Miller Electric MT-24VF-12-1 Specifications

I,
Millerfi
November 1990
FORM: OM-1558A
Effective With
Style
No. KB-8
MODEL: MT-24-12-1
MT-24-25-1
MT-24F-1 2-1
MT-24 F-25-1
MT-24VF-12-1
MT-24VF-25-1
..,,n~
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 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 equip
MILLER ELECTRIC
A Miller
Mfg.
Co.
Group Ltd., Company
P.O. Box 1079
Appleton,
WI
54912 USA
Tel. 414-734-9821
ment. Do not allow untrained persons to install, operate, or maintarn this unit.
Contact your distributor if you do not fully understand these instructions.
SA-120 672
PRINTED IN U.S.A.
lii
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
This warranty supersedes all
LIMITED WARRANTY
MILLER warranties and is exclusive with
previous
Subject
to the terms and conditions
hereof, MILLER Electric Mfg. Co., Appleton, Wisconsin
rants
to
its
Distributor/Dealer
that
all
and
new
war
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
subject to the warranties of their respective manufacturers,
if any. All engines are warrant ied by their manufacturer for two
years from date of original purchase, except Deutz engines
sold
which have
a one
year, 2000 hour warranty.
Except as specified below, MILLERs warranty does not apply
to 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 wire
including nozzles and nozzle insulators where failure does not
result from defect in workmanship or material.
MILLER shall be required to honor warranty claims on war
ranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of
Equipment to the original user;
1.
Arc welders, power sources, robots, and
1 year
components
1 year
2.
3.
Original
Load banks
main power rectifiers
4.
All
5.
All other MILLERMATIC Feeders
6.
Replacement
7.
Batteries
repair parts,
and torches
.
.
.
exclusive of labor
provided that MILLER is notified in
of the date of such failure.
90
days
1 year
60
days
6 months
writing within thirty (30) days
As a matter of general policy only, MILLER may honor claims
submitted by the original user within the foregoing periods.
I
dther
guarantees
or
warranties
expressed
or
implied.
breach of warranty or any other duty
quality of any goods, the exclusive remedies
therefore shall be. at MILLERs option (1) repair or (2) replace
ment or, where authorized in writing 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 return of the goods at Customers risk
and expense. MILLERs option of repair or replacement will be
FOB.. 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
In the
with
case
respect
of MILLERs
to the
notice of apparent defect or failure, MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
ANY
EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE
SENTATION 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 IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
EQUIPMENT
WITH
RESPECT
ANY
AND
ALL
TO
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
I
3 years
(labor 1 year only)
welding guns, feeder/guns
or
no
AS EXPRESSLY PROVIDED BY MILLER IN
MILLER PRODUCTS ARE INTENDED FOR
ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED
AND EXPERIENCED IN 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 MILLERS WARRANTIES TO, ANY CONSUMER.
EXCEPT
WRITING,
ii
OM-1558A
11/90
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufactur-
spaces to record the Model Designa
Style Number of your unit. The infor
mation is located on the data card or the nameplate.
Use the
following
tion and Serial
or
Model
_________________________________________
ers
Transportation Department.
Serial
When requesting information about this equipment, al
ways provide the Model Description and Serial or Style
or
Style
No.
____________________________
Date of Purchase
_______________________________
Number.
TABLE OF CONTENTS
Section No.
SECTION 1
Page
SAFETY RULES
1-1.
Prevent Electric Shock
1-2.
Provide Protection From Fumes And Gases
1-3.
Protect
1-4.
Prevent Fires And Burns
1-5.
Protect
1-6.
Provide Protection For
1-7.
Provide
1 -8.
Additional
SECTION 2
Eyes
1
And Skin From Arc
Proper Equipment Maintenance
Safety
SECTION 4
Alert
Symbol
And
3
Duty Cycle
Description
3
INSTALLATION
Torch
Gas Hose Connections And Gas Valve
4-3.
Power Cable Connection
5-2.
SECTION 6
3
SPECIFICATIONS
4-2.
5-1.
1
2
3
Safety
Signal Words
4-1.
SECTION 5
1
SAFETY PRECAUTIONS AND SIGNAL WORDS
General Information And
3-2.
1
2
Information
Safety
1
1
Cylinders
Speial Situations
2-1.
3-1.
Protect Ears From Noise
Gas
Compressed
2-2.
SECTION 3
Rays;
Body
4
(If Applicable)
5
6
SEQUENCE OF OPERATION
Gas
Tungsten Arc Welding (GTAW)
Shutting Down
6
6
MAINTENANCE
6-1.
