KB8

Miller KB8, MT-20-12, MT-20-25, MT-20V-12, MT-20V-25 Owner's manual

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Millerﬁ

May

1993

Form:

OM-1562B

Effective

With

Style

No.

KB-8

OWNERS

MANUAL

MT-20-1

2,

MT-20-25,

MT-20V-1

2,

And

MT-20V-25

Torches

U

U

U

Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.

U

Give

this

manual

to

the

operator.

1I~fl

U

For

help,

call

your

distributor

U

or:

MILLER

ELECTRIC

Mtg.

1079,

Appleton,

WI

54912

Co.,

P.O.

Box

414-734-9821



~IIII~

~



Water-Cooled

Torch

For

GTAW

Welding



Rated

At

250

Amperes

100%

Duty

Cycle

Using

Argon

Shielding

Gas



.020

Thru

1/8

in

(0.5

Thru

3.2

mm)

Tungsten

Size

Capacity

U

Includes

12-1/2

Or

25

ft

(3.8

m

Or

7.6

m)

Cable



Available

With

Or

Without

A

Gas

Valve

U

Tungsten

Electrode

And

Consumables

Needed

cove,

8/92



ST-800

152

PRINTED

IN

USA

J

-I_u

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

sit

previous

MILLER

warranties

end

is

exclusive

with

no

other

guarantees

or

wsrrsnties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below,

MILLER

Electric

Ml

g.

Co..

Appleton.

Wisconsin,

warrsnts

10

its

origlnsl

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

dste

of

this

limited

warranty

is

free

of

de

tects

in

msterisl

and

workmanship

at

the

lime

it

is

shipped

by

MILLER.

TIllS

WAR

RANT?

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

OR

IMPLIEO.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below.

MILLER

will

repair

or

replace

any

wer

ranted

parts

or

components

that

fail

due

to

such

defects

in

material

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedurea

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

taiture

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

the

distributor.

1.

5

Yearn

Parts



3

Years

Labor

*

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor

*

Transtormer/Rectifier

Power

Sources

*

Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warrants

separately

by

the

engine

manufacturer.)



Air

Compressors



Remote

Controls

Accessory

Kits

*

Replacement

Parts

MILLERS

True

Blue

Limited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER,

but

manutactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components:

such

as

contact

tips,

cuBing

nozzles.

contaclors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operalion

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENt

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be.

at

MILLERS

option:

(1)

repair,

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases.

(3)

the

reasonable

cost

of

repair

or

replace

ment

at

an

authorized

MILLER

service

alalion;

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton.

Wisconsin,

or

FOB,

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburxa

ment

for

transportation

costa

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMItTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECt

SPECIAL,

INCIDENTAL

OR

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT).

WHETHER

BASED

ON

CON

TRACt

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANT?

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANT?,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE.

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION.

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING.

IN

CLUDING

ANY

IMPLIED

WARRANT?

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE.

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

stales

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental.

indirect,

special

or

consequential

damages,

so

the

above

limilalion

or

exclusion

may

not

apply

10

you.

This

warranty

provides

ape

citic

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

slale

10

slate.

In

Canada.

legislation

in

some

provinces

provides

br

certain

additional

warranties

or

remedies

other

than

as

slated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply

This

Limited

Warranly

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

I

S

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



HF

Units



Grids



Spot

Welders

*

Load

Banks



SDX

Tranatormers



Running

Gear/Trailers

*

Field

Options

(NOTE:

Field

options

are

covered

under

True

Blue

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

6.

90

Days



Parts

and

Labor

*

M113

Guns/TIG

Torches

*

Plasma

Cutting

Torches

1_U

RECEIVING-HANDLING

Before

unpacking

eqUipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

Fi(e

any

C)aimS

for

loss

or

damage

with

the

delivering

carrier.

Ass(stance

for

filing

or

sett)irig

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Mode)

Designation

and

Seria(

or

Sty(e

Number.

Use

the

fol(owing

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

)ocated

on

the

rating

(abel

or

namep(ate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

.

miller

5193a

/

/

/GTAW

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Do

not

touch

torch

parts

if

in

contact

with

the

work

or

ground.

5.

Turn

off

power

before

checking,

cleaning,

or

changing

torch

parts.

6.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

CFR

1910.147

(see

Safety

Standards).

