Miller Electric MTL-20 Torches Specifications
Contents
1. December 1993 Form OM 1568B Effective With Style No KB 8 Q Miller OWNER S MANUAL MTL 20 Torches Water Cooled Torches For GTAW Welding Rated At 250 Amperes 100 Duty Cycle Using Argon Shielding Gas 020 Thru 5 32 in 0 5 Thru 4 0 mm Tungsten Size Capacity Includes 12 1 2 Or 25 ft 3 8 Or 7 6 m Cable Remote Contactor And Current Control Available Tungsten Electrode And Some Torch Parts Needed m Read and follow these instructions and all Give this manual to the operator safety blocks carefully m Have only trained and qualified persons install operate or service this unit For help call your distributor s or MILLER Electric Mfg Co P O Box 1079 Appleton WI 54912 414 734 9821 cover 7 93 ST 141 476 A 1993 MILLER Electric Mtg Co PRINTED IN USA m Call your distributor if you do not understand the directions MILLER S TRUE BLUE LIMITED WARRANTY Effective January 1 1992 Equipment with a serial number preface of KC or newer This limited 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 conditions below MILLER Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new MILLER equipment sold after the effective date of this limited warranty is free of de fects in material and2. 17 116269 18 116232 18 116233 19 118512 20 116236 21 116269 22 116228 23 116231 23 116230 OPTIONAL 5 includes Item 6 Le 29 21 23 ons mE SB 141 475 Figure 6 1 Complete Torch Assembly Model No Description Quantity Figure 6 1 Complete Torch Assembly DES wa etie TUNGSTEN electrode consult your welding supply distributor putas ud Aree CUP see Figure 6 2 diria COLLET BODY see Figure 6 2 FL3L SERIES HEAD consisting of 1 300HS HEAT SHIELD Sd an rie een nat 1 01 0009 HEAD ADJUSTMENT STEM consisting of 1 300R O RING 2 E 1 3GHS HEAT SHIELD small dia gas lens 1 3GHSLD HEAT SHIELD large gas lens 1 EE dd COLLET see Figure 6 2 300L BACKCAP long consisting 1 300M BACKCAP medium consisting of 1 300R O RING esee eer ER as 1 FLWB FLEX LOC TORCH BODY consisting of 1 01 0002 O RING curru Re e RERO ed Ae een 2 HANDLE ee 212 GAS HOSE 12 1 2 ft consisting of 1 225AH GAS HOSE 25ft consisting of 1 pm HOSE black 1 8 ID order by ft
3. As Req d 2AN GAS N T seo finer ee arent ak aca dex 1 3HF HOSE FITTING 5r fale nb ER dida Ween e 1 212WH WATER HOSE 12 1 2ft consisting of 1 225WH WATER HOSE 25ft consisting 1 beet dee HOSE black 1 8 ID order by ft As Req d 2WN SI WATERING dad me Bikes BAL ek D ex aba NS 1 s HOSE FITTING i 2 a iR ee C SER RR E 1 2PCA POWER CABLE ADAPTER 1 212PC POWER CABLE 12 1 2ft 1 225PC POWER CABLE 25ft 1 BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS OM 1568 Page 9 19105 904 ar 01661 606611 806 611 06 611 906611 S06 61 2510 811v 22519 9119 OID 0310b omm omn 98 3A BEE 398 3A ar BEI NL 35vsn 31V2IQNI SV3HY G30VHS 2 9 a1nbly E 9 35 e 8E MEILEN 09 GSE 91L BSE 911 LSE 911 956 9LL SSE 911 ON 4901S 0rgov 02902 ON I9poW seo 81vgot OIL 659 816 911 005 546 066 02 052 051 01 0 667 00 525 051 552 001 061 06 fan a 2 9 89 1 le Vt XXX 24 18109 as aray D XXX Dv
4. e Use plain distilled or deionized water or use high quality tap water In freezing temperatures use only a mix of pure ethylene glycol and distilled or deionized water such as MILLER coolant Part No 128 705 or equivalent DO NOT USE AUTOMOTIVE ANTIFREEZE Follow these guidelines to de crease corrosion in torch and cool ing system Material in contact with coolant can only be brass copper silver solder 300 Series stainless steel or plastic 1 Coolant See table for coolant mixture need ed for operating temperature 2 Coolant System Tank Keep coolant ievel full Length of coolant hoses affects amount of coolant needed in unit Changing Coolant Change coolant when dirty or every 6 months Below 0 F 18 C See Ethylene Glycol Manufacturer s Suggestion 4 Connections Keep connections tight Make elec trical connections with connectors of the same metal gt Tighten Connections 4 Figure 3 4 Coolant Guidelines OM 1568 Page 5 SECTION 4 MAINTENANCE amp TROUBLESHOOTING N READ SAFETY BLOCKS at beginning of manual before proceeding gt Replace Cracked Parts Y Torch Body Coolant Hose Also Keep Hose Clean Tighten Weld Terminals Replace Cracked 2 Weld Cable Gas Hose Torch Cable Figure 4 1 Maintenance Schedule Table 4 1 Troubleshooting Before using troubleshooting table
