Miller Electric MTTC-1525NR Specifications

Miller.
March 1991
FORM: OM-1 561
Effective With
Style
N o. JJ-23
MODEL: MTTC-1512HR
MTTC-1 525HR
MTTC-1 51 2NR
MTTC-1 525NR
MTTC-1 51 2VHR
MTTC-1 525VHR
MTTC-1 51 2VNR
MTTC-1 525VN A
OWNERS
MANUAL
IMPORTANT:
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
ment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not
SA-120 674
fully
MILLER ELECTRIC
A Miller
Mfg.
Co.
Group Ltd., Company
P.O. Box 1079
Appleton,
WI
54912 USA
Tel. 414-734-9821
understand these instructions.
PRINTED IN U.S.A.
1.~
LIMITED WARRANTY
EFFECTIVE: AUGUST 6, 1990
This warranty
supersedes
previous
all
LIMITED WARRANTY
hereof. MILLER Electric
MILLER warranties and is exclusive with
Subject to the terms and conditions
Mfg. Co., Appleton, Wisconsin war
Distributor/Dealer that all new and unused
by MILLER is free from defect in
workmanship and material as ot 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 warrantied by their manufacturer for two
rants
to
its
Equipment
furnished
years from date of original purchase, except Deutz
which have a one year, 2000 hour warranty.
engines
Except 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 wire
including nozzles and nozzle insulators where failure does not
result from defect in workmanship or material.
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) replace
ment or, where authorized in writing by MILLER in appropriate
(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
cases,
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 FOB. at a MILLER
authorized service facility, therefore, no compensation for
transportation costs of any kind will be allowed. Upon receipt of
notice of apparent defect or failure, MILLER shall instruct the
claimant on the warranty claim procedures to be followed.
to
MILLER shall be
required to honor warranty claims on war
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:
ranted
1.
2.
Arc welders, power
components
1 year
sources, robots, and
Load banks
main power rectifiers
1 year
3 years
3.
Original
4.
All
5.
All other MILLERMATIC Feeders
1 year only)
welding guns. feeder/guns
EXPRESS WARRANTY NOT PROVIDED HEREIN
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.
WITH
ANY
AND
RESPECT
TO
EQUIPMENT
ALL
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
ANY
AND ANY IMPLIED
(labor
6.
Replacement
7.
Batteries
or
and torches
.
.
90
days
1 year
repair parts, exclusive
provided that MILLER is notified in
of the date of such failure.
.
of labor
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.
11
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,
:f
OM-1561A
3/91
RECEIVING-HANDLING
Before
unpacking equipment, check carton for any damthat
age
may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
spaces to record the Model Designa
or Style Number of your unit. The infor
mation is located on the data card or the nameplate.
Use the
following
tion and Serial
Assistance for
filing or settling claims may be obtained
from the distributor and/or the equipment manufactur
ers Transportation Department.
_________________________________________
Serial
When requesting information about this equipment, al
ways provide the Model Description and Serial or Style
N umber.
or
Style
No.
____________________________
Date of Purchase
______________________________
TABLE OF CONTENTS
Section No.
SECTION 1
Page
SAFETY RULES
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
SECTION 2
Prevent Electric Shock
Provide Protection From Fumes And Gases
Protect Eyes And Skin From Arc Rays; Protect Ears From Noise
Prevent Fires And Burns
1
Protect Compressed Gas Cylinders
Provide Protection For Special Situations
Provide Proper Equipment Maintenance
Additional Safety Information
1
1
1
1
1
2
2
SAFETY PRECAUTIONS AND SIGNAL WORDS
General Information And
Safety Alert Symbol And
2-1.
2-2.
SECTION 3
Safety
Signal
Words
3
3
SPECIFICATIONS
3-1.
3-2.
Duty Cycle
Description
SECTION 4
3
3
INSTALLATION
Torch Body
Gas Hose Connections And Gas Valve (If Applicable)
Power Cable Connection
4-1.
4-2.
4-3.
SECTION 5SEQUENCE
Tungsten Arc Welding (GTAW)
Shutting Down
5-2.
SECTION 6
4
5
OF OPERATION
Gas
5-1.
4
6
6
MAINTENANCE
6-1.
6-2.
Routine Maintenance
Electrode
Tungsten
SECTION 7
6
7
PARTS LIST
Figure
Figure
7-1.
Complete
Torch
Assembly
7-2. Consumable Parts
10
12
LIST OF CHARTS AND TABLES
Table
Table
Table
Table
3-1.
Specifications
6-1. Maintenance Schedule
6-2. Tungsten Size
7-1. Cross Reference To Competitive Model
3
6
8
13
No.
SAFETY RULES
SECTION 1
a
WARNING:
PRACTICES
jury
or
UNSAFE
can cause
PROCEDURES OR
serious personal in-
ARC
death.
Read, understand, and follow ALL of these
safety rules before installing, operating,
seniicing 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.
2.
PREVENT ELECTRIC SHOCK
Touching live electrical parts can cause severe burns to
the body or fatal shock. Severity of electrical shock is de
termined by the path and amount of current through the
body. Therefore:
Do not touch live electrical parts.