WELDING

can

cause

explosion

or

fire.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

7.

Properly

install

and

ground

the

welding

power

source

orwelding

generator

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

8.

Turn

oft

input

power

on

all

equipment

not

in

use.

9.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

10.

Inspect

and

replace

any

worn

or

damaged

torch

cable

leads.

11.

Do

not

wrap

torch

cable

around

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

use

a

separate

connection



do

not

use

work

cable.

13.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Wear

a

safety

harness

if

working

above

floor

level.

Keep

all

panels

and

covers

securely

in

place.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

4.

Be

alert

that

welding

sparks

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.

1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Wear

oil-free

protective

garments.

10.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

11.

Allow

work

and

equipment

to

cool

before

handling.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

I

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

wearing

an

air-supplied

respirator.

Always

have

a

trained

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damage

hearing.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

ANSI

Z49.

I

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses

with

side

shields.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

/

GTAW

WELDING

can

be

hazardous.

PROTECT

YOIY~SELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACI~V~&KER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

Is

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

infc/nation

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

~ndards

listed

on

the

next

page.

Read

and

follow

all

Safety

Standards.

See

also

Safety

Precautions

in

powe~.iource

manual.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

Ql~ALlFlED

PEOPLE.

/

/

15.

16.

17.

1.

2.

3.

sr3

2/93

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury

and

start

fires.

Grinding

the

tungsten

electrode

causes

flying

metal.

1.

Shape

tungsten

electrode

only

on

a

grinder

with

proper

guards

in

a

safe

location.

2.

Keep

flammables

away.

3.

Wear

approved

face

shield

or

safety

goggles

with

side

shields.

4.

Wear

gloves

and

proper

body

protection

to

protect

skin

and

hands.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,from

American

Welding

Society,

550

NW.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

Gas

Shielded

Arc

Welding,

Ameri

can

Welding

Society

Standard

A6.1,from

American

Welding

Society,

550

NW.

LeJeune

Rd.

Miami,

FL

33126

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1,from

American

Welding

So

ciety,

550

NW.

LeJeune

Rd.

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park.

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i.

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

W117.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion.

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute.

1430

Broadway.

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

SiB,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

..

.

r~..j

CYLINDERS

can

explode

if

damaged.

4.

Never

allow

electrical

contact

between

a

Gas

Tungsten

Arc

.~

~

..

.

.

.

torch

and

a

cylinder.



Shielding

gas

cylinders

contain

gas

under

high

-~

~-

pressure.

If

damaged,

a

cylinder

can

explode.

Since

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

~,:;

gas

cylinders

are

normally

part

of

the

welding

fittings

designed

for

the

specific application;

maintain

them

and

process,

be

sure

to

treat

them

carefully.

associated

parts

in

good

condition.

g

T,

rn

fnrn

n,n,n,,

frnm

,,nI,,n

ni

tint

,nhon

nnoninn

r,,iinrlar

,,ni,,o

1.

Protect

gas

cylinders

from

excessive

heat,

mechanical

shocks,



slag,

open

flame,

sparks,

and

arcs.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

in

use

or

connected

for

use.

them

to

a

stationary

support

or

equipment

cylinder

rack

to

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

prevent

falling

or

tipping.

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

3.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Standards.

sr3

2/93

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

2-1.

Duty

Cycle

2

SECTION

3INSTALLATION

3-1.

Torch

Parts

And

Consumables

2

Assembling

Torch

Body

Installing

Gas

Supply

Coolant.Guidelines

3-5.

Connecting

Torch

6

SECTION

4OPERATING

THE

TORCH

7

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

8

5-2.

Troubleshooting

Table

9

SECTION

6

TUNGSTEN

ELECTRODE

6-1.

Selecting

Tungsten

Electrode

6-2.

Preparing

Tungsten

SECTION

7

PARTS

LIST

Figure

7-1.

Complete

Torch

Assembly

Table

7-1.

Consumable

Parts

And

Cross

Reference

Chart

NOTE

LII~=

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

.

.

there

is

now

a

very

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.

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

procedures:

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

3.

Do

not

coil

or

drape

cables

around

the

body.

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.-

Connect

work

clamp

to

workpiece

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.

modlO

1

4/9~

3-2.

3-3.

3-4.

