Miller WP-125 MICRO SERIES TORCHES Le manuel du propriétaire
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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, and our extensive service
network is there to help fix the problem. Warranty and maintenance
information for your particular model are also provided.
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.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Milan_Thank
2020−01
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. California Proposition 65 Warnings 2.......................................................
1-4. Principal Safety Standards 2.............................................................
1-5. EMF Information 2......................................................................
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 3............................
2-1. Signification des symboles 3.............................................................
2-2. Dangers relatifs au soudage à l’arc 3......................................................
2-3. Proposition californienne 65 Avertissements 4...............................................
2-4. Principales normes de sécurité 4..........................................................
2-5. Informations relatives aux CEM 4.........................................................
SECTION 3 − SPECIFICATIONS 5................................................................
3-1. Specifications 5........................................................................
3-2. Duty Cycle 5...........................................................................
SECTION 4 − INSTALLATION 6..................................................................
4-1. Required Torch Parts And Torch Assembly 6................................................
4-2. Connecting Torch 7.....................................................................
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 9...........................................
5-1. Routine Maintenance 9..................................................................
5-2. T
roubleshooting
9......................................................................
SECTION 6 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING
WITH INVERTER MACHINES 11.....................................................
6-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 11.......
6-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines 12...................................................
SECTION 7 − GUIDELINES FOR TIG WELDING (GTAW) 13..........................................
7-1. Positioning The Torch 13..................................................................
7-2. Torch Movement During Welding 14........................................................
7-3. Positioning Torch Tungsten For Various Weld Joints 14........................................
SECTION 8 − PARTS LIST 15.....................................................................
WARRANTY
OM-266276 Page 1
SECTION 1 −SAFETY PRECAUTIONS FOR GTAW
TORCHES − READ BEFORE USING
SR6 (TIG) 2020-02
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 ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid
these hazards.
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 Principal Safety Standards listed in Section 1-4,
and in welding power source Owner’s Manual. Read and fol-
low 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, train-
ing and experience, has successfully demonstrated the abili-
ty 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.
Always wear dry insulating gloves.
Insulate yourself from work and ground.
Do not touch live electrode or electrical parts.
Before welding, verify torch head is firmly attached to the torch
body.
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.
Replace worn, damaged, or cracked torches or cables.
Turn off welding power source before changing tungsten elec-
trode or torch parts.
Keep all covers and handle securely in place.
ELECTRIC SHOCK can kill.
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.
ARC RAYS can burn eyes and skin.
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).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
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.
FUMES AND GASES can be hazardous.
Keep your head out of the fumes.
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.
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.
Shut off compressed gas supply when not in
use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
WELDING can cause fire or explosion.
Do not weld near flammable material.
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 ac-
cording to AWS F4.1 and AWS A6.0 (see Safety Standards).
Watch for fire; keep extinguisher nearby.
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.
Allow torch to cool before touching.
Do not touch hot metal.
Protect hot metal from contact by others.
NOISE can damage hearing.
Check for noise level limits exceeding those spe-
cified by OSHA.
Use approved ear plugs or ear muffs if noise level
is high.
Warn others nearby about noise hazard.
OM-266276 Page 2
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.
READ INSTRUCTIONS.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and loc-
al codes.
1-3. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals in-
cluding 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.P65W
arnings.ca.gov
.
1-4. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1 from American National Standards Institute.
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. Website: www
.global.ihs.com.
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0 from Global
Engineering Documents. Website: www.global.ihs.com.
National Electrical Code, NFPA Standard 70 from National Fire Protection
Association. Website: www.nfpa.org and www. sparky.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association. Website:www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association.
Website: www.csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
1-5. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF).The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and induc-
tion 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 pro-
cedures 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.
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 recom-
mended.
OM-266276 Page 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
SR6(TIG)_2020-02_fre
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Reportez−vous aux symboles et aux directives
ci−dessous afin de connaître les mesures à prendre pour éviter tout
danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez vigilant
et suivez les directives mentionnées afin d’éviter tout danger.
Les consignes de sécurité présentées ci−après ne font que rés-
umer les informations contenues dans les principales normes
de sécurité énumérées à la section 2-4 et manuel d’utilisation
du poste de soudage. Veuillez lire et respecter toutes ces
normes de sécurité.
