Download Miller MTTF-1512V Specifications

March 1988
FORM: OM-1 563
Effective With Style No. JJ-23
Millerfi
MODEL
MTTF-1512
MTTF-1 525
MTTF-1512V
MTTF-1 525V
ALE COPY
RETURN TO FOLDER
OWNERS
IMPORTANT
MANUAL
Read and understand the entire contents of both this
manual and the power source manual used with this unit, with special
emphasis on the safety material throughout both manuals, before in-
stalling, operating,
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 to
install, operate,
not
fully
PRINTED IN U.S.A.
or
or
Miller Electric
Mfg.Co.
~,C0m~
P0. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
maintain this unit. Contact your distributor if you do
understand these instructions.
ADDITONAL COPY PRICE 35 CENTS
LIMITED WARRANTY
EFFECTIVE: FEBRUARY 16. 1988
This warranty supersedes all previous MILLER warranties and
is
LIMITED WARRANTY
Subject to the terms and condjtions hereof, Miller Electric Mfg. Co., Appleton. Wisconsin
warrants to its Distributor/Dealer that all new 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
by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
~
engines
~
have
.
warranted
are
a two
year warranty,
exclusive with
as
specified below, Millers warranty does
not
to components having normal useful life of less than
year, such as spot welder tips, relay and contactor
MILLERMATIC parts that come in contact with the
~1
f
~
~f
apply
one
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 service station
(4) payment of
or
or
credit for the purchase
price (less reasonable depreciation based upon actual.use) upon
risk and expense. MILLERs
retum 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
Except
no
claim
or failure, Miller shall instruct the claimant
procedures to be followed.
on
the warranty
(1)
points,
welding
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA
T1ON AS TO PERFORMANCE, AND ANY REMEDY FOR
Miller shall be required to honor warranty claims
ranted Equipment in the event of failure resulting from
MIGHT
wire
including
7~\\
within the
.,~)
ment to
following periods
the original user:
from the date of
on war-
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
ARISE BY IMPLICATION, OPERATION OF LAW,
defect
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
delivery of Equip-
ANY IMPUED WARRANTY OF MERCHANTABILITY OR OF
a
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
j~
1. Arc welders, p~r sources, robots, and components
LOad banks
2.
j
i)
3.
4.
~J
~
Original
main power rectifiers
(labor
1 year
Replacement
7.
Batteries
or
1 year
repair parts, exclusive of
labor
60 days
6 months
..
(1
I
that Miller is notified in
writing
within
thirty (30) days
of the date of such failure.
As
I
AS
EXPRESSLY
BY
PROVIDED
MILLER
a
matter
of
genera! policy only, Miller
submitted by the original
,,
.
,,,
user
within the
may honor claims
MILLER
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.
.
.
,~
,$~
.
-
IN
FOR
PRODUCTS ARE INTENDED
ULTIMATE
PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
WRITING,
WELDING
provided
!~
CLUDED AND DISCLAIMED BY MILLER.
EXCEPT
9Odays
5. All other Millermatic Feeders
6.
1 year
1 year
3 years
onlyl
Allweldingguns,feeder/gunsandtorches
-
.
--.
._...,~,
.
,-
-
SECTION 1
-
WARNING
UNSAFE PROCEDURES OR PRAC
serious personal injury or death.
Read, understand, and follow ALL of these safety
ru/es before installing, operating, or servicing this
_________
TICES
can cause
equipment.
Be
sure
that all end
users
equipment, the
of this
SAFETY RULES
PROTECT EYES AND SKIN FROM ARC
RAYS; PROTECT EARS FROM NOISE
1 -3.
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
1
a welding helmet fitted with a proper filter
(ens (see ANSI Z49.1 for detailed information).
a.
Wear
b.
Use
PREVENT ELECTRIC SHOCK
1.
-
rules.
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:
a.
Do not touch live electrical parts.
b.
Do not work in wet
c.
Wear
or
damp
protective
c.
Wear protective
d.
Always
work
1 -4.
areas.
dry insulating gloves and body protection.
screens
others from flash and
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
Disconnect all power before
ing this equipment.
installing
e.