5. 116 335 3A10 10N45 116 310 2A4 13N08 116 336 3A12 10N44 116 311 2A5 13N09 119 926 3GL20 45V29 116312 246 13N10 119927 3GL40 45V24 116313 2A7 13N11 119 928 3GL116 45V25 116314 2A8 13N12 119 929 3GL332 45V26 116 315 2A10 13N13 119 930 3GL418 45V27 119 905 4GL20 N A 119 931 3GL532 45V28 119 906 4GL40 N A 119 917 3CG4 54N35 119 907 4GL116 N A 119918 3CG5 54N34 119 908 4GL332 N A 119919 3CG6 54N33 119 909 4GL418 N A 119 920 3CG7 54N32 119 910 4GL532 N A 119 921 3CG8 54N31 119 893 2AG4 53N58 119 922 3CG11 54N35 119 894 2AG5 53N59 119 923 3CG12 N A 119 895 2AG6 53N60 119 924 3CG14 N A 119 896 2AG7 53N61 OM 1568 Page 11 OPTIONS AND ACCESSORIES For TOTAL TIG system select one each of the following items welding power source TIG torch TIG kit see TIG kits listed below coolant system if using water cooled torch eremote control NOTE The other items necessary to weld are power source primary cable shielding gas and filler metal KIT FOR 250 AMP WATER COOLED TIG TORCH 12 1 2 ft 3 8 m length 129 594 25 ft 7 6 m length 129 593 Kit includes Hose amp hardware hook up kit THK 1 Consumable accessory kit TAK 2 one backcap and three sizes 1 16 in 3 32 in 1 8 in of collets collet bodies cups and 296 thoriated tungsten Regulator flowmeter HRF 2425 Ground cable with clamp clamp rated for 350 Amps 12 1 2 ft 3 8 m or 25 ft 7 6 m lengths to match TIG torch leng
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7. check selection and preparation of tungsten electrode according to Section 5 Check cables andtorch for cracks or bad connections Be sure that torch cables are not close to any grounded metal Repair or replace necessary parts Check welding power source high frequency control and if necessary check and adjust spark gaps Reduce gas flow rate according to welding power source Owner s Manual Tungsten electrode oxidizing and not remaining gt Shield weld zone from drafts Check and tighten all gas fittings bright after conclusion of weld Increase postflow time according to welding power source Owner s Manual Check gas valve Torch and or power cable coolant out hose Check cooling system operation Make sure coolant hoses are clear of obstruc overheats tions and are not pinched OM 1568 Page 6 SECTION 5 TUNGSTEN ELECTRODE mod2 1 3 93 For additional information see your distributor for a handbook on the Gas Tungsten Arc Welding GTAW process Wear clean gloves to prevent contamination of tungsten electrode 5 1 Selecting Tungsten Electrode Table 5 1 Tungsten Size Amperage Range Gas Types Polarity Electrode Diameter DC Argon Electrode DC Argon Electrode AC Argon Using AC Argon Balanced Negative Straight Polarity Positive Reverse Polarity High Frequency Wave Using High Freq Pure Tungsten Green Band 010 Up to 15 Up to 15 Up to 10 020 5