2.
Do not work in wet
3.
Wear
or
damp
dry insulating gloves
body protection.
a
welding helmet fitted with a proper filter
(see ANSI Z49.1 for detailed information).
Use
protective
a
screens or
from flash and
Wear
barriers to protect oth
glare.
protective clothing
and foot
protection.
1-4.
PREVENT FIRES AND BURNS
The hot
workpiece, hot equipment, other hot metal, spat
arc sparks can cause fires and burns.
1.
Wear correct eye, face, and
work area.
2.
Allow work and
areas.
and
damage hearing.
helmet fitted with
lens
ter, and
1.
can
processes
a proper filter
welding
for
detailed
Z49.1
ANSI
information).
(see
Wear
ers
4.
some
Wear
lens
3.
1-I.
PROTECT EYES AND SKIN FROM
RAYS; PROTECT EARS FROM NOISE
1-3.
body protection
equipment
in the
to cool before han
dling.
4.
Disconnect all power before
this
5.
Turn off all
6.
Properly
equipment when
install and
according
applicable codes.
source
7.
installing or servicing
3.
Do not weld
4.
Watch for fire,
Do not
not in
ground
the
to its Owners
small
or
welding
power
Manual and all
5.
Do not touch electrode and any
or circuit at the same time.
grounded object
or
at once.
available from the National
Batterymarch Park,
PROTECT COMPRESSED GAS CYLINDERS
2.
PROVIDE PROTECTION FROM FUMES AND
GASES
3.
can
be hazardous
4.
to your health.
cylinder are normally part of the welding
carefully.
Protect compressed gas cylinders from
sive heat, mechanical shocks, and arcs.
proc
exces
cylinder so that they cannot fall
by fastening them to a mounting
bracket, wall, or other stationary support.
Install and secure
or
and gases
extinguisher
ess, be sure to treat them
1.
only well-maintained equipment. Repair
Breathing welding fumes
fire
body.
Since gas
replace damaged parts
a
For additional information, refer to NFPA StanPrevention in Use of Cutting and
Fire Protection Association,
Quincy, MA 02269.
1-5.
9.
keep
dard 51 B, Fire
damaged cables or cables that
poorly spliced.
Do not wrap cables around your
1-2.
and
Welding Processes,
8.
Use
flammable material.
nearby.
use.
use worn or
are too
10.
near
equipment.
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
2.
Use
head out of the fumes.
1-6.
adequate ventilation
in the work
fumes and gases from your
the
general
area
breathing
to
keep
zone
PROVIDE PROTECTION FOR SPECIAL SITU-
ATIONS
and
1.
work area.
Do not weld
have held
3.
If ventilation is
breathing
4.
inadequate,
use
an
approved
rials used.
cut containers or materials which
been in contact with hazardous sub
or
stances unless
device.
Read the Material Safety Data Sheets (MSDSs)
andthemanufacturersinstructionsforanymate-
or
they
are
properly cleaned and
in
spected.
2.
Do not weld
or
cut
special ventilation
toxic fumes
or
painted or plated parts unless
is provided to remove highly
gases.
OM-1561 Page 1
3.
Since
welding can affect pacemakers, keep all
pacemaker wearers out of the work area. Have
them consult a doctor before coming near a weld
ing operation.
1.
ami, FL 33126.
2.
PROPER
PROVIDE
NANCE
1-7.
Improperly
EQUIPMENT MAINTE
maintained
1.
through
fires
Always
have
equipment
or
can
cause
qualified personnel perform the
and
2.
Maintain cables,
4.
5.
Keep all safety devices, guards, panels, and cov
in position and in good repair.
equipment for its intended purpose. Do
modify it in any manner.
Use
ANSI Standard Z87.1 Safe Practice for Occupa
tion and Educational Eye and Face Protection,
available from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
7.
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.
8.
CSA Standard WI 17.2, Code for Safety in Weld
ing and Cutting, available from the Canadian
Standards Association, 178 Rexdale Blvd., Rex
not
ADDITIONAL SAFETY INFORMATION
For more information on 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:
Page
2
NFPA Standard 70, National Electrical Code,
available from the National Fire Protection Asso
6.
ers
OM-1561
available from
accessories.
equipment
Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles,
oil or grease, corrosive atmospheres, and inclem
1-8.
Prevention in Use of
Welding Processes,
ciation, Batterymarch Park, Quincy, MA 02269.
or
ent weather.
6.
and
the National Fire Protection Association, Bat
terymarch Park, Quincy, MA 02269.
source.
able condition.
5.
N.W. LeJeune Rd, Miami,
NFPA Standard 51 B, Fire
Cutting
grounding wire, connections,
Do not abuse any
,
FL 33126.
power cord, and power supply in a safe working
order. Do not operate any equipment in question
4.
