Miller MTT-1512HR User manual

March
1988
FORM:
OM-i
559
Millerfi
ALE
COpy
~ETURN
TO
FOLDER
Effective
With
Style
No.
JJ-23
MODEL
MTT-1512HR
MTT-1525HR
MTT-1512NR
MTT-1525NR
MTF-1512VHR
MU-i
525VH
R
MU-1512VNR
MU-i
525
VN R
MU-i
512
H F
MU-1525HF
MU-1512NF
MU-i
525N
F
MU-1512VHF
MU-i
525
VH
F
MU-1512VNF
MU-i 525
VN
F
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
emphasis
on
the
safety
material
throughout
both
manuals,
before
in-
~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
Te1
414-734-9821
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.
ADOmONAL COPY
PRICE 35
CENTS

LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
16.
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
breach of
warranty
or
any
other
duty
tions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goods,
the
exclusive remedies
warrants
to
its
Distributor/Dealer
that all
new
and
unused
therefore
shall
be,
at Millers
option
(1)
repair
or
(2)
replacement
Equipment
furnished
by
Miller is
free
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
actualuse)
upon
engines,
trade
accessories
and
other
items
are
sold
subject
to
return
of
the
goods
at
Customers
risk and
expense.
MILLER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,
Wisconsin,
or
F.O.B.,
at
a
MILLER
authorized service
date of
original
purchase,
except
Tecumseh
engines
which facality,
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
$J
wire
including
nozzles
and nozzle
insulators
where
failure does
ANY IMPUED
WARRANTY,
GUARANTY OR
REPRESENTA
P~
not result
from
defect
in
workmanship
or
material.
T1ON
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,
~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF TRADE OR
COURSE
OF
DEALING,
INCLUDING
~
within
the
following
periods
from
the date
of
delivery
of
Equip-
ANY IMPUED WARRANTY OF
MERCHANTABIUTY
OR
OF
~J
ment
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER IS
EX
~f
1.
Arc
welders,
p~r
sources,
robots,
and
components
.
1
year
CLUDED
AND
DISCLAIMED
BY
MILLER.
2.
Load
banks
1
year
~
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
only)
EXCEPT
AS EXPRESSLY
PROVIDED
BY
MILLER IN
i.)
4.
Allweldingguns,feeder/gunsandtorches
90days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
~J
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
~
7.
Batteries
6
months
EXPERIENCED
IN
THE
USE
AND MAINTENANCE OF
WELDING EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
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
at
general
policy
ony,
Miller
may
honor
claims
MILLERS WARRANTIES
TO,
ANY
CONSUMER.
fl
submitted
by
the
original
user
within
the
foregoing periods.
-.
 ......
..-...
-...
.

1
-
5.
Since
cess,
a.
WARNING
SECTION
1
-
_________
UNSAFE
PROCEDURES
OR
PRAC
TIGES
can
cause
serious
personal
injury
or
death.

Read,
understand,
and
follow
ALL of
these
safety
rules before
installing, operating,
or
servicing
this
equipment.

