Miller DIVERSION 165 And Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS - READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Symboles utilisés

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-4. Proposition californienne 65 Avertissements

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2-5. Principales normes de sécurité

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2-6. Informations relatives aux CEM

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SECTION 3

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SPECIFICATIONS

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3-1. Included with Your Unit

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3-2. Specifications

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3-3. Serial Number And Rating Label Location

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3-4. Dimensions And Weights

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3-5. Duty Cycle Charts

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SECTION 4

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INSTALLATION

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4-1. Selecting A Location (All Models)

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4-2. Remote Receptacle For Optional Foot Control

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4-3. Shielding Gas Connections

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4-4. Electrical Service Guide

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4-6. Connecting 230 Volts Input Power For Diversion 165 Models

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4-7. Connecting 115 Volts Input Power For Diversion 180 Models

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4-8. Connecting 230 Volts Input Power For Diversion 180 Models

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4-9. Multi

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Voltage Plug (MVP) Connection

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SECTION 5

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OPERATION

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5-1. Controls For Diversion 165 Models

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5-2. Controls For Diversion 180 Models

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SECTION 6

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MAINTENANCE AND TROUBLESHOOTING

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6-1. Routine Maintenance

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6-2. Circuit Breaker CB1

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6-3. Meter Troubleshooting Displays For Diversion 180 Models

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6-4. Troubleshooting

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SECTION 7

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ELECTRICAL DIAGRAMS

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SECTION 8

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HIGH FREQUENCY

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8-1. Welding Processes Requiring High Frequency

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8-2. Incorrect Installation

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8-3. Correct Installation

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SECTION 9

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SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER

MACHINES

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9-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)

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9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With

Inverter Machines

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Summary of Contents for DIVERSION 165 And

Page 1: ...180 w Auto Linet Processes TIG GTAW Welding Visit our website at www MillerWelds com Description Diversion 180 115 230 VAC Arc Weld ing Power Source w Auto Linet File TIG GTAW Diversion 165 230 Volt Arc Welding Power Source DIVERSIONt165 And ...

Page 2: ...ontinue 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 operati...

Page 3: ...acle For Optional Foot Control 14 4 3 Shielding Gas Connections 15 4 4 Electrical Service Guide 15 4 6 Connecting 230 Volts Input Power For Diversion 165 Models 16 4 7 Connecting 115 Volts Input Power For Diversion 180 Models 17 4 8 Connecting 230 Volts Input Power For Diversion 180 Models 18 4 9 Multi Voltage Plug MVP Connection 19 SECTION 5 OPERATION 20 5 1 Controls For Diversion 165 Models 20 5...

Page 4: ...ON 10 GUIDELINES FOR TIG WELDING GTAW 32 10 1 Positioning The Torch 32 10 2 Torch Movement During Welding 33 10 3 Positioning Torch Tungsten For Various Weld Joints 33 SECTION 11 PARTS LIST 34 OPTIONS AND ACCESSORIES WARRANTY ...

Page 5: ...lds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant vol...

Page 6: ...less they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw f...

Page 7: ... panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing u...

Page 8: ... 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 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office...

Page 9: ...urant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou ...

Page 10: ... ou laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le co...

Page 11: ...D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonctionnem...

Page 12: ...ecte et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipement commandé par ordinateur tel que les robots D Veiller à ce que tout l équipement de la zone de soudage soit comp...

Page 13: ...n 5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov N...

Page 14: ...OM 246 522 Page 10 ...

Page 15: ... 60 A at 12 4 V 100 Duty Cycle 11 3 88 1 3 1 1 2 03 80 VDC 125 A at 15 V 35 Duty Cycle 26 5 88 3 1 1 3 0 03 230 VAC 10 180 60 A at 12 4 V 100 Duty Cycle 5 6 44 1 3 1 1 2 03 150 A at 16 V 20 Duty Cycle 16 44 3 7 1 3 6 03 180 A at 17 2 V 10 Duty Cycle 20 44 4 7 1 4 6 03 While idling Diversion 165 230 VAC 10 165 60 A at 12 4 V 100 Duty Cycle 8 20 1 8 04 1 2 02 80 VDC 150 A at 16 V 20 Duty Cycle 23 20...

Page 16: ...3 4 Dimensions And Weights Ref 805 474 A 9 7 8 in 251 mm 23 15 16 in 608 mm 17 in 432 mm Dimensions Height 17 in 433 mm Width 9 88 in 251 mm Length 23 93 in 608 mm w handles 19 25 in 489 mm w o handles Weight 50 lbs 23 kg ...