AWS Standard F4.1 Recommended Safe Prac
tices for the Preparation for Welding and Cutting
of Containers and Piping That Have Held Hazard
available from the American
ous Substances,
Welding Society, 550
work unless
performing any maintenance work inside
power supply, disconnect the power supply from
the electrical power
3.
in
Before
a
3.
maintenance
troubleshooting,
perform any electrical
fully qualified.
work. Do not
are
,
result in poor
physical injury or
electrical shock. Therefore:
stallation,
you
AWS Standard A6.1 Recommended Safe Prac
tices for Gas Shielded Arc Welding, available
from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 331 26.
work, but most importantly it can
death
ANSI Standard Z49.1 available from the Ameri
can Welding Society, 550 N.W. LeJeune Rd, Mi
,
dale, Ontario, Canada M9W 1 R3.
9.
See also the Standards Booklet Index in the weld
ing power source Owners Manual.
SECTION 2
SAFETY PRECAUTIONS AND SIGNAL WORDS
GENERAL INFORMATION AND SAFETY
2-1.
General
Information presented in this manual and on various la
bels, tags, and plates on the unit pertains to equipment
SAFETY
WORDS
2-2.
SYMBOL
ALERT
AND
SIGNAL
A.
installation,
design,
maintenance, and
troubleshooting which should be read, understood, and
operation,
The
following safety alert symbol and signal words are
throughout this manual to call attention to and iden
used
tify different
This
levels of hazard and special instructions.
safety alert symbol is used with the signal
equipment.
a
WARNING statements
The installation, operation, maintenance, and trouble
a
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
followed for the safe and effective
B.
use
of this
Safety
shooting of arc welding equipment requires practices
procedures which ensure personal safety and 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 applicable
and
codes such as, but not limited to, those listed at the end
of Section 1
Safety Rules.
SECTION 3
Table 3-1.
Ampere Rating
Tun9sten
at
Model
100%Dut
Size
DCEN,
Capacity
XCl~F
.020 thru
1/8 in.
*150 Amperes
With Argon
(0.5
thru
3.2
mm)
damage
to this
equipment.
Specifications
Weight
Cable
Length
Torch
Cooling
Body
Method
Length:
8.0 in.
(203 mm)
25 ft.
Weight:
(7.6 m)
Net
Ship
2.5 lbs.
3.0 lbs.
(1.1 kg)
(1.4 kg)
Length:
12.5 ft.
25 ft.
MUG-i 525VNR
(7.6 m)
*Rated With Gas Lens Collet
oz.
5.0 lbs.
5.5 lbs.
(2.3 kg)
(2.5 kg)
8.8 in.
(222 mm)
Handle Diameter:
0.9 in. (23 mm)
Weight:
7.5
oz.
(210 g)
2.5 lbs.
3.0 lbs.
(1.1 kg)
(1.4 kg)
5.0 lbs.
5.5 lbs.
(2.3 kg)
(2.5 kg)
Body
DUTY CYCLE
3-2.
welding
a
4.6
(130 g)
Air
MUG-i 525VHR
torch is the percentage of a
torch can be operated at a given
load. This torch is rated at 100%
shielding
or
statements
SPECIFICATIONS
(3.8 m)
MUC-1512VNR
that
personal injury
or
to avoid seri
Handle Diameter:
0.9 in. (23 mm)
MUG-i 51 2VHR
a
identify procedures
ment.
12.5 ft
duty cycle of
minute period
statements.
identify special instructions
efficient
the
most
for
operation of this equip
necessary
(3.8 m)
The
safety
practices which must be followed
ous personal injury or loss of life.
IMPORTANT
MTTC-1512NR
MUC-1525NR
ten
tion to the
MTTC-1512HR
MUG-i 525HR
3-1.
words WARNING and CAUTION to call atten
duty cycle using argon
gas. This means that the torch
at rated load conditions continuously.
can
be
operated
DESCRIPTION
heavy duty torch is specifically for use
Tungsten Arc Welding (GTAW) process.
The alphanumeric model designation refers to the
following:
This air-cooled
with the Gas
150 Amperes
(3.8 m) Cable
25 25 ft. (7.6 m) Cable
H High-Flex Cable (1 piece assembly)
N High-Performance Cable (2 piece assembly)
R Rigid Head
15
-
Ampere Rating:
12- 12.5 ft.
a
CAUTION:
EXCEEDING
THE
RATED
AMPERAGE and duty cycle can result in
damage to the torch.
-
-
-
Do not exceed rated amperage and duty cycle
stated in Table 3-1.
-
V
-
Gas Valve
OM-1561 Page 3
SECTION 4INSTALLATION
0-Ring
Short
Backcap
Heat Shi
Gas Valve
*Coliet
(If Applicable)
Handle
*Cup
Flex Cable
High
Fitting
7
S
~
Power Cable
_S5_
*Power Cable
Adapter
*pequlred Consumables and Accessories
*~0btain from Welding Equipment Supplier
SA-120 751
Figure
4-1. Torch
TORCH BODY (Figure 4-1)
4-1.
Components
properly prepared tungsten electrode (see
6-2) through front of collet body to posi
tion electrode tip outside cup rim. Securely tight
en backcap.