8. 20 5 20 10 20 040 15 80 10 60 20 30 1116 70 150 50 100 30 80 3 32 125 225 100 160 60 130 1 8 225 360 150 210 100 180 5 32 360 450 200 275 160 240 3 16 450 720 250 350 190 300 1 4 720 950 325 450 250 400 010 Up to 25 020 15 40 040 25 85 1 16 50 160 3 32 135 235 1 8 250 400 5 32 400 500 300 450 200 320 3 16 500 750 400 500 290 390 1 4 750 1000 600 800 340 525 Zirconium Alloyed Tungsten Brown Band 010 Up to 20 Up to 15 020 15 35 5 20 040 20 80 20 60 1116 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 4 Typical argon shielding gas flow rates are 15 to 35 cfh cubic feet per hour Not Recommended The figures listed are intended as a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers S 0009 Up to 20 15 35 20 80 50 150 130 250 225 360 Up to 15 5 20 20 60 60 120 100 180 160 250 OM 1568 Page 7 5 2 Preparing Tungsten 1 Tungsten Electrode 2 Balled End Ball endoftungsten before welding by applying either an ac amperage 1 1 2 Times slightly higher than what is recom mendedf ora given electrode diam eter see Table 5 1 or a dc elec trode positive ampe
9. Blue tor tne remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 6 Months Batteries 90 Days Parts and Labor E MIG Guns TIG Torches Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts MILLER S True Blue IM Limited Warranty shall not apply to 1 Items furnished by MILLER bul manufactured by others such as engines or trade accessories These items are covered by the manutacturer s warranty if any Consumable components such as contact tips cutting nozzles contactors and relays or parts that fail due to normal wear Equipment that has been modified by any party other than MILLER or equip ment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used lor operation outside of the specifications for the equipment MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER CIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at MILLER S option 1 repair or 2 replacement or where authorized in writing by MILLER in appropriate cases 3 the reasonable cost of repair or replace mentatan authorized MILLER service station or 4 payment of
10. SCFH with argon gas TIG ACCESSORY KITS TAK Accessory kits include one backcap and three each of the following collet collet body alumina cup and 296 throriated tungsten pieces TIG TORCH CABLE COVERS Reinforced plastic cable covers made of tear and flame resistant material A large and small cover is available in length to fit 12 1 2 ft and 25 ft 3 8 and 7 6 m torches CC 12S 126 150 For 12 1 2 ft 3 8 m torches CC 25S 4126 151 For 25 ft 7 6 m torches 8 90
11. with 14 pin plug for direct connection to all Miller solid state TIG power sources RFTC H14 S 129 332 Note Cannot be used on torches with manual gas valve For field installa tion only replaces standard torch hanale FTC 14 REMOTE CONTACTOR AND CURRENT CONTROL 129 338 Fastens to TIG torch handle Includes 28 ft 8 5 m cord and 14 pin plug RMC H14 AND RLC H14 CONTACTOR SWITCHES Torch handles with a built in switch for remote contactor control of Miller solid state TIG power sources Includes 25 ft 7 6 m contro cord with 14 pin Amphenol plug RMC H14 S Momentary 129 336 RLC H14 S Locking 129 335 Note Cannot be used on torch with manual gas valve For field installa tion only replaces standard torch handle TIG HOSE HOOK UP KITS THK THK 1 128 065 Provides the necessary hoses and hardware to connect water cooled torches to apower source and water coolant system 8 90 OPTIONS AND ACCESSORIES GAS REGULATORS HRF 2425 127 661 The HRF 2425 regulator flowmeter is designed for MIG TIG and other inert gas welding applications It includes the 580 CGA connector The outlet pressure is preset at 25 PSIG the maximum inlet is 3000 PSIG and has 5 40 SCFH gas delivery AF 150 127 662 The AF 150 is a flowgauge regulator which includes the 580 CGA inlet connector for use with argon and argon CO gases The AF 150 is ad justable for gas delivery of 8 25
