Miller | JJ23 | Owner Manual | Miller MATT-425 User manual

Miller MATT-425 User manual
FORM: OM-1564
April 1988
Effective With Style No. JJ-23
Millerfi
OWNERS
MODEL
MATr-412
MATI-425
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 in-
Miller Electric
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
Appleton, WI 54912 USA
stalling, operating,
install, operate,
not
or
or
Mfg.Co.
AU,I~G,oo~1Id CornO~n~
p.o. Box 1079
Tel. 414-734-9821
maintain this unit. Contact your distributor if you do
these instructions.
fully understand
PRINTED IN U.S.A.
ADDITIONAL COPY PRICE 35 CENTS
LIMITED WARRANTY
EFFECTIVE: FEBRUARY 18. 1988
supersedes
This warranty
all
previous MILLER
warranties and is exclusive with
or
implied.
or, where authorized in
a
two year
warranty.
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 goode at Customers
risk and expense. MIU.ERs
option of repair or replacement will be F.O.B., Factory, at
Appleton, Weconsin, 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
claim
or
failure, Miller shall instruct the claimant
procedures
on
the warranty
followed.
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.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
Miller shall be required to honorwarranty claims on warranted Equipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equip-
BREACH OF CONTRACT WHICH, BUT FOR THIS PROViSION,
MIGHT ARISE BY IMPLICATiON, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEAUNG, INCLUDING
ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
Except
?~
warranties expressed
Equipment furnished by Miller is tree from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
have
~j
or
In the case of Millers breech of warranty or any other duty
with respect to the quality of any goode, the exclusive remedies
therefore shall be, at Millers option (1) repair or (2) replacen,ent
.
~
other guarantees
LIMITED WARRANTY
Subject to the terms and conditions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its Distributor/Dealer that all new and unused
-
~
no
as
the
ment to
original
to be
FITNESS FOR PARTICULAR PURPOSE, WiTH RESPECT TO
user:
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
~
1. Arc v~ders, p~r sources, robots, and components
Loadbanks
2.
~
3.
Original
(labor
4. All
-
main power rectifiers
1 year only)
welding
guns,
feeder/guns
6.
r~
7. Batteries
Replacement
or
EXCEPT
90
and torches
days
1 year
repair parts, exclusive of labor
..
60
days
6 months
(1
~$j
!~
~
(1
provided
that Miller is notified in
writing
within
thirty (30) days
of the date of such failure.
As
a
matter of
submitted by the
CLUDED AND DISCLAIMED BY MILLER.
lyear
3 years
5. All other Millermatic Feeders
~
~
1 yeer
.
general policy only, Miller may honor claims
original user within the foregoing periods.
WRITING,
AS
EXPRESSLY PROVIDED
PRODUCTS
ARE
MILLER
BY MILLER IN
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.
SECTION 1
-
1 -3.
rules before
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.
TJCES
can cause
installing, operating,
or
servicing
this
equipment.
Be sure that all end
operator and
safety rules.
-
PROTECT EYES AND SKIN FROM ARC
RAYS; PROTECT EARS FROM NOISE
UNSAFE PROCEDURES OR PRACserious personal injury or death.
Read, understand, and follow ALL of these safety
~NARNING
_________
1
SAFETY RULES
users of this equipment, the
helpers, read and understand these
a welding helmet fitted with a proper~filter
lens (see ANSI Z49.1 for detailed information).
a.
Wear
b.
Use protective screens or barriers to protect
others from flash and glare.
c.
Wear
d.
Always
1. PREVENT ELECTRIC SHOCK
Touching
the body
live electrical parts can cause severe burns to
or fatal shock. Severity of electrical shock is
determined by the path and amount of current
the body. Therefore:
a.
Do not touch live electrical parts.
b.
Do not work in wet
c.
Wear
or
damp
dry insulating gloves
through
work
1
areas.
and
body protection.
-
protective clothing and foot protection.
wear
safety glasses
or
safety goggles in
a
area.
4. PREVENT FIRES AND BURNS
The hot
workpiece, hot equipment, other hot metal,
arc sparks can cause fires and burns.
spatter, and
d.
Disconnect all power before
ing this equipment.
installing
equipment when
or
Turn off all
f.