L
’installation,
l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une per-
sonne qualifiée est définie comme celle qui, par la posses-
sion d’un diplôme reconnu, d’un certificat ou d’un statut pro-
fessionnel, ou qui, par une connaissance, une formation et
une expérience approfondies, a démontré avec succès sa ca-
pacité à résoudre les problèmes liés à la tâche, le travail ou
le projet et a reçu une formation en sécurité afin de recon-
naître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Porter toujours des gants secs et isolants.
S’isoler de la pièce et de la terre.
Ne jamais toucher une électrode ou des pièces
électriques
sous tension.
Avant de souder, vérifier que la tête de torche est solidement fixée
au corps de la torche.
Ne pas regrouper les flexibles de torche refroidis par eau- et les
câbles d’alimentation à l’aide de ruban adhésif ou d'attaches en
plastique, cela restreint l'écoulement de l’eau, ce qui peut causer
une surchauffe du câble d’alimentation et un éclatement des
flexibles de torche.
Remplacer une torche qui est usée, endommagée ou craquée.
Mettre la soudeuse hors tension avant de remplacer un électrode
de tungstène ou des pièces de torche.
S’assurer que tous les couvercles et poignées sont fermement
assujettis.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans
les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LES VAPEURS ET LES FUMÉES
peuvent être nocives.
Éloigner sa tête des endroits renfermant des
vapeurs.
Aérer la zone de travail ou porter un appareil respiratoire. Pour
déterminer
la bonne ventilation, il est recommandé de procéder à
un prélèvement pour la composition et la quantité de fumées et de
gaz auxquels est exposé le personnel.
Lire et comprendre les fiches de données de sécurité et les
instructions du fabricant concernant les adhésifs, les revête-
ments, les nettoyants, les consommables, les produits de ref-
roidissement, les dégraisseurs, les flux et les métaux.
L’ACCUMULATION DE VAPEURS
peut causer des lésions ou la mort.
Après utilisation, fermer l’alimentation de gaz
sous pression.
Assurer toujours la ventilation des zones fer-
mées ou utiliser un appareil respiratoire avec
alimentation
en air.
OM-266276 Page 4
LE SOUDAGE peut causer un
incendie ou une explosion.
Ne pas souder à proximité de matériaux inflam-
mables.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
Lire et comprendre les fiches de données de sécurité et les
instructions du fabricant concernant les adhésifs, les
revêtements,
les nettoyants, les consommables, les produits de
refroidissement, les dégraisseurs, les flux et les métaux.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Laisser refroidir la torche avant de le toucher.
Ne pas toucher d’objets métalliques chauds.
Abriter les objets métalliques contre tout
contact par les personnes à proximité.
Le BRUIT peut endommager l’ouïe.
Vérifier si les niveaux de bruit excèdent les li-
mites spécifiées par l’OSHA.
Utiliser des bouche-oreilles ou des serre-tête
antibruit approuvés si le niveau de bruit est
élevé.
Avertir les personnes à proximité au sujet du danger inhérent au bruit.
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes
et le Mode d’emploi avant
l’installation,
l’utilisation ou l’entretien de
l’appareil.
Lire les informations de sécurité au
début du manuel et dans chaque section.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie,
ainsi que les codes municipaux.
2-3. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des pro-
duits chimiques tels que le plomb, reconnus par l’État de Ca-
lifornie comme cancérigènes et sources de malformations ou
d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65W
arnings.ca.gov
.
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1 from American National Standards Institute.
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. Website: www
.global.ihs.com.
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0 from Global
Engineering Documents. Website: www.global.ihs.com.
National Electrical Code, NFPA Standard 70 from National Fire Protection
Association. Website: www.nfpa.org and www. sparky.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association. Website:www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association.
Website: www.csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques
(CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants
médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1 Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2 Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3 Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4 Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5 Connecter la pince sur la pièce aussi près que possible de la
soudure.
6 Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7 Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par
induction. Si le médecin approuve, il est recommandé de suivre les pro-
cédures précédentes.