Be
sure
that
all end
users
of this
equipment,
the
operator
and
helpers,
read and
understand
these
safety
rules.
1
-
1.
PREVENT
ELECTRIC
SHOCK
Touching
live
electrical
parts
can
cause
severe
burns to
the
body
or
fatal
shock.
Severity
of
electrical
shock
is
determined
by
the
path
and
amount
of
current
through
the
body.
Therefore:
a.
Do
not
touch
live
electrical
parts.
b. Do
not
work
in
wet
or
damp
areas.
c.
Wear
dry
insulating
gloves
and
body
protection.
d.
Disconnect
all
power
before
installing
or
servic
ing
this
equipment.
e.
Turn
off
all
equipment
when
not
in
use.
f.
Properly
install and
ground
the
welding
power
source
according
to
its
Owners
Manual
and
all
applicable
codes.
g.
Do
not
use
worn
or
damaged
cables
or
cables
that
are
too
small
or
poorly
spliced.
h.
Do
not
wrap
cabes
around
your
body.
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.
Use
adequate
ventilation in the
work
area
to
keep
fumes
and
gases
from
your
breathing
zone
and the
general
work
area.
c.
If
ventilation
is
inadequate,
use an
approved
breathing
device.
d. Read the
Material
Safety
Data
Sheets
(MSDSs)
and the
manufacturers
instructions
for
any
materials
used.
SAFETY
RULES
1
-3.
PROTECT
EYES
AND
SKIN
FROM ARC
RAYS;
PROTECT
EARS
FROM
NOISE
Arc
rays
from
the
welding
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise from
some
processes
can
damage
hearing.
a.
Wear
a
welding
helmet
fitted
with
a
proper
filter
lens
(see
ANSI
Z49.1
for
detailed
information).
b.
Use
protective
screens or
barriers
to
protect
others
from flash
and
glare.
c.
Wear
protective
clothing
and
foot
protection.
d.
Always
wear
safety
glasses
or
safety
goggles
in
a
work
area.
1
-4.
PREVENT
FIRES
AND
BURNS
The hot
workpiece,
hot
equipment,
other
hot
metal,
spatter,
and
arc
sparks
can cause
fires
and burns.
a.
Wear
correct
eye,
face,
and
body
protection
in
the work
area.
b.
Allow work and
equipment
to
cool
before
handl
ing.
c.
Do
not
weld
near
combustible
material.
d.
Watch for
fire,
and
keep
a
fire
extinguisher
near
by.
e.
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.
PROTECT
COMPRESSED
GAS
CYLINDERS
gas
cylinders
are
normally
part
of
the
welding
pro
be
sure
to treat
them
carefully.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
b.
Install
and
secure
cylinders
so
that
they
cannot
fall
or
tip
over
by
fastening
them
to
a
mounting
bracket, wall,
or
other
stationary
support.
c.
Keep
cylinders
away
from
any
welding
or
other
electrical circuits.
d.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
aM-i 559
Page
1

1
-6.
PROVIDE
PROTECTION
FOR
SPECIAL
S ITU
ATIO
N
S
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
I
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
516,
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-1559
Page
2

SECTION
1
-
INTRODUCTION
Rated
with
Gas
Lens
Collet
Body
Figure
2
-
1.
Specifications
2
-2.
GENERAL
INFORMATION
AND
SAFETY
A.
General
B.
Safety
M
-
Miller
T
-
TIG/GTAW
T
-
Torch
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
F
-
Flexible
Head
V
-
Gas
Valve
Ampere
Rating
Model
at
100%
Duty
Cycle
DCEN: ACHF
Tungsten
Size
Capacity
Cable
£~~h
Torch
Body
Cooling
Method
Weight
Net
Ship
MTT-1512HR
MTT-1512HF
MTr-1512VHF
.
2.5 lbs.
(1.1
kg)
3.0 lbs.
(1.4
kg)
MTT-1512VHR
MTT-1512NR
MTT-1512NF
12.5
ft.
(3.8
m)
Length:
8.0
in.
(203.0 mm)
3.0 lbs.
3.5
lbs.
MTT-1512VNR
MTT1512VNF
MTT-1525HR
MTT-1525HF
150
Amperes
With
Argon
.020 thru
1/8
in.
(0.5
thru
3.2 mm)
Handle Diameter:
0.9
in.
(22.9 mm)
Weight:
4.5
oz.
(127.6
9)
Air
(1.4
kg)
(1.6
kg)
4.5 lbs.
5.0 lbs.
MTT-1525VHR
(2.0
kg)
(2.3
kg)
MTT-1525VHF
MIT-i
525NR
25
ft.
(7.6
m)
MTT-i
525NF
5.5
lbs~
6.0 lbs.
MTT-1525VNR
MIT-i
525VNF
(2.5
kg)
(2.7
kg)
CAUTION
2
-
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
con
ditions
continuously.
~
EXCEEDING THE
RATED
AMPERAGE
and
duty cycle
can
result
in
damage
to
the torch.

Do
not
exceed rated
amperage
and
duty
cycle
stated in
Figure
2-1.
statements
include
installation,
operation,
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,
Il~I~s]
~
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
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
number
is
located
on a
label
under
the
torch
handle.
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:
Information
presented
in this
manual and
on
various
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.
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.
Safety
instructions
specifically
pertaining
to
this unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
and
___________
which
identify
different
levels of
hazard.
____________statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which if
not
carefully
followed
could
result
in
serious
personal injury
or
loss of life.
WARNING
WARNING
CAUTION
OM-1559
Page3

