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OM-246 522B
2010−04
TIG (GTAW) Welding
Description
Diversion 165: 230 Volt Arc Welding
Power Source
Diversion 180: 115-230 VAC Arc Welding Power Source w/Auto-Linet
DIVERSIONt165 And
DIVERSIONt180 w/Auto-Linet
File: TIG (GTAW)
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 build and sell Miller products continue 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 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,
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System
Standard.
there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide the exact part you may need to fix the problem.
Warranty and service information for your particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most hassle-free warranty in the business.
Miller Electric manufactures a full line of welders and welding related equipment.
For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
Mil_Thank 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance
1-4. California Proposition 65 Warnings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements
2-5. Principales normes de sécurité
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Serial Number And Rating Label Location
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Shielding Gas Connections
6-3. Meter Troubleshooting Displays For Diversion 180 Models
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) . . . . . . . .
31
31
9-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter
Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Positioning Torch Tungsten For Various Weld Joints
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
33
33
OPTIONS AND ACCESSORIES
WARRANTY
1
3
4
1
1
4
4
5
9
7
8
9
5
5
7
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2010−03
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
.
Indicates special instructions.
DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.
D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly with a separate cable.
D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.
D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
D Do not connect more than one electrode or work cable to any single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-246 522 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
D 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).
D Wear approved safety glasses with side shields under your helmet.
D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, unless 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 frozen pipes.
OM-246 522 Page 2
D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
D Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect ImplantedMedical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling boards or parts.
D Use proper static-proof bags and boxes to store, move, or ship PC boards.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do so.
D Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, 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 unit. Read the safety information at the beginning of the manual and in each section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local codes.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
D Have only qualified persons familiar with electronic equipment perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots.
D Be sure all equipment in the welding area is electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive electronic equipment.
D Be sure this welding machine is installed and grounded according to this manual.
D If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.
OM-246 522 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
1-6. EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: 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 Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: 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 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-246 522 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2010−03
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
.
Indique des instructions spécifiques.
DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures personnelles.
2-2. Dangers relatifs au soudage à l’arc
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y afférant pour les actions nécessaires afin d’éviter le danger.
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Sec-
tion 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.
Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber.
D Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant 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 conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, provinciales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez−les contre les étincelles et les pièces métalliques chaudes.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage.
OM-246 522 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intense
D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.
OM-246 522 Page 6
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 contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester
à distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut affecter l’ouïe.
D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser si elles sont endommagées.
Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment 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 sécurité.
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94–110) lors du levage manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et les yeux.
D Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
OM-246 522 Page 7
Les PIÈCES MOBILES peuvent causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.
Les PIÈCES MOBILES peuvent causer des blessures.
D S’abstenir de toucher des organes mobiles tels que des ventilateurs.
D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux.
2-4. Proposition californienne 65 Avertissements
LE SOUDAGE À L’ARC risque de provoquer des interférences.
D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement
électronique sensible 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 compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants) des cancers, des malformations congénitales ou d’autres problèmes de procréation. Se laver les mains après utilisation.
Pour les moteurs à essence :
Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation.
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation.
Pour les moteurs diesel :
Ce produit contient des produits chimiques, notamment du plomb, dont l’État de Californie reconnaît qu’ils provoquent
Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation.
OM-246 522 Page 8
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global
Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet : www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, de American National Standards Institute,
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage. Les CEM peuvent créer des interférences avec certains implants médicaux comme des stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants médicaux doivent être prises: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser 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.
25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−le téléphone de la région 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 internet : 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/NIOSH).
4. Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-246 522 Page 9
OM-246 522 Page 10
SECTION 3 − SPECIFICATIONS
3-1. Included with Your Unit
6
1
4
3
2
1 Welding Power Source
2 5 ft (1.5 m) Primary Cord
With Plug
3 Gas Hose
4 Gas Regulator
5 12 ft (3.7 m) Work Cable
With Clamp
6 Air-Cooled 150 Amp TIG
Torch with 12 ft (3.7 m)
Cable
.
Some assembly is required.
For options and accessories see back of book or contact your distributor.
.
a Diversion 180 is illustrated throughout this manual unless otherwise indicated.
5
805 474-A
3-2. Specifications
Input Power
115 VAC
Welding Amperage
Range
10 − 125
230 VAC
* () While idling.
