Miller MU-1512VNR, MTT-1525NR, MTT-1512HR, MU-1525VHR, MU-1525VNR Owner's 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

withnoother

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

furnishedbyMiller

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

accessoriesorother

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

warrantedbytheir

manufacturer

for

one

year

from

Appleton,

Wisconsin,orF.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

willbeallowed.

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,orservicing

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

determinedbythe

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

circuitatthe

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

ventilationinthe

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

ATIONS

a.

Do

not

weld

or

Cut

containers

or

materials

which

have

heldorbeen

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

torchisthe

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

occasiontofile

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

referstothe

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

lossoflife.

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.Ifusing

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