Turn off all
not in use.
f.
Properly install and ground the welding power
Manual and all
source according to its Owners
applicable codes.
c.
Do not weld
cables
d.
Watch for fire, and keep
d.
g.
h.
equipment when
Do not use worn
that are too small
or
or
damaged cables
poorly spliced.
Do not wrap cables around your
or
or
servic
a.
Wear correct eye, face, and body protection in
the work area.
b.
Allow work and
equipment
to cool before handl
ing.
near
combustible material.
a
fire
extinguisher
near
by.
body.
e.
to NFPA Stan
Prevention in Use of Cutting and
Welding Processes, available from the National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
For additional
information, refer
dard 51 B, Fire
i.
Do not touch electrode and any
circuit at the same time.
grounded object
or
j.
only well-maintained equipment. Repair
replece damaged parts at once.
Use
or
1 -5. PROTECT COMPRESSED GAS CYLINDERS
1 -2.
PROVIDE
AND GASES
PROTECTION
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 arcs.
your head out of the fumes.
a.
Keep
b.
Use adequate ventilation in the work area to
keep fumes and gases from your breathing zone
b.
and the
general work
cylinders so that they cannot
by fastening them to a mounting
bracket, wall, or other stationary support.
Install and
fall
or
tip
secure
over
area.
c.
c.
If ventilation is inadequate,
breathing device.
d.
Read the Material Safety Data Sheets (MSDSs)
instructions for any
and the manufacturers
use
an
Keep cytinders away from
any
welding
or
other
electrical circuits.
approved
d.
Never allow
a
welding electrode
to touch any
cylinder.
materials used.
OM-1 563
Page
1
1
-
6.
PROVIDE
PROTECTION
FOR
SPECIAL
1 -8. ADDITIONAL SAFETY INFORMATION
SITUATIONS
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.
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
and
more
N.W. LeJuene Rd., Miami, FL 33126,
b.
Do not weld
or cut
toxic fumes
or
plated parts unless
painted
special ventilation is provided
or
to remove
are
recommend
ed to you:
highly
a.
gases.
Safety in Welding and Cutting
-
AWS Z49.1
(ANSI)
Since
affect pacemakers, keep all
pacemaker wearers out of the work area. Have
them consult a doctor before coming near a
c.
welding
can
b.
Recommended
Arc
Welding
-
Safe Practices for Gas-Shielded
AWS A6.1
welding operation.
c.
PROVIDE
MAINTENANCE
1 -7.
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
a.
b.
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances
AWS F4.1
Always have qualified personnel perform the in
stallation, troubleshooting, and maintenance
work. Do not perform any electrical work unless
you are fully qualified.
performing any maintenance work inside
power supply, disconnect the power supply
form the electrical power source.
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 Electrical Code,
available from the National Fire Protection
Association, Batterymarch Park, Quincy, MA
02269.
Before
a
c.
d.
Maintain cables, grounding wire, connections,
power cord, and power supply in safe working
order. Do not operate any equipment in ques
tionable condition.
or
ment
f.
grease, corrosive atmospheres, and incle
weather.
equipment for its intended purpose. Do
modify it in any manner.
OM-1563 Page 2
not
Broadway, New York,
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.
for Safety in
CSA Standard W117.2, Code
Welding and Cutting, available from the Cana
dian Standards Association, 178 Rexdale Blvd.,
Keep all safety devices, guards, panels, and
covers in position and in good repair.
Use
ANSI Standard Z87.1, Safe Practice for Oc
cupation and Educational Eye and Face Protec
tion, available from the American National
Standards Institute, 1430
NY 10018.
Do not abuse any equipment or accessories.
Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles,
oil
e.
f.
Rexdale, Ontario, Canada M9W 1 R3.
i.
See also the Standards Booklet Index in the
welding power source Owners Manual.
I
SECTION 2
-
INTRODUCTION
Ampere Rating
Model
at
Tungsten
100% Duty Cycle
DCEN; ACHF
Size
Cable
Torch
Cooling
Capacity
Length
Body
Method
~
Net
Ship
2.5 lbs.
