Miller Millermatic 211 Owner's Manual
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Summary of Contents for Miller Millermatic 211
- Page 1 OM265809B 2016−01 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Millermatic 211 Visit our website at File: MIG (GMAW) 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 7 − MAINTENANCE &TROUBLESHOOTING ......... . 7-1.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. - Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.
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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 injure. 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: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille. -
Page 12: Proposition Californienne 65 Avertissements
RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé... -
Page 13: Section 3 − Definitions
SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away. -
Page 14: Section 4 − Specifications
A complete Parts List is available on-line at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. -
Page 15: Duty Cycle And Overheating
A complete Parts List is available on-line at www.MillerWelds.com 4-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. -
Page 16: Volt-Ampere Curves
A complete Parts List is available on-line at www.MillerWelds.com 4-5. 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. 240V MAX 120/240V MIN. -
Page 17: Section 5 − Installation
A complete Parts List is available on-line at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Movement Do not move or operate unit where it could tip. Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. -
Page 18: Multi−Voltage Plug (Mvp) Connection
A complete Parts List is available on-line at www.MillerWelds.com 5-2. Multi−Voltage Plug (MVP) Connection Selecting Plug Do not cut off power cord con- nector and rewire. The power cord connector and plugs will work with standard NEMA re- ceptacles. Modifying power cord, connector, and plugs will void product warranty. -
Page 19: Electrical Service Guide
A complete Parts List is available on-line at www.MillerWelds.com 5-3. Electrical Service Guide Elec Serv 2014−01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source. In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. -
Page 20: Connecting 1-Phase Input Power For 240 Vac
A complete Parts List is available on-line at www.MillerWelds.com 5-5. Connecting 1-Phase Input Power For 240 VAC =GND/PE Earth Ground 240 VAC, 1 Tools Needed: input4 2012-05 − 271714A / 803766C / Ref. 802443A OM265809 Page 16... - Page 21 A complete Parts List is available on-line at www.MillerWelds.com 5-5. Connecting 1-Phase Input Power For 240 VAC (Continued) automatically links the power source to the Connect green or green/yellow grounding Installation must meet all National and primary voltage being applied, either 120 or conductor to disconnect device grounding Local Codes −...
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Page 22: Installing Work Clamp
A complete Parts List is available on-line at www.MillerWelds.com 5-6. Installing Work Clamp Tighten connection hardware with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and ex- cessive heating of the work clamp. -
Page 23: Process/Polarity Table
A complete Parts List is available on-line at www.MillerWelds.com 5-8. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output ing gas put terminal terminal... -
Page 24: Installing Welding Gun Or Spool Gun
A complete Parts List is available on-line at www.MillerWelds.com 5-10. Installing Welding Gun Or Spool Gun Drive Assembly Gun Trigger Plug Gun Trigger Receptacle Route gun trigger plug through front panel. Insert plug into receptacle, and tighten threaded collar. Gun Securing Knob Gun End Loosen knob. -
Page 25: Changing Drive Roll Or Wire Inlet Guide
A complete Parts List is available on-line at www.MillerWelds.com 5-11. Changing Drive Roll Or Wire Inlet Guide Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of hole. Push new guide into hole from rear until it snaps in place. -
Page 26: Installing Wire Spool And Adjusting Hub Tension
A complete Parts List is available on-line at www.MillerWelds.com 5-12. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in. (203 mm) Wire Spool Adapter and retaining ring When a slight force is... -
Page 27: Threading Welding Wire
A complete Parts List is available on-line at www.MillerWelds.com 5-13. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Conduit Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. -
Page 28: Installing Gas Supply
A complete Parts List is available on-line at www.MillerWelds.com 5-14. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter with CO shielding gas. -
Page 29: Removing Mig Gun After Installation To Replace With A Spool Gun
A complete Parts List is available on-line at www.MillerWelds.com 5-15. Removing MIG Gun After Installation To Replace With A Spool Gun Open Pressure Assembly Cut Off End Of Wire Turn Off Power Knob Hold wire tightly to keep it from unraveling. Loosen Knob, Disconnect Gun Trigger Rewind Wire Onto Spool, Fasten Plug, And Remove Gun From Unit... -
Page 30: Spool Gun Calibration Procedure
A complete Parts List is available on-line at www.MillerWelds.com 5-16. Spool Gun Calibration Procedure To optimize performance, spool guns must be calibrated before being used with the Auto-Set feature. Installing Spool Gun Turn off power to Millermatic. Install welding wire in spool gun (See Spool Gun Owner’s Manual). -
Page 31: Section 6 − Operation
A complete Parts List is available on-line at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Manual Setup Rear View 265381A / 270208A Voltage/Material Thickness Control Wire Speed/Wire Diameter Control Power Light Turn control clockwise inside white scale Power light illuminates when the unit is Turn control clockwise inside white scale (10-100) to increase wire feed speed. -
Page 32: Using Auto-Set
A complete Parts List is available on-line at www.MillerWelds.com 6-2. Using Auto-Set 265381A Process Select Control Auto-Set LED Voltage/Material Thickness Control Turn control to select process, material, Adjust the Voltage/Material Thickness The Auto-Set light illuminates indicating and type of shielding gas. control knob to the desired steel material Auto-Set is on. -
Page 33: Weld Parameter Chart
A complete Parts List is available on-line at www.MillerWelds.com 6-4. Weld Parameter Chart 267705A OM265809 Page 29... -
Page 34: Weld Parameters
A complete Parts List is available on-line at www.MillerWelds.com 6-5. Weld Parameters Ref. 267705A OM265809 Page 30... -
Page 35: Section 7 − Maintenance &Troubleshooting
A complete Parts List is available on-line at www.MillerWelds.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months... -
Page 36: Troubleshooting Table
A complete Parts List is available on-line at www.MillerWelds.com 7-4. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 5-4 and 5-5). No weld output; wire does not feed; fan does not run; no power light. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). - Page 37 Notes OM265809 Page 33...
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Page 38: Section 8 − Electrical Diagram
SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM265809 Page 34... - Page 39 265 808-E OM265809 Page 35...
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Page 40: Section 9 − Gmaw Welding (Mig) Guidelines
SECTION 9 − GMAW WELDING (MIG) GUIDELINES 9-1. Typical GMAW (MIG) Process Connections Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as Regulator/ close to the weld as possible. Flowmeter Wire Feeder/ Power Source... -
Page 41: Holding And Positioning Welding Gun
9-3. Holding And Positioning Welding Gun 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 42: Gun Movement During Welding
9-5. Gun Movement During Welding 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 43 9-8. 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 44 9-11. 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 45 9-14. 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.
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Page 46: Troubleshooting Guide For Semiautomatic Welding Equipment
9-16. Common GMAW (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 47 Problem Probable Cause Remedy Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder. Gas nozzle plugged. Clean or replace gas nozzle. Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate. Restriction in gas line.
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Page 48: Section 10 − Parts List
SECTION 10 − PARTS LIST A complete Parts List is available on-line at www.MillerWelds.com 10-1. Recommended Spare Parts Item Part Description Quantity ..... 246372 NOZZLE, slip type .500 orf flush . - Page 49 Notes...
- Page 50 Notes...
- Page 51 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
- Page 52 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...