Miller Electric DVI-2 R manual Maintenance &TROUBLESHOOTING, Routine Maintenance, Unit Overload

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.A complete Parts List is available at www.MillerWelds.com

SECTION 6 − MAINTENANCE &TROUBLESHOOTING

6-1. Routine Maintenance

!	Disconnect power	.Maintain more often
	before maintaining.	during severe conditions.

n = Check	Z = Change	~ = Clean	l = Replace
* To be done by Factory Authorized Service Agent

Every

3 Months

	l Unreadable Labels	~ Weld Terminals	nl Weld Cables
Every
6	OR
Months	OR
Months
	~ Inside Unit	n Apply Light Coat Of Oil
		Or Grease To Drive Motor
		Shaft

Reference

6-2. 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, and the Over Temp light will turn on. Wait until Over Temp light turns off before trying to weld.

6-3. Changing Drive Roll and Wire Inlet Guide

2			1	Securing Screw
2			2	Inlet Wire Guide
			2	Inlet Wire Guide
			Loosen screw. Slide tip as close to
			drive rolls as possible without
		4	touching. Tighten screw.
		4
			3	Drive Roll
			The drive roll consists of two
			different sized grooves. The
			stamped markings on the end
			surface of the drive roll refers to the
	1		groove on the opposite side of the
	1		drive roll. The groove closest to the
			drive roll. The groove closest to the
			motor shaft is the proper groove to
			thread (see Section 4-13).
			4 Drive Roll Securing Nut
			Turn nut one click to secure drive
			roll.
		3

Tools Needed: 7/16 in

Ref. 804 914-A

OM-232 386 Page 26

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Contents Description OM-232 386BProcesses File MIG GmawFrom Miller to You Table of Contents − Parts List − MIG Welding Gmaw GuidelinesTypical MIG Process Connections 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 mortDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion 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 blesserProposition californienne 65 Avertissements LES Fils DE Soudage peuvent provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécurité Information EMFEn ce qui concerne les implants médicaux 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 11/16Installing Gas Supply Rear PanelTools Needed 8, 5/8 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 GroundElectrical Service Guide For 230 VAC Hz Single PhaseExtension Cord Data Selecting a Location And Connecting Input Power Do not move or operate unit where it could tip18 in 457 mm of space for airflow Scale Threading Welding WirePressure Remove gun nozzle and contact tipTurn Off unit, and disconnect input power Connecting An Optional Spool Gun − Operation ControlsVoltage Control 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 LongPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Excessive Penetration Troubleshooting − Excessive SpatterTroubleshooting − Porosity Possible Causes Corrective ActionsTroubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Troubleshooting − Waviness Of Bead Troubleshooting − DistortionWeld bead 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 KitsService Your distributor also givesSupport 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