Install
5.
Section
J~
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
_____
Shut down
welding power
source, and dis
input power employing lockout/tag
ging procedures before installing torch.
To
6.
electrode
readjust
connect
Lockout/tagging procedures
locking line disconnect switch
consist of pad
in open position,
removing fuses from fuse box, or shutting off
red-tagging circuit breaker or other discon
necting device.
and
The torch
body
is
shipped requiring consumables and
Figure 4-1: cup, collet body,
collet, power cable adapter (with High-Flex Cable only),
and tungsten electrode. Assemble torch as follows:
accessories indicated in
1.
Install collet
body into
place.
torch
body making
sure
heat shield is in
2.
3.
4.
Install cup onto collet
Remove
backcap
IMPORTANT:
and install standard collet,
a
general rule,
electrode extension
should equal electrode diameter; but exact electrode ex
tension may vary
according
to
application.
GAS HOSE CONNECTIONS AND GAS VALVE
4-2.
(If Applicable) (Figures
4-1 Thru
4-3)
IMPORTANT: If powersource is not equipped with a gas
a torch gas valve is required (see Figure 4-2).
valve,
A.
High-Flex
Cable
Assembly
high-flex cable assembly contains the power cable
within the gas hose. The high-flex cable has a 5/8-18
male right-hand fitting (see Figure 4-1).
The
To install
body.
As
position, loosen backcap.
high-flex cable,
to power cable
connect
high-flex
cable
fitting
adapter.
slotted end first, through back of torch body into
collet body. If using reverse collet, install collet
If torch includes a gas valve, connect a suitable length of
gas hose (extra hose not supplied) from power cable
with slotted end toward
adapter
backcap.
Loosely install backcap and 0-ring (supplied
backcap) onto torch body.
OM-1 561
Page
4
on
to
regulator/flowmeter (see Figure 4-2).
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).
B.
Thru
High-Performance Cable Assembly
The
If torch includes
a
5/8-18
Shut down
connect
4-2).
Torch Gas Valve
regulator/flowmeter
Operation (If Applicable)
A.
The gas valve allows gas flow control at the torch. A onehalf turn counterclockwise opens the gas valve, and a
The gas valve allows control of gas postflow time, or the
length of time gas flows after the arc is extinguished. In
power source, and dis
before
installing torch.
High-Flex
Cable
Assembly
Connect power cable adapter to weld output terminal
(see Figures 4-2 and 4-3).
sufficient gas postflow results in an oxidized (black) elec
an oxidized electrode were used, the
black surface would contaminate the weld and cause
trode surface. If
arc
welding
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.
one-half turn clockwise closes the valve.
poor
kill.
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.
If torch is without gas valve, connect gas hose fitting to
gas valve outlet. Connect gas hose (extra hose not
C.
can
input power employing lockout/tag
ging procedures
gas valve, connect gas hose fitting to
regulator/flowmeter (extra hose not supplied, see Figure
to
4-1
Do not touch live electrical parts.
a
supplied) from gas valve inlet
(see Figure 4-3).
(Figures
4-3)
WARNING: ELECTRIC SHOCK
a
high-performance cable assembly has separate
power cable and gas hose. The gas hose has
male right-hand fitting (see Figure 4-1).
POWER CABLE CONNECTION
4-3.
High-Performance Cable Assembly
B.
The
direction.
high-performance
cable
has separate
assembly
power cable and gas hose.
IMPORTANT: As a general rule, allow 10 seconds of
gas postflow time per 100 amperes of weld current be
fore closing valve.
To install power cable, connect power cable connector to
weld output terminal (see Figures 4-2 and 4-3).
Torch
7
Power Cable
Work
Clamp
Adapter
Gas
Power Cable
Work
Cylinder
Clamp
Gas
Cylinder
Ret. SA-120 824
High-Flex Cable Assembly
Figure
Connector
High-Performance
4-2. GTAW Torch Connection
Cable
Assembly
For Models With Gas Valve
Diagram
Regulator/
Flowmeter
Torch
7Work
Clamp
Power Cable
Adapter
Work
Gas Valve
Gas
High-Flex
Figure
Cable
Clamp
Connector
Gas Valve
Gas
Cylinder
Cylinder
Ret. SA.1 20824
High-Performance Cable Assembly
Assembly
4-3. GTAW Torch Connection
Power Cable
Diagram
For Models Without Gas Valve
OM-1561
Page
5
SECTION 5
a
WARNING:
ELECTRIC SHOCK
SEQUENCE OF OPERATION
can
kill.
GAS TUNGSTEN ARC WELDING
5-1.
1.
Install and connect torch
place while
2.
Make sure backcap
securely tightened.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
3.
With
4.
Set power
5.
Wear
Do not touch live electrical parts.
Keep all covers
operating.
and handle in
FUMES AND GASES
your health.
Keep your
can
body protection.
seriously
Ventilate to
keep
from
If ventilation is inadequate,
device.
use
approved
Set gas flow to desired level
7.
