Miller Electric MT-24-12-1 User manual

I,
Millerfi
November
1990
FORM: OM-1558A
Effective With
Style
No.
KB-8
MODEL:
MT-24-12-1
MT-24-25-1
MT-24F-1
2-1
MT-24
F-25-1
MT-24VF-12-1
MT-24VF-25-1
OWNERS
MANUAL
IMPORTANT:
Read and
understand
the
entire
contents
of both this
manual
and the
power
source
manual
used
with this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing, operating,
or
maintaining
this
equipment.
This
unit and these
instructions
are
for
use
only
by
persons
trained and
experienced
in the
safe
operation
of
welding
equip
ment.
Do
not
allow untrained
persons
to
install,
operate,
or
maintarn
this unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.,
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
..,,n~
SA-120
672
PRINTED IN
U.S.A.

LIMITED WARRANTY
EFFECTIVE: AUGUST
6,
1990
lii
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
dther
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY

Subject
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin
war
rants to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free 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
warrant
ied
by
their
manufacturer
for
two
years
from date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000 hour
warranty.
Except
as
specified
below,
MILLERs
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.
MILLER shall
be
required
to
honor
warranty
claims
on war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following periods
from
the date
of
delivery
of
Equipment
to
the
original
user;
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
.
.
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive of labor 60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty (30) days
of the
date
of
such
failure.
As
a
matter
of
general policy
only,
MILLER
may
honor claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the exclusive remedies
therefore shall
be.
at
MILLERs
option
(1)
repair
or
(2)
replace
ment
or,
where authorized
in
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
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB..
Factory
at
Appleton.
Wisconsin.
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
or failure,
MILLER
shall instruct the
claimant
on
the
warranty
claim
procedures
to
be followed.
ANY
EXPRESS
WARRANTY
NOT PROVIDED HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY OR REPRE
SENTATION AS TO
PERFORMANCE,
AND ANY REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED WARRANTY OF MERCHAN
TABILITY OR OF FITNESS
FOR
PARTICULAR
PURPOSE,
WITH RESPECT
TO
ANY AND ALL
EQUIPMENT
FURNISHED
BY MILLER
IS EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY PROVIDED BY MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE INTENDED FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING EQUIPMENT
AND
NOT FOR
CONSUMERS
OR
CONSUMER USE. MILLERS WARRANTIES DO NOT
EXTEND
TO,
AND NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
I
ii
I

OM-1558A
11/90
RECEIVING-HANDLING
Before
unpacking equipment,
check
carton
for
any
dam- Use the
following
spaces
to
record the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion and
Serial
or
Style
Number of
your
unit. The infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation is
located
on
the data card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_________________________________________
ers
Transportation
Department.
Serial
or
Style
No.
____________________________
When
requesting
information
about
this
equipment,
al
ways
provide
the Model
Description
and
Serial
or
Style
Date
of
Purchase
_______________________________
Number.
TABLE
OF CONTENTS
Section
No.
Page
No.
SECTION 1

SAFETY
RULES
1-1.
Prevent
Electric Shock
1
1-2.
Provide
Protection
From
Fumes
And
Gases
1
1-3. Protect
Eyes
And
Skin
From
Arc
Rays;
Protect Ears
From
Noise
1
1-4.
Prevent Fires
And Burns
1
1-5.
Protect
Compressed
Gas
Cylinders
1
1-6.
Provide
Protection
For
Speial
Situations
1
1-7.
Provide
Proper
Equipment
Maintenance
2
1
-8.
Additional
Safety
Information
2
SECTION
2
SAFETY PRECAUTIONS
AND
SIGNAL WORDS
2-1.
General Information
And
Safety
3
2-2.
Safety
Alert
Symbol
And
Signal
Words
3
SECTION
3
SPECIFICATIONS
3-1.
Duty
Cycle
3
3-2.
Description
3
SECTION 4
INSTALLATION
4-1.
Torch
Body
4
4-2.
Gas
Hose
Connections
And
Gas
Valve
(If
Applicable)
5
4-3. Power
Cable Connection
6
SECTION
5
SEQUENCE
OF OPERATION
5-1.
Gas
Tungsten
Arc
Welding (GTAW)
6
5-2.
Shutting
Down
6
SECTION
6
MAINTENANCE
6-1.
Routine
M~intenance
7
6-2.
Tungsten
Electrode
7
SECTION 7
PARTS
LIST
Figure
7-1.
Complete
Torch
Assembly
9
Figure
7-2.
Consumable
Parts
And
Cross Reference Chart
10
LIST OF
CHARTS
AND
TABLES
Table
3-1.
Specifications
3
Table
6-1.
Maintenance Schedule
7
Table
6-2.
Tungsten
Size
8

SECTION
1

SAFETY
RULES
a
WARNING: UNSAFE
PROCEDURES OR
1-3.
PROTECT
EYES
AND
SKIN
FROM ARC
PRACTICES
can cause
serIous
personal
in-
RAYS;
PROTECT EARS
FROM
NOISE
jury
or
death.
Arc
rays
from the
welding
process
produce
intense heat

Read, understand,
and
follow
ALL
of these
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
safety
rules
before
installing,
operating,
or
servicing
this
equipment.
Noise
from
some
processes
can
damage
hearing.

