Miller Multimatic 200 Owner's Manual
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Miller Multimatic 200 Owner's Manual

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Multimatic 200
OM-253392L
2019−01
Processes
Processes
Multiprocess Welding
Description
Arc Welding Power Source
Wire Feeder
®
File: Multiprocess

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Summary of Contents for Miller Multimatic 200

  • Page 1 OM-253392L 2019−01 Processes Processes Multiprocess Welding Description Arc Welding Power Source Wire Feeder ® Multimatic 200 For product information, File: Multiprocess Owner’s Manual translations, and more, visit 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 6 − OPERATION ..............6-1.

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 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 Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

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

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre 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 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • 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: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Suitable for Some Conventional Amperage Hazardous Load Voltage Locations Gas Input Rated No Load Lift Arc (GTAW) Voltage (OCV) TIG / Remote Primary Voltage Voltage Duty Cycle Gas Tungsten Arc Welding (GTAW) / Increase...

  • Page 15: Section 4 − Specifications

    A complete Parts List is available 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 the side. Use rating label to determine input power requirements and/or rated output.

  • Page 16: Unit Specifications For Stick (Smaw)

    A complete Parts List is available at www.MillerWelds.com 4-4. Unit Specifications For Stick (SMAW) Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-10, 5-12, and 5-13 for information on connecting input power. This equipment will deliver rated output at an ambient air temperature up to 1045F (405C). Maximum Open- Amperes Input at Rated Input...

  • Page 17: Duty Cycle And Overheating For Mig

    A complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating For MIG Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

  • Page 18: Duty Cycle And Overheating For Tig

    A complete Parts List is available at www.MillerWelds.com 4-8. Duty Cycle And Overheating For TIG Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

  • Page 19: Duty Cycle And Overheating For Stick

    A complete Parts List is available at www.MillerWelds.com 4-9. Duty Cycle And Overheating For Stick Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

  • Page 20: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Selecting a Location Do not move or operate unit where it could tip. Movement Location And Airflow Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 21: Tig Welding Connections Dcen (Direct Current Electrode Negative)

    A complete Parts List is available at www.MillerWelds.com 5-3. TIG Welding Connections DCEN (Direct Current Electrode Negative) Turn off unit and disconnect input power before making connections. Do not use worn, damaged, undersized, or repaired cables. Positive Weld Output Receptacle Negative Weld Output Receptacle TIG Torch And Cable...

  • Page 22: Process/Polarity Table

    A complete Parts List is available at www.MillerWelds.com 5-4. Process/Polarity Table Cable Connections Process Polarity Wire Drive Assembly Cable Work Cable GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) out- put receptacle put receptacle FCAW −...

  • Page 23: Wire Gun Connection Inside Unit

    A complete Parts List is available at www.MillerWelds.com 5-6. Wire Gun Connection Inside Unit Ref. 254 249-C Gun Securing Knob Loosen knob. Insert end of gun through Route trigger control cable through MIG opening in front panel until gun end bottoms gun hole.

  • Page 24: Connecting Shielding Gas Supply

    A complete Parts List is available at www.MillerWelds.com 5-7. Connecting Shielding Gas Supply Obtain gas cylinder and chain to running gear, wall, other stationary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly.

  • Page 25: Multi−Voltage Plug (Mvp) Connection

    A complete Parts List is available at www.MillerWelds.com 5-8. 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 26: Selecting Cable Sizes

    A complete Parts List is available at www.MillerWelds.com 5-9. Selecting Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 27: Connecting 120 Volt Input Power

    A complete Parts List is available at www.MillerWelds.com 5-12. Connecting 120 Volt Input Power Installation must meet National and Local Codes − have only qualified persons make this installation. Special installation required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

  • Page 28: Connecting 1-Phase Input Power For 230 Vac

    A complete Parts List is available at www.MillerWelds.com 5-13. Connecting 1-Phase Input Power For 230 VAC =GND/PE Earth Ground 230 VAC, 1 Tools Needed: input4 2012-05 − 803 766-C / Ref. 802 443-A / 253 921-B OM-253392 Page 24...
  • Page 29 A complete Parts List is available at www.MillerWelds.com 5-13. Connecting 1-Phase Input Power For 230 VAC (Continued) NOTICE − The Auto-Line circuitry in this unit Connect green or green/yellow grounding Installation must meet all National and automatically links the power source to the conductor to disconnect device grounding Local Codes −...