3 lbs.
(1.4 kg)
in.
Length: 8.0
(203.0 mm)
12.5 ft.
MTTF-1 512
Wei g ht
(1.1 kg)
(3.8m)
Handle Diameter:
0.75 in.
(19.0 mm)
MTTF-1 525
150 Amperes
With Argon*
.020 thru 1/8 in.
(0.5 thru 3.2 mm)
Air
25 ft.
(7.6 m)
Weight: 5.6
(160 g)
Length:
4.5 lbs.
5 lbs.
(2.0 kg)
(2.3 kg)
2.5 lbs.
3 lbs.
(1.4 kg)
8.75 in.
(222.0 mm)
12.5 ft.
MTTF-1512V
oz.
(1.1 kg)
(3.8m)
Handle Diameter:
0.88 in.
(22.5 mm)
25 ft.
MTTF-1525V
(7.6 m)
Weight:
7.5
oz.
5 lbs.
5 lbs.
(2.3 kg)
(2.3 kg)
(210 g)
*Rated With Gas Lens Collet
Body
Figure 2
-
1.
Specifications
The duty cycle of a welding
DUTY CYCLE
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
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
ditions continuously.
include installation, operation,
WARNING
____________statements
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
2
-
1.
-
RATED
THE
EXCEEDING
AMPERAGE and duty cycle can result in damage
to the torch.
Do not exceed rated amperage and duty cycle
stated in Figure 2-1.
~
2 -2. GENERAL INFORMATION AND SAFETY
A.
___________
different levels of hazard.
or
loss of life.
CAUTION
statements include
and maintenance
procedures
or
installation, operation,
practices which if not
personal injury
carefully followed could result in minor
or damage to this equipment.
signal word, IMPORTANT highlights instruc
special emphasis to obtain the most
efficient operation of this equipment.
A third
General
tions which need
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip
ment design, installation, operation, maintenance, and
read, understood, and
troubleshooting
followed for the safe and effective use of this equip
which should be
ment.
B.
-
-
this
by the purchaser with the carrier. A copy of the bill of
lading will be furnished by the manufacturer on request
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
The
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
Before installing
HANDLING
3. RECEIVING
from around
material
all
clean
packing
equipment,
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
2
-
Safety
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 hande.
When
Rules.
OM-1 583 Page 3
2
4. DESCRIPTION
This torch is specifically for
with the Gas Tungsten Arc Welding (GTAW) pro
cess. The alphanumeric model designation refers to the
T
following:
F
-
-
use
M
T
-
-
Torch
Flex Loc Head
-
-
15
-
12
25
V
SECTION 3
-
Miller
TIG/GTAW
-
-
-
.
Ampere Rating: 150 Amperes
12.5 ft. (3.8 m) Cable
25 ft. (7.6 m) Cable
Gas Valve
INSTALLATION
Collot
Flex bc
Heat
-I
Cup
Tungsten
----J
Electrode~
Torch
Body
Adjusting
Stem
I
~
1/
High
flequlred Consumables and Accessories
**Ob~jn from Welding Equipment Supplier
Cable
Figure
ELECTRIC SHOCK
WARNING
can
3
-
1. Torch
kill.
5.
Do not touch live electrical parts.
Shut down welding power source and disconnect
power
cedures
employing lockout/tagging
installing torch.
pro
consist of
line
Lockout/tagging procedures
-
1. TORCH BODY
Torch
padlocking
Install properly prepared tungsten electrode (see
Section 5-4) through front of collet body to posi
tion electrode tip outside cup rim. Securely
To
readjust electrode, loosen backcap.
IMPORTANT As a general rule, electrode extension
should equal electrode diameter; but exact electrode ex
tension may var, according to application.
Flex Loc Head
1.
Install collet body into torch head
heat shield is in place.
2.
Install cup onto collet body.
making
sure
The flex bc head can be locked in any
360 degree rotation (Figure 3-1).
