h I p
7.5 in.
Length:
MTT2512W
MTT2512WV
Coolant
Flow
Rate
2.5
Weight:
1
1.5 lbs.
(0.7 kg)
2 lbs.
(0.9 kg)
2.5 lbs.
(1.1 kg)
3 lbs.
(1.4 kg)
qt/min
(0.94 1/mm
oz.
(70.9 g)
Specifications
statements include
I~Ii1 : II ~
and maintenance
procedures
carefully followed could result
or
in
installation, operation,
practices which if not
serious personal injury
loss of life.
or
THE
RATED
CAUTION statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
result in
damage
or
____________
~
EXCEEDING
AMPERAGE and
duty cycle
can
damage
to
this equipment.
to the torch.
Do not exceed rated amperage and
stated in Figure 2-1.
S
duty cycle
signal word, IMPORTANT highlights instruc
tions which need special emphasis to obtain the most
efficient operation of this equipment.
A third
2 -2. GENERAL INFORMATION AND SAFETY
RECEIVING-HANDLING
Before installing
equipment, clean all packing material from around
the unit, and carefully inspect for any damage that may
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 re
2
A.
General
Information
3.
-
-
this
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-
quest if occasion
to
file claim arises.
ment.
When
B.
The
Safety
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
persons in accordance with this manual and all ap
plicable codes such as, but not limited to, those listed at
the end of Section 1
requesting information concerning
this
equip
ment, it is essential that Model Description and Style
-
Safety Rules.
2
different levels of hazard.
with the Gas
cess.
The
-
This torch is specifically for
Arc Welding (GTAW) pro
Tungsten
alphanumeric model designation refers
to the
following:
M
T
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
on a
4. DESCRIPTION
-
use
be supplied. The style
label under the torch handle.
equipment
Numbers of the
number is located
T
-
25
TIG/GTAW
Torch
Ampere Rating: 250 Amperes
-
12
25
W
V
Miller
-
-
-
-
-
-
12.5 ft. (3.8 m) Cable
25 ft. (7.6 m) Cable
Water-Cooled
Gas Valve
OM-1562
Page 3
SECTION 3
-
INSTALLATION
Medium
0-ring
Backcap
~
Gas Valve
(If Applicable)
Heat Shield
~ 0-ring
Hose
left-hand threaded
Consumables and Accessories
from Welding Equipment Supplier
Required
Obtain
coolant
TA-120 502
fittings
Power Cable/Coolant-Out
Hose
Figure 3
ELECTRIC SHOCK
can
-
1. Torch
kill.
Components
CAUTION OVERHEATING
Gas
Tungsten
Arc
_________
Do not touch five electrical parts.
Shut down welding power source and disconnect
Welding (GTAW) torch can damage torch.
If using recirculating coolant system, do not make
pro
connections from the coolant system to water
valve; instead, make connections directly from the
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.
coolant system to torch hoses.
If receptacle is available on power source, connect
coolant supply/pump power cord to power source
input power employing
cedures
3
-
before
lockout/tagging
installing
1. TORCH BODY
torch.
The torch body
consumables and accessories in
(Figure 3-1)
dicated in
1.
Install collet
body into torch body making
place.
Install cup onto collet
The coolant-in hose has
hand
4.
5.
5/8-18 male, notched, left-
To install coolant hose, connect coolant-in hose
supply outlet (Figures 3-2 and 3-3).
sure
B.
fitting
body.
Power Cable/Coolant-Out Hose
The power cable/coolant-out hose has
left-hand
3.
a
fitting (Figure 3-1).
to coolant
heat shield is in
2.
Coolant-In Hose
A.
-
shipped requiring
Figure 3-1: cup, collet body, collet, power
cable adapter, and tungsten electrode. Assemble torch
body as follows:
is
receptacle.
Remove backcap and install collet, slotted end
first, through back of torch body into collet
body.