10 − 180
Diversion 180
Rated Output
60 A at 12.4 V, 100% Duty Cycle
125 A at 15 V, 35% Duty Cycle
60 A at 12.4 V, 100% Duty Cycle
150 A at 16 V, 20% Duty Cycle
180 A at 17.2 V, 10% Duty Cycle
Amps Input At
Rated Output
11.3 (.88)*
26.5 (.88)*
5.6 (.44)*
16 (.44)*
20 (.44)*
230 VAC 10 − 165
Diversion 165
60 A at 12.4 V, 100% Duty Cycle
150 A at 16 V, 20% Duty Cycle
165 A at 16.6 V, 15% Duty Cycle
8 (.20)*
23 (.20)*
25.5 (.20)*
* () While idling.
KVA
1.3 - (.1)*
3.1 (.1)*
1.3 (.1)*
3.7 (.1)*
4.7 (.1)*
KW
1.2 - (.03)*
3.0 - (.03)*
1.2 - (.03)*
3.6 - (.03)*
4.6 - (.03)*
Max. OCV
80 VDC
1.8 (.04)*
5.3 (.04)*
5.9 (.04)*
1.2 (.02)*
3.7 (.02)*
4.2 (.02)*
80 VDC
3-3. Serial Number And Rating Label Location
The serial number and rating information for the power source is located on the rear of the machine. Use the rating labels to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual.
OM-246 522 Page 11
3-4. Dimensions And Weights
23-15/16 in.
(608 mm)
9-7/8 in.
(251 mm)
Dimensions
17 in.
(432 mm)
Height
Width
17 in. (433 mm)
9.88 in. (251 mm)
Ref. 805 474-A
Length
23.93 in. (608 mm) w/handles
19.25 in. (489 mm) w/o handles
Weight
50 lbs (23 kg)
OM-246 522 Page 12
3-5. Duty Cycle Charts
Diversion 165 Models
200
150
100
50
0
10
% Duty Cycle
20% Duty Cycle at 150 A AC/DC
200
150
100
50
0
10
2 Minutes Welding 8 Minutes Resting
Diversion 180 Models
230 VAC
115VAC
% Duty Cycle
20% Duty Cycle at 150 A AC/DC
Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
NOTICE − Exceeding duty cycle can damage unit and void warranty.
100
100
232 918-B
2 Minutes Welding 8 Minutes Resting
246 526-A
OM-246 522 Page 13
SECTION 4 − INSTALLATION
4-1. Selecting A Location
Movement
!
Do not move or operate unit where it could tip.
Location And Airflow
1
3
2
1 Handles
Use Handles to lift welder; get help if necessary.
2 Cart
Place welder on cart to move unit.
3 Line Disconnect Device
Locate unit near correct input power supply.
Position unit so air can circulate.
For information about sources of
For carts and caster kits see back of book or contact your distributor.
!
Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC
Section 20.
18 in. (460 mm)
18 in. (460 mm)
18 in. (460 mm)
18 in. (460 mm)
805 475-A
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.
Socket* Socket Information
1 8
805 113-A
A
1
2
3
4
Command reference; +10 volts DC output to remote control.
0 to +10 volts DC input command signal from remote control.
Remote control circuit common.
15 volts DC.
Foot Select
6
5
7
8
Contact closure to 4 completes 15 volts DC contactor control circuit.
Foot control select; jumper to 7 in foot control.
Chassis common.
Not Used
OM-246 522 Page 14
4-3. Shielding Gas Connections
Tools Needed:
5/8, 1-1/8 in.
3
2
1
.
Use argon shielding gas for best performance.
1 Cylinder Valve
Open valve slightly so gas flow blows dirt from valve. Close valve.
2 Regulator/Flow Gauge
Connect regulator/flow gauge to gas cylinder. Do not over tighten.
Connect gas hose to gas in fitting.
3 Flow Adjust
Typical flow rate is 20 cfh (cubic feet per hour).
Ref. 805 474-A
4-4. Electrical Service Guide
.
All values calculated at 10% duty cycle.
.
Actual input voltage cannot exceed ± 10% of indicated required input voltage shown in table. If actual input voltage is outside of this range, damage to unit may occur.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
60 Hz Single Phase
Input Voltage
Input Amperes At Rated Output
Max Recommended Standard Fuse or circuit breaker Rating In Amperes
1
Time-Delay
2
Normal Operating 3
Min Input Conductor Size In AWG
4
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG 4
Diversion 165
230 Volts AC
23
30
35
14
64 (20)
14
230 Volts AC
20
Diversion 180
115 Volts AC
25
30
14
55 (17)
14
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5”. See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
OM-246 522 Page 15
4-5. Connecting Input Power
A. Connecting Input Power For Diversion 165 Models
6
3
1
1
4
9
10
L2
8
=GND/PE Earth
Ground
5
7
L1
L2
2
L1
!
Installation must meet all National and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input conductors from unit.
!
Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.
1 Rating Label
Supply correct input power (see Sec-
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 terminal first.
Connect input conductors L1 and L2 to disconnect device line terminals.