OM-266276 Page 5
SECTION 3 − SPECIFICATIONS
3-1. Specifications
Model
W-125L (WP-125L) W-125M (WP-125M)
Amperage Rating 125 Amps W/Argon Gas At 100% Duty Cycle DCEN; 80 Amps W/Argon Gas At 100%duty Cycle ACHF
Combining Quartz Nozzles And 3/32 In. Chucks Increases Rating To 160 Amps w/Argon Gas At 100% Duty Cycle
DCEN
Cooling Method Liquid Cooled
Cooling
Requirements
0.31 L/min (.33 qt/min or .083 gal/min)
Tungsten Size .040 Thru 3/32 In. (1.0 Thru 2.4 mm)
Cable Options 12.5 ft (3.8 m) or 25 ft (7.6 m) Three-Piece Tri-Flex
12.5 ft (3.8 m) or 25 ft (7.6 m) Three-Piece Vinyl
Dimensions Length: 7 in. (178 mm);
Handle Diameter: .76 in. (19 mm)
Weight: 3.05 oz (87 g)
Length: 8.25 In. (210 mm);
Handle Diameter: .76 In. (19 mm)
Weight: 3.35 oz (95 g)
3-2. Duty Cycle
Continuous Welding
sb1.5* 8/93
Duty Cycle is percentage of 10
minutes that torch can weld at
rated load without overheating.
0
10
Minutes
Definition
100% Duty Cycle At 125 Amperes Using Argon Gas w/DCEN
NOTICE − Do not exceed rated amperage or duty cycle (see Section 3-1). Exceeding
rated amperage or duty cycle can damage torch and void warranty.
OM-266276 Page 6
SECTION 4 − INSTALLATION
4-1. Required Torch Parts And Torch Assembly
WC0226-B
10
Assembling Torch Parts
1 Cup
2 Chuck
3 Torch Body
4 Handle
5 Water Hose
6 Gas Hose
7 Power Cable
8 Power Cable Adapter
9 International Style Adapter
10 Water Hose For International
Style Adapter
Assembling Torch
Keep connections tight. Replace cup,
heat shield, and backcap as needed.
11 Tungsten Electrode (see Section
6-1)
Installing Tungsten
• Prepare tungsten electrode (see
Section 6-2)
• Cut tungsten to desired length
• Insert electrode into chuck
• Install glass/quartz nozzle
• Turn tungsten clockwise to tighten
(use 53N20 chuck wrench with 180°
chucks)
• Adjust nozzle to center electrode
1
2
3
4
5
7
6
8
9
11
OM-266276 Page 7
4-2. Connecting Torch
A. Connecting Torch To A PipeWorx With A PipeWorx Cooler
802 560-A
If applicable, install high-frequency unit.
Tools Needed:
11/16 in.
5
1
3
11
! Turn Off welding power source
power before installing torch..
1 Welding Power Source
2 Gas Hose
3 TIG Block (Customer Supplied)
4 Coolant In Hose 237 416 (Short
Red Hose Supplied With Cooler)
5 TIG (−) Weld Cable/Coolant In
6 Coolant Out Hose
7 Work (+) Weld Cable
8 TIG Torch
9 Foot Control (Optional)
10 Workpiece
11 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
close to the weld.
Use wire brush or sandpaper to clean
weld joint area.
12 Volt Sense Lead
Attach volt sense lead to work
clamp and attach work clamp as
close to arc as possible.
2
4
6
7
10
8
9
12
OM-266276 Page 8
B. Connecting Torch To A Dynastyt 200 Or Maxstar 200 TIGRunnert Unit
803 311-A
! Turn Off welding power source
and cooling system power be-
fore installing torch.
1 Gas Hose With 5/8-18 Right-Hand
Fittings (Customer Supplied)
Connections:
2
Regulator/Flowmeter
3 Gas Cylinder
4 Coolant System
5 Torch
6 Coolant-Into Torch Hose (Blue)
7 Torch Gas Hose
8 Coolant-Out Of Torch/Power
Cable (Red)
9 International Style Adapter
Connect coolant-out of torch/power
cable to power cable adapter, and con-
nect adapter to weld output terminal.
10 Work Clamp
Connect work clamp to a clean, paint-
free location on workpiece, close to the
weld.
Use wire brush or sandpaper to clean
weld joint area.
11 Welding Power Source
12 Foot Control
Tools Needed:
5/8, 7/8, 1-1/8 in.
2
3
1
10
5
6
8
11
4
7
9
12
C. Connecting Torch To A Syncrowave 250 DX Or 350 LX TIGRunner Unit
804 994-C
! Turn Off welding power source
power before installing torch.
1 Gas Hose With 5/8-18 Right-Hand
Fittings (Customer Supplied)
Connections:
2 Gas Cylinder
3
Regulator/Flowmeter
4 Power Source
5 Coolant System
6 Torch
7 Coolant-Into Torch Hose (Blue)
8 Coolant-Out Of Torch/Power Cable
(Red)
Connect torch coolant-out of torch/power
cable to power cable adapter, and connect
adapter to weld output terminal.