Adjust
the flex bc head
Remove 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.
backcap)
OM-1563 Page 4
backcap
and
onto torch head.
0-ring (supplied
on
as
position within
its
follows:
place, and
1.
Hold head adjusting stem in
head clockwise one full turn.
2.
Push head into torch body until
turns
Loosely install
Adjustment (Figures 3-1, 3-2,
and 3-3)
Body Assembly
body is shipped requiring consumables and
accessories indicated in Figure 3-1: cup, colIet body,
collet, power cable adapter and tungsten electrode.
Assemble torch body as follows:
4.
TB-12o867
(Figure 3-1)
The torch
3.
Adapter
tighten backcap.
B.
A.
Power Cable
before
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
3
Fitting
Components
__________
input
Flex
adjusting
rotate
stem
freely.
3.
Rotate head and adjusting stem simultaneously
in same direction until desired angle is attained.
4.
Hold adjusting stem in place, and rotate head
counterclockwise until secure.
To install
high flex cable,
adapter.
connect
high flex cable fitting
to power cable
If torch includes a gas valve, connect a suitable length
of gas hose (extra hose not supplied) from power cable
adapter
to
regulator/flowmeter (Figure 3-4).
If torch is without gas valve, connect a suitable length
supplied) from power cable adapter to
gas valve outlet. Connect extra gas hose (not supplied)
of gas hose (not
from gas valve inlet to regulator/flowmeter
B.
TA-120 998
Torch Gas Valve
(Figure 3-5).
Operation (If applicable)
The gas valve allows gas flow control at the torch. A
one-quarter turn clockwise opens the gas valve, and a
one-quarter turn counterclockwise closes the valve.
Figure 3
-
2. Clockwise Head Rotation
The gas valve allows control of gas postflow time, or
the length of time gas flows after the arc is extinguish
ed. Insufficient gas postflow results in an oxidized
(black) electrode surface. If
an
oxidized electrode
were
used, the black surface would contaminate the weld
and
cause
poor
arc
direction.
IMPORTANT As
a general rule, allow 10 seconds
gas postflow time per 100 amperes of weld current
before closing valve.
______________
3
3. POWER CABLE CONNECTION
3-4 and 3-5)
-
WARNING
ELECTRIC SHOCK
can
(Figures 3-1,
kill.
_________
Do not touch live electrical parts.
Shut down welding power source and disconnect
TA-120 998
Figure 3
-
3. Counterclockwise Head Rotation
3-2. GAS HOSE CONNECTIONS
VALVE (If applicable)
AND
GAS
IMPORTANT: If power source is not
gas
valve,
A.
a
torch gas valve is
equioped with a
required (Figure 3-4).
input
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
before
The high flex cable assembly contains the power cable
within the gas hose. The high flex cable has a 3/8-24
male right-hand fitting (Figure 3-1).
Gas Hose and Connection
To install
The
high flex cable contains the power cable within the
gas hose. The high flex cable has a 3/8-24 male righthand fitting (Figure 3-1).
high flex cable, connect high flex cable fitting
adapter (see Section 3-2A). Connect
cable adapter to weld output terminal (Figures
to power cable
power
3-4 and 3-5).
OM-1563 Page 6
Torch
Valve
Work
Clamp
Power Cable
Adapter
Gee
Cylinder
TA-120 871
Figure 3
-
4. Torch Connection
Diagram For Models With Gas Valve
r/Flowmeter
Torch
Work
Power Cable
Clamp
Adapter
Gas
Cylinder
Figure 3
-
5. GTAW Torch Connection
SECTION 4
-
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Keep all covers and handle in place
TA-120 871
Diagram For Models Without Gas Valve
SEQUENCE OF OPERATION
WARNING
_________
while
MAGNETIC FIELDS FROM HIGH CURRENTS can
affect pacemaker operation.
Wearers should consult with their doctor before
going near
operations.
operating.
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 can cause fire
and burns.
Watch for fire.
Have a fire extinquisher nearby, and know how to
See Section 1
mation.