8 Over-Current Protection
Select type and size of over-current
protection using Section 4-4 (fused
disconnect switch shown).
Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.
9 Plug (NEMA 6-50P)
10 Receptacle (NEMA 6-50R)
Connect plug to receptacle.
!
Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC
Section 20.
230 VAC, 1
Tools Needed:
Ref. 805 116-A
OM-246 522 Page 16
B. Connecting 115 Volts Input Power For Diversion 180 Models
18 in.
(460 mm)
Airflow Distance
Requirements
18 in. (460 mm)
1
1
2 3
4
5
!
Do not move or operate unit where it could tip.
!
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.
.
The Auto-Line circuitry in this unit automatically links the power source to the primary voltage being applied, either
115 or 230 VAC.
NOTICE − Do Not cut off power cord connector and rewire. The power cord connector and plugs will work with standard NEMA receptacles. Modifying power cord, connector, and plugs will void product warranty.
For 115 volts AC input power, a
15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. For 230 volts
AC input power, see Section
1 Power Cord Connector
2 Plug − NEMA Type 5−15P
3 Receptacle − NEMA Type
5−15R (Customer Supplied)
4 Plug − NEMA Type 6−50P
5 Receptacle − NEMA Type
6−50R (Customer Supplied)
Select plug for power supply receptacle available at site.
Install plug onto power cord adapter. As threaded collar is tightened, push plug onto adapter until collar is completely tight.
Connect plug to receptacle.
Ref. 805 474-A
OM-246 522 Page 17
C. Connecting 230 Volts Input Power For Diversion 180 Models
1
6
3
10
L2
4
1
9
230 VAC, 1
!
Installation must meet all National and Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input power before connecting input conductors from unit.
L1
L2
5
7
8
L1
2
=GND/PE Earth
Ground
!
Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line terminal.
1 Rating Label
Supply correct input power (see Sec-
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 terminal first.
Connect input conductors L1 and L2 to disconnect device line terminals.
8 Over-Current Protection
Select type and size of over-current
protection using Section 4-4 (fused
disconnect switch shown).
Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.
9 Plug (NEMA 6-50P)
10 Receptacle (NEMA 6-50R)
Connect plug to receptacle.
!
Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC
Section 20.
Tools Needed:
Ref. 805 476-A
OM-246 522 Page 18
Notes
OM-246 522 Page 19
SECTION 5 − OPERATION
5-1. Controls For Diversion 165 Models
3
4
2
5
1
1 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.
!
Do not change position of switch while welding or while under load.
.
Unit is equipped with Fan-On-Demandt.
Fan only runs when output is on or cooling is required.
Use switch to select DC for steel, stainless steel, and chrome-moly, or AC for aluminum applications.
2 Material Thickness/Amperage Control
Use control to select material thickness and corresponding amperage.
When Material switch is in the DC position, use the blue scale to select the appropriate material 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 corresponding amperage from the white scale.
AC parameters have been optimized and automatically set as follows:
• Preflow is preset at .4 seconds for DC or AC
• Postflow is preset for one second for every ten amps of output, with a minimum of eight seconds for DC or AC.
• Balance is 72% EN (electrode negative)
• Frequency is 120 Hz
3 Power Switch
Use switch to turn unit On and Off.
4 Power On LED
Power is on when LED is lit. LED flashes when input power is more than ±10% of 230 volts. No output available when LED is flashing.
5 Output Indicator LED
Output is On when LED is lit. LED flashes
when unit is overheated (see Section 3-5).
LED stops flashing when unit has cooled.
805 163-A / 232 896
OM-246 522 Page 20
6
7
8
9
6 Torch
Torch Operation:
7 Amperage Adjustment Wheel
Use wheel to adjust amperage from ten amps to maximum value set on the machine’s Material Thickness/
Amperage Control.
8 On/Off Switch
Switch has three features that control the machine in different ways:
• Trigger hold − Push and release
On/Off switch to start welding. After switch is released, the Amperage Adjustment wheel can be adjusted to ramp amperage to desired value for the material being welded. To end weld sequence, push and release switch.
• Tacking/Fitting Feature − Press and hold On/Off switch for more than one second to start weld output. Release switch to end weld output. This feature is useful for tacking and fitting, or in other situations when weld output is needed for short periods of time.
• Crater-Out Feature − Press and hold On/Off switch at end of weld sequence to ramp weld amperage down until arc is extinguished. Use this feature at the end of the weld sequence to help fill the crater that can form in the weld puddle.
9 Optional Foot Control
This is a dedicated foot control which can be purchased as an accessory.
When the optional foot control is plugged into the Remote Recep-
tacle (see Section 4-2), the fingertip
control on the torch is disabled.
