Miller WP-23A, WP-26, WP-150, WP-200, WP-18 Owner's Manual

OM-251981C 2018-02

Processes

TIG (GTAW) Welding

Description

Hand-Held Water-Cooled TIG
(GTAW) Torches

Hand-Held Air-Cooled TIG
(GTAW) Torches

WP And CS Series Torches

File: TIG (GTAW)

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES − READ BEFORE USING 1............

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

1-3. Proposition 65 Warnings 2...............................................................

1-4. Principal Safety Standards 2.............................................................

1-5. EMF Information 2.....................................................................

SECTION 2 −DEFINITIONS 3..................................................................

SECTION 3 − SPECIFICATIONS 4..............................................................

3-1. Specifications Table 4...................................................................

3-2. Duty Cycle 5..........................................................................

SECTION 4 − INSTALLATION 5................................................................

4-1. Required Torch Parts And Torch Assembly − CS Series Torches 5.............................

4-2. Required Torch Parts And Torch Assembly − WP Series Water-Cooled Torches 6................

4-3. Required Torch Parts And Torch Assembly − WP Series Air-Cooled Torches 6...................

4-4. Remote 6 Receptacle Information For 15 Volts DC 7.........................................

4-5. Remote 14 Receptacle Information For 15 Volts DC 7........................................

4-6. Remote 14 Receptacle Information For 24 Volts AC 7........................................

4-7. Connecting Torch 8.....................................................................

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 10.........................................

5-1. Routine Maintenance 10.................................................................

5-2. Troubleshooting 10......................................................................

SECTION 6 − ELECTRICAL DIAGRAMS 11.......................................................

SECTION 7 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC PHASE

MACHINE WELDING 12........................................................................

7-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 12......

7-2. Preparing Tungsten Electrode For Welding With Phase Control Machines 12.....................

SECTION 8 − GUIDELINES FOR TIG WELDING (GTAW) 13.........................................

8-1. Positioning The Torch 13.................................................................

8-2. Torch Movement During Welding 14........................................................

8-3. Positioning Torch Tungsten For Various Weld Joints 14........................................

SECTION 1 −SAFETY PRECAUTIONS FOR GTAW

TORCHES − READ BEFORE USING

SR6 (TIG) 2018-01

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the welding power source Owner’s Manual. Read
and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train­ing and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recog­nize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

D Always wear dry insulating gloves.
D Insulate yourself from work and ground.
D Do not touch live electrode or electrical parts.

D Before welding, verify torch head is firmly attached to the torch

body.

D Do not wrap water-cooled torch hoses and power cables together

with tape or plastic wire ties. Wrapping restricts water flow which
can cause power cable to overheat and torch hose to burst.

D Replace worn, damaged, or cracked torches or cables.
D Turn off welding power source before changing tungsten elec-

trode or torch parts.

D Keep all covers and handle securely in place.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

D Wear an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame-resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes.
D Ventilate area, or use breathing device. The

recommended way to determine adequate

ventilation is to sample for the composition and quantity of fumes

and gases to which personnel are exposed.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in

use.

D Always ventilate confined spaces or use ap-

proved air-supplied respirator.

WELDING can cause fire or explosion.

D Do not weld near flammable material.

D Do not weld on containers that have held com-

bustibles, or on closed containers such as
tanks, drums, or pipes unless they are properly prepared ac­cording to AWS F4.1 and AWS A6.0 (see Safety Standards).

D Watch for fire; keep extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

HOT PARTS can burn.

D Allow torch to cool before touching.
D Do not touch hot metal.
D Protect hot metal from contact by others.

NOISE can damage hearing.

D Check for noise level limits exceeding those spe-

cified by OSHA.

D Use approved ear plugs or ear muffs if noise level

is high.

D Warn others nearby about noise hazard.

OM-251981 Page 1

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at

the beginning of the manual and in each section.

1-3. Proposition 65 Warnings

WARNING: This product can expose you to chemicals in­cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.

For more information, go to www.P65Warnings.ca.gov.

1-4. Principal Safety Standards

D Use only genuine replacement parts from the manufacturer.

D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and loc­al codes.

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website: www.glo­bal.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

1-5. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF).The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and induc­tion heating operations) creates an EMF field around the welding circuit.
EMF fields can interfere with some medical implants, e.g. pacemakers.
Protective measures for persons wearing medical implants have to be
taken. For example, restrict access for passers−by or conduct individu-
al risk assessment for welders. All welders should use the following pro­cedures in order to minimize exposure to EMF fields from the welding
circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:
www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02169 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern­ment Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: [phone]) (there are 10 OS­HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).

4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-251981 Page 2