Miller MTL-17 User manual

Millerﬁ

January

1994

Form:

OM-1563B

Effective

With

Style

No.

KB-8

OWNERS

MANUAL

MTL-1

Torches

~'

F'~~

Read

and

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

service

this

unit.



Give

this

manual

the

operator.



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

54912

414-734-9821



Call

your

distributor

you

not

understand

the

directions.



Air-Cooled

Torches

For

GTAW

Welding



Rated

150

Amperes

100%

Duty

Cycle

Using

Argon

Shielding

Gas



.020

Thru

1/8

(0.5

Thru

3.2

mm)

Tungsten

Size

Capacity



Includes

12-1/2

(3.8

7.6

Cable



Remote

Contactor

And

Current

Control

Available



Tungsten

Electrode

And

Some

Torch

Parts

Needed

cover

7/93



ST-120

869

1993

MILLER

Electric

Mig.

co.

PRINTED

USA

MILLERS

TRUE

BLU

ETM

LIMITED

WARRANTY

Effective

January

1.1992

(Equipment

with

serial

number

preface

KC

newer)

This

Limited

warranty

suoersedes

all

MILLER

warranties

and

exclusive

with

ire

other

gualantees

warlantres

expressed

implied

:I~I

LIMITED

WARRANTY



Sub~ect

the

terms

and

conditions

below.

MILLER

Electric

MIp

Appleton

Wisconsin

warrants

its

original

retail

osrchaser

that

new

MILLER

equipment

sold

alter

the

ehectine

dale

Cl this

limited

warranty

is tree

feels

ir

m,rteriLtl

wnrknrannhip

the

time

shipped

MILLER

THIS

WAR.

PANTS

b\PPESSLX

LIEU

ALL

OTHER

WARRANTIFS

EXPRESS

l,tpI

lED

INCLUDING

THE

WARRANTIES

MERCHANTAITILITY

AND

FIT.

NESS

Within

the

warrants

aerinds

listed

below

MILLER

will

ypair

replace

any

war

ranted

parts

comooirents

that

laI

due

such

defects

material

wprbmansnio

stIllER

must

notified

writing

within

thirty

130)

days

such

defect

lailure.

which

MILLER

will

pronide

instructions

the

warranty

claim

procedures

tollowelt

MILLER

un.~fI

honor

wariants

claims

warranted

eQuipment

listed

below

the

event

such

Inure

withn

the

warranty

time

periods

All

warranty

time

periods

start

the

ante

that

the

equipment

was

delisered

the

original

retail

purchaser

one

veil

ahni

the

edsioment

sent

the

distributor

ears

Pt-tv

Vnii5

Lapor

-a-s

.iint

LrtOrtr

T-arvtrrrrvr

Pn1,riyr

Power

Sources

Pacr,,r

Cutto

owei

Sources

Sn

Avtcrnat~c

and

Automatic

Wire

Pneders

r

-rain

Pris

ano

LAPOr

~

D

..ni

,,nlrtiin

On~nratcrs

n

,~,,,-,

.~:n

ef,ltnct

vec,rrotnis cv

v

enema

-Vr--iIlactmirvt

t,rcrcr

fli

C,snc

cot

e.ons

Load

Banks

SOY

Transcrrrers

Runnino

Gear

Trailers

F.e.c

flommns

NOTE

meId

c.ptions

are

covereo

unoen

True

Blue

or

the

remaining

viarranty

perod

the

product

they

are

installed

for

minimum

onn

year

nhichever

greater

Months

Batteries

Days

Parts

and

Labor

taIG

OvnhiTIG

Torches



asnr,t

Cuimro

Torches

Remote

Controls

Accessory

Kits

Replacement

Parts

MILLERS

f-ire

Blue

Limited

Warranty

snaIl

not

apply

items

tsrnrshed

MILLER

but

manslactsred

others

ssch

engines

trade

accessories

These items

are

cosered

the

manufacturers

warranty,

any

Consumable

components.

ssch

contact

tips,

cutting

noodles,

contactors

and

relaes

p~rt~

that

fail

due

normal

wear

Eaumpment

that

has

been

moditied

any

party

other

than

MtLLER

equip.

menl

that

nas

been

improperly

installed

improperly

operated Pr

misused

based

upon

industry

standards.

equipment

which has

npt

had

reasonable

arid

necessary

maintenance,

edsrpment

which

has

been

used

tot

oseratron

outside

the

nqecrticatrons

ICr

the

eqsrpmenr

MIILEP

POOUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BYCOMMEP.