Assemble
torch
body
as
follows:
SECTION
3
-
INSTALLATION
1.
Instafl
collet
body
into torch
body
making
sure
heat
shield is
in
place.
2. Install
cup
onto
collet
body.
3.
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.
Install
backcap
and
0-ring (supplied
on
backcap)
onto
torch
body.
5.
Install
properly
prepared
tungsten
electrode
(see
Section
5-4)
through
front of
collet
body
to
posi
tion electrode
tip
outside
cup
rim.
Securely
tighten
backcap.
3 -2. GAS
HOSE
CONNECTIONS
AND GAS
VALVE
(If
applicable)
The
high
flex cable contains the
power
cable
within
the
gas
hose. The
high
flex cable has
a
3/8-24
male
right-
hand
fitting (Figure
3-1).
To install
high
flex
cable,
connect
high
flex
cable
fitting
to
power
cable
adapter.
Connect
a
suitable
length
of
gas
hose from
power
cable
adapter
to
gas
valve
outlet
or
regulator/flowmeter
(Figures
3-2
and
3-3).
B.
High
Performance Cable
Assembly
The
high
performance
cable
assemby
has
separate
power
cable
and
gas
hose. 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
or
regulator/flowmeter.
Connect
gas
hose
(extra
hose not
supplied)
from
gas
valve
inlet
to
regulator/flowmeter
(Figures
3-2
and
3-3).
.
0-ring
Collate
Torch
Body
Collet
Short
Backcap
Tungsten
Eiectrode
Power Cable
Connector
Gas
Valve
applicable)
9~.*__
0-ring
Power
Cable~
Adapter
Handle
Gas
Hose
Fitting
High
Flex
Cable
Fitting
WARNING
Required
Consumables
and
Accessories
*Obthin
from
Welding
Equipment
Supplier
Figure
3
-
1.
Torch
Components
>,
__________
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.
Loc~.out/tagging
procedures
consist of
padlocking
line
dis
onnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
TA-120
873
To
readjust
electrode,
loosen
backcap.
IMPORTANT
______________
As
a
general
rule,
electrode
extension
should
equal
electrode
diameter;
exact
electrode
exten
s/on
may
va,y
according
to
application.
3
-
1.
TORCH
BODY
(Figure
3-1)
-
The torch
body
is
shipped
requiring
consumables and accessories
in
diated
in
Figure
3-1:
cup,
collet
body,
collet,
power
cable
adapter
(with
High
Flex Cable
only),
and
tungsten
electrode.
IMPORTANT
______________
If
power
source
is
not
equipped
with
a
gas
valve,
a
torch
gas
valve
is
required.
To
install
gas
hose,
connect
gas
hose
fitting
to
regulator/flowmeter.
An
extra
hose
may
be
required
to
make
connection.
A.
High
Flex Cable
Assembly
OM-1
559
Page
4

Torch
r
Work
Clamp
Power
Cable
Adapter
Gas
Power
Source
Gas
r
Work
Power
Clamp
Adapter
Regulator/Flowmeter
Power
Source
Work
Clamp
High
Flex
Cable
Assembly
Gas
I
Power
Connector
High
Peformance
Cable
Assembly
Figure
3
-
2.
GTAW
Torch
Connection
Diagram
For
Models
With
Gas
Valve
Gas
Cylinder
TA-120 824
Torch
Regulator!
Flowmeter
Torch
Power
Source
Power
Source
Gas
Valve
High
Flex
Cable
Assembly
Work
Clamp
Gas
Power
Cable
Gas
Connector
Valve
High
Performance
Cable
Assembly
Figure
3
-
3.
GTAW
Torch Connection
Diagram
For
Models
Without
Gas Valve
TA-120
824
OM-1559
Page
5

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
cJockwise
closes
the
valve.
The
gas
valve
allows
control of
gas
postf
low
time,
or
~he
length
of
time
gas
flows after
the
arc
is
extinguish
ed.
Insufficient
gas
postflow
results
in
an
oxidized
(black)
electrode
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
pos(flow
time
per
100
amperes
of
weld.
current
before
closing
valve.
3
-3.
POWER
CABLE CONNECTION
(Figures
3-1,
3-2.
and
3-3)
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.
WARNING:
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.
High
Flex
Cable
Assembly
The
high
flex
cable
assembly
contains
the
power
cable
within the
gas
hose.
The
high
flex
cable
has
a
3/8-24
male
right-hand
fitting
(Figure
3-1).
To
install
high
flex
cable,
connect
high
flex cable
fitting
to
power
cable
adapter
(see
Section
3-2A).
Connect
power
cable
adapter
to
weld
output
terminal
(Figures
3-2
and
3-3).
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
(Figures
3-2
and
3-3).
SECTION
4-
SEQUENCE OF
OPERATION
WARNING
_________
ELECTRIC SHOCK
can
kill.

