Miller Electric Millermatic DVI User manual

Miller Electric Millermatic DVI User manual
Millermatic DVI 2
Issued Sept. 2008 • Index No. DC/12.52
™
®
Quick
Specs
Industrial Applications
Processes
Light Fabrication
Garages/Body Shops
Farm/Ranch
Vocational/Technical Schools
MIG (GMAW)
Flux Cored (FCAW)
Rated Output
Input Power
230 V, 25 A, 60 Hz, single-phase
115 V, 20 A, 60 Hz, single-phase
115 V, 15 A, 60 Hz, single-phase*
*CSA ratings.
MIG Arc Welding
Power Source
150 A at 23 VDC, 40% Duty Cycle (230 V)
90 A at 18 VDC, 20% Duty Cycle (115 V)
68 A at 19.5 V, 20% duty cycle (115 V)*
Max. Open-Circuit Voltage 32 VDC
Amperage Range 30 –175 A
Wire Feed Speed 50 – 700 IPM (1.3 – 17.8 m/min)
Weight 169 lb (77 kg)
The Power of Blue .
®
Comes Complete With:
10 ft (3 m) power cord and plug
10 ft (3 m) M-10 MIG gun for
.030/.035 in wire (0.8/0.9 in wire)
10 ft (3 m) work cable and clamp
Argon mix regulator/flow gauge
and hose
Extra contact tips
Factory-installed running gear with
EZ-Change™ Low Cylinder Rack
.030/.035 in reversible drive rolls
Set-up and operation interactive CD
Six taps provide wider welding range of
30 – 175 amps with superior performance
throughout its operating range. Welds
from 22 gauge up to 3/8 in (9.5 mm) thick
on 230 VAC power and 22 gauge to 3/16 in
(4.8 mm) thick on 115 VAC.
Millermatic DVI (DUAL VOLTAGE INPUT):
This unique system allows you to connect
to 115 V or 230 V power receptacles
without any tools. With Miller’s exclusive
MVP™ (multi-voltage plug) power cord
adapters, just pick the MVP that matches
the power receptacle, connect it to the
power cord and you are ready to weld.
Angled, dual-gear driven, cast
aluminum drive system features
no-tool, quick-change reversible drive
rolls and an easy-to-set, scaled tension
knob. See page 3 for more information.
EZ-Access™ Consumable Compartment and
Parameter Chart — set weld parameters
right the first time with convenient new flipdown compartment that provides fast access to
parameter chart and consumables. See page 3
for more information.
Patent-pending EZ-Change™
Low Cylinder Rack allows operators to
easily roll cylinders on and off of rack —
no need to lift cylinders. See page 3 for
more information.
Thermal overload
protection shuts down
unit and activates over
temperature light if airflow
is blocked or duty cycle is
exceeded. Automatically
resets when fault is
corrected and unit cools.
Add the Spoolmate™ 3035 spool gun for
aluminum welding with optional Spoolmate
Gas Valve Kit. And with Miller’s exclusive
Gun-On-Demand,™ simply pull the trigger
for either gun and you’re ready to weld.
No time wasted toggling switches!
Less weld cleanup with Active Arc
Stabilizer ™ — patented Miller design
provides excellent starts proven superior to
the competition.
Welder is warranted for 3 years, parts and labor. Original
main power rectified parts are warranted for 5 years.
Gun warranted for 90 days, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Subject to change without notice.)
Amperage
Range
Max.
Open-Circuit
Voltage
Amps Input at Rated Output, 60 Hz
115 V 230 V KVA
KW
90 A, 18 V
20% Duty Cycle
30 –135 A
32
24.8
—
2.78
2.23
150 A, 23 V
40% Duty Cycle
30 –175 A
32
—
25
5.74
4.93
Rated Output
Wire Feed
Speed
Wire Type and Diameter
Solid/Stainless Steel:
.023 – .035 in (0.6 – 0.9 mm)
Flux Cored:
.030 – .035 in (0.8 – 0.9 mm)
Max.
Spool
Size
Net
Dimensions Weight
50 –700 IPM 12 in
(305 mm)
(1.3 –17.8
m/min)
H: 30 in
(762 mm)
169 lb
(77 kg)
W: 19 in
(483 mm)
D: 40 in
(1061 mm)
Aluminum:
.030 – .035 in (0.8 – 0.9 mm)
Note: Operating Temperature Range: -4˚ to +104˚ F (-20 to +40˚ C) Storage Temperature Range: -22˚ to +122˚ F (-30 to +50˚ C)
Control Panel
1
1. Wire Feed Speed Control
2. Overtemp Light
3. Voltage Control
3
2
Performance Data
DUTY CYCLE (115 V)
DUTY CYCLE (230 V)
150
125
WELD AMPERES
WELD AMPERES
100
75
50
37.5
25
0
10
15
20
25
30
40
50
500
450
400
350
300
250
200
150
100
50
10
60 70 80 90100
15
% DUTY CYCLE
30
40
% DUTY CYCLE
VOLT/AMP CURVE
35
DC VOLTS
30
25
20
Range 4
Range 3
Range 2
Range 1
15
Range 6
Range 5
10
5
0
0
50
100
150
DC AMPS
2
20
200
250
50
60 70 80 90100
Standard Fully Loaded Features
EZ-Change™ Low Cylinder Rack
Patent-pending design — operators no
longer need to lift cylinders. Cylinders
now easily roll on and off our EZ-Change™
Low Cylinder Rack.