12. To Competitive Model COMPETITIVE COMPETITIVE STOCK NO MODEL NO NO STOCK NO MODEL NO NO 116 367 3C20 10N21 119 925 3CG16 N A 116 368 3040 10N22 119 932 3AG4 54N18 116 369 30116 10N23 119 933 3AG5 54N17 116 370 3C332 10N24 119 934 3AG6 54N16 116 371 3C418 10N25 119 935 3AG7 54N15 116 372 3C532 54N20 119 936 3AG8 54N14 116 379 7C20 N A 119 937 3AG11 54N19 116 380 7040 N A 119 902 3GLL332 45V64 116 381 70116 N A 119 903 3GLL418 995795 116 382 70332 N A 119 904 3GLL532 45V63 116 383 70418 N A 119 911 3AG8LD 57N74 116 384 70532 N A 119912 53N88 116 361 3CB20 10N29 119913 3AG12LD 53N87 116 362 3CB40 10N30 116 373 4620 116 363 3CB116 10N31 116 374 4040 10N22S 116 364 3CB332 10N32 116 375 40116 10N23S 116 365 3CB418 10N28 116 376 40332 10N24S 116 366 3CB532 406488 116 377 4C418 10N25S 116 347 3C3 N A 116 378 4C532 N A 116 348 3C4 105743 116 355 4CB20 N A 116 349 3C5 105242 116 356 4CB40 17CB20 116 350 3C6 105244 116 357 4CB116 17CB20 116 351 3C7 105245 116 358 4CB332 17CB20 116 352 3C8 08N78 116 359 4CB418 17CB20 116 353 3C10 08N79 116 360 4CB532 N A 116 354 3C12 08N80 116 337 2C4 13N14 116 343 3C4L 12N03 116 338 2C5 13N15 116 344 3C5L 105760 116 339 2C6 13N16 116 345 3C6L 12N02 116 340 207 13N17 116 346 3C7L 105Z61 116 341 208 13N18 116 330 3A4 10N50 116 342 2C10 13N19 116 331 3A5 10N49 116 326 2C3L 796F70 116 332 3A6 10N48 116 327 2C4L 796F71 116 333 3A7 10N47 116 328 2C5L 796F72 116 334 3A8 10N46 116 329 2C6L 796F73
13. To adjust tungsten position loosen backcap Keep connections tight Replace cup heat shield backcap and O rings if cracked Installing Tungsten Loosen Distance Tungsten Diameter Ret ST 800 454 Figure 3 1 Required Torch Parts And Torch Assembly OM 1568 Page 2 3 2 Adjusting Flex Lok Head CAUTION A A TOOLS can damage torch e Do not use hand tools to adjust torch flex lok head 1 Stem 2 Head Hold stem and turn head one full turn Turn head and stem to desired angle Hold stem and turn head until tight Ret ST 141 477 B Figure 3 2 Adjusting Flex Lok Head OM 1568 Page 3 3 3 Connecting Torch READ SAFETY BLOCKS at beginning of manual before proceeding BUILDUP OF SHIELDING GAS can harm health or kill e Shut off shielding gas supply when not in use warn1 1 9 91 Turn Off welding power source and disconnect input power before installing torch If applicable install high frequency unit Obtain the following hoses 1 Gas Hose With 5 8 18 Right Hand Fittings 2 Coolant Hose With 5 8 18 3 Left Hand Fitting Connections 7 5 1 3 Regulator Flowmeter 4 Gas Cylinder 4 5 Welding Power Source 6 Gas In Hose 7 Gas Valve Valve controls gas preflow and postflow Preflow aids arc starting Preflow and postflow prevent elec trode from forming a black surface oxidizing After welding allow 10 seconds of gas postflow for every 100 a
14. as DCEN ACHF Cooling Method Water Cooling Coolant Flow Rate 1 qt min 0 94 L min Tungsten Size Capacity 020 Thru 5 32 in 0 5 Thru 4 0 mm Torch Body Dimensions And Weight Length 9 1 2 in 241 mm Handle Diameter 3 4 in 19 mm Weight 5 oz 140 g Options And Accessories See Rear Cover 12 1 2 ft 3 8 m Cable 25 ft 7 6 m Cable Total Weight Net 2 Ib 0 9 kg Ship 2 Ib 0 9 kg Net 3 Ib 1 4 kg Ship 3 Ib 1 4 kg OM 1568 Page 1 2 1 Duty Cycle WELDING LONGER THAN RATED DUTY CYCLE can damage torch and void warranty Do not weld at rated load longer than shown below wtwarn8 1 8 93 100 Duty Cycle At 250 Amperes Using Argon Gas Definition Duty Cycle is percentage of 10 minutes that torch can weld at rated load without overheating Minutes Continuous Welding sb1 5 8 93 Figure 2 1 Duty Cycle SECTION 3 INSTALLATION 8 OPERATION 3 1 Required Torch Parts And Torch Assembly Required Torch Parts Obtain the following parts see Section 6 4 1 Tungsten Electrode See yo Section 5 Cup Collet Body Standard Collet 5 Reverse Collet Reverse collet improves electrical contact of tungsten electrode 6 Power Cable Adapter Assembling Torch Body 7 Flex Lok Head 8 Heat Shield 9 Long Backcap Shown 10 O Ring Installing Tungsten Q 2 gt ae 5 Bn 3 e 4 Assembling Torch Parts
