Miller MILLERMATIC DVI Owner's Manual
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Miller MILLERMATIC DVI Owner's Manual

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Millermatic DVI
And M-10 Gun
OM-1330
220 237A
July 2004
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R

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  • Page 1 OM-1330 220 237A July 2004 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic DVI And M-10 Gun Visit our website at www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 8 − MIG WELDING (GMAW) GUIDELINES ..........8-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _8/03 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- (phone: 305-443-9353, website: www.aws.org). ternational.org).

  • Page 9: Section 2 − Consignes De Sécurité − À Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION som_fre 8/03 2-1. Signification des symboles Signifie « Mise en garde. Faire preuve de vigilance. » Cette procédure présente des risques identifiés par les symboles adjacents aux directives. Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigi- lance.
  • Page 10 LES RAYONS DE L’ARC peuvent cau- LES ACCUMULATIONS DE GAZ peu- ser des brûlures oculaires et cuta- vent causer des blessures ou même nées. la mort. Le rayonnement de l’arc génère des rayons visibles et D Couper l’alimentation en gaz protecteur en cas de invisibles intenses (ultraviolets et infrarouges) suscep- non utilisation.

  • Page 11: Autres Symboles Relatifs À L'installation, Au Fonctionnement Et À L'entretien De L'appareil

    2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. Risque D’INCENDIE OU D’EXPLO- LES ORGANES MOBILES peuvent SION causer des blessures. D Ne pas placer l’appareil sur une surface inflam- D Se tenir à l’écart des organes mobiles comme les mable, ni au−dessus ou à...

  • Page 12: Principales Normes De Sécurité

    2-4. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1, Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800) de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna- (téléphone : (305) 443−9353, site Web : www.aws.org).

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Do Not Switch Wire Feed Output Duty Cycle While Welding Volts Increase Gas Metal Arc Wire Feed Spool Welding (GMAW) Gas Input Gas Output Rated No-Load Voltage Input Press To Reset Voltage (Average) SECTION 4 −...

  • Page 14: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) A. 115 VAC opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 15: Volt-Ampere Curves

    4-3. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. Ranges 4, 5, and 6 apply to 230 VAC only. Range 6 Range 5 Range 4...

  • Page 16: Installing Work Clamp

    4-5. Installing Work Clamp Work Cable Boot Route cable through front panel opening. Slide boot onto work cable. Negative (−) Output Terminal Connect cable to terminal and cover connection with boot. Close door. Tools Needed: 3/4 in 803 859-B 4-6. Installing Welding Gun Drive Assembly Gun Securing Knob Gun End...

  • Page 17: Installing Gas Supply

    4-8. Installing Gas Supply Obtain gas cylinders and chain to DO NOT use Argon/Mixed gas regulator/flowmeter running gear, wall, other with CO shielding gas. See Parts List for optional stationary support so cylinders gas regulator/flowmeter. cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly.

  • Page 18: Installing Mig Wire Spool And Adjusting Hub Tension

    4-9. Installing MIG Wire Spool and Adjusting Hub Tension Use compression spring When a slight force is needed with 8 in (200 mm) spools. to turn spool, tension is set. To install either a 1 lb or 2 lb wire Installing 1 Or 2 lb Wire Spool spool, follow the procedure as Spindle...

  • Page 19: Input Power For 230 Vac

    4-10. Input Power For 230 VAC See unit rating label for correct input power (see Section 4-13). Receptacle (NEMA 6-50R) Customer Supplied Line Disconnect Device See Section 4-11. Y Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 20: Selecting A Location And Connecting Input Power

    4-13. Selecting A Location And Connecting Input Power Y Do Not cut off power cord connector and attempt to hard wire the power cord. The power cord connector and plugs are designed to work with pre-installed outlet receptacles. 18 in (457 mm) of space for airflow 803 862-C Y Do not move or operate unit...

  • Page 21: Threading Welding Wire

    4-14. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open pressure assembly.

  • Page 22: Installing Diverter Valve And Switch For Optional Spool Gun

    4-15. Installing Diverter Valve And Switch For Optional Spool Gun Tools Needed: 1/4 in 9/16 in Ref. 803 906-B / 803 908-A Y Turn Off unit, and disconnect input onto output barbed fitting on diverter valve. Switch Plug power. Secure with hose clamp. Receptacle RC4 On Circuit Board Disconnect and remove MIG (GMAW) Slide hose clamp down gas hose from gun.

  • Page 23: Connecting An Optional Spool Gun

    4-16. Connecting An Optional Spool Gun If a MIG gun is connected to the unit, remove it before connecting spool gun. Diverter Valve If spool gun gas hose is equipped with a pre-installed barbed fitting, cut off fitting from end of hose. Connect spool gun gas hose to diverter valve barbed fitting (see Section 4-15).