Routine M~intenance
7
6-2.
Tungsten Electrode
7
SECTION 7
Figure
Figure
PARTS LIST
7-1.
Complete Torch Assembly
7-2. Consumable Parts And Cross Reference Chart
9
10
LIST OF CHARTS AND TABLES
Table 3-1.
Specifications
Table 6-1. Maintenance Schedule
Table 6-2. Tungsten Size
3
7
8
No.
SECTION 1
a
WARNING:
PRACTICES
jury
or
SAFETY RULES
PROCEDURES OR
serIous personal in-
UNSAFE
can cause
PROTECT EYES AND SKIN FROM
RAYS; PROTECT EARS FROM NOISE
1-3.
death.
Read, understand, and follow ALL of these
safety rules before installing, operating,
servicing this equipment.
or
Be sure that all end users of this equipment,
the operator and helpers, read and understand these safety rules.
Arc rays from the welding process produce intense heat
and strong ultraviolet rays that can burn eyes and skin.
Noise from
1.
some
Wear
a
processes
welding
can
damage hearing.
helmet fitted with
lens (see ANSI Z49.1 for detailed
2.
Wear
a
welding
3.
PREVENT ELECTRIC SHOCK
Use
ers
Touching live electrical parts can cause severe burns to
the body or fatal shock. Severity of electrical shock is de
term med by the path and amount of current through the
body. Therefore:
~
screens or
from flash and
Wear
proper filter
a
proper filter
information).
barriers to protect 0th-
glare.
protective clothing
and foot protection.
PREVENT FIRES AND BURNS
1-4.
The
protective
a
information).
helmet fitted with
lens (see ANSI Z49.1 for detailed
1-1.
ARC
hotworkpiece, hot equipment, other hot metal, spat
arc sparks can cause fires and burns.
ter, and
1.
Do not touch live electrical parts.
2..
Do not work in wet
3.
Wear
or
damp
dry insulating gloves
1.
Wear correct eye, face, and
work area.
2.
Allow work and
areas.
and
body protection.
body protection
equipment
in the
to cool before han
dling.
Disconnectallpowerbeforeinstallingorservicing
equipment.
4.
3.
Do not weld
4.
Watch for fire,
flammable material.
near
this
Turn off all
5.
equipment
when not in
use.
Properly install and ground the welding
according to its Owners Manual
6.
source
power
and all
5.
Do not
are
1-5.
8.
Do not wrap cables around your
9.
Do not touch electrode and any
or circuit at the same time.
Use
,
grounded object
at once.
2,
3.
and gases
can
are
normally part of the welding proc
carefully.
Protect
compressed gas cylinders from
Install and
secure
cylinder
so
that
exces
arcs.
they
cannot fall
by fastening them to a mounting
bracket, wall, or other stationary support.
PROVIDE PROTECTION FROM FUMES AND
be hazardous
4.
to your health.
cylinder
sive heat, mechanical shocks, and
or
GASES
Breathing welding fumes
Batterymarch Park,
PROTECT COMPRESSED GAS CYLINDERS
~r
1-2.
extinguisher
ess, be sure to treat them
1.
only well-maintained equipment. Repair
replace damaged parts
fire
body.
Since gas
10.
a
For additional information, refer to NFPA StanFire Prevention in Use of Cutting and
Welding Processes, available from the National
Fire Protection Association,
Quincy, MA 02269.
damaged cables or cables that
poorly spliced.
use worn or
too small or
keep
dard 51 B,
applicable codes.
7.
and
nearby.
tip
over
Keep cylinders away from any
electrical circuits.
Never allow
a
welding
welding
or
other
electrode to touch any
cyl
inder.
1.
Keep your head
2.
Use
out of the fumes.
1-6.
adequate ventilation
in the work areato
fumes and gases from your
the general work area.
breathing
keep
zone
PROVIDE PROTECTION FOR SPECIAL SITU-
ATIONS
and
1.
Do not weld
have held
3.
If ventilation is
breathing
4.
inadequate,
an
approved
Read the Material
cut containers or materials which
been in contact with hazardous sub
or
stances unless
device.
they
are
properly cleaned and
in
spected.
Safety
and the manufacturers
rials used.
use
or
Data Sheets
(MSDSs)
instructions for any mate-
2.
Do not weld or cut painted or plated parts unless
special ventilation is provided to remove highly
toxic fumes
or
gases.
OM-1558 Page 1
Since welding
3.
pacemaker
can
affect pacemakers, keep all
out of the work area. Have
1.
them consult
a
doctor before
coming
near a
ANSI Standard Z49.t available from the Ameri
can
wearers
Welding Society,
550 N.W. LeJeune Rd, Mi
ami, FL 33126.
weld
ing operation.