15. ble but may vary from state to state in Canada legislation in some provinces provides tor certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal nghts and other rights may be available but may vary from province to province RECEIVING HANDLING Before unpacking equipment check carton for any damage that may have occurred during shipment File any claims for loss or damage with the delivering carrier Assistance for filing or settling claims may be obtained from distributor and or equipment manufacturer s Transportation Department When requesting information about this equipment always provide Model Designation and Serial or Style Number Use the following spaces to record Model Designation and Serial or Style Number of your unit The information is located on the rating label or nameplate Model Serial or Style No Date of Purchase miller 9 93 SAFETY PRECAUTIONS FOR GTAW TORCHES WARNING 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 informatio
16. m peres of weld current 8 Coolant In Hose 9 Power Cable Coolant Out Hose 10 Power Cable Adapter 14 Connect hoses to adapter before connecting adapter to weld output terminal 2 12 11 Cooling System 10 Mix coolant according to cooling a system owner s manual Torch is rated at 1 qumin 0 94L 2 min coolant flow rate Maintain proper flow rate at all times 12 Input Power Plug 13 Grounded AC Receptacle 13 Connect plug to proper receptacle 8 14 Work Clamp Connect work clamp to a clean paint free location on workpiece as close to weld area as possible Use wire brush or sandpaper to clean metal at weld joint area Tools Needed LTS I 588 7 8 in Ret ST 800 454 Figure 3 3 Connecting Torch OM 1568 Page 4 3 4 Coolant Guidelines WARNING ELECTRIC SHOCK can kill MOVING PARTS can cause serious injury e Do not touch live electrical parts Keep away from moving parts e Disconnect input power plug from receptacie before cleaning system components FAILURE TO PROPERLY MAINTAIN COOLANT SYSTEM can cause damage to the coolant system and torch gun e Circulate and flush clear water through entire system and replace coolant every six months Above 32 F 0 C 0 F 18 C to 32 0 C Distilled Deionized Or High Quality Tap Water 35 Ethylene Glycol And Coolant 65 Water Draining Filing INCORRECT COOLANT will damage torch and cooling system
17. n 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 ELECTRIC SHOCK can kill WELDING can cause fire or explosion 1 Always wear dry insulating gloves 1 Do not weld near flammable material 2 Insulate yourself from work and ground 2 Do not weld on closed containers 3 Do not touch live electrode or electrical parts 3 Watch for fire keep extinguisher nearby 4 Repair or replace worn damaged or cracked An HOT SURFACES can burn skin Turn off welding power source before changing tungsten electrode or torch parts 1 Allow torch to cool before touching Keep all covers and handle securely in place 2 Donottouch hot metal 7 3 Protect hot metal from contact by others ARC RAYS can burn eyes and skin 1 Wear welding helmet with correct shade of filter NOISE damage hearing SOME 2 Wear correct eye and body protection APPLICATIONS SUCH AS PULSING are noisy FUMES AND GASES can be hazardous Check for noise level limits exceeding those to your health specified by OSHA 1 Keep your head out of the fumes Use approved ear plugs or ear muffs if noise 2 Ventilate area or use breathing device level is high 3 ReadMaterial Safety Data Sheets MSDSs and Warn others nearby about noise hazard manufacturer s instructions for material used Consideratio