Angled Wire Drive
Angled industrial aluminum dual-gear
drive system significantly improves
wirefeeding and runs large spools of wire.
Allows quick change of drive rolls
without tools.
Drive roll storage — no more lost drive
rolls, extra drive rolls are conveniently
stored next to drive motor.
Operators no longer bump into and bend
MIG gun and gun liner.
Dual Front Handles
Exclusive split handle with rubber grips
designed to move machine easily and
allow work lead and MIG gun to be
stored independently.
Handles provide protection for front panel
and MIG gun during transportation.
EZ-Access™ Consumable
Compartment and Parameter Chart
Convenient flip-down compartment
holds parameter chart and storage for
consumables.
MVP™ Plugs and Built-in Storage
With Miller’s exclusive MVP (multivoltage plug) power cord adapters, just
pick the MVP that matches the power
receptacle, connect to the power cord
and you are ready to weld. (Two standard
and one optional MVP plugs shown.)
Handy holders store MVP plugs when
not in use.
3
Optional Fully Loaded Features
Elevated Gun and Cable Rack
#300 335
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
No more running over spool gun cables
or cables dragging on the floor.
Elevated Gun and Cable Rack can be
used with either a single or dual cylinder
rack. (Elevated Gun and Cable Rack is
included with the Dual EZ-Change™ Low
Cylinder Rack.)
Dual EZ-Change™ Low Cylinder Rack
with Elevated Gun and Cable Rack
#300 337
Dual cylinder rack allows for easy
storage for two cylinders.
EZ-Change™ Low Cylinder rack eliminates
the need to lift cylinders on and off
cylinder rack.
No more running over spool gun cables
or cables dragging on the floor.
Tangle-free, independent way to store
spool gun cables, keeping them off of
the floor.
4
Genuine Miller Accessories
M-10 Replacement Gun #195 605
10 ft (3 m). Shipped with liner #194 011.
Spoolmate™ 3035 Spool Gun #195 016
Spool gun for aluminum and other wires.
4 in spools; .023 –.035 in (0.6 – 0.9 mm)
aluminum, steel and stainless steel. Rated
at 150 amps, 60% duty cycle with 20 ft
(6 m) cable assembly.
Gas Valve and Trigger Receptacle Kit
#300 338
Required to connect a Spoolmate™ 3035 to
the Millermatic DVI2.
Spoolmate™ 3035 25 ft Extension Cable Kit
#194 996
Extends Spoolmate 3035 an additional
25 ft (7.6 m) from power source.
Heavy-Duty Barrel for Spoolmate 3035
#195 375
Use for demanding applications, rated at
200 A, 60% duty cycle.
Adapter Cable #195 287
Allows Spoolmatic® 15A or 30A to be used
with Millermatic DVI2.
Note: WFS is controlled at the machine, not the gun.
Protective Cover with Helmet Bag
#195 142
Features side pocket and helmet bag.
(Not for use with Dual Cylinder Rack or
Elevated Gun and Cable Rack.)
Dual EZ-Change™ Low Cylinder Rack with
Elevated Gun and Cable Rack #300 337
Dual cylinder rack allows operators to
easily roll cylinders on and off the rack with
no lifting. Gun and cable rack keeps cables
off the floor and tangle free.
Elevated Gun and Cable Rack #300 335
For use with single cylinder rack. (Included
with Dual EZ-Change Low Cylinder Rack.)
Argon/Mixed Gas Regulator and Gas Hose
#195 050
(Order from Miller Service Parts.)
CO2 Regulator/Flow Gauge #237 702
Required if using 100% CO2 gas.
(Order from Miller Service Parts.)
MVP™ Adapter Plugs
(Order from Miller Service Parts.)
#219 258
For Power Cable 6-50P
(230 V/50 A).
Included with machine.
#219 261
For Power Cable 5-15P
(115 V/15 A).
Included with machine.
#219 259
For Power Cable 5-20P
(115 V/20 A). Optional.
5
Consumables
(Order from Miller Service Parts.)
