Miller Electric DVI-2 R manual From Miller to You

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Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

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, 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.

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 4/05

Working as hard as you do

−every power source from Miller is backed by the most hassle-free warranty in the business.

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Contents Description OM-232 386BProcesses File MIG GmawFrom Miller to You Table of Contents Typical MIG Process Connections − Parts List− MIG Welding Gmaw Guidelines Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsWelding can cause fire or explosion Fumes and Gases can be hazardousARC Rays can burn eyes and skin Flying Metal or Dirt can injure eyesFalling Unit can cause injury Welding Wire can cause injuryFire or Explosion hazard Moving Parts can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings About Implanted Medical DevicesSymboles utilisés UNE Décharge Électrique peut entraîner la mortLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux Risque D’INCENDIE OU D’EXPLO LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-232 386 Specifications − InstallationSymbols And Definitions − DefinitionsOverheating Duty Cycle And Overheating40% duty cycle at 150 amps Minutes Welding Minutes Resting MinutesVolt-Ampere Curves Connecting To Weld Output TerminalsCorrect Installation Range Range 4 RangePolarity Changeover Label Information Installing Work Cable And ClampSetting Gun Polarity For Wire Type 11/16Tools Needed 8, 5/8 Installing Gas SupplyRear Panel Use compression spring Installing MIG Wire Spool and Adjusting Hub TensionInstalling 1 Or 2 lb Wire Spool With 8 in 200 mm spools To turn spool, tension is setConnecting 1-Phase Input Power For 230 VAC 230 VAC =GND/PE Earth GroundExtension Cord Data Electrical Service Guide For 230 VACHz Single Phase 18 in 457 mm of space for airflow Selecting a Location And Connecting Input PowerDo not move or operate unit where it could tip Scale Threading Welding WirePressure Remove gun nozzle and contact tipTurn Off unit, and disconnect input power Connecting An Optional Spool Gun Voltage Control − OperationControls Input Line Weld Parameter ChartVoltage Chart Settings Parameter226 652-A Changing Drive Roll and Wire Inlet Guide − Maintenance &TROUBLESHOOTINGRoutine Maintenance Unit OverloadTurn Off power Aligning Drive Rolls and Wire GuideTroubleshooting Welding Trouble RemedyWire Drive/Gun Trouble Remedy OM-232 386 − Electrical Diagram Welding Power Source Circuit Diagram229 598-B − MIG Welding Gmaw Guidelines Typical MIG Process ConnectionsAmperage Typical MIG Process Control SettingsWire Size Amperage Range Select VoltageHolding And Positioning Welding Gun Groove WeldsPerpendicular Drag Conditions That Affect Weld Bead ShapePush Short Normal LongGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Troubleshooting − Excessive Penetration Troubleshooting − Excessive SpatterTroubleshooting − Porosity Possible Causes Corrective ActionsTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Weld bead Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Common MIG Shielding Gases Troubleshooting Guide For Semiautomatic Welding EquipmentProblem Probable Cause Remedy ApplicationWelding power source Welding arc not stable Wire slipping in drive rollsReadjust welding parameters Drive rolls if necessary− Parts List Drive Roll And Wire Guide KitsSupport ServiceYour distributor also gives For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s