3

4

5

10

11

12

14

OM-1562B

-

6/93

.

SECTION

1

-

SAFETY

IN

FORMATION

modl.1

2/93



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

I

I~

ELECTRIC

SHOCK

can

kilI.~~

~

~\

S

Do

not

touch

live

electrical

parts,



Disconnect

input

power

before

L,

installing

or

servicing,

Figure

1-1.

Safety

Information

SECTION

2

SPECIFICATIONS

Table

2-1.

Welding

Torch

1

2 2

\

a

CAUTION

/

5



MOVING

PARTS

can

injure.



Kee~

away

from

moving

parts.



Keep

all

panels

and

covers

closed

when

operating.

6

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

related

to

safety.

READ

SAFETY

BLOCKS

at

start

of

_____

Section

3-1

before

proceeding.

H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Specification

Model

Description

Description

MT:

Miller

Torch;

20:

250

Ampere

Rating;

12:

12-1/2

ft

(3.8

m)

Cable;

25:

25

ft

(7.6

m)

Cable;

V:

Gas

Valve

Example:MT-20-12



Miller

Torch,

250

Ampere

Rating,

12-1/2

ft

Cable

250

A

With

Argon

Gas

And

Gas

Lens

Collet

Body

Installed

(see

Section

3-1)

Ampere

Rating

At

100%

Duty

Cycle

DCEN,

ACHF

Cooling

Method

Coolant

Requirements

Tungsten

Size

Capacity

Options

And

Accessories

Torch

Body

Dimensions

And

Weight

Water

1

qtlmin

(0.94

L/min)

.020

Thru

1/8

in

(0.5

Thru

3.2

mm)

See

Section

7

And

Rear

Cover

Length:

7-1/2

in

(191

mm);

Handle

Diameter:

3/4

in

(19

mm);

Weight:

2.5

oz

(71

g)

Total

Weight

Net:

1-1/2

lb

(0.7

kg);

Ship:

2

lb

(0.9

kg)

12-1/2

ft

Cable

25

ft

Cable

Net:

2-1/2

lb

(1.1

kg);

Ship:

3

lb

(1.4

kg)

OM-1562

Page

1

2-1.

Duty

Cycle

a

CAUTION

EXCEEDING

RATED

AMPERAGE

and

duty

cycle

can

damage

torch.



Do

not

exceed

rated

amperage

and

duty

cycle

in

Table

2-1.

warn7.1

2)92

Duty

cycle

is

how

long

the

torch

can

operate

within

a

ten

minute

period

without

causing

overheating

or

damage.

This

torch

is

rated

at

100%

duty

cycle

allowing

continuous

operation

when

using

argon

shielding

gas

at

rated

amperage.

SECTION

3INSTALLATION

a

WARNING

3-1.

Torch

Parts

And

Consumables

1

Handle

2

Gas

Hose

3

Power

Cable/Coolant-Out

Hose

.-

4

Coolant-In

Hose

5

Heat

Shield

6

Torch

Body

7

0-Ring

7

8

Backcap

9

Gas

Valve

(Optional)

Obtain

the

following

GTAW

11

12

\

13\

lk~I:5

~

~

~

-

,-

-

9

\

\

~

consumables

(see

Section

7):

10

Power

Cable

Adapter

(Acces

sory)

11

Tungsten

Electrode

12

Cup

13

Collet

Body

14

Collet

4

2

3



~



10

ST-120

502

Figure

3-1.

Torch

Parts

And

Consumables

~

E



LECTRIC

SHOCK

can

kill.

Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

installing

torch.

swarnl.12/93

OM-1562

Page

2

3-2.

Assembling

Torch

Body

I

Torch

Body

2

Heat

Shield

3

Collet

Body

4

Cup

-4

5

Backcap

(Long

Backcap

Shown)

6

0-Ring

7

Standard

Collet

8

Reverse

Coltet

Reverse

collet

improves

electrical

contact

of

tungsten

electrode.

9

Installing

Tungsten

10

Tungsten

Electrode

To

adjust

tungsten

position,

loosen

backcap.

Keep

connections

tight.

Replace

cup,

heat

shield,

backcap,

and

0-rings

if

cracked.

Distance

about

same

as

diameter

of

tungsten

5

3

4

Install

Check

9

Ttghten

Figure

3-2.