805 059-A / 805 158-A
OM-246 522 Page 21
5-2. Controls For Diversion 180 Models
5
4
3
2
1
1 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.
!
Do not change position of switch while welding or while under load.
.
Unit is equipped with Fan-On-Demandt.
Fan only runs when output is on or cooling is required.
Use button to select DC for steel, stainless steel, and chrome-moly, or AC for aluminum applications. Corresponding LED lights to verify selection of AC or DC.
2 Material Thickness/Amperage Control
Check chart to find correct material thickness and use control to select corresponding amperage.
With DC selected and DC LED lit , use the blue scale to select the appropriate material thickness and corresponding amperage from the white scale. When AC is selected and AC LED is lit, use the gray scale to select the appropriate material thickness and corresponding amperage from the white scale.
AC parameters have been optimized and automatically set as follows:
• Preflow is preset at .4 seconds for DC or AC
• Postflow is preset for one second for every ten amps of output, with a minimum of eight seconds for DC or AC.
• Balance is 72% EN (electrode negative)
• Frequency is 120 Hz
3 Amps Meter
Select preset amps with Material Thickness/
Amperage Control. Preset amperage range for
115 volts is 10−125 amps, and 10−180 amps for 230 volts. When output is on, meter displays output amps.
4 Output Indicator LED
Output is On when LED is lit.
5 Power Switch
Use switch to turn unit On and Off.
805 477-A /
OM-246 522 Page 22
6
7
8
9
6 Torch
Torch Operation:
7 Amperage Adjustment Wheel
Use wheel to adjust amperage from ten amps to maximum value set on the machine’s Material Thickness/
Amperage Control.
8 On/Off Switch
Switch has three features that control the machine in different ways:
• Trigger hold − Push and release
On/Off switch to start welding. After switch is released, the Amperage Adjustment wheel can be adjusted to ramp amperage to desired value for the material being welded. To end weld sequence, push and release switch.
• Tacking/Fitting Feature − Press and hold On/Off switch for more than one second to start weld output. Release switch to end weld output. This feature is useful for tacking and fitting, or in other situations when weld output is needed for short periods of time.
• Crater-Out Feature − Press and hold On/Off switch at end of weld sequence to ramp weld amperage down until arc is extinguished. Use this feature at the end of the weld sequence to help fill the crater that can form in the weld puddle.
9 Optional Foot Control
This is a dedicated foot control which can be purchased as an accessory.
When the optional foot control is plugged into the Remote Recep-
tacle (see Section 4-2), the fingertip
control on the torch is disabled.
805 059-A / 805 158-A
OM-246 522 Page 23
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
!
Disconnect power before maintaining.
.
Maintain more often during severe conditions.
n = Check Z = Change ~ = Clean
* To be done by Factory Authorized Service Agent
Δ = Repair l = Replace
Every
3
Months
Every
3
Months nl Labels n l Gas Hoses
Every
6
Months nΔ lCables And Cords
~:Durning heavy service, clean monthly.
6-2. Circuit Breaker CB1
1 Supplementary Protector CB1
If CB1 opens, unit will be completely inoperative.
If CB1 opens repeatedly, have a Factory Authorized Service Agent check unit..
1
805 395-A
OM-246 522 Page 24
6-3. Meter Troubleshooting Displays For Diversion 180 Models
1
TEMP MAG
Repeat
.
All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit.
1 Typical meter display may be in several segments. Each segment is shown for two seconds, and then scrolls to the remaining segments of the display. The message then repeats itself.
w [TEMP] [FAIL] [MAG]
Indicates a short or open in the thermal protection circuitry located in the transformer of the unit. Contact a Factory Authorized Service Agent if this display is shown.
w [TEMP] [FAIL] [SEC]
Indicates a short or open in the thermal protection circuitry located in the secondary of the unit. Contact a Factory Authorized
Service Agent if this display is shown.
w [TEMP] [FAIL] [PRI]
Indicates a short or open in the thermal protection circuitry located in the primary of the unit. Contact a Factory Authorized Service Agent if this display is shown.
w [SEC] [CLMP] [ERR]
Secondary clamp voltage too high.
Straighten out or shorten weld cables. If this does not correct the problem, contact a
Factory Authorized Service Agent.
w [Over][Temp]
On for two seconds then flashes:
[SEC] − Indicates the secondary of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section
3-5). Operation will continue when the unit
has cooled.
[PRI] − Indicates the primary of the unit has overheated. The unit has shut down to
allow the fan to cool it (see Section 3-5). Op-
eration will continue when the unit has cooled.
[MAG] − Indicates that the transformer has overheated. The unit has shut down to
allow the fan to cool it (see Section 3-5). Op-
eration will continue when the unit has cooled.
w [REL][TRIG]
Indicates that the torch trigger is depressed. Release trigger to continue.
w [NOT][VALD]
Indicates a non-allowable set-up on the front panel.