  • Page 24: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls Ref. 220 079-B Voltage Control Wire Speed Control Power Switch/Circuit Breaker The switch energizes the main transformer Set Wire Speed control according to the Positions 4, 5, and 6 are for 230 volts and control circuitry. The 20 ampere circuit parameter chart.
  • Page 25 Notes OM-1330 Page 21...

  • Page 26: Weld Parameter Chart

    5-2. Weld Parameter Chart OM-1330 Page 22...
  • Page 27 220 493-A OM-1330 Page 23...

  • Page 28: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining. during severe conditions. 3 Months Replace unreadable labels Repair or replace cracked weld cable Clean and tighten weld terminals 6 Months Remove drive roll and Blow out or vacuum inside.

  • Page 29: Unit Overload

    6-3. 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. Wait several minutes before trying to weld. Circuit breaker CB2 (Power switch) protects transformer T1 from overload. If CB2 opens, unit power will shut off. Check input power supply, and press Power switch to turn unit back on.

  • Page 30: Aligning Drive Rolls And Wire Guide

    6-6. Aligning Drive Rolls and Wire Guide Y Turn Off power. View is from top of drive rolls look- ing down with pressure assembly open. Drive Roll Securing Nut Correct Incorrect Drive Roll Wire Guide Welding Wire Drive Gear Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.

  • Page 31: Cleaning Or Replacing Gun Liner

    6-8. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 3/8 in Head Tube Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 1/2 in Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Install and tighten new liner.

  • Page 32: Replacing Switch And/Or Head Tube

    6-9. Replacing Switch And/Or Head Tube Y Disconnect gun first. Remove handle locking nut. Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure.

  • Page 33: Troubleshooting

    6-10. Troubleshooting Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 4-13). Check power switch/circuit breaker, and reset if necessary. If circuit breaker is not tripped, replace power switch. Check circuit breaker CB1, and reset if necessary (see Section 6-2). Replace building line fuse or reset circuit breaker if open (see Section 4-13).

  • Page 34: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM Figure 7-1. Welding Power Source Circuit Diagram OM-1330 Page 30...
  • Page 35 220 197-B OM-1322 Page 31...

  • Page 36: Section 8 − Mig Welding (Gmaw) Guidelines

    SECTION 8 − MIG WELDING (GMAW) GUIDELINES 8-1. Typical MIG Process Connections Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a Regulator/ vehicle. Place work clamp as Flowmeter close to the weld as possible. Shielding Supply Hose...

  • Page 37: Typical Mig Process Control Settings

    8-2. Typical MIG Process Control Settings NOTE 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 1/8 or parameters.

  • Page 38: Holding And Positioning Welding Gun

    8-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Hold Gun and Control Gun Trigger Workpiece...

  • Page 39: Conditions That Affect Weld Bead Shape

    8-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long...

  • Page 40: Gun Movement During Welding

    8-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...

  • Page 41: Troubleshooting − Excessive Spatter

    8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.

  • Page 42: Troubleshooting − Lack Of Penetration

    8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

  • Page 43: Troubleshooting − Waviness Of Bead

    8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.

  • Page 44: Common Mig Shielding Gases

    8-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.
  • Page 45 Problem Probable Cause Remedy Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn Welding arc not stable. drive rolls if necessary. 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 Readjust welding parameters.

  • Page 46: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 803 864-D Figure 9-1. Main Assembly OM-1330 Page 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....Fig 9-2 BAFFLE,CENTER ...........
  • Page 48 Hardware is common and not available unless listed. 803 865-C Figure 9-2. Baffle, Center w/Components OM-1330 Page 44...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1) ......SPOOL HUB ASSEMBLY (INCLUDING) .
  • Page 50 Hardware is common and not available unless listed. 803 866-B Figure 9-3. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 9-3. Panel, Rear w/Components (Fig 9-1 Item 2) ... . . 049399 NUT, 312−18 PUSH ON .63D .07H STL .
  • Page 51 ..220079 LABEL,NAMEPLATE MILLERMATIC DVI ......
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 9-5. Wire Drive And Gears (Fig 9-2 Item 18) 204857 ... . . 602009 SCREW,.250-20 x 1.25 soc hd gr 8 ........
  • Page 53 802 388-A / Ref. 800 792-C Figure 9-6. M-10 Gun Item Part Description Quantity Figure 9-6. M-10 Gun (Fig 9-1 Item 19 ) ..169 715 NOZZLE, slip type .500 orf flush ......... . . ♦087 299 .

  • Page 54: Drive Roll And Wire Guide Kits

    Item Dia. Part Mkgs. Description Quantity 207 642 Optional Spoolmate Spool Gun Switch ....186420 SWITCH ASSY ..........
  • Page 55 Effective January 1, 2004 (Equipment with a serial number preface of “LE” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets below, Miller Electric Mfg.
  • Page 56 Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...

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