Miller MATT-412 User manual

April
1988
FORM: OM-1564
Millerfi
Effective
With
Style
No.
JJ-23
MODEL
MATr-412
MATI-425
OWNERS
MANUAL
IMPORTANT
Read
and
understand the
entire
contents
of
both this
Miller Electric
Mfg.Co.
manual and
the
power
source
manual
used with
this
unit,
with
special
AU,I~G,oo~1Id CornO~n~
emphasis
on
the
safety
material
throughout
both
manuals,
before
in-
p.o.
Box
1079
stalling,
operating,
or
maintaining
this
equipment.
This unit
and these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
Appleton,
WI
54912
USA
Tel. [phone]
safe
operation
of
welding equipment.
Do
not allow
untrained
persons
to
install,
operate,
or
maintain this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
PRINTED
IN
U.S.A.
ADDITIONAL
COPY PRICE
35
CENTS

LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
18.
1988
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
condi-
In
the
case
of
Millers breech
of
warranty
or
any
other
duty
tions
hereof,
Miller
Electric
Mfg.
Co., Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goode,
the exclusive
remedies
warrants
to
its
Distributor/Dealer
that
all
new
and
unused
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacen,ent
Equipment
furnished
by
Miller is tree
from defect
in
workman-
or,
where
authorized
in
Writing
by
Miller
in
appropriate
cases,
(3)
ship
and
material
as
of
the
time and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
No
warranty
is
made
by
Miller with
respect
to
engines,
trade
Miller
service station
or
(4)
payment
of
or
credit
for the
purchase
accessories
or
other items
manufactured
by
others.
Such
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
engines,
trade
accessories
and other items
are
sold
subject
to
return of
the
goode
at
Customers
risk and
expense.
MIU.ERs
the
warranties
of
their
respective
manufacturers,
if
any
.
All
option
of
repair
or
replacement
will be
F.O.B.,
Factory,
at
engines
are
warranted
by
their
manufacturer for
one
year
from
Appleton,
Weconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecumseh
engines
which
facility,
therefore,
no
compensation
for
transportation
costs
of
have
a two
year warranty.
any
kind
will
be allowed.
Upon
receipt
of notice of
apparent
defect
or
failure,
Miller shall instruct the claimant
on
the
warranty
Except
as
specified
below,
Millers
warranty
does
not
apply
claim
procedures
to
be
followed.
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
ANY
EXPRESS WARRANTY NOT
PROVIDED HEREIN AND
~
wire
including
nozzles
and nozzle
insulators where
failure
does
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA
not
result
from
defect
in
workmanship
or
material.
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR THIS
PROViSION,
~
Miller
shall
be
required
to
honorwarranty
claims
on
war-
MIGHT ARISE
BY
IMPLICATiON,
OPERATION
OF
LAW,
~j
ranted
Equipment
in the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE OR
COURSE
OF
DEAUNG,
INCLUDING
?~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
ANY
IMPUED
WARRANTY
OF
MERCHANTABIUTY
OR
OF
ment
to the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WiTH
RESPECT
TO
ANY
AND ALL
EQUIPMENT FURNISHED
BY MILLER
IS EX
~
1.
Arc
v~ders,
p~r
sources,
robots,
and
components .
1
yeer
CLUDED AND
DISCLAIMED
BY MILLER.
2. Loadbanks
lyear
~
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
only)
EXCEPT AS EXPRESSLY PROVIDED
BY MILLER
IN
4.
All
welding
guns,
feeder/guns
and
torches
90
days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED FOR
~
5. All
other
Millermatic
Feeders
1
year
ULTIMATE PURCHASE
BY
COMMERCIAL/INDUSTRIAL
~
6.
Replacement
or
repair
parts,
exclusive of labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED AND
r~
7. Batteries
6 months
EXPERIENCED
IN THE USE
AND MAINTENANCE OF
(1
WELDING
EQUIPMENT
AND
NOT
FOR CONSUMERS OR
~$j
provided
that Miller is notified
in
writing
within
thirty
(30)
days
CONSUMER USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
!~
of the date
of such failure.
TO,
AND
NO
RESELLER IS AUTHORIZED
TO
EXTEND
~
As
a matter
of
general policy only,
Miller
may
honor
claims
MILLERS
WARRANTiES
TO,
ANY
CONSUMER.
(1
submitted
by
the
original
user
within
the
foregoing periods.