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 Agent check unit.
There are no user serviceable parts inside unit.
Trouble
No weld output; unit completely inoperative.
No weld output; unit on.
Unit provides only maximum or minimum weld output.
Erratic or improper weld output.
No control of weld output.
Lack of high frequency; difficulty in starting GTAW arc.
Wandering arc − poor control of direction of arc.
Remedy
Place machine power switch in On position (see Section 5-1 or 5-2).
Place line disconnect switch in On position (see Section 4-5).
Check and replace line fuse(s), if necessary (see Section 4-5).
Check for proper input power connections (see Section 4-5).
Check, repair, or replace remote control.
Have Factory Authorized Service Agent check unit.
Make sure Material Thickness/amperage control is in proper position (see Section 5-1 or 5-2).
Have Factory Authorized Service Agent check unit.
Lay weld cables out straight, do not leave weld cables coiled.
Check position of Material Selector switch (see Section Figure 5-1 or 5-2).
Check position of Material Thickness/amperage control (see Section 5-1 or 5-2).
Make sure Material Thickness/amperage control is in proper position (see Section 5-1 or 5-2).
Select proper size tungsten (see Section 9-1).
Be sure torch cable is not close to any grounded metal.
Check cables and torch for cracked insulation or bad connections. Repair or replace.
Reduce gas flow rate (see Section 4-3).
Select proper size tungsten (see Section 9-1).
OM-246 522 Page 25
Trouble Remedy
Tungsten electrode oxidizing and not remaining bright after conclusion of weld.
Properly prepare tungsten (see Section 9-2).
Shield weld zone from drafts.
Check and tighten all gas fittings.
Fan not operating.
No weld output; fan does not run.
Properly prepare tungsten (see Section 9-2).
Unit equipped with Fan-On-Demandt. Fans run only when necessary. Unit equipped with circuitry to protect against overheating.
Place line disconnect switch in On position (see Section 4-5).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-5).
Check for proper input power connections (see Section 4-5).
For Diversion 165 models, be sure Material Selector switch is set in position (see Section 5-1).
No weld output; fan on.
Fan not operating; weld output available.
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).
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
Input voltage out of usual range of 230 volts ±10%.
Power LED flashes (Diversion 165
Models).
Output On LED flashes (Diversion 165
Models).
Unit has overheated. Do not use until LED stops flashing (see Sections 3-5 and 5-1 or 5-2).
OM-246 522 Page 26
SECTION 7 − ELECTRICAL DIAGRAMS
Figure 7-1. Circuit Diagram For Diversion 165 Models
232 891-E
OM-246 522 Page 27
OM-246 522 Page 28
Figure 7-2. Circuit Diagram For Diversion 180 Models
246 520-A
SECTION 8 − HIGH FREQUENCY
8-1. Welding Processes Requiring High Frequency
1 High-Frequency Voltage
TIG − helps arc jump air gap between torch and workpiece and/ or stabilize the arc.
1
Work
TIG high_freq 7/05 − S-0693
8-2. Incorrect Installation
13
Weld Zone
11, 12
50 ft
(15 m)
9
8
7
10
2
3
1
4 5 6
14
Sources of 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 Fixtures
14 External Phone and Power Lines
OM-246 522 Page 29
8-3. Correct Installation
3 50 ft
(15 m)
Weld Zone 7
50 ft
(15 m)
5
6
1
4
2
8
8
Ground all metal objects and all wiring in welding zone using
#12 AWG wire.
Nonmetal
Building
Ground workpiece if required by codes.
9
Metal Building
8
8
11
10
1 High-Frequency Source (welding power source with built-in HF or separate HF unit)
Ground metal machine case, work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all directions.
4 Weld Output Cables
Keep cables short and close together.
OM-246 522 Page 30
5 Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
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 across seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
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 )
Electrode Diameter
Amperage Range - Gas Type ♦ - Polarity
(DCEN) − Argon
Direct Current Electrode Negative
(For Use With Mild Or Stainless Steel)
AC − Argon
Balance Control @ 65% Electrode Negative
(For Use With Aluminum)
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.010 in. (1 mm)
.020 in. (1 mm)
.040 in. (1 mm)
1/16 in. (1.6 mm)
3/32 in. (2.4 mm)
1/8 in. (3.2 mm)
Up to 25
15-40
25-85
50-160
130-250
250-400
Up to 20
15-35
20-80
50-150
135-235
225-360
5/32 in. (4.0 mm)
3/16 in (4.8 mm)
1/4 in. (6.4 mm)
400-500
500-750
750-1000
300-450
400-500
600-800
♦ Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations 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 information. 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 environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Radial Grinding
Causes Wandering Arc
Wrong Tungsten
Preparation
2
2-1/2 Times
Electrode Diameter
3
1
4
Ideal Tungsten Preparation − Stable Arc
1 Grinding Wheel
Grind end of tungsten on fine grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.
