Miller W-200(WP-25) Owner'S Manual Download | Manualshive

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Processes

OM-225 425F

2015−03

Visit our website at

www.MillerWelds.com

File: TIG (GTAW)

Hand-Held Water-Cooled TIG
(GTAW) Torch

TIG (GTAW) Welding

Description

W-250 Series (WP-20 Series)

W-250

W-250V

W-225

W-200

(WP-20)

(WP-20V)

(WP-20P)

(WP-25)

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Summary of Contents for W-200(WP-25)

Page 1: ...225 425F 2015 03 Visit our website at www MillerWelds com File TIG GTAW Hand Held Water Cooled TIG GTAW Torch TIG GTAW Welding Description W 250 Series WP 20 Series W 250 W 250V W 225 W 200 WP 20 WP 20V WP 20P WP 25 ...

Page 2: ...ducts 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 The par...

Page 3: ...5 SECTION 3 SPECIFICATIONS 7 3 1 Specifications 7 3 2 Duty Cycle 7 SECTION 4 INSTALLATION 8 4 1 Required Torch Parts And Torch Assembly 8 4 2 International Style Connector Assembly 8 4 3 Connecting Torch 9 SECTION 5 MAINTENANCE TROUBLESHOOTING 11 5 1 Routine Maintenance 11 5 2 Troubleshooting 11 SECTION 6 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 13 6 1 Selecti...

Page 4: ......

Page 5: ...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 watc...

Page 6: ...rnational org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 webs...

Page 7: ...surée 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 p...

Page 8: ...Welding Society at http www aws org or purchased from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Safe Practices for the Preparation of Containers and Pi...

Page 9: ...iser 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 mat...

Page 10: ...OM 225 425 Page 6 ...

Page 11: ...225 Amps W Argon Gas At 100 Duty Cycle DCEN 160 Amps W Argon Gas At 100 duty Cycle ACHF Cooling Method Liquid Cooled Cooling Requirements 1 1 quart min 1 0 l min Tungsten Size 020 Thru 1 8 in 0 5 Thru 3 2 mm Cable Options 12 5 ft 3 8 m or 25 ft 7 6 m Three Piece Rubber 12 5 ft 3 8 m or 25 ft 7 6 m Three Piece Vinyl Dimensions Length 6 5 in 165 mm Handle Diameter 76 in 19 mm Weight 3 oz 85 g Model ...

Page 12: ...h and void warranty 100 Duty Cycle At 225 Amperes Using Argon Gas For WP 20P Models SECTION 4 INSTALLATION 4 1 Required Torch Parts And Torch Assembly WC0202 B 1 Cup 2 Collet Body 3 Collet 4 Backcap Includes O Ring 5 Torch Body 6 Handle 7 Water Hose 8 Gas Hose 9 Power Cable 10 Power Cable Adapter 11 International Style Adapter 12 Water Hose For International Style Adapter Assembling Torch Body Kee...

Page 13: ...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 156 496 Tools Needed 1 2 3 1 in 26 mm 3 4 5 ...

Page 14: ... 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 wo...

Page 15: ...e 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 So...

Page 16: ...s complete see Section 4 3 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 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 a...

Page 17: ... 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 ...

Page 18: ...lectrode For Welding With Phase Control 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 infor mation Consider using tungsten containing ceria lanthana or yttria instead of thoria Grinding dust from thoriated electrodes contains low ...

Page 19: ...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 ade quate shielding gas coverage For example if ...

Page 20: ...rch 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 ...

Page 21: ...OM 225 425 Page 17 SECTION 8 PARTS LIST WC0203 B 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 18 20 15 21 22 16 17 25 29 23 24 26 27 28 30 31 Figure 8 1 Complete Torch Assembly ...

Page 22: ... 1 1 1 1 6 45V43 Gas Lens 1 16 in 1 6 mm 1 1 1 1 6 45V44 Gas Lens 3 32 in 2 4 mm 1 1 1 1 6 45V45 Gas Lens 1 8 3 2 mm 1 1 1 1 7 796F74 Nozzle Lava X Long 3 3 16 in 1 1 1 1 7 796F75 Nozzle Lava X Long 4 1 4 in 1 1 1 1 7 796F76 Nozzle Lava X Long 5 5 16 in 1 1 1 1 7 796F77 Nozzle Lava X Long 6 3 8 in 1 1 1 1 8 796F70 Nozzle Lava Long 3 3 16 in 1 1 1 1 8 796F71 Nozzle Lava Long 4 1 4 in 1 1 1 1 8 796F...

Page 23: ...r 12 5 Ft 3 8 m Rubber 1 1 1 1 26 45V08 Hose Water 25 Ft 7 6 m Vinyl 1 1 1 1 26 45V08R Hose Water 25 Ft 7 6 m Braided 1 1 1 1 27 45V09 Hose Gas 12 5 Ft 3 8 m Vinyl 1 1 1 1 27 45V09R Hose Gas 12 5 Ft 3 8 m Rubber 1 1 1 1 27 45V10 Hose Gas 25 Ft 7 6 m Vinyl 1 1 1 1 27 45V10R Hose Gas 25 Ft 7 6 m Braided 1 1 1 1 28 45V03 Cable Power 12 5 Ft 3 8 m Vinyl 1 1 1 1 28 45V03R Cable Power 12 5 Ft 3 8 m Brai...

Page 24: ...uns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine d...

Page 25: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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