Miller | KE000000 | Owner Manual | Miller MWTIG User manual

Miller MWTIG User manual
June 1995
Form:
OM-171 108A
L._
1~oLsfi
OWNERS
MANUAL
MWTIG
Read and follow these instructions and all
Give this manual to the operator.
safety blocks carefully.
Have
only trained and qualified
install, operate,
or
persons
service this unit.
For
help, call
your distributor
Call your distributor if you do not understand
the directions.
cover
5/94
ST- 800 877
PRINTED IN USA
SAFETY PRECAUTIONS FOR GTAW TORCHES
WARNING
4A
GTAW WELDING
can
be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information found in the welding
power source Owners Manual. Read and follow all safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
1.
Always
2.
Insulate yourself from work and
3.
Do not touch live electrode
4.
Repair
torch
5.
6.
wear
or
or
dry insulating gloves.
replace
worn,
or
ground.
electrical parts.
damaged,
or
near
2.
Do not weld
on
3.
Watch for fire;
explosion.
or
flammable material.
closed containers.
keep extinguisher nearby.
cracked
cable insulation.
A
HOT SURFACES
welding power source before changing
tungsten electrode or torch parts.
Keep all covers and handle securely in I
can
burn skin.
can
Allow torch to cool before
2.
Do not touch hot metal.
3.
Protect hot metal from contact
Wear
Wear correct eye and
Cover exposed skin.
FUMES AND GASES
1.
Keep
Ventilate area,
by
others.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING, are
noisy.
body protection.
can
be hazardous
1.
Check for noise level limits
specified by OSHA.
2.
Use
to your health.
2.
touching.
helmet with correct shade of filter.
1.
welding
1.
burn eyes and skin.
2.
3.
fire
cause
Do not weld
1.
Turn off
ARC RAYS
3.
WELDING can
your head out of the fumes.
or use breathing device.
Read Material
Safety Data Sheets (MSDS5) and
manufacturers
instructions for material used.
exceeding
approved ear plugs or ear
high.
Warn others nearby about noise
those
muffs if noise
level is
3.
hazard.
EMF INFORMATION
N OTE D~
Considerations About We Iding And The Effects Of Low
Magnetic
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989):.
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
The
To reduce
of the U.S.
procedures:
.
Frequency
Electric And
Fields
magnetic
fields in the
workplace,
1.
Keep cables close together by twisting
2.
Arrange cables
3.
Do not coil
4.
Keep welding power source and
practical.
5;
Connect work clamp to workpiece
or
use
taping
to one side and away from the
the
following
them.
operator.
.
or
drape cables
around the
body.
cables
as
as
tar away
as
close to the weld
as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
4/93
modlO.1
sr6 7/93
SECTION 1
SAFETY INFORMATION
-
modl.l 2/93
U
Read all safety messages throughout this manual.
Obey
all
to avoid
safety messages
Learn the
meaning
injury.
of WARNING and CAUTION.
1
Safety
Alert
2
Signal
Word
.
1
2
2
Symbol
~
r~
~ &vI
:1~II~c~
ELECTRIC SHOCK
can
klIl.~~
a_CAUTION
MOVING PARTS
Do not touch live electflcal parts.
Disconnect
installing
or
input
power
I
Keep
Keep
before
away from
all
can
injure.
moving parts.
panels and
covers
CO~
when operating.
servicing.
5
A~
READ SAFETY BLOCKS at start
Section 3-1 before proceeding.
WARNING
6
of
I
I
i
WARNING means possible death
or serious injury can happen.
CAUTION
means possible minor
injury or equipment damage can
happen.
3
Statement Ot Hazard And
Result
4
Safety
5
Hazard
6
Safety
Instructions To Avoid
Hazard
Symbol (If Available)
Banner
Read safety blocks for each sym
bol shown.
NOTE
127~
Turn Off switch when
1
using high frequency.
7
NOTE
Special instructions for best opera
not related to safety.
tion
Figure
1-1.
Safety
Information
SECTION 2- SPECIFICATIONS
Table 2-1.
Specifications
Description
Specification
GTAW Torch; 150 Ampere
Mounted Switch
Model Description
At 100%
Ampere Rating
Duty Cycle
Rating;
12 ft
(3.7 m) Direct Connect, High-Flex Cable
Amperes Using Argon Gas And Gas
150
Lens Collet
Body
Installed
With Handle
(See Section 2-1)
DCEN
Cooling
Method
Tungsten
Size
Capacity
Air
Cooling
1/16 in
(1.6 mm)
Torch Body Dimensions And Weight
Length: 9-1/2 in (241 mm); Handle Diameter: 1-1/4 in (34 mm); Weight:
Cable Length
12 ft
Total
Net: 2.3 lb
Weight
10
oz
(198 g)
(3.7 m)
(1.1 kg); Ship:
3.0 lb
(1.4 kg)
OM-171 108
Page
1
Table 2-2. Recommended Safe
MW 100
MW 130
Operating Ranges
MW 150
MW 250
Low
High Tap
Tap
Low Mm.