Properly install and ground the welding
Manual
source according to its Owners
applicable codes.
Do not
that
h.
use worn
or
small
or
are too
damaged cables
poorly spliced.
Do not wrap cables around your
Wear correct eye, face, and body
the work area.
b.
Allow work and
or
cables
equipment
to
cool before handl
combustible material.
c.
Do not weld
d.
Watch for fire, and
near
keep
a
fire extinguisher
near
by.
body.
e.
grounded object
j.
Use only well-maintained equipment. Repair
For additional information, refer to NFPA Stan
dard 51 B, Fire Prevention in Use of Cutting and
Welding Processes, available from the National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
or
at once.
1 -5.
PROVIDE
AND GASES
in
and all
Do not touch electrode and any
or circuit at the same time.
PROTECTION
1 -2.
protection
in9.
power
i.
replace damaged parts
a.
not in use.
e.
g.
servic
FROM
PROTECT COMPRESSED GAS CYLINDERS
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.
b.
Install and secure cylinders so that they cannot
fall or tip over by fastening them to a mounting
bracket, wall, or other stationary support.
c.
Keep cylinders away from
your head out of the fumes.
a.
Keep
b.
Use
c.
If ventilation
adequate ventilation in the work area to
keep fumes and gases from your breathing zone
and the general work area.
is
inadequate,
use
an
any
welding
or
other
electrical circuits.
approved
breathing device.
d.
d.
Read the Material Safety Data Sheets (MSDSs)
instructions for any
and the manufacturers
materials used.
Never allow
a
welding
electrode to touch any
cylinder.
OM-1564
Page
1
1 -6.
PROVIDE
SITUATIONS
PROTECTION
FOR
SPECIAL
1 -8. ADDITIONAL SAFETY INFORMATION
information on safe practices for setting up
operating electric welding and cutting equipment
and on good working habits, ask your welding equip
ment supplier. The following publications, which are
available from the American Welding Society, 550
N.W. LeJuene Rd., Miami, FL 33126, are recommend
For
a.
Do not weld or cut containers or materials which
have held or been in contact with hazardous
substances unless they are properly cleaned and
inspected.
b.
Do not weld or cut painted or plated parts unless
special ventilation is provided to remove highly
toxic fumes
or
gases.
more
and
ed to you:
a.
Safety
in
Welding
and
Cutting
-
AWS Z49.1
(ANSI)
c.
Since
welding
pacemaker
can
affect pacemakers, keep all
of the work area. Have
wearers out
them consult
a
doctor before
coming
near
b.
a
Recommended Safe Practices for Gas-Shielded
AWS A6.1
Arc Welding
-
welding operation.
c.
PROVIDE
MAINTENANCE
1 -7.
PROPER
EQUIPMENT
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances
-
AWS F4.1
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.
Always have qualified personnel perform the in
stallation, troubleshooting, and maintenance
work. Do not perform any electrical work unless
you are fully qualified.
d.
NFPA Standard 51 B, Fire Prevention in Use of
Cutting and Welding Processes, available from
the National Fire Protection Association, Bat
terymarch Park, Quincy, MA 02269.
e.
NFPA Standard
70, National
available
the
from
National
Electrical Code,
Fire Protection
Association, Batterymarch Park, Quincy, MA
b.
02269.
Before
performing any maintenance work inside
a power supply, disconnect the power supply
form the electrical power source.
c.
Maintain cables, grounding wire, connections,
power cord, and power supply in safe working
order. Do not operate any equipment in ques
tionable condition.
d.
Do not abuse any equipment or accessories.
Keep equipment away from heat sources such as
furnaces, wet conditions such as water puddles,
oil or grease, corrosive atmospheres, and incle
ment weather.
e.
Keep all safety devices, guards, panels, and
covers in position and in good repair.
f.
Use
equipment for its intended
modify it in any manner.
OM-1564 Page 2
purpose. Do not
f.
ANSI Standard Z87.1, Safe Practice for Oc
cupation and Educational Eye and Face Protec
tion, available from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
g.
OSHA Standard 29 CFR, Part 1910, Subpart Q,
Welding, Cutting, and Brazing, available from
the Superintendent of Documents, U.S. Govern
ment
h.
i.