-
arc
we/ding, gouging,
or
spot welding
Safety Rules for additional safety infor
4-1. GAS TUNGSTEN ARC WELDING (GTAW)
1.
Install and connect torch according to Section 3.
2.
Make
3.
With
4.
Set power
use.
sure backup and all gas connections
securely tightened.
regulator/flowmeter valve closed,
cylinder valve.
are
open gas
Allow work and equipment to cool before handl
ing.
OM-1 563 Page 6
source
for desired
welding
amperage.
Wear dry insulating clothing and gloves and
welding helmet with proper filter lens according
to ANSI Z49.1.
5.
6.
Energize welding
7.
power
Stop welding.
1.
IMPORTANT: As
source.
Set gas flow to desired level
4 -2. SHUTIING DOWN
(requires
open gas
gas postflow
before closing
a
general rule,
allow 10 seconds of
time per 100 amperes of weld current
valve.
valve).
Purge gas hose to c/ear hose of air,
any other contaminants. Allow gas to flow
~
moisture,
or
2 to 3 minutes
on new
torch; 5
to
6 seconds thereafter.
SECTION 5
-
UPKEEP
1. INSPECTION AND
Usage and
shop conditions will determine frequency and type of
maintenance required. Perform, inspections once a
5
-
-
week.
SHOCK can kill; HOT
burns.
Do not touch live electrical parts.
Shut down welding power source before working
ELECTRIC
WARNING:
SURFACES
3.
Turn off the
power
source.
shielding gas.
OF
MAINTENANCE
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.
Once
a
week inspect hoses and connections.
can cause severe
torch.
on
Turn off
CONCENTRATION
HIGH
SHIELDING GAS can harm health or kill.
Shut off gas supply when not in use.
Begin welding.
8.
welding
2.
torch from welding power source
inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
Disconnect
Gas Hose
A.
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
before
1.
Inspect torch for broken
parts; tighten, repair
2.
areas, cracks and loose
and
replace
as
required.
Remove grease and dirt from components, and
moisture from electrical parts and cables.
5-2. TORCH BODY MAINTENANCE (Figure 3-1)
B.
Power Cable
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 at each
5 -4. PREPARING
inspection.
TUNGSTEN
ELECTRODES
(Figure 5-1)
ELECTRIC
WARNING:
SURFACES
SHOCK can
burns.
HOT
kill;
can cause severe
CAUTION:
Do not touch live electrical parts.
Shut down welding power source before working
on torch.
Disconnect torch from welding power source
inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
before
Once
week inspect condition of torch body
a
com
____
HOT FLYING METAL PARTICLES can
start fires, and damage equip
injure personnel,
ment; TUNGSTEN CONTAMINATION
weld quality.
can
lower
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
tungsten will become contaminated.
ponents.
Replace
cup, heat
shield, backcap, and 0-rings if crack
ed. Maintain tight fit of torch components to
good weld quality.
ensure
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
5 -3. INSPECTING HOSES, CONNECTIONS AND
CABLES
WARNING
ELECTRIC SHOCK
can
kill.
_________
Do not touch live electrical parts.
Shut down
welding power source
run
lengthwise
with the electrode.
For additional information,
see
quest a handbook from factory
Arc Welding (GTAW) process.
your distributor or re
on the Gas Tungsten
and disconnect
input power employing lockout/tagging pro
cedures before inspecting, maintaining, or ser
vicing.
OM-1563
Page 7
TUNGSTEN PREPARATAION: IDEAL
TUNGSTEN PREPARATION: WRONG
Stable Arc
Arc Wander
Point
Flat (the Die. of
Radial Ground
Flat Govern.
Amperage Capacity)
TA-120 630
Figure 5
Table 5
Tungsten
(Green Band)
.
-
1.
Tungsten Preparation
Tungsten Size Chart
Amperage Range
Electrode Diameter
Pure
1.
-
DC-Argon
Negative/
Straight Polarity
Electrode
-
Polarity
DC-Argon
Electrode Positive/
Reverse Polarity
.020
5-20
*
.040
15-80
70-150
*
1/16
3/32
125-225
1/8
225-360
Gas Type
-
AC-Argon
Using High
Frequency
5-20
10-60
50-100
10-20
15-30
25-40
100-160
150-210
2% Thorium
Alloyed Tungsten
.