9 Torch Gas Hose
10 Work Clamp
Connect work clamp to a clean, paint-free
location on workpiece, close to the weld.
Use wire brush or sandpaper to clean weld
joint area.
11 Foot Control
Tools Needed:
11/16 in.
4
1
3
6
11
8
10
9
7
2
5
OM-266276 Page 9
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
! Disconnect torch before maintaining.
= Check = Change = Clean = Replace
* To be done by Factory Authorized Service Agent
Daily
Nozzle For Cracks − If Necessary
Check Tungsten Preparation (See Section 6-1)
Weekly
Collet For Wear −
If Necessary
Collet Body Threads −
If Necessary
Gas Lens Screen −
If Necessary
Gas Valve, If Applicable −
If Necessary
Monthly
Power Cable For Cracks,
Wear − If Necessary
Gas Hose For
Cracks, Leaks, Wear −
If Necessary
Water Hose, If Applic-
able, For Cracks, Leaks,
Wear − If Necessary
*
Back Cap O-Ring −
If Necessary
Power, Gas, And Water
Cable Connections To En-
sure They Are Tight
Cable Cover For
Tears, Holes, Or Wear −
If Necessary
When using a water-cooled torch, maintain cooling equipment according to the manufactures recommendations.
*
5-2. Troubleshooting
Before using troubleshooting table, check selection and preparation of tungsten electrode according to Section 6-1.
Trouble Remedy
Arc will not start. High frequency present
and visible at the torch.
Check cable and work connections. Be sure weld circuit is complete (see Section 4-2).
Check and be sure shielding gas is present.
Lack of high frequency; difficulty in es-
tablishing arc.
Select proper size and type tungsten. Properly prepare tungsten according to Section 6-1.
Check cables and torch for cracks or bad connections. Be sure that torch cables are not close to any
grounded metal. Repair or replace necessary parts.
Check torch consumables. Be sure collet and collet body are correctly installed and tightened (see Sec-
tion 4-1).
Check welding power source High Frequency control, and if necessary, check and adjust spark gaps.
Torch gas valve not working properly (if
applicable).
Have Factory Authorized Service Station/Service Distributor check valve.
No shielding gas flow from torch. Be sure valves on gas supply are open.
Check cable for kinks, blockage, or leaks.
Check and tighten all gas supply fittings.
Check cables and torch for cracked insulation or bad connections. Repair or replace (see Section 5-1).
Tighten collet body or gas lens before tightening backcap.
Tungsten electrode oxidizing and not re-
maining bright after conclusion of weld.
Shield weld zone from drafts.
Increase postflow time.
Increase gas flow rate. Check manufacture’s recommendations.
Check and tighten all gas fittings.
Check gas valve and flow meter/regulator.
Select proper size and type tungsten. Properly prepare tungsten (see Section 6-1).
OM-266276 Page 10
Trouble Remedy
Excessive tungsten electrode con-
sumption.
Select proper size and type tungsten. Properly prepare tungsten according to Section 6-1.
Check polarity setting on welding power source (see welding power source Owner’s manual).
Check for proper gas flow rate. Check manufacture’s recommendations.
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Sec-
tion 5-1).
Wandering arc Shield weld zone from drafts.
Reduce gas flow rate.
Select proper size and type tungsten. Properly prepare tungsten according to Section 6-1.
When using AC, check welding power source High Frequency control setting, and increase setting if nec-
essary.
Yellow powder or smoke on cup. Use proper type shielding gas.
Check for proper gas flow rate. Check manufacture’s recommendations.
Increase postflow time.
Check torch cup size. Match cup size to joint being welded.
Erratic arc When using DC, check polarity, and/or polarity of welding cables.
When using AC, check welding power source High Frequency control setting, and be sure it is operating
continuously.
Select proper size and type tungsten. Properly prepare tungsten according to Section.
Use proper arc length. Arc length may be too long or too short.
Make sure base material is clean and free of contaminates.
When using AC, slow travel speed can cause erratic arc. Adjust travel speed.
Porosity in weld. Check for proper gas flow rate. Check manufacture’s recommendations.
Check and tighten gas fittings.
Make sure base material and filler material is clean and free of contaminates.
Check for impurities and moisture in gas lines. Purge if necessary.