2.
PROVIDE
1-7.
PROPER
EQUIPMENT
MAINTE
AWS Standard A6.1, Recommended Safe Prac
tices for Gas Shielded Arc Welding, available
from the American
NANCE
Welding Society,
550 N.W.
LeJeune Rd, Miami, FL 33126.
improperly maintained equipment can result in poor
most importantly it can cause physical injury or
work, but
death
1.
2.
through
fires
or
performing any maintenance work inside
power supply, disconnect the power supply from
Before
the electrical power
4.
equipment
equipment
in
1-8.
4.
NFPA Standard 51B, Fire
Cutting
Fire Protection
terymarch Park, Quincy,
5.
Prevention in Use of
Welding Processes, available from
Association, Bat
MA 02269.
NFPA Standard 70, National
Electrical Code,
available from the National Fire Protection Asso
ciation, Batterymarch Park, Quincy, MA 02269.
or
accessories.
6.
ANSI Standard Z87. 1, Safe
Practice for
Occupa
and Face Protection,
available from the American National Standards
tion and Educational
ent weather.
Institute, 1430 Broadway, New York, NY 10018.
Keep
in
all
safety devices, guards, panels, and
position and in good repair.
cov
Use equipment for its intended purpose. Do
modify it in any manner.
ADDITIONAL SAFETY INFORMATION
OSHA Standard 29 CFR, Part 1910, Subpart 0,
Welding, Cutting, and Brazing, available from
the Superintendent of Documents, U.S. Govern
ment Printing Office, Washington, DC 20402.
8.
CSA Standard Wi 17.2, Code
ing
more
OM-1558
information
Page
2
on
Eye
7.
not
safe
practices for setting up and
operating electric welding and cutting equipment and on
good working habits, ask your welding equipment sup
plier. For your protection, read and comply with the latest
editions of the following standards:
For
and
furnaces, wet conditions such
ers
6.
FL 33126.
question
Keep equipment away from heat sources such as
as water puddles,
oil or grease, corrosive atmospheres, and inclem
5.
available from the American
550 N.W. LeJeune Rd, Miami,
the National
Maintain cables, grounding wire, connections,
power cord, and power supply in a safe working
Do not abuse any
Substances,
Welding Society,
ous
source.
order. Do not operate any
able condition.
AWS Standard F4.1, Recommended Safe Prac
tices for the Preparation for Welding and Cutting
of Containers and Piping That Have Held Hazard
Always have qualified personnel perform the in
stallation, troubleshooting, and maintenance
work. Do not perform any electrical work unless
you are fully qualified.
a
3.
3.
electrical shock. Therefore:
and
Cutting,
for
Safety
in Weld
available from the Canadian
Standards Association, 178 Rexdale Blvd., Rex
dale, Ontario, Canada M9W 1 R3.
9.
See also the Standards Booklet Index in the weld
ing power source Owners Manual.
I
SAFETY PRECAUTIONS AND SIGNAL WORDS
SECTION 2
GENERAL INFORMATION AND SAFETY
2-1.
SAFETY
2-2.
ALERT
SYMBOL
AND
SIGNAL
WORDS
General
A.
The
Information presented in this manual and on various la
bels, tags, and plates on the unit pertains to equipment
tify different
maintenance, and
troubleshooting which should be read, understood, and
design,
installation,
operation,
followed for the safe and effective
B.
use
of this
a
equipment.
The installation, operation, maintenance, and trouble
shooting of arc welding equipment requires practices
procedures
which
personal safety and
ensure
the
safety of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
Sons
in accordance with this manual and all
Ampere Rating
At
100% Duty
Cycle
DCEN; ACHF
Tun9sten
Size
Capacity
symbol
special instructions.
signal
is used with the
words WARNING and CAUTION to call atten
safety
statements.
a
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
4~
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
statements
identify special
SPECIFICATIONS
Specifications
Cable
Torch Body
Length
Method
(206.0 mm)
Handle Diameter:
0.75 in.
25 ft
80 Amperes
With Argon*
MT-24F-1 2-1
MT-24-VF-12-1
.020 thru
3/32 in.
(0.5 thru
2.4
mm)
(7.6 m)
*Rated With Gas Lens Collet
a
a
torch is the percentage of a
can be operated at a given
duty cycle using argon
can beoperated
continuously.
means
at rated load conditions
(19.0 mm)
Weight:
3.0
oz.
(85.0 g)
4.5 lbs.
