Miller Electric MTTC-1512HR User manual

Miller.
March
1991
FORM: OM-1
561
Effective
With
Style
N
o.
JJ-23
MODEL:
MTTC-1512HR
MTTC-1
525HR
MTTC-1
51
2NR
MTTC-1
525NR
MTTC-1
51
2VHR
MTTC-1
525VHR
MTTC-1
51
2VNR
MTTC-1
525VN A
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
maintain
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
SA-120
674
PRINTED
IN
U.S.A.

LIMITED
WARRANTY
EFFECTIVE: AUGUST
6,
1990
This
warranty
supersedes
all
previous
MILLER
warranties and is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
1.~
11
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
ot
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
warrantied
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 Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton.
Wisconsin.
or
FOB.
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.
:f

OM-1561A
3/91
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
_________________________________________
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
______________________________
N
umber.
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
Special
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)
4
4-3.
Power Cable
Connection
5
SECTION
5SEQUENCE
OF
OPERATION
5-1.
Gas
Tungsten
Arc
Welding
(GTAW)
6
5-2.
Shutting
Down
6
SECTION
6
MAINTENANCE
6-1.
Routine
Maintenance
6
6-2.
Tungsten
Electrode
7
SECTION
7
PARTS
LIST
Figure
7-1.
Complete
Torch
Assembly
10
Figure
7-2.
Consumable
Parts
12
LIST OF
CHARTS
AND
TABLES
Table
3-1.
Specifications
3
Table
6-1.
Maintenance Schedule
6
Table
6-2.
Tungsten
Size 8
Table
7-1.
Cross
Reference
To
Competitive
Model
13

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.

Read, understand,
and
follow
ALL
of these
Arc
rays
from
the
welding
process
produce
intense
heat
safety
rules before
installing, operating,
or
and
strong
ultraviolet
rays
that
can
burn
eyes
and skin.
seniicing
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
oth
1-I.
PREVENT
ELECTRIC SHOCK
ers
from
flash and
glare.
Touching
live
electrical
parts
can
cause severe
burns
to
4.
Wear
protective
clothing
and
foot
protection.
the
body
or
fatal
shock.
Severity
of
electrical
shock is de
1-4.
PREVENT
FIRES
AND
BURNS
termined
by
the
path
and
amount
of
current
through
the
body.
Therefore:
The hot
workpiece,
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.
Disconnect
all
power
before
installing
or
servicing
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
or
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
Breathing
welding
fumes
and
gases
can
be hazardous
electrical
circuits.
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
area
to
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
andthemanufacturersinstructionsforanymate-
special
ventilation
is
provided
to
remove
highly
rials
used.
toxic
fumes
or
gases.
OM-1561
Page
1

3.
Since
welding
can
affect
pacemakers,
keep
all
pacemaker
wearers
out
of
the work
area.
Have
them
consult
a
doctor
before
coming
near a
weld
ing
operation.
1-7.
PROVIDE
PROPER
EQUIPMENT
MAINTE
NANCE
Improperly
maintained
equipment
can
result
in
poor
work,
but
most
importantly
it
can cause
physical injury
or
death
through
fires
or
electrical shock.
Therefore:
1.
Always
have
qualified
personnel
perform
the
in
stallation,
troubleshooting,
and maintenance
work. Do
not
perform
any
electrical
work
unless
you
are
fully
qualified.
2.
Before
performing
any
maintenance
work
inside
a
power
supply,
disconnect
the
power
supply
from
the
electrical
power
source.
3.
Maintain
cables,
grounding
wire, connections,
power
cord,
and
power
supply
in
a
safe
working
order.
Do
not
operate
any
equipment
in
question
able condition.
4.
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 inclem
ent
weather.
5.
Keep
all
safety
devices,
guards, panels,
and
cov
ers
in
position
and
in
good
repair.
6. Use
equipment
for its
intended purpose.
Do
not
modify
it in
any
manner.
1-8.
ADDITIONAL SAFETY
INFORMATION
For
more
information
on
safe
practices
for
setting
up
and
operating
electric
welding
and
cutting equipment
and
on
good
working
habits,
ask
your
welding
equipment
sup
plier.
For
your
protection,
read
and
comply
with
the
latest
editions of
the
following
standards:
1.
ANSI
Standard
Z49.1
available from
the Ameri
can
Welding
Society,
550
N.W.
LeJeune
Rd,
Mi
ami,
FL
33126.
2.
AWS
Standard
A6.1
,
Recommended
Safe
Prac
tices
for
Gas Shielded
Arc
Welding,
available
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd, Miami,
FL
331
26.
3.
AWS Standard
F4.1
,
Recommended
Safe
Prac
tices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
and
Piping
That Have Held Hazard
ous
Substances,
available
from the American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
4.
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.
5.
NFPA
Standard
70,
National
Electrical
Code,
available
from
the
National
Fire
Protection Asso
ciation,
Batterymarch
Park,
Quincy,
MA
02269.
6.
ANSI
Standard
Z87.1
,
Safe Practice
for
Occupa
tion
and
Educational
Eye
and Face
Protection,
available
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
7.
OSHA
Standard
29
CFR,
Part
1910,
Subpart
Q,
Welding,
Cutting,
and
Brazing,
available from
the
Superintendent
of
Documents,
U.S. Govern
ment
Printing
Office,
Washington,
DC
20402.
8.
CSA
Standard
WI
17.2,
Code
for
Safety
in
Weld
ing
and
Cutting,
available
from
the
Canadian
Standards
Association,
178
Rexdale
Blvd.,
Rex
dale,
Ontario,
Canada
M9W
1
R3.
9.
See
also
the
Standards
Booklet
Index
in
the
weld
ing power
source
Owners
Manual.
OM-1561
Page
2