Keep
a
fire
extinguisher nearby,
use
Do not
use near
open gas
Purge gas hose to clearhose of air, mois
contaminants. Allow gas to flow 2 to 3
other
ture,
any
minutes on new torch; 5 to 6 seconds thereafter.
can
and know
it.
equipment
to cool before
MAGNETIC FIELDS FROM HIGH CURRENTS
affect pacemaker operation.
can
Wearers should consult their doctor before
going neararc welding, gouging, or spot weld
ing operations.
-
Safety
Rules for additional
6-1.
ROUTINE MAINTENANCE
a
WARNING: ELECTRIC SHOCK can kill; HOT
SURFACES can cause severe burns.
2.
Turn off welding power
3.
Turn off the
a
on
source.
shielding gas
at the source.
HIGH CONCENTRATION OF
WARNING:
SHIELDING GAS can harm health or kill.
supply
when not in use.
MAINTENANCE
Table 6-1. Maintenance Schedule
Maintenance
Frequency*
Every
welding power source and discon
input power before working
Week
Inspect and clean torch, cables,
and hoses (see Sections 6-lA thru
6-iC).
torch.
Disconnect torch from welding power source
before inspecting, maintaining, or sen/icing.
a
IMPORTANT: As a general rule, allow 10 seconds of
gas postflow time per 100 amperes of weld current be
fore closing valve.
(Table 6-1)
Do not touch live electrical parts.
Allow
Stop welding.
Shut off gas
SECTION 6
Shut down
SHUTTING DOWN
5-2.
1.
handling.
See Section 1
information.
Begin welding.
flammable material.
Allow work and
6
(requires
IMPORTANT:
8.
how to
Page
source.
tire and burns.
Watch for fire.
OM-1561
welding amperage.
or
METAL, SPATTER, AND SLAG
nect
open gas
valve).
breathing
cause
for desired
Energize welding power
gases.
HOT
source
are
ANSI Z49.1.
6.
fumes and
breathing
and all gas connections
dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
harm
head out of (he fumes.
to Section 4.
regulator/flowmeter valve closed,
cylinder valve.
hearing.
Wear correct eye, ear, and
according
(GTAW)
cooling period before servicing.
Check and replace torch parts or
weld cables as necessary (see
Sections 6-lA thru 6-10).
is based on uruts operated
40 hours per week. Increase frequency of maint
enance if usage exceeds 40 hours per week.
*Frequency of service
A.
Inspection
a
And
Cleaning
trode to form the balled end. The diameter of the end
should not exceed the diameter of the tungsten elec
by more than 1-1/2 times. For example, the end of
WARNING: Read and follow safety informa
tion at beginning of entire Section 6-1 before
trode
proceeding.
a
1/8 in. (3.2 mm) diameter tungsten electrode should
a 3/16 in. (4.8 m) diameter end.
not exceed
Inspect torch for broken areas, cracks and loose parts;
tighten, repair and replace as required.
H H1~1/2
Times
Electrode
Diameter
A IE
Remove grease and dirt from components, and mois
ture from electrical parts and cables.
B.
Torch
Once
Electrode
Diameter
Body
WARNING:
a
2-1/2 TImes
Read and follow safety informa
of entire Section 6-1 before
tion at
beginning
proceeding.
a
week
inspect
condition of torch
body
compo
nents.
DC Electrode
Ac And DC
Electrode Positive
Replace cup, heat shield, backcap, and 0-rings if
cracked. Maintain tight fit of torch components to ensure
good weld quality.
Figure
6-1.
Negative
s.olGl
Properly Prepared Tungsten
Electrodes
C.
Hoses, Connections, And Cables
B.
WARNING: Read and follow safety informa
tion at beginning of entire Section 6-1 before
a
Once
1.
proceeding.
week
a
inspect hoses
For DC Electrode
And
a
and connections.
Gas
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing
proper face, hand, and body protection.
Power Cable
Inspect cables for breaks
Do not use same wheel for any other job,
the tungsten will become contaminated.
in
insulation, and ensure that
tight. Repair or replace
cables if insulation breaks are present. Clean and tight
en connections at each inspection.
all connections
6-2.
are
Figures
ELECTRODE
6-1 And
(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.
trode is essential in
A.
For
AC
or
A
elec
Grind the end of the tungsten electrode to a taper for a
distance of 2 to 2-1/2 electrode diameters in length. For
Welding
example, the ground surface for a 1/8 in. (3.2 mm) di
ameter tungsten electrode should be 1/4 to 5/16 in. (6.4
to 8.0 mm) long.
properly prepared tungsten
obtaining a satisfactory weld.
DC
Electrode
Positive
(Figure 6-1)
Ball the end of tungsten electrodes used for ac or dc
welding before beginning the welding
operation. Weld amperage causes the tungsten elec
electrode positive
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.
clean and
TUNGSTEN
6-1
CAUTION: HOT FLYING METAL PARTICLES
can injure personnel, start fires, and dam
age equipment; TUNGSTEN CONTAMINA
TION can lower weld quality.
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
2.