5.0 lbs.
(2.0 kg)
(2.3 kg)
2 lbs.
3 lbs.
(0.9 kg)
(1.1 kg)
4.5 lbs.
5.0 lbs.
(2.0 kg)
(2.3 kg)
DESCRIPTION
This air-cooled torch is
torch
load. This torch is rated at 100%
Tungsten
meric model
to the torch.
Do not exceed rated amperage and duty cycle
stated in Table 3-1.
24
specifically
for
use
with the Gas
Welding (GTAW) process. The alphanu
designation refers to the following:
Arc
that the torch
EXCEEDING
RATED
THE
CAUTION:
AMPERAGE and duty cycle can result in
damage
(57.0 g)
Length:
in. (203.0 mm)
0.75 in.
3-2.
welding
period that
shielding gas. This
a
2.5 lbs.
(1.1 kg)
Body
DUTY CYCLE
duty cycle of
2 lbs.
(0.9 kg)
Handle Diameter:
MT-24VF-25-1
ten minute
8.0
(3.8 m)
25 ft.
The
oz.
Ship
Air
12.5 ft.
MT-24F-25-1
3-1.
2.0
Net
(19.0 mm)
Weight:
(7.6 m)
Wei ght
Cooling
Length:
8.1 in.
(3.8 m)
MT-24-25-1
instructions
ment.
12.5 ft.
MT-24-12-1
alert
necessary for the most efficient operation of this equip
Table 3-1.
Model
safety
IMPORTANT
applicable
codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules.
SECTION 3
levels of hazard and
This
tion to the
Safety
and
following safety alert symbol and signal words are
throughout this manual to call attention to and iden
used
Ampere Rating: 80 Amperes.
(3.8 m) Cable
25 ft. (7.6 m) Cable
One-Piece, High-Flex Cable
-
12- 12.5 ft.
25
1
V
F
-
-
-
-
Gas Valve
Flex Head
OM-1 558
Page
3
SECTION 4
INSTALLATION
Torch Body
(Neck Portion)
Heat Shield
Gas Valve
*Collet
*ColIet
(If Applicable)
Body
*Cup
0-Ring
~Tungsten
Electrode
Handle
-~
>
High
Cable
Flex
*POwer Cable
Adapter
Fitting
*Required Consumables and Accessories
**Obtain from Welding Equipment Supplier
SA-120 671
Figure
TORCH BODY
4-1.
WARNING:
a
4-1. Torch
(Figure 4-1)
Components
3.
ELECTRIC SHOCK
can
Install
kill.
Do not touch live electrical parts.
Shut down
welding power source, and dis
input power employing lockout/tag
ging procedures before installing torch.
properly prepared tungsten
4.
Install cup onto collet
5.
To
connect
readjust
consist of
pad
in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon
necting device.
The torch
shipped requiring consumables and
Figure 4-1: Cup, collet body,
cable adapter (with flex cable only), and
body
is
accessories indicated in
collet, power
tungsten electrode.
A.
as
2.
Install collet
Page
4
position,
remove
cup and
body.
a
general rule, electrode
extension
tension may vary
B.
according
Flexible Head
a
to
ex
application.
Adjustment
CAUTION: BENDING RIGID HEAD TORCH
can
damage torch.
Do not bend
rigid
is void if
head model torches.
rigid
head torch is bent in any
follows:
Install collet, slotted end last, into collet
OM-1 558
As
body.
manner.
1.
making
(see
should equal electrode diameter; but exact electrode
Warranty
Assembly
Assemble torch
electrode
loosen collet
IMPORTANT:
Lockoutltagging procedures
locking line disconnect switch
electrode
Section 6-2) into collet body, and position elec
trode tip outside cup rim. Tighten collet body.
sure
body.
body and collet into torch body
heat shield is in place.
Improper bending of flexible head torch can damage gas
hose. Make sureto bend onlywithin the middle portion of
torch neck (see Figure 4-1). Restrict bending angle to 90
degrees.
GAS HOSE CONNECTIONS AND GAS VALVE
4-2.
(If Applicable) (Figures
4-1 Thru
To install
high flex cable,
connect
high flex cable fitting
to
power cable adapter.
4-3)
IMPORTANT:
If torch includes
valve,
gas hose
gas valve, connect a suitable length of
not supplied) from power cable
hose
(extra
adapter
regulator/flowmeter (see Figure 4-2).
A.
a
lfpower source is not equipped with a gas
torch gas valve is required (see Figure 4-2).