SECTION 2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various la
bels,
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
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding equipment
requires practices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only by
qualified
per
sons
in
accordance with
this
manual and all
applicable
codes
such
as,
but
not
limited
to,
those listed
at
the end
of
Section 1

Safety
Rules.
2-2. SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this manual
to
call attention
to
and
iden
tify
different
levels of hazard
and
special
instructions.
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be followed
to
avoid
seri
ous
personal injury
or
loss
of
life.
a
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
3
SPECIFICATIONS
Table
3-1.
Specifications
Model
Ampere
Rating
at
100%Dut
DCEN,
XCl~F
Tun9sten
Size
Capacity
Cable
Length
Torch
Body
Cooling
Method
Weight
Net
Ship
MTTC-1512HR
MTTC-1512NR
MUG-i
525HR
MUC-1525NR
MUG-i
51
2VHR
MUC-1512VNR
MUG-i
525VHR
MUG-i
525VNR
*150
Amperes
With
Argon
.020 thru
1/8
in.
(0.5
thru
3.2
mm)
12.5
ft
(3.8
m)
25 ft.
(7.6 m)
Length:
8.0
in.
(203
mm)
Handle
Diameter:
0.9
in.
(23
mm)
Weight:
4.6
oz.
(130
g)
Air
2.5 lbs.
(1.1
kg)
3.0 lbs.
(1.4
kg)
5.0 lbs.
(2.3
kg)
5.5
lbs.
(2.5
kg)
12.5
ft.
(3.8 m)
25
ft.
(7.6
m)
Length:
8.8
in.
(222 mm)
Handle
Diameter:
0.9
in.
(23 mm)
Weight:
7.5
oz.
(210
g)
2.5 lbs.
(1.1
kg)
3.0
lbs.
(1.4
kg)
5.0 lbs.
(2.3
kg)
5.5
lbs.
(2.5
kg)
*Rated
With
Gas
Lens
Collet
Body
3-1.
DUTY
CYCLE
The
duty
cycle
of
a
welding
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
that
the torch
can
be
operated
at
rated
load
conditions
continuously.
a
CAUTION:
EXCEEDING
THE
RATED
AMPERAGE
and
duty
cycle
can
result
in
damage
to
the
torch.

Do
not
exceed
rated
amperage
and
duty cycle
stated
in
Table
3-1.
3-2.
DESCRIPTION
This air-cooled
heavy duty
torch
is
specifically
for
use
with
the
Gas
Tungsten
Arc
Welding
(GTAW)
process.
The
alphanumeric
model
designation
refers
to
the
following:
15
-
Ampere Rating:
150
Amperes
12-
12.5
ft.
(3.8
m)
Cable
25
-
25
ft.
(7.6
m)
Cable
H
-
High-Flex
Cable
(1
piece
assembly)
N
-
High-Performance
Cable
(2 piece
assembly)
R
-
Rigid
Head
V
-
Gas
Valve
OM-1561
Page
3

*Cup
*pequlred
Consumables
and
Accessories
*~0btain
from
Welding Equipment
Supplier
SECTION 4INSTALLATION
0-Ring
Gas
Valve
(If
Applicable)
Handle
High
Flex
Cable
Fitting

7
S
_S5_
~
SA-120
751
Figure
4-1.
Torch
Components
4-1. TORCH
BODY
(Figure
4-1)
J~
WARNING:
ELECTRIC
SHOCK
can
kill.
_____

Do
not
touch live
electrical
parts.