in9.
Do
not
weld
near
combustible material.
Watch
for
fire,
and
keep
a
fire
extinguisher
near
by.
For
additional
information,
refer
to
NFPA
Stan
dard 51
B,
Fire Prevention
in
Use
of
Cutting
and
Welding
Processes,
available from
the National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1
-5.
PROTECT COMPRESSED
GAS
CYLINDERS
Since
gas
cylinders
are
normally
part
of the
welding
pro
cess,
be
sure
to treat
them
carefully.
a.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
Install
and
secure
cylinders
so
that
they
cannot
fall
or
tip
over
by
fastening
them
to
a
mounting
bracket,
wall,
or
other
stationary
support.
Keep
cylinders
away
from
any
welding
or
other
electrical circuits.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
~NARNING
SECTION
1
-
SAFETY
RULES
_________
UNSAFE PROCEDURES
OR PRAC-
1
-3.
PROTECT
EYES
AND SKIN FROM
ARC
TJCES
can
cause
serious
personal injury
or
death.
RAYS;
PROTECT
EARS
FROM
NOISE

Read, understand,
and
follow
ALL
of
these
safety
rules
before
installing,
operating,
or
servicing
this
Arc
rays
from
the
welding
process
produce
intense
heat
equipment.
and
strong
ultraviolet
rays that
can
burn
eyes
and
skin.

Be
sure
that
all
end
users
of
this
equipment,
the
Noise
from
some
processes
can
damage
hearing.
operator
and
helpers,
read and
understand
these
safety
rules.
a.
Wear
a
welding
helmet
fitted
with
a
proper~filter
lens
(see
ANSI
Z49.1
for
detailed
information).
1
-
1.
PREVENT
ELECTRIC
SHOCK
b.
Use
protective
screens
or
barriers
to
protect
Touching
live
electrical
parts
can cause severe
burns
to
others
from
flash and
glare.
the
body
or
fatal
shock.
Severity
of electrical shock is
determined
by
the
path
and
amount
of
current
through
c.
Wear
protective
clothing
and foot
protection.
the
body.
Therefore:
d.
Always
wear
safety glasses
or
safety
goggles
in
a
a.
Do
not
touch
live
electrical
parts.
work
area.
b. Do not
work
in
wet
or
damp
areas.
1
-
4.
PREVENT FIRES
AND BURNS
c.
Wear
dry
insulating gloves
and
body protection.
The
hot
workpiece,
hot
equipment,
other
hot
metal,
spatter,
and
arc
sparks
can
cause
fires and burns.
d.
Disconnect
all
power
before
installing
or
servic
ing
this
equipment.
a.
Wear
correct
eye,
face,
and
body
protection
in
the work
area.
e.
Turn
off
all
equipment
when
not
in
use.
b.
Allow
work
and
equipment
to
cool
before
handl
f.
Properly
install and
ground
the
welding
power
source
according
to
its Owners
Manual
and all
applicable
codes.
c.
g.
Do
not
use
worn
or
damaged
cables
or
cables d.
that
are
too
small
or
poorly
spliced.
h.
Do
not
wrap
cables around
your
body.
e.
i.
Do
not
touch electrode
and
any
grounded
object
or
circuit
at
the
same
time.
j.
Use
only
well-maintained
equipment.
Repair
or
replace damaged
parts
at
once.
1
-2.
PROVIDE PROTECTION
FROM
FUMES
AND
GASES
Breathing
welding
fumes and
gases
can
be
hazardous
to
your
health.
a.
Keep
your
head
out
of the
fumes.
b.
b. Use
adequate
ventilation in
the work
area
to
keep
fumes and
gases
from
your
breathing
zone
and the
general
work
area.
c.
c.
If
ventilation is
inadequate,
use
an
approved
breathing
device.
d.
d. Read
the
Material
Safety
Data
Sheets
(MSDSs)
and the
manufacturers
instructions
for
any
materials
used.
OM-1564
Page
1

