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TABLE OF CONTENTS

SECTION 8 − MIG WELDING (GMAW) GUIDELINES

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8-1.

Typical MIG Process Connections

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8-2.

Typical MIG Process Control Settings

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8-3.

Holding And Positioning Welding Gun

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8-4.

Conditions That Affect Weld Bead Shape

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8-5.

Gun Movement During Welding

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8-6.

Poor Weld Bead Characteristics

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8-7.

Good Weld Bead Characteristics

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8-8.

Troubleshooting − Excessive Spatter

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8-9.

Troubleshooting − Porosity

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8-10. Troubleshooting − Excessive Penetration

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8-11. Troubleshooting − Lack Of Penetration

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8-12. Troubleshooting − Incomplete Fusion

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8-13. Troubleshooting − Burn-Through

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8-14. Troubleshooting − Waviness Of Bead

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8-15. Troubleshooting − Distortion

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8-16. Common MIG Shielding Gases

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8-17. Troubleshooting Guide For Semiautomatic Welding Equipment

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SECTION 9 − PARTS LIST

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COMPLETE PARTS LIST - www.MillerWelds.com

OPTIONS AND ACCESSORIES

WARRANTY

Содержание DVI-2 R

Страница 1: ...Processes Description Arc Welding Power Source and Wire Feeder OM 232 386B 2007 11 Millermatic DVI 2 R Flux Cored FCAW Welding MIG GMAW Welding File MIG GMAW Visit our website at www MillerWelds com...

Страница 2: ...tinue 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...

Страница 3: ...uty Cycle And Overheating 12 4 3 Volt Ampere Curves 13 4 4 Connecting To Weld Output Terminals 13 4 5 Installing Work Cable And Clamp 14 4 6 Setting Gun Polarity For Wire Type 14 4 7 Installing Gas Su...

Страница 4: ...teristics 36 8 8 Troubleshooting Excessive Spatter 37 8 9 Troubleshooting Porosity 37 8 10 Troubleshooting Excessive Penetration 37 8 11 Troubleshooting Lack Of Penetration 38 8 12 Troubleshooting Inc...

Страница 5: ...cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in...

Страница 6: ...s they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the...

Страница 7: ...ans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance as necessary D Reinstall doors panels cove...

Страница 8: ...York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 91...

Страница 9: ...source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autres consignes de s curit sont n cessaires dans les condi tions suivante...

Страница 10: ...de protection Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peu provoquer leur clatement Des tincelles peuven tre projet es de l arc de soudure La proj...

Страница 11: ...e pour usage ult rieur D Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles D Lire et suivre les instructions sur les bouteil...

Страница 12: ...de provoquer des interf rences D L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur t...

Страница 13: ...O Box 371954 Pittsburgh PA 15250 7954 t l phone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Consid r...

Страница 14: ...OM 232 386 Page 10...

Страница 15: ...Hz Single Phase KVA KW 90 A 18 0 Volts DC 20 Duty Cycle 30 135 32 24 8 2 78 2 23 90 A 18 0 Volts DC 20 Duty Cycle 30 135 32 24 8 2 78 2 23 B 230 VAC Rated Welding Output Amperage Range Maximum Open Ci...

Страница 16: ...ostat s opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit or gun and void warranty...

Страница 17: ...wer before connecting to weld output terminals Failure to properly connect weld cables may cause excessive heat and start a fire or damage your ma chine 1 Weld Output Terminal 2 Supplied Weld Output T...

Страница 18: ...4 6 Setting Gun Polarity For Wire Type 1 Polarity Changeover Label Information Always read and follow manufac ture s recommended polarity 1 3 4 11 16 in Ref 190 821 A Changing Polarity D D Wire Drive...

Страница 19: ...3 Cylinder 4 Regulator Flowmeter Install so face is vertical 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection For MIG Gun Connect gas hose between regulator flowmet...

Страница 20: ...o turn spool tension is set 15 16 in Use compression spring with 8 in 200 mm spools Tools Needed 072573 B 802 922 Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire spool follow the...

Страница 21: ...een Or Green Yellow Grounding Conductor 3 Input Power Cord 4 Disconnect Device switch shown in the OFF position 5 Disconnect Device Grounding Terminal 6 Disconnect Device Line Terminals Connect green...

Страница 22: ...nce 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current curves comparable to a Time Delay Fuse 2 Time Delay fuses are UL class RK5 3 Normal Operating g...

Страница 23: ...5 Plug NEMA Type 5 20P Optional 6 Receptacle NEMA Type 5 20R Customer Supplied 7 Plug NEMA Type 6 50P 8 Receptacle NEMA Type 6 50R Customer Supplied Select plug for power supply receptacle available a...

Страница 24: ...mbly Pull and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trig...

Страница 25: ...rd PC1 7 Receptacle RC1 8 Receptacle RC2 Remove snap in blank from rear panel and install supplied gas valve Connect plug from gas valve wiring harness into receptacle RC1 Install supplied barbed fitt...

Страница 26: ...un 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 receptacle with spool gun...

Страница 27: ...ameter chart for good starting point Turn control clockwise to increase voltage 2 Wire Speed Control Set Wire Speed control according to the parameterchart Increase or decrease wire speed to obtain de...

Страница 28: ...er 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 affect weld out...

Страница 29: ...A complete Parts List is available at www MillerWelds com OM 232 386 Page 25 226 652 A...

Страница 30: ...ct 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 Chan...

Страница 31: ...receptacle see Section 4 12 Check power switch supplementary protector and reset if necessary If supplementary protector is not tripped replace power switch Replace building line fuse or reset circui...

Страница 32: ...welding Adjust drive roll pressure see Section 4 13 Readjust hub tension see Section 4 8 Replace contact tip if blocked see welding gun Owner s Manual Clean or replace wire inlet guide or liner if di...

Страница 33: ...OM 232 386 Page 29 Notes...

Страница 34: ...OM 232 386 Page 30 SECTION 7 ELECTRICAL DIAGRAM Figure 7 1 Welding Power Source Circuit Diagram...

Страница 35: ...OM 232 386 Page 31 229 598 B...

Страница 36: ...kpiece Gun Regulator Flowmeter Gas Shielding Gas Work Clamp 8 1 Typical MIG Process Connections Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a...

Страница 37: ...arameters 035 in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 03...

Страница 38: ...in 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle...

Страница 39: ...electrode extension stickout travel speed thickness of base metal wire feed speed weld current and voltage Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WE...

Страница 40: ...t Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 8 6 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slig...

Страница 41: ...in weld metal S 0635 Possible Causes Corrective Actions Insufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove s...

Страница 42: ...welding power source 8 12 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actio...

Страница 43: ...upport hand on solid surface or use two hands 8 15 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of th...

Страница 44: ...aged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wire feed rolls Decrease pressure setting on wire...

Страница 45: ...ecessary Wrong size gun liner or contact tip Match liner and contact tip to wire size and type Incorrect voltage setting for selected wire feed speed on welding power source Readjust welding parameter...

Страница 46: ...helled cored wires 5 Drive roll types may be mixed to suit particular requirements e g V Knurled roll in combination with U Grooved Wire Diameter Kit No Drive Roll Inlet Wire Guide Fraction Decimal Me...

Страница 47: ...nduction Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers...

Страница 48: ...retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal...

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