High
Flex Cable
Assembly
If torch is without gas valve, connect a suitable length of
gas hose (not supplied) from power cable adapter to gas
valve outlet. Connect extra gas hose (not supplied) from
gas valve inlet to regulator/flowmeter (see Figure 4-3).
The high
flex cable assembly contains the power cable
within the gas hose. The high flex cable has a 3/8-24 fe
male
to
a
right-hand fitting (see Figure 4-1).
Torch
Regulator!
Flowmeter
Work
Clamp
Power
Cable
Adapter
Rot. SA.120 909
Figure
4-2. GTAW Torch Connection
Diagram
For Models With Gas Valve
Torch
Gas
Cylinder
Work
Clamp
Power
Cable
Gas
Valve
Adapter
Figure
4-3. GTAW Torch Connection
Ref. SA.120 909
Diagram
For Models Without Gas Valve
OM-1 558
Page
5
B.
Torch Gas Valve
Operation (If Applicable)
POWER CABLE CONNECTION
4-3.
Thru
The gas valve allows gas flow control at the torch. A onehalf turn counterclockwise opens the gas valve, and a
one-half turn clockwise closes the valve.
4-1
4-3)
WARNING: ELECTRIC SHOCK
a
(Figures
can
kill.
Do not touch live electrical parts.
Shut down
welding
power source, and dis
employing lockout/tag
ging procedures before installing torch.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon
necting device.
connect in put power
The gas valve allows control of gas postflow time, or the
length of time gas flows after the arc is extinguished. In
sufficient gas postflow results in an oxidized (black) elec
trode surface. If an oxidized electrode were used, the
black surface would contaminate the weld and
cause
poor arc direction.
allow 10 seconds of
The power cable is part of the high flex cable assembly.
For connection of both power cable and gas hose to
power cable adapter, see Section 4-2A.
gas postflow time per 100 amperes of weld current be
fore closing valve.
Connect power cable adapter to weld output terminal
(see Figures 4-2 and 4-3).
IMPORTANT: As
a
general rule,
SEQUENCE OF OPERATION
SECTION 5
a
WARNING:
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Keep all covers
operating.
and handle in
1.
place
GAS TUNGSTEN ARC WELDING
5-1.
while
2.
Install and connect torch
Make
tions
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
body, cup, and
securely tightened.
sure
are
according
collet
(GTAW)
to Section 4.
all gas
connec
regulator/flowmeter valve closed, open gas
cylinder valve.
3.
With
4.
Set power
5.
Wear
hearing.
Wear correct eye, ear, and
FUMES AND GASES
your health.
Keep your head
Ventilate to
can
body protection.
seriously
harm
6.
out of the fumes.
keep from breathing fumes
and
welding
amperage.
dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
7.
Energize welding power
source.
Set gas flow to desired level
(requires open gas
valve).
If ventilation is inadequate,
device.
use
approved
breathing
METAL, SPATTER, AND SLAG
HOT
for desired
ANSI Z49.1.
gases.
cause
source
IMPORTANT: Purge gas hose to clear hose of air, mois
ture, or any other contaminants. Allow gas to flow 2 to 3
minutes on new torch; 5 to 6 seconds thereafter.
can
fire and burns.
Begin welding.
8.
Watch for fire.
Keep
extinguisher nearby, and
fire
a
know
it.
how to
use
Do not
use near
flammable material.
equipment
to cool before
handling.
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
can
Wearers should consult their doctor before
going near arc welding, gouging, or spot weld
ing operations.
OM-1558
Page
6
Stopwelding.
1.
Allow work and
See Section 1
information.
SHUTTING DOWN
5-2.
-
Safety
Rules for additional
IMPORTANT: As a general rule, allow 10 seconds of
gas postflow time per 100 amperes of weld current be
fore closing valve.
2.
Turn off
3.
Turn off the
a
welding power
source.
shielding gas
at the source.
HIGH CONCENTRATION OF
WARNING:
SHIELDING GAS can harm health or kill.
Shut off gas
supply
when not in use.
SECTION 6
6-1.
ROUTINE MAINTENANCE
a
WARNING: ELECTRIC SHOCK can kill; HOT
SURFACES can cause severe burns.
MAINTENANCE
(Table 6-1)
Power Cable
2.
in
Inspect cables for breaks
all connections
are
cables if insulation breaks
Do not touch live electrical parts.
en
Shut down
nect
welding power source and discon
input power before working on torch.
Disconnect torch from we/ding power source
before inspecting, maintaining, or servicing.
Allow
a
cooling period
before
servicing.
connections at each
Figures
(Table
6-2
And
6-2)
Use Table 6-2 to select the correct size and type tung
Prepare the tungsten electrode using the
sten electrode.
following guidelines.