Printing Office, Washington, DC 20402.
CSA Standard W117.2, Code
for Safety in
Welding and Cutting, available from the Cana
dian Standards Association, 178 Rexdale Blvd.,
Rexdale, Ontario, Canada M9W 1 R3.
See also the Standards Booklet Index in the
power source Owners Manual.
welding
SECTION 2- INTRODUCTION
Ampere Rating
Tungsten
at
100%
Model
Torch
Cooling
DCEN; ACHF
Capacity
Length
Body
Method
12.5ft.
4 lbs.
4 lbs.
(3.8 m)
(1.8 kg)
(1.8 kg)
400 Amperes
With Argon
.020 thru
5/32 in.
(0.6 thru
4.0 mm)
MATT-425
Weight:
1. DUTY CYCLE
The
-
duty cycle of
that the torch
ditions continuously,
can
1
Water
oz.
a
2
-
1.
welding
be operated at rated load
Net
Ship
qt/min
(0.94 I/mm)
25 ft.
(7.6 m)
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
8.0
(230 g)
Figure
-
ht
Cable
MATT-412
2
Coolant
Flow
Rate
Size
Duty Cycle
7 lbs.
7 lbs.
(3.2 kg)
(3.2 kg)
Specifications
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words
WARNING and
different levels of hazard.
CAUTION
which identify
con
WARNING
include installation, operation,
or practices which if not
carefully followed could result in serious personal injury
or loss of life.
and maintenance
THE
RATED
EXCEED I N G
AMPERAGE and duty cycle can result in damage
to the torch.
Do not exceed rated amperage and duty cycle
stated in Figure 2-1.
~~WtI~L~JL
1.1 In.
CAUTION
procedures
include installation, operation,
or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
statements
and maintenance
procedures
mm)
A third signal word, IMPORTANT highlights instruc
tions which need special emphasis to obtain the most
efficient operation of this equipment.
.75 In.
2
3. RECEIVING
HANDLING
Before installing
equipment, clean all packing material from around
the unit, and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill of
lading will be furnished by the manufacturer on request
-
-
this
TA-121 198
Figure
2
-
2. Overall Dimensions
if occasion to file claim arises.
2 -2. GENERAL INFORMATION AND SAFETY
When
A.
General
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective
use
of this
equip-
2
.
-
use
This torch is specifically for
4. DESCRIPTION
with the Gas Tungsten Arc Welding (GTAW) pro-
cess.
-
The alphanumeric
designation refers
to
the
Safety
M
The
model
following:
ment.
B.
requesting information concerning this equip
ment, it is essential that Model Description and Style
Numbers of the equipment be supplied. The style
number is located on a label under the torch handle.
installation,
operation,
maintenance,
and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap
plicable codes such as, but not limited to, those listed at
the end of Section 1
-
A
T
-
T
4
-
-
-
-
12
25
Miller
Automatic
TIG/GTAW
Torch
Ampere Rating: 400 Amperes
-
-
12.5 ft. (3.8 m) Cable
25 ft. (7.8 m) Cable
Safety Rules.
OM-1 584 Page 3
SECTION 3
-
INSTALLATION
Power Cable/Coolant
Hose Fittings
Notches Indicate Left-Hand
Threaded Coolant Fittings
Power
Cable
Adapter
Backcap
Hose Fittings
Torch
Body
Adapters
Adjusting
Cap
Shield
Tungsten.
Eloctrode
Required Consumables and Accessories
Welding Equipment Supplier
~ObtaIn from
TA-121 196
Figure
WARNING
ELECTRIC SHOCK
3
-
1. Torch
Components
4.
Install standard collet, slotted end first,
back of adjusting cap.
pro
5.
before 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.
Loosely install backcap and 0-ring (supplied
backcap) onto torch body.
6.
Install properly prepared tungsten electrode (see
Section 5-4) through front of collet body to posi
tion electrode tip outside cup rim. Tighten
can
kill.
__________
Do not touch live electrical parts.
Shut down we/ding power source and disconnect
input
power
employing lockout/tagging
cedures
through
on
backcap.