Do not
touch five
electrical
parts.

Keep
all
covers
and
handle
in
place
white
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.
METAL,
SPATTER,
AND SLAG
can
cause
fire
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.
Set
power
source
for
desired
welding
amperage.
5.
Wear
dry
insulating
clothing
and
gloves
and
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
clear
hose
of
air,
moisture,
or
any
other
contaminants.
Allow
gas
to
flow
2
to
3 minutes on new
torch;
5 to
6
seconds
thereafter.
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.
4
-
1.
GAS TUNGSTEN
ARC WELDING
(GTAW)
1.
Install
and
connect
torch
according
to
Section
3.
2. Make
sure
backup
and all
gas
connections
are
securely
tightened.
3. With
regulator/flowmeter
valve
closed,
open gas
cylinder
valve.
3.
Turn
off the
shielding
gas
and
coolant
supplies
at
their
sources.
L~~U~E
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.

Shut
off
gas
supply
when
not
in
use.
HOT
and

.
8.
Begin
welding.
4
-2.
SHUTTING
DOWN
1.
Stop
welding.
OM-1559
Page
6

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
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.
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.
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.
5
-
4.
PREPARING
TUNGSTEN
ELECTRODES
(Figure
5-1)
t~Uiis1~
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.
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.
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
wed
quaity.
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,
maintaini,?g,
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.
Once
a
week
inspect
hoses
and connections.
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.
A.
Gas
Hose
TA-IZO
630
Gas
leaks
may
result
in
poor
weld
quality.
Inspect
hoses
for
breaks.
Keep
connections
clean
and
tight.
Figure
5
-
1.
Tungsten
Preparation
5 -2. TORCH
BODY
MAINTENANCE
(Figure
3-1)
TUNGSTEN
PREPARATION:
IDEAL
Stable
Arc
Straight
Ground
Flat
(the
DIa.
of
Flat Governs
Amperage
Capacity)
TUNGSTEN
PREPARATION:
WRONG
Arc Wander
,
~~~iiII
Point
Radial
OM-1
559
Page
7

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
5-20
15-80
70-150
125-225
225-360
*
*
10-20
15-30
25-40
5-20
10-60
50-100
100-160
150-210
2%
Thorium
Alloyed
Tungsten
(Red Band)
.
.020
.040
1
/
16
3/32
1/8
15-40
25-85
50-160
135-235
250-400
*
*
10-20
15-30
25-40
15-35
20-80
50-150
130-250
225-360
Zirconium
Alloyed
Tungsten
(Brown Band)
020
040
1/16
3/32
1/8
*
*
*
*
*
*
.
*
*
*
*
15-35
20-80
50-150
130-250
225-360
NOT
RECOMMENDED
The
figures
are
intended
as
a
guide
and
are a
composite
of recommendations from
American
Welding
Society
(AWS)
and
electrode manufacturers.
Item
Miller
Miller
No.
Stock
No.
Model
No.
Description
HR NR
HF
NF
VHR
VNR
VHF
VNF
Figure
A
Complete
Torch
Assembly
116252
115 251
116
256
t119
914
t119