18. ns About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section To reduce magnetic fields in the workplace use the following of the U S Congress Office of Technology Assessment Biological procedures Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is now a very 2 Arrange cables to one side and away from the operator large volume of scientific findings based on experiments at the 3 Do not coil or drape cables around the body 4 1 Keep cables close together by twisting or taping them 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 is of very high quality the results are complex Current scientific Connect work clamp to workpiece as close to the weld as understanding does not yet allow us to interpret the evidence in a possible single coherent framework Even more frustrating it does not yet About Pacemakers allow us to draw definite conclusions about questions of possible The above procedures are among those also normally risk or to offer clear science based advice on strategies to minimize recommended for pacemaker wearers Consult your doctor for or avoid potential risks complete inf
19. or credit for the pur chase price less reasonable depreciation based upon actual use upon return ofthe goods at customer s risk and expense MILLER S option of repair or replacement willbeF OB Factory at Appleton Wisconsin or F O B ata MILLER authorized ser vice facility as determined by MILLER Therefore no compensation or reimburse ment for transportation costs of any kind will be allowed TO THE EXTENT PERMITTEO BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CON TRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR RANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING IN CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER Some states in the U S do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides spe Cific legal rights and other rights may be availa
20. ormation Keep welding power source and cables as far away as practical mod10 1 4 93 sr6 7 93 SECTION 1 SAFETY INFORMATION mod1 1 2 93 W Read all safety messages throughout this manual B Obey all safety messages to avoid injury W Learn the meaning of WARNING and CAUTION 1 Safety Alert Symbol 2 Signal Word WARNING means possible death or serious injury can happen CAUTION means possible minor Keep away from moving parts injury or equipment damage can Do not touch live electrical parts 9 Disconnect input power before 4 Keep all panels and covers closed happen installing or servicing when operating 3 Statement Of Hazard And Result 5 4 Safety Instructions To Avoid Hazard 5 Hazard Symbol If Available amp WARNING J e READ SAFETY BLOCKS at start of 6 Safety Banner We Section 3 1 before proceeding Read safety blocks for each sym bol shown 7 7 Er Turn Off switch when using high frequency Special instructions for best oper ation not related to safety Figure 1 1 Safety Information SECTION 2 SPECIFICATIONS Table 2 1 Welding Torch Model Description MT Miller Torch L Flex Lok 20 250 Ampere Rating 12 12 1 2 ft 3 8 m Cable 25 25 ft 7 6 m Cable Example MTL 20 12 Miller Torch Flex Lok 250 Ampere Rating 12 1 2 ft 3 8 m Cable Ampere Rating At 10096 Duty Cycle 250 Amperes Using Argon G
21. rage Electrode Diameter Ref S 0161 Figure 5 1 Preparing Tungsten For AC Or DC Electrode Positive DCEP Welding a CAUTION FLYING SPARKS AND HOT METAL can cause injury and start fires e Shapetungstenelectrode only on grinder with proper guards in a safe location wearing proper face hand and body protection O Keep flammables away warn2 1 9 91 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit hard abrasive wheel before weld ing Do not use wheel for other jobs or tungsten can become contami MEER nated causing lower weld quality 2 1 2 Times Electrode Diameter Ref S 0161 1 Stable Arc 2 Flat Diameter of this flat determines amperage capacity 3 Grinding Wheel 4 Straight Ground Ideal Tungsten Preparation Stable Arc Ret S 0162 1 p IN o 4 Wrong Tungsten Preparation Wandering Arc Arc Wander Point Grinding Wheel Radial Ground Ref S 0162 Figure 5 2 Preparing Tungsten For DC Electrode Negative DCEN Welding OM 1568 Page 8 SECTION 6 PARTS LIST Item Stock No No 1 2 3 4 118526 5 116256 6 116203 7 116260 5 119914 5 e 119915 o 9 116257 9 0116258 10 116260 11 116204 12 116217 18 117585 14 116267 14 116268 15 116512 16 116266