Loosely install backcap and 0-ring (supplied
backcap) onto torch body.
on
properly prepared tungsten electrode (see
Section 5-4) through front of collet body to posi
tion electrode tip outside cup rim. Securely
Install
tighten backcap.
a general rule, electrode extension
equal electrode diameter; exact electrode exten
7/8-14 male,
Install coolant-out/power hose fitting into power cable
adapter. Connect a suitable length of coolant hose (not
supplied) from power cable adapter to coolant supply
return
fitting.
3 -3. COOLANT REQUIREMENTS
Where
coolant
freezing conditions may be encountered, mix
according to the manufacturers recommenda
tions for the ambient temperature encountered.
CAUTION
To readjust electrode, loosen backcap.
a
fitting (Figure 3-1).
INCORRECT COOLANT
LEVEL
can
_________
damage coolant system and torch.
Maintain correct coolant level at all times.
IMPORTANT As
should
sion may vary
according
to
application.
3 -2. COOLANT
HOSES
(Figures 3-1, 3-2,
and 3-3)
OM-1562 Page 4
AND
CONNECTIONS
This torch is rated at a 1 qt./min (0.94 1/mm) coolant
flow rate. Changes in flow rate may effect operating
temperature of torch. Maintain proper flow rate at all
times.
Regulator! Flowmeter
Recirculating
Coolant
Supply
Work
Clamp
Gas
TA-120 503
Figure
3
-
2. GTAW Torch Connection
Diagram For Models With Gas Valve
Regulator/Flowmeter
Torch
Work
Ciamp
TA120
Figure 3
3 -4. GAS
VALVE (If
A.
HOSE
-
3. GTAW Torch Connection
CONNECTIONS
AND
GAS
applicable) (Figures 3-1. 3-2, and 3-3)
Diagram For Models Without Gas Valve
The gas valve allows gas flow control at the torch. A
one-half turn counterclockwise opens the gas valve,
and a one-half turn clockwise closes the valve.
Gas Hose And Connection
The gas hose has
The gas valve allows control of gas postflow time, or
length of time gas flows after the arc is extinguish
the
a
5/8-18 male,
right-hand fitting
(Figure 3-1).
If torch includes a gas valve, connect gas hose fitting to
regulator/flowmeter outlet (Figure 3-2). An extra hose
may be required to make connection.
If torch is without gas valve, connect gas hose fitting to
gas valve outlet. Connect gas hose (extra hose not sup
plied) from gas valve inlet to regulator/flowmeter
(Figure 3-3).
ed.
Insufficient gas postflow results in
Torch Gas Valve
oxidized
IMPORTANT As
a
general rule, allow 10 seconds of
gas postflow time per 100 amperes of weld current
before closing valve.
3
-
CABLE ADAPTER CONNECTION
and 3-3)
The power cable adapter
5/8-18 and 7/8-14 female, notched, left-
5. POWER
(Figures 3-1, 3-2,
Operation (If Applicable)
an
(black) electrode surface. If an oxidized electrode were
used, the black surface would contaminate the weld
and cause poor arc direction.
has both
B.
603
hand
a
-
fitting (Figure 3-1).
OM-1 562 PageS
Install power cable adapter
as
follows (Figures 3-2 and
3-3):
ELECTRIC SHOCK
WARNING
kill; MOVING
can
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.
_________
PARTS
can cause
serious
injury.
1.
Install power cable/coolant-out hose fitting into
power cable adapter (see Section 3-2).
2.
Connect power cable
minal.
Do not touch five electrical parts.
Shut down welding power source and disconnect
input
power
cedures
employing lockout/tagging
installing torch.
pro
before
SECTION 4
ELECTRIC SHOCK
WARNING
can
all
Keep
covers
and
kill.
in
place
operating.
health.
Ventilate to keep from breathing fumes and gases.
If ventilation
is inadequate,
use
approved
breathing apparatus.
HOT METAL, SPATTER, AND SLAG can cause fire
and burns.
Watch for fire.
use
fire ext/n quisher
nearby,
and know how to
it.
Allow work and
equipment
to
regulator/flowmeter valve closed, open gas
cylinder valve.
With
5.
Set power
6.
Wear 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
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
a
ter
while
ARC RAYS, SPARKS, AND HOT SURFACES can
burn eyes and skin; NOISE can damage hearing.