CISL

t4DUSTRIAL

USES

AND

ERSONS

cOAINED

AND

EXEEPiENCED

N

THy

ICE

AND

MAINTENANCE

WELDING

EQUIPMENT

the

njent

warranty

claim

covered

this

warranty

Inn

esclvsm:e

nmedies

ynaS

tILLER

option

Ill

repair

replacement,

where

authorized

writing

MILLER

apprspria(e

cases.

13)

the

reasonable

cost

repair

replace

ment

autaorized

MILLER

sernrce

station,

tat

payment

credit

for

pur

chase

price

less

reasorrabledepreciation

based

soon

actual

asel

upon

return

the

goods

csstomer

risk

and

espense

MILLERS

oplion

epair

replacement

will

Pactory

Appleton

Wisconsin

MILLER

asthonoed

ser.

ice

acmlil,

cntn-mmind

MILLER

Thnrelorn

comcnnsat.on

rnmmpsrse

0

i,lnspOrtatmcn

costs

any

~ind

will

sllnwed

F

E.,~yrtT

PEAMIOTED

Wi

0LV

cuE

PE.IEDIES

500i,iDEC

FOCI,

APE

c,y

SOI,E

AND

EXCLUSIVE

REMEDIES

EVENT

SALL

MILLER

LIABLE

OP

DIRECT

INDIRECT

SPECIAL,

INCIDENTAL

CONSEQUENTIAL

DAMAGPS

INCLUDING

LOSS

PRDFITI

WHETHER

BASED

CON

TPACT

TORT OR

ANY

OTHER

LEGAL

THEORY

AN0

~~~ES

.TARPANTr

NOT

000VIDED

HEPEIN

AND

ANV

IMPLIED

NAP.

cANT.

0~AA,.

ILO

APOPESENTATION

EOPOAMANCE

AND

ANS

E,IED

~QP

PREACH

COtITPACT

OpT

ANN

OTHER

LEGAL

THEC1Pr

WHICH

BUT

FOB

THIS

ROVISION

MIGHT

ARISE

IMPLICATION

OPERATION

LAW

CUSTOM

TRADE

COURSE

DEALING.

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

PITNESS

FOR

PARTICULAR

PURPOSE

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER

Somn

statna

n

nor

allow

limitations

bow

lone

implied

warranty

lasts

the

exclusion

incidental

indirect,

special

consequential

damages.

the

aPove

limitation

exclusion

may

not

apply

you

Thi5

warranty

provides

spe

cific

tngal

rights,

and

other

rights

may

available.

Out

may

vary

1rpm

stale

state

Canada.

legislation

some

prosinces

prqsrdes

certain

additional

warrantIes

remedies

other

than

stated

herein,

and

the

extent

that

they

may

not

waived

the

limitations

and

exclusions

set

oat

abose

may

not

apply

This

Lrmrted

Warranty

provides

specilrc

legal

rights

and

other

rights

may

anarlable.

but

may

-5r

l-sm

province

ptosmece

I

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

haMe

occurred

during

shipment.

File

any

claims

for

loss

damage

with

the

delivering

carrier

Assistance

for

filing

settling

claims

may

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

Style

Number.

Use

the

folloWing

spaces

record

Model

Designation

and

Serial

Style

Number

your

unit.

The

Information

tocafed

the

rating

label

nameplate

Model

__________

Serial

Style

No.

Date

Purchase

miller

9i93

SAFETY

PRECAUTIONS

FOR

GTAW

TORCHES

ELECTRIC

SHOCK

can

kill.

Always

wear

dry

insulating

gloves.

Insulate

yourself

from

work

and

ground.

not

touch

live

electrode

electrical

parts.

Repair

replace

worn,

damaged,

cracked

torch

cable

insulation.

Turn

oft

welding

power

source

before

changing

tungsten

electrode

torch

parts.

Keep

all

covers

and

handle

securely

ARC

RAYS

can

burn

eyes

and

skin.

Wear

welding

helmet

with

correct

shade

filter.

Wear

correct

eye

and

body

protection.

Cover

exposed

skin.

FUMES

AND

GASES

can

hazardous

your

health.

Keep

your

head

out

the

fumes.

Ventilate

area,

use

breathing

device.

Read

Material

Safety

Data

Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

explosion.

not

weld

near

flammable

material.

not

weld

closed