For M-10 Gun
Contact Tips
#087 299 .023/.025 in (0.6 mm)
#000 067 .030 in (0.8 mm)
#000 068 .035 in (0.9 mm)
Contact Tip Adapter #169 716
For Spoolmate 3035 Gun
™
Consumable Kits
#234 607 .023 in (0.6 mm)
#234 608 .030 in (0.8 mm)
#234 609 .035 in (0.9 mm)
Contains 10 contact tips, 1 nozzle, and
1 contact tip adapter.
Contact Tips (5 per package)
#199 730 For .023/.025 in (0.6 mm) wire.
#186 419 For .030 in (0.8 mm) wire.
#186 406 For .035 in (0.9 mm) wire.
Nozzle #186 405
Drive Rolls
Replacement Liners
#194 010 .023/.025 in
#194 011 .030 –.035 in (standard)
Nozzle #169 715
1/2 in (13 mm) diameter orifice. Nozzle
flush with contact tip (standard).
Spot Nozzles
#176 237 Flat
#176 239 Inside corner
#176 241 Outside corner
6
Note: Drive roll kits include two drive rolls and an
inlet guide.
V-Grooved Drive Roll Kits (solid wire)
#204 579 .030 & .035 in (0.8 & 0.9 mm)
Combination (Reversible)
#087 131 .023/.025 in (0.6 mm)
#079 594 .030 in (0.8 mm)
#079 595 .035 in (0.9 mm)
Drive Roll (1)
#199 731 For .023 in (0.6 mm) wire.
#186 413 For .030/.035 in (0.8/0.9 mm)
wire.
V-Knurled Drive Roll Kits
(Flux Cored or difficult-to-feed wire)
#079 606 .035 in (0.9 mm)
Push Roll (1)
#199 732 For .023 in (0.6 mm) wire.
#186 414 For .030/.035 in (0.8/0.9 mm)
wire.
Notes
7
Ordering Information
Steel Configuration
Stock No.
Description
™
2
Millermatic DVI
#907 323
115/230 V, 60 Hz
V-Groove Drive Roll Kits (solid wire)
#087 131
#079 594
#079 595
#204 579
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
.030/.035 (0.8/0.9 mm)
V-Knurled Drive Roll Kits (flux cored)
#079 606
.035 (0.9 mm)
Contact Tips (10 per package)
#087 299
#000 067
#000 068
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
Nozzles
#169 715
1/2 in (13 mm) diameter, flush
Millermatic® DVI™2 Spool Gun Package
(Also includes standard M-10 MIG gun)
#951 067
115/230 V, 60 Hz with Spoolmate™ 3035, gas valve and trigger
receptacle kit, dual cylinder rack, elevated gun and cable rack,
regulator and hose
Spool Gun Drive Roll
#199 731
#186 413
.023 (0.6 mm)
.030/.035 (0.8/0.9 mm)
Spool Gun Push Roll
#199 732
#186 414
.023 (0.6 mm)
.030/.035 (0.8/0.9 mm)
Spool Gun Contact Tips (5 per package)
#199 730
#186 419
#186 406
.023/.025 (0.6 mm)
.030 (0.8 mm)
.035 (0.9 mm)
Spool Gun Nozzle
#186 405
®
Qty.
Aluminum Configuration
For M-10 gun consumables and Millermatic DVI2 drive rolls see steel configuration chart above.
Accessories
Gun Convenience Kit for Steel
#193 973
M-10 Gun
#195 605
Spoolmate™ 3035 Spool Gun
#195 016
Gas Valve and Trigger Receptacle Kit
#300 338
Spoolmate™ 3035 25 ft Extension Cable Kit
#194 996
(Order from Miller Service Parts.)
10 ft (3 m), .030 –.035 in (0.8 – 0.9 mm)
Spool gun for aluminum
Required to connect a Spoolmate™ 3035 to the Millermatic DVI2
Heavy-Duty Barrel for Spoolmate™ 3035
#195 375
200 A, 60% Duty Cycle
Adapter Cable
#195 287
Allows Spoolmatic® 15A or 30A to be used with Millermatic DVI2
Dual EZ-Change Low Cylinder Rack with
Elevated Gun and Cable Rack
#300 337
Elevated Gun and Cable Rack
#300 335
Protective Cover with Helmet Bag
#195 142
Argon/Mixed Gas Regulator and Gas Hose
#195 050
CO2 Regulator/Flow Gauge
#237 702
MVP™ Adapter Plugs
(Order from Miller Service Parts)
#219 258
#219 261
#219 259
Date:
Total Quoted Price:
Distributed by:
Litho in USA
For use with single cylinder rack.
(Included with Dual EZ-Change Low Cylinder Rack.)
Features side pocket and helmet bag
(Order from Miller Service Parts.)
Required if using 100% CO2 gas. (Order from Miller Service Parts.)
For Power Cable 6-50P (230 V/50 A). Included with machine
For Power Cable 5-15P (115 V/15 A). Included with machine
For Power Cable 5-20P (115 V/20 A). Optional
Price
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