Miller DIVERSION 165 And Owner's Manual
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Miller DIVERSION 165 And Owner's Manual

Miller diversion 165 and; diversion 180 w/auto-line welder
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DIVERSIONt165 And
DIVERSIONt180 w/Auto-Linet
OM-246 522E
2011−03
Processes
Processes
TIG (GTAW) Welding
Description
Diversion 165: 230 Volt Arc Welding
Power Source
Diversion 180: 115-230 VAC Arc Weld-
ing Power Source w/Auto-Linet
File: TIG (GTAW)

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  • Page 1 OM-246 522E 2011−03 Processes Processes TIG (GTAW) Welding Description Diversion 165: 230 Volt Arc Welding Power Source Diversion 180: 115-230 VAC Arc Weld- ing Power Source w/Auto-Linet DIVERSIONt165 And DIVERSIONt180 w/Auto-Linet File: TIG (GTAW) Visit our website at www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) ........10-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−01 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser.

  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...

  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-246 522 Page 10...

  • Page 15: Section 3 − Specifications

    SECTION 3 − SPECIFICATIONS 3-1. Included with Your Unit Welding Power Source 5 ft (1.5 m) Primary Cord With Plug Gas Hose Gas Regulator 12 ft (3.7 m) Work Cable With Clamp Air-Cooled 150 Amp TIG Torch with 12 ft (3.7 m) Cable Some assembly is required.

  • Page 16: Dimensions And Weights

    3-4. Dimensions And Weights Dimensions 23-15/16 in. (608 mm) 17 in. Height 17 in. (433 mm) (432 mm) Width 9.88 in. (251 mm) 23.93 in. (608 mm) w/handles Length 19.25 in. (489 mm) w/o handles 9-7/8 in. (251 mm) Ref. 805 474-A Weight 50 lbs (23 kg) OM-246 522 Page 12...

  • Page 17: Duty Cycle Charts

    3-5. Duty Cycle Charts Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle Diversion 165 Models can damage unit and void warranty. % Duty Cycle 20% Duty Cycle at 150 A AC/DC 2 Minutes Welding 8 Minutes Resting 232 918-B...

  • Page 18: Section 4 − Installation

    SECTION 4 − INSTALLATION 4-1. Selecting A Location (All Models) Handles Use Handles to lift welder; get help if necessary. Cart Movement Place welder on cart to move unit. Tipping Do not move or operate unit where it could tip. Line Disconnect Device Locate unit near correct input pow- er supply.

  • Page 19: Shielding Gas Connections

    4-3. Shielding Gas Connections Use argon shielding gas for best performance. Cylinder Valve Open valve slightly so gas flow blows dirt from valve. Close valve. Tools Needed: Regulator/Flow Gauge 5/8, 1-1/8 in. Connect regulator/flow gauge to gas cylinder. Do not over tighten. Connect gas hose to gas in fitting.

  • Page 20: Connecting 230 Volts Input Power For Diversion 165 Models

    4-5. Selecting Extension Cord (Use Shortest Cord Possible) Conductor Size − AWG (mm Single Phase AC 4 (21.2) 6 (13.3) 8 (8.4) 10 (5.3) 12 (3.3) Input Voltage Maximum Allowable Cord Length in ft (m) 160 (49) 107 (33) 71 (22) 47 (14) 29 (9) 471 (144)

  • Page 21: Connecting 115 Volts Input Power For Diversion 180 Models

    4-7. Connecting 115 Volts Input Power For Diversion 180 Models Installation must meet all National and Local Codes − have only qualified persons make this installation. Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 22: Connecting 230 Volts Input Power For Diversion 180 Models

    4-8. Connecting 230 Volts Input Power For Diversion 180 Models Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. Always connect green or green/yellow conductor supply grounding terminal first, and never to a line termi- nal.

  • Page 23: Multi−Voltage Plug (Mvp) Connection

    4-9. Multi−Voltage Plug (MVP) Connection Selecting Plug Do not cut off power cord connec- tor and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product war- ranty. Connecting Plug To Power Cord Selecting Plug Plug −...

  • Page 24: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls For Diversion 165 Models Material Switch Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control.
  • Page 25 Torch Torch Operation: Amperage Adjustment Wheel Use wheel to adjust amperage from ten amps to maximum value set on the machine’s Material Thickness/ Amperage Control. On/Off Switch Switch has three features that con- trol the machine in different ways:  Trigger hold − Push and release On/Off switch to start welding.