3
1. TORCH BODY
(Figure 3-1)
The torch body
is shipped requiring consumables and accessories in
dicated in Figure 3-1: cup, collet body, collet, power
cable adapter, and tungsten electrode. Assemble torch
body as follows:
-
1.
Install collet body into torch
heat shield is in place.
2.
Install cup onto collet
3.
Remove
OM-1564 Page 4
backcap.
body.
-
body making
sure
IMPORTANT
The
adjusting
cap provides an approx
range of .20 in. while
welding. Turn adjusting cap clockwise to decrease elec
trode extension, or counterclockwise to increase exten
_____________
imate
electrode
extension
sion. Electrode adjustment greater than .20 in. can not
be completed while we/ding. To further adjust elec
trode, loosen backcap.
IMPORTANT As a general rule, electrode extension
should equal electrode diameter; exact extension
may
______________
vary
according
to
application.
3 -2. COOLANT HOSES
(Figures 3-1 and 3-2)
AND
CONNECTIONS
within
a coolant hose. The power cable/coolant hoses
have 3/8-24 male, notched, right-hand fittings (Figure
3-1).
CAUTION OVERHEATING
Gas
Tungsten
damage torch.
_________
Arc
Welding (GTAW) torch can
If using recirculating coolant system, do
not make
connections from the coolant system to water
vavie; instead, make connections directly from the
coolant system to torch hoses.
If receptacle is available on power source, connect
coo/ant supply/pump power cord to power source
receptacle.
A.
To install power cable/coolant hoses, connect power
cable/coolant hose fittings into the power cable adapter
(Figure 3-2).
B.
Coolant Hoses (extra hoses
not
supplied)
Two coolant hoses with 5/8-18 male, notched, lefthand fittings are required for the torch to coolant supply
connection.
To install coolant hoses, connect coolant hoses from
power cable adapter to the coolant supply fittings
Power Cable/Coolant Hoses
The power cable/coolant hoses contain
power cable
a
(Figure 3-2).
Regulator/Flowmeter
Aol. TA-120 199
Figure 3
3
3. COOLANT REQUIREMENTS
-
-
-
2. GTAW Torch Connection
Where freez
ing conditions may be encountered, mix coolant accor
ding to the manufacturers recommendations supplied
in coolant
supply
owners
Diagram
oxidized (black) electrode surface. If an oxidized
electrode were used, the black surface would con
taminate the weld and cause poor arc direction.
an
manual.
IMPORTANT: As
a general rule, allow 10 seconds
posiflow time per 100 amperes of weld current
before closing valve.
_______
INCORRECT COOLANT LEVEL
damage coolant system and torch.
Maintain correct coolant level at all times.
CAUTION
can
________
This torch is rated at a 1 qt./min (0.94 I/minI coolant
flow rate. Changes in flow rate may effect operating
temperature of torch. Maintain proper flow rate at all
times.
gas
3 -5. POWER CABLE ADAPTER CONNECTION
(Figures 3-1 and 3-2) The power cable adapter has
2, 5/8-18 female, notched, left-hand fittings (Figure
-
3-1).
Install power cable adapter
3 -4. GAS HOSE CONNECTIONS
(Figures
as
follows
(Figure 3-2):
3-1 and
3-2)
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect
__________
IMPORTANT
Power
source
gas valve
required.
input
A.
Gas Hose and Connection
The gas hose has
a
5/8-18 male,
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
right-hand fitting
(Figure 3-1).
before
To install gas hose, connect gas hose fitting to gas valve
outlet. Connect gas hose (extra hose not supplied) from
gas valve inlet to regulator/flowmeter (Figure 3-2).
1.
Install power cable/coolant hose fittings into
power cable adapter (see Section 3-2A).
The power
2.
Connect power cable adapter to weld output ter
minal (Figure 3-2).
gas valve allows control of gas
the length of time gas flows after the
is extinguished. Insufficient gas postflow results in
source
postflow time,
arc
or
OM-1564 Page 5
SECTION 4
-
SEQUENCE OF OPERATION
WARNING
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Keep all covers and handle in place
4.
With
5.
Set power
6.
Wear dry
regulator/flowmeter valve closed,
cylinder valve.