If torch is water cooled, check torch and cables for water leaks. Repair or replace if necessary (see Sec-
tion 5-1).
Notes
OM-226276 Page 11
SECTION 6 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2018-01
Whenever possible and practical, use DC weld output instead of AC weld output.
6-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)
A. Select Tungsten Electrode.
Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter (DCEN) − Argon
Direct Current Electrode Negative
(For Use With Mild Or Stainless Steel)
AC − Argon
Unbalanced Wave
(For Use With Aluminum)
2% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (.25 mm) Up to 15 Up to 15
.020 in. (.50 mm) 5-20 5-20
.040 in. (1 mm) 15-80 15-80
1/16 in. (1.6 mm) 70-150 70-150
3/32 in. (2.4 mm) 150-250 140-235
1/8 in. (3.2 mm) 250-400 225-325
5/32 in. (4.0 mm) 400-500 300-400
3/16 in (4.8 mm) 500-750 400-500
1/4 in. (6.4 mm) 750-1000 500-630
♦Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).
B. Electrode Composition.
Tungsten Type Application Notes
2% Cerium
(Grey*)
Good all−around tungsten for both AC and DC welding.
1.5−2% Lanthanum
(Yellow/Blue)
Excellent low amp starts for AC and DC welding.
2% Thorium
(Red)
Commonly used for DC welding, not ideal for AC.
Pure Tungsten
(Green)
Not Recommended for inverters!
For best results in most applications use a sharpened cerium or lanthanum electrode for AC and DC welding.
* Color may vary depending on manufacturer, please refer to manufacturer’s guide for color designation.
OM-226276 Page 12
6-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Ideal Tungsten Preparation − Stable Arc
1 Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated
causing lower weld quality.
2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Ideal Grind Angle Range: 15° to 30°
30 degrees is the recommended elec-
trode grind angle.
4 Straight Ground
Grind lengthwise, not radial.
1
3
Causes Wandering Arc
2
Wrong Tungsten
Radial Grinding
Preparation
15° to 30°
4
1-1/2 To 4 Times
Electrode Diameter
Notes
OM-226276 Page 13
SECTION 7 − GUIDELINES FOR TIG WELDING (GTAW)
7-1. Positioning The Torch
Ref. ST-161 892
1
10−25°
10−15°
6
2
3
4
90°
4
5
3/16 in.
1/16 in.
6
5
Bottom View Of Gas Cup
! Grinding the tungsten electrode
produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
an approved respirator. Read
MSDS for safety information.
Consider using cerium or lantha-
num based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flam-
mables away.
1 Workpiece
Make sure workpiece is clean before
welding.
2 Work Clamp
Place as close to the weld as possible.
3 Torch
4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
Select and prepare tungsten according
to Section 6.
Guidelines:
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the
tungsten extends out gas cup of torch.
The tungsten extension should be no
greater than the inside diameter of the
gas cup.
Arc length is the distance from the
tungsten to the workpiece.
OM-226276 Page 14
7-2. Torch Movement During Welding
ST-162 002-B
Tungsten Without Filler Rod
Tungsten With Filler Rod
Form pool Tilt torch Move torch to front
of pool. Repeat process.
75°
75°
Welding direction
Form pool Tilt torch Add filler metal
Move torch to front
of pool. Repeat process.
Remove rod
Welding direction
15°
7-3. Positioning Torch Tungsten For Various Weld Joints
ST-162 003 / S-0792
75°
70°
90°
20°
20°
10°
15°
75°
20-40°
30°
15°
75°
90°
15°
Butt Weld And Stringer Bead
“T” Joint
Lap Joint
Corner Joint
OM-266276 Page 15
SECTION 8 − PARTS LIST
WC0227-B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Figure 8-1. Complete Torch Assembly
OM-266276 Page 16
Quantity
Description
Part
No.
Item
No.
Figure 8-1. Complete Torch Assembly
(WP-125M)
W-125 M
(WP-125L)
W-125 L
1 ♦53N20 Wrench, Collet Body 1 1... ............. .. ............................... ...........
2 ♦125N180Q Nozzle, Quartz 180 180 Deg 1 1... ......... .. ........................ ...........
3 ♦50C40 Chuck 180 Deg 0.040 in. (1.0 mm) 1 1... ............. .. ................... ...........
3 ♦125C116 Chuck 180 Deg 1/16 in. (1.6 mm) 1 1... ........... .. .................... ...........