Installing

Torch

Body

5T-800

153

OM-1562

Page

3

3-3.

Installing

Gas

Supply

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

6

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

This

flowmeter

can

be

adjusted

between

5

and

40

cfh.

7

CO2

Adapter

8

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

Figure

3-3.

Typical

Regulator/Flowmeter

Installation

F.

S

warn4.1

9/91

2

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

2

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

3

Cylinder

4

Regulator/Flowmeter

Install

so

face

is

vertical.

5

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Obtain

and

install

gas

hose.

3

Argon

Gas

6

5

4







OR

2

7

8

3

Tools

Needed:

~::=::::::::r

1-1/8,5/Bin

CO2

Gas

ssb3.1

12/92



ST-158

697-A

OM-1562

Page

4

3-4.

Coolant

Guidehnes

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Oft

welding

power

source,

and

disconnect

input

power

before

working

on

torch.

FAILURE

TO

PROPERLY

MAINTAIN

COOLANT

SYSTEM

can

cause

damage

to

the

coolant

system

and

torch.



Circulate

and

flush

clear

water

through

entire

system,

and

replace

coolant

everj

six

months.

INCORRECT

COOLANT

will

damage

unit.



Use

plain

distilled

or

deionized

water,

or

use

high

quality

tap

water.



In

freezing

temperatures

use

only

a

mix

of

pure

ethylene

glycol

and

distilled

or

deionized

water

such

as

MILLER

coolant

Part

No.

128

705

or

equivalent.

DO

NOT

USE

AUTOMOTIVE

ANTIFREEZE.

2

Figure

3-4.

Coolant

Guidelines

This

torch

is

rated

at

a

I

qt/min

(0.94

L/min)

coolant

flow

rate.

Changes

in

flow

rate

will

affect

operating

temperature

of

torch.

Follow

these

guidelines

to

de.

crease

corrosion

in

torch.

Material

in

contact

with

coolant

can

only

be

brass,

copper,

silver

solder,

300

Series

stainless

steel,

or

plas

tic.

I

Coolant

See

table

for

coolant

mixture

need

ed

for

operating

temperature.

2

Coolant

Supply

See

coolant

supply

Owners

Manual

for

installation

instructions.

Ref.

ST-137

225-0

OM-1562

Page

5

3-5.

Connecting

Torch

A

Torch

Without

A

Gas

Valve

To

A

Welding

Power

Source

With

A

Gas

Valve

Figure

3-5.

Connecting

A

Torch

Without

A

Gas

Valve

To

A

Welding

Power

Source

With

A

Gas

Valve

B.

Connecting

A

Torch

With

A

Gas

Valve

To

A

Welding

Power

Source

Without

A

Gas

Valve

Figure

3-6.

Connecting

A

Torch

With

A

Gas

Valve

To

A

Welding

Power

Source

Without

A

Gas

Valve

OM-1562

Page

6

I

~

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

.

8

a

Tools

Needed:

~

5/8,

7/8

in

1

Torch

2

Welding

Power

Source

3

Coolant

Hose

(Customer

Supplied)

Obtain

correct

length

with

5/8-18

left-hand

fittings.

4

Coolant

System

5

Coolant

In

Fitting

6

Coolant

Out

Fitting

7

Regulator/Flowmeter

8

Gas

Cylinder

9

Gas

Hose

(Customer

Supplied)

Obtain

correct

length

with

5/8-18

right-hand

fittings.

10

Power

Cord

11

Gas

Valve

Ret.

ST-120

503

12

Power

Cable

Adapter

13

Torch

Gas

In

Hose

14

Torch

Coolant

In

Hose

15

Torch

Power

Cable/Coolant

Out

Hose

Connect

torch

power

cable/coolant

out

hose

to

power

cable

adapter,

and

connect

adapter

to

weld

output

terminal.

16

Work

Clamp



READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

Tools

Needed:

14

13

12

11

10

5/8,

7/Bin

Ret

ST-120

503

1

Torch

6

Coolant

In

Fitting

12

Power

Cable

Adapter

2

Gas

Valve

7

Coolant

Out

Fitting

13

Torch

Coolant

In

Hose

3

Welding

Power

Source

8

Regulator/Flowmeter

14

Torch

Power

Cable/Coolant

Out

Hose

4

Coolant

Hose

(Customer

Supplied)

Obtain

correct

length

with

5/8-18

left-hand

fittings.

