Miller Electric DB1812R, DB1825R User Manual

OM-1603 199 528C

1/2005

Processes

TIG (GTAW) Welding

Description

TIG Torch

Diamondback Series

GTAW Torches

DB1812R And DB1825R

ESPAÑOL FRANÇAIS ENGLISH

Visit our website at

www.MillerWelds.com

TABLE OF CONTENTS

SECTION 1 −SAFETY PRECAUTIONS FOR GT AW TORCHES − READ BEFORE USING 1 . . . . . . . . . . . . . .

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

1-2. GTAW Torch Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMF INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SECTION 3 − INSTALLATION 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Required Torch Parts And Torch Assembly 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. International Style Connector Assembly 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Connecting Torch 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − MAINTENANCE & TROUBLESHOOTING 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Troubleshooting 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING 9 . . . .

5-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 9 . . . . . . . .

5-2. Preparing Tungsten Electrode For Welding 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − GUIDELINES FOR TIG WELDING (GTAW) 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Positioning The Torch 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Torch Movement During Welding 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Positioning Torch Tungsten For V arious Weld Joints 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − PARTS LIST 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

SECTION 1 −SAFETY PRECAUTIONS FOR GTAW

TORCHES − READ BEFORE USING

SR6_1/00

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.

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

1-2. GTAW Torch Hazards

GTAW WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. 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 precautions.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.

 Marks a special safety message.

 Means NOTE; not safety related.

ENGLISH

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked
torch or cable insulation.

5. Turn off welding power source before changing
tungsten electrode or torch parts.

6. Keep all covers and handle securely in place.

ARC RAYS can burn eyes and skin.

1. Wear welding helmet with correct shade of filter.

2. Wear correct eye and body protection.

3. Cover exposed skin.

FUMES AND GASES can be hazardous
to your health.

1. Keep your head out of the fumes.

2. Ventilate area, or use breathing device.

3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.

BUILD UP OF GAS can injure or
kill

1. Shut of f shielding gas supply when not in
use.

2. Always ventilate confined spaces or use
approved air-supplied respirator.

WELDING can cause fire or explosion.

1. Do not weld near flammable material.

2. Do not weld on closed containers.

3. Watch for fire; keep extinguisher nearby.

HOT SURFACES can burn skin.

1. Allow torch to cool before touching.

2. Do not touch hot metal.

3. Protect hot metal from contact by others.

NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING,
are noisy.

1. Check for noise level limits exceeding those
specified by OSHA.

2. Use approved ear plugs or ear muffs if noise level
is high.

3. Warn others nearby about noise hazard.

OM-1603 Page 1

EMF INFORMATION

-

Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away from oper­ator as practical.

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

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doc
tor, then following the above procedures is recommended.

OM-1603 Page 2

SECTION 2 − SPECIFICATIONS

2-1. Specifications

Model

DB1812R DB1825R

Ampere Rating 350 Amps W/Argon Gas @ 100% Duty Cycle DCEN, ACHF

Cooling Method Water

Cooling Requirements 1.1 quart/minute (1.0 liter/minute)

Tungsten Size .020 Thru 5/32 in (0.5 Thru 4.0 mm)
Cable Options 12-1/2 ft (3.8 m) One-Piece High−Flex 25 ft (7.6 m) One-Piece High−Flex

Dimensions Length: 9 in (229 mm); Handle Diameter: 1−1/8 in (29 mm); Weight: 5.8 oz (165 g)

2-2. Duty Cycle

ENGLISH

0

Minutes

10

Definition

Duty Cycle is percentage of 10
minutes that torch can weld at
rated load without overheating.

100% Duty Cycle At 350 Amperes Using Argon Gas

Continuous Welding

EXCEEDING RATED AMPERAGE can damage torch and void warranty.

• Do not exceed rated amperage (see Section 2-1)

sb1.5* 8/93

OM-1603 Page 3

SECTION 3 − INSTALLATION

3-1. Required Torch Parts And Torch Assembly

7

12

11

10

16

Assembling T orch Parts

3

2

1

6

5

4

8

9

15

14

1 Cup
2 Collet Body
3 Heat Shield
4 Backcap Insulator
5 Collet
6 O-Ring
7 Backcap
8 Torch Body
9 Handle
10 Power Cable
11 Water Hose
12 Gas Hose
13 Power Cable Adapter
14 International Style Adapter
15 Water Hose For International

13

Style Adapter

Assembling Torch Body

Keep connections tight. Replace
cup, heat shield, and backcap as
needed.

16 Tungsten Electrode (See Sec-

tion 5)

Installing Tungsten

To adjust tungsten position, loosen
backcap.

3-2. International Style Connector Assembly

1

2

Tools Needed:

3

1 in

(26 mm)

5
4

3

Ref. 802 676

1 Weld Output Cable
2 Insulating Boot
3 Sleeve
Slide insulating boot onto cable;

strip cable and install sleeve.
4 Connector Body
5 Setscrew
Insert cable with sleeve fully into

connector body, tighten setscrew,
and slide insulating boot over con­nector.

ST-156 496

OM-1603 Page 4