915
116
250
4
116253
TUNGSTEN,
electrode
(consult
your
welding
supply
distributor)
CUP
(see
Figure
B)
COLLET
BODY
(see
Figure
B)
TORCH
BODY,
rigid
hd
w/heat
shield
(consisting
of)
TORCH
BODY,
flex
hd
w/heat
shield
(consisting
of)
HEATSHIELD,std
HEAT
SHIELD,
small
dia
gas
lens
HEAT
SHIELD,
large
dia
gas
lens
TORCH
BODY,
rigid
hd
w/heat
shield &
valve
(con
sisting
of)
TORCH
BODY,
flex hd
w/heat
shield
&
valve
(con
sisting
of)
HEATSHIELD,
std
VALVE,
knob
(consisting
of)
0-RING
COLLET
(see
Figure
B)
BACKCAP,
short
(consisting
of)
BACKCAP,
medium
(consisting
of)
BACKCAP,
long
(consisting
of)
1
1
1
11
1
11
1 1
1
1
1
1
1 1
1 1 1
2
22
11
1
1
1 1
1
1 1
4
Quantity
Model
1
2
3
4
4
5
5
5
4
300HS
3GHS
3GHSLD
1
6
116255
100VK
7
116254
100R
8
9
116259
300S
9
t116258
300M
9
t116
257
300L
4.
1
1
1
1
1
1
1
2
1
1
1
OM-1 559
Page
8

Quantity
Figure
A
-
Complete
Torch
Assembly
tOptional
Equipment
BE
SURE
TO
PROVIDE
MODEL
AND
STYLE
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
TA-120
673
Item Miller
Miller
Nb.
Stock No.
Model
No.
Figure
A
Description
Complete
Torch
Assembly
(Contd.)
Model
HR NR
HF
NF
VHR
VNR VHF
VNF
10
116260
300R .0-RING
~.
i
i 1
11
115 271
1512PCHF
HI-FLEX POWER
CABLE,
12-1/2ft
(consisting
of)
1
1
11
116 272
1525PCHF
HI-FLEXPOWER
CABLE,25ft(consistingof)
1
1
12
120721
.RHNUT
22
13
120720
.RINGNUT
22
14 117
585
HANDLE
1
1 1
14 118 514
HANDLE,
medium
w/hole
for
valve
11 1
15 t115
276
15PCA
POWER
CABLEADAPTER
1 1
16 116
261
1
512PCN
HI-PERFORMANCE
POWER
CABLE
&
HOSE,
12-1/2
ft
(consisting
of)
1
16
17
116262
116 267
1525PCN
212AH
HI-PERFORMANCE
POWER CABLE
&
HOSE,
25
ft
(consisting
of)
.
GAS
HOSE,
12-1
/2ft(consisting
of)
1
1
17
116
268
225AH
.
GAS
HOSE,
25
ft
(consisting
of)
1
18
116 512
. .
HOSE,
black
1/8
ID
(order
by
ft
as
reqd.)
19
116266
2AN
..GASNUT
20
116269
3HF
.
.HOSEFITTING
21
116
264
1512CN
.
POWER
CABLE,
12-1
/2ft(consisting
of)
21 116
265
1525CN
.
POWER
CABLE,
25ft(consisting
of)
22
600
317
.
.
CABLE,
weld-copper
No.
4
(order
by
ft
as
reqd.)
23
116270
5PF
. .
POWER
CABLE
FITTING
24
116 263
15PFN
.
.
POWER
CABLE
FITTING
(consisting
of)
25
120729
..
.CRIMP,cable
26
120 761
...
FITTING,
gas
(consisting
of)
27
120720
.
.. .
RING
NUT
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
3.
1
11



/
Includes
Item
242322
20
19 18
,~
16
14



>-
OM-1559
Page
9

CONSUMABLE
PARTS SELECTOR
Not.:
Coilet.
Coii.t
Body
And
0..
Cup
R.qulr.d
To
Complet.
Torch.)
Torch.. With
High
Flex
Compo.lt.
C.bl.
Also
Require
A
Power
C.bi.
Adapter.
020 040
I
1/16
I
3/32
I
1/8
I
8TANDAROLENOTHF8ONTENOS
r_SH0RTF80NTENO8
lungaten
Diameter
ImmI
I
10.51
(
(1.0)
1.6)
(2.4)
(3.2
S1.od.rd
L.nath
cou~,
Dody
Coil.,
body
4CB-XXX
ACHFI
5-20
10-80 50-150
100-2351
150-3251
3C8-0XX
Amperage
Range
DCSPI
620
16.80
I
70-160
1160-2501220-3501
ii..
308118
~
308H8
Collet
(Standard)
Model
No.1
3C20
I
3C40
I
3C116
I
3C332