containers.

Watch

for

fire;

keep

extinguisher

nearby.

HOT SURFACES

can

burn

skin.

Allow

torch

cool

before

touching.

not

touch

hot metal.

Protect

hot

metal

from

contact

others.

NOISE

can

damage

hearing;

SOME

APPLICATIONS,

SUCH

PULSING,

are

noisy.

Check

for

noise

level

limits

exceeding

those

specified

OSHA.

Use

approved

ear

plugs

ear

muffs

noise

level

high.

Warn

others

nearby

about

nos~e

hazard.

EMF

INFORMATiON

WARNING

GTAW

WELDING

can

hazardous.

PROTECT YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

welding,

most

jobs,

exposure

certain

hazards

occurs.

Welding

safe

when

precautions

are

taken.

The

safety

information

given

below

only

summary

the

complete

safety

information

found

the

welding

power

source

Owners

Manual.

Read

and

all

safety

precautions.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

QUALIFIED

PEOPLE

______________________________

NOTE

Considerations

About

We/ding

And

The

Effects

Low

Frequency

Electric

And

Magnetic

Fields

The

following

quotation

from

the

General

Conclusions

Section

the

U.S.

Congress,

Office

Technology

Assessment,

Biological

Effects

Power

Frequency

Electric

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

there

now

very

large

volume

scientific

findings

based

experiments

the

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of this

work

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

interpret

the

evidence

single

coherent

framework.

Even

frustrating,

does

not

yet

allow

draw

definite

conclusions

about

questions

possible

risk

offer

clear

science-based

advice

strategies

minimize

avoid

potential

risks.

reduce

magnetic

fields

the

workplace,

use

the

following

procedures:

Keep

cables

together

twisting

taping

them.

Arrange

cables

one

side

and

away

from

the

operator.

not

coil

drape

cables

around

the

body.

Keep

welding

power

source

and

cables

far

away

practical.

Connect

work

clamp

workpiece

the

weld

possible.

About

Pacemakers;

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modlo,1

4/93

5t6

7/93

TABLE

CONTENTS

SECTION

SAFETY

INFORMATION

SECTION

SPECIFICATIONS

2-1.

Duty

Cycle

SECTION

INSTALLATION

OPERATION

3-1.

Required

Torch

Parts

And

Torch

Assembly

3-2.

Adjusting

Flex-Lok

Head

3-3.

Connecting

Torch

SECTION

MAINTENANCE

TROUBLESHOOTING

SECTION

5

TUNGSTEN

ELECTRODE

5-1.

Selecting

Tungsten

Electrode

5-2.

Preparing

Tungsten

SECTION

6

PARTS

LIST

Figure

6-1.

Complete

Torch

Assembly

Figure

6-2.

Consumable

Parts

Table

6-1.

Cross

Reference

Competitive

Model

OM-15636



1/94

SECTION

SAFETY

INFORMATION

Figure

1-1.

Safety

Information

SECTION

SPECIFICATIONS

Table

2-1.

Welding

Torch

modl.t

2.93

Specification

Description

Model

Description

MT:

Miller

Torch;

Flex

Lok;

17:

150

Ampere

Rating;

Gas

Valve

12:12-1/2

ft(3.8

Cable;

25:

(7.6

Cable;

One-Piece

Cable

Example:

MTL-17-12



Miller

Torch;

Flex

Lok;

150

Ampere

Rating;

12-1/2

(3.8

m);

One-Piece

Cable

Ampere

Rating

100%

Duty

Cycle

DCEN,

ACHF

150

Amperes

Using

Argon

Gas

Cooling

Method

Air

Cooling

Tungsten

Size

Capacity

.020

Thru

1/8

(0.5

Thru

3.2

mm)

Options

And

Accessories

Total

Weight

Torch

Body

Dimensions

And

Weight

See

Rear

Cover

12-1/2

(3.8

Cable

(7.6

Cable

12-1/2

(3.8

Cable

With

Gas

Valve

(7.6

Cable

With

Gas

Valve~

Net:

Ib(1.1

kg);

Ship:

(1.4

