Miller Millermatic 210 Owner's Manual
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Miller Millermatic 210 Owner's Manual

Miller Millermatic 210 Owner's Manual

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Millermatic 210
And M-25 Gun
OM-1325
204 902F
May 2003
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R

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Summary of Contents for Miller Millermatic 210

  • Page 1 OM-1325 204 902F May 2003 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 210 And M-25 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 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 6 – MIG WELDING (GMAW) GUIDELINES ........6-1.
  • Page 5 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 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 D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
  • Page 7 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 1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.
  • Page 9 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
  • Page 11 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...
  • Page 12 1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
  • Page 13 SECTION 2 – INSTALLATION 2-1. Welding Power Source And MIG Gun Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Rated Output Amperage Amperage Max. Open Circuit Max. Open Circuit 200 (208) V 230 V Range DC Voltage DC 160 A at 24.5 VDC, 30-210 34.5...
  • Page 14 2-3. MIG Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Definition .023 To .045 in (0.6 To 1.1 mm)
  • Page 15 2-5. 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 Ref. 802 474-D 2-6.
  • Page 16 2-7. Connecting An Optional Spool Gun Barbed Fitting 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 barbed fitting. Gun Trigger Plug Insert plug into receptacle labeled “SPOOL GUN”, tighten...
  • Page 17 2-9. Installing Gas Supply Obtain gas cylinders and chain to running gear, wall, or other stationary support so cylinders cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter Cylinder Valve with CO shielding gas. See Parts List for optional gas regulator/flowmeter.
  • Page 18 2-10. 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 2-11. Positioning Jumper Links Check input voltage available at site and listed on the machine rating label. Jumper Links Access Door Open door. Jumper Link Label 200 VOLTS Check label – only one is on unit. Input Voltage Jumper Links Move jumper links to match input voltage.
  • Page 20 2-13. Selecting A Location And Connecting Input Power Rating Label Supply correct input power. Plug (NEMA Type 6-50P) Receptacle (NEMA Type 6-50R) Connect plug to receptacle. Input And Grounding 18 in (457 mm) of Y Do not move or operate unit Conductors space for airflow where it could tip.
  • Page 21 2-14. 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 2-15. Using Gun/Cable Holder Side Panel Latch Cable Holder Press latch down to release and open door. Holster (2) Wrap cable around cable holder, and place gun nozzle into holster. 802 726 OM-1325 Page 18...
  • Page 23 SECTION 3 – OPERATION 3-1. Controls WIRE SPEED VOLTAGE DO NO T SWITCH WHILE WELDING MIG GUN SPOOL GUN Ref. 200 034-B Voltage Control Power Switch MIG Gun Receptacle Set Voltage control according to the This switch energizes the main transformer parameter chart for good starting point.
  • Page 24 3-2. Weld Parameter Chart *Line voltage can affect weld output, settings on this chart are starting values only. You may need to adjust voltage and wire feed speed to optimize your settings. Input Line Parameter Voltage* Chart Settings Higher Weld Will Be e.g.
  • Page 25 204 890 OM-1325 Page 21...
  • Page 26 SECTION 4 – MAINTENANCE &TROUBLESHOOTING 4-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. 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 27 4-4. Replacing Gun Contact Tip Y Turn Off power. Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. 800 797-C 4-5. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw.
  • Page 28 4-6. 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 29 4-8. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit first. 5/16 in, 10 mm Head Tube Remove nozzle, contact tip, and adapter. 5/16 in 10 mm Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Blow out gun casing.
  • Page 30 4-9. 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 31 4-10. Troubleshooting Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-13). Check and replace power switch if necessary. Check circuit breaker CB1, and reset if necessary (see Section 4-2). Replace building line fuse or reset circuit breaker if open (see Section 2-13). Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-6 and/or 4-9).
  • Page 32 SECTION 5 – ELECTRICAL DIAGRAM 204 891 Figure 5-1. Welding Power Source Circuit Diagram OM-1325 Page 28...

  • Page 33: Section 6 - Mig Welding (Gmaw) Guidelines

    SECTION 6 – MIG WELDING (GMAW) GUIDELINES 6-1. 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 34: Typical Mig Process Control Settings

    6-2. 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 parameters. 1/8 or Convert Material .125 in Thickness to...

  • Page 35: Holding And Positioning Welding Gun

    6-3. 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 36: Conditions That Affect Weld Bead Shape

    6-4. 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 37: Gun Movement During Welding

    6-5. 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 38: Troubleshooting - Excessive Spatter

    6-8. 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 39: Troubleshooting - Lack Of Penetration

    6-11. 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 40: Troubleshooting - Waviness Of Bead

    6-14. 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 41: Common Mig Shielding Gases

    6-16. 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 42 Problem Probable Cause Remedy Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn 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 43 Notes OM-1325 Page 39...

  • Page 44: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 802 993-C Figure 7-1. Main Assembly OM-1325 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ... Figure 7-2 BAFFLE,CENTER ...........
  • Page 46 Hardware is common and not available unless listed. 802 989-A Figure 7-2. Baffle, Center w/Components OM-1325 Page 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 7-2. Baffle, Center w/Components (Figure 7-1 Item 1) ......SPOOL HUB ASSEMBLY,(CONSISTING OF) .
  • Page 48 Hardware is common and not available unless listed. Ref. 802 988 Figure 7-3. Panel, Rear w/Components Item Dia. Part Mkgs. Description Quantity Figure 7-3. Panel, Rear w/Components (Figure 7-1 Item 2) ... . . 049399 NUT, 312–18 PUSH ON .63D .07H STL .
  • Page 49 ..208359 LABEL,NAMEPLATE MILLERMATIC 210 ......
  • Page 50 Ref. 800 792-C Figure 7-5. M-25 Gun OM-1325 Page 46...
  • Page 51 Item Part Description Quantity Figure 7-5. M-25 Gun (Fig 7-1 Item 16 ) ..200 258 NOZZLE, slip type .500 orf flush ......... . . ♦169 724 .
  • Page 52 Item Dia. Part Mkgs. Description Quantity Figure 7-6. Wire Drive And Gears (Figure 7-2 Item 23) 204857 ... . . 602009 SCREW,.250-20 x 1.25 soc hd gr 8 ........
  • Page 53 Table 7-1. Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires.
  • Page 54 Notes...
  • Page 55 Effective January 1, 2002 (Equipment with a serial number preface of “LC” 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 APT, ZIPCUT &...

  • Page 56: Options And Accessories

    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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M-25

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