I
3C418
I
Ho.l
Shl.4d
61.nd.,d
I
Hoot
881.14
Stook
No. Iii 258
CoIl.t
I
$1008
No.118
264
Stock
No.1116
367 116
368
J
116 369
1116
370 116
371
I
3C-XXX
I
81.040,4
L.oglh
Collet
Reverse)
Model
No.
I
7C20 7C40
7C1
16 I
7C332
I
7C418
I
0..
L.n.
I
Short
StockNo,11163791116380111638111163821116383I
SQL-SOS
lion.,..
OL
Model No,
3CB20 I
3CB40
I
3CB116
I
3CB332
I
3CB418
I
U..
3OHS
Cotl.t
I
XXX
Collet
Body
(SW.
Lglh.}
Stock
No.1116
3611116
362
111636311
t6
36411163651
Ho.t
$hl.ld
7C.XXX
Stock No. 118814
I
U..
40H8
Stock/Model
No.
________________________
I
Ho.t 881.1.
L.r5.
01.0,000,
1
8100k
NO.
118 itS
11634
0..L.o.
3OLL.XXX
1~
R.dono
Caotlflhi000
DOIY
U
3OHSLD
I
~ ~i.,,coo.,
Body.
R.tlne By
26%
Wh.n
U.lflg
Cup,
Ceramic
_________
H.aI 8hh1.d
1.27/32
Long
116
________
Stock
No
118816
Cup,
Alumina
1-27/32
Long
~
116 330
116 331
I
116 332
13A61
:~i~4
:~:~1ii~:.?
116333
l3A7l
116334
l3A8l
116335
l3AlOl
116336
13A12(
Gas
Len.
Collet
BodyStd.Lgth.
Model No.
StockNo.
3GL20
119928
3GL40
119927
3GL1
16
119928
3GL332 3GL418
119929 119930
Cup.
Ceramic
-GasLen.
1.5/8
Long
C
3CG11 ia
1-1/8
Long
Stock/Model
No.
119 917
I
119919
119919
I3CG6I
119920
(3CG7I
119921
(3C081
119922
I3CG1II
119923
(3CGI2I
119 924
I3CG14I
I19925l3CG16l
119 932
i.
119933
1
119934
(3AG6(
1t9 935
13AG71
119 936
13AG81
11993713AG111
3/8.
7/16
1/2
11/16
Gas
Lone
Collet
Body
Lg.
Die,
Model No.
Stock
No.
3GLL332
3GLL418
119 902
119
903
Cup.
Alumina
17/8Long
~4%
~
.
Stock/Model
No.
119911
I3AGBLDI
19912
I3AG1OLDI
i/i *~i1~
1/2
6/8
19913
I3AG12LDI
~yI~II~
~/.//?,~/
3/4
Cup,
Alumina
Ga.
Lena
1-6/8
Long
Figure
B
-
Consumable
Parts
And
Cross
Reference
Chart
.
0
01
(7l
CD
-o
0)
0)
0
116350
13C61
116361
l3C7l
116 352
13C8(
116 353
l3ClOl
118 364
(3C121
(
Short
~
Call.,
4C.SXX
QII000110
7C.Sxx
Cup,
Ceramic
3-7/32
Long
116
343
116344
116 345
I3C6LII
116346 I3C7LI
I
I
Cup
Orifice
________________
3/16
__________________
1/4
________
6/16
3/B
7/16
1/2
_____________
5/~~
3/4
1/4
5/16
3/8
7/16
________
1/4
_________
5/18
________
3/8
__________
7/16
1/2
5/8
3/4..
-
1/4
5/16
3/8
____________
7/~~
112
_flfl6
3/4
___________________
1/4
5/16
in..020
.040
1/16
3/32
1/8
Tungsten
Diameter
(mm)
10,51 11.01
11.61 12.41
(3.21
ACIIF
5-20
10-80
50-150
tOO-235
150-325
Amperage
Range
DCSP
5-20 15-80 70-150
150-250
220-350
ColletlShort)
ModelNo.
4C20
4C40
4C116
4C332 4C418
StockNo.
116373
116374 116375
116376 116377
Collet
(Reversal
ModelNo.
7C20
7C40
7C116
7C332 7C418
StockNo.
116379
116380
116381
116382 116383
4CB332
StockNo.
116355 116356 116357 116356
116359
Stock/Model
No.
Cup
Orifice
1t6337l2C4l
1/4
Cup,
Ceramic
1-5/32
Long
116338
12C51
5/16
116339
12C61
3/8
116340)2C7l
7/16
1-1/8
Long
116 341
12C81
1/2
_________________________________
5/8
Cup,
Ceramic
116 326
(2C3L(
3/16
-
Long
1-7/8
116 327
12C4L1
1/4
116328
12C5L1
~
5/18
116329
12C6L1

3/8
116310i,