Shut
down
welding
power
source,
and dis
connect
input
power employing
lockout/tag
ging
procedures
before
installing
torch.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
discon
necting
device.
The
torch
body
is
shipped
requiring
consumables and
accessories
indicated
in
Figure
4-1:
cup,
collet
body,
collet,
power
cable
adapter
(with
High-Flex
Cable
only),
and
tungsten
electrode.
Assemble
torch
as
follows:
1.
Install
collet
body
into
torch
body making
sure
heat shield
is
in
place.
2.
Install
cup
onto
collet
body.
3.
Remove
backcap
and
install
standard
collet,
slotted end
first,
through
back of
torch
body
into
collet
body.
If
using
reverse
collet,
install collet
with
slotted
end
toward
backcap.
4.
Loosely
install
backcap
and
0-ring
(supplied
on
backcap)
onto
torch
body.
5.
Install
properly
prepared
tungsten
electrode
(see
Section
6-2)
through
front of collet
body
to
posi
tion
electrode
tip
outside
cup
rim.
Securely
tight
en
backcap.
6.
To
readjust
electrode
position,
loosen
backcap.
IMPORTANT:
As
a
general
rule,
electrode
extension
should
equal
electrode
diameter;
but
exact
electrode
ex
tension
may
vary
according
to
application.
4-2. GAS
HOSE
CONNECTIONS
AND
GAS VALVE
(If
Applicable)
(Figures
4-1
Thru
4-3)
IMPORTANT:
If
powersource
is
not
equipped
with
a
gas
valve,
a
torch
gas
valve is
required
(see
Figure
4-2).
A.
High-Flex
Cable
Assembly
The
high-flex
cable
assembly
contains
the
power
cable
within the
gas
hose.
The
high-flex
cable
has
a
5/8-18
male
right-hand
fitting
(see
Figure
4-1).
To install
high-flex
cable,
connect
high-flex
cable
fitting
to
power
cable
adapter.
If
torch
includes a
gas
valve,
connect
a
suitable
length
of
gas
hose
(extra
hose
not
supplied)
from
power
cable
adapter
to
regulator/flowmeter
(see
Figure
4-2).
If
torch
is
without
gas
valve,
connect
a
suitable
length
of
gas
hose
(not
supplied)
from
power
cable
adapter
to
gas
Heat
Shi
*Coliet
Short
Backcap
Power
Cable
*Power Cable
Adapter
OM-1
561
Page
4

valve
outlet.
Connect
extra
gas
hose
(not
supplied)
from
gas
valve
inlet
to
regulator/flowmeter
(see
Figure
4-3).
B.
High-Performance
Cable
Assembly
The
high-performance
cable
assembly
has
separate
power
cable and
gas
hose.
The
gas
hose
has
a
5/8-18
male
right-hand
fitting
(see
Figure
4-1).
If
torch includes
a
gas
valve,
connect
gas
hose
fitting
to
regulator/flowmeter
(extra
hose
not
supplied,
see
Figure
4-2).
If
torch is without
gas
valve,
connect
gas
hose
fitting
to
gas
valve outlet.
Connect
gas
hose
(extra
hose
not
supplied)
from
gas
valve inlet
to
regulator/flowmeter
(see
Figure
4-3).
C.
Torch
Gas
Valve
Operation
(If
Applicable)
The
gas
valve allows
gas
flow control
at
the
torch.
A
one-
half
turn
counterclockwise
opens
the
gas
valve,
and
a
one-half
turn
clockwise
closes the valve.
The
gas
valve
allows
control
of
gas
postflow
time,
or
the
length
of
time
gas
flows
after
the
arc
is
extinguished.
In
sufficient
gas
postflow
results
in
an
oxidized
(black)
elec
trode
surface.
If
an
oxidized
electrode
were
used,
the
black
surface
would
contaminate the weld and
cause
poor
arc
direction.
IMPORTANT:
As
a
general
rule,
allow 10
seconds of
gas
postflow
time
per
100
amperes
of weld
current
be
fore
closing
valve.
Torch
High-Flex
Cable
Assembly
4-3.
POWER
CABLE
CONNECTION
(Figures
4-1
Thru
4-3)
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shut
down
welding
power
source,
and dis
connect
input
power
employing lockout/tag
ging
procedures
before
installing
torch.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
discon
necting
device.
A.
High-Flex
Cable
Assembly
The
power
cable
is
part
of
the
high-flex
cable
assembly.
For
connection
of
both
power
cable
and
gas
hose
to
power
cable
adapter,
see
Section
4-2A.
Connect
power
cable
adapter
to
weld
output
terminal
(see
Figures
4-2
and
4-3).
B.
High-Performance
Cable
Assembly
The
high-performance
cable
assembly
has
separate
power
cable
and
gas
hose.
To install
power
cable,
connect
power
cable
connector to
weld
output
terminal
(see
Figures
4-2
and
4-3).
High-Performance
Cable
Assembly
Ret.
SA-120
824
Figure
4-2.
GTAW
Torch
Connection
Diagram
For
Models
With
Gas
Valve
Torch
7-
Work
Clamp
High-Flex
Cable
Assembly
High-Performance
Cable
Assembly
Figure
4-3.
GTAW
Torch
Connection
Diagram
For
Models
Without
Gas
Valve
7
Power
Cable
Work
Clamp
Adapter
Gas
Cylinder
Power
Cable
Work
Clamp
Connector
Gas
Cylinder
Regulator/
Flowmeter
Power
Cable
Adapter
Gas Valve
Gas
Cylinder
Power
Cable
Work
Clamp
Connector
Gas
Valve
Gas
Cylinder
Ret. SA.1
20824
OM-1561
Page
5

