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Miller Electric Millermatic DVI manual

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Table of contents for the manual

  • Page 1

    Processes Description Arc Welding Power Source and Wire Feeder OM-1330 220 237H 2007 − 02 Millermatic DVI And M-10 Gun R Flux Cored (FCA W) W elding MIG (GMAW) Welding File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

  • Page 2

    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. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 8 − MIG WELDING (GMA W) GUIDELINES 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical MIG Process Connections 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. T ypical MIG Process Control Settin[...]

  • Page 5

    OM-1330 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety messa[...]

  • Page 6

    OM-1330 Page 2 Arc rays from the weld ing process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (s[...]

  • Page 7

    OM-1330 Page 3 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. F [...]

  • Page 8

    OM-1330 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A WS F[...]

  • Page 9

    OM-1330 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es r is ques poss ibles[...]

  • Page 10

    OM-1330 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau.[...]

  • Page 11

    OM-1330 Page 7 2-3 . Da ngers s uppl émenta ires en r el ation avec l’installa tion, le f onctionne ment et la m a intenanc e Risque D’INCENDIE OU D’EXPLO- SION. 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[...]

  • Page 12

    OM-1330 Page 8 2-5. Princi pales normes de sécur ité Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices f or the Preparation for W elding and Cut- ting of Containers and Piping , American W elding[...]

  • Page 13

    OM-1330 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Wire Feed Output X Duty Cycle Do Not Switch While W elding V V olts Increase On Of f Gas Metal Arc W elding (GMAW) Gun Wire Feed Spool Gun Gas Input Gas Output V oltage Input Press T o Reset U 0 Rated No-Load V oltage (A verage) SECTION 4 − INST ALLA TION 4-1. Specifications A.[...]

  • Page 14

    OM-1330 Page 10 4-2. Duty Cycle And Overheating Duty Cyc le is percenta ge of 10 minutes t hat unit can weld a t rated load without ov erheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit or g[...]

  • Page 15

    OM-1330 Page 1 1 4-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. . Ranges 4 , 5 , and 6 apply to 2 30 V AC only . ssb1.1 10/91 − 199 212 0 5 10 15 20 25 30 35 0 50 100 150 200 250 DC AMPERES D[...]

  • Page 16

    OM-1330 Page 12 4-5. Connecting T o Weld Output T erminals 803 778-A Y T urn off power before connecting to weld output terminals. Y Failure to properly connect weld cables may cause excessive heat an d start a fire, or damage your ma- chine. 1 W eld Output T erminal 2 Supplied Weld Output T erminal Nut 3 Weld Cable T erminal 4 Copper Bar Remove su[...]

  • Page 17

    OM-1330 Page 13 4-7. Installing W elding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gun en d through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). T ighten knob. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar . Close door . 803 860-B [...]

  • Page 18

    OM-1330 Page 14 4-9. Installing Gas Supply 803 861-B T ools Needed: Obtain gas cylinders and chain to running gear , wall, or other stationary support so cylinders cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove cap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4[...]

  • Page 19

    OM-1330 Page 15 4-10. Installing MIG Wire Spool and Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 15/16 in Use compression spring with 8 in (200 mm) spools. T ools Needed: 072573-B / 802 922 Installing 1 Or 2 lb Wire Spool T o install either a 1 lb or 2 lb wire spool, follow the procedure as shown in the illust[...]

  • Page 20

    OM-1330 Page 16 4-1 1. Connecting 1-Phase Input Power For 230 V AC 803 766-B / Ref. 802 443-A Y Ins tallatio n mus t meet all National and L ocal Codes − have only qualifie d persons mak e this installation. Y Disconnect and lockout/tagout input power before connecting input conductors from unit. Y Always connect green or green/ yellow conductor [...]

  • Page 21

    OM-1330 Page 17 4-12. Electrical Service Guide For 230 V AC 60 Hz Single Phase Input V oltage 230 Input Amperes At Rated Output 25 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker 1 , Time-Delay 2 30 Normal Operating 3 35 Min Input Conductor Size In A WG 4 12 Max Recommended Input Conductor Length In Feet (Meters) 79 (24) Min Groundi[...]