__________
while
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, SPATTER, AND SLAG
and burns.
can cause
Watch for fire.
a fire extinquisher nearby, and know how to
use.
equipment
to
welding
insulating clothing
and
amperage.
gloves and
according
helmet with proper filter lens
to ANSI Z49.1.
7..
Energize welding
8.
Set gas flow to desired level
power
source.
(requires
open gas
valve).
IMPORTANT
Purge
gas hose to c/ear hose of air,
______________
any other contaminants. Allow gas to flow
2 to 3 minutes on new torch; 5 to 6 seconds thereafter.
moisture,
9.
MAGNETIC FIELDS FROM HIGH CURRENTS can
affect pacemaker operation.
Wearers should consult with their doctor before
near arc
for desired
or
cool before handl
ing.
going
source
welding
fire
Have
Allow work and
open gas
welding, gouging,
or
spot welding
Begin welding.
4 -2. SHUTTING DOWN
1.
Stop welding.
operations.
See Section 1
mation.
4
-
Safety Rules for additional safety infor
IMPORTANT As
a general rule, allow 10 seconds of
gas postflow time per 100 amperes of weld current
before closing valve.
______________
1. GAS TUNGSTEN ARC WELDING (GTAW)
-
1.
Install and connect torch
2.
Make
3.
Turn
backcap
securely tightened.
sure
according
to
2.
Turn off
3.
Turn off the shielding gas and coolant supplies at
their sources.
welding
and all gas connections
are
L~~U~E
on
coolant
power
source.
Section 3.
supply.
HIGH
SHIELDING GAS
can
CONCENTRATION
harm health
or
Shut off gas supply when not in
SECTION 5
5
-
1.
INSPECTION
AND
UPKEEP
-
Usage
-
and
shop conditions will determine frequency and type of
maintenance required. Perform inspections once a
ELECTRIC
WARNING
SHOCK
can
kill;
5 -2. TORCH BODY MAINTENANCE
can cause severe
on
Allow
from
welding
2.
Inspect torch for broken areas, cracks and loose
parts; tighten, repair and replace as required.
Remove grease and dirt from components, and
moisture from electrical parts and cables.
OM-1564 Page 6
can
kill;
HOT
burns.
inspecting, maintaining, or servicing.
cooling period before servicing.
a
power source
before inspecting, maintaining, or servicing.
Allow a cooling period before servicing.
1.
before
working
torch.
Disconnect torch
SHOCK
can cause severe
Do not touch live electrical parts.
Shut down we/ding power source before working
on torch.
Disconnect torch from welding power source
HOT
burns.
Do not touch live electrical parts.
Shut down welding power source before
ELECTRIC
WARNING
(Figure 3-1)
_________
__________
SURFACES
use.
MAINTENANCE
SURFACES
week.
OF
kill.
Once
a
week
inspect condition of
torch
body
com
ponents.
Replace cup, heat shield, backcap, and 0-rings if crack
ed. Maintain tight fit of torch components to ensure
good weld quality.
Table 5
Electrode Diameter
Pure
Tungsten
(Green Band)
-
1. Tungsten Size Chart
Amperage Range
DC-Argon
Negative/
Straight Polarity
Electrode
.020
.040
1/16
3/32
1/8
5/32
-
Polarity
-
Gas Type
DC-Argon
Electrode Positive/
Reverse
Polarity
*
5-20
15-80
70-150
125-225
225-360
360-450
*
10-20
15-30
25-40
40-55
AC-Argon
Using High
Frequency
5-20
10-60
50-100
100-160
150-210
200-275
2% Thorium
Alloyed Tungsten
(Red_Band)
.020
.040
1/16
3/32
1/8
5/32
*
15-35
*
10-20
20-80
50-150
15-30
25-40
40-55
130-250
225-360
300-450
*
*
~
*
*
*
15-35
20-80
50-150
130-250
225-360
300-450
15-40
25-85
50-160
135-235
250-400
400-500
Zirconium Alloyed
Tungsten
(Brown_Band)
020
.040
1/16
3/32
1/8
5/32
*
*
*
*
*
*
*NOT RECOMMENDED
The figures are intended as a guide, and are a composite of recommendations
from American Welding Society and electrode manufacturers.