Have
output
4.
parts.
handle
to weld
SEQUENCE OF OPERATION
-
_________
Do not touch five electrical
adapter
source
for desired
power
welding
amperage.
source.
(requires
open gas
valve).
Purge gas hose to c/ear hose of air,
any other contaminants. Allow gas to flow
2 to 3 minutes on new torch; 5 to 6 seconds thereafter.
Il~Ils]:Ifith~l~
moisture,
or
cool before handl
ing.
9.
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
Begin welding.
can
4 -2. SHUTTING DOWN
Wearers should consult with their doctor before
going
near arc
welding, gouging,
or
spot
welding
1.
Stop welding.
operations.
See Section 1
-
Safety Rules for additional safety infor
mation.
4
-
As a genera/rule, allow 10 seconds of
gas post/low time per 100 amperes of weld current
before closing valve.
1. GAS TUNGSTEN ARC WELDING (GTAW)
1.
Install and connect torch
2.
Make
sure
according
to
2.
Turn off
3.
Turn off the
welding
power
source.
Section 3.
backcap and all gas connections
are
their
shielding gas and coolant supplies
at
sources.
securely tightened.
CONCENTRATION
HIGH
SHIELDING GAS can harm health or kill.
Shut off gas supply when not in use.
~
3.
Turn
OM-1562 Page 6
on
coolant
supply.
OF.
SECTION 5
-
MAINTENANCE
INSPECTION AND UPKEEP
Usage and
shop conditions will determine frequency and type of
maintenance required. Perform inspections once a
5
-
1.
Disconnect torch
from we/ding power source
inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
-
before
week.
Once
SHOCK
ELECTRIC
WARNING
can
HOT
kill;
week
a
inspect condition of torch body
com
ponents.
_________
SURFACES
can cause severe
burns.
Do not touch live electrical parts.
Shut down
on torch.
welding power source before working
from welding power source
maintaining, or servicing.
cooling period before servicing.
Disconnect torch
before inspecting,
Allow
1.
2.
a
Inspect torch for broken areas, cracks and loose
parts; tighten, repair and replace as required.
Replace cup, heat shield, backcap, and 0-rings if crack
ed. Maintain tight fit of torch components to ensure
good weld quality.
5 -3. INSPECTING HOSES. CONNECTIONS AND
CABLES
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect
WARNING
_________
Remove grease and dirt from components, and
moisture from electrical parts and cables.
5 -2. TORCH BODY MAINTENANCE
ELECTRIC
WARNING
SHOCK
can
(Figure 3-1)
kill;
HOT
_________
SURFACES
can cause severe
burns.
input
power
cedures
employing lockout/tagging pro
inspecting, maintaining, or ser
before
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.
Do not touch live electrical parts.
Shut down
on torch.
we/ding
power
source
Table 5
Electrode Diameter
Tungsten
Pure
(Green Band)
working
before
-
1.
Once
Tungsten Size
Amperage Range
DC-Argon
Negative/
Straight Polarity
Electrode
a
inspect hoses
week
and connections.
Chart
-
Polarity
-
Gas T ype
DC-Argon
Electrode Positive/
Polarity
Reverse
AC-Argon
Using High
Frequency
.020
5-20
*
.040
15-80
*
1/16
3/32
70-150
125-225
10-20
50-100
15-30
100-160
1/8
225-360
25-40
150-210
5-20
10-60
2% Thorium
Alloyed Tungsten
(Red Band)
.020
15-40
*
.040
25-85
*
1/16
50-160
10-20
3/32
1/8
135-235
15-30
250-400
25-40
15-35
20-80
50-150
130-250
225-360
Zirconium
Alloyed
Tungsten
(Brown Band)
020
*
*
15-35
040
*
*
20-80
1/16
*
*
3/32
1/8
*
50-150
130-250
*
225-360
*NOT RECOMMENDED
figures are intended as a guide and are a composite
Welding Society (AWS) and electrode manufacturers.
