Miller Electric DVI-2 R manual

Processes Description Arc Welding Power Source and Wire Feeder OM-232 386B 2007−11 Millermatic DVI-2 R Flux Cored (FCA W) W elding MIG (GMAW ) W elding File: MIG (GMA W) V isit our website at www.MillerWelds.com[...]

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[...]

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

T ABLE OF CONTENTS SECTION 8 − MIG WELDING (GMA W) GUIDELINES 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical MIG Process Connections 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. T ypical MIG Process Control Settin[...]

OM-232 386 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage 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 o[...]

OM-232 386 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. 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 poo[...]

OM-232 386 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.[...]

OM-232 386 Page 4 1-4. California Proposition 65 W arnings W elding 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 [...]

OM-232 386 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2007−04 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es u t ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures grave[...]

OM-232 386 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. 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. DES PIÈCES CH[...]

OM-232 386 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. LES CHAMPS MAGNETIQUES peuv- ent affecter des implants m[...]

OM-232 386 Page 8 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 per- sonnes ou toute pièce mécanique en enga- geant le fil de soudage. DES ORGANES MOBILES peuvent provoquer des blessures. D S’abstenir de t o ucher[...]

OM-232 386 Page 9 2-5. P ri nc ipa le s no rm es de séc ur it é Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American [...]

OM-232 386 Page 10[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 1 1 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 (GMA W) Gun Wire Feed Spool Gun Gas Input Gas Output V oltage Input Press T o Reset U 0 Rated No-Load V o[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 12 4-2. Duty Cycle And Overheating Duty Cyc l e is percen tage of 10 minutes t hat unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty c[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 13 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 −[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 14 4-5. Installing W ork Cable And Clamp T ools Nee d e d : 3/4 in 1 W ork Cable 2 Boot Route cable through front panel opening. Slide boot onto work cable. 3 Negative (−) Output T erminal Connect cable to terminal and cover connection with boot. Close door . 2 3 1 804 [...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 15 4-7. Installing Gas Supply Ref. 804 654-A / Ref. 804 898-A T ools Nee d e d : 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, a[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 16 4-8. 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[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 17 4-9. Connecting 1-Phase Input Power For 230 V AC 803 766-B / Ref. 802 443-A ! 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[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 18 4-10. Electrical Service Guide For 230 V AC Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the w[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 19 4-12. Selecting A Location And Connecting Input Power ! 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 ind ividual branch circuit protect[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 20 4-13. 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: . Hold wire tightly to keep it from unraveling. WOOD Open pressure ass[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 21 4-14. Installing Optional Gas V alve, Receptacle, And Barbed Fitting For Optional Spool Gun T ools N eeded: ! T urn Off unit, and disconnect input power . Remove wrapper . 1 Rear Panel 2 Snap-in Blank Location 3 Center Baffle Barbed Fitting Hole Location 4 Front Panel [...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 22 4-15. Connecting An Optional Spool Gun 3 2 1 4 804 922-A 1 Barbed Fitting . 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 barbed fitting. 2 Gun Trigger Plug Insert plug into recept[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 23 SECTION 5 − OPERA TION 5-1. Controls 1 V oltage Control 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 o[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 24 5-2. W eld Parameter Chart Input Line Voltage* Parameter Chart Settings Higher e.g. 240 Volts AC 230 Volts AC Lower e.g. 218 Volts AC Weld Will Be Hotter Lower Settings Use Parameter Chart Weld Will Be Colder Raise Settings *Line voltage can af fect weld output, settin[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 25 226 652-A[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 26 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 27 6-4. Aligning Drive Rolls and Wire Guide ! 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 d[...]

. A complete Parts List is available at www .MillerW elds.com OM-232 386 Page 28 Wire Drive/Gun T rouble Remedy Electrode wire feeding stops during welding. Straighten gun cable and/or replace damaged parts (see welding gun Owner’s Manual). welding. Adjust drive roll pressure (see Section 4-13 ). Readjust hub tension (see Section 4-8). Replace co[...]

OM-232 386 Page 29 Notes[...]

OM-232 386 Page 30 SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Welding Power Source Circuit Diagram[...]

OM-232 386 Page 31 229 598-B[...]

OM-232 386 Page 32 SECTION 8 − MIG WELDING (GMA W) GUIDELINES Wire Feeder/ Power Source W orkpiece Gun Regulator/ Flowmeter Gas Shielding Gas W ork Clamp 8-1. T ypical MIG Process Connections ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl a c e w o r k c l a m p a s close t [...]

OM-232 386 Page 33 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. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A C[...]

OM-232 386 Page 34 8-3. Holding And Positioning Welding Gun . W elding 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. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electrod[...]

OM-232 386 Page 35 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. Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROF[...]

OM-232 386 Page 36 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 acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Alon[...]

OM-232 386 Page 37 8-8. T roubleshooting − Excessive Spatter Excessive Spa tter − scattering of molten metal partic les that cool t o 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.[...]

OM-232 386 Page 38 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 maintai[...]

OM-232 386 Page 39 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 h[...]

OM-232 386 Page 40 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 Cir[...]

OM-232 386 Page 41 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 o n welding power [...]

OM-232 368 Page 42 SECTION 9 − P ARTS LIST 9-1. Drive Roll And Wire Guide Kits . Base selection of drive rolls upon the following recommended usages: 1 V -Grooved rolls for hard wire. 2 U-Grooved rolls for soft and soft shelled cored wires. 3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4 V -Knurled rolls for ha[...]

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 expert[...]

PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01 Miller Elect ric Mfg. Co. An I l li noi s T ool W ork s Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarters− USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X : 9 20-735-4134 Int ernational F AX : 9 20-735-4125 European Headquart ers[...]