4 ♦125N45Q Nozzle, Quartz 45 Deg 1 1... ........... .. ............................. ...........
5 ♦125C40-45 Chuck 45 Deg 0.040 in. (1.0 mm) 1 1... ......... .. .................... ...........
5 ♦125C116-45 Chuck 45 Deg 1/16 in. (1.6 mm) 1 1... ........ .. ..................... ...........
5 ♦125C332-45 Chuck 45 Deg 3/32 in. (2.4 mm) 1 1... ........ .. ..................... ...........
6 ♦125N90SQ Nozzle, Quartz GL Short 90 Deg 1 1... ......... .. .................... ...........
7 ♦125N90Q Nozzle, Quartz 90 Deg 1 1... ........... .. ............................. ...........
8 ♦125C40-90 Chuck 90 Deg 0.040 in. (1.0 mm) 1 1... ......... .. .................... ...........
8 ♦125C116-90 Chuck 90 Deg 1/16 in. (1.6 mm) 1 1... ........ .. ..................... ...........
8 ♦125C332-90 Chuck 90 Deg 3/32 in. (2.4 mm) 1 1... ........ .. ..................... ...........
9 ♦WP-125M 3.5 in. Torch Body125A W/C (Includes) 1... .......... .. ...............
♦125S35 Boot Insulator, 3.5 in. (88.9 mm) 1.................. .... ...................
10 ♦WP-125L 5 in. Torch Body125A W/C (Includes) 1... ........... .. ..............................
♦125S50 Boot Insulator, 5 in. (127 mm) 1.................. .... ...................................
11 ♦53N06 Handle, Knurled Thrd 1 1... ............. .. .............................. ...........
12 ♦53N04 Clamp, Wire 1 1... ............. .. ...................................... ...........
13 ♦45V07HD Hose, Water 12.5 Ft (3.8 m), HD, Vinyl 1 1... .......... .. ............... ...........
13 ♦45V07RBB Hose, Water 12.5 Ft (3.8 m) Braided, Blue 1 1... ......... .. ............ ...........
13 ♦45V08HD Hose, Water 25 Ft (7.6 m) HD, Vinyl 1 1... .......... .. ................. ...........
13 ♦45V08RBB Hose, Water 25 Ft (7.6 m) Braided, Blue 1 1... ......... .. ............. ...........
14 ♦45V09 Hose, Gas 12.5 Ft (3.8 m) Vinyl 1 1
... ............. .. ..................... ...........
14 ♦45V09R Hose, Gas 12.5 Ft (3.8 m) Rubber 1 1... ............ .. ................... ...........
14 ♦45V10 Hose, Gas 25 Ft (7.6 m) Vinyl 1 1... ............. .. ....................... ...........
14 ♦45V10R Hose, Gas 25 Ft (7.6 m) 1 1... ............ .. ........................... ...........
15 ♦45V03HD Cable, Power 12.5 Ft (3.8 m) HD, Vinyl 1 1... .......... .. ............... ...........
15 ♦45V03RR Cable, Power 12.5 Ft (3.8 m) Braided, Red 1 1... .......... .. ........... ...........
15 ♦45V04HD Cable, Power 25 Ft (7.6 m) HD, Vinyl 1 1... .......... .. ................ ...........
15 ♦45V04RR Cable, Power 25 Ft (7.6 m) Braided, Red 1 1... .......... .. ............. ...........
16 ♦WC-3-10 Cover, Cable 10 Ft (3.0 m) 1 1... ........... .. ......................... ...........
16 ♦WC-3-22 Cover, Cable 22 Ft (6.7 m) 1 1... ........... .. ......................... ...........
17 ♦45V11 Adapter, Power Cable 1 1... ............. .. .............................. ...........
18 ♦195377 Conn, Water 50 mm 1 1... ............ .. ............................... ...........
18 ♦195380 Adapter, Torch-intnl Style Water(#20) 1 1... ............ .. ................ ...........
18 ♦225028 Adapter, Torch-thread Lock Water (7/8 Lht) Sing Wet 1 1... ............ .. ... ...........
♦AK125C Kit, Accessory 1 1.................. .. .................................... ...........
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND STYLE NUMBER WHEN ORDERING REPLACEMENT PARTS.
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Miller WP-125 MICRO SERIES TORCHES Le manuel du propriétaire
- Catégorie
- Système de soudage
- Taper
- Le manuel du propriétaire
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