DIVERSION 165 And DIVERSION 180 w/auto-line

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TM-246 522C 2011 0 Processes TIG (GTAW) Welding 20 Volt Arc Welding Power Source DIVERSION 165 And DIVERSION 180 w/auto-line Diversion 165 And 180 Models Eff w/ma080041j And Following For OM-246 522 Revision A And Following Visit our website at www.millerwelds.com

SECTION 11 PARTS LIST EFF. W/MA080041J AND FOLLOWING Diversion 165 Models 11 1 2 8 9 40 4 5 6 7 12 9 8 15 16 17 1 4 5 6 7 14 2 1 27 11 28 29 0 22 24 2 25 19 18 20 21 26 805 115-E TM-246 522 Page 74 Figure 11-1. Main Assembly For Diversion 165 Models

Item Dia. Mkgs. Part Quantity Figure 11-1. Main Assembly For Diversion 165 Models... 1... +22 868.. Wrapper,... 1... 2... 20 66.. Label, Warning General Precautionary Static... 1...... 22 915.. Cord Set, 250v 6 50p 12ga /C 7ft Spt Jkt... 1... 4... 188 048.. Hose, Nprn Brd No 1 X.250 Id X 18.000... 1... 5... GS1... 216 607.. Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict... 1... 6... 111 44.. Bushing, Strain Relief.240/.510 Id X.875 Mtg Hole... 1... 7... CB1... 2 184.. Supplementary Protector, Man Reset 1p 5a 250vac... 1... 8... 22 865.. Panel, Rear (Prior to MB080009J)... 1... 8... 246 515.. Panel, Rear (Eff w/mb080009j)... 1... 9... 17 761.. Nut, 750 NPT 1.1 Hex.27 H Nyl Blk... 1... 10... 22 940.. Ftg, Hose Brs Barbed M /16 Tbg X 5/8 18 Thrd (Prior To MA270269J) 1... 11... 22 901.. Handle, Carrying... 2... 12... 248 169.. Hose, Gas 12 Ft w/fittings... 1... 1... 24 26.. Regulator/Flowgauge, 0 50 CFH Argon/CO2/Mix/w/Filter... 1... 14... L1... 27 414.. Inductor, Input (Prior to MB080009J)... 1... 14... L1... 250 74.. Inductor, Input (Eff w/mb080009j)... 1... 15... 22 922.. Windtunnel, Assembly (see Figure 11-)... 1... 16... 08 147.. Grommet, Scr No 8/10 Panel Hole.12 Sq.500 High... 4... 17... PC1... 240 718.. Circuit Card Assy, Control & Interface... 1... 18... FM1... 22 92.. Fan, Muffin 24vdc 4500 Rpm 240 Cfm 4.125 Mtg Holes... 1... 19... 22 866.. Plenum, Air... 1... 20... 22 86.. Base... 1... 21... 29 88.. Bumper, RBR.875 OD X.188 ID X.9 High Recessed... 4... 22... 2 200.. Cable Assy, RJ45... 1... 2... S2... 14 847.. Switch, Tgl Spdt 15a 125vac On none on Spd Term Blk... 1... 24... 21 28.. Nut, 468 2.56 Hex.09 H Brs Blk Use w/switches... 2... 25... 217 89.. Nut, Nylon Strain Rlf Pg1.5.250thk 1.062od... 1... 26... 22 908.. Work Cable, W/Clamp (12 )... 1... 27... 25 92.. Torch, Tig 150a 12ft Air Cooled... 1... 28... 2 187.. Strain Relief, Cable.250 Cable Dia.5x.450 D Hole... 1... 29... 207 079.. Knob, Pointer 1.125 Dia... 1... 0... 178 55.. Nut, 75 2.54 Hex.25 H Nyl Flange.62 D... 1... 1... 22 896.. Nameplate, Miller Diversion 165... 1... 2... 22 864.. Panel, Front... 1...... 22 20.. Nut, Nylon Thd Pg 16... 1... 4... S1... 124 511.. Switch, Tgl Dpst 40a 600vac Scr Term... 1... 5... P1... 2 165.. Pot Assy, W/Leads & Connector & Leds Cp Flat 1t 2.... 1... 6... T2... 22 909.. Inductor, Arc Starter/Output 150 Amp... 1... 7... PC... 228 59.. Circuit Card Assy, Arc Starter... 1... 8... L2... 208 066.. Inductor, Toroid 5 Amp 180 Uh, 12 Leads W/Quick Con... 1... 9... 210 2.. Insulator, Washer Inductor... 1... 40... 185 85.. Label, Warning Electric Shock/Exploding Parts... 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. TM-246 522 Page 75

Diversion 180 Models 11 2 1 8 6 5 6 4 5 7 12 28 2 29 0 1 4 15 16 17 9 14 1 27 2 11 24 26 25 19 18 20 7 21 22 805 479-B Figure 11-2. Main Assembly For Diversion 180 Models TM-246 522 Page 76