  • Page 30: Installing Wire Spool And Adjusting Hub Tension

    A complete Parts List is available at www.MillerWelds.com 5-14. Installing Wire Spool And Adjusting Hub Tension Wire Spool Retaining Nut (For 8 in. [203 mm] Spool Only) Tools Needed: 1/2 in. Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set.

  • Page 31: Threading Welding Wire

    A complete Parts List is available at www.MillerWelds.com 5-15. 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.

  • Page 32: Section 6 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Controls Process Select Knob Turn knob to select the desired welding process. Auto-Set Button Press button to turn Auto-Set On or Off. Wire/Rod/Tungsten Buttons Press the Plus (+) or Minus (−) button to select the size of wire, rod, or tungsten for the selected process.

  • Page 33: Weld Parameter Chart

    A complete Parts List is available at www.MillerWelds.com 6-2. Weld Parameter Chart 252671-H OM-253392 Page 29...

  • Page 34: Entering Setup Menu

    A complete Parts List is available at www.MillerWelds.com 6-3. Entering Setup Menu Wire/Rod/Tungsten Minus (−) Button Material Thickness Plus (+) Button Display When unit is turned off, press and hold Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button simultaneously. Turn unit power on.

  • Page 35: Adjusting Display Contrast (Menu 1 Of 10)

    6-5. Calibrating Drive Motor (Menu 2 Of 10) The unit’s internal drive motor is calibrated at the factory. No calibration is needed unless drive motor or user interface board is changed. Contact nearest factory authorized Service Agent or Miller Electric Mfg. LLC Service department. OM-253392 Page 31...

  • Page 36: Calibrating Spoolmate 100 Or Spoolmate 150 (Menu 3 Of 10)

    Motor calibration is necessary any time a different Spoolmate is connected to the Multimatic 200. Connect Spoolmate to unit. Cut wire flush at nozzle. Follow instructions in Section 6-3 to enter the setup menu.

  • Page 37: Enable/Disable Auto−Cratert (Menu 4 Of 10)

    A complete Parts List is available at www.MillerWelds.com 6-7. Enable/Disable Auto−Cratert (Menu 4 Of 10) Adjustment Knob Material Thickness Plus (+) Button Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) but- ton three times after entering setup to enter the Auto−Crater feature menu.

  • Page 38: Viewing Burn-In Information (Menu 5 Of 10)

    A complete Parts List is available at www.MillerWelds.com 6-8. Viewing Burn-In Information (Menu 5 Of 10) Burn-In information is for factory and service use only. Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) button four times after entering setup to enter the Burn-In information screen. Burn-In information displays electrical information unique to the unit.

  • Page 39: Viewing Process Logs (Menu 8 Of 10)

    A complete Parts List is available at www.MillerWelds.com 6-11. Viewing Process Logs (Menu 8 Of 10) Material Thickness Plus (+) Button Process Select Knob Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) button seven times after entering setup to enter the Process Logs screen.

  • Page 40: Viewing Error Logs (Menu 9 Of 10)

    A complete Parts List is available at www.MillerWelds.com 6-12. Viewing Error Logs (Menu 9 Of 10) Material Thickness Plus (+) Button Follow instructions in Section 6-3 to enter the setup menu. Press Material Thickness Plus (+) button eight times after entering setup to enter the Process Logs screen.