1/4
Cup,
Alumina
116
311

5/16
1-5/32
Long
116312
12A6(
318
116313(2A7(
7/16
11631412A81
1/2
116315(2A10(
5/8
Gas
Lens Collet
Model
No.
4GL20
4GL40
4GL1 16
4GL332
4GL418
Body-Short
StockNo.
119905
119906 119907
119908 119909
Stock/Model
No
Cup,
Alumina
1
Long
11989312AG4(
1/4
~
11989412AG51
5/16
119 895
12AG61
3/8
11989812AG7(
S~S1~i 7/16
SHADED AREAS INDICATE
RECOMMENDED
USAGE

CROSS
REFERENCE
TO
COMPETITIVE
MODEL
MILLER
STOCK
NO.
MILLER
MODEL
NO.
COMPETITIVE
NO.
MILLER
STOCK NO.
MILLER
MODEL NO.
COMPETITIVE
NO.
116367
3C20
10N21
119934
3AG6
54N16
116368
3C40
10N22
119935
3AG7 54N15
116369
3C116
10N23

119936
3AG8
54N14
116370
3C332
10N24

119937
3AG11
54N19
116371
3C418
10N25
119902
3GLL332
45V64
116379
7C20
N/A
119903
3GLL418
995795
116380
7C40
N/A
119911
3AG8LD
57N74
116381
7C116 N/A
119912
3AG1OLD
53N88
116382 7C332
N/A
119913
3AG12LD
53N87
116383 7C418
N/A
116373
4C20
N/A
116361
3CB20
10N29
116374
4C40
10N22S
116362 3CB40 10N30
116375
4C116
10N23S
116363 3CB116
10N31
116376
4C332
10N24S
116364
3CB332
10N32
116377
4C418
10N25S
116365 3CB418
10N28
116379
7C20
N/A
116347
3C3 N/A
116380
7C40
N/A
116348 3C4 105Z43
116381
7C116
N/A
116349 3C5 105Z42
116382 7C332
N/A
116350
3C6 105Z44
116 383 7C418
N/A
116351
3C7 105Z45
116355
4CB20
N/A
116352 3C8 08N78
116356
4CB40
17CB20
116353
3C10
08N79
116357
4CB116
17CB20
116354
3C12 08N80
116358 4CB332
17CB20
116343 3C4L 12N03
116359 4CB418
17CB20
116344
3C5L 105Z60
116337
2C4
13N14
116345 3C6L
12N02
116338
2C5
13N15
116346
3C7L
105Z61
116339
2C6 13N16
116330 3A4
10N50
116340
2C7 13N17
116331
3A5 10N49
116341
2C8 13N18
116332
3A6
10N48
116342
2C10 13N19
116333
3A7
10N47
116326 2C3L
796F70
116334 3A8
10N46
116327 2C4L
796F71
116335 3A10
10N45
116328
2C5L
796F72
116336 3A12
10N44
116329 2C6L 796F73
119926 3GL20
45V29
116310 2A4
13N08
119927
3GL40
45V24
116311
2A5
13N09
119928
3GL116
45V25
116312
2A6 13N10
119929 3GL332
45V26
116313
2A7
13N11
119930
3GL418
45V27
116314
2A8
13N12
119917 3CG4
54N35
116315 2A10 13N13
119918
3CG5
54N34
119905
4GL20 N/A
119919 3CG6
54N33
119906
4GL40
N/A
119920
3CG7
54N32
119907
4GL116
N/A
119921
3CG8
54N31
119908
4GL332
N/A
119922 3CG11
54N36
119909
4GL418
N/A
119923 3CG12
N/A
119893
2AG4
53N58
119924
3CG14
N/A
119894
2AG5
53N59
119925
3CG16
N/A
119895
2AG6
53N60
119932 3AG4
54N18
119896
2AG7
.53N61
119933
3AG5 54N17
OM-1 559
Page
11

.
3

ERRATA
SHEET
After this
manual
was
printed,
refinements
in
equipment design
occurred.
This sheet lists
exceptions
to
data
appearing
iater
in
this manual.
AMEND MEN T
TO PARTS LIST
Amend Parts List
as
follows:
Part
Replaced
No.
With
Description
Quantity
9-11
115271
116271
HI-FLEX
POWER
CABLE
9-14
117585 117586
HANDLE
1
1
**First
digit
represents
page
no
-
digits following
dash
represent
item
no.
BE
SURE TO PROVIDE MODEL
AND
STYLE NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.