5 -3. INSPECTING HOSES, CONNECTIONS AND
CABLES
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down welding power source and disconnect
WARNING
A.
Gas Hose
Gas leaks may result in poor weld quality. Inspect hoses
for breaks. Keep connections clean and tight.
_________
input power employing lockout/tagging pro
cedures before inspecting, maintaining, or ser
vicing.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
Once
a
week inspect hoses and connections.
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 inspection.
C.
Coolant Hose
Inspect coolant hoses for breaks and clogs. Keep
con
nections clean and tight to prevent coolant leaks.
OM-1 564
Page
7
5 -4. PREPARING
TUNGSTEN
ELECTRODES
TUNGSTEN PREPARATION: IDEAL
(FIgure 5-1)
HOT FLYING METAL PARTICLES can
start fires, and damage equip
ment; TUNGSTEN CONTAMINATION can lower
weld quality.
Shape tungsten electrode only with properly
CAUTION
Stable Arc
~
injure personnel,
guarded grinder in a safe location wearing proper
face, hand, and body protection.
Do not use same wheel for any other job or the
Straight Ground
Flat (the Dia. of this
Flat Governs
Amperage Capacity)
tungsten will become contaminated.
TUNGSTEN PREPARATION: WRONG
Tungsten electrode shaping should be done on a fine
grit, hard abrasive wheel. Since tungsten is harder than
most grinding wheels, causing the tungsten to be chip
ped away rather than cut away, the grinding marks
should run lengthwise with the electrode.
For additional information, see your distributor or re
quest a handbook from factory on the Gas Tungsten
Arc
Welding (GTAW)
Arc
~
Point
Radial Groun
TA-120 630
process.
Figure 5
-
1.
Tungsten Preparation
1
14
20
TA-121 196
Figure
OM-1 564
Page
8
A
-
Complete
Torch
Assembly
Item
No.
Miller
Stock No.
Figure
1
2
2
2
3
4
5
6
6
7
8
9
9
10
11
12
13
14
14
14
15
16
17
18
19
20
21
Miller
Model No.
118 507
t116 240
t116 239
120 230
120720
120721
116 246
116 247
120720
120721
116 267
116 268
118 512
116266
116269
t116 248
116 243
ti 16 242
t116 241
116244
Quantity
Complete Torch Assembly
A
116245
Description
M4G-HS
M-HS
M3G-HS
BODY, gun (consisting of)
1
.HEATSHIELD
.HEATSHIELD
HEAT SHIELD
POWER CABLE FITTING, 90
..RINGNUT
1
.
M412PC
M425PC
212AH
225AH
1
1
.
(consisting of)
..RHNUT
WATER COOLED POWER CABLE, 12-1/2 ft (consisting of)
WATER COOLED POWER CABLE, 25 ft (consisting of)
.RINGNUT
.RHNUT
GAS HOSE, 12-1 /2 ft (consisting of)
GAS HOSE, 25 ft (consisting of)
HOSE, black 1/8 ID (order by ft as required)
.GAS NUT
2
1
1
2
2
1
1
1
1
.
2AN
3HF
M3PCA
AS35
AM35
AL35
A2R35
116 249
116244
ACM
A2R35
1
.HOSEFITTING
POWER CABLE ADAPTER
BACK CAP, short (consisting of)
BACK CAP, medium (consisting of)
BACK CAP, long (consisting of)
.0-RING
1
COLLET(seeFigureB)
1
ADJUSTING CAP (consisting of)
.0-RING
COLLET BODY (see Figure B)
CUP (see Figure B)
TUNGSTEN, electrode (consult your welding supply distributor)
1
1
1
1
1
1
1
1
1
1
tOptional Equipment
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1564 Page 9
I
Orif ce 1/4 5/16 3/8 7/16
Cup
20 -425 375- 0 4C532 1 6378 4CB532 1 63 0
1/8 13.2) 150-325 2 0-350 4C418 1 637 4CB418 1 6359
3/32 12.4) 10 -235 150-250 4C3 2 1 6376 4CB3 2 1 6358
1/16 (1.6) 50-150 70-150 4C1 6 1 6375 4CB1 6 1 6357
.040 1 .01 10-80 15-80 4C40 1 6374 4CB40
.020 (0.5) 5-20 5-20 4C20 1 637 4CB20
1/2 5/8
5/32 4.0
Short CoS.t
FRONT
Body
SHORT
coast
4
1 240
4CB-X U.N-HS H.tsh ld Stock
Dt.ty Using Body.