2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage capacity.
4 Straight Ground
Grind lengthwise, not radial.
OM-246 522 Page 31
SECTION 10 − GUIDELINES FOR TIG WELDING (GTAW)
10-1. Positioning The Torch
10−25 °
4
1
2
10−15 °
90 °
5
6
3
5
6
1/16 in.
3/16 in.
Bottom View Of Gas Cup
4
!
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.
Consider using cerium or lanthanum based tungsten instead of thoriated. Thorium dust contains low-level radioactive material.
Properly dispose of grinder dust in an environmentally safe way.
Wear proper face, hand, and body protection. Keep flammables 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
Guidelines:
The inside diameter of the gas cup should be at least three times the tungsten diameter to provide adequate shielding gas coverage. (For example, if tungsten is 1/16 in. diameter, gas cup should be a minimum of 3/16 in.
diameter.
Tungsten extension is the distance the tungsten extends out gas cup of torch.
The tungsten extension should be no greater than the inside diameter of the gas cup.
Arc length is the distance from the tungsten to the workpiece.
Ref. ST-161 892
OM-246 522 Page 32
10-2. Torch Movement During Welding
Tungsten Without Filler Rod
Welding direction
Form pool
Tungsten With Filler Rod
Welding direction
Form pool
Tilt torch
Tilt torch
75 °
75 °
15 °
Move torch to front of pool. Repeat process.
Add filler metal
Remove rod Move torch to front of pool. Repeat process.
10-3. Positioning Torch Tungsten For Various Weld Joints
Butt Weld And Stringer Bead
“T” Joint
ST-162 002-B
20 °
90 °
70 °
75 °
20 °
Lap Joint
10 °
15 °
Corner Joint
20-40 °
90 °
75 °
75 °
15 °
30 °
15 °
ST-162 003 / S-0792
OM-246 522 Page 33
SECTION 11 − PARTS LIST
Diversion 165 Models
1
2
11
29
30
31
27
28
32
33
34 35
36
38
39
40
37
25
24
23
22
21
3
4
5 6
7
15
16
17
11
8
9 10
12
13
14
20
19
18
26
805 115-B
OM−246 522 Page 34
Figure 11-1. Main Assembly For Diversion 165 Models
Item
No.
Dia.
Mkgs.
Part
No.
Description Quantity
Figure 11-1 . Main Assembly For Diversion 165 Models
. . . 1 . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . .
. . . 5
6
. . . . GS1 . . .
. . . . . . . . . . . . . . . . .
. . . 7
8
. . . . CB1 . . .
. . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . .
. . . 14 . . . . .
15
L1 . . . .
. . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . .
. . .
. . .
17
18
. . . .
. . . .
PC1
FM1
. . .
. . .
. . . 19 . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . .
. . .
. . .
23
24
. . . . . S2 . . . .
. . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . .
. . .
. . .
34
35
. . . . .
. . . . .
. . . 36 . . . . .
S1
P1
T2
PC3 . . . 37 . . . .
. . .
. . .
38
39
. . . . . L2
. . . . . . . . . . . . .
. . . 40 . . . . . . . . . . . . .
+232 868
230 366
232 915
216 607 Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict
111 443
233 184
232 865
. .
. .
. .
. .
. .
. .
. .
. .
Wrapper,
Panel, Rear
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning General Precautionary Static
Cord Set, 250v 6−50p 12ga 3/C 7ft Spt−3 Jkt
188 048 Hose, Nprn Brd No 1 X .250 Id X 18.000
137 761 Nut, 750 NPT 1.31 Hex .27 H Nyl Blk
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Strain Relief .240/.510 Id X .875 Mtg Hole
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
Supplementary Protector, Man Reset 1p 35a 250vac
. . . . . . . . . . . . . . . . . .
232 940
232 901
235 424
237 414
083 147
230 058
. .
. .
. .
. .
. .
. .
. .
. .
. .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductor, Input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ftg, Hose Brs Barbed M 3/16 Tbg X 5/8−18 Thrd
Handle, Carrying
232 939 Hose, Sae .187id X .410od X 12 Ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 922
Windtunnel, Assembly (see Figure 11-3)
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator/Flowmeter, 10−50 CFH Argon/CO2
232 866
. .
. . Plenum, Air
232 863 Base
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High
Circuit Card Assy, Control & Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 923 Fan, Muffin 24vdc 4500 Rpm 240 Cfm 4.125 Mtg Holes
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
239 388
. .