  • Page 22

    OM-1330 Page 18 4-14. Selecting A Location And Connecting Input Power Y Special installation may be required where gasoline or volatile liquids ar e present − see NEC Article 51 1 or CEC Section 20. For 1 15 volts ac input power , a 15 or 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. For 230 vol[...]

  • Page 23

    OM-1330 Page 19 4-15. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. T ools Needed: 6 in (150 mm) . Hold wire tightly to keep it from unraveling. WOOD Open pressure assembly . Pull and hold wire; cut off end. Push wire [...]

  • Page 24

    OM-1330 Page 20 4-16. Installing Diverter V alve And Switch For Optional Spool Gun Ref. 803 906-B / 803 908-A T ools Needed: Y T urn Off unit, and disconnect input power . Disconnect and remove MIG (GMAW) welding gun, if applicable. 1 Input End Of Existing Gas Hose 2 Output End Of Existing Gas Hose 3 Spool Gun Gas Hose 4 Gas Diverter V alve T o ins[...]

  • Page 25

    OM-1330 Page 21 4-17. Connecting An Optional Spool Gun If a MIG gun is connected to the unit, remove it before connecting spool gun. 1 Diverter V alve . If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose. Connect spool gun gas hose to diverter valve barbed fitting (see Section 4-16 ). 2 Gun Trigg[...]

  • Page 26

    OM-1330 Page 22 SECTION 5 − OPERA TION 5-1. Controls 1 V oltage Control . Positions 4, 5, and 6 are for 230 volts ac input only . Set V oltage control according to the parameter chart for good starting point. Turn control clockwise to increase voltage. 2 Wire Speed Control Set Wire Speed control according to the parameter chart. Increase or decre[...]

  • Page 27

    OM-1330 Page 23 Notes[...]

  • Page 28

    OM-1330 Page 24 5-2. W eld Parameter Chart[...]

  • Page 29

    OM-1330 Page 25 220 493-A[...]

  • Page 30

    OM-1330 Page 26 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Blow out or vacuum inside. OR Remove drive roll and carrier .[...]

  • Page 31

    OM-1330 Page 27 6-3. Unit Overload Thermostats TP1 in rectifier SR1 and TP2 in stabilizer Z1 protect the unit from damage due to overheating. If TP1 and/or TP2 opens welding output will shut off. W ait several minutes before trying to weld. Supplementary protector CB2 (Power switch) protects transformer T1 from overload. If CB2 opens, unit power wi[...]

  • Page 32

    OM-1330 Page 28 6-6. Aligning Drive Rolls and Wire Guide Y T urn Off power . V iew is from top of drive rolls looking down with pressure assembly open. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire 5 Drive Gear Insert screwdriver , and turn screw in or out until drive roll groove lines up with wire guide. Close pressure roll as[...]

  • Page 33

    OM-1330 Page 29 6-8. Cleaning Or Replacing Gun Liner Ref. 802 399-A 3/8 in Y Disconnect gun from unit. T ools Needed: Lay gun cable out straight before installing new liner . Head Tube 1/2 in Remove liner . Remove nozzle, contact tip, adapter , gas dif fuser , and wire outlet guide. Blow out gun casing. T o Reassemble Gun: Install and tighten new l[...]

  • Page 34

    OM-1330 Page 30 6-9. Replacing Switch And/Or Head T ube Ref. 800 795-C 1 Remove handle locking nut. 2 Remove switch housing. Note : If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to en[...]

  • Page 35

    OM-1330 Page 31 6-10. T roubleshooting W elding T rouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 4-14 ). Check power switch/supplementary protector , and reset if necessary . If supplementary protector is not tripped, replace power switch. Check supplementary protector CB1, and reset if necessary[...]

  • Page 36

    OM-1330 Page 32 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Welding Power Source Circuit Diagram[...]

  • Page 37

    OM-1330 Page 33 220 197-E[...]

  • Page 38

    OM-1330 Page 34 SECTION 8 − MIG WELDING (GMA W) GUIDELINES 8-1. T ypical MIG Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ac e wo rk c la mp a s close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Hose Shiel[...]

  • Page 39

    OM-1330 Page 35 8-2. T ypical MIG Process Control Settings These settings are guidelines only . Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. T est welds to be sure they comply to specifications. NOTE 1/8 or .125 in Material thickness determines weld parameters. Convert Material (.001 in = 1 ampere) .12[...]