The
of recommendations from American
OM-1562
Page
7
Coolant-In
A.
Inspect coolant-in hose for breaks and clogs. Keep
tight to prevent coolant leaks.
con
nections clean and
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.
Gas
B.
For additional
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
quest
Arc
Inspect cables for breaks in insulation, and ensure that
all connections are clean and tight. Repair or replace
cables if insulation breaks are present. Clean and
tighten connections
5
-
4.
at
PREPARING
Welding (GTAW)
process.
IDEAL
Stable Arc.,.
Straight
each inspection.
TUNGSTEN
information, see your distributor or re
factory on the Gas Tungsten
handbook from
TUNGSTEN PREPARATION:
Power Cable/Coolant-Out
C.
a
Ground
Fiat (the Die, of this
Fiat Governs
ELECTRODES
Amperage Capacity)
0
(Figure 5-1)
TUNGSTEN PREPARATION:
HOT FLYING METAL PARTICLES can
injure personnel, start fires, and damage equip
ment; TUNGSTEN CONTAMINATION can lower
CAUTION
WRONG
_________
Arc Wander
~
weld quality.
Point
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
____1:::::~~~:::::::::::::
RadIal Ground
Figure 5
tungsten will become contaminated.
-
1.
TA-120 630
Tungsten Preparation
9
1
1
17 & 18
22
Figure A
OM-1562 Page 8
-
Complete Torch Assembly
TA-120 502
Item
Miller
No.
Stock No.
Figure
Miller
Model No.
Description
Quantity
Complete Torch Assembly
A
1
TUNGSTEN, electrode (consult your welding supply distributor)
2
3
CUP (see Figure B)
COLLET BODY (see Figure B)
TORCH BODY, W/ heat shield (consisting of)
TORCH BODY, wlheat shield & valve (consisting of)
VALVE KNOB, wlo-rings (consisting of)
..O-RING
2
4
4
5
6
7
116 223
116 222
116 279
116254
116221
7
300VK
100R
200HS
2GHS
8
9
116 225
200M
9
ti 16 226
9
t116 224
116227
200S
200L
10
200R
12
117585
118 516
116 205
116 206
13
13
116 232
116 233
14
118 512
15
16
116 236
2WN
116 269
116 231
3HF
212PC
18
116 230
116 267
225 PC
212AH
18
19
116 268
225AH
116 269
3HF
2AN
11
11
12
17
17
20
116 266
21
118 512
22
ti 16 228
212TF
225TF
212WH
225WH
.
1
1
.HEATSHIELD,std
1
HEATSHIELD,gaslens
COLLET (see Figure B)
BACK CAP, long (consisting of)
BACK CAP, short (consisting of)
BACK CAP, medium (consisting of)
1
.0-RING
HANDLE
1
1
1
1
1
HANDLE, models w/valve
CABLE, Tn-Flex 12-1/2 ft (consisting of)
1
1
CABLE, Tn-Flex 25 ft (consisting of)
.WATER HOSE, 12-1 /2ft (consisting of)
WATER HOSE, 25 ft (consisting of)
HOSE, black 1/8 ID (order by ft as required)
.
.
.
WATER NUT
HOSE FITTING
.
.
.
.
.
.
.
1
1
1
1
POWERCABLE,w/fittingsl2-1/2ft
POWER CABLE, wlfittings 25 ft
GAS HOSE, 12-1/2 ft (consisting of)
GAS HOSE, 25 ft (consisting of)
1
1
1
HOSE FITTING
.
GAS NUT
HOSE, black 1/8 LD (order by ft
POWER CABLE ADAPTER
.
1
1
.
.
.
2PCA
1
1
1
.
.
as
required)
1
tOptional Parts
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1562
Page 9
TO
REF NC
CROS
COMPETIV
MODEL
NO.
13N20 13N21 13N2 13N23 13N24 N/A N/A N/A N/A N/A 13N25 13N26 13N27 13N28 13N29 45V41 45V42 45V43 45V4 45V45 13N14 13N15 13N16 13N17 13N18 13N19 796F70 796F71 796F72 796F73 13N08 13N09 13N10 13N1 13N12 13N13 53N58 53N59 53N60 53N61
NO.