~
No.
Short
When
Condt. Coil.t/
26%
246
~1~
III
No.
By
M40-HS Shield R.doc. Retina Short
U.S Heat Stock
I
~
1635! 6
No.
(m ) ACHF DCSP
ModalNo. Stock MdoelN. StockN.
I
I
L
~
I
I
I
S.
I
~:
No.
SELCTOR
TungsteDiamor Amperage ColetShr)
Range
Stock/Mdel 16340(2C7I
1 63 7
ENDS
FRONT
Length
LENGTH
PARTS
CONSUMABLE Required.
Body
Standr CoU.t 3CB-X
STANDR
M-HS Shld
240
115
No.
U.. H. t Stock
(Short)
338 339
116 116
341 342 326 327 328
116
1 6 116 116 116
310
116
Col et
1 6329 1 631 1 6312
(Note:
0
a 0)
I
>
INDCATE USAGE
~-
>
I
AREAS
~>
No.
(2AG4)
893
119
I
Col ot
Lens
Gas
Alumina
Body-Shrt
~\k.
Parts
Cup
Consumable
Shield No.
US
-
B
Orif ce 3/16 1/4 5/16 3/8 7/16
Cup
1/2 5/8 3/4 1/4
5/16
3/8 7/16 1/4
5/16 3/8 71 6
~
1/8 (32)
in
(m ) ACHF DCSP
No. No.
ModeiNo. StockN. ModelNo. Stock
Body
Col et.
,~
Standr Ga.Lean 30L-X M30-HS Heat Stock
1/2 5/8 3/4.
Lgth.)
Diametr
Range
Tungsten Amperage
-u or
or
C
Cofte(Sandr)
Stock/Mdel
13C8( )3C7( l3~8)
)3C31
i: ~:
t3~6U (3C7L( (3A4) (3A5 13A6)
(3C10) (3C12
(3A71 13A8)
(3A10( (3A12)
I
347 348 349
116 116 116
(Std.
Body
Ceramic Long
Col et
Cup.
1-27/3
1 6350 1 6351 1 6352 116 1 63 4
353
343 344 345
116 116 116
Ceramic Long
Cup, 3-7/32
330
1/4
332 333 334 335 336
1 6346 116 1 63 1 116 116 116 116 116
ModelNo. StockN.
Alumina Long
Coilet l. ~th.
Cup.
Lens
1-27/3
5/16 3/8 7/16
1/2
1 /16
3/4. 7/B
1
14
5/16
Gas
BodySt.
3/8 7/16 1/2
1 /16
...
3GL532 1 9 31
3GL418 1 9 30
3GL3 2 1 9 29
3GL1 6 1 9 28
3GL40 1 9 27
3GL20 1 9 26
to
Col et
7/16
3/8
1 239
Length
150-325 2 0-350 3C418 1 6371 3CB418 1 63 5
Torch.) 3/32 l2A) 10 -235 150-250 3C3 2 1 6370 3CB3 2 1 63 4
Complet 1/16 (1.6) 50-150 70-150 3C1 6 1639 3CB16 163
.040 (1.0) 10-80 15-80 3C40 1 63 8 3CB40 1 63 2
Required 105)
Cup .02 5-20 5-20 3C20 1 63 7 3CB20 1 63 1
And
4GL532 1 9 10
4GL41B 1 9 09
4GL3 2 1 9 08
4GL1 6 1 9 07
4GL40 1 9 06
4GL20 1 9 05
5/16
163 12A7(1 6314(2A8)I 1635(2A10)I Stock/Mdel 19B4(2AG5) 19B5(2AG6) 1986(2AG7) SHADE RECOMND
-
Cable
Ga.