1
-6.
PROVIDE
PROTECTION FOR
SPECIAL
SITUATIONS
a.
Do
not
weld
or
cut
containers
or
materials which
have
held
or
been
in
contact
with
hazardous
substances
unless
they
are
properly
cleaned
and
inspected.
b.
Do
not
weld
or
cut
painted
or
plated
parts
unless
special
ventilation
is
provided
to
remove
highly
toxic fumes
or
gases.
c.
Since
welding
can
affect
pacemakers, keep
all
pacemaker
wearers
out
of
the
work
area.
Have
them consult
a
doctor
before
coming
near
a
welding
operation.
1 -7.
PROVIDE
PROPER EQUIPMENT
MAINTENANCE
Improperly
maintained
equipment
can
result in
poor
work,
but
most
importantly
it
can cause
physical
injury
or
death
through
fires
or
electrical shock.
Therefore:
a.
Always
have
qualified
personnel
perform
the in
stallation,
troubleshooting,
and
maintenance
work. Do
not
perform
any
electrical
work
unless
you
are
fully qualified.
b.
Before
performing
any
maintenance
work inside
a
power
supply,
disconnect
the
power
supply
form the electrical
power
source.
c.
Maintain
cables,
grounding
wire,
connections,
power
cord,
and
power
supply
in
safe
working
order.
Do
not
operate
any
equipment
in
ques
tionable
condition.
d.
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
incle
ment
weather.
e.
Keep
all
safety
devices,
guards,
panels,
and
covers
in
position
and
in
good repair.
f.
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
equip
ment
supplier.
The
following
publications,
which
are
available
from
the American
Welding
Society,
550
N.W.
LeJuene
Rd.,
Miami,
FL
33126,
are
recommend
ed
to
you:
a.
Safety
in
Welding
and
Cutting
-
AWS
Z49.1
(ANSI)
b.
Recommended
Safe
Practices for
Gas-Shielded
Arc
Welding
-
AWS
A6.1
c.
Recommended
Safe
Practices
for the
Prepara
tion for
Welding
and
Cutting
of
Containers
and
Piping
That Have
Held
Hazardous
Substances
-
AWS
F4.1
d.
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.
e.
NFPA
Standard
70,
National Electrical
Code,
available from the
National
Fire Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
f.
ANSI
Standard
Z87.1,
Safe Practice
for
Oc
cupation
and
Educational
Eye
and Face
Protec
tion,
available from the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
g.
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.
h.
CSA
Standard
W117.2,
Code for
Safety
in
Welding
and
Cutting,
available
from the
Cana
dian Standards
Association,
178
Rexdale
Blvd.,
Rexdale,
Ontario,
Canada
M9W
1
R3.
i. See
also
the
Standards
Booklet
Index in
the
welding
power
source
Owners
Manual.
OM-1564
Page
2

SECTION
2-
INTRODUCTION
Model
Ampere Rating
at
100%
Duty
Cycle
DCEN;
ACHF
Tungsten
Size
Capacity
Cable
Length
Torch