(Red Band)
.020
.040
1/16
3/32
1 /8
*
15-35
*
20-80
10-20
15-30
50-150
130-250
225-360
15-40
25-85
50-160
135-235
250-400
25-40
Zirconium
Alloyed
Tungsten
.
(Brown Band)
.020
.040
1/16
3/32
1/8
15-35
*
*
*
*
20-80
*
*
50-150
130-250
225-360
.
*
*
NOT RECOMMENDED
figures are intended as a guide and are a composite of recommendations from American
Welding Society (AWS) and electrode manufacturers.
The
Item
No.
Miller
Stock No.
Figure
Miller
Model No.
A
Description
Complete
Torch
Quantity
Assembly
1
TUNGSTEN, electrode (consult your welding supply distributor)
2
CUP (see Figure B)
COLLET BODY (see Figure B)
3 SERIES HEAD (consisting of)
1
.HEATSHIELD,std
1
HEATSHIELD,smalldiagaslens
HEATSHIELD, largediagaslens
HEAD ADJUSTMENT STEM (consisting of)
1
3
4
5
5
5
6
7
8
9
9
9
118 526
116256
t119 914
t119 915
116 203
116260
116 259
ti 16 258
t116 257
OM-1 563 Page 8
FL3L
300HS
3GHS
3GHSLD
01-0009
300R
300S
300M
300L
.0-RING
COLLET (see Figure B)
BACKCAP, short (consisting of)
BACKCAP, medium (consisting of)
BACKCAP, long (Consisting of)
1
1
1
1
1
1
Item
Miller
Miller
No.
Stock No.
Model No.
Figure
10
11
12
13
14
15
16
17
11
13
18
19
20
20
21
22
Complete Torch Assembly (Contd)
A
116260
116208
116219
116217
116220
116217
116216
116218
116207
116217
118510
t116276
116271
116272
120721
120720
Quantity
Description
300R
01-0012
01-0002
0 1-0013
01-0002
FLHV
01-0007
01-0002
15PCA
1512PCHF
1525PCHF
1
0-RING
FLEX LOC TORCH BODY, w/valve (consisting of)
.0-RING
.0-RING
HANDLE ADAPTER, models w/valve (consisting of)
0-RING
VALVED HANDLE, models wf valve (consisting of)
SCREW, non-conductive
FLEX LOC TORCH BODY (consisting of)
1
1
2
1
.
.
1
.
1
.
.
1
.
.0-RING
1
2
HANDLE
1
POWER CABLE ADAPTER
HI-FLEX POWER CABLE, 12-1/2 ft(consisting of)
HI-FLEX POWER CABLE, 25 ft (consisting of)
1
1
1
2
2
RH NUT
.RING NUT
9
18
11
4
1
H
20
Figure
A
-
Complete Torch Assembly
18-120 867
tOptional
Parts
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 563 Page 9
0
CONSUMABLE PARTS SELECTOR
U
Body And 0.. Cup R.quir.d To Compl.t. Torch.) Torch.. With High Fi.x Composite C.bi. Also R.qulr. A Power C.bI. Adspt.r.
Not.: Coil.t. Colist
SHORT FRONT ENDS
STANDARD LENOTH FRONT ENDS
0
Tungaten
Diameter
mm)
1/16
3/32
(1.0)
1.6)
2.4)
(3.2)
50-150
70-150
100-235
150-325
150-250
220-350
3C332
118370
3C418
ACHF
5-20
DCSP
5-20
10-80
15-80
ModelNo.
3C20
3C40
3C116
SIOCkNO.
116367
116368
1t6369
Amperage Range
1/8
Shod
Standard La..ath
CelloS Cody
Standard
5100k No.111 211
7C20
7C40
7Ct16
7C332
7C418
StockNo.
116379
116380
118381
116382
116383
Lgth.)
ModelNo.
3CB20
StockNo.