Table 6-1. Maintenance Schedule
A.
AC
For
or
A properly prepared tungsten elec
obtaining a satisfactory weld.
DC
Electrode
Positive
Welding
(Figure 6-1)
Maintenance
Every Week
replace
tight. Repair
present. Clean and tight
inspection.
6-1 And
trode is essential in
Frequency*
are
that
ensure
or
ELECTRODE
TUNGSTEN
6-2.
insulation, and
clean and
Ball the end of tungsten electrodes used for ac or dc
positive welding before beginning the welding
Inspect and clean torch, cables,
and hoses (see Sections 6-IA thru
electrode
6-iC).
operation. Weld amperage
causes
the tungsten elec
trode to form the balled end. The diameter of the end
Check and replace torch parts or
weld cables as necessary (see
Sections 6-lA thru 6-iC).
should not exceed the diameter of the tungsten elec
trode by more than 1-1/2 times. For example, the end of
a
of service is based on units operated
40 hours per week. Increase frequency of maint
enance if usage exceeds 40 hours per week.
*Frequency
1/8 in. (3.2 mm) diameter tungsten electrode should
3/16 in. (4.8 m) diameter end.
not exceed a
I-4-1-1/2
~
I
A.
Inspection
And
Cleaning
Times
Electrode
Diameter
~
A ]~_
I.
2-1/2 Times
Electrode
Diameter
WARNING: Read and follow safety informa
tion at beginning of entire Section 6-1 before
a
proceeding.
Inspect torch for broken areas, cracks and loose parts;
and replace as required.
tighten, repair
Remove grease and dirt from components, and mois
parts and cables.
>J.
ture from electrical
B.
Torch
AC And DC
Electrode Positive
Figure
Read and follow safety informa
tion at beginning of entire Section 6-1 before
B.
proceeding.
a
week
inspect condition of torch body
compo
nents.
Replace cup, heat shield, arid 0-ring if cracked. Main
tain tight fit of torch components to ensure good weld
quality.
C.
Hoses, Connections, And Cables
a
WARNING: Read and follow safety informa
tion at beginning of entire Section 6-1 before
Once
week
1.
proceeding.
a
S-0161
inspect hoses and connections.
Gas
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
6-1.
Properly Prepared Tungsten
Electrodes
For DC Electrode Negative
And
Once
Negative
Body
WARNING:
a
DC Electrode
a
Welding (Figures
6-1
6-2)
CAUTION: HOT FLYING METAL PARTICLES
can injure personnel, start fires, and dam
age equipment; TUNGSTEN CONTAMINA
TION can lower weld quality.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing
proper face, hand, and body protection.
Do not use same wheel for any other job,
the tungsten will become contaminated.
or
Shape tungsten electrodes on a fine grit, hard
abrasive wheel used only for tungsten shap
ing. Grind tungsten electrodes so that grind
ing marks run lengthwise with the electrode.
These procedures reduce the possibility of
the tungsten electrode transferring foreign
matter into the weld and help reduce arc
wander.
OM-1 558
Page
7
Grind the end of the tungsten electrode to
a
taper for
For additional information, see your distributor for a
handbook on the Gas Tungsten Arc Welding (GTAW)
a
distance of 2 to 2-1/2 electrode diameters in length. For
example, the ground surface for a 1/8 in. (3.2 mm) di
tungsten electrode should be 1/4
8.0 mm) long.
ameter
to
to
process.
5/16 in. (6.4
TUNGSTEN PREPARATION: IDEAL
TUNGSTEN PREPARATiON: WRONG
Stable Arc
Arc Wander
Straight
~
Point
Fiat
(The Dia. Of
Radial Ground
This
Fiat Governs
S-0162
Amperage Capacity)
Figure
6-2.
Tungsten Preparation
Table 6-2.
Amperage Range
Electrode Diameter
Pure
Tungsten
(Green Band)
.010
.020
.040
1/16
3/32.
1/8
5/32
3/16
1/4
Tungsten Size
DC-Argon Electrode
Negative/Straight Polarity
DC-Argon
-
Electrode
Positive/Reverse Polarity
Polarity
-
Gas
Type
AC-Argon Using
High Frequency
AC-Argon Balanced
Using High Freq.