9

10

Gas

Cylinder

Torch

Gas

In

Hose

Connect

torch

power

cable/coolant

out

hose

to

power

cable

adapter,

and

connect

adapter

to

weld

output

terminal.

5

Coolant

System

11

Power

Cord

15

Work

Clamp

.

SECTION

4-

OPERATING

THE

TORCH

a

WARNING

ELECTRIC

SHOCK

can

kill.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.



Do

not

touch

live

electrical

parts.



Keep

all

covers

and

handle

securely

in

place

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.



Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handling.

,~

~

.

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.



~

I

~

.~_

~

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

opera

tions.

Figure

4-1.

Safety

Equipment

Figure

4-3.

Gas

Valve

(Optional)

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

Swam6.1

10/91

3

12

1

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

Helmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

sb3.1

10/91

1

Work

Clamp

Connect

work

clamp

to

a

clean,

paint-free

location

on

workpiece,

as

close

to

weld

area

as

possible.

Tools

Needed:

Use

wire

brush

or

sandpaper

to

clean

metal

at

weld

joint

area.

sb4.1

2/93

Figure

4-2.

Work

Clamp

1

Gas

Valve

Use

valve

to

control

gas

preflow

and

postfiow

at

torch.

Posifiow

pre

vents

electrode

from

oxidizing,

or

becoming

contaminated

with

a

black

surface.

Open

valve

just

before

welding.

If

welding

power

source

and

torch

have

gas

valves,

open

both

valves

before

welding.

After

welding,

leave

valve

open

about

10

seconds

for

every

100

amperes

of

weld

current.

Close

valve

when

postflow

is

finished.

ST-800

152

OM-1562

Page

7

a

WARNING

r

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use

warnl.1

9/91

1

Shielding

Gas

Cylinder

2

Valve

3

3

Foot

Control

Open

valve

on

cylinder

just

before

_____________

welding.

Foot

control

turns

weld

output

and

gas

flow

on

and

off.

Close

valve

on

cylinder

when

fin

ished

welding.

sb5.3

6/92



S.062i-C

Figure

4-4.

Shielding

Gas

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

a

WARNING

Figure

5-1.

Maintenance

Schedule

.

Connect

High-Frequency

~

)

Tungsten Tungsten

Per

________________

Unit

))

(See

Section

6)

Into

Torch

D)

Equipment

J~Source

Install

Install

&

Connect\

Selec~~))

Insert

Put

O~~\

Set

Controls

sonal

Safety

)

On

Welding

J

Equipment

_________________

________________

________________

________________

Turn

On

))

Turn

On

))

Turn

On

Turn

On

)

Shielding

Gas

Coolant

Supply

High-Frequenc

Welding

Pow~~)

Begin

Weldin~

Unit

Source

ssb8

1*9/92

Figure

4-5.

Sequence

Of

Gas

Tungsten

Arc

Welding

(GTAW)

E

LECTRIC

SHOCK

can

kill.

HOT

PARTS

can

cause

se

vere

burns.



Do

not

touch

live

electrical

parts.



Allow

cooling

period

before

maintaining

or



.

Turn

Off

welding

power

source,

and

input

power

before

working

on

torch.

.

disconnect

~stt((S~li,l~l~

servicing.

Maintenance

and

troubleshooting

only

by

qualified

persons.

to

be

performed

swarn8.i~

2/93

5-1.

Routine

Maintenance

40

Hours

Replace

Cracked

Parts

Torch

Body

~

ST-Boo

152

Gas

Hose

Torch

Cable

I

OM-1562

Page

8

5-2.

Troubleshooting

Table

Table

5-1.

Welding

Trouble

Decreased

coolant

flow

rate.



-.

*

See

welding

power

source

Owners

Manual.

**

See

coolant

supply

Owners

Manual.

Add

coolant

Check

for

clogged

hoses

or

coolant

strainer.

I

Section

-~

6-1

-a

*

---

--

---

--

-

*

3-3

Figure

4-3

6-1

6-2

--a

--

Figure

4-3

-~

3-3,3.5

-..