kg)

Net:

4.5

lb(2

kg);

Ship:

(2.3

kg)

Net:

2.5

lb(1.1

kg);

Ship:

(1.4

kg)

Net:

lb(2.3

kg);

Ship:

(2.3

kg)

Length:

(203

mm);

Handle

Diameter:

3/4

(19

mm)

Weight:

5.6

(160

Length:

8-3/4

(222

mm);

Handle

Diameter:

7/8

(23

mm);

Weight:

7.5

(210



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

avoid

injury.



Learn

the

meaning

WARNING

and

CAUTION.

CAUTION

_______

ELECTRIC

SHOCK

can

kill.

MOVING

PARTS

can

injure.



not

touch

live

electrical

parts.



Keep

away

trom

moving

parts.



Disconnect

input

power

beforejj_

~



Keep

all

panels

and

covers

closed

installing

servicing.

when

operating.

WARNING

READ

SAFETY

BLOCKS

start of

SectIon

3-1

before

proceeding.

Safety

Alert

Symbol

Signal

Word

WARNING

means

possible

death

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

equipment

damage

can

happen.

Statement

Hazard

And

Result

Safety

Instructions

Avoid

Hazard

Symbol

(If

Available)

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

NOTE

Special

instructions

for

best

oper

ation



not

safety.

H

NOTE

Turn

Off

switch

when

using

high

frequency.

OM-1563

Page

2-1.

Duty

Cycle

Obtain

the

following

parts

(see

Section

6):

Tungsten

Electrode

(See

Section

Cup

Collet

Body

Standard

Collet

Reverse

Collet

Reverse

collet

improves

electrical

contact

tungsten

electrode.

Power

Cable

Adapter

Assembling

Torch

Body

Flex-Lok

Head

Heat

Shield

Backcap

(Short

Backcap

Shown)

0-Ring

Installing

Tungsten

adjust

tungsten

position,

loosen

backcap.

5Keep

connections

tight.

Replace

cup,

heat

shield,

backcap,

and

0-rings

cracked.

Installing

Tungsten

ST-800

486

Figure

3-1.

Required

Torch

Parts

And

Torch

Assembly

CAUTIONS

WELDING

LONGER

THAN

RATED

DUTY

CYCLE

can

damage

torch

and

void

warranty.



not

weld

rated

load

longer

than

shown

below.

wfwarn8.1~

8/93

Definition

Duty

Cycle

percentage

rated

load

without

overheating.

minutes

that

torch

can

weld

Minutes

100%

uty

Cycle

At 150

Amperes

Using

Argo

Continuous

Welding

Gas

sb1.5~

8/93

Figure

2-1.

Duty

Cycle

SECTION

INSTALLATION

OPERATION

3-1.

Required

Torch

Parts

And

Torch

Assembly

Required

Torch

Parts

Assembling

Torch

Parts

~-

Loosen

Tighten

OM-1563

Page

3-2.

Adjusting

Flex-Lok

Head

CAUTION

TOOLS

can

damage

torch.



not

use

hand

tools

adjust

torch

flex-bk

head.

Hold

stem

and

turn

head

one

lull

turn.

Head

Adjusting

Stem

Head

Turn

head

and

stem

desired

angle.

Figure

3-2.

Adjusting

Flex-Lok

Head

ST-~42

083.A

~1~

Hold

stem

and

turn

head

until

tight.

OM-1563

Page

3-3.

Connecting

Torch

READ

SAFETY

BLOCKS

beginning

4jj~1

manual

before

proceeding.

BUILDUP

SHIELDING

GAS

can

harm

health

kill.

Shut

off

shielding

gas

supply

when

not

use.

warnl.1

9/91

Turn

Off

welding

power

source,

and

applicable.

install

high-frequency

unit,

disconnect

input

power

before

stalling

torch.

Obtain

the

following

hose:

Torch

With

Gas

Valve

Gas

Hose

With

5/8-18

Right-

Hand

Fittings

Connections:

Regulator/Flowmeter

Gas

Cylinder

Welding

Power

Source

Gas

Valve

Torch

Cable

Power

Cable

Adapter

Connect

hose

and

cable

adapter

before

connecting

adapter

weld

output

terminal.

Work

Clamp

Connect

work

clamp

clean,

paint-

free

location

workpiece.

weld

area

possible.

Use

wire

brush

sandpaper

clean

metal

weld

joint

area.

