Miller Electric DB1712RDI25 User manual

www.MillerWelds.com
Processes
Description
TIG Torch
OM-1600 199 525E
1/2005
DB1712RDI25, DB1725RDI25, DB17V12R,
Diamondback Series
GTAW Torches
TIG (GTAW) Welding
DB1712R, DB1725R, DB1712RDI, DB1725RDI,
DB17V25R, DB17V12-2, And DB17V25-2

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.
Working as hard as you do
−every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 7/03

TABLE OF CONTENTS
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES −READ BEFORE USING 1. . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. GTAW Torch Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMF INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 −SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 −INSTALLATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Required Torch Parts And Torch Assembly 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. International Style Connector Assembly 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Connecting Torch 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 −MAINTENANCE & TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 −SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING 9. . . .
5-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 9. . . . . . . .
5-2. Preparing Tungsten Electrode For Welding 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 −GUIDELINES FOR TIG WELDING (GTAW) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Positioning The Torch 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Torch Movement During Welding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Positioning Torch Tungsten For Various Weld Joints 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 −PARTS LIST 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

Notes

OM-1600 Page 1
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW
TORCHES −READ BEFORE USING
SR6_8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.
This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions to avoid the hazards.
YMarks a special safety message.
.Means NOTE; not safety related.
1-2. GTAW Torch Hazards
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 Owner’s Manual. Read and follow all safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
GTAW WELDING can be hazardous.
ARC RAYS can burn eyes and skin.
1. Wear welding helmet with correct shade of filter.
2. Wear correct eye and body protection.
3. Cover exposed skin.
ELECTRIC SHOCK can kill.
1. Always wear dry insulating gloves.
2. Insulate yourself from work and ground.
3. Do not touch live electrode or electrical parts.
4. Repair or replace worn, damaged, or cracked
torch or cable insulation.
5. Turn off welding power source before changing
tungsten electrode or torch parts.
6. Keep all covers and handle securely in place.
WELDING can cause fire or explosion.
1. Do not weld near flammable material.
2. Do not weld on closed containers.
3. Watch for fire; keep extinguisher nearby.
NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.
1. Check for noise level limits exceeding those
specified by OSHA.
2. Use approved ear plugs or ear muffs if noise level
is high.
3. Warn others nearby about noise hazard.
HOT SURFACES can burn skin.
1. Allow torch to cool before touching.
2. Do not touch hot metal.
3. Protect hot metal from contact by others.
FUMES AND GASES can be hazardous
to your health.
1. Keep your head out of the fumes.
2. Ventilate area, or use breathing device.
3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.
BUILD UP OF GAS can injure or
kill
1. Shut off shielding gas supply when not in
use.
2. Always ventilate confined spaces or use
approved air-supplied respirator.

OM-1600 Page 2
EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
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 your body.
4. Keep welding power source and cables as far away from oper-
ator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doc-
tor, then following the above procedures is recommended.

OM-1600 Page 3
SECTION 2 −SPECIFICATIONS
2-1. Specifications
Model
DB17 DB17V (With Gas Valve)
Ampere Rating 150 Amps W/Argon Gas @ 100% Duty Cycle DCEN, ACHF
Cooling Method Air
Tungsten Size .020 Thru 1/8 in (0.5 Thru 3.3 mm)
Cable Options 12-1/2 ft (3.8 m) or 25 ft (7.6 m) One-Piece High−Flex 12-1/2 ft (3.8 m) Or 25 ft (7.6 m) One-Piece High−Flex, Or
12-1/2 ft (3.8 m) Or 25 ft (7.6 m) Two-Piece High−Flex
Dimensions Length: 8 in (203 mm); Handle Diameter: 15/16 in (24 mm);
Weight: 3.7 oz (105 g)
Length: 8 in (203 mm); Handle Diameter: 15/16 in (24 mm);
Weight: 4.5 oz (138 g)
2-2. Duty Cycle
Continuous Welding sb1.5* 8/93
100% Duty Cycle At 150 Amperes Using Argon Gas
Duty Cycle is percentage of 10
minutes that torch can weld at
rated load without overheating.
0
10
Minutes
Definition
EXCEEDING RATED AMPERAGE can damage torch and void warranty.
•Do not exceed rated amperage (see Section 2-1)