SECTION
5
SEQUENCE OF
OPERATION
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch live electrical
parts.

Keep
all
covers
and
handle
in
place
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.

Keep
your
head
out
of (he
fumes.

Ventilate
to
keep
from
breathing
fumes
and
gases.

If
ventilation is
inadequate,
use
approved
breathing
device.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
tire
and
burns.

Watch
for fire.

Keep
a
fire
extinguisher nearby,
and
know
how
to
use
it.

Do
not
use near
flammable
material.

Allow
work and
equipment
to
cool
before
handling.
MAGNETIC
FIELDS
FROM HIGH
CURRENTS
can
affect
pacemaker
operation.

Wearers
should
consult
their
doctor
before
going
neararc
welding,
gouging,
or
spot
weld
ing
operations.
See
Section
1
-
Safety
Rules for
additional
information.
5-1.
GAS
TUNGSTEN
ARC WELDING
(GTAW)
1.
Install
and
connect
torch
according
to
Section
4.
2.
Make
sure
backcap
and
all
gas
connections
are
securely
tightened.
3.
With
regulator/flowmeter
valve
closed,
open
gas
cylinder
valve.
4. Set
power
source
for desired
welding
amperage.
5.
Wear
dry
insulating
gloves
and
clothing,
and
wear
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
6.
Energize
welding
power
source.
7.
Set
gas
flow
to
desired
level
(requires
open
gas
valve).
IMPORTANT:
Purge
gas
hose
to
clearhose
of
air,
mois
ture,
or
any
other
contaminants.
Allow
gas
to
flow
2
to
3
minutes
on
new
torch;
5
to
6
seconds
thereafter.
8.
Begin
welding.
5-2.
SHUTTING
DOWN
1.
Stop
welding.
IMPORTANT:
As
a
general
rule,
allow 10 seconds
of
gas
postflow
time
per
100
amperes
of weld
current
be
fore
closing
valve.
2.
Turn off
welding
power
source.
3.
Turn
off
the
shielding
gas
at
the
source.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm health
or
kill.
Shut
off
gas
supply
when
not
in
use.
SECTION
6
MAINTENANCE
6-1.
ROUTINE
MAINTENANCE
(Table
6-1)
a
WARNING:
ELECTRIC SHOCK
can
kill;
HOT
SURFACES
can cause
severe
burns.

Do
not
touch
live
electrical
parts.

Shut
down
welding
power
source
and
discon
nect
input
power
before
working
on
torch.

Disconnect
torch
from
welding
power
source
before
inspecting,
maintaining,
or
sen/icing.

Allow
a
cooling
period
before
servicing.
Table 6-1.
Maintenance
Schedule
Frequency*
Maintenance
Every
Week
Inspect
and clean
torch, cables,
and hoses
(see
Sections
6-lA
thru
6-iC).
Check
and
replace
torch
parts
or
weld cables
as
necessary
(see
Sections
6-lA
thru
6-10).
*Frequency
of
service
is
based
on
uruts
operated
40
hours
per
week. Increase
frequency
of
maint
enance
if
usage
exceeds
40 hours
per
week.
OM-1561
Page
6