Operating

Torch

Gas

Valve:

Valve

controls

gas

preflow

and

post

flow.

Preflow

aids

arc

starting.

Pre

low

and

postflow

prevent

electrode

from

forming

black

surface

(oxidizing).

Open

valve

just

before

welding.

Turn

valve

clockwise

1/4

turn

open,

and

counterclockwise

1/4

turn

close.

________

After

welding,

leave

valve

open

about

seconds

for

every

100

amperes

weld

current.

valve

when

postflow

finished.

Tools

Needed:

5/8,

7/8

sT-BOO

487

Torch

Without

Gas

Valve

Figure

3-3.

Connecting

Torch

OM-1563

Page

SECTION

4

MAINTENANCE

TROUBLESHOOTING

4..

READSAF

manual

ETYBLOCKSatbeginning

before

proceeding.

Figure

4-1.

Maintenance

Schedule

Table

4-1.

Troubleshooting

OTE

Before

using

troubleshooting

table,

check

selection

and

preparation

tungsten

electrode

according

Section

Trouble

Remedy

Lack

of high

frequency~

difficulty

establishing



Check

cables

and

torch

for

cracks

bad

connections.

sure

that

torch

cables

arc.

Torch

gas

valve

not

working

properly



are

not

any

grounded

metal.

Repair

replace

necessary

parts.

Check

welding

power

source

high

frequency

control.

and

necessary.

check

and

adjust

spark

gaps.

Have

Factory

Authorized

Service

Station/Service

Distributor

check

valve.

(if

applicable).

Wandering

arc



poor

control

direction

arc.

~



-..j

Reduce

gas

flow

rate.

Tungsten

electrode

oxidizing

and

not

remaining



Shield

weld

zone

from

drafts.

Check

and

tighten

all

gas

fittings.

bright

after

conclusion

weld.

Increase

postflow

time.

Check

gas

valve.

Turn

Off

all

power

before

maintaining.

~~Replace

Cracked

Parts

3-1,

3-3

Torch

Body

Gas

Hose

Torch

Cable

OM-1563

Page

SECTION

TUNGSTEN

ELECTRODE

mod2.

3/93

NOTE

Foradditional

information,

see

your

distributor

fora

handbook

the

Gas

Tungsten

Arc

Welding

(GTAW)

process.

Wear

clean

gloves

prevent

contamination

tungsten

electrode.

5-1.

Selecting

Tungsten

Electrode

Table

5-1.

Tungsten

Size

Electrode

Diameter

Amperage

Range.

Gas

Type,

Polarity



Argon



Electrode



Argon



Electrode



Argon



Using



Argon



Balanced

Negative/Straight

Polarity

Positive/Reverse

Polarity

High

Frequency

Wave

Using

High

Freq.

Pure

Tungsten

(Green

Band)

.010,

Uptol5

UptolO

.020

5-20

10-20

.040

15-80

10-60

20-30

1/16

70-150

10-20

50-100

30-80

3/32

1/8

125-225

15-30

100-160

60-130

225-360

25-40

150-210

100-180

5/32

360450

4055

200275

160:240

3/16

450-720

55-80

250-350

190-300

1/4

720-950

80-125

325-450

250-400

Thorium

Alloyed

Tungsten

(Red

Band)

010

.020

15-40

15-35

5-20

.040

25-85

20-80 20-60

1/16

50-160

10-20

50-150 60-120

3/32

135-235

15-30

130-250

100-180

1/8

250-400

25-40

225-360

160-250

5/32

400-500

40-55

300-450 200-320

3/16

500-750

55-80

400-500 290-390

1/4

750-1000

80-125

600-800

340-525

Zirconium

Alloyed

Tungsten

(Brown

Band)

.010

Upto2O

Uptol5

.020

15-35

5-20

.040



20-80 20-60

1/16

50-150

60-120

3/32



130-250 100-180

1/8

225-360

160-250

5/32

300-450

200-320

3/16



400-550

290-390

1/4

600-800

340-525



Typical

argon

shielding

gas

flow

rates

are

cfh

(cubic

feet

per

hour),

Not

Recommended.

The

figures

listed

are

intended

guide

and

are

composite

recommendations

from

American

Welding

Society

(AWS)

and

electrode

manufacturers.

S-0009

OM-1563

Page

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