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumper, RBR .875 OD X .188 ID X .39 High Recessed
233 200 Cable Assy, RJ45
134 847
231 238
. .
. .
. .
Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Blk
Nut, 468−32 .56 Hex .09 H Brs Blk Use w/Switches
217 839 Nut, Nylon Strain Rlf Pg13.5 .250thk 1.062od
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 908
. .
. . Work Cable, W/Clamp (12’)
235 392 Torch, Tig 150a 12ft Air Cooled
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
233 187
. .
. . Strain Relief, Cable .250 Cable Dia .5x.450 D Hole
207 079 Knob, Pointer 1.125 Dia
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
178 355 Nut, 375−32 .54 Hex .25 H Nyl Flange .62 D
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 896
. .
. . Nameplate, Miller Diversion 165
232 864 Panel, Front
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 320 Nut, Nylon Thd Pg 16
. . . . .
. . . .
. . . .
. . .
. . . .
124 511
233 165
232 909
. .
Pot Assy, W/Leads & Connector & Leds Cp Flat 1t 2.
212 890 Circuit Card Assy, Arc Starter
208 066 Inductor, Toroid 5 Amp 180 Uh, 12” Leads W/Quick Con
210 323
. .
. .
. .
. .
. .
. .
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Tgl Dpst 40a 600vac Scr Term
Inductor, Arc Starter/Output 150 Amp
Insulator, Washer Inductor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
185 835 Label, Warning Electric Shock/Exploding Parts
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
2
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-246 522 Page 35
Diversion 180 Models
23
11
25
26
24
27
3
1
2
28
29 30
31
32
34
33
35
36
4
5
7
15
16
17
19
18
20
37
21
8
6
11
12
9
10
13
14
22
805 479-A
OM−246 522 Page 36
Figure 11-2. Main Assembly For Diversion 180 Models
Item
No.
Dia.
Mkgs.
Part
No.
Description Quantity
Figure 11-2. Main Assembly For Diversion 180 Models
. . . 1 . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . .
. . . 5
6
. . . .
. . . 7 . . . .
GS1 . . .
. . . . . . . . . . . . . . . .
8
CB1 . . .
. . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . .
+232 868
. . . 3 . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
230 366
241 271
219258
188 048
216 607
233 184
. .
. .
. .
. .
. .
. .
. .
. .
. .
. .
Wrapper,
246 515 Panel, Rear
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning General Precautionary Static
Cable, power 10 ft 2 in. 14GA 3C w/ MVP & Adapter
219261 Adapter, Power Cable 5-15P (115V/15A
Adapter, Power Cable 6-50P (230V/50A
Hose, Nprn Brd No 1 X .250 Id X 18.000
137 761 Nut, 750 NPT 1.31 Hex .27 H Nyl Blk
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
Supplementary Protector, Man Reset 1P 35A 250VAC
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . . . . .
217 028 Bushing, Strain Relief.390/.560 Id X .830 Mtg Hole
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
232 940
. .
. . Ftg, Hose Brs Barbed M 3/16 Tbg X 5/8−18 Thrd
232 901 Handle, Carrying
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
237 592 Hose, gas 12 ft w/clamps
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . .
. . . .
. .
. .
246 538 Inductor, Input
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
235 424 Regulator/Flowmeter, 10−50 CFH Argon/CO2
+246 525
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windtunnel, Assembly (see Figure 11-3)
. . . . . . . . . . . . . . . . . . . . . . .
. .
. .
244 389 Circuit Card Assy, Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
083 147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High
. . . 14
15
. . . . . L1
. . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . .
. . . 17 . . . .
. . . 18 . . . .
PC1
FM1
. . .
. . .
. . . 19 . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . .
. . . 22 . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
24
232 923
232 866
239 388
232 908
LS0011
. .
. .
. .
. .
. .
. .
. .
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, Muffin 24vdc 4500 Rpm 240 Cfm 4.125 Mtg Holes
Plenum, Air
232 863 Base
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch & Potentiometer, Momentary
233 187 Strain Relief, Cable .250 Cable Dia .5x.450 D Hole
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Work Cable, W/Clamp (12 Ft)
235 392 Torch, Tig 150a 12ft Air Cooled
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumper, RBR .875 OD X .188 ID X .39 High Recessed . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
231 297
. .
. . Actuator Push Button Assy
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
228 546 Knob, Pointer 1.125 Dia x 6mm Id W/Spring Clip− 4.5mm Flat . . . . . . . .
Nameplate, Miller Diversion 180 (order by model and serial number)
. . . . . . . . . . . . . . . .
. . . 25
26
. . . . . . . . . . . . .
. . .