Page 17: ...ty cycle can damage unit and void warranty 20 Duty Cycle at 150 A AC DC 246 526 A 2 Minutes Welding 8 Minutes Resting 230 VAC 115VAC Diversion 180 Models 20 Duty Cycle at 150 A AC DC 232 918 B 2 Minutes Welding 8 Minutes Resting 0 50 100 150 200 10 100 Duty Cycle Output Amperes A Output Amperes A Duty Cycle 10 100 0 50 100 150 200 Diversion 165 Models ...

Page 18: ...ile liquids are present see NEC Article 511 or CEC Section 20 2 Movement 4 18 in 460 mm Location And Airflow 18 in 460 mm 18 in 460 mm 18 in 460 mm 1 805 475 A 3 4 2 Remote Receptacle For Optional Foot Control NOTICE Use this receptacle to connect the dedicated optional foot control only Connecting other types of equipment to this receptacle may damage your machine 1 8 Socket Socket Information A ...

Page 19: ...age 230 Volts AC 230 Volts AC 115 Volts AC Input Amperes At Rated Output 23 20 A 15 or 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required See Section 4 7 Max Recommended Standard Fuse or circuit breaker Rating In Amperes 1 Time Delay 2 30 25 Normal Operating 3 35 30 Min Input Conductor Size In AWG 4 14 14 Max Recommended Input Conductor Length In Feet ...

Page 20: ...icle 511 or CEC Section 20 1 Rating Label Supply correct input power see Sec tion 4 4 2 Black And White Input Conductor L1 And L2 3 Green Or Green Yellow Grounding Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding...

Page 21: ...ent see NEC Article 511 or CEC Section 20 The Auto Line circuitry in this unit automatically links the power source to the primary voltage being applied either 115 or 230 VAC For 115 volts AC input power a 15 or 20 ampere individual branch circuit protected by time delay fuses or circuit breaker is required 1 Multi Voltage Plug And Power Cord Connector NEMA Type 5 15P Plug Shown For multi voltage ...

Page 22: ...een Or Green Yellow Grounding Conductor 4 Input Power Cord 5 Disconnect Device switch shown in the OFF position 6 Disconnect Device Grounding Terminal 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 and L2 to disconnect device line terminals 8 Over Current Protection Select type and size ...

Page 23: ...Supplied Follow electrical service guide for 230 VAC in Section 4 4 Do not use plug rating to size branch circuit protection Connecting Plug To Power Cord Align arrow on plug with arrow on power cord connector Push together Tighten threaded collar As threaded collar is tightened push plug onto adapter until collar is completely tight Connect plug to receptacle MVP Plug1 2010 10 Ref 803 812 C Do no...

Page 24: ...ale to select the appropriate materi al thickness and corresponding amperage from the white scale When Material switch is in the AC position use the gray scale to select the appropriate material thickness and corre sponding amperage from the white scale AC parameters have been optimized and auto matically set as follows Preflow is preset at 4 seconds for DC or AC Postflow is preset for one second ...

Page 25: ...g Feature Press and hold On Off switch for more than one second to start weld out put Release switch to end weld output This feature is useful for tacking and fitting or in other situ ations when weld output is need ed for short periods of time Crater Out Feature Press and hold On Off switch at end of weld sequence to ramp weld amper age down until arc is extin guished Use this feature at the end ...

Page 26: ...ng am perage With DC selected and DC LED lit use the blue scale to select the appropriate material thick ness and corresponding amperage from the white scale When AC is selected and AC LED is lit use the gray scale to select the appropri ate material thickness and corresponding am perage from the white scale AC parameters have been optimized and auto matically set as follows Preflow is preset at 4...

Page 27: ...g Feature Press and hold On Off switch for more than one second to start weld out put Release switch to end weld output This feature is useful for tacking and fitting or in other situ ations when weld output is need ed for short periods of time Crater Out Feature Press and hold On Off switch at end of weld sequence to ramp weld amper age down until arc is extin guished Use this feature at the end ...

Page 28: ...Clean Repair l Replace To be done by Factory Authorized Service Agent Every 3 Months nl Labels n l Gas Hoses Every 3 Months n lCables And Cords Every 6 Months Durning heavy service clean monthly 6 2 Circuit Breaker CB1 805 395 B 1 SupplementaryProtector CB1 If CB1 opens unit will be completely inoperative If CB1 opens repeatedly have a Fact ory Authorized Service Agent check unit 1 ...

Page 29: ...5 Op eration will continue when the unit has cooled w REL TRIG Indicates that the torch trigger is de pressed Release trigger to continue w NOT VALD Indicates a non allowable set up on the front panel 1 TEMP 2 Sec FAIL 2 Sec MAG Repeat 6 4 Troubleshooting The remedies listed below are recommendations only If these remedies do not fix the trouble with your unit have a Factory Authorized Service Age...