Negative Welding (Figures
6-2)
For additional information,
handbook
on
the Gas
see
Tungsten
your distributor for a
Arc Welding (GTAW)
process.
OM-1561 Page 7
TUNGSTEN PREPARATION: IDEAL
TUNGSTEN PREPARATION: WRONG
Stable Arc
Arc Wander
Straight
~
Flat
Dia. Of This
Flat Governs
Radial Ground
S -0 162
(The
Amperage Capacity)
Figure
6-2.
Tungsten Preparation
Table 6-2.
Electrode Diameter
Pure
Tungsten
(Green Band)
.010
.020
.040
1/16
3/32
1/8
5/32
3/16
1/4
2% Thorium
Tungsten Size
Amperage Range
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
200-275
250-350
325-450
10-20
20-30
30-80
60-130
100-180
160-240
190-300
250-400
*
10-20
15-30
25-40
40-55
55-80
80-1 25
Alloyed
Tungsten
(Red_Band)
.010
Upto25
*
Upto2O
Uptol5
.020
.040
15-40
25-85
50-160
135-235
250-400
400-500
500-750
750-1000
*
10-20
15-30
25-40
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
.010
.020
.040
1/16
3/32
1/8
5/32
3/16
*
*
*
1/4
to 20
15-35
20-80
50-150
130-250
225-360
300-450
400-550
600-800
Up
*
1/16
3/32
1/8
5/32
3/16
1/4
*
Zirconium
Alloyed
Tungsten
(Brown_Band)
*
*
*
*
~
*
*
*
~
*
~
*
*
*
*NOT RECOMMENDED
The figures listed are intended as a guide and
Society (AWS) and electrode manufacturers.
OM-1561
Page
8
are a
Up
to 15
5-20
20-60
60-120
100-180
160-250
200-320
290-390
340-525
composite of recommendations from American Welding
S-0009/8-88
SECTION 7
PARTS LIST
OM-1561
Page
9
Quantity
Model
Stock
No.
Item
No.
Model
No.
Figure
2
3
4
116 211
5
116 256
300HS
5
119
914
3GHS
5
ii~
915
3GHSLD
4
116 212
5
116 256
300HS
6
116 219
01 -00 12
7
116 217
01-0002
FLHV
HR
VHR
Description
7-1.
Complete
Torch
Assemly
TUNGSTEN, electrode (consult your welding supply distributor)
CUP, (see Fig 7-2)
COLLET BODY, (see Fig 7-2)
TORCH BODY, w/ heatshield (consisting of)
HEATSHIELD, std
HEATSHIELD, sm dia gas lens
HEATSHIELD, Ig dia gas lens
TORCH BODY, w/ heatshield, valve & handle adapter
8
116 216
116 218
10
116 220
01-0007
01 -0013
11
116 217
01-0002
13
116 259
13
116
258
13
116
257
300L
14
116 260
300R
15
117 585
1
1
1
1
1
0-RING
0-RING
1
1
2
2
1
1
1
1
1
1
0-RING
COLLET (see Fig 7-2)
BACKCAP, short (consisting of)
1
1
1
1
BACKCAP, medium (consisting of)
BACKCAP, long (consisting of)
I
I
(consisting of)
HANDLE ADAPTER
300S
1
1
1
SCREW, non-conductive
300M
1
1
1
VALVE HANDLE
12
1
HEATSHIELD, medium
(consisting of)
9
NR
VNR
(consisting of)
1
1
0-RING
1
1
HANDLE
1
1
4
7-2
Fig
Fig
7-2
\3
8
10
2
1
-5
Includes
Item 30
__5
5
5__.
28
Includes
Item2827
19
-
26
~24
23
5.-.-
22~
_______________
25
21~
20
SA-120 751
FIgure
OM-1561 Page 10
7-1.
Complete
Torch
Assembly
Quantity
Model
Item
No.
Stock
No.
Model
No.
Figure
16
16
116 271
17
120721
18
116 272
1512PCHF
1525PCHF
120 720
7-1.
Complete
Torch
of)
RING NUT
2
1512PCN
POWER CABLE ADAPTER
HI-PERFORMANCE POWER CABLE & HOSE, 12-112ft
20
116 262
1525PCN
HI-PERFORMANCE POWER CABLE & HOSE, 25ft
21
116 267
212AH
21
116 268
225AH
22
116 512
23
116 266
2AN
24
116 269
25
116 264
3HF
1512CN
25
116 265
1525CN
26
600 317
27
116 270
5PF
28
116 263
15PFN
29
120729
30
120 761
.
31
120720
~~~~RINGNUT
276
1
2
116 261
116
1
RHNUT
20
19
1
1
(consisting of)
1
(consisting of)
.
.
1
GAS HOSE, 12 -1/2ft (consisting of)
GAS HOSE, 25ft (consisting of)
HOSE, black 1/8 ID (order by ft as reqd)
1
.
.
.
.
.
1
GAS NUT
HOSE FITTING
POWER CABLE, 12-1/2ft (consisting of)
POWER CABLE, 25ft (consisting of)
CABLE, weld-copper No. 4 (order by ft as
POWER CABLE FITTING
POWER CABLE FITTING, (consisting of)
.