Body
Cooling
Method
Coolant
Flow
Rate
ht
Net
Ship
MATT-412
MATT-425
400
Amperes
With
Argon
.020
thru
5/32
in.
(0.6
thru
4.0
mm)
12.5ft.
(3.8
m)
25
ft.
(7.6
m)
Weight:
8.0
oz.
(230
g)
Water
1
qt/min
(0.94
I/mm)
4
lbs.
(1.8
kg)
4
lbs.
(1.8
kg)
7
lbs.
(3.2
kg)
7
lbs.
(3.2
kg)
Figure
2
-
1.
Specifications
A.
General
B.
Safety
WARNING
WARNING
CAUTION
CAUTION
IMPORTANT
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end of
Section
1
-
Safety
Rules.
M
-
Miller
A
-
Automatic
T
-
TIG/GTAW
T
-
Torch
4
-
Ampere
Rating:
400
Amperes
12
-
12.5
ft.
(3.8
m)
Cable
25
-
25
ft.
(7.8
m)
Cable
1.1
In.
mm)
.75
In.
2
-
1.
DUTY
CYCLE
-
The
duty
cycle
of
a
welding
Safety
instructions
specifically
pertaining
to
this unit
ap
torch
is
the
percentage
of
a
ten
minute
period
that
a
pear
throughout
this
manual
highlighted
by
the
signal
torch
can
be
operated
at
a
given
load.
This torch
is
rated
words
and which
identify
at
100%
duty
cycle
using
argon
shielding
gas.
This
different
levels
of
hazard.
means
that
the
torch
can
be
operated
at
rated
load
con
ditions
continuously,
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
~~WtI~L~JL
EXCEED
I N
G
THE RATED
AMPERAGE
and
duty
cycle
can
result in
damage
carefully
followed could result in
serious
personal
injury
or
loss of
life.
to the torch.

Do
not
exceed rated
amperage
and
duty cycle
statements
include
installation,
operation,
stated
in
Figure
2-1.
and
maintenance
procedures
or
practices
which
if
not
carefully
followed could
result in minor
personal
injury
or
damage
to
this
equipment.
A
third
signal
word,
highlights
instruc
tions which
need
special emphasis
to
obtain
the
most
efficient
operation
of this
equipment.
2
-
3.
RECEIVING
HANDLING
-
Before
installing
this
equipment,
clean
all
packing
material
from
around
the
unit,
and
carefully
inspect
for
any
damage
that
may
have
occurred
during shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
TA-121
198
by
the
purchaser
with
the
carrier.
A
copy
of the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
request
if
occasion
to
file claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is essential that Model
Description
and
Style
Numbers of
the
equipment
be
supplied.
The
style
Information
presented
in this
manual
and
on
various
number
is
located
on
a
label
under the
torch
handle.
labels,
tags,
and
plates
on
the
unit
pertains
to
equip-
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should
be
read, understood,
and
followed
for
the
safe
and
effective
use
of
this
equip-
ment.
.
2
-
4.
DESCRIPTION
-
This
torch
is
specifically
for
use
with
the
Gas
Tungsten
Arc
Welding
(GTAW)
pro-
cess.
The
alphanumeric
model
designation
refers
to
the
following:
Figure
2
-
2.
Overall
Dimensions
2
-2.
GENERAL
INFORMATION
AND
SAFETY
OM-1
584
Page
3

Required
Consumables
and
Accessories
~ObtaIn
from
Welding
Equipment
Supplier
SECTION
3
-
INSTALLATION
WARNING
__________
ELECTRIC
SHOCK
can
kill.

Do
not touch live
electrical
parts.

Shut
down
we/ding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
installing
torch.
Lockout/tagging procedures
consist of
padlocking
line
disconnect
switch in
open
position,
removing
fuses
from fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
3
-
1.
TORCH
BODY
(Figure
3-1)
-
The
torch
body
is
shipped
requiring
consumables and
accessories
in
dicated
in
Figure
3-1:
cup,
collet
body,
collet,
power
cable
adapter,
and
tungsten
electrode.
Assemble
torch
body
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.
4.
Install
standard
collet,
slotted
end
first,
through
back
of
adjusting
cap.
5.
Loosely
install
backcap
and
0-ring
(supplied
on
backcap)
onto
torch
body.
6.
Install
properly
prepared
tungsten
electrode
(see
Section
5-4)
through
front
of
collet
body
to
posi
tion electrode
tip
outside
cup
rim.
Tighten
backcap.
IMPORTANT
_____________
The
adjusting
cap
provides
an
approx
imate
electrode
extension
range
of
.20
in.
while
welding.
Turn
adjusting
cap
clockwise
to
decrease
elec
trode
extension,
or
counterclockwise
to
increase
exten
sion.
Electrode
adjustment
greater
than
.20 in.
can
not
be
completed
while
we/ding.
To
further
adjust
elec
trode,
loosen
backcap.
IMPORTANT
______________
As
a
general
rule,
electrode
extension
should
equal
electrode
diameter;
exact extension
may
vary
according
to
application.
Power
Cable/Coolant
Hose
Fittings
Notches
Indicate
Left-Hand
Threaded
Coolant
Fittings
Hose
Fittings
Power
Cable
Adapter
Torch
Body
Adapters
Backcap
Tungsten.
Eloctrode
Adjusting
Cap
Shield
Figure
3
-
1.
Torch
Components
TA-121
196
OM-1564
Page
4