6-2

-~

7

.~

3-4

-~

**

-~

3.4

-~

**

OM-1562

Page

9

Trouble

Lack

of

high

frequency;

difficulty

in

es-

 

-~

tablishing

arc.

Remedy

Select

proper

size

tungsten.

Check

High

Frequency

control

on

welding

power

source.

Be

sure

that

electrode

holder

cable

is

not

close

to

any

grounded

metal.

Check

cables

and

torch

for

cracked

insulation

or

bad

connections.

Repair

or

replace

necessary

parts.

Check

and

adjust

spark

gaps

in

welding

power

source,

if

neces

sary.

Wandering

arc



poor

control

of

direc-





-~

tion

of

arc.

Reduce

gas

flow

rate.

Select

proper

size

tungsten.

Tungsten

electrode

oxidizing

and

not

re-





-~

maining

bright

after

conclusion

of

weld.

Properly

prepare

tungsten.

Shield

weld

zone

from

drafts.

Increase

postflow

time.

Check

and

tighten

all

gas

fittings.

Properly

prepare

tungsten.

No

coolant

flow.

1



-.

Replace

torch

parts

if

water

has

leaked

into

torch.

Add

coolant.

Check

for

clogged

hoses

or

coolant

strainer.

SECTION

6-

TUNGSTEN

ELECTRODE

Typical

argon

shielding

gas

flow

rates

are

15

to

35

cfh

(cubic

feet

per

hour).

Not

Recommended.

The

figures

listed

are

intended

as

a

guide

and

are a

composite

of

recommendations

from

American

Welding

manufacturers.

mod2,1

3/93

.

NOTE

~

For

additional

information,

see

your

distributor

fora

handbook

on

the

Gas

Tungsten

Arc

Welding

(GTAW)

process.

Wear

clean

gloves

to

prevent

contamination

of

tungsten

electrode.

6-1.

Selecting

Tungsten

Electrode

Table

6-1.

Tungsten

Size

Electrode

Diameter

Amperage

flange

-

Gas

Type

-

Polarity

DC



Argon



Electrode

DC



Argon



Electrode

AC



Argon



Using

AC



Argon



Balanced

Negative/Straight

Polarity

Positive/Reverse

Polarity

High

Frequency

Wave

Using

High

Freq.

Pure

Tungsten

(Green

Band)

.010

.020

.040

1/16

3/32

1/8

5/32

3/16

1/4

Uptol5

5-20

15-80

70-150

125-225

225-360

360-450

450-720

720-950

*

*

*

10-20

15-30

25-40

40-55

55-80

80-125

Uptol5

5-20

10-60

50-100

100-160

150-210

200-275

250-350

325-450

UptolO

10-20

20-30

30-80

60-130

100-180

160-240

190-300

250-400

2%

Thorium

Alloyed

Tungsten

(Red

Band)

.010

.020

.040

1/16

3/32

1/8

5/32

3/16

1/4

Up

to

25

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

Up

to

20

15-35

20-80

50-150

130-250

225-360

300-450

400-500

600-800

Up

to

15

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Zirconium

Alloyed

Tungsten

(Brown

Band)

.010

.020

040

1/16

3/32

1/8

5/32

3/16

1/4

*

*

*

*

*

*

*

*

*

*

*

*

*

*

*

Upto2O

15-35

20-80

50-150

130-250

225-360

300-450

400-550

600-800

Uptol5

5-20

20-60

60-120

100-180

160-250

200-320

290-390

340-525

Society

(AWS)

and

electrode

S

-0009

OM-1562

Page

10

6-2.

Preparing

Tungsten

Figure

6-1.

Preparing

Tungsten

For

AC

Or

DC

Electrode

Positive

(DCEP)

Welding

a

CAUTION

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury

and

start

fires.



Shape

tungsten

electrode

only

on

grinderwith

proper

guards

in

a

safe

location

wearing

proper

face,

hand,

and

body

protection.



Keep

flammables

away.

warn2.1

9(91



Ref.

S-0161

1

1

Stable

Arc

4

2

.

2

FIat

Diameter

of

this

flat

amperage

capacity.

3

Grinding

Wheel

4

Straight

Ground

determines

Ideal

Tungsten

Preparation



Stable

Arc

Ref.

S-0162

Figure

6-2.