27
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . .
. . . 29 . . . . .
. . . 30 . . . .
S1
PC4
. . . .
. . .
. . . 31 . . . . . . . . . . . . .
. . .
. . .
. . .
. . .
32
33
34
35
. . . . . T2 . . . .
. . . . . . . . . . . . .
. . . . . L2 . . . .
. . . . . . . . . . . . .
. . . 36
37
. . . . PC3 . . .
. . . . . . . . . . . . . . . .
246 541 . . Panel, Front
208 550
244 354
233 200
. .
. .
. .
. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Rocker DPST 16A 250VAC On−off Blk Panel Mtg
Circuit Card Assy, & Interface W/Program
Cable Assy, RJ45
246 530 Inductor, Arc Starter/Output 150 Amp
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
210 323
. .
. . Insulator, Washer Inductor
208 066 Inductor, Toroid 5 Amp 180 Uh, 12” Leads W/Quick Con
185 835
245 589
. .
. .
. .
Label, Warning Electric Shock/Exploding Parts
RFCS−RJ45 Foot Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
235 476 Circuit Card Assy, Arc Starter (R)
. .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-246 522 Page 37
.
Hardware is common and not available unless listed.
1
2
3
4
5 6
8
Figure 11-3. Windtunnel Assembly
7
805 135-C
Item
No.
Dia.
Mkgs.
Part
No.
Description Quantity
Figure 11-3. Windtunnel Assembly (Figures 11-1 And 11-2, Item 15)
. . .
. . .
1
2
. . . PC2 .
. . . . . . . . . .
230 144
242 084
. .
. .
Circuit Card Assy, Commutator Control
Bushing, Snap-In Nyl
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
3
4
. . . . . . . . . .
. . . . . . . .
212 458
+232 867
. .
. .
Stand-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Midplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
5
5
. . . .
. . . .
T1
T1
. .
. .
237 413
246 540
. .
. .
XFMR, Main (Includes) (165 Models)
XFMR, Main (Includes) (180 Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. . .
6
7
. . . RT3 .
. . . . . . . . .
207 890
232 917
. . . .
. .
Thermistor, NTC 10K Ohm @ 25 Deg C 27.50 In Lead
Heat Sink, Secondary Assy (See Figure 11-4)
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . Z1 . . 237 412 . . Inductor, Output (165 Models)
. . . 8 . . . . Z1 . . 246 539 . . Inductor, Output (180 Models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
4
1
1
6
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM−246 522 Page 38
.
Hardware is common and not available unless listed.
2
1
4
3
5
3
6
3
3
Figure 11-4. Heat Sink, Secondary Assembly
805 123-A
Item
No.
Dia.
Mkgs.
Part
No.
232 917
Description Quantity
Figure 11-4. Heat Sink, Secondary Assembly (Figure 11-3, Item 7)
. . .
. . .
1
2
. . . . . . . . .
. .
232 869
D9,D12 231 396
. .
. .
Heat Sink, Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diode, Ultra-Fast Recovery 90 A 600 V Dual SOT-227 . . . . . . . . . . . . . . . . . .
. . .
. . .
3
4
. Q2,3,4,5 231 393
. . . RT2 . 213 353
. .
. .
Transistor, IGBT 100 A 600 V SOT-227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor, NTC 30K Ohm @ 25 Deg C 8 In Lead . . . . . . . . . . . . . . . . . . . . . .
4
1
1
2
. . .
. . .
5
6
. . . . . . . . .
. . . SR1 .
212 038
199 952
. .
. .
Screw, M4 .7 x 8.5 Pan HD-PHL STL PLD Sems Split/Fl
Diode, Power Module 50 Amp 600 V 1 PH Fast Recovery
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
15
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-246 522 Page 39
Notes
Notes
Notes
Warranty Questions?
Call
1-800-4-A-MILLER for your local
Miller distributor.
Your distributor also gives you ...
Service
You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Support
Need fast answers to the tough welding questions?
Contact your distributor.
The expertise of the distributor and Miller is there to help you, every step of the way.
Effective January 1, 2010
(Equipment with a serial number preface of MA or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.
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 not apply to:
Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an
International distributor.
1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs, diodes, and discrete rectifier modules
2. 3 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter
Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)
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-driven products.)
2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B.,
Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
3. 2 Years — Parts
* Auto-Darkening Helmet Lenses (No Labor)
4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors
* HF Units
* ICE Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
* Load Banks
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Work Stations/Weld Tables (No Labor)
5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 2010−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
City
State
Serial/Style Number
(Date which equipment was delivered to original customer.)
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Contact the Delivering Carrier to:
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
To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller
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
©
2010 Miller Electric Mfg. Co. 2010−01
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit www.MillerWelds.com
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