3
-2.
COOLANT
HOSES
AND
CONNECTIONS
(Figures
3-1
and
3-2)
CAUTION
_________
OVERHEATING
Gas
Tungsten
Arc
Welding
(GTAW)
torch
can
damage
torch.

If
using
recirculating
coolant
system,
do
not
make
connections from
the
coolant
system
to
water
vavie;
instead,
make
connections
directly
from
the
coolant
system
to
torch
hoses.

If
receptacle
is available
on
power
source,
connect
coo/ant
supply/pump
power
cord
to
power
source
receptacle.
A. Power
Cable/Coolant
Hoses
The
power
cable/coolant
hoses
contain
a
power
cable
3
-
3.
COOLANT
REQUIREMENTS
-
Where
freez
ing
conditions
may
be
encountered,
mix
coolant
accor
ding
to
the
manufacturers
recommendations
supplied
in
coolant
supply
owners
manual.
CAUTION
________
INCORRECT COOLANT
LEVEL
can
damage
coolant
system
and torch.

Maintain
correct coolant
level
at
all
times.
This torch
is rated
at a
1
qt./min
(0.94
I/minI
coolant
flow
rate.
Changes
in
flow
rate
may
effect
operating
temperature
of torch.
Maintain
proper
flow
rate at
all
times.
3
-4.
GAS
HOSE CONNECTIONS
(Figures
3-1
and
3-2)
IMPORTANT
Power
source
gas
valve
required.
A.
Gas Hose
and
Connection
The
gas
hose
has
a
5/8-18
male,
right-hand
fitting
(Figure
3-1).
To install
gas
hose,
connect
gas
hose
fitting
to
gas
valve
outlet.
Connect
gas
hose
(extra
hose
not
supplied)
from
gas
valve
inlet
to
regulator/flowmeter
(Figure
3-2).
within
a
coolant
hose.
The
power
cable/coolant
hoses
have
3/8-24
male, notched,
right-hand
fittings
(Figure
3-1).
To
install
power
cable/coolant
hoses,
connect
power
cable/coolant
hose
fittings
into
the
power
cable
adapter
(Figure
3-2).
B.
Coolant
Hoses
(extra
hoses
not
supplied)
Two
coolant
hoses
with
5/8-18
male,
notched,
left-
hand
fittings
are
required
for the
torch
to
coolant
supply
connection.
To
install
coolant
hoses,
connect
coolant
hoses
from
power
cable
adapter
to
the
coolant
supply
fittings
(Figure
3-2).
Aol.
TA-120
199
an
oxidized
(black)
electrode
surface. If
an
oxidized
electrode
were
used,
the
black
surface
would
con
taminate
the
weld
and
cause
poor
arc
direction.
IMPORTANT:
_______
As
a
general
rule,
allow
10
seconds
gas
posiflow
time
per
100
amperes
of weld
current
before
closing
valve.
3
-5.
POWER
CABLE
ADAPTER
CONNECTION
(Figures
3-1
and
3-2)
-
The
power
cable
adapter
has
2,
5/8-18
female,
notched,
left-hand
fittings
(Figure
3-1).
Install
power
cable
adapter
as
follows
(Figure
3-2):
WARNING
__________
ELECTRIC
SHOCK
can
kill.

Do
not
touch live
electrical
parts.

Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
installing
torch.
Lockout/tagging
procedures
consist of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
1.
Install
power
cable/coolant
hose
fittings
into
power
cable
adapter
(see
Section
3-2A).
The
power
source
gas
valve
allows control
of
gas
postflow
time,
or
the
length
of
time
gas
flows after the
arc
is
extinguished.
Insufficient
gas
postflow
results
in
2.
Connect
power
cable
adapter
to weld
output
ter
minal
(Figure
3-2).
Regulator/Flowmeter
Figure
3
-
2.
GTAW
Torch
Connection
Diagram
OM-1564
Page
5

SECTION
4
-
SEQUENCE
OF
OPERATION
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.

Ventilate
to
keep
from
breathing
fumes
and
gases.

If
ventilation is
inadequate,
use
approved
breathing
apparatus.
HOT
METAL,
SPATTER,
AND SLAG
can cause
fire
and
burns.

Watch
for
fire.

Have
a
fire
extinquisher
nearby,
and know how
to
use.

Allow
work and
equipment
to
cool before handl
ing.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.

Wearers
should
consult with
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
See
Section
1
-
Safety
Rules for
additional
safety
infor
mation.
4
-
1.
GAS
TUNGSTEN
ARC
WELDING
(GTAW)
1. Install
and
connect
torch
according
to
Section 3.
2.
Make
sure
backcap
and all
gas
connections
are
securely tightened.
3. Turn
on
coolant
supply.
4. With
regulator/flowmeter
valve
closed,
open
gas
cylinder
valve.
5.
Set
power
source
for
desired
welding
amperage.
6.
Wear
dry
insulating
clothing
and
gloves
and
welding
helmet
with
proper
filter
lens
according
to
ANSI
Z49.1.
7..
Energize welding
power
source.
8.
Set
gas
flow
to
desired level
(requires
open
gas
valve).
IMPORTANT
______________
Purge
gas
hose
to
c/ear hose of
air,
moisture,
or
any
other
contaminants. Allow
gas
to
flow
2
to
3 minutes
on new
torch;
5
to
6 seconds thereafter.
9.
Begin
welding.
4 -2.
SHUTTING DOWN
1.
Stop
welding.
IMPORTANT
______________
As
a
general
rule,
allow
10
seconds
of
gas
postflow
time
per
100
amperes
of
weld
current
before
closing
valve.
2. Turn off
welding
power
source.
3.
Turn off the
shielding
gas
and
coolant
supplies
at
their
sources.
L~~U~E
HIGH
CONCENTRATION
SHIELDING
GAS
can
harm health
or
kill.

Shut
off
gas
supply
when
not
in
use.
OF
SECTION
5
-
MAINTENANCE
5
-
1.
INSPECTION AND UPKEEP
-
Usage
and
shop
conditions
will
determine
frequency
and
type
of
maintenance
required.
Perform
inspections
once
a
week.
WARNING
__________
ELECTRIC SHOCK
can
kill;
HOT
SURFACES
can cause
severe
burns.

Do
not
touch live electrical
parts.

Shut
down
welding
power
source
before
working
on
torch.

Disconnect torch
from
welding
power
source
before
inspecting,
maintaining,
or
servicing.

Allow
a
cooling
period
before
servicing.
1.
Inspect
torch for
broken
areas,
cracks
and
loose
parts;
tighten, repair
and
replace
as
required.
2.
Remove
grease
and
dirt from
components,
and
moisture from
electrical
parts
and
cables.
WARNING
_________
ELECTRIC SHOCK
can
kill;
HOT
SURFACES
can
cause severe
burns.

Do
not
touch live electrical
parts.

Shut
down
we/ding
power
source
before
working
on
torch.

Disconnect
torch
from
welding
power
source
before
inspecting, maintaining,
or
servicing.