  • Page 40

    OM-1330 Page 36 8-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger , be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electrode[...]

  • Page 41

    OM-1330 Page 37 8-4. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. NOTE Short Normal Long Short Normal Long 10 ° 10 ° GUN ANGLES AND WELD BEAD PROFILES ELECTRODE EXTENSIONS (STICKO[...]

  • Page 42

    OM-1330 Page 38 8-5. Gun Movement During Welding Normally , a single stringer bead is satisfactory for most narrow groove weld joints; however , for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Along[...]

  • Page 43

    OM-1330 Page 39 8-8. T roubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use s[...]

  • Page 44

    OM-1330 Page 40 8-1 1. T roubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintainin[...]

  • Page 45

    OM-1330 Page 41 8-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand[...]

  • Page 46

    OM-1330 Page 42 8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Gas Spray Arc Steel Short Circuiting Steel Short Circui[...]

  • Page 47

    OM-1330 Page 43 Problem Remedy Probable Cause W elding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary . W rong size gun liner or contact tip. Match liner and contact tip to wire size and type. Incorrect voltage setting for selected wire feed speed on welding power sour[...]

  • Page 48

    OM-1330 Page 44 SECTION 9 − P ARTS LIST . Hardware is common and not available unless listed. Ref. 803 864-E 3 4 6 7 8 9 11 12 13 14 15 16 17 20 21 22 23 25 26 27 28 29 30 10 24 5 1 Fig. 9-2 2 Fig. 9-3 18 Fig. 9-4 19 Fig. 9-6 Figure 9-1. Main Assembly[...]

  • Page 49

    OM-1330 Page 45 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quantity 1 Fig 9-2 BAFFLE,CENTER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fig 9-3 P ANEL,REAR 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 50

    OM-1330 Page 46 803 865-C . Hardware is common and not available unless listed. 18 17 16 15 13 11 10 9 8 7 6 5 4 3 2 1 12 14 19 Figure 9-2. Baffle, Center w/Components[...]

  • Page 51

    OM-1330 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1) Quantity SPOOL HUB ASSEMBL Y (INCLUDING) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 058427 RING,RET AINING SPOOL 1 . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 52

    OM-1330 Page 48 803 866-B . Hardware is common and not available unless listed. 9 8 6 5 4 3 2 1 7 10 Figure 9-3. Panel, Rear w/Components Description Part No. Dia. Mkgs. Item No. Figure 9-3. Panel, Rear w/Components (Fig 9-1 Item 2) Quantity 1 049399 NUT , 312 − 18 PUSH ON .63D .07H STL 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 53

    OM-1330 Page 49 803 867-B . Hardware is common and not available unless listed. 1 2 3 4 5 6 8 10 12 13 9 11 7 Figure 9-4. Panel, Front w/Components Description Part No. Dia. Mkgs. Item No. Figure 9-4. Panel, Front w/Components (Fig 9-1 Item 18) Quantity 1 220079 LABEL,NAMEPLA TE MILLERMA TIC DVI 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 54

    OM-1330 Page 50 Description Part No. Dia. Mkgs. Item No. Figure 9-5. Wire Drive And Gears (Fig 9-2 Item 18) Quantity 204857 1 602009 SCREW ,.250-20 x 1.25 soc hd gr 8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172075 CARRIER,DRIVE ROLL W/COMPONENTS 1 . . . . . . . . . . . . . . . . . . [...]

  • Page 55

    OM-1330 Page 51 802 388-B 1 2 3 4 5 6 7 13 9 8 11 14 15 10 12 Figure 9-6. M-10 Gun Quantity Description Part No. Item No. Figure 9-6. M-10 Gun (Fig 9-1 Item 19 ) 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 087 299 TIP , contact scr .023 [...]

  • Page 56

    OM-1330 Page 52 Description Part No. Dia. Mkgs. Item No. Quantity Optional Spoolmate Spool Gun Switch 207 642 186420 SWITCH ASSY 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195539 GAS DIVERTER V AL VE 1 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 57

    Notes[...]

  • Page 58

    Notes[...]

  • Page 59

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2007 − 01 Y our distributor also gives you ... Service Y ou 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 expe[...]

  • Page 60

    PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 920-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters − [...]