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

Mig (gmaw) welding, flux cored (fcaw) welding, arc welding power source and wire feeder
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Millermatic 210
OM-1325
204 902R
2007−02
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
File: MIG (GMAW)

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Summary of Contents for Miller Millermatic 210

  • Page 1 OM-1325 204 902R 2007−02 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 210 File: MIG (GMAW) Visit our website at www.MillerWelds.com...
  • Page 2 ISO 9001:2000 Quality System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets.

  • 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 _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • 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 Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard...

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.

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

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels à...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.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: Welding Power Source Duty Cycle And Overheating

    4-2. Welding Power Source 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) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool.

  • Page 15: Connecting To Weld Output Terminals

    4-4. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar. Tools Needed: 3/4 in (19 mm) 803 778-A Correct Installation Incorrect Installation Y Turn off power before connecting to Weld Output Terminal minal. Slide weld cable terminal onto weld weld output terminals.

  • Page 16: Connecting An Optional Spool Gun

    4-6. 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: Installing Gas Supply

    4-8. 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: 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: Positioning Jumper Links

    4-10. 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 Check label − only one is on unit. 200 VOLTS 230 VOLTS Input Voltage Jumper Links Move jumper links to match input voltage.

  • Page 20: Selecting A Location And Connecting Input Power

    4-12. Selecting A Location And Connecting Input Power =GND/PE Earth Ground 18 in (457 mm) of space for airflow Y Do not move or operate unit where it could tip. 230 VAC, 1 Ref. 802 991-B / 803 766-B Y Installation must meet all National Plug (NEMA Type 6-50P) Disconnect Device Line Terminals and Local Codes −...

  • Page 21: Threading Welding Wire

    4-13. 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: Using Gun/Cable Holder

    4-14. 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 5 − Operation

    SECTION 5 − OPERATION 5-1. Controls Ref. 200 034-B Voltage Control Wire Speed Control Power Switch This switch energizes the main transformer Set Wire Speed control according to the and control circuitry. Set Voltage control according to the parameter chart. Increase or decrease wire Spool Gun Receptacle parameter chart for good starting point.

  • Page 24: Weld Parameter Chart

    5-2. 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 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 27: Changing Drive Roll And Wire Inlet Guide

    6-4. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two differ- ent sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll.

  • Page 28: Removing Knob From Front Panel

    6-6. Removing Knob From Front Panel Y Turn Off power. Front Panel Knob Spring Clip Control Shaft Slot Rotate knob to allow access to slot. Insert Allen wrench (or stiff piece of wire) into slot, and while depressing spring clip, slide knob off control shaft.
  • Page 29 Welding Trouble Remedy Replace contact tip if blocked (see welding gun Owner’s Manual). Clean or replace wire inlet guide or liner if dirty or plugged (see welding gun Owner’s Manual). Replace drive roll if worn or slipping (see Section 6-4). Secure gun plug in receptacle or repair leads, or replace trigger switch (see welding gun Owner’s Manual).

  • Page 30: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 204 891-A Figure 7-1. Welding Power Source Circuit Diagram OM-1325 Page 26...

  • Page 31: 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 32: 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 33: 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 34: 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 35: 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 36: 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 37: 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 38: 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 39: 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 40 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 41: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 802 993-C Figure 9-1. Main Assembly OM-1325 Page 37...
  • Page 42 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....Fig 9-2 BAFFLE,CENTER ...........
  • Page 43 Hardware is common and not available unless listed. 802 989-A Figure 9-2. Baffle, Center w/Components OM-1325 Page 39...
  • Page 44 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1) ......SPOOL HUB ASSEMBLY (INCLUDING) .
  • Page 45 Hardware is common and not available unless listed. Ref. 802 988 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) ... . . 137761 NUT, 750NPT 1.31HEX .27H NYL BLK .
  • Page 46 ..208359 LABEL,NAMEPLATE MILLERMATIC 210 ......
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-5. Wire Drive And Gears (Fig 9-2 Item 23) 204857 ... . . 602009 SCREW,.250-20 x 1.25 soc hd gr 8 ........

  • Page 48: Drive Roll And Wire Guide Kits

    9-6. 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 49 Notes...
  • Page 50 Notes...
  • Page 51 LIMITED WARRANTY − Subject to the terms and conditions Induction Heating Coils and Blankets, Cables, and Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after APT &...
  • 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. © PRINTED IN USA 2007 Miller Electric Mfg. Co. 2007−01...

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