  • Page 26: Controls For Diversion 180 Models

    5-2. Controls For Diversion 180 Models Material Button And AC/DC LEDs Do not use AC output in damp areas, if movement is confined, or if there is danger of falling. Use AC output ONLY if required for the welding process, and then use a remote control.
  • Page 27 Torch Torch Operation: Amperage Adjustment Wheel Use wheel to adjust amperage from ten amps to maximum value set on the machine’s Material Thickness/ Amperage Control. On/Off Switch Switch has three features that con- trol the machine in different ways:  Trigger hold − Push and release On/Off switch to start welding.

  • Page 28: Section 6 − Maintenance And Troubleshooting

    SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months nl Labels...

  • Page 29: Meter Troubleshooting Displays For Diversion 180 Models

    6-3. Meter Troubleshooting Displays For Diversion 180 Models ..FAIL ..TEMP 2 Sec 2 Sec Repeat Service Agent if this display is shown. 3-5). Operation will continue when the unit All directions are in reference to the has cooled. front of the unit.
  • Page 30 Trouble Remedy Properly prepare tungsten (see Section 9-2). Tungsten electrode oxidizing and not Shield weld zone from drafts. remaining bright after conclusion of weld. Check and tighten all gas fittings. Properly prepare tungsten (see Section 9-2). Fan not operating. Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to protect against overheating.

  • Page 31: Section 7 − Electrical Diagrams

    SECTION 7 − ELECTRICAL DIAGRAMS 232 891-E Figure 7-1. Circuit Diagram For Diversion 165 Models OM-246 522 Page 27...
  • Page 32 246 520-A Figure 7-2. Circuit Diagram For Diversion 180 Models OM-246 522 Page 28...

  • Page 33: Section 8 − High Frequency

    SECTION 8 − HIGH FREQUENCY 8-1. Welding Processes Requiring High Frequency High-Frequency Voltage TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc. Work high_freq 7/05 − S-0693 8-2. Incorrect Installation Weld Zone 11, 12 50 ft (15 m) Sources of Direct High-Frequency...

  • Page 34: Correct Installation

    8-3. Correct Installation Weld Zone 50 ft (15 m) 50 ft (15 m) Ground all metal ob- jects and all wiring in welding zone using #12 AWG wire. Ground workpiece if required by codes. Nonmetal Building Metal Building High-Frequency Source (welding Conduit Joint Bonding and Grounding Metal Building Requirements power source with built-in HF or...

  • Page 35: Section 9 − Selecting And Preparing A Tungsten For Dc Or Ac Welding With Inverter Machines

    SECTION 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2010-04 Whenever possible and practical, use DC weld output instead of AC weld output. 9-1. Selecting Tungsten Electrode ( Wear Clean gloves To Prevent Contamination Of Tungsten ...

  • Page 36: Section 10 − Guidelines For Tig Welding (Gtaw)

    SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) 10-1. Positioning The Torch 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.

  • Page 37: Torch Movement During Welding

    10-2. Torch Movement During Welding Tungsten Without Filler Rod  Welding direction Form pool Tilt torch Move torch to front of pool. Repeat process. Tungsten With Filler Rod   Welding direction Form pool Tilt torch Add filler metal Remove rod Move torch to front of pool.

  • Page 38: Section 11 − Parts List

    SECTION 11 − PARTS LIST Diversion 165 Models 805 115-E Figure 11-1. Main Assembly For Diversion 165 Models OM−246 522 Page 34...
  • Page 39 232 896 Nameplate, Miller Diversion 165 ........
  • Page 40 Diversion 180 Models 805 479-B Figure 11-2. Main Assembly For Diversion 180 Models OM−246 522 Page 36...
  • Page 41 ......Nameplate, Miller Diversion 180 (order by model and serial number) . . .
  • Page 42 Hardware is common and not available unless listed. 805 135-C Figure 11-3. Windtunnel Assembly Item Dia. Part Mkgs. Description Quantity Figure 11-3. Windtunnel Assembly (Figures 11-1 And 11-2, Item 15) ..230 144 Circuit Card Assy, Commutator Control .
  • Page 43 Hardware is common and not available unless listed. 805 123-A Figure 11-4. Heat Sink, Secondary Assembly Item Dia. Part Mkgs. Description Quantity 232 917 Figure 11-4. Heat Sink, Secondary Assembly (Figure 11-3, Item 7) ... . 232 869 Heat Sink, Secondary .
  • Page 44 Notes...
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 Effective January 1, 2011 (Equipment with a serial number preface of MB 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 90 Days —...

  • Page 48: Options And Accessories

    Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2011 Miller Electric Mfg. Co. 2011−01...

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Diversion 180 w/auto-line

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