80 A
Range
1
100 A
Range
1
125 A
Range
1
105 A
Range
1
Low Max.
85 A
Range
2
115 A
Range
2
155 A
Range
2
130 A
Range
2
High Mm.
105 A
Range
3
135 A
Range
3
*
Range
3
160 A
Range
3
110 A
Range
4
150 A
Range
4
Range
4
*
Range
4
Range
5
*
Range
5
Range
6
*
Range
6
High
*
Max.
.
Do not operate in this range.
~
2-1.
Duty Cycle
£~
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE
Do
n ot
weld at rated load
longer
can
torch and void warranty.
wtwam8.1
DefinItion
0
damage
than shown below.
100%
Duty Cycle
At 150
Amperes Using
8/93
A rgon Gas
~
~
10
Duty Cycle is percentage of 10
minutes that torch can weld at
rated load without overheating.
Minutes
Continuous
Welding
sbl.5 8/93
Figure
2-1.
Duty Cycle
4
OM-171 108 Page 2
SECTION 3-INSTALLATION & OPERATION
Required Torch
3-1.
Required
Parts And Torch
Assembly
Obtain the following parts
Section 6):
Torch Parts
1
Tungsten Electrode (See
Section 5)
2
Cup
3
Collet
4
Standard Collet
4
3
(see
Body
Assembiing
Torch
Body
5
Torch
6
Heat Shield
7
Backcap (Long Backcap
Shown)
8
0-Ring
Body
Instaliing Tungsten
To adjust tungsten position, loosen
backcap.
Keep
connections
cup, heat shield,
0-rings
tight. Replace
backcap, and
if cracked.
Assembling Torch Parts
7
8
4
2
installing Tungsten
lighten
ST-BOO 880
Figure
3-1.
Required Torch Parts
And Torch
Assembly
OM-171 108 Page 3
3-2.
Connecting Torch
READ SAFETY BLOCKS at beginning
of manual before proceeding.
BUILDUP OF SHIELDING GAS
Shut off
shielding gas supply when
can
harm health
or
kill.
not in use.
waml.1 9/91
For
Welding
Power Sources
Turn Off welding power source,
and disconnect input power before
Using Friction Terminai Lead Connections
installing
Connecting Trigger
Set all welding power sources
for straight polarity.
2
torch.
Leads
1
Torch
2
Welding Power Source Trig
Trigger
Leads
ger Leads
insert torch trigger leads, one at a
time through grommet in front pan
el. Connect torch trigger leads to
matching welding power source
trigger leads, polarity is not impor
tant.
Or
3
Adapter Plug Trigger Leads
Connect torch
trigger leads to
matching adapter plug trigger
leads, polarity is not important.
7
4
Torch
insert into
Trigger Plug
matching receptacle on
tighten
power source, and
threaded collar.
welding
For
Weiding
Power Sources
Requiring
A
Trigger
Leads
installing Torch
Plug Adapter
5
Set all welding power
for straight polarity.
Torch End
6
Drive
Assembly
7
Torch
Securing
Nut
sources
Insert torch end until it bottoms
drive assembly. Tighten
against
nut.
Tools Needed:
~
1/2in
ST-800 878-A / ST-BOO 879-A
Figure
OM-171 108
Page
4
3-2.
Connecting
Torch And
Trigger
Leads
1
Trigger
Press tngger to pull in contactor
and start gas flow. While trigger is
pressed, use scratch
start method
to start an arc.
extinguish arc, md for proper
posthow and cooling, momentarily
release and repress trigger for
To
aboUt ten seconds.
ST-800 877
Figure
SECTION 4
4-1. Maintenance Schedule
Table 4-1.
NOTE ~
Operation
MAINTENANCE & TROUBLESHOOTING
Figure
_____________________
3-3.
Before
Troubleshooting
using troubleshooting table,
according to Section 5.
check selection and
Trouble
Wandering arc
of tungsten
Remedy
poor control of direction of
Tungsten electrode oxidizing and
bright after conclusion of weld.
preparation
electrode
not
arc.
remaining
~
I.
I
-
Reduce gas flow rate.
~
Shield weld
zone
from drafts. Check and
I
tighten
all gas
fittings.
_________________________________________________________________
Increase
postflow time (see Figure 3-3).
OM-171 108
Page
5
SECTION 5
TUNGSTEN ELECTRODE
mod2.1 1/94
NOTE ~
5-1.