I
Ceramic 1~7/8 c:::3 Alumina Long ~
Cup, 1-5/32
Cup, Long
Adapter 5/32 (4.0) 20-425 375-0 3C532 1 6372 3CB532 1 63 6
Power
I
I
1/4
ModelNo. StockN.
III
Ceramic Long 0 Long
1- /8
Cup. 1-5/32
Body
F
I
I
(2C4)i (2C5) )2C6)I (2C8I 12C10) (2~3Ll 12C4L) (2C5L) (2C6L) l2A4) (2A5) (2A61
I
Standr Col .t SC-X
1/2 5/8
_~ i
I
~.
in
7/16
3/8
~-~-
-
ENDS
(6~
~
~_
No.
Stock/Mdel
)3CG4~ (3CG5 13CG6) 13CG7( (3CG8) )3CG1 I
....:
. .~: .
...
.
)3CG12 )3CG14) (3CG18) (3AG4 13AG5 13AG81 13AG8) I3AG1 I
1 9 17 119 119 119 1 9 21 1 9 2 923119 1 9 24 925119 932119 933119 934119 936119 937119
Cer mic LGasens Long 3 3CG1 Long Alumina Lens Long
1935AG7
918 919 920
is
Cup,
-
1-5/8
1- /8
Cup.
Gas
-
1-5/8
Figure
CROSS REFERENCE TO
COMPETITIVE MODEL
MILLER
STOCK NO.
MILLER
COMPETITIVE
MODEL NO.
NO.
116367
116368
116369
116370
116371
116372
3C20
3C40
3C116
3C332
3C418
3C532
10N21
10N22
10N23
10N24
10N25
54N20
116361
116362
116363
116364
116365
116366
116347
116348
116349
3CB20
3CB40
3CB116
3CB332
3CB418
3CB532
3C3
3C4
3C5
3C6
3C7
3C8
3C10
3C12
3C4L
3C5L
3C6L
3C7L
3A4
3A5
3A6
3A7
3A8
3A10
3A12
3GL20
10N29
10N30
10N31
10N32
116350
116351
116352
116353
116354
116343
116344
116345
116346
116330
116331
116332
116333
116334
116335
116336
119926
119927
119928
119929
119930
119931
119917
119918
119919
119920
119921
119922
119923
119924
.
3GL40
3GL116
10N28
406488
N/A
105Z43
105Z42
105Z44
105Z45
08N78
08N79
08N80
12N03
105Z60
12N02
105Z61
10N50
10N49
10N48
10N47
10N46
10N45
10N44
45V29
45V24
45V25
3GL332
3GL418
3GL532
3CG4
3CG5
3CG6
3CG7
3CG8
3CG11
3CG12
3CG14
45V26
45V27
45V28
54N35
54N34
54N33
54N32
54N31
54N36
N/A
N/A
MILLER
STOCK NO.
.
119925
119932
119933
119934
119935
119936
119937
116373
116374
116375
116376
116377
116378
116355
116356
116357
116358
116359
116360
116337
116338
116339
116340
116341
116342
116326
116327
116328
116329
116310
116311
116312
116313
116314
116315
119905
119906
119907
119908
119909
119910
119893
119894
119895
119896
MILLER
MODEL NO.
3CG16
3AG4
3AG5
3AG6
3AG7
3AG8
3AG11
4C20
4C40
4C116
4C332
4C418
4C532
4CB20
4CB40
4CB116
4CB332
4CB418
4CB532
2C4
2C5
2C6
2C7
2C8
2C10
2C3L
2C4L
2C5L
2C6L
2A4
2A5
2A6
2A7
2A8
2A10
4GL20
4GL40
4GL116
4GL332
4GL418
4GL532
2AG4
2AG5
2AG6
2AG7
COMPETITIVE
NO.
N/A
54N18
54N17
54N16
54N15
54N14
54N19
N/A
10N225
10N235
10N24S
10N25S
N/A
N/A
17CB20
17CB20
17CB20
17CB20
N/A
13N14
13N15
13N16
13N17
13N18
13N19
796F70
796F71
796F72
796F73
13N08
13N09
13N10
13N11
13N12
13N13
N/A
N/A
N/A
N/A
N/A
N/A
53N58
53N59
53N60
53N61
OM-1 564
Page 11
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