116361
3CB40
118362
3CB116
118363
3CB332
116364
Short
0
0.. Loon
CmoS.
COL.xXS
U. SOHS
Cotl.t
116365
H.., SItlald
Stmk No. hg aie
7C.SXS
Cup
Stock/Model No.
._!!–~..
~
Cup, Ceramic
,...~Li!
~
1-27/32
Long
c:~
116350 13C61
3/8
116351 13C71
7/16
Go.
1/2
5/8
R.d005
Amperage Range
1/4
ColletlShort)
3.7/32
116344(3C5L)
5/16
3/8
7/16
11633e
3/32
(1.6)
12.41
(3.2)
5-20
10-80
50.150
100-235
OCSP
5-20
15-80
70-150
150-250
150-325
220-350
ModelNo.
StockNo.
4C20
4C40
4C332
4C41B
116373
11637~
4C116
~16375
116376
116377
ColletlReverse)
ModelNo.
7C20
7C40
7C116
7C332
7C418
StockNo.
116379
116380
116381
116382
116383
Collet Body (Short)
Model No.
4CB20
4CB40
4CB1 16
4CB332
4CB418
StocliNo.
116355
116356
116357
116358
116359
114
~
1/8
1/16
.040
(0.51
1mm)
ACHF
3/4
116 346 )3C7L(
UaIne
(1.01
Diameter
116 343 )3C4L1
116 345 )3C6L)
Who.
Short CoiI.l/CoIlot Cody.
116 354 (3C12)
c:::::)
Conunuoua Duty
1.1101 Cy 2C%
U.. 3GHSLD
Heal ShIald
Stmk No. Ill R1C
Tungsten
:
7C.w
Cloak No.111 II
Cup, Ceramic
LOng
c~uu.~
Laq.
in
116352 )3c81
116 353 l3ClOl
~
Hoot Shield
Lore. Dlont.t.r
3GLL.xSo
,
Cellos
UI. 4OHS
Orifice
3/16
:
116~
1h12CI
StookNo
3CB418
Short
.l
ccxxx
L.ngSh
0.. Lan.
30L.XXX
(
H.., ShIeld
3C.Sxx
___________
__________________________
Collet Body )Std.
-
dual
116371
ModelNo.
%
U. IShHS
Heat Sfll.ld
Standard
ColIet)Revemel
S
(.0
___________
ColletlStendard)
~
CoilS aodn
4CC-SAX
~
Cup. Alumina
1.27/32 Long
5/16
~ F1~I
116 332 l3A6)
Stock/Model No
3/9
Cuo Orifice
116 337 )2C41
1/4
116 338 )2C5
5/18
Cup, Ceramic
7/16
116333(3A7)
~
116334l3A8)
1/2
116 335 (3A10)
5/8
1-5/32
0
3/4
116 338 (3A12l
Body
Std.
Lgth.
Mode) No.
3GL20
3GL40
3GL1 16
3GL332
Stock No.
119 926
119 927
119 928
119 929
-
Gas Lena
I-S/B
Long
119 I
3/8
7/16
Long
Cup, Ceramic
Stock/Model No.
Cup, Ceramic
t16 339
116 340 12C7)
1-1/8
Gee Lena Co)let
Long
-
11
.040
in .020
0.5)
-U
Long 1-7/8
116 341 )2C8)
1/2
116 342 12C10)
5/8
116 326
I
3/16
1163271
/4
1/4
~~
5/16
110 .2~5
5/16
119 918 )1l~C.Sl
116329 l2CSLl
119 919 )3CG6I
3/8
cD
119 920 )3CG7I
7/16
3CG11 Is
119 922 I3CG11I
11/16
119 923 13CG12)
3/4..
3/8
116
1-1/8
Long
Cup,
119921 l3CG8l
1/2
Alumina
1.5/32 Long
1/4
116311 )2A5
5/16
116 312 )2A6)
3/B
116 313 l2A7)
..~
116 314 )2A8)
116 315 )2AtO)
119 925 (3CG161
1191
1/4
1191
5/18
Cup. Alumina
Body-Short
Mode) No.