22. th Power cable adapter NOTE Optional fuse block assembly is recommended for water cooled torches POWER CABLE ADAPTERS Required on torches with one piece high flex cable assembly and all water cooled torches at Stock No 4116 228 INTERNATIONAL TIG TORCH CONNECTOR KIT 250 350 Amp Torch 135 495 For direct connection of one piece torches or water cooled TIG torches into power sources with International style connectors Adapter 45V11 FUSE BLOCK ASSEMBLY For use with water cooled torches Five fuse links included Up to 260 Amps 116 163 260 to 550 Amps 116 164 Protects torch from overheating and damage if water is not circulating or if torch is run considerably higher than its rated capacity CABLE EXTENSION BOX For use with water cooled torches CEB non fused 4120 797 CEB 260FA 116 161 Fused up to 260 Amps CEB 550FA 4116 162 260 to 550 Amps Designed to allow a water cooled torch hose and cable assembly to be extended from the power source Available with or without fuse protec tion All components are protected by a strong non conductive enclo sure Note Hose and cables from power source to CEB box are not supplied Use large diameter extension hoses and heavy welding cable for optimum performance RFTC H14 AMPERAGE AND CONTACTOR CONTROLS Torch handle with built in contactor and amperage control Includes 25 ft 7 6 m control cord
23. tt ei sud SE save 666 611 eunumiy dng CESEN BEE A CEDEN 959 616 611 8 1 1 1 PIS 191020 sue SEE CESTDE BLPTDE 266196 91119 07196 OSIDE ONIePONWN owen BA 28 22 1 OYE cee out dno oce 911 oen 190 Sve CC 150 911 Woe Eve 911 2106 5 911 1 ESE 911 896 266 911 298 LSE 9 90 OSE 911 96 6 911 sien did 911 EOE vE 911 ON IBPOWPIIOIS 99 911 soe 911 vos 911 escort zac 911 19 911 Ton 19015 ZESAIE 81 255958 91199 07 06855 UBT pis pog lero 2 4 dns vec 9 escort ege oui tee gr 08 911 6 5 ou ZEGOL 8194 26594 91127 oraz 0224 191109 246911 t 9H OZE 911 69E 896911 zoe 911 19015 65596 BPE zegos 9110e 0225 ON rapow 005 646 051 04 08 61 051 05 08 01 Ser 002 555 061 GEIS Bil Vi OO 030 ul 5 18109 abejedwy eYdepa 21989 1amod e asinba osje 94540 1 ojqe2 ajysoduioo M SIYO y210 pasynbaz dng pue pog 19109 31109 NON OM 1568 Page 10 Table 6 1 Cross Reference
24. workmanship at the time its shipped by MILLERA THIS RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT NESS Within the warranty periods listed below MILLER will repair or replace any war ranted parts or components that fail due to such defects n material or workmanship MILLER must be notified in writing within thirty 30 days of such defect or failure al which time MILLER will provide instructions on the warranty claim procedures to be followed MILLER shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to the distributor 1 5 Years Parts 3 Years Labor Onginal main power rectifiers 3 Years Parts and Labor Transtormer Rectitier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Robots 2 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer lor a period of two years Air Compressors Year Parts and Labor Motor Driven Guns Process Controllers Water Coolant Systems HF Units Grids Spot Welders Load Banks SOX Transformers Running Gear Trailers Field Options NOTE Field options are covered under True
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