Miller Electric DVI-2 R manual Typical MIG Process Control Settings, Wire Size Amperage Range

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8-2. Typical MIG Process Control Settings

.These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

Material thickness determines weld
parameters.	Convert Material
1/8 or 0.125 in	Convert Material
	Thickness to
	Amperage (A)
	(0.001 in = 1 ampere)
	0.125 in = 125 A

.035 in

Wire Size	Amperage Range

0.023 in		30 − 90 A
0.030 in	40 − 145 A
0.035 in	50 − 180 A

Select Wire Size

	Wire	Recommendation	Wire Speed	Select Wire Speed
	Size	Recommendation	(Approx.)	(Amperage)
	Size		(Approx.)	(Amperage)

	0.023 in	3.5 in per ampere	3.5 x 125 A = 437 ipm	125 A based on 1/8 in
				125 A based on 1/8 in
	0.030 in	2 in per ampere	2 x 125 A = 250 ipm	material thickness
	0.035 in	1.6 in per ampere	1.6 x 125 A = 200 ipm

ipm = inches per minute

	Low voltage: wire stubs into work	Select Voltage
	High voltage: arc is unstable (spatter)	Select Voltage
	High voltage: arc is unstable (spatter)
	Set voltage midway between high/low voltage

Voltage controls height and				Wire speed (amperage) controls weld
width of weld bead.				penetration (wire speed = burn-off rate)

OM-232 386 Page 33

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Contents Processes OM-232 386BDescription File MIG GmawFrom Miller to You Table of Contents − MIG Welding Gmaw Guidelines − Parts ListTypical MIG Process Connections Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyesFire or Explosion hazard Welding Wire can cause injuryFalling Unit can cause injury Moving Parts can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesserLES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Information EMF Principales normes de sécuritéEn ce qui concerne les implants médicaux OM-232 386 Symbols And Definitions − InstallationSpecifications − Definitions40% duty cycle at 150 amps Minutes Welding Minutes Resting Duty Cycle And OverheatingOverheating MinutesCorrect Installation Connecting To Weld Output TerminalsVolt-Ampere Curves Range Range 4 RangeSetting Gun Polarity For Wire Type Installing Work Cable And ClampPolarity Changeover Label Information 11/16Rear Panel Installing Gas SupplyTools Needed 8, 5/8 Installing 1 Or 2 lb Wire Spool Installing MIG Wire Spool and Adjusting Hub TensionUse compression spring With 8 in 200 mm spools To turn spool, tension is set230 VAC =GND/PE Earth Ground Connecting 1-Phase Input Power For 230 VACHz Single Phase Electrical Service Guide For 230 VACExtension Cord Data Do not move or operate unit where it could tip Selecting a Location And Connecting Input Power18 in 457 mm of space for airflow Pressure Threading Welding WireScale Remove gun nozzle and contact tipTurn Off unit, and disconnect input power Connecting An Optional Spool Gun Controls − OperationVoltage Control Voltage Chart Settings Weld Parameter ChartInput Line Parameter226 652-A Routine Maintenance − Maintenance &TROUBLESHOOTINGChanging Drive Roll and Wire Inlet Guide Unit OverloadTroubleshooting Aligning Drive Rolls and Wire GuideTurn Off power Welding Trouble RemedyWire Drive/Gun Trouble Remedy OM-232 386 Welding Power Source Circuit Diagram − Electrical Diagram229 598-B Typical MIG Process Connections − MIG Welding Gmaw GuidelinesWire Size Amperage Range Typical MIG Process Control SettingsAmperage Select VoltageGroove Welds Holding And Positioning Welding GunPush Conditions That Affect Weld Bead ShapePerpendicular Drag Short Normal LongGood Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Burn-Through Troubleshooting − Distortion Troubleshooting − Waviness Of BeadWeld bead Problem Probable Cause Remedy Troubleshooting Guide For Semiautomatic Welding EquipmentCommon MIG Shielding Gases ApplicationReadjust welding parameters Welding arc not stable Wire slipping in drive rollsWelding power source Drive rolls if necessaryDrive Roll And Wire Guide Kits − Parts ListYour distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s