Allow
a
cooling
period
before
servicing.
Once
a
week
inspect
condition
of
torch
body
com
ponents.
Replace
cup,
heat
shield,
backcap,
and
0-rings
if
crack
ed.
Maintain
tight
fit
of
torch
components
to
ensure
good
weld
quality.
5
-2.
TORCH BODY
MAINTENANCE
(Figure
3-1)
OM-1564
Page
6

Table
5
-
1.
Tungsten
Size Chart
Electrode
Diameter
Amperage Range
-
Polarity
-
Gas
Type
Pure
Tungsten
(Green
Band)
DC-Argon
Electrode
Negative/
Straight
Polarity
DC-Argon
Electrode
Positive/
Reverse
Polarity
AC-Argon
Using High
Frequency
.020
.040
1/16
3/32
1/8
5/32
5-20
15-80
70-150
125-225
225-360
360-450
*
*
10-20
15-30
25-40
40-55
5-20
10-60
50-100
100-160
150-210
200-275
2%
Thorium
Alloyed
Tungsten
(Red_Band)
.020
.040
1/16
3/32
1/8
5/32
15-40
25-85
50-160
135-235
250-400
400-500
*
*
10-20
15-30
25-40
40-55
15-35
20-80
50-150
130-250
225-360
300-450
Zirconium
Alloyed
Tungsten
(Brown_Band)
020
.040
1/16
3/32
1/8
5/32
*
~
*
*
*
*
*
*
*
*
*
*
15-35
20-80
50-150
130-250
225-360
300-450
*NOT
RECOMMENDED
The
figures
are
intended
as
a
guide,
and
are a
composite
of
recommendations
from
American
Welding Society
and
electrode
manufacturers.
5 -3.
INSPECTING
HOSES,
CONNECTIONS AND
CABLES
WARNING
_________
ELECTRIC SHOCK
can
kill.

Do not
touch live
electrical
parts.

Shut
down
welding
power
source
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
inspecting,
maintaining,
or ser
vicing.
Lockout/tagging
procedures
consist of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from fuse
box,
or
shutting
off and
red-tagging
circuit
breaker
or
other
disconnecting
device.
A.
Gas
Hose
Gas
leaks
may
result
in
poor
weld
quality.
Inspect
hoses
for
breaks.
Keep
connections
clean
and
tight.
B. Power
Cable
Inspect
cables for
breaks
in
insulation,
and
ensure
that
all
connections
are
clean
and
tight.
Repair
or
replace
cables
if
insulation
breaks
are
present.
Clean
and
tighten
connections
at
each
inspection.
C.
Coolant
Hose
Once
a
week
inspect
hoses and
connections.
Inspect
coolant
hoses
for
breaks
and
clogs.
Keep
con
nections
clean
and
tight
to
prevent
coolant
leaks.
OM-1
564
Page
7

5 -4.
PREPARING
TUNGSTEN
ELECTRODES
(FIgure
5-1)
HOT
FLYING
METAL
PARTICLES
can
injure
personnel,
start
fires,
and
damage
equip
ment;
TUNGSTEN
CONTAMINATION
can
lower
weld
quality.

Shape
tungsten
electrode
only
with
properly
guarded grinder
in
a
safe
location
wearing
proper
face, hand,
and
body protection.

Do
not
use same
wheel for
any
other
job
or
the
tungsten
will become
contaminated.
Tungsten
electrode
shaping
should be
done
on a
fine
grit,
hard
abrasive wheel.
Since
tungsten
is
harder than
most
grinding
wheels,
causing
the
tungsten
to
be
chip
ped
away
rather than cut
away,
the
grinding
marks
should
run
lengthwise
with
the electrode.
For
additional
information,
see
your
distributor
or re
quest
a
handbook
from
factory
on
the
Gas
Tungsten
Arc
Welding
(GTAW)
process.
1
CAUTION
TUNGSTEN
PREPARATION:
IDEAL
Stable
Arc
~
Straight
Ground
Flat
(the
Dia.
of
this
Flat
Governs
Amperage
Capacity)
TUNGSTEN
PREPARATION:
WRONG
Arc
~
Point
Radial Groun
Figure
5
-
1.
Tungsten
Preparation
TA-120
630
TA-121
196
Figure
A
-
Complete
Torch
Assembly
14
20
OM-1
564
Page
8