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

Arc welding power source and wire feeder
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Millermatic 210
And M-25 Gun
OM-1325
204 902M
2005−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source
and Wire Feeder
R
File: MIG (GMAW)

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  • Page 1 OM-1325 204 902M 2005−09 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source and Wire Feeder Millermatic 210 And M-25 Gun File: MIG (GMAW) 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

    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

    D Read Owner’s Manual before using or servic- support unit. ing unit. D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement long enough to extend beyond opposite side of parts. unit.

  • 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

    D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange suffisante pour lever l’appareil. Miller/Hobart. D En utilisant des fourches de levage pour déplacer l’unité, s’assu- rer que les fourches sont suffisamment longues pour dépasser du côté...

  • 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: Volt-Ampere Curves

    4-4. Volt-Ampere Curves Volt-ampere curves show minimum and maximum voltage and amper- age output capabilities of unit. Curves of other settings fall be- tween curves shown. va_curve1 4/95 − 192 436 4-5. Connecting To Weld Output Terminals Do not place anything between weld cable terminal and copper bar.

  • Page 16: Installing Work Clamp

    4-6. 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 4-7.

  • Page 17: Connecting An Optional Spool Gun

    4-8. 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 18: Installing Gas Supply

    4-10. 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 19: Installing Mig Wire Spool And Adjusting Hub Tension

    4-11. 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 20: Positioning Jumper Links

    4-12. 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 21: Selecting A Location And Connecting Input Power

    4-14. 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 22: Threading Welding Wire

    4-15. 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. 6 in (150 mm) Open pressure assembly.

  • Page 23: Using Gun/Cable Holder

    4-16. 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 19...

  • Page 24: 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 25 Notes OM-1325 Page 21...

  • Page 26: 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 27 204 890 OM-1325 Page 23...

  • Page 28: Section 6 − Maintenance &Troubleshooting

    SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. 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 29: Replacing Gun Contact Tip

    6-4. 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 6-5. Changing Drive Roll and Wire Inlet Guide Securing Screw Inlet Wire Guide Loosen screw.

  • Page 30: Aligning Drive Rolls And Wire Guide

    6-6. 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 31: Cleaning Or Replacing Gun Liner

    6-8. 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 32: Replacing Switch And/Or Head Tube

    6-9. 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 33: Troubleshooting

    6-10. Troubleshooting Welding Trouble Remedy No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 4-14). Check and replace power switch if necessary. Check supplementary protector CB1, and reset if necessary (see Section 6-2). Replace building line fuse or reset circuit breaker if open (see Section 4-14). Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 4-7 and/or 6-9).

  • Page 34: Section 7 − Electrical Diagram

    SECTION 7 − ELECTRICAL DIAGRAM 204 891-A Figure 7-1. Welding Power Source Circuit Diagram OM-1325 Page 30...

  • Page 35: 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 36: 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 parameters. 1/8 or Convert Material .125 in Thickness to...

  • Page 37: 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 38: 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 39: 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 40: 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 41: 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 42: 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 43: 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 44 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 45 Notes OM-1325 Page 41...

  • Page 46: 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 42...
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ....Fig 9-2 BAFFLE,CENTER ...........
  • Page 48 Hardware is common and not available unless listed. 802 989-A Figure 9-2. Baffle, Center w/Components OM-1325 Page 44...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Baffle, Center w/Components (Fig 9-1 Item 1) ......SPOOL HUB ASSEMBLY (INCLUDING) .
  • Page 50 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 51 ..208359 LABEL,NAMEPLATE MILLERMATIC 210 ......
  • Page 52 Ref. 800 792-C Figure 9-5. M-25 Gun OM-1325 Page 48...
  • Page 53 Item Part Description Quantity Figure 9-5. M-25 Gun (Fig 9-1 Item 19 ) ..200 258 NOZZLE, slip type .500 orf flush ......... . . ♦169 724 .
  • Page 54 Item Dia. Part Mkgs. Description Quantity Figure 9-6. Wire Drive And Gears (Fig 9-2 Item 23) 204857 ... . . 602009 SCREW,.250-20 x 1.25 soc hd gr 8 ........

  • Page 55: Drive Roll And Wire Guide Kits

    9-7. 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 56 Notes...
  • Page 57 Notes...
  • Page 58 Notes...
  • Page 59 Effective January 1, 2005 (Equipment with a serial number preface of “LF” 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 Induction Heating Coils and Blankets below, Miller Electric Mfg.
  • Page 60 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 2005 Miller Electric Mfg. Co. 1/05...

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