Wear clean
Selecting Tungsten
gloves
to
prevent contamination of tungsten electrode.
Electrode
Table 5-1.
Tungsten
Size
Amperage Range
Electrode Diameter
DC
Argon Electrode
Negative/Straight Polarity
-
Gas
DC
Argon Electrode
Positive/Reverse Polarity
Type
Polarity
-
AC
Argon Using
High Frequency
AC
Argon
Wave Using
Balanced
High Freq.
Pure
Tungsten
(Green Band)
.010
Uptol5
.020
.
.040
Uptol5
UptolO
5-20
*
5-20
10-20
15-80
*
10-60
20-30
1/16
70-150
10-20
50-100
30-80
3/3~
125-225
15-30
100-160
60-130
150-210
100-180
1/8
225-360
25-40
5/32
360-450
40-55
200-275
160-240
3/16
450-720
55-80
250-350
190-300
1/4
720-950
80-1 25
325-450
250-400
Up
Up
2% Thorium
Alloyed
Tungsten (Red Band)
.010
Up
.
to 25
to 20
to 15
.020
15-40
.040
25-85
*
1/16
50-160
10-20
50-150
60-120
3/32
135-235
15-30
130-250
100-180
1/8
250-400
25-40
225-360
160-250
5/32
400-500
40-55
300-450
200-320
15-35
5-20
20-80
20-60
3/16
500-750
55-80
400-500
290-390
1/4
750-1000
80-125
600-800
340-525
*
*
Up
Up
Zirconium Alloyed
Tungsten (Brown Band)
.010
.020
15-35
to 15
5-20
.040
*
20-80
20-60
1/16
*
50-150
60-120
3/32
*
*
130-250
100-180
*
225-360
160-250
*
300-450
200-320
400-550
290-390
600-800
340-525
1/8
*
5/32
3/16
*
1/4
Typical argon shielding
Not
to 20
gas flow rates
are
15 to 35 cf h
(cubic feet
per
hour).
Recommended.
The figures listed
manufacturers.
OM-171 108
Page
are
intended
as a
guide
and
are a
composite
of recommendations from American
Welding Society (AWS)
and electrode
s-coos
6
5-2.
Preparing Tungsten
1
Tungsten Electrode
2
Balled End
Ball end of tungsten before
P
O~IIE
welding
by applying either an ac amperage
slightly higher than what is recom
1-1/2 Times
mended for
a given electrode di(see Table 5-1), or a dc
electrode positive amperage.
Electrode Diameter
ameter
2
Ref. S-0161
Figure
a
5-1.
Preparing Tungsten
For AC Or DC Electrode Positive
(DCEP) Welding
CAUTION
FLYING SPARKS AND HOT METAL
can cause
injury
and start tires.
Shape tungsten electrode only on gnnder with proper guards in a safe location wearing proper face, hand, and body protection.
Keep flammables away.
wam2.1 9/91
1
2
1
Tungsten
2
Tapered
Electrode
End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld
ing. Do not use wheel for other jobs
or tungsten can become contami
nated causing lower weld quality.
2-1/2 Times
Electrode Diameter
Ret. S-01 61
1
1
Stable Arc
2
Flat
2
Diameter of this flat determines
amperage capacity.
3
Wheel
3
Grinding
4
Straight Ground
4
Ideal
Tungsten Preparation
Stable Arc
1
2
~i3
Ret. 5-0162
1
Arc Wander
2
Point
3
Grinding Wheel
4
Radial Ground
4
Wrong Tungsten Preparation
Figure
5-2.
Preparing Tungsten
Wandering Arc
For DC Electrode
Ref. S-0162
Negative (DCEN) Welding
OM-171 108
Page
7
SECTION 6-PARTS LIST
5
9
8
6
20
ST-800 881
Figure
Item
No.
Part
No.
COLLETS,1/16
COLLET BODIES, 1/16
1
CERAMIC NOZZLE
MOMENTARY CONTACT MICROSWITCH
0-RING, .500 ID x .1O3CS RBR
1
2
171 127
HANDLE
MOMENTARY CONTACT SWITCH w/12 FT LEADS
1
170 622
CABLE, trigger
1
171 113
171 114
171 115
171 117
171 118
171 119
171 124
079 974
OM-171 108
171 126
Page
8
Complete Assembly
1
171 111
18
6-1.
Quantity
TORCH BODY AIR COOLED
POWER CABLE ASSY 12 FT W/SPEC FITTINGS
BACKCAPSHORT
0-RING FOR BACK CAP
CUP GASKET
171 110
16
Complete Assembly
Description
Figure
...4
6-1.
..
1
1
1
1
1
1
1
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