Item Dia. Mkgs. Part Quantity Figure 11-2. Main Assembly For Diversion 180 Models... 1... +22 868.. Wrapper,... 1... 2... 20 66.. Label, Warning General Precautionary Static... 1...... 241 271.. Cable, power 10 ft 2 in. 14GA C w/ MVP & Adapter... 1... 219261.. Adapter, Power Cable 5-15P (115V/15A... 1... 219258.. Adapter, Power Cable 6-50P (20V/50A... 1... 4... 188 048.. Hose, Nprn Brd No 1 X.250 Id X 18.000... 1... 5... GS1... 216 607.. Valve, 24vdc 2way Custom Port 1/8 Orf W/Frict... 1... 6... 217 028.. Bushing, Strain Relief.90/.560 Id X.80 Mtg Hole... 1... 7... CB1... 2 184.. Supplementary Protector, Man Reset 1P 5A 250VAC... 1... 8... 246 515.. Panel, Rear... 1... 9... 17 761.. Nut, 750 NPT 1.1 Hex.27 H Nyl Blk... 1... 10... 22 940.. Ftg, Hose Brs Barbed M /16 Tbg X 5/8 18 Thrd (Prior To MA270269J) 1... 11... 22 901.. Handle, Carrying... 2... 12... 248 169.. Hose, Gas 12 ft w/fittings... 1... 1... 24 26.. Regulator/Flowgauge, 0 50 CFH Argon/CO2/Mix w/filler... 1... 14... L1... 246 58.. Inductor, Input... 1... 15... +246 525.. Windtunnel, Assembly (see Figure 11-)... 1... 16... 08 147.. Grommet, Scr No 8/10 Panel Hole.12 Sq.500 High... 4... 17... PC1... 244 89.. Circuit Card Assy, Control... 1... 18... FM1... 22 92.. Fan, Muffin 24vdc 4500 Rpm 240 Cfm 4.125 Mtg Holes... 1... 19... 22 866.. Plenum, Air... 1... 20... 22 86.. Base... 1... 21... 29 88.. Bumper, RBR.875 OD X.188 ID X.9 High Recessed... 4... 22... 22 908.. Work Cable, W/Clamp (12 Ft)... 1... 2... 25 92.. Torch, Tig 150a 12ft Air Cooled... 1... LS0011.. Switch & Potentiometer, Momentary... 1... 24... 2 187.. Strain Relief, Cable.250 Cable Dia.5x.450 D Hole... 1... 25... 21 297.. Actuator Push Button Assy... 1... 26... 228 546.. Knob, Pointer 1.125 Dia x 6mm Id W/Spring Clip 4.5mm Flat... 1... 27... Nameplate, Miller Diversion 180 (order by model and serial number)... 1... 28... 246 541.. Panel, Front... 1... 29... S1... 208 550.. Switch, Rocker DPST 16A 250VAC On off Blk Panel Mtg... 1... 0... PC4... 244 54.. Circuit Card Assy, & Interface W/Program... 1... 1... 2 200.. Cable Assy, RJ45... 1... 2... T2... 246 50.. Inductor, Arc Starter/Output 150 Amp... 1...... 210 2.. Insulator, Washer Inductor... 1... 4... L2... 208 066.. Inductor, Toroid 5 Amp 180 Uh, 12 Leads W/Quick Con... 1... 5... 185 85.. Label, Warning Electric Shock/Exploding Parts... 1... 6... PC... 25 476.. Circuit Card Assy, Arc Starter (R)... 1... 7... 245 589.. RFCS RJ45 Foot Control... 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. TM-246 522 Page 77

Hardware is common and not available unless listed. 4 1 2 5 6 8 7 Figure 11-. Windtunnel Assembly For Diversion 165 And 180 Models 805 15-C Item Dia. Mkgs. Part Quantity Figure 11-. Windtunnel Assembly For Diversion 165 And 180 Models (Figures 11-1 And 11-2, Item 15)... 1... PC2. 20 144.. Circuit Card Assy, Commutator Control... 1... 2... 242 084.. Bushing, Snap-In Nyl... 6...... 212 458.. Stand-Off... 4... 4... +22 867.. Panel, Midplane... 1... 5... T1.. 27 41.. XFMR, Main (Includes) (165 Models)... 1... 5... T1.. 246 540.. XFMR, Main (Includes) (180 Models)... 1... 6... RT. 207 890... Thermistor, NTC 10K Ohm @ 25 Deg C 27.50 In Lead... 1... 7... 22 917.. Heat Sink, Secondary Assy (See Figure 11-4)... 1... 8... Z1.. 27 412.. Inductor, Output (165 Models)... 1... 8... Z1.. 246 59.. Inductor, Output (180 Models)... 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. TM-246 522 Page 78

Hardware is common and not available unless listed. 1 2 4 5 6 Figure 11-4. Heat Sink, Secondary Assembly For Diversion 165 And 180 Models 805 12-A Item Dia. Mkgs. Part 22 917 Quantity Figure 11-4. Heat Sink, Secondary Assembly For Diversion 165 And 180 Models (Figure 11-, Item 7)... 1... 22 869.. Heat Sink, Secondary... 1... 2.. D9,D12 21 96.. Diode, Ultra-Fast Recovery 90 A 600 V Dual SOT-227... 2.... Q2,,4,5 21 9.. Transistor, IGBT 100 A 600 V SOT-227... 4... 4... RT2. 21 5.. Thermistor, NTC 0K Ohm @ 25 Deg C 8 In Lead... 1... 5... 212 08.. Screw, M4.7 x 8.5 Pan HD-PHL STL PLD Sems Split/Fl... 15... 6... SR1. 199 952.. Diode, Power Module 50 Amp 600 V 1 PH Fast Recovery... 1 To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. TM-246 522 Page 79

Miller Electric Mfg. Co. An Illinois Tool Works Company 165 West Spencer Street Appleton, WI 54914 USA International Headquarters USA USA Phone: 920-75-4505 Auto-Attended USA & Canada FAX: 920-75-414 International FAX: 920-75-4125 For International Locations Visit www.millerwelds.com ORIGINAL INSTRUCTIONS PRINTED IN USA 2011 Miller Electric Mfg. Co.

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