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OM-1600 199 525E
1/2005
Processes
TIG (GTAW) Welding
Description
TIG Torch
Diamondback Series
GTAW Torches
DB1712R, DB1725R, DB1712RDI, DB1725RDI,
DB1712RDI25, DB1725RDI25, DB17V12R,
DB17V25R, DB17V12-2, And DB17V25-2
www.MillerWelds.com
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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 bu
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TABLE OF CONTENTS SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES − READ BEFORE USING . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. GTAW Torch Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EMF INFORMATION . . . . . . . . . . . . . . . . . . . . . . .
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Notes
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SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES − READ BEFORE USING SR6_8/03 1-1. Symbol Usage Marks a special safety message. Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Means NOTE; not safety related. 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 Hazar
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EMF INFORMATION Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such 3. Do not coil or drape cables around your body. fields. However, after examining more than 500 studies spanning 17 years of research,
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SECTION 2 − SPECIFICATIONS 2-1. Specifications Model DB17 DB17V (With Gas Valve) Ampere Rating 150 Amps W/Argon Gas @ 100% Duty Cycle DCEN, ACHF Cooling Method Air Tungsten Size .020 Thru 1/8 in (0.5 Thru 3.3 mm) Cable Options 12-1/2 ft (3.8 m) or 25 ft (7.6 m) One-Piece High −Flex 12-1/2 ft (3.8 m) Or 25 ft (7.6 m) One-Piece High −Flex, Or 12-1/2 ft (3.8 m) Or 25 ft (7.6 m) Two-Piece High −Flex Dimensions Length: 8 in (203 mm); Handle Diameter: 15/16 in (24 mm); Length: 8 in (203 mm); Handle Di
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SECTION 3 − INSTALLATION 3-1. Required Torch Parts And Torch Assembly 7 6 Assembling Torch Parts 5 4 3 2 13 1 9 15 10 14 8 Or Ref. ST-802 566-B 12 11 1 Cup 10 One-Piece Power Cable Note: Connector needed only if torch is equipped with two-piece cable (see Section 2 Collet Body 11 Power Cable Adapter 3-2). 3 Heat Shield 12 International Style Flow-Through Assembling Torch Body 4 Backcap Insulator Adapter Keep connections tight. Replace cup, heat 5 Collet shield, and backcap as needed. Note: Adapt
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3-3. Connecting Torch A. Connecting Torch With One-Piece Cable Turn Off welding power source power before install- If applicable, install high-frequency unit. ing torch. Obtain the following hose: Torch Without Gas Valve 1 Gas Hose With 5/8-18 Right- Hand Fittings Connections: 4 2 Regulator/Flowmeter 2 3 Gas Cylinder 3 4 Welding Power Source 5 Gas Valve Operating Torch Gas Valve: 1 Valve controls gas preflow and post- flow. Open valve on torch just before welding. Preflow is used to purge the
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B. Connecting Torch With Two-Piece Cable Turn Off welding power If applicable, install high-frequency unit. 2 source power before install- 4 3 ing torch. Obtain the following hose: 1 Gas Hose With 5/8-18 Right- 1 Torch Without Gas Valve Hand Fittings Connections: 2 Regulator/Flowmeter 3 Gas Cylinder 6 4 Welding Power Source 5 Torch Gas-In Hose 6 Torch Power Cable 7 5 7 Work Clamp Connect work clamp to a clean, paint-free location on workpiece, close to weld area. Use wire brush to clean weld j
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SECTION 4 − MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Disconnect torch before maintaining. 40 Hours Repair or Clean and Replace replace tighten weld unreadable cracked terminals. labels. weld cable. Replace cracked parts Torch Body Torch Cable 4-2. Troubleshooting Before using troubleshooting table, check selection and preparation of tungsten NOTE electrode according to Section 5. Trouble Remedy Arc will not start. High frequency present Check cable and work connections. Be sure
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Trouble Remedy Wandering arc Shield weld zone from drafts. Reduce gas flow rate. Select proper size and type of tungsten. Properly prepare tungsten according to Section 5. 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. Er
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SECTION 5 − SELECTING AND PREPARING TUNGSTEN ELECTRODE FOR DC OR AC WELDING ac/dc_gtaw 2/2004 Whenever possible and practical, use DC weld output instead of AC weld output. 5-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) Amperage Range - Gas Type♦ - Polarity Electrode Diameter DC − Argon − Electrode DC − Argon − Elec- AC − Argon AC − Argon − Negative/Straight Po- trode Positive/Rev- Balanced Wave larity erse Polarity 2% Ceria (Orange Band), 1.5% Lan-
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5-2. Preparing Tungsten Electrode For Welding 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 infor- mation. 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 environ- mentally sa
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6-2. Torch Movement During Welding Tungsten Without Filler Rod 75° Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod 75° 15° Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool. Repeat process. ST-162 002-B 6-3. Positioning Torch Tungsten For Various Weld Joints “T” Joint Butt Weld And Stringer Bead 20° 90° 70° 75° 20° 15° 10° Corner Joint Lap Joint 20-40° 90° 75° 75° 15° 15° 30° ST-162 003 / S-
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SECTION 7 − PARTS LIST 1 3 4 7 6 8 2 5 11 9 12 15 16 20 10 13 14 21 18 17 19 17 17 22 or 23 802 567-B Figure 7-1. Complete Torch Assembly OM-1600 Page 12
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Quantity Model DB DB DB DB DB DB 1712R 1725R 1712RDI 1725RDI 1712 1725 RDI25 RDI25 Item Stock No. No. Description Figure 7-1. Torch Models Without Gas Valve . . 1 . . . . . . 57Y02 . . . . . . . BACK CAP, long . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1 . . 2 . . . . . ♦57Y04 . . . . . . . BACK CAP, button . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1 . . . . . . . . . 199 591 . . . . . . . . .
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Quantity Model DB DB DB DB DB DB 1712R 1725R 1712 RDI 1725 RDI 1712 1725 Item Stock RDI 25 RDI 25 No. No. Description Figure 7-1. Torch Models Without Gas Valve (continued) . 21 . . ♦194 722 . . . . . . . ADAPTER, intl style flow through . . . . . 1 . . . . 1 . . . . 1 . . . . . 1 . 21 . . . . 195 234 . . . . . . . ADAPTER, intl style flow through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . 22 . . ♦127 836 . . . . . . . PLUG, international style, tw lk ins
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Quantity Model DB DB DB DB Item Stock 17V12R 17V25R 17V12-2 17V25-2 Description No. No. Figure 7-1. Torch Models With Gas Valve . . 1 . . . . . . 57Y02 . . . . . . . BACK CAP, long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1 . . 2 . . . . . ♦57Y04 . . . . . . . BACK CAP, button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . 1 . . . . . 1 . . . . . 1 . . . . . . . . . 199 591 . . . . . . . . . O-RING . . .
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Quantity Model DB DB DB DB Item Stock 17V12R 17V25R 17V12-2 17V25-2 Description No. No. Figure 7-1. Torch Models With Gas Valve (continued) . 22 . . ♦127 836 . . . . . . . PLUG, international style, tw lk insul male . . . . . . . . . . . . 1 . . . . . . . . . . . . 1 . . . . . 1 . 23 . . ♦129 527 . . . . . . . PLUG, international style tw lk insul male . . . . . . . . . . . . 1 . . . . . . . . . . . . 1 . . . . . 1 . . . . . . . . . ♦AK2C . . . . . . . ACCESSORY KIT (included in DTP kit) . . . .