Wave
Uptol5
*
Uptol5
UptolO
5-20
15-80
70-150
125-225
225-360
360-450
450-720
720-950
*
5-20
10-60
50-100
100-160
150-210
10-20
20-30
30-80
60-130
100-180
200-275
250-350
325-450
160-240
190-300
250-400
*
10-20
15-30
25-40
40-55
55-80
80-1 25
2% ThorIum
Alloyed
Tungsten
(Red Band)
.010
.020
.040
1/16
3/32
1/8
5/32
3/16
1/4
Upto25
*
Upto2O
Uptol5
15-40
25-85
50-160
135-235
250-400
400-500
500-750
750-1000
*
40-55
55-80
80-125
15-35
20-80
50-150
130-250
225-360
300-450
400-500
600-800
5-20
20-60
60-120
100-180
160-250
200-320
290-390
340-525
*
10-20
15-30
25-40
Alloyed
Tungsten
(Brown Band)
Zirconium
*
*
Upto2O
Uptol5
*
*
*
*
1/16
3/32
1/8
5/32
3/16
*
*
*
*
~
*
5-20
20-60
60-120
100-180
160-250
*
~
*
*
1/4
*
*
15-35
20-80
50-150
130-250
225-360
300-450
400-550
600-800
.010
.020
.040
*NOT RECOMMENDED
The figures listed are intended as a guide and
Society (AWS) and electrode manufacturers.
OM-1558 PageS
are a
200-320
290-390
340-525
composite of recommendations from American Welding
S-000gf888
.
SECTION 7
PARTS LIST
Quantity
Model
Item
No.
24
Stock No.
Description
Model No.
Figure
7-1.
Complete
24VF
Torch Assembly
TUNGSTEN, electrode (consult your welding distributor)
CUP, (see Fig 7-2)
COLLET BODY, (see Fig 7-2)
1
2
3
COLLET, (see Fig 7-2)
4
HEAT SHIELD
1
1
116557
TORCH BODY
TORCH BODY
116 556
TORCH BODY, with valve (consisting of)
8OTHS
5
120602
6
116540
6
6
7
116 255
100VK
8
116254
100R
9
117585
HANDLE
9
118 516
HANDLE, model w/valve
10
24F
116572
VALVE
1
1
1
KNOB, (consisting of)
1
~0-RING
1PCA
1
1
POWERCABLEADAPTER
1
1
HI-FLEX POWER
1
1
CABLE, 12-1/2ft (consisting of)
HI-FLEX POWER CABLE, 25ft (consisting of)
112PCW
125PCW
1
1
11
116 550
11
116 551
12
120720
.
13
120 723
.
RING NUT
POWER CABLE NUT
1
1
2
2
2
2
5
Fig
Fig
Fig
7-2
7-2
7-2
4
3
7
2
9
1N>2
>
10
11
SA120
Figure
7-1.
Complete
Torch
761
Assembly
OPTIONAL
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 558 Page 9
Orif ce
1/4
Cup
5/16
3/8
10-235 150-250 8CG3 2 234120 2GL3 2 1 9 0
1/16 (1.6) 50-150 70-150 8CG1 6 233120 2GL1 6 1 98 9
.040 (1.0) 10-80 15-80 8CG40 232120 2GL40 1 98
.020 (0.5) 5-20 5-20 8CG20 231120 2GL20 1 98 7
7/16
3/32 (2.4)
lena Body Sari.,
Col at
shield 887
Col at Sane,
8G1IS Stock
Ga~ 2GL
heat 119
No.
Len.
Use
Ga. 8CG
in
Body Sari.
Standr Coliat 8C8
SELCTOR
PARTS
CONSUMABLE
(m ) ACHF DCSP
heat 120
No.
ModelN. Stock ModelNo. Stock
Standr Colet Series
U.e
8C
torch.
Orif ce
complet
165 1/4
Cup
5/16
3/8
Body
Gas
Col et
For
Body,
Col et
Col et.
Note:
ModelN. StockN. ModelN. Stock
1/4
3/8
(8C1)
(8C5)
(8C4L) (8C6L)
1 941
409
421 420
119 119
Diametr Range (Standr) (Standr) Cup
Body Ceramic
Tungsten Amperag Colet Colet
_
C
O
M
P
E
T
I
V
1986(2AG7) STOCK
~
Cup Long
Ceramic 1/8
1
2AG4 2AG5 2AG6 2AG7
2
G
L
2
0
2
G
L
4
0
8
C
G
2
0
8
C
G
4
0
2
G
L
3
2
2
G
L
1
6
8
C
G
1
6
8
C
G
3
2
MODEL
CROS
NO.
231
120
234 898
120 119
120 32 120 3 1 98 7 1 98 9 1 9 0 1 98 3 1 98 4 1 98 5 1 98 6
Chart
Refrnce
Cros
Parts
Indicate Usage
Consumable
Recomnd
7-2.