OM-1600 Page 4
SECTION 3 −INSTALLATION
3-1. Required Torch Parts And Torch Assembly
Ref. ST-802 566-B
1 Cup
2 Collet Body
3 Heat Shield
4 Backcap Insulator
5 Collet
6 O-Ring
7 Backcap
8 Torch Body
9 Handle
10 One-Piece Power Cable
11 Power Cable Adapter
12 International Style Flow-Through
Adapter
Note: Adapter needed only if torch is
equippedwith one-piece cable.
13 Two-Piece Power Cable
14 International Style Connector
Note: Connector needed only if torch is
equippedwith two-piece cable (see Section
3-2).
Assembling Torch Body
Keep connections tight. Replace cup, heat
shield, and backcap as needed.
15 Tungsten Electrode (See Section 5)
Installing Tungsten
To adjust tungsten position, loosen back-
cap.
Assembling Torch Parts
12
3
4
11
12
5
7
9
6
15
Or
14
8
10
13
3-2. International Style Connector Assembly
1 Weld Output Cable
2 Insulating Boot
3 Sleeve
Slide insulating boot onto cable;
strip cable and install sleeve.
4 Connector Body
5 Setscrew
Insert cable with sleeve fully into
connector body, tighten setscrew,
and slide insulating boot over con-
nector.
ST-156 496
Tools Needed:
1
2
3
1 in
(26 mm)
3
4
5

OM-1600 Page 5
3-3. Connecting Torch
A. Connecting Torch With One-Piece Cable
YTurn Off welding power
source power before install-
ing torch.
Obtain the following hose:
1 Gas Hose With 5/8-18 Right-
Hand Fittings
Connections:
2 Regulator/Flowmeter
3 Gas Cylinder
4 Welding Power Source
5 Gas Valve
Operating Torch Gas Valve:
Valve controls gas preflow and post-
flow. Open valve on torch just before
welding.
Preflow is used to purge the immedi-
ate weld area of atomsphere.
Postflow is required to cool tungsten
and weld, and to prevent contamina-
tion of tungsten and weld. After weld-
ing, leave valve open about 1 sec-
ond for every 10 amperes of weld
current. Close valve on torch when
postflow is finished.
6 One-Piece Torch Cable
7 Power Cable Adapter
Connect gas hose and power cable
to adapter before connecting adapt-
er to weld output terminal.
8 Work Clamp
Connect work clamp to clean, paint-
free location on workpiece, close to
weld.
Use wire brush to clean weld joint
area.
9 Foot Control
803 313
If applicable, install high-frequency unit.
Tools Needed:
5/8, 7/8 in
1
2
3
5
Torch Without Gas Valve
4
87
6
1
2
3
4
5
6
7
8
Torch With Gas Valve
9
9

OM-1600 Page 6
B. Connecting Torch With Two-Piece Cable
803 664-A
YTurn Off welding power
source power before install-
ing torch.
Obtain the following hose:
1 Gas Hose With 5/8-18 Right-
Hand Fittings
Connections:
2 Regulator/Flowmeter
3 Gas Cylinder
4 Welding Power Source
5 Torch Gas-In Hose
6 Torch Power Cable
7 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
close to weld area.
Use wire brush to clean weld joint
area.
8 Foot Control
9 Gas Valve
Valve controls gas preflow and
postflow. Open valve on torch just
before welding.
Preflow is used to purge the imme-
diate weld area of atomsphere.
Postflow is required to cool tung-
sten and weld, and to prevent con-
taminationof tungsten and weld. Af-
ter welding, leave valve open about
1 second for every 10 amperes of
weld current. Close valve on torch
when postflow is finished.
If applicable, install high-frequency unit.
Tools Needed:
5/8, 7/8 in
Torch With Gas Valve
9
5
6
7
4
2
3
Torch Without Gas Valve
4
2
3
1
6
7
8
5
803 314
−
C. Connecting Torch With Flow-Through Type Connection
YTurn Off welding power
source power before install-
ing torch.
Obtain the following hose:
1 Gas Hose With 5/8-18 Right-
Hand Fittings
Connections:
2 Regulator/Flowmeter
3 Gas Cylinder
4 Welding Power Source
5 Gas Valve
6 One-Piece Torch Cable
7 Work Clamp
Connect work clamp to clean, paint-
free location on workpiece, close to
weld area.
Use wire brush to clean metal at
weld joint area.
Ref. ST-802 540-A
If applicable, install high-frequency unit.
Tools Needed:
5/8, 7/8 in
1
2
3
4
5
6
7
Torch Without Gas Valve