1
1
1
reqd)
1
.
.
NR
VNR
Assemly (Continued)
HI-FLEX POWER CABLE, 12-1/2ft (consisting
HI-FLEX POWER CABLE, 25ft (consisting of)
.
15PCA
HR
VHR
Description
.
.
.
1
1
CRIMP,cable
FITTING, gas (consisting of)
1
1
OPTIONAL
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 561
Page
11
I
I
Orif ce 5/16 3/8 7/16
Cop
150-325 2 0-350 4C418 1 637 7C418 1 638 4CB418 1 6359
3/32 (2.4) 10 -235 150-250 4C3 2 1 6376 7C3 2 1 6382 4CB3 2 1 6358
1/16 (1.6) 50-ISO 70-150 4C1 6 1)6375 7C1 6 1 6381 4CB)16 1 6357
~ (1.0) 10-80 15-80 4C40 1)6374 7C40 1 6380 4CB40 1 635
.02 0.5) 5-20 5-20 4C20 1 637 7C20 1 6379 4C520 1635
I
1/2 5/8
3/16
5/16
1/4
5/16
3/8 1/4
I
3/8
7/16
1/2 5/8
1/4
~ ic.x
Dory U.ioa Body.
Q
ENDS
Adapter.
Wh.n
4
(~
25%
tt~
By
4045 $1.4 No Raduc. R.!ia Shon
U.. H. ! Stoch
G.La. 401-50
U..
CC
ConcuO. Col.I/ a
916
25d
FRONT
tIC
B
u
d
y
S
h
i
e
l
d
3
0
4
5
SHORt 9.0
Shot! Cal .!
H. ! StochN
Cable
in
(m ) ACHF DCSP
.,
4GL418 1 9 09
4GL3 2 1 9 08
401 6 1 9 07
4GL40 1 9 06
40120 1 9 05
_j__
I
I
I
I
Mode)No. StockN. ModelN. StockN. Mode)No. StockN, 1637) 1638 )2C6) )2C7) )2C8)I )2C10)
Stock/Mdel
1 16
No.
)2C6L) (2A5l
339 340 341 342
Power
311
116
329
116 116 116
A
~ 7/16
I
1/8 (3.2)
Shot! Coil.! C SX
5/16
,,,,~
116
ii
1
~
_j 1~I
~_.
1632)A3It)2A7)I StockN. Stock/Mdel )2AG4 I2A1G9S8I!4 1985)2AG6I1986)2AG7I~,
)2A8)
No.
)2A10)
No.
Model
314 315
116 116 116
INDCATE USAGE
AREAS
893
SHADE
119
I
Require
SELCTOR
PARTS
Coil.! 3C.0
Diametr
Tongstey
Aieo reos
Cable FRONT
Compelt
Flex
CONSUMABLE Torch.,
-
L.ne!h
LENGTH
254
ite
Bean
Ss.ndr Coil.,
STANDR
I40 S Shi.ld No
U.. H.ai Sto.h
114
L.n4th
Standr LGa.ane 3GL-X
3045 Shield
U..
Torch.i
Complet
To
Required
Cup
Ga,
And
Diem.!, L.a. 3GHSLO Shield
3GL.X
Body
Co(let Col et Cd).!
Cofet
Lens
-
Gas
A(unva
Body-Shrt
Parts
~
Cup.
H.a! Sro h LarRo 0..
Consumable
119
NO
U.. Heat Sto c
Orif ce 3/16 1/4 5/16 3/8 71 6
Cop
_
7-2.
1/2 5/8 3/4 1/4
5/16
3/8
7/16
1/4
3/8
7/16
1/4
1/2 5/8 3/4.
5/16
3/8
7/16
1/2
1 /16
3/4.
19
1
7
5/16
1/4
3/8
7/16
1/2
1 /16
1/2 5/8
Figure
~
383
150-325 2 0-350 3C419 1 6371 7C418 116 3C8418 1 63 5
3/32 (2.4) 10 -235 150-250 3C3 2 1 6370 7C3 2 382116 3CB3 2 1 63 4
1/16 1.6) 50-150 70-150 3C1 6 1 63 9 381116 3CB1 1 63
.040 (1.0) 10-80 15-80 3C40 1 63 8 7C40 1 6380 3CB40 1 63 2
.020 (0.51 5-20 5-20 3C20 1 63 7 7C20 1 6379 3CB20 1 63 1
1/8 (3.2)
16
.~
3GL 418 1 9 03 1.:4IuiU~
3GL32 902
.
~
~
301,3 2 1 9 29
3GL1 6 1 9 28
3GL40 1 9 27
3GL20 1 9 26
.
16
id
119
F
1...-.
I
in
(m ) ACHF DCSP
Body
NO. No. No.
Mode(N. StockN. Model Stock Mode) StockN.
Coil.! D~amet Range
Tongsten Amperag
No.