Preparing

Tungsten

For

DC

Electrode

Negative

(DCEN)

Welding

1

Tungsten

Electrode

2

BaIled

End

Ball

end

of

tungsten

before

welding

by

applying

either

an

ac

amperage

_______________________

1-1/2

rimes

slightly

higher

than

what

is

recom

iE~~ctrode

Diameter

mended

for

a

given

electrode

diam

eter

(see

Table

6-1),

or

a

do

elec

trode

positive

amperage.

2

Ref.

S-0161

1

Tungsten

Electrode

2

2

Tapered

End

Grind

end

of

tungsten

on

fine

grit,

hard

abrasive

wheel

before

weld

~)

ing.

Do

not

use

wheel

forother

jobs

or

tungsten

can

become

contami

nated

causing

lower

weld

quality.

2-1/2

Times

Electrode

Diameter

2

1

Arc

Wander

2

Point

3

3

Grinding

Wheel

4

Radial

Ground

Wrong

Tungsten

Preparation



Wandering

Arc

Ref.

S-0l

62

Om-1

562

Page

11

SECTION

7

PARTS

LIST

Figure

7-1.

Complete

Torch

Assembly

.

9

4

Table

7-1

Table

7-1

2

5

11

18

i~12

19

18

ST-120

502

OM-1562

Page

12

Item

Stock

Model

No.

No.

No.

OPTIONAL

Description

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Figure

7-1.

Complete

Torch

Assembly

Quantity

TUNGSTEN,

electrode

(consult

your

welding

supply

distributor)

CUP,

(see

Table

7-1)

COLLET

BODY,

(see

IbIe

7-1)

116

223

TORCH

BODY,

wlheat

shield

(consisting

of)

1

116

222

TORCH

BODY,

w/heat

shield

and

valve

(consisting

of)

1

5

...

116

279

.

300VK

....

VALVE

KNOB,

with

0-rings

(consisting

of)

I

6

...

116254

..

100R

0-RING

2

7

200HS

....

HEAT

SHIELD,

std

1

7

2GHS

HEAT

SHIELD,

gas

lens

I

8

COLLET,

(see

Table

7-1)

9

...

116

224

...

200L

BACK

CAP,

medium

(consisting

of)

1

9

..

116

225

..

200M

BACK

CAP,

long

(consisting

of)

1

9

..

116

226

.

.

.

200S

BACK

CAP,

short

(consisting

of)

1

10

..

116227

..

200R

...

0-RING

1



11

..

117585

HANDLE

1

11

..

118516

HANDLE,

models

w/valve

1

12

.

116

228

..

2PCA

POWER

CABLE

ADAPTER

1

13

..

116

205

.

212TF

CABLE,

Tn-Flex

12-1/2ft

(consisting

of)

1

13

..

116

206

.

225TF

CABLE,

Tn-Flex

25ft

(consisting

of)

1



14

..

116

267

.

212AH

....

GAS

HOSE,

12-1/2ft

(consisting

of)

1

14

..

116

268

.

225AH

....

GAS

HOSE,

25ft

(consisting

of)

1

15

.

118

512

HOSE,

black

2

series

1/8

in

ID

(order

by

ft

as

required)



16

.

116

266

...

2AN

GAS

NUT

1

17

.

116

269

...

3HF

HOSE

FITTING

1

18

..

116231

.

212PC

...

POWER

CABLE,

w/fittings

12-1/2ft

1

18

.

116

230

.

225PC

...

POWER

CABLE,

w/fittings

25ft

1



19

.

116

232

.

212WH

...

WATER

HOSE,

12-1/2ft

(consisting

of)

1



19

.

116

233

.

225WH

...

WATER

HOSE,

25ft

(consisting

of)

1

20

.

116

269

...

3HF

HOSE

FITTING

1



21

.

116236

..

2WN

WATER

NUT

1

22



.

118

512

HOSE,

black

2

series

1/8

in

ID

(order

by

ft

as

required)

OM-1562

Page

13

th

0

LUC

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lx:L;5

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,*-*LOLO(0(0

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ZZZ;2:zz

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0

C,

C-)

C

C,

C,

C,

U,

U)

0

I

C,

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0

p.-

0

LU

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LU

U)

U)

p.

LU

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4

U)

z

0

0

a

C.

a

0

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a

0

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0

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a

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C-,

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LU

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Ui

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OM-1562

Page

14

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