TO
119
NO.
1
Shade
Stock/Mdel 1940(8C) 19408C6)
24GLC32
53N62 53N63 53N64 45V41 45V42 45V43 45V4 53N58 53N59 53N60 53N61
Long ~
Areas
No. No.
(m ) ACHF DCSP
Alumina
CMODEL OMPETIV
And
3/32 (2.4)
in
119 119 119
Lens Cup
10 -235 150-250 8C3 2 1 9416 8CB3 2 1 98 6
1/16 (1.6) 50-150 70-150 8C1 6 1 9417 8CB1 6 1 98 5
Cable .040 (1.0) 10-80 15-80 8C40 1 9418 8CB40 1 98 4
Power
.020 (0.5) 5-20 5-20 8C20 1 9419 8CB20 1 98 3
and
Cup
Gas
893 894 895
(Gas
to
required
Adapter
Stock/Mdel
(2AG4) (2AG5) (2AG6)
Lens)
Diametr Range Lens)
(Gas
Tungsten Amperag Colet
BaTHS Stock
REF NC
No. No.
No.
shield 602
TO
REF NC
CMODEL OMPETIV
NO.
CCROS OMPETIV MODEL
NO.
Figure
53N15 53N16 53N14 24C3 2 53N17 53N18 53N19 24CB3 2 53N23 53N24 53N25 53N27 53N28 53N26
8C20 8C40 8C1 6 8C3 2 8CB20 8CB40 8CB1 6 8CB3 2 8C1 8C4 8C5 8C6 .8C4L 8C6L
STOCK 1 9419 1 9418 1 9417 1 9416 1 98 3 1 98 4 1 98 5 1 98 6 1 941 1 9410 1 9409 1 9408 1 9421 1 9420
OPTIONS AND ACCESSORIES
POWER CABLE ADAPTERS
FTC-14
torches with one-piece,
(Required
high-flex cable assembly and all
water-cooled torches.)
AND CURRENT CONTROL
on
REMOTE
CONTACTOR
HRF-2425
TIG
Fastens
handle.
to
torch
Includes 28 ft. (8.5 m) cord and
14-pin plug.
80
Stock No.
53N43
(#116 572)
Torch
TIG
CGA
inlet
580
outlet pressure is
preset at 25 PSIG; the maximum
inlet is 3000 PSIG and has 5-40
SCFH gas delivery.
includes
TORCH
(#135 492)
For direct connection of one-piece
or water-cooled TIG torches
into power sources with International
torches
style
the
AF-150
Torch handles with a built-in switch
for remote contactor control of Miller
TIG
sources.
power
Includes 25 ft. (7.6 m) control cord
with
RLC-H14-S
cord with 14-pin plug
for direct connection to all Miller
solid-state TIG power sources.
(#129 332)
of 8-25
SCFH with argon gas.
TIG TORCH CABLE COVERS
available in length to fit 12-1/2 ft. and
25 ft. (3.8 and 7.6 m) torches.
(Locking)
(#129 335)
(7.6 m) control
gases. The AF-150 is
Reinforced plastic cable covers
made of tear and flame resistant
material. A large and small cover is
(Momentary)
(#129 336)
Torch handle with built-in contactor
and amperage control. Includes 25 ft.
argon/CO2
adjustable for gas delivery
14-pin Amphenol plug.
RMC-H14-S
RFTC-H14 AMPERAGE AND
CONTACTOR CONTROLS
(#127 662)
The AF- 150 is a flowgauge regulator
which includes the 580 CGA inlet
connector for use with argon and
RMC-H14 AND RLC-Hi4
CONTACTOR SWITCHES
solid-state
connectors.
RFTC-H14-S
The HRF-2425 regulator/flowmeter
is designed for MIG, TIC, and other
inert gas welding applications. It
connector. The
Adapter
Amp
(#127 661)
(#129 338)
:q
INTERNATIONAL
CONNECTOR KIT
GAS REGULATORS
CC-i 2S
(#126 150)
Note: Cannot be used on torch with
manual gas valve. For field installa
tion only; replaces standard torch
handle.
For 12-1/2 ft. (3.8 m) torches.
TIG HOSE HOOK-UP KITS
For 25 ft.
THK-2
(air-cooled)
(THK)
CC-25S
(#126 151)
(7.6 m) torches.
(#128 066)
Provides the necessary hoses and
hardware to connect air-cooled
torches to a power source.
Note: Cannot be used on torches with
manual gas valve. For field installa
tion only; replaces standard torch
handle.
8/90