)3C31
)3C5 )3C6( (3d) 13C8)
1 6347
116 116
SLgth.) tock/Mdel 16348)Cl
Coilet
INot.:
(Revrse)
(Short)
Ceramic 1-7/8 c~ Alumina Long
Cup. 1-5/32
Cup. Long
Ceramic Long 0 Long
1 /8
Cup. 1-5/32
115
Iti
No.
High
With
AmperagRn
(Short)
RECOMND
Cote(Sandl
(Revtsel
lStd.
Body
Col et Cadet
349 350
Ceramic
Cup,
1 6351 352116 353116
Long
1-27/32
)3C10) )3C4L( 13C5L1 )3C6L) 13C7L) )3A4 )3A5l )3A6) (3A7) 13A10) (3A12)
16354C2)
343 344 345 346 330 331 332 333
116 116 116 116 116 116 116 116
Ceramic
~
Cop,
Long
37/32 ~
A)omina
Cop,
1634)A8
335
116
1 63 6
Mode)No. StockN.
13AG8) I3AGJ) )3AGB) )3AG1 ) MNo.odel No.Stock
)3CG6) )3CG7) 13CG8) (3CG1 ) )3CG12) )3CG14) 13CG16)
Stock/Mdel
919 920
119 119
934
1 9 21 119 119 1 9 24 119
922 923
925
119
936
119
1 9 35 1 9 37
No.
Stock/Mdel
I
Long
1-27/32
No.
~
GasLenCo)t RodvSt.Lk
Ceramic Gas c~ 3CG1
1. /8
Cup, 1-5/8
Lens Long
-
is
Long
A(umina Gas
Lens Long
Cup,
-
1-5/8
)3AG8LD) (3AG1OLDI
911 912
119 19
Ii
Co( ei Die. A)omina Long
Lens Lg.
Gas Body Cop,
h
193(AG12LD)~
t~
1-7/8 ~
Table 7-1. Cross Reference To
STOCK NO.
MODEL NO.
NO.
Competitive
STOCK NO.
116367
3C20
10N21
116368
10N22
119934
10N23
10N24
119935
10N25
119937
N/A
N/A
N/A
N/A
N/A
119902
10N29
10N30
116 373
10N31
1 0N32
10N28
116 347
3C40
3C116
3C332
3C418
7C20
7C40
7C116
7C332
7C418
3CB20
3CB40
3CB116
3CB332
3CB418
3C3
116348
3C4
116349
3C5
105Z42
116381
116350
3C6
3C7
3C8
3010
3012
3C4L
3C5L
3C6L
3C7L
105Z44
116382
105Z45
116383
08N78
116 355
08N79
08N80
12N03
105Z60
12N02
116356
105Z61
116338
3A4
10N50
116339
10N49
116340
116332
3A5
3A6
116341
116333
3A7
10N48
10N47
116 334
3A8
1 0N46
116 326
116335
3A10
10N45
116327
116369
116370
116371
116379
116380
116381
116382
116383
116 361
116 362
116363
116 364
116365
116351
116 352
116353
116354
116343
116344
116345
116346
116330
116331
116336
119 926
119927
119928
119929
119930
119917
119918
119919
119 920
119921
119 922
119923
119 924
119 925
119 932
119933
3A12
3GL20
3GL40
3GL116
3GL332
3GL418
3CG4
3CG5
3CG6
3CG7
3CG8
3CG11
3CG12
3CG14
3CG16
3AG4
3AG5
Model
MODEL NO.
COMPETITIVE
NO.
116375
3AG6
3AG7
3AG8
3AG11
3GLL332
3GLL418
3AG8LD
3AG1OLD
3AG12LD
4C20
4C40
4C116
10N22S
10N23S
116 376
40332
1 0N24S
116377
40418
N/A
116 379
105Z43
116380
7C20
7C40
10N25S
N/A
N/A
N/A
N/A
N/A
N/A
17CB20
17CB20
17CB20
17CB20
13N14
119936
119903
119911
119912
119913
116 374
116357
116358
7C116
7C332
70418
4CB20
4CB40
4CB116
4CB332
54N16
54N15
54N14
54N19
45V64
995795
57N74
53N88
53N87
N/A
10N44
116328
45V29
116 329
4CB418
204
2C5
2C6
2C7
208
2010
203L
2C4L
2C5L
2C6L
45V24
116310
2A4
45V25
116311
2A5
13N08
13N09
116359
116337
116342
13N15
13N16
13N17
13N18
13N19
796F70
796F71
796F72
796F73
45V26
116312
2A6
13N10
45V27
116313
2A7
54N35
54N34
116314
2A8
116315
54N33
54N32
119905
2A10
4GL20
13N11
13N12
13N13
N/A
N/A
54N31
119907
54N35
119 908
N/A
N/A
N/A
119 893
54N18
54N17
119 906
119909
119 894
119 895
119896
4GL40
4GL116
4GL332
4GL418
2AG4
2AG5
2AG6
2AG7
N/A
N/A
N/A
53N58
53N59
53N60
53N61
OM-1561
Page 13,