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OM-1603 199 528C
1/2005
Processes
TIG (GTAW) Welding
Description
TIG Torch
Diamondback Series
GTAW Torches
DB1812R And DB1825R
Visit our website at
www.MillerWelds.com
ESPAÑOL FRANÇAIS ENGLISH
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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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SECTION 1 −SAFETY PRECAUTIONS FOR GTAW TORCHES − READ BEFORE USING SR6_1/00 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 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 100% Duty Cycle At 350 Amperes Using Argon Ga
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SECTION 3 − INSTALLATION 3-1. Required Torch Parts And Torch Assembly 1 Cup 2 Collet Body 3 Heat Shield 7 Assembling Torch Parts 4 Backcap Insulator 6 5 Collet 5 4 6 O-Ring 3 7 Backcap 2 1 8 Torch Body 9 Handle 16 10 Power Cable 11 Water Hose 8 12 Gas Hose 12 9 13 Power Cable Adapter 14 International Style Adapter 11 15 Water Hose For International Style Adapter 13 Assembling Torch Body Keep connections tight. Replace 14 10 cup, heat shield, and backcap as needed. 16 Tungsten Electrode (See Sec-
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3-3. Connecting Torch A. Connecting Torch When Using A Freestanding Coolant System If applicable, install high-frequency unit. 2 1 3 4 11 7 10 12 6 8 9 5 Tools Needed: 802 560 5/8, 7/8, 1-1/8 in Turn Off welding power source and 5 Torch 9 Torch Gas Hose cooling system power before in- 6 Power Cable Adapter 10 Coolant-Into Torch Hose (Blue) stalling torch. 7 Coolant Hose (Customer Supplied) 11 Cooling System 1 Welding Power Source Obtain correct length with 5/8-18 left-hand fittings. 2 Regulato
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B. Connecting Torch To A Dynasty 300 DX Or Maxstar 300 DX TIGRunner Unit Turn Off welding power source 2 Tools Needed: power before installing torch. 1 11 1 Gas Hose With 5/8-18 Right- Hand Fittings (Customer Sup- plied) 3 Connections: 5/8, 7/8, 1-1/8 in 2 Regulator/Flowmeter 9 3 Gas Cylinder 7 4 Coolant System 8 5 Torch 6 Coolant-Into Torch Hose (Blue) 7 Torch Gas Hose 6 8 Coolant-Out Of Torch/Power Cable (Red) 9 International Style Adapter Connect coolant-out of torch/power 5 cable to pow
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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 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. Errat
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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 6 5 7 2 10 8 11 14 15 9 12 18 13 17 19 20 16 21 Ref. 802 676-A Figure 7-1. Complete Torch Assembly OM-1603 Page 12
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Quantity Model Item Stock Model Description No. No. No. DB1812R DB1825R Figure 7-1. Complete Torch Assembly . . 1 . . . . . . 57Y02 . . . . . . . . . . . . . . . BACK CAP, long (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . 2 . . . . . ♦57Y04 . . . . . . . . . . . . . . . BACK CAP, button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . . . 199 591 . . . . . . . . . . . . . . . . O-Ring . . .
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Quantity Model Item Stock Model Description No. No. No. DB1812R DB1825R Figure 7-1. Complete Torch Assembly (continued) . 21 . . ♦198 314 . . . . . . . . . . . . . . . HOSE, water side adapter international style (included w/190 219) 1 . . . . 1 . . . . . . . . . ♦AK3C . . . . . . . . . . . . . . . ACCESSORY KIT (included in DTP kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . ♦CC322HD . . . . . . . . . . . . . . . CABLE COVER, 22 ft (not shown) . . . . . ♦CC310HD . .
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Notes ENGLISH
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Notes
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Effective January 1, 2005 (Equipment with a serial number preface of “LF” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Call * Induction Heating Coils and Blankets below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to * APT & SAF Model Plasma Cutting Torches 1-800-4-A-MILLER its original retail purchaser
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Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Wo