COMPETIV
MIL ER MODEL 2C20 2C40 2C1 6 2C3 2 2C418 6C20 6C40 6C1 6 6C3 2 6C418 2CB20 2CB40 2CB1 6 2CB3 2 2CB418 2GL20 2GL40 2GL1 6 2GL3 2 2GL418 2C4 2C5 2C6 2C7 2C8 2C10 2C3L 2C4L 2C5L 2C6L 2A4 2A5 2A6 2A7 2A8 2A10 2AG4 2AG5 2AG6 2AG7
NO.
MIL ER STOCK 1 6316 1 6317 1 6318 1 6319 1 6320 1 98 1 98 9 1 98 0 1 98 1 1 98 2 1 6321 1 632 1 632 1 6324 1 6325 1 98 7 1 98 1 98 9 1 9 0 907119 1 63 7 1 63 8 1 63 9 1 6340 1 6341 1 6342 1 6326 1 6327 1 6328 1 6329 1 6310 1 631 1 6312 1 631 1 6314 1 6315 1 98 3 894119 1 98 5 1 98 6
With
Col et Series
S
t
a
n
d
r
1 62 1
C
o
l
e
t
Heat
Body
20 H5 Stand r Stock Stand r Col et S2CBeries
Shield Body
INDCATE USAGE
2C
No.
RSHADE ECOMND
AREAS
tI~
Rev rse Col et Series
With
Lens Body Series
Heat
Shield
6C
Chart
Col et 120
Lens
No.
Refrnce
2GHS Gas Stock
Gas Col et 2GL
Use
Body 529
Use
Cros
Orif ce 1/4 5/16
Cup
3/8
7/16
3/16
1/2 5/8
1/4
5/16
3/8
5/16
1/4
3/8
7/16
1/2
5/8
L1~
7/16
3/B
Parts
I
150-325 20-350 2C418 1 6320 6C418 1 98 2 2CB418 1 6325
3/32 (2.4) 10 -235 150-250 2C3 2 1 6319 6C3 2 1 98 1 2CB3 2 1 6324
torch(
SELCTOR complet 1/16 (1.6) 50-150 70-150 2C16 16318 6C16 1980 2CB1 1632
PARTS required .040 (1.0) 10-80 15-80 2C40 1 6317 6C40 1 98 9 2CB40 1 632
ad pter .020 )~.5) 5-20 5-20 2C20 1 6316 6C20 1 98 2CB20 1 6321
cable
(3.2)
4
16
:.
j
I
~.
to
CONSUMABLE
power (m ) ACHF DCSP
in
end
cup
ModelN. StockN. ModelNo. Stock Mode) StockN.
(Note:
Diametr Range
Tungsten Amperag
Body
CoIlet(Sandr) Co)let(Rvrs
Col et
,fl
r
:~ .:~
No. No. No.
gas
body,
col(et
co(iet.
~
(2C4) (2C5)
y
(2C8)
(2C10)
No.
(2C4L)
No.
:1wti: ju~c ~ 2GL418 1 9 01
2GL3 2 1 9 0
2GL1 6 1 98 9
2GL40 1 98
2GL20 1 98 7
(2A4) (2A5l
(2A10)
310 311
116 116
315
116
ModelNo. StockN.
j
Cup Long
0
C
e
r
a
m
i
c
1
5
/
3
2
Standr
2C8andlOcups
Cup Long
Long
1 /8
Cup
Ceramic 17/8 ~ Alumina
.
C
GasLenColtBdy
~
J
Consumable
-
B
~..
Figure
..
L,
~
No,
::2::: (2AG6) (2AG7)
Stock/Mde) 1637 1639(2C) 16340(2C7) 16341 16342 Stock/Mdel 1632)CL 16327 16328(C5L) 16329(CL) Stock/Mdel 1632(A) 163(2A7) 1634(2A8) Stock/Mdel ~::::
338
116
and
Lens Cup
Gas
~
For
Alumina
895 896
119 119
0