Be
sure
that all
end
users
of
this
equipment,
1.
Wear
a
welding
helmet
fitted
with
a
proper
filter
the
operator
and
helpers,
read
and under-
lens
(see
ANSI
Z49.1 for
detailed
information).
stand these
safety
rules.
2.
Wear
a
welding
helmet
fitted
with
a
proper
filter
lens
(see
ANSI
Z49.1 for
detailed
information).
3.
Use
protective
screens or
barriers
to
protect
0th-
1-1.
PREVENT
ELECTRIC SHOCK
ers
from
flash
and
glare.
Touching
live electrical
parts
can
cause
severe
burns
to
~
Wear
protective clothing
and
foot
protection.
the
body
or
fatal shock.
Severity
of
electrical shock is de
1-4.
PREVENT
FIRES
AND
BURNS
term
med
by
the
path
and
amount
of
current
through
the
body.
Therefore:
The
hotworkpiece,
hot
equipment,
other
hot
metal,
spat
ter,
and
arc
sparks
can
cause
fires
and
burns.
1.
Do
not
touch
live electrical
parts.
1.
Wear
correct
eye,
face,
and
body
protection
in
the
2.. Do
not
work
in
wet
or
damp
areas.
work
area.
3.
Wear
dry insulating gloves
and
body
protection.
2.
Allow work and
equipment
to
cool
before han
dling.
4.
Disconnectallpowerbeforeinstallingorservicing
3.
Do
not
weld
near
flammable
material.
this
equipment.
4.
Watch for
fire,
and
keep
a
fire
extinguisher
5.
Turn
off
all
equipment
when
not
in
use.
nearby.
6.
Properly
install
and
ground
the
welding
power
5.
For
additional
information,
refer
to
NFPA
Stan-
source
according
to
its
Owners
Manual
and
all
dard 51
B,
Fire Prevention
in
Use
of
Cutting
and
applicable
codes.
Welding
Processes,
available
from
the National
Fire Protection
Association,
Batterymarch
Park,
7.
Do
not
use
worn or
damaged
cables
or
cables that
Quincy,
MA
02269.
are
too
small
or
poorly
spliced.
1-5.
PROTECT
COMPRESSED GAS
CYLINDERS
8.
Do
not
wrap
cables around
your
body.
Since
gas
cylinder
are
normally
part
of
the
welding
proc
9.
Do
not
touch
electrode and
any
grounded object
ess,
be
sure
to
treat
them
carefully.
or
circuit
at
the
same
time.
1.
Protect
compressed
gas
cylinders
from
exces
10.
,
Use
only
well-maintained
equipment. Repair
or
sive
heat,
mechanical
shocks,
and
arcs.
replace damaged
parts
at
once.
2,
Install and
secure
cylinder
so
that
they
cannot
fall
~r
tip
over
by
fastening
them
to
a
mounting
1-2.
PROVIDE
PROTECTION FROM
FUMES
AND
bracket,
wall,
or
other
stationary
support.
GASES
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Breathing welding
fumes
and
gases
can
be hazardous
to
your
health.
4.
Never
allow
a
welding
electrode
to
touch
any
cyl
inder.
1.
Keep
your
head
out
of
the
fumes.
1-6.
PROVIDE
PROTECTION
FOR
SPECIAL
SITU-
2.
Use
adequate
ventilation
in
the work
areato
keep
ATIONS
fumes and
gases
from
your
breathing
zone
and
the
general
work
area.
1.
Do
not
weld
or
cut
containers
or
materials which
have held
or
been
in
contact
with
hazardous
sub
3.
If
ventilation
is
inadequate,
use an
approved
stances
unless
they
are
properly
cleaned
and
in
breathing
device.
spected.
4.
Read the
Material
Safety
Data
Sheets
(MSDSs)
2.
Do
not
weld
or
cut
painted
or
plated
parts
unless
and the
manufacturers instructions for
any
mate-
special
ventilation is
provided
to
remove
highly
rials
used.
toxic
fumes
or
gases.
OM-1558
Page
1