Page 30: ...reset circuit breaker see Section 4 6 Check for proper input power connections see Section 4 6 No weld output fan on For Diversion 165 models be sure Material Selector switch is set in position see Section 5 1 Check connection to remote control receptacle see Section 4 2 Check remote control see remote control Owner s Manual Unit overheated Allow unit to cool see Section 3 5 Fan not operating weld...

Page 31: ...OM 246 522 Page 27 SECTION 7 ELECTRICAL DIAGRAMS 232 891 E Figure 7 1 Circuit Diagram For Diversion 165 Models ...

Page 32: ...OM 246 522 Page 28 246 520 A Figure 7 2 Circuit Diagram For Diversion 180 Models ...

Page 33: ...f Direct High Frequency Radiation 1 High Frequency Source welding power source with built in HF or separate HF unit 2 Weld Cables 3 Torch 4 Work Clamp 5 Workpiece 6 Work Table Sources of Conduction of High Frequency 7 Input Power Cable 8 Line Disconnect Device 9 Input Supply Wiring Sources of Reradiation of High Frequency 10 Ungrounded Metal Objects 11 Lighting 12 Wiring 13 Water Pipes and Fixture...

Page 34: ...6 Water Pipes and Fixtures Ground water pipes every 50 ft 15 m 7 External Power or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Grounding Rod Consult the National Electrical Code for specifications Metal Building Requirements 9 Metal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire acros...

Page 35: ...ommendations from American Welding Society AWS and electrode manufacturers 9 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 informati...

Page 36: ...onmentally 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 9 Guidelines The inside diameter of the gas cup should be at least three times the tungsten d...

Page 37: ...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 10 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 38: ...34 SECTION 11 PARTS LIST 805 115 E 1 2 3 4 5 6 7 8 11 9 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 11 29 30 31 32 33 34 35 36 37 38 39 40 Diversion 165 Models Figure 11 1 Main Assembly For Diversion 165 Models ...

Page 39: ...h Recessed 4 22 233 200 Cable Assy RJ45 1 23 S2 134 847 Switch Tgl Spdt 15a 125vac On none on Spd Term Blk 1 24 231 238 Nut 468 32 56 Hex 09 H Brs Blk Use w Switches 2 25 217 839 Nut Nylon Strain Rlf Pg13 5 250thk 1 062od 1 26 232 908 Work Cable W Clamp 12 1 27 235 392 Torch Tig 150a 12ft Air Cooled 1 28 233 187 Strain Relief Cable 250 Cable Dia 5x 450 D Hole 1 29 207 079 Knob Pointer 1 125 Dia 1 ...

Page 40: ...OM 246 522 Page 36 805 479 B 1 2 3 4 5 6 7 8 11 9 12 13 14 15 16 17 18 19 20 21 22 23 24 11 25 26 27 28 29 30 31 32 33 34 35 36 Diversion 180 Models 37 Figure 11 2 Main Assembly For Diversion 180 Models ...

Page 41: ...66 Plenum Air 1 20 232 863 Base 1 21 239 388 Bumper RBR 875 OD X 188 ID X 39 High Recessed 4 22 232 908 Work Cable W Clamp 12 Ft 1 23 235 392 Torch Tig 150a 12ft Air Cooled 1 LS0011 Switch Potentiometer Momentary 1 24 233 187 Strain Relief Cable 250 Cable Dia 5x 450 D Hole 1 25 231 297 Actuator Push Button Assy 1 26 228 546 Knob Pointer 1 125 Dia x 6mm Id W Spring Clip 4 5mm Flat 1 27 Nameplate Mi...

Page 42: ... 413 XFMR Main Includes 165 Models 1 5 T1 246 540 XFMR Main Includes 180 Models 1 6 RT3 207 890 Thermistor NTC 10K Ohm 25 Deg C 27 50 In Lead 1 7 232 917 Heat Sink Secondary Assy See Figure 11 4 1 8 Z1 237 412 Inductor Output 165 Models 1 8 Z1 246 539 Inductor Output 180 Models 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the ...

Page 43: ...1 396 Diode Ultra Fast Recovery 90 A 600 V Dual SOT 227 2 3 Q2 3 4 5 231 393 Transistor IGBT 100 A 600 V SOT 227 4 4 RT2 213 353 Thermistor NTC 30K Ohm 25 Deg C 8 In Lead 1 5 212 038 Screw M4 7 x 8 5 Pan HD PHL STL PLD Sems Split Fl 15 6 SR1 199 952 Diode Power Module 50 Amp 600 V 1 PH Fast Recovery 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested ...

Page 44: ...Notes ...

Page 45: ...Notes ...

Page 46: ...Notes ...

Page 47: ...vers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall...

Page 48: ...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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