4GL20
4GL40
4GL1 16
4GL332
4GL418
StockNo.
119905
119906
119907
119908
119909
Stock/Model No
Cup,
Alumina
119 934 13AG61
3/8
119 935 I3AG7I
7/16
t19 894 )2AG5
1/2
119 895 )2AG6)
3/8
11/16
119 896 )2AG7)
7/16
1
119 936 13AG81
119937 l3AGlll
Gee Lena Collet
Body Lg. Die.
Cup, Alumina
1-7/8 Long
5/8
1
Gas Lens Collet
-
Mode) No.
Stock No.
~119
911
.
1/2
7/8
119 924 (3CG14)
Gee Lena
1-5/8 Long
7/16
3GLL332
119902
I3AG8LD)I
Long
119 893 )2A~4
1/4
5/16
3GLL418
119903
1/2
6/8
3/4.,
Figure
B
-
SHADED AREAS INDICATE
RECOMMENDED USAGE
Consumable Parts And Cross Reference Chart
.
CROSS REFERENCE TO
COMPETITIVE MODEL
MILLER
STOCK NO.
MILLER
MODEL NO.
COMPETITIVE
NO.
116367
116368
116369
116370
116371
116379
116380
116381
116382
116383
116361
116362
116363
116364
116365
116347
116348
116 349
116350
116351
116352
116353
116354
116343
116344
116345
116346
116330
116331
116332
116333
116334
116335
116336
119926
119927
119928
3C20
3C40
3C116
3C332
3C418
7C20
7C40
7C116
7C332
7C418
3CB20
3CB40
3CB116
3CB332
3CB418
3C3
10N21
10N22
10N23
10N24
119 929
119930
119917
119918
119919
119920
119921
119922
119923
119924
119925
119932
119933
3GL332
3GL418
3CG4
3CG5
3CG6
3CG7
3CG8
3CG11
3CG12
3CG14
3CG16
3AG4
3AG5
3C4
3C5
3C6
3C7
3C8
3C10
3C12
3C4L
3C5L
3C6L
3C7L
3A4
3A5
3A6
3A7
3A8
3A10
3A12
3GL20
3GL40
3GL116
10N25
N/A
N/A
N/A
N/A
N/A
10N29
10N30
10N31
10N32
10N28
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
54N35
54N34~
54N33
54N32
54N31
54N36
N/A
N/A
N/A
54N18
54N17
MILLER
MILLER
STOCK NO; MODEL NO.
119934
.
.119 935
119936
119937
119902
119903
119911
119912
119913
116373
116374
116375
116376
116377
116379
116380
116381
116 382
116383
116355
116356
116357
116358
116359
116337
116338
116339
116340
116341
116342
116326
116327
116328
116329
116310
116311
116312
116 313
116314
116315
119905
119906
119907
119908
119909
119893
119894
119895
119896
COMPETITIVE
NO.
3AG6
3AG7
3AG8
3AG11
3GLL332
3GLL418
3AG8LD
3AG1OLD
3AG12LD
4C20
4C40
4C116
4C332
54N16
54N15
54N14
54N19
45V64
995795
57N74
53N88
53N87
N/A
10N22S
4C418
10N25S
N/A
7C20
7C40
7C116
7C332
7C418
4CB20
4CB40
4CB116
4CB332
4CB418
2C4
2C5
2C6
2C7
2C8
2C10
2C3L
2C4L
2C5L
2C6L
2A4
2A5
2A6
2A7
2A8
2A10
4GL20
4GL40
4GL116
4GL332
4GL418
2AG4
2AG5
2AG6
2AG7
10N235
10N245
N/A
N/A
N/A
N/A
N/A
17CB20
17CB20
17CB20
17CB20
13N14
13N15
13N16
13N17
13N18
13N19
796F70
796F71
796F72
796F73
13N08
13N09
13N10
13N1 1
13N12
13N13
N/A
N/A
N/A
N/A
N/A
53N58
53N59
53N60
53N61
OM-1583 Page 11
.
L
.