  • Page 41: Performing A Factory Reset (Menu 10 Of 10)

    A complete Parts List is available at www.MillerWelds.com 6-13. Performing A Factory Reset (Menu 10 Of 10) Material Thickness Plus (+) Button Auto-Set Button A Factory Reset will reset the primary log data, process log data, and error log data. Contrast settings, motor calibration set- tings, Spoolmate Calibration set- tings, Burn-In information, and...

  • Page 42: Section 7 − Maintenance &Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent Every Months l Damaged Or Unreadable...

  • Page 43: Changing Drive Roll Or Wire Inlet Guide

    The two microcontrollers on the control board are no Cycle the power to clear this error. If this error longer communicating. persists after a power cycle, contact Miller Electric Mfg. LLC service department. NETWORK 2 ERROR The microcontroller on the user interface board is Cycle the power to clear this error.

  • Page 44: Troubleshooting

    Too much current has passed through the inverter Cycle the power to clear this error. If this error bridge circuit of the unit. persists after a power cycle, contact Miller Electric Mfg. LLC service department. PRIMARY THERMISTOR The primary circuit thermistor is reading too high or Contact Miller Electric Mfg.
  • Page 45 Notes OM-253392 Page 41...

  • Page 46: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-253392 Page 42...
  • Page 47 264 018-A OM-253392 Page 43...

  • Page 48: 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 close to the weld as possible. Regulator/ Flowmeter Wire Feeder/...
  • Page 49 9-3. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trig- ger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned cor- rectly on seam.
  • Page 50 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 51 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 52 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 53 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.
  • Page 54 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. Application Short Short...
  • Page 55 9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire feed motor operates, but wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match wire size and type if necessary.

  • Page 56: Section 10 − Stick Welding (Smaw) Guidelines

    SECTION 10 − STICK WELDING (SMAW) GUIDELINES 10-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery Equipment Needed: Tools Needed: cables before welding on a vehicle. Place work clamp as close to the weld as possible.
  • Page 57 10-2. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN 6013...
  • Page 58 10-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode.   Hold the electrode nearly per- pendicular to the work, although tilting it ahead (in the direction of ...
  • Page 59 10-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle Angle Too Large  -  Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short...
  • Page 60 10-10. Welding Groove (Butt) Joints Tack Welds Prevent butt joint distortion by tack welding the materials in position before final weld. Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will curl up toward the weld.
  • Page 61 10-12. Weld Test Vise Weld Joint Hammer Strike the weld joint in the direction shown. A good weld bends over but does not break. If the weld breaks, examine it to determine the cause. If the weld is porous (many holes), the arc length was probably too long.
  • Page 62 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.

  • Page 63: Section 11 − Selecting And Preparing A Tungsten For Dc Or Ac Welding

    SECTION 11 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES gtaw_Inverter_2018-01 Whenever possible and practical, use DC weld output instead of AC weld output. 11-1. Selecting Tungsten Electrode ( Wear Clean Gloves To Prevent Contamination Of Tungsten A.

  • Page 64: Preparing Tungsten Electrode For Dc Electrode Negative (Dcen) Welding

    11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety information.

  • Page 65: Section 12 − Parts List

    SECTION 12 − PARTS LIST A complete Parts List is available at www.MillerWelds.com 12-1. Drive Rolls Part No. Wire Diameter In. (mm) 261157 0.024 (.6), 0.030/0.035 (0.8 and 0.9) (Standard) and 0.030/0.035 (0.8 and 0.9) (VK Groove) 0.024 (0.6) and 0.030/0.035 (0.8 and 0.9) (Standard) 220179 0.030/0.035 (0.8 and 0.9) and 0.045 (1.2 VK Groove) 202926...
  • Page 66 Notes...
  • Page 67 Effective January 1, 2019 (Equipment with a serial number preface of MK or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Subarc Wire Drive Assemblies below, Miller Electric Mfg.
  • Page 68 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 2019 Miller Electric Mfg. LLC 2019−01...

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