Miller Electric DVI-2 R manual

Contents

Main Millermatic DVI-2 From Miller to You Page TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage . 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. FLYING M E TAL o r DIRT can injure eyes. BUILDUP OF GAS can injure or kill. MAGNETIC FIELDS can affect Implanted Medical Devices. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING FLYING SPARKS can cause injury. 1-4. California Proposition 65 Warnings 1-5. Principal Safety Standards 1-6. EMF Information SECTION 2 2-1. Symboles utiliss . 2-2. Dange rs relatifs au soudage larc UNE DCHARGE LECTRIQUE peut entraner la mort. DES PICES CHAUDES peuvent provoquer des brlures graves. et ro- tre LES FUMES ET LES GAZ peuvent 2-3. e Risque DINCENDIE OU DEXPLO- SION. LA CHUTE DE LAPPAREIL peut blesser. LEMPLOI EXCESSIF peut SUR- CHAUFFER LQUIPEMENT. 2-4. Proposition californienne 65 Avertissements 2-5. Principales normes de scurit 2-6. Information EMF Page SECTION 3 DEFINITIONS 3-1. Symbols And Definitions V SECTION 4 INSTALLATION 4-1. Specifications A. 115 VAC B. 230 VAC 4-2. Duty Cycle And Overheating A or V A. 115 VAC B. 230 VAC 4-3. Volt-Ampere Curves . 4-4. Connecting To Weld Output Terminals 4-5. Installing Work Cable And Clamp 4-6. Setting Gun Polarity For Wire Type Changing Polarity + - 4-7. Installing Gas Supply 4-8. Installing MIG Wire Spool and Adjusting Hub Tension Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire 4-9. Connecting 1-Phase Input Power For 230 VAC ! 1 4-10. Electrical Service Guide For 230 VAC 4-11. Extension Cord Data . Phase Hertz Conductor Size Max. Cord Length 4-12. Selecting A Location And Connecting Input Power ! 4-13. Threading W elding Wire . 4-14. Installing Optional Gas Valve, Receptacle, And Barbed Fitting For Optional Spool Gun ! 4-15. Connecting An Optional Spool Gun SECTION 5 OPERATION 5-1. Controls 5-2. Weld Parameter Chart Input Line Voltage* Parameter Chart Settings Page SECTION 6 MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance ! 6-2. Unit Overload 6-3. Changing Drive Roll and Wire Inlet Guide 6-4. Aligning Drive Rolls and Wire Guide ! 6-5. Troubleshooting Welding Trouble Remedy Wire Drive/Gun Trouble Remedy Page Page Page SECTION 8 MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections ! 8-2. Typical MIG Process Control Settings . 8-3. Holding And Positioning Welding Gun . 8-4. Conditions That Affect Weld Bead Shape . 8-5. Gun Movement During Welding . 8-6. Poor Weld Bead Characteristics 8-7. Good Weld Bead Characteristics 8-8. Troubleshooting Excessive Spatter 8-9. Troubleshooting Porosity 8-10. Troubleshooting Excessive Penetration 8-11. Troubleshooting Lack Of Penetration 8-12. Troubleshooting Incomplete Fusion 8-13. Troubleshooting Burn-Through 8-14. Troubleshooting Waviness Of Bead 8-15. Troubleshooting Distortion 8-16. Common MIG Shielding Gases 8-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Page SECTION 9 PARTS LIST 9-1. Drive Roll And Wire Guide Kits . Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2